Generator Problem

[AWF1945]

Generator wows! This trip out generator started acting up. Cranks and starts fine. When adding a load it starts to surge up and down! Called Cummins in Nashville they said bring it by and they’d troubleshoot. $162.00 later, couldn’t find anything ran perfect.. “of course”. Thought I’d give it one more load before I left the lot, boom did it again. They came out looked it over sure enough it’s now doing it!

The repair they said, it needs a new electronic board of some type. Price $1900.00 for the part. Gen has to be removed to get to it, cost out the door labor included 4K. But, they can’t find the part and said it could be a month or so before they can get it... not sure how they came to that conclusion in the parking lot without any type of test???

It’s a Onan 8kw 500 hours on it. Lost for words... drove it home started again, worked perfect with full load 2 airs running and water heater element frig and all the rest. Shut it down started it again, back to the surging up and down... any Ideas??

Thanks

[Magnatudes]

I had this happen to me many moons ago in my Country Coach. It was an Onan 8000 quiet diesel of 2003 vintage. My problem then was air in the fuel supply due to hairline cracks in the fuel lines. I swapped all my lines to dual wall marine grade and it solved the problem.
Engine hunting or surging can also be due to a restriction in the fuel supply or a governor maladjustment. Prime the fuel supply by holding the stop switch for about a minute to build up pressure in the fuel line and without starting the gen check for leaks in the supply and return lines. Also, if you haven't already, replace the fuel filter to make sure it is not creating a restriction. When the gen is under load it will require a higher fuel pressure and if there is a leak, air in the lines, or a clogged filter, the engine could produce the symptoms you are experiencing.

[AWF1945]

Originally Posted by Magnatudes

I had this happen to me many moons ago in my Country Coach. It was an Onan 8000 quiet diesel of 2003 vintage. My problem then was air in the fuel supply due to hairline cracks in the fuel lines. I swapped all my lines to dual wall marine grade and it solved the problem.
Engine hunting or surging can also be due to a restriction in the fuel supply or a governor maladjustment. Prime the fuel supply by holding the stop switch for about a minute to build up pressure in the fuel line and without starting the gen check for leaks in the supply and return lines. Also, if you haven't already, replace the fuel filter to make sure it is not creating a restriction. When the gen is under load it will require a higher fuel pressure and if there is a leak, air in the lines, or a clogged filter, the engine could produce the symptoms you are experiencing.

Thanks, I'm on it today. Hopefully I'll get it figured out.

[AWF1945]

No luck today either. New filters, fuel, air, plus oil and filter. Checked all wiring and harnesses I could get to. Same problem. Putting in a fuel pump tomorrow. Looking like I'll be installing an inverter controller unit. Aint cheap and hard to find right now.

[AWF1945]

End result for the 100s monitoring this post. Make sure you check your generator covers. Top, sides and so on. The 2015s and other models the generators are installed in front of the rear duals. During rain storms water will get sprayed into the area of the generator and rear slide motor. Make sure water is not making its way into the generator itself, especially above the converter control unit. Water intrusion can, and will destroy that component over time. As well as rear slide motor. An extended panel will certainly help keep the amount of water at bay. $4200.00 later I'm running again. I usually fix everything myself, but wasn't up to pulling the generator out. However, still like my coach.. just part of owning one. Pay attention!
-slim

[Jpheifer]

Originally Posted by AWF1945

End result for the 100s monitoring this post. Make sure you check your generator covers. Top, sides and so on. The 2015s and other models the generators are installed in front of the rear duals. During rain storms water will get sprayed into the area of the generator and rear slide motor. Make sure water is not making its way into the generator itself, especially above the converter control unit. Water intrusion can, and will destroy that component over time. As well as rear slide motor. An extended panel will certainly help keep the amount of water at bay. $4200.00 later I'm running again. I usually fix everything myself, but wasn't up to pulling the generator out. However, still like my coach.. just part of owning one. Pay attention!
-slim

Slim - great attitude seems like sometimes these things are like a rocket ship and we get to go from system to system over time to keep them going - I about lose my mind sometimes - the parts can be hard to find and identify and expensive - I LOVE my coach still too! ITS ALL PART OF THE HOBBY

[AWF1945]

Originally Posted by Jpheifer

Slim - great attitude seems like sometimes these things are like a rocket ship and we get to go from system to system over time to keep them going - I about lose my mind sometimes - the parts can be hard to find and identify and expensive - I LOVE my coach still too! ITS ALL PART OF THE HOBBY

Joe, sometimes I get frustrated and lash out over stuff that should have been installed or handled differently during the build. But, it don't matter what you own... and I've owned a bunch. None a perfect. It would be nice if all builders could get together on stuff that works, and stuff that don't. I've seen way less expensive units with thing that make since to me..lol. anyway, it's all good. Hope what I've shared helps others.

[Webefine]

Glad you got it fixed too bad it was so expensive! I’ll have to take a close look at mine. I know on mine the storage compartment on the passenger side in front of the rear wheels was cut out to accommodate the slide motor without any provisions made to stop water intrusion into the storage compartment. When driving in the rain that compartment would have water pouring into it.
It boggles my mind how companies have been building Motorhomes for so many years but still can’t provide dry storage compartments, seal roofs properly and may other things that we all find and repair, and hopefully find before it cost thousands of dollars.

[mookieblaylock]

Glad you got it fixed!

A few years back there was lengthy thread discussing the exposed rear slide motor in that area and how it was getting damaged/destroyed by the constant spray of water etc from the rear tires on that side...several users ended up having to replace that rear slide motor. As a result, many went in and installed DIY covers in that area using thin sheet metal, aluminum, cut-to-size mud flap rubber, etc, and I think Dynamax actually corrected this issue on the newer coaches after this was discovered. Long story, but my question is - having dealt with this issue with the generator, do you think that covering that area in an effort to protect the slide motor is sufficient to protect the generator as well?

[AWF1945]

Originally Posted by mookieblaylock

Glad you got it fixed!

A few years back there was lengthy thread discussing the exposed rear slide motor in that area and how it was getting damaged/destroyed by the constant spray of water etc from the rear tires on that side...several users ended up having to replace that rear slide motor. As a result, many went in and installed DIY covers in that area using thin sheet metal, aluminum, cut-to-size mud flap rubber, etc, and I think Dynamax actually corrected this issue on the newer coaches after this was discovered. Long story, but my question is - having dealt with this issue with the generator, do you think that covering that area in an effort to protect the slide motor is sufficient to protect the generator as well?

I'm hoping so. I'm repairing the top cover and painting it. The seam that was leaking was the forward section by breaker and starter button. Water was running down into the lip that slides under the black breaker/switch box directly onto inverter control unit. I was driving in a terrible rain storm the day it started acting up. So it all comes together now. I'm going to add medal tape the length of that section and seal it off. The generator itself is a 2014 so it is 7yrs old. Hopefully this won't happen again when I'm finished.

I don't store mine in a heated garage with wheel covers and fans blowing on it with rag and polish in hand lol. I use mine regardless of weather conditions. They're not supposed to be built for sunny days or fair weather. Water intrusion has been my biggest challenge with this coach. But it's all been fixed properly and doesn't leak in those areas anymore.

Word of the day VIGILANT! Be VIGILANT..

-slim