Onan Generator Rescue

[redbaron]

Ever heard the saying “When you hear hoofbeats, think horses not zebras”?

Well this is my story.

Getting ready for a trip, I had a lot of things to do for work, the stick and brick, and the coach. I had the best of plans. Murphy first appeared a week ago when I started to do my annual PMs on the generator. Just as I was getting ready to head to the shop, my daughter calls with a crisis for her jeep. Spent the day doing full brakes, rotors, fluid, diffs, etc. 8 hrs in the Texas heat on Father’s Day wasn’t my plan, but I was able to get her back in the road safely.
Delayed the generator until yesterday ( Friday)

I started at 6am as the weather was ideal. Drained oil, did the fuel filter, air filter, and soot canister. It was about 6:40 when I checked the overflow and found it bone dry. This is when I heard distant hoofbeats.

I removed the plastic canister and verified no crack or evidence of leaking.

I then noticed some fluid gathering at the bottom of the generator. I check the hose for the radiator cap, overflow and going into the radiator. No evidence of leaks, but the radiator appears dirty.

Hoofbeats now clearly heard, and I am sure it’s zebras.

It’s now approaching 7:00am and I decide that I need to pull the radiator. I don’t have a pressure test kit, autozone doesn’t open for another hour and I may as well get it out and inspect it.

As I go to remove the 8 bolts to the access cover for radiator, I realize only 6 are accessible. 2 are behind the frame.

Without much thought I make the decision to just remove the generator and do the service. A quick review tells me I am taking the front end cap off, disconnecting a handful of wires, a few bolts and then sliding the generator forward about 6 inches for access.

As I am walking back to the equipment shop to get the tractor and pallet forks I start asking myself about my experience, time, and desire to undertake this job. I then ask what alternatives are there?

I get the equipment connected and drive up to the RV garage, where my wife meets me with my morning cup of coffee and a question about what I am doing. As I explain the process she asks me can someone else do this? As I start to answer her, I realize that there is only one place that I would even consider, and they are also the only place that might be able to do this kind of work so quickly.

I sent a text to Eddie Braley and explained that I had a coolant leak on the generator. He responded within 2 minutes saying bring it up.
2 hours later, 10am, I arrived at Lewisville and Eddie met me in the lobby with Shannon and James and said they would take it from there.

Later that day Eddie explained to me that they found a leaking fuel filter (the one I had just installed), about 1/4 turn loose. I am positive last year I used the same level of tightening, so that explains the mess under there, I was not installing it tight enough and caused the gunk buildup.

He also explained that the radiator was full, it was just the overflow empty. He didn’t tell me how silly I was to think about zebras, but should have.

Instead he told me that it was most likely an air pocket that finally settled and took the fluid. Makes sense as the prior year flush only had about 40 hrs of use along with the exercise.

After fixing my fuel filter leak, and as a precaution, Shannon did an extended pressure test on the radiator, then ran it under load just to ensure it was ready.

So once again NIRVC has saved my trip, provided excellent care, and performed the perceived impossible task of same day turn around.

I remain ever thankful for Brett, Eddie, Shannon, and the rest of the NIRVC team.

 

[Richpatty]

Love the story…. I have been there too…thinking the worst.