Cummins Onan 5500 - Dutchmen Owners

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Old 03-24-2019, 04:06 PM   #1
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Cummins Onan 5500

Have had issues with my generator running for awhile and stopping. The codes thrown are inconsistent. Went online and most folks report fuel pump carburetor issues. Started off with fuel pump and filter but same issue persists. Next you canít rebuild carburetor so I bought one, nearly $300 and the unit still shuts down . I decide now to take it to Rocky Mountain Cummins in Reno and have them repair yikes. First thing tech said carburetor was over fueling...what??? He pulled plugs and number two cylinder plug was fouled by overfueling that what the tech said. Hmm now he adjusted valves, new plugs starts it runs about 15 minutes and shut down code indicate high temp condition in muffler. Now he shows me plate on intake manifold has popped rivet and leaking this surely the problem. At this point repairs have reached $800 and if he replaces intake it will be at least $1500. I paid $800 left Cummins with new carb in my hands, new plugs, adjusted valves but not a fixed generator.
Got home pulled intake manifold. Drilled out rivets used forma gasket and used small bolts to replace rivets looks good. Fire up generator runs 10 minutes shuts down sure glad I didnít spend $1500. Call it quits had an adult beverage and called it a day. Next decided to pull plugs amazing plug from cylinder two is wet.hmmm plug one is fine as before. Now what??? Went online any number of stories. Checked plug wire resistance it seemed good. Read somewhere that coil going bad could work for awhile but when heated up could short out ok. Now time to replace coil. Pulled 288lb generator out of the front compartment after disconnecting and unbolting. Had a table that was roughly the same height as the generator compartment and using pry bars and 2 x4ís got the generator on the table. Next I put another table next to the first table and slid generator to where I could perform my magic lol, coils are buried so I had to separate base from generator after disconnecting many plugs, exhaust etc etc. ahh finally the coils. Took about one minute to remove. Called Cummins they have them in stock. I decided to change both. Now a quick 160 mile round trip to buy 2 coil. Replaced reassembled carefully slid generator by use of tables to reinstall. Finished on Friday but didnít have oil to replace and Saturday had to go to a desert race for my grandson. Great day he won his division after 46 cold rainy and windy miles. Picked up oil on my way home. Sunday morning having coffee looking forward to Indy car races but soon I am headed to oil up and fire up. I am anxious to say the least but in an hour or so,for anyone who should want to know if the damn things stays running Iíll let you know soon
Bill
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Old 03-24-2019, 06:41 PM   #2
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Well? LOL. Hope it worked!
Rusty
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Old 03-24-2019, 07:23 PM   #3
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Well here it goes purring like a kitten. My unit is a 2014 I did find one very obscure post indicating Cummins had a batch of bad coils. Changed both

Yippee on with the day
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Old 03-24-2019, 07:41 PM   #4
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Congrats Bill, you done good and saved $1500 from another incompetent knucklehead mechanic. Wonder why I work on all my stuff myself too. Glad you got it fixed this is for you.
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Old 03-24-2019, 11:45 PM   #5
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Good 4 you,, it was like watching a good movie and at the end lights go out ugh. Couldn't wait to see what you found
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Old 03-25-2019, 12:15 AM   #6
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Quote:
Originally Posted by Wbgran View Post
Well here it goes purring like a kitten. My unit is a 2014 I did find one very obscure post indicating Cummins had a batch of bad coils. Changed both

Yippee on with the day


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Old 03-25-2019, 12:37 AM   #7
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Haha too funny
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Old 03-25-2019, 10:16 AM   #8
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WooHoo!
Rusty
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Old 03-26-2019, 12:28 AM   #9
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Thanks guys!!! Life can be funny
Bill
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Old 03-28-2019, 03:33 AM   #10
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Generator coils

Hey Bill I have a 2013 and after 1500 hours my Onan did the same thing. Took it to Pacific Power that works on generators and they were able to pin point the problem and they replaced both coils and the belt and tensioner and did all the labor for about $1200. They also replaced the choke on the carberator. We have ran it about 125 hours since and itís nice to be able to know itís going to run. Glad you were able to get it fixed. Steve
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