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Onan genset update

Yahoo Message Number: 71264
Problem . . .

"Genset in '06 Inspire will not stay running. Fault code 33 . . .
overheating(!). Gen will run for about 1 minute stone cold. Starts to pick up the load then shuts down. Still have overheating fault code, makes no sense. Fluids fine, even shut off all major circuit breakers to prevent a high load. Will run with 1 amp load, then as soon as a load starts (mystery since all the breakers are off . . .) gets to about 10 amps and shuts down.
So next I isolated the genset by turning off the gen power at the unit.
Still shuts down. 128 hours total on the genset, serviced at about 122 six months ago. Sensor issue?
I'm stumped. Of course this happens on a Saturday afternoon . . . any ideas?

Lon"

Solution . . . $1000

Onan dealer claims dropping gen was necessary, tried to replace sensor in the head and it broke, had to remove exhaust and radiator to get to it. CSP (Good Sam) covered 40% as a good will since they say they did not have time to inspect the work or problem. Not sure I feel good about this on either end. Writing a letter to CSP and copy to Good Sam as we speak. Mine you I am in the middle of nowhere, 120 miles out of Phoenix and they want to inspect it? I think not . . .

Re: Onan genset update

Reply #1 –
Yahoo Message Number: 71273
Lon,

My Inspire is an '05 and I'm sure has the same generator set up as yours...small access panel on fromt of coach and only other choice is from underneath. I've had some intermittent shutdowns with "overheat" fault code as well. I've been reading with interest some of the posts about possible solutions...fan belt, temp sensor, etc. I'm curious if the Onan dealer had to drop the generator to change these parts or just because the sensor broke and then required better access to replace?

I appreciate your input.
Tom

'05 Inspire #51334

Re: Onan genset update

Reply #2 –
Yahoo Message Number: 71275
Hi I had the same overheating problem last summer and solved it by having the fan belt replaced. It was not easy to access (took service tech 4-5 hours) but it has worked perfectly ever since. I had Bob's Generator (he worked for Onan for 26 years) do the work and he is mobile (888)426-2743 in Junction City, OR for the summer and Quartzite, AZ in the winter. My generator is a 12.5KW if that makes any difference. He did not have to remove the generator from the coach. Good luck and happy travelin' Paul

'01 Affinity 40', #5951

Re: Onan genset update

Reply #3 –
Yahoo Message Number: 71276
On our 06 inspire they had to drop the gen set. They used wheel jacks to lift the coach and slid the gen out.
Lot of work to save $500 on cost of the coach. The Howards needed the money though.

Jw

06 inspire 51544

Re: Onan genset update

Reply #4 –
Yahoo Message Number: 71293
These folks did not use jacks, which I was just as happy with since they don't know where to put them. Had more cars floor pans ruinied by careless mechs than I care to count, no telling what kind of damage they could do on a coach. They drove it up on railroad ties and said that was the easiest for them. Dropped the genset and hauled it out with a forklift. Why CC buried the genset is truly a mystery and in my humble opion, one of their worst engineering mistakes.
The Onan dealer stated few options other than dropping the genset for analysis. Labor on that alone was almost $400. I understand belt changes can be done with a great deal of effort in place. Certainly not much more other than general service. While they had it out they looked over everything, replaced radiator fluids and ran a load test for 30 minutes before returning it to the nest.

Still a lot of money and effort for a cheap sensor . . .

Re: Onan genset update

Reply #5 –
Yahoo Message Number: 77744
Not sure if I should start another thread or update this one but will try this. We read that the recommended belt change is about 1000 hours. We talked to Cummins and they recommended that if we decided to change the belt we should also change the thermoast and the temperature sending unit at the same time. So we made an appt at Cummins/Coach Care in Tulsa OK. It is true that they must drop the generator to properly do this service. Our genset had about 1100 hours on it. Cummins in Tulsa did a great job. They had to remove a piece of angle iron to remove the genset. When they replaced the angle iron they made brackets and bolted it back in place (no welding!) which was a recommendation from another CC owner. The belt was cracked and wouldn't have lasted much longer, and the bulb of the temperature sending unit was corroded. The tech at Cummins said that the type of anti freeze (green) could cause the corrosion. He replaced the anti freeze with ES Complete. He said that the corrosion on the seending unit will cause it to send false codes. Hope this helps someone else.
If you need any more info, feel free to email SDLIVINGSTON48@... Lonny & Diane
'04 Allure 33'
#31065
 

Re: Onan genset update

Reply #6 –
Yahoo Message Number: 77757
Probebly to late to post but dropping the genset from a coach in my other life working for Cat did this to help out the truck shop. I would of gotten the service Man. for your engine like ours is a Power Tech with a Kubota 3 cyl. diesel engine and with those hours look up the mtn. sched. I know at least removing the Valve cover and do a Intake/Ehhaust valve Insp. Adj. would be done. I would always call the cust. and suggest this as they only wanted to pay for repair. You have allready spent the big dollars to have it dropped. Sharing my Expertise. Ken in Yuma Az. 99 Allure 30356