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Old 09-23-2017, 05:29 AM   #1
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Newbie and Onan Saga

In interest of assisting anyone else going through this; I am going to share my Onan saga to date and through resolution. Here goes
I bought a 2008 Tiffin Allegro 2 weeks ago that has an Onan Marquis Gold 7000 with app 150 hours on it.
I discovered pretty quickly that when parked the generator would run 45 minutes to at most 2 hours before it died and showed a code 36.
The generator runs closer to 45 minuted with the covers closed and closer to 2 hours with the hatch open and cover off.
I am in South La and the temp has been in the low to mid 80s. Also, the gas tank is 3/4 full and I checked the gas cap for tightness
So, here is what I have done.
I inspected the unit for obstructions to air flow- there were none.
I changed the oil (15-W40), air filter and oil filter. Unit still died in that time window.
Then I siphoned some oil and reduced the amount of oil from near the high acceptable range to the low acceptable range.Unit still died in that time window.
Next I changed the fuel filter - Unit still died in that time window.
I attempted to inspect the fuel line - I can't see any cracks that are obvious.
Last night I ordered a fuel pump as replacing it would be about the last thing I am mechanically capable of doing myself and I will keep folks posted on how a new pump works out.
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Old 09-23-2017, 05:51 AM   #2
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How long before it will restart?
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Old 09-23-2017, 06:07 AM   #3
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How long before it will restart?
App 20 to 30 minutes. I should have mentioned that. Thanks
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Old 09-23-2017, 06:52 AM   #4
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Next I changed the fuel filter - Unit still died in that time window.
I attempted to inspect the fuel line - I can't see any cracks that are obvious.
Last night I ordered a fuel pump as replacing it would be about the last thing I am mechanically capable of doing myself and I will keep folks posted on how a new pump works out.
Fuel pump worked for me.
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Old 09-23-2017, 07:01 AM   #5
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Fuel pump worked for me.
That's my hope. Is there any trick to putting it in? It seems pretty straight forward and I have watched a couple YouTube videos.
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Old 09-23-2017, 07:49 AM   #6
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That's my hope. Is there any trick to putting it in? It seems pretty straight forward and I have watched a couple YouTube videos.
no trick. It was easy I changed both fuel filters at the same time. Have something to plug the fuel line from the coach.
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Old 09-23-2017, 08:12 AM   #7
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If the fuel pump doesn't fix it, check out the over heat sensor.
Happy Glamping.
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Old 09-23-2017, 09:41 AM   #8
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no trick. It was easy I changed both fuel filters at the same time. Have something to plug the fuel line from the coach.
Any trick to the electrical connections in terms of reaching in there? I'm not quite sure I can get my fingers in there to uncouple the old pump and then to reconnect the new pump.
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Old 09-23-2017, 11:11 AM   #9
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Any trick to the electrical connections in terms of reaching in there? I'm not quite sure I can get my fingers in there to uncouple the old pump and then to reconnect the new pump.
One other question just occurred to me. The fuel line coming from the gas tank basically pressure fits with a little hose clamp onto a barbed fuel filter. That is easy to disconnect. My question though is how do I connect the other side of the fuel pump which is female threaded to the hose that then feeds the generator? In other words, is there some type of male threaded coupling that fits into the female threaded fuel pump and then attaches to the fuel line? If so, is that reusable? Or is that something I need to order in advance before I change the pump?
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Old 09-23-2017, 02:16 PM   #10
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I LOVE Onan problems! I've had my 1992 Challenger a few weeks now. When we bought it, the owner SWORE "this thing was running perfect yesterday". It wouldn't quite start until he manipulated the throttle linkage, then it ran great. Removed carburetor, cleaned, and re assembled. Unit runs sometimes 20 minutes, sometimes an hour....It "pops" like a .22, surges, then dies. Looked at fuel line from tank to pump, all new. Tried to get to fuel filter, said screw it, removed gen set. Ordered fuel pump and filter. Discovered that there was no ground wire running from the tray to the frame. Grabbed one from Autozone. Re-installing Monday. Easy Peasy! I'll keep on it until I get it...
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Old 09-23-2017, 10:47 PM   #11
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I had the same problems with my '07 Onan 7000. Fuel pumps on those gas gennys are known for this. When the engine gets warm, the fuel pump gets tight. A warn pump can stop pumping in 10 minutes when it is real hot out. Replacing the fuel pump should fix the problem.

The OP's unit has only 150 hrs in 10 years and could have had periods of inactivity. I would recommend running some concentrated Sea-Foam Motor Treatment through the carburetor after you repair it. All the best.
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Old 09-26-2017, 03:20 PM   #12
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I had the same problems with my '07 Onan 7000. Fuel pumps on those gas gennys are known for this. When the engine gets warm, the fuel pump gets tight. A warn pump can stop pumping in 10 minutes when it is real hot out. Replacing the fuel pump should fix the problem.

The OP's unit has only 150 hrs in 10 years and could have had periods of inactivity. I would recommend running some concentrated Sea-Foam Motor Treatment through the carburetor after you repair it. All the best.
I ran into a simple problem, but I can't figure out how to work around it. It's easy to access one of the bolts holding the fuel pump, the other is blocked by the frame that actually holds the generator. So, I can't get a socket to it. Any ideas?Click image for larger version

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Old 09-29-2017, 06:28 PM   #13
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I ran into a simple problem, but I can't figure out how to work around it. It's easy to access one of the bolts holding the fuel pump, the other is blocked by the frame that actually holds the generator. So, I can't get a socket to it. Any ideas?Attachment 177914
So; I used a flex socket extension and it allowed me to get the hard to reach bolt out. I added some wiring, and some fuel line to make it easier to change in the future. Here is a picture, I'm going to add some type of insulation to the electrical lines but I need to go get some.Click image for larger version

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Old 09-30-2017, 01:01 PM   #14
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Got mine re-installed with the new fuel pump. Seems to run fine, just "pops" randomly....
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