Fixed! Troubleshooting an Onan Marquis Gold 5500 Generator - Part 3
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- Опубліковано 4 жов 2024
- After exhausting all the DIY troubleshooting and repairs to the Onan 5500 Marquis Gold generator that is in my 2001 Bounder (see my 3 previous videos), I took it to Eric’s RV Performance Center. The mechanic narrowed the problem down to the air-fuel ratio being too lean. Since I had installed a new carburetor, fuel filter, air filter and spark plugs, he suspected it might be an engine vacuum leak. Upon removing and inspecting the intake manifold, he discovered a long gap between the two-part manifold. The thinner part was bent, and thus the gasket had failed. Simply replacing the intake manifold with a new one solved the problem!
So, what was the total cost for repairing the generator? $848.76
This is the breakdown:
1. Replace Intake Manifold: Parts $133,21, Labor $220, Supplies $7.95, Tax $31.78: $392.94
2. New Carburetor: Cummins 5410765 Onan Carburetor Kit: $334.77
3. Third gasket for Onan carburetor: Part No. 141-0983: $23.71
4. Onan Generator Tune Up Kit: Air filter, fuel filter, 2 spark plugs, 2 QT oil, oil filter: $97.34
I hope that you enjoyed watching my troubleshooting journey and that you learned something from the process.
Thank you for watching this video and visiting my channel!
I’ve got the exact model generator and it’s doing the same thing , flashing code 14,37 and runs for 30 seconds. Mine is the LP model instead of gasoline. It’s only got 21 hours on the meter but it’s set up for years . Thank you for taking the time to put the video out .
I have the same issue now. Exactly like this first video. Do you replace the Manifold?
My dad and I watched all three videos and we were rooting for you the whole time! We got quite invested in the outcome hahahaha.
That’s great to hear! Especially about you spending time like this with your dad. Thank you for watching my videos and for your comment!
- Randall
Thank you very much for these three videos.. your DIY is very helpful. Mine is doing the same thing while I am flipping back on a Florida to CA trip. Running great, generator has low hours and serviced with new filter at start of trip.
Very good sir. Thnku for your video. It helped me a lot. I have a 2002 Bounder, same colors as yours, but mine isn't as nice as yours.😊
Did they say why the intake wrapped
I have EXACTLY the same issue. Primes good, wants to run, sounds great for 1-2 seconds then dies.
New carb, fuel pump, filter, etc. Starts and command shuts it down immediately. My code is 14. That is "Over Frequency". Troubleshooters say to move the spring one notch or two at a time one way or the other, try holding the governor up during starting. I tried all of that and nothing has helped so it's not a simple adjustment. There is no code for warped intake manifold. Tried disconnecting the oil pressure sending unit. Didn't work. Tried unplugging the RV from shore power before starting. That didn't work, flipping the 30A breakers on the generator, didn't work, new carb made it soumd better and doesn't ever sputter. starts in 3-5 seconds of cranking, but still won't stay running for more than 1 or 2 seconds before it dies. Spraying starting fluid into the intake on the carb doesn't work. I've found nothing so far that worked.
Someone said that if it sits too long (it sat on the oregon coast salty air for about 9 years and was virtually unattended and not maintained), the pully might sieze and cause it to shut down like that. Someone else said a critter could have bit through a wire when it was nesting. I cannot see behind the generator without dropping it out of the chasis. I aint doing that!!
Background: Bought this 2008 Class A Damon 37' for $42K with 6,000 actual miles. 40 hours on the generator. Started and ran at time of purchase. Never once after. Fule is half tank right now. Sat in the sun for many years and was neglected. Rat or squirrel had built a huge nest on the generator at the sellers home 3 years ago. I cleaned it all off this month 2024. Carb was caked over with shelaque. Replaced carb and now it wants to start. Won't go more than 1-2 seconds and dies.
You said the intake was warped. Did they say what caused it to warp?
I see a couple of other have asked the same question I have...what caused the intake manifold to warp? That is not an easy thing to do. Was it heat? Is it exposed where it can be easily hit (unlikely). You put a lot of work into diagnosing the problem and in putting together the videos but I have to be honest, I feel like I got to the end of a really good book, but the ending...not quite complete.
That's a very good question. Maybe an inexperienced mechanic bent the intake manifold while attempting to replace the gasket that was leaking? I'm not confident that the RV repair shop was being honest with me, especially when I discovered that they overfilled the oil tank, which was filled to the top of the oil filler cap far beyond the full mark on the dipstick. That said, the generator has been working flawlessly since this repair almost two years ago, after I drained the excess oil. Also, I have been exercising the generator once a month, running it for about an hour under a load. Thank you for watching and for your comment!
@@randallwingett Sorry to hear you don't trust their work; that is why I make every effort to do as much work as I can on my own and why I love UA-cam posters like yourself! This was not my issue, at least I don't think so. Your symptoms are different, I'm pretty sure I have a fuel pump issue. Parts on order and I'm crossing my fingers that is my issue. If not, I'm back to square one. thank you for providing the close out to your story. FYI, Kevin Caudill has a great UA-cam play list of Onan repair videos for your genset. He does a great job on his videos with a lot of great info. I think he owns his own small engine repair shop but shows a lot of work he has had to do on his own Onan 5500 Marquis Gold.
Update for all having similar issues w/ and Onan 5500 series. I have a model 5.5HGJAB -6755K installed in our 2015 Momentum 350M. I was fuel starved and couldn't figure out why. Kept shutting down un-commanded. I replaced the fuel pump and filter (on my model year they moved the filter and it attaches directly to the pump on the input side older models placed the filter after the pump but before the carb). Unfortunately, that did not fix my issue, it still shutdown un-commanded.
I got the idea to run a fuel line from the input side of the fuel filter/pump assembly directly to a gas can; in trying that I confirmed that the genset ran fine. Therefore , fuel filter pump and carb were all eliminated as culprits. I also confirmed there was little to know fuel coming from the fuel line when I detached it from the filter. At this point I was thinking a blockage in the line and or the tank and my next step was to replace the line, but first I used my air compressor to blow out the line from the end that connects to the filter...using less than 50 psi, the rated psi of the fuel line.
When I blew out the line I found a hole in the line fairly close to the tank where it traverses through a hole in a frame members. Likely caused an abrasion at this point. Just like trying to suck soda out of a glass w/ a cracked straw, the pump could not pull adequate fuel from the tank w/ a hole in the line. I repaired the hole w/ a male to male brass barbed nipple and I'm back up and running. I needed to replace the fuel filter anyway and the pump was not that expensive...and now I have a spare but I did want to put this out as another possible cause of un-commanded shutdown, fuel starvation, and/or generic code 36. Quick additional note, my unit has what is called a "purge line" another fuel line that runs from the genset all the way back to the tank. I'm not completely certain of the purpose but when you are tracing your fuel line you may need to ensure you are tracing the correct one back to the two separate attachment points on the tank. Thank you for the video and trouble shooting techniques, learned a lot!
Mine is a marquis 5500 not the Gold,it only runs when the switch is pressed in
What did it end up being? Same issue I’m having
wonder if a machine shop could check that warped surface. then mill it if its not to bad?
Could you have just replaced the gasket instead of the complete unit
Part #154-3067-03 for Intake Manifold, #154-3085 for Intake gaskets takes 2, #141-0982 for Carb. gaskets takes 2
By chance did you get the part number for that manifold? I cant find it anywhere
why was there so much oil .. ??
If you still have receipt could you give me part number for intake. I need one as well. Cummins said it’s 154-3070 for $647!!!! But 154-3067 seems the same for $82. I have same generator as you and you obviously didn’t pay $647 for part. Any help is appreciated
See prior reply by @chipfruge above. He says 154-3067-03 Manifold (way less expensive).
Randall do you still have the pond
No pond. Miss it though.
Dang those vids were the best
ALL the repairs you did were a waste of time and money. Twice you ignored the diagnostics. The shop ripped you off. They corrected the problem in 10 minutes with a simple adjustment and took you for the manifold.
What adjusment was it? because mine is doing the same thanks
@@GermanSweetLife I have the same problem tried everything except the manifold so far.
@@CABELmc The problem I’m having right now is whenever I put the cover back on and close the door to the motorhome that’s covering the generator after 10 minutes turned off so I’m guessing it’s overheating everybody on Facebook keeps on telling me that it’s not getting enough air
That sounds like crap to me. I have EXACTLY the same issue. New carb, fuel pump, filter, etc. Starts and command shuts it down immediately. My code is 14. That is "Over Frequency". Troubleshooters say to move the spring one notch or two at a time one way or the other, try holding the governor up during starting. I tried all of that and nothing has helped so it's not a simple adjustment. There is no code for warped intake manifold. Tried disconnecting the oil pressure sending unit. Didn't work. Tried unplugging the RV from shore power before starting. That didn't work, flipping the 30A breakers on the generator, didn't work, new carb made it soumd better, but still won't stay running for more than 1 or 2 seconds before it dies. Spraying starting fluid into the intake on the carb doesn't work. I've found nothing so far that worked.
Background: Bought this 2008 Class A Damon 37' for $42K with 6,000 actual miles. 40 hours on the generator. Started and ran at time of purchase. Never once after. Fule is half tank right now. Sat in the sun for many years and was neglected. Rat or squirrel had built a huge nest on the generator at the sellers home 3 years ago. I cleaned it all off this month 2024. Carb was caked over with shelaque. Replaced carb and now it wants to start. Won't go more than 1-2 seconds and dies.
@@GermanSweetLife If you are going to attempt the adjustment, there's a 6" spring on the upper choke linkage. It connects on the bottom side to the governor. It has notches in the bottom side. The farther to the right the spring sits in those notches, the faster the RPMs and thus the Hz frequency may go over limit. Try moving it a couple spots to the left each try. If it's actually a Code 14 Over Frequency fault (and not misdiagnosed by the system), it should cure but you need a frequency meter. And...usually that fault will let the unit run for several minutes and then....kick it off. That is not...repeat...NOT what is happening here. This kicks off immediately and there is no frequency to measure when the governor goes all the way down just to get the gen started. So, no way to measure. If you can't measure the Hz and the gen shuts off before that, no adjustment of the governor will suffice. So, we're back at square 1!