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 8/12/2010 5:29 PM
 

Onan 7.5 KW Diesel Generator. Problem started a month ago in VA when it was very hot. Was running both ACs for several hours. Then the geny quit. I shut everything off and restarted the genny. It ran the first AC OK but when I turned the second one on it quit. The code read 22 translates into overload. So we used only one AC at a time and it was OK. On a recent trip I tried to run one AC but got the overload code again. Now it starts, runs in normal start-up speed for a few seconds and then dies. Won't run long enough to put a load on it.

Fuel level OK

Any ideas except paying an $80/hr service fee?

Bob K from PA


Bob and Gwen K from PA '99 Endeavor 37WDS4 2009 Ford Tarus or boat Four cats
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 8/12/2010 5:53 PM
 

Off the wall, and not overlaod but I can not get to my book right now, try checking the coolant, the cap under the switch plate not the one you see on the out side that is only for the coolant recovery. It sounds just like mine did the first time I changed the coolant and did not know about the cap under the switch. It may be just low collant and gets worse each run


2000 Discovery 2009 Malibu
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 8/12/2010 7:08 PM
 

Bob - Here's what Onan has to say about fault code 22....

GOVERNOR ACTUATOR OVERLOAD FAULT—CODE NO. 22

(Duration of operation at or near full-duty cycle beyond design limit)

You might also find THIS thread interesting. Good luck. - Dave

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 8/13/2010 10:45 AM
 
 Modified By johnchurn  on 8/13/2010 6:58:00 PM

Bob,

This is from our experience but as we all know these units can have their own pecularities.

We have a Power Tec 7000 driven via a Kubota Diesel. We have 50 amp service on a Dutch Star.

Only after about 8 years of service did I encounter this problem.

We were stopped at a Walmart for the night, it was 4:30 in the after noon 102 degrees in Columbia,SC. Both airs were running for about an hour and the generator just shut down. We don't have codes for this model so you are on your own to trouble shoot.

My first thought was maybe I was low on oil, so I checked it. They all have low oil sensors. Down maybe a 1/2 quart, so I topped it off. Started right up and ran for about 1/2 hour. Shut down again.

Still very hot, we went to eat some dinner. When we came back started up again no problem. This time it was cooling off so we only ran 1 AC. Ran all night no problem.

About a year late we were at the same location at the same time frame and the problem showed it self again, running two airs in extreamly hot weather. Shut down. So from experience I let it cool down and went to one AC. Again no problem all night long.

I talked to power Tec this time to get some answers. Come to find out, 7000 watts it on the edge of the curve for running two AC;s. It has a heat/overload sensor for the generator and in extreame heat two AC's will activate this sensor.

Now we know what the problem is, we run 2 airs to cool it down for 15 to 20 minutes and switch to one air for the evening and have no problems.

Later on Newmar went to 7500 watts on their units of our size. Probably for this reason.

Sounds like with 2 airs running you may be pushing your overload limit also.

BBJ


Big Bad John & Runaround Sue & Paris *Hammock,Florida* *97 Dutch Star Diesel* *76 VW Bay Window Bus* *91 Classic Harley Davidson* *1949 Ford Lead Sled* *2012 HD LSV
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 8/13/2010 11:48 AM
 
Dave and John, Thanks for the replies. I checked the radiator and oil and they are full. It may have started out as as running against the limit of the generator but has progressed to where it will start, run 30 to 45 seconds then shut down. It indicates there is a code but nothing shows when the button is pushed. It has an on off seitch on the genny. I shut it off, thinking this would diable all loads and it acts the same. I haven't checked the air filter but it doesn't act like it is flooded or has too much fuel. It just shuts down like a gas engine would when the plug is shorted. Afraid I'm going to have to go for service. Bob K from PA

Bob and Gwen K from PA '99 Endeavor 37WDS4 2009 Ford Tarus or boat Four cats
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 8/13/2010 12:26 PM
 
 Modified By RVA  on 8/13/2010 11:44:59 AM

Bob - I know your unit is a diesel, but you might also check out the solutions shown in the Onan gas genset manual regarding fault code 22. Hopefully, it will be as simple as a dirty air cleaner or obstructed exhaust. Good luck. - Dave

GOVERNOR ACTUATOR OVERLOAD FAULT—CODE NO. 22

(Duration of operation at or near full-duty cycle beyond design limit)

Corrective Action:

1. Reduce the number of connected appliances, especially when air conditioners and battery chargers are running.

2. Service the air cleaner (Page 19).

3. Check for and repair a blocked exhaust system.

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 8/13/2010 5:52 PM
 
 Modified By RJKossman  on 8/13/2010 4:54:24 PM

Dave,

I checked the exhaust and it is clear. I had the air cleaner out and it is not plugged, however, I ordered a new one from NAPA ( $7 instead of $19 from Onan). It will be here in the morning.

The motor will start and run for 30 seconds and shut down. I still get the 3 code indicating it needs service but the secondary code does not come up when the stop button is pressed so I no longer have the 22 code. There is no load on it because it always ran for a few minutes before it connected to the coach

I ordered a service manual from ebay so maybe that will give me some insight. My son is an electronics tech but won't touch it without the schematics. Don't really blame him because as he says, "Dad, we can really screw it up if we don't know what we are doing."

This new generation doesn't fly by the seat of their pants like we always did. I admit, if is new enough to have fuel injection it has me baffled.

Bob K from PA


Bob and Gwen K from PA '99 Endeavor 37WDS4 2009 Ford Tarus or boat Four cats
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 8/13/2010 7:11 PM
 

Bob - While it sounds like the problem is more with the engine than the "generator" portion of the genset, there is another possibility. Some Onan gensets have a sensor that shuts them down if no electricity is being produced, and yours may be one of them. You might have your son check to see if ANY voltage is being produced in that first 30 seconds, before it shuts down. He can do this by taking a reading at the generator side of the breakers. Good luck. - Dave

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 8/14/2010 10:11 AM
 

Bob,

It appears as you say. Probably started off as an marginal overload and has progressed in to a hard fault of some type. It sounds as if you may have a sensor problem. Probably going to be hard to find on your own, without the proper equipment.

The biggest pain is taking the unit in and waiting on it.

Good Luck


Big Bad John & Runaround Sue & Paris *Hammock,Florida* *97 Dutch Star Diesel* *76 VW Bay Window Bus* *91 Classic Harley Davidson* *1949 Ford Lead Sled* *2012 HD LSV
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 9/3/2010 11:46 PM
 

John, the biggest pain is the $98 per hour the local Onan shop charges.

We (my son and I) removed the grill and slid the genny far enough forward to get the top cover off. I'll tell you, there isn't much room to work. As my son said, "In a thing 38 feet long, why can't they give us an extra 3/4" to move a wrench?"

When we got the top cover off we discovered magnet chunks, shards and dust everywhere. The rotor just plain blew up! I removed the front cover, controller/inverter, blower, stator and rotor. The stator and blower are showing considerable damage and the rotor is missing three segments. I'm going to pull the genny out so I can do a good inspection and cleaning, I concocted a cart affair that will handle the 450 lb generator and have everything ready to remove it from the coach. Probably get it out tomorrow.

Will keep you posted.

Bob K from PA


Bob and Gwen K from PA '99 Endeavor 37WDS4 2009 Ford Tarus or boat Four cats
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