Three R’s - Removing, Rebuilding and Replacing our Onan 6.3KW LP Generator

Well, we were having trouble with our generator last year and kinda ignored it …   but now this Spring, dear Steveio wanted it fixed and working.   We have a little time before camping season begins.

The great guys at Flight Systems were VERY helpful with troubleshooting.   Randy was “The Guy” to talk to about the system.
Their diagnostic troubleshooting information is the best and we sure appreciated their help.   They have downloads of information and what things to test first, second, third etc. and using a voltmeter, you can diagnose what is wrong with your own generator before paying for costly repairs.

http://www.flightsystems.com/rv-generator-controls/

So after checking it all out, we found a shorted brown burnt spot in the control board, and a bubbled area on the voltage regulator.  We think that our old batteries with the bad cells and the exploding expanded case on two of them ruined our generator somehow with a back surge of something or other.  (we have all new batteries now)
We threw a new control board at it, then a new voltage regulator, then cleaning the slip rings, and replacing the brushes (plus the ceramic holder cracked so had to replace that too)  … finally we came to the conclusion that it was only putting out 55 volts and not 120vac.   That meant the half of windings on the rotor were bad.  Sigh. 
So that meant a removal of the generator, and take off the rotor and send it in to be completely rebuilt.  We found a great guy down in Ohio,  name of :

SAM BORCK - 11392 CTY RD 5 - DELTA, OH  43515 -   419- 466-0485

He seemed to know the generators inside and out, exactly the specific stuff about our model and year and did very prompt turnaround, we got it back within a week of him getting it!  Cost was $365 including his shipping it back to us.  What a deal compared to what Onan wanted for a new one, or what even other places on the net wanted for a rebuilt one.

I was the Gopher Girl and Steve patiently stopped from time to time to let me take pics of each step.

Here are the pics of removing it last month while we still had snow.

 

(p.s.  in case you are wondering, that funny yellow adaptor and orange cord hanging off the side of the rig is our AC  line from the garage 20amp outlet for shore power.  This adaptor is a screw on type bayonet mount for 50amp plugs.  Instead of keeping our heavy black 50amp cord out there all the time, temping for copper thieves, we use this adaptor and a regular extension cord, sufficient for light enough loads while parked in our driveway)

Okay.. back to the generator---    Now it’s a couple weeks later and we got the rotor rebuilt and back.. and the snow is gone!  

 

All those pics were taken yesterday evening …  now it’s Saturday morning and Steve finished up the connections. We attached the propane line, bled it, checked for leaks… double checked all our connections…. and hit the button!

annnndd it WORKS!!!!! 

wheeeeeeeee  120 vac at the outlets… yahhhhoooooooooo

Generator Muffler Replacement:
On day five years ago, when Steve went to start up the generator for a little exercise (plus he wanted to run our vacuum cleaner to do the lower compartment carpeting)   it started up with big roar and a backfire BANG!    What was up with that?  The dogs almost went through the roof!

We shut it down immediately and went out to investigate.  Yikes!  It blew the back off the rusty muffler-----   time for a replacement!   Plus, Steve looked at the throttle linkage again which needed more lubricant.  It had hung up once in January and he lubed it then, but it was still a little sticky.  That is probably what caused the backfire.

Steve called around to various places to see about getting a new muffler, and explored the internet to see if he could find one cheaper.  Amazingly, the cheapest place he found, was right from the Onan / Cummins place in DePere, WI (just south of Green Bay)

 $77.76 with tax

part number 542-0472  RV exhaust kit Emerald LP Generator

It was a muffler, a hanger bracket, a manifold connector, and 2 clamps and bolts and a gasket

First step was to take off the old manifold connector.  Of course, it was rusty and the bolts broke off when trying to remove them.  Steve was working flat on his back on the ground with the manifold opening being up over his head.  ARGGGHHHH

He had to drill out the broken off bolts....  Once he got it off, he used a tap and re-tapped the threads of the two holes.  These photos are from looking up from underneath the rig.  When he attached the new manifold adapter and gasket, he felt the two bolts just screwed into the new threads might not be enough.  There is a lot of vibration on a generator---   (flashback to last summer when oil was pouring out of ours... seems the filter had vibrated loose and oil was leaking out all over)   

In this case, Steve decided to use longer bolts, lock washers and locking nuts on the top end of the bolts where his fingers could barely get up on the top side of the flange.  But now it is more secure and won't rattle loose (we hope) 

This is looking up from the ground to where he attached the manifold adaptor

Next comes the muffler itself.  It came with a hanging bracket and muffler clamps.  Don't you just LOVE new metal pretty shiny parts????

We set it up into place, clamped on the hanging bracket to where the old one was attached and then added the muffler clamp around the manifold adapter.  It was a really snug fit and we are sure it's nice and tight.   Last step yet to go, he has to attach a tail pipe.  (a section of conduit piping will work just fine)  but he has to go buy it today as he was not sure of the length and diameter needed until I brought home the muffler.

Once it was all in place, we started up the generator, with no backfires and no stuck linkage.  Wheeeeee!!!!     It was very quiet again.


Generator Oil Change:
Every year we take care of our generator with an oil and filter change.   We do it every spring, even though we have only put on about 61 hours since last spring when it was done.  The little hour gauge inside helps keep track of the time in between changes.

Here is how we do it:

First, we warm up the oil by running it for a while.  Then we shut it down and set a bucket underneath by the drain.  We write it on the filter with a permanent marker at what hours of usage we are at each time we change it.

Steve unscrewed the petcock to let the old oil drain out into the bucket...   It starts running out, but also carefully opening the top fill cap lets it run out even faster.  We are careful to not let anything get into the opening, so we replace the cap quickly as soon as the stream into the bucket slows down.

 Looks pretty good... 

and once it's all out, time to unscrew the filter.  

Notice Steve's wonderful filter wrench?? LOL

It's the same "secret special tool" that is used to remove injectors

after sitting 4 days on a corner in Winslow, Arizona---- 

for more information--- see the blog at:
http://kareninthewoods-kareninthewoods.blogspot.com/2011

Added the new oil --- here are the specs and part numbers:

3 QUARTS 30 WT
 filter number WIX 51762
or 122--0800 ONAN

Oil change all done, and ready to run again....

Update on Family and Macramé Woven Lawn Chairs

Update on some family medical problems....

Steveio's mom has undergone her first chemo for her breast cancer.  She is feeling ok and will join us for Easter Dinner on Sunday.  We are hosting the event with 28 of the Pfundtner Clan on Sunday.  Hope she has the strength to come this far (110 miles) and doesn't over do it.

Brother-in-law Fuzz made it through about 14 hours of cancer of the bone surgery yesterday.  He was in the recovery room as of last night and doing good.  The cancer has spread more than they thought, not just the jaw bone and lymph nodes, it was also around to the base of the skull, the back of the tongue and the front lower lip.  It will be a long haul from here for him and my sister, Linda.

Our little grandsons' other grandfather, Kevin (Jesses' dad)  is on day 8 in the ICU in critical care for a pancreatic attack.  Things are dicey and he is being sedated and is on ventilator and  feeding tubes.  He is such a strong and hearty man, this is a real shock to know he is so sick.

Please pray if you feel so inclined for our family at this time.



Some of my blog readers have asked about our woven lawn chairs.

Our lawn chairs are handmade by me… its a technique that uses macramé cord (the braided is better than the twisted)  and two big crochet hooks.  Using graph paper,  one can make just about any design.   They are very comfortable and warmer to sit on around campfires at night compared to the plastic strap webbing type, or thin canvas.   We use the heaviest frames we can find.  Usually the rounded metal pipe frames are better than the lightweight square aluminum tube frames.   We have been known to buy new chairs, cut off the webbing, and then weave them into the desired patterns.

This is a link to the website that has instructions:
http://kingskountry.com/free-macrame-patterns.htm

Here are some that myself and my sister have made over the years, starting with ours:

(the pine tree motif matches the ones used on our home)

 

These are ones made for family and friends:





 

Campground Review - Runkle Lake at Crystal Falls, MI Canning Pickles and Humungus Fungus Fest

(this is one of series of posts of various campgrounds we have been to over the years... I am going through my files in alphabetical order and posting past camping trips in my blog.... something to do over this long long winter---- sigh)


Runkle Lake is located on the east end of Crystal Falls, Michigan in the Upper Peninsula.  It’s my father’s hometown and many of the Bicigo’s still live there.  The Bicigo Shoe Shop is still functioning on main street, run by some second cousins and great uncles. 

 

The campground is down on the end of main street, across the river and up past the cemetery and on the left.   I took a Google Earth shot to show the campground.  As you drive in past the ball diamond, dump station and tennis courts, the campground is divided into two halves.  The right side is very hilly, rutted with tree roots and you park just about anywhere, willy nilly.   There are only a few water spigots and the power pedestals are kinda catch as you can or run long long cords.    The left side is a newer section with definite sites and logically spaced power pedestals and water hookups.

Runkle Lake campground information

CAMPING RATES
    SITES #1 - #17
    (WATER, ELECTRIC & SEWER HOOKUPS)
                    $23.00/DAY
                  $300.00/MONTH*

   SITES #18 - #57
    (WATER & ELECTRIC HOOKUPS)
                    $18.00/DAY
                  $300.00/MONTH*

The lake is experiencing an invasion of the milfoil plants, which are choking out other plants and causing real problems with boating and swimming.  The beach area is cleaned out regularly, but the weeds are encroaching and causing a lot of extra work.

These photos are from a combination of a few years worth of camping at the lake.  Our family gathers here twice yearly… once for the Bass Festival and once for the Fungus Fest.  (more on that later)


Poor photo here, from old cheap digital camera pre-2002 camping shots…. but it shows how campers just park willy nilly here under the tall trees.

Here is the crew gathered around my sister’s trailer.  This is her favorite spot as its right next to the horseshoe courts.  At both festivals we attend, the guys join the horseshoe tournaments.  It’s their main priority of coming to this park!  LOL

Here is my Mister Steveio, doing what he does best!

My brother is the beer distributor during the time these photos were taken… he would set up the beer tent and haul back the empties in the back of his pickup truck, as there wasn’t a lot of room to bring in the big beer truck just to unload empty half barrels.

 

Parked in the willy nilly area of campers, also is my brother’s boat.   This is common for folks to want have boats and campers when camping in the UP of Michigan… so it usually means also having a spouse drive a separate vehicle to tow a boat, in addition to their fifth wheels or travel trailers. But my brother no longer has a spouse!    Steveio had made him the extra hitch on back of his fifth wheel to tow triple…  but it kinda scares him.   This particular time he had me drive his fiver and truck back to town for him after camping was done.
This is the morning after …. poor Beerman Butch and his hangover.   Pass around the Tylenol.   This is kinda common among our crew of beer drinkers.  (I drink wine)

We strung up a hammock and took turns relaxing.   Even the doggers like to swing.

Here is a more recent shot, I think from 2008…  twilight before heading over to the pavilion for dancing to the live music.   Yup, this is our Crew.  LOL  Smokey foreground from the campfire smoke.  Mother hung incicle lights from her motorhome, oh geesh. 

We all went over to the pavilion for some dancing.. here are the folks, Ma and Pa Hall.   Then our crew out on the dance floor.  Steveio was doing his best “Frog in the Blender” rendition of dance moves.. heh heh

 

 

Steveio and I, the Honeymooners… dancing late into the night!  This was the ubiquitous camera shot  of holding it at arms length and hoping it catches both of us in the lens.

The festivals in the town of Crystal Falls have themes such as Bass Fest, Harvest Fest, Fungus Fest.  They are all just excuses for a PARTY~!



Now here is a little bit I gleaned from this site about the Fungust Fest:

 

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http://www.humungusfungusfest.com/

What is a Humungus Fungus?

Several years ago a "humongous fungus" (a gigantic mushroom) was discovered in the Crystal Falls area. It weighs roughly 11 tons and covers 37 acres. This makes it the largest mushroom (fungus) in the world - it's hard to believe this monster mushroom is growing in Michigan and not Texas! Based on the average rate of growth through the soil, the Humongous Fungus is probably more than 1,500 years old.

After the benevolent giant mushroom was discovered it did not take long for the city fathers to decide to share this wonder with the world - hence "The Humungus Fungus Fest" was born.

For three days each August tourists and locals alike celebrate this giant fungus phenomenon with a spectacular celebration. The main event seems to be the making and eating of the HUMUNGUS PIZZA.  The fungus topped pizza is 10 feet by 10 feet! It is the largest mushroom pizza in the world.

There is also an extensive assortment of other activities such as a Buckboard and Horseshoe Tournament; a Tube Float - here's your chance to float down a river on an old tire tube; or register for the Volley Ball or Golf Tournament. If your tastes run to a more sedentary pastime you can begin the day at the Veterans of Foreign Wars' Hall for a Pancake Breakfast then view the Fungus Fest Parade, watch the softball game, or gobble up ice cream at the Ice Cream Social then toddle on over to the Pie Social for home made pies. If you are still able to walk the Salad Luncheon at St. Mark's Church offers tasty culinary selections. At the end of the day pull up a chair and view a fabulous fireworks display - a bang-pow! conclusion for a fabulous event.

Taken from "Humungus Fungus Festival - Crystal Falls, Michigan" by © Maxine Sommers in 2008. Read the entire article by Maxine Sommers.

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This particular weekend, I was able to get 3 bushels of cucumbers from a local truck farmer to make dill pickles with.  My sister and my mom love to do pickles, so we hauled all the gear up to make them.  The canning kettle sets on the LP burner stand from our turkey fryers.  The other kettle is the hot pickling brine. 

 


Yup, that’s me.. the Pickling Queen of Oconto County! 

(not kidding, a little *brag* here--  at the County Fair,  I won Best in Show for my pickles, and got a ton of great prizes from the Kerr-Ball canning company to boot!)

Mother sat for hours, scrubbing pickles clean before processing.  What a gal….  as children, we helped her many many years canning pickles, saur kraut, tomatoes etc.

And here are the lovely results of our labors… some slices, some whole, some spears….

(don’t ask, our recipe is a prize-winning secret!)