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Old 06-20-2018, 08:45 PM   #1
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Generator fuel pump

We have a
2016 2861 Forester Our generator has 208 hours During one of our day trips while utilizing the generator After about an hour of the generator turned off It was not because the fuel It was probably because of the high temperature The outside temperature is about 90 degrees and we are running the air conditioner . The next day I started the generator It ran for approximately 15 minutes and then shut off . I restarted the generator it ran Approximately one minute And then shut off .The oil is 15 W 40 And it is not over filled Or low on oil When I started the generator from the outside switch I can hear the fuel pump clicking Or making a clicking sound Not sure if that's a good thing. I'll try it again tomorrow to Start the generator And let it run
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Old 06-21-2018, 10:44 AM   #2
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We had the same problem with keeping the generator running. Replacing the fuel pump solved the problem. There are several threads about this problem caused by a bad batch of fuel pumps.
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Old 06-21-2018, 06:26 PM   #3
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Generator fuel pump

Went out this morning and started the generator It started right up Ran for approximately 2 minutes And then shut down . I could hear the fuel pump making a clicking noise Before it started And again I started it and ran for another minute shut down again .Call the Cummings dealer to make an appointment in Nashville Tennessee And will see what they say I'll keep you updated
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Old 06-23-2018, 01:52 AM   #4
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Quote:
Originally Posted by daywalker567 View Post
Went out this morning and started the generator It started right up Ran for approximately 2 minutes And then shut down . I could hear the fuel pump making a clicking noise Before it started And again I started it and ran for another minute shut down again .Call the Cummings dealer to make an appointment in Nashville Tennessee And will see what they say I'll keep you updated
The clicking is normal when starting. The fuel pump is priming.
When you say it's not the gas I'm assuming you mean you have more than 1/4 tank of gasoline. 90 degrees ambient temperature shouldn't make it shut down unless the air flow is somehow restricted. Also check air filter. There are several safety interlocks that will also shut it down.
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Old 06-23-2018, 04:10 AM   #5
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Quote:
Originally Posted by daywalker567 View Post
Went out this morning and started the generator It started right up Ran for approximately 2 minutes And then shut down . I could hear the fuel pump making a clicking noise Before it started And again I started it and ran for another minute shut down again .Call the Cummings dealer to make an appointment in Nashville Tennessee And will see what they say I'll keep you updated
Do you have water separators in the gas line? How long has it been sitting? Do you use non-ethanol fuel? If not to you some sort of fuel treatment while in storage?
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Old 06-23-2018, 08:20 AM   #6
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Generator update

Brought the motorhome to onan generator service in Nashville Tennessee They gave me a quote to fix the generator of $568 They said the issue was the fuel pump That the old ring inside the fuel pump it started to deteriorate or actually meltdown Here is the breakdown of the charges Diagnostic $172 Fuel pump $63 Filter $12 Labor $232 Miscellaneous $48 Text $33 for a total Actually was $563 Not 568 I couldn't believe the cost of the diagnostic test which only took the technician A few seconds that died not to diagnose In my generator was out of the 2 year warranty only by 3 weeks I was not happy
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Old 06-23-2018, 12:51 PM   #7
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you might try to go back to them to waive the diagnose charge. their warranty is 2 years for everything and 3 years for major components. they'll probably say the fuel pump is not a major component (but it won't work without it). but they would have to do the diagnosis first without knowing if it was a major component or not. we had a problem out of the two year but still in the three year period. turned out to be a major component and we were not charged for the diagnosis or repair. you're still looking a pretty good amount to replace their $63 pump. if it is out of warranty and you now know what the problem is. you might get a quote from an independent service tech. there are even mobile guys who can do that type of repair.
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Old 06-23-2018, 03:54 PM   #8
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Are you running the coach engine and the genset at the same time when not in motion? If so, that could cause the fuel pump to overheat. Error code 36 will be displayed if that is the case.
This little guy is easy to replace. Its on the left side behind the circuit board.
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Old 06-23-2018, 03:58 PM   #9
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Replacing an overheated pump will fix the problem but will not necessarily fix the causal factor. Here is one thing that can help...
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Old 06-23-2018, 04:01 PM   #10
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Allowing the genset to intake only outside ambient air will help reduce the over temp problem but you will need a thermocouple to run a diagnostic to determine if operating temps are within specs. That looks like this...
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Old 06-23-2018, 04:05 PM   #11
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If after getting the numbers and redirecting the intake to a cooler source you still burn up fuel pumps, the next step is to shield (build a bottomless box around the genset ) so it cannot ingest the very hot air coming from your coach engine.
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Old 06-24-2018, 01:40 AM   #12
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Quote:
Originally Posted by daywalker567 View Post
Brought the motorhome to onan generator service in Nashville Tennessee They gave me a quote to fix the generator of $568 They said the issue was the fuel pump That the old ring inside the fuel pump it started to deteriorate or actually meltdown Here is the breakdown of the charges Diagnostic $172 Fuel pump $63 Filter $12 Labor $232 Miscellaneous $48 Text $33 for a total Actually was $563 Not 568 I couldn't believe the cost of the diagnostic test which only took the technician A few seconds that died not to diagnose In my generator was out of the 2 year warranty only by 3 weeks I was not happy
I had the same issue with gasoline powered lawn equipment. Gasoline containing ethanol was to blame. Since I switched to marine gasoline I've had no more rubber disintegration issues.
Since I can't/won't run marine gasoline in my motorhome I always add SeaFoam when I fill up at the end of every trip. That along with monthly exercising will hopefully extend the life of my generator.
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Old 06-24-2018, 09:05 AM   #13
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Riddle me this Batman. How do you know that an o-ring inside the fuel pump has started to “deteriorate or actually meltdown” when the fuel pump is a non-serviceable sealed unit? (look at the photo) I’m thinking Ferdinand has made a guest appearance in Nashville.
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Old 06-24-2018, 09:52 AM   #14
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daywalker, I am having a hard time accepting the fuel pump diagnosis on a unit that young. I also thought I had a pump problem recently due to shutting down after a couple of minutes, would restart, then shut down after a few minutes. Remembering what I had read on here about the Onan mis-leading dipstick marks, I turkey bastered the level down to just 1/4" above the add line. 50 trouble free hours since then. Just sayin', this dipstick marking "interpretation" is different than any other I have experienced and can really lead to a lot of money being spent.
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Old 06-24-2018, 04:34 PM   #15
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Generator update

After our generator was repaired I still had problems about the $172 diagnostic charge I went to the service manager Explain to him how was just out of warranty a little over 2 weeks He put in for a policy exception to the warranty And within the hour The whole bill was paid for by onan. Now after watching many YouTube videos on changing a fuel filter And fuel pump I think I will do that myself if the same case happens again Seems pretty straightforward .I wanna thank everybody for their posts Their tips And suggestions This forum is great I didn't work
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Old 06-25-2018, 12:40 PM   #16
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Glad to hear it!
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Old 07-05-2018, 10:49 AM   #17
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Generator Fuel Pump

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Originally Posted by Gidyupgo View Post
daywalker, I am having a hard time accepting the fuel pump diagnosis on a unit that young. ... I turkey bastered the level down to just 1/4" above the add line. 50 trouble free hours since then....
apologies daywalker ....pardon me while I chew on some crow.... My gen trouble came back while down in Fla. and the oil level was not the problem. After checking it out further and scouring the forums, I have the pump, filter and extra fuel line coming to replace and move the pump outside of the enclosure. Using the Airtex E8251, its companion filter and adding a valve too, to make it easier to add the gas treatment. Will change out the pump this weekend and see how it does.

I ran across an interesting post where a fellow had a friend that was an "ex" ONAN tech, who told him that they know heat is a problem but there has to be a fuel pump and their market requires gensets to be an "off the shelf" install in food trucks, tool trucks, RV's, Horse Trailers, boats...etc.

Also found more support for Duckogram' s mod to improve airflow. Want to add fan to generator bay - Page 2 - iRV2 Forums
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Old 07-06-2018, 06:16 PM   #18
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Had today off, so got 'er done!
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Old 07-06-2018, 06:25 PM   #19
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If you are looking to improve air flow check out the thread Here. It may be in the FR3 forum but it is the same issue...
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Old 07-06-2018, 06:28 PM   #20
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Thanks
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