ONAN 4000 RUNS FOR ONE HOUR AND DIES--ANY IDEAS WHY?

Sometimes people mistakenly think there's a problem with a carb on Onan 4000 generators. Be sure to ensure the fuel pump is pumping fuel to the carb by pulling the hose off the carb and watching for adequate flow. A faulty electric fuel pump can often only show symptoms or act up after it is warmed up. Sometimes it may run for 10 or 20 minutes and just shut down. Check for fuel flow immediately upon stalling if this is your symptom. Mine would shut down after 20 minutes and not restart for awhile. I pulled the hose off the carb immediately and noted there was no fuel in the line and it would not pump fuel while holding the start switch on either. If you are mechanically savy you can disconnect the hot wire the positive wire (red) leading into the fuel pump and connect it with 12 V and see if it pumps fuel out the hose also, but be careful to capture the fuel coming out the hose). Once cooled down it pumped fuel in a weaker than normal stream. Replaced the fuel pump (and new filter while at it) and everything worked fine again on my 1995 Onan. Much stronger fuel stream noted too from the hose.

Try to restart to see what happens. However, make sure to have a volt meter to check output voltage. You may be loosing voltage and therefore it shuts down. Check oil pressure switch, rings, brushes. Replace brushes if they are less than 1/2" short and clean rings with emory cloth until copper is noticable.