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Old 09-27-2022, 05:24 PM   #1
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Join Date: Jun 2016
Posts: 107
Onan 5500 Housing Insulation

I have a 2008 Onan 5500 HGJAB Spec D. I noticed almost all of the OEM insulation is missing from the inside of the housing. There is a small pieces when looking gat the generator from the front on the right side, or on the exhaust side. Isn't there supposed to be insulation throughout the inside, and if so, does it help with cooling, meaning does it deflect or anything, or just to quiet it down? I'm having an overheating issue when temp is 90 degree plus. I just installed a new fuel pump and filter, insulated all of the fuel lines from the frame to the pump, and the lines inside the housing, I also installed the OEM Onan carb insulator. I rerouted my exhaust tubing to get it from directly underneath the fuel pump to the opposite side. I also installed an Onan intake duct that was built for Jayco that allows the incoming air to be pulled from the side of the RV, versus underneath to help with separating the incoming cool air and the exhausted hot air. Next on the list is a pusher pump to be installed towards the rear of the RV, near the engine fuel tank, and build a better intake plenum. Note, my generator is located behind the front driver side front wheel. The fault code was 36, now its throwing a 47, which I've read can be associated to running out of fuel, from Vapor lock.
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Old 09-27-2022, 09:35 PM   #2
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Join Date: Aug 2020
Location: Ohio
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Have you cleaned and adjusted the carb ? I thought the insulation is for sound and heat from exhaust.. but now I am wondering.. if critters used insulation for a nest.. critters love to eat on rubber fuel lines and short wiring and nest in worst places.. when things go haywire and don't make sense then keep critters in the back of your mind all the time.. I found holes eaten in my rubber fuel lines.. on very top of fuel tank.. fuel did not leak out.. but air got sucked in.. this took me 2yrs to trace down.. because I would not listen to the great members post.. you need to replace.. not just wrap.. all and I mean all.. hard lines and rubber.. your lines are 14+ yrs old.. in can develop cracks that suck air.. here is what they suggest.. run your own new fuel line from 5 gallon fuel can to back of fuel pump.. run it until all gone.. under full load.. if no change.. then it's not fuel line.. if repeats .. then you know.. somewhere it is sucking air in old line.. and sorry but it will be up over tank or where you can't see it.. now.. if you are handy .. get a universal oil cooler kits.. and put your own oil cooler on it.. I feel that onan missed adding this.. I am in process of figuring out how to add one.. I got the kit.. just got to get time to drill holes in mounting plate.. most commercial generator have one..
You need to pull generator and remove all engine covers and find out if You have a blockage.. I bet if carb is ok.. and fuel checks out ok.. critters used insulation for a nest inside engine cover.. now you can. With hi pressure air.. blow out all the cooling fins.. use your cellphone with flash on and record as far as you can over each fin.. and look for any trash inside engine cover.. my generator only had 250hr on 22yrs coach.. because it would only run well when fuel tank was full.. and I found all sorts of trash in engine covers... took days to blow it all out.. I finally had to replace all fuel lines and make a very long air nozzle to reach in back under engine covers.. you can buy one.. they are cheap and handy ..
Good luck and keep us posted
2000 southwind storm, workhorse custom chassis with 7.4l vortec
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Old 09-27-2022, 09:44 PM   #3
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Join Date: Aug 2020
Location: Ohio
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Sorry.. some members suggest adding carb cleaner to 5 gallon fuel can or sea foam and running that through too.. I just cleaned mine.. they are made to be cleaned in the field.. so they are easy to take apart and cleaned.. I don't suggest taking apart unless all else fails.. you can clean carb on engine and it works 80% of time.. I like adding carb cleaner to to fuel can best.. and I put little over suggested amount in 5 gallon can.. I like techtron fuel cleaner.. but you use what you feel is best.. last thing.. big THANK YOU TO ALL MEMBERS FOR YOUR HELP..
Good luck and keep us posted
2000 southwind storm, workhorse custom chassis with 7.4l vortec
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