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Old 11-07-2015, 02:12 PM   #1
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Fuel line to Gen Issue

Hi all, am trying to fix an issue I just had on a trip to FL. (98 Fltwd Pace Arrow Vision 36Z w/Onan 5.5kw Genset) A number of years ago, my uncle (previous owner) had fuel problems with the gen, so a service center disconnected the gen from the fuel line going to the main tank, then plugged that line. They then installed a regular marine 5 gl tank in the next bay, and ran it fuel line to the gen.

Back to the present, I am rolling along and stop for a quick bathroom break, and notice a strong fuel smell in the aft bedroom (engine still running). I go out side, and see fuel dripping from the gen bay, open it up and see that the rubber hose plugging the old metal fuel line is dripping fuel... I reach in and wiggle it a bit, and it seems to be pressurized, as fuel now squirts out from cracks in the rubber....

I hop back inside, turn off the engine, grab a bucket to put under the drip, but now with the engine off, I see that the old rubber fuel line plug is no longer leaking... even when I wiggle it, no more pressure...

I make a new plug from some new rubber fuel line and a torx socket, tape it all up, attach it with a hose clamp, and no more leak, even when running....

Now, I want to fix this correctly, want to reconnect the gen to the old metal fuel line that goes to the main tank, but what puzzles me is why should that line have pressurized fuel in it when the main engine is running. As far as I know, the gen fuel line just goes from the gen to the main tank, and a tube that goes about 3/4 down into the tank, allowing the gen to suck fuel when it is running....

Before I hook the gen back to this line, I'd like to understand this pressure better... I thought the fuel cap was vented, or the tank is somehow, preventing pressure from forcing fuel up the gen line to the gen... I may have this pressure thing all wrong, maybe its correct, and all I have to do is reconnect the gen fuel line to it like is came from the factory... but,

if there is not supposed to be pressure in that line going to the gen, I need to figure out why its happening, and fix it, any help someone can offer me on this will be greatly appreciated,
Thank you,
Jerry
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Old 11-09-2015, 04:55 PM   #2
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Update... Tried to run genny after reconnecting original fuel line, no joy... am going to disconnect fuel line from filter at carb, then try to start and see if any fuel is pushed through...
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Old 11-11-2015, 07:57 PM   #3
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Are you sure the leaking line was genny or could it be a return line?
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Old 11-13-2015, 07:25 PM   #4
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I didn't know the genny had a return fuel line... The pipe I'm identifying as the genny fuel line is the one that comes out of the chassis slot right above the genny fuel pump, and its the one that some tech in the past plugged off with a piece of tubing and plug, so am fairly certain it is in fact the genny fuel line... I;m going to drop the fuel tank and check any rubber tubing on top for decay, will replace any tubing I find there, then trace all fuel lines leaving the main tank, I expect 2 or 3, 1 to genny, 1 to main engine, and maybe 1 return line from main engine (7.4 vortec, 454 chevy)...
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Old 11-14-2015, 07:45 AM   #5
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Genny does not but engine may.

Yiu have a good plan.
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Old 11-22-2015, 07:26 PM   #6
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Fuel line update

Thanks for the info, am shutting down for winter now, this issue will have to wait til spring, not looking forward to all the projects and repairs next spring, but it is what it is, thanks to all again, closing this out for now...
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Old 11-23-2015, 03:45 PM   #7
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On my 2002 Fleetwood Flair with a Workhorse chassis, the fuel line to the generator rotted. When I lower the fuel tank, there was a brass fitting on top of the fuel tank to fuel the generator. It had a 3" rubber fuel hose that connected to a metal fuel line that ran back toward the generator and then a 2 foot rubber line to the generator fuel pump. The 3 inch rubber hose was dry rotted and cracked and my fuel line was rusted. I just ran a new 10 foot rubber hose from the top of the fuel tank to the generator fuel pump. worked great for years , then I sold it.

FYI Don't drop the fuel tank, ----tilt it. then reach in and replace the line with new rubber fuel line. Get a couple of friends and a couple of floor jacks. and a few cinder blocks. Good Luck.
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Old 11-25-2015, 01:04 AM   #8
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It just so happens I have a 99 Pace arrow vision with the same genny. I just dropped my tank cause the RV had been sitting for 5 years (yuck) had to clean out a 1/4 full tank, wasn't gas any longer. And ways the line you mentioned is the feed line to the genny. The line runs along the frame rail next to the evap line which is bigger dia. If you need to get the fuel pump out, recommend 2 car jacks with wood. Drop it down about 10 inch. Should be enough room to get the pump out from the right had side even though the pump is more to the left(no room on the left on mine atleast). Don't forget the quick disconnect tools.
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