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Genset dying with no fault codes???

Yahoo Message Number: 73877
Over the last weekend while on a trip, my 8kw Onan HDKAK died numerous times but set no blink codes on the rocker switch nor left any error or fault indications on the Silverlief. The only thing I can think of that could do that would be a auto stop setting on the Zantrex RC7GS, but both start and stop are set to Manual Push(ON/OFF). I'm stumped, does anyone have any ideas as to what could cause this besides a short in a remote stop control wire?

Stuart Thornton, 05 Allure #31217

Re: Genset dying with no fault codes???

Reply #1 –
Yahoo Message Number: 73882
Sounds to me like you have bad fuel lines and air is being sucked in starving the genset. I've been there and done that and it always happens at the worst time. It seems to be a common problem for coaches

of that period. If that's the case, plan on replacing the fuel lines to the hydro-hot soon. Make sure both the feed and return lines are replaced.
TWI 2004 Intrigue 11731

Original Message:
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From: stuart3488 stuart.thornton1@... Date: Mon, 22 Aug 2011 17:25:43 -0000 To: Country-Coach-Owners@yahoogroups.com Subject: [Country-Coach-Owners] Genset dying with no fault codes???

Over the last weekend while on a trip, my 8kw Onan HDKAK died numerous times but set no blink codes

on the rocker switch nor left any error or fault indications on the Silverlief. The only thing I can think of that could do that would be a auto stop setting on the Zantrex RC7GS, but both start and stop are set to

Manual Push(ON/OFF). I'm stumped, does anyone have any ideas as to what could cause this besides a

short in a remote stop control wire?

Stuart Thornton, 05 Allure #31217

mail2web.com ? What can On Demand Business Solutions do for you? http://link.mail2web.com/Business/SharePoint

Re: Genset dying with no fault codes???

Reply #2 –
Yahoo Message Number: 73884
Fuel starvation generates a code 36. Have seen that before. As I said, no codes are generated.
I should note that the genset may only run a matter of minutes, several hours, and on one occasion this last weekend, it ran overnight driving the air conditioning. When it stops, it is sudden with nothing unusual taking place.
I disconected the remote control wiring harness this morning and let the generator run for a few hours. Did not fail but I can't go forever in the driveway with neighbors so unless someone knows what is going on, I my have to wait for our next trip, then run it with the remote cable unplugged and see if it ever fails. Then I at least know where to start looking.

Re: Genset dying with no fault codes???

Reply #3 –
Yahoo Message Number: 73886
Some generators have a water level sensor in the radiator. Check your radiator cap and see if you have any signs of leaking. Then when the unit is cold, remove the radiator cap and check the level. I am talking about the radiator not the overflow bottle.

Mikee

Re: Genset dying with no fault codes???

Reply #4 –
Yahoo Message Number: 73890
Just checked. Water level is right at the Max level Mike.
While I was looking around, I did fine some nesting debris above the generator up by the windshild wiper motor and linkage. Pack rats are a real problem in Arizona and I keep a box of D-Don poison under a tire which is always getting consumed. They got up in the engine of my car and chewed through two wires which control the stability system. I was throwing codes all over the place until I found that damage. I'm beginning to think a rat may have gotten into the remote control wiring circuitry somewhere. The generator stop circuit is ground enabled according to the schematic so a knawed wire intermitantly touching the frame would do the trick. While nothing is visible around the generator, the wiring to the Zantrex RC7GS remote runs 25 feet towards the back of the coach, and that's a lot of potential exposure.

If it is rat damage, what a bear it might be to find.

Re: Genset dying with no fault codes???

Reply #5 –
Yahoo Message Number: 73891
Mikee, I just reread your post and realize I did not accurately read what you said the first time. I went back out and took off the radiator cover plate and opened the rad cap itself. It is full to the top, and like I said, the overflow bottle is on the Max line.

Re: Genset dying with no fault codes???

Reply #6 –
Yahoo Message Number: 73892
Stuart, Remember, the pick up line for the generator is shorter then the pick up for the engine. Do you have sufficient fuel in your tank?

David

Re: Genset dying with no fault codes???

Reply #7 –
Yahoo Message Number: 73902
Fuel delivery has been eliminated David because no code was set. Thanks.
Stuart, 05 Allure 31217

Re: Genset dying with no fault codes???

Reply #8 –
Yahoo Message Number: 74115
Have same generator. Did the same thing. No codes. Bad fuel lines.

Rich 2002 Magna

Re: Genset dying with no fault codes???

Reply #9 –
Yahoo Message Number: 74121
That is really interesting. Bad fuel lines would interupt the flow of fuel. Fuel starvation, just like a plugged fuel filter should set code 36. I wonder how bad fuel lines could suddenly stop fuel delivery (even after hours of normal running) and not set a code. Do bad fuel line act differently on the systems that monitor fuel flow? Does anyone have a theory?

Re: Genset dying with no fault codes???

Reply #10 –
Yahoo Message Number: 74124
Interesting that it seems to run with the remote cable disconnected. I had a 7.5kw Onan in my previous coach that self started once and cleaning and using dielectric grease on the remote cable connector seemed to be the fix. At least that's what many posts on the forums suggested and I never had it start up by itself again.

Perhaps just cleaning these connections may help. pete

2000 40' Magna #5892
Pete
 2000 40'  Magna #5892  CAT C-10

Re: Genset dying with no fault codes???

Reply #11 –
Yahoo Message Number: 74128
I had an interesting genset problem in 2008 on my Allure 2007, but unlike yours, it did produce an error code.
Just because the generator runs without a signal cable connected, does not necessarly means that the problem is with some component connected to the signal cable, or the cable itself!!!!

Interesting summary and solution for my genset problem below.

Herb

Forum Moderator

-------------- Message 39566-----------------

I had a problem which stumped two Cummins shops and Country Coach.
CC called Lazy Days and got an answer to the problem. Here was my situation:

Generator would shut down with approx 25 to 35 amp load but would run with 0-25 amp or 35-65+ amps. Load test when conducted by Cummins showed no problems - ran 0 thru 65+ amps.

When it shuts down, does the start/stop switch over the door flash.
Mine was reporting an error of an AC short. I tested with load of water heater, microwave, clothes dryer, floor heat and/or A/Cs, and it would shut down in the 25 to 35 amp range.

Whenever Cummins tested, they disconnect the signal line to the generator. Hmmm, so we though it might be one of the control units (Silverleaf, EMS, Inverter, or even the manual switch failing) was shutting it down. Wrong...

Turned out to be a bad Inverter Control Board in the generator!!!! Cummins would not replace. CC told Cummins that CC would pay for a new board (based upon Lazy Days experience with three coaches of various brands). Cummins replaced the inverter control board in the generator. Problem solved. Works beautifully. Cummins paid!!!!!
So when it shuts down, check for error flashes on the gen start/stop switch. Try forcing other loads instead of two A/C to produce the equivalent loads to see if it fails. Try running without the start/stop/etc control cable connected -- manually start it at the generator, then applying your loads.

Herb

2007 Allure #31466
 

Re: Genset dying with no fault codes???

Reply #12 –
Yahoo Message Number: 74146
That is good information Herb. I was unsuccessful in getting it to die in the driveway, mostly becasue I couln't run it long enough due to not wanting to bother the neighbors. The cable is currently disconnected, cleaned and waiting to be put back. First though, on our next trip I will start it from the genset and apply my normal loads. Then we will see what happens.

Good to know about that board, just in case. Thanks.

Stuart Thornton, 05 Allure, 31217