Generator

[Wehren]

I have a 1999 7500 quiet diesel Onan generator. Just found out that all the magnets fell out breaking the fan and other things unknown so far. Has anyone else had this problem? What more can I expect? Its going to the shop next week to be repaired. Right now the estimate to fix it is over $2,000. Of course, its all my nickel. Jim

[busyguy]

Mine blew in Dec 2006. We were in Huntsville Tx at the time. Was lucky and found a repair place about 2 miles from where we were at. Called and said they weren't busy and to bring it in. We drove over and they inspected the generator and decided it had blew the magnets.
They tore the unit down and my wife and I went to the Onan dealer in Houston and picked up a new stator and rotor. By the time we got back they were ready to put it back together. Took almost 10 hours for the repairs as they had to drop it from the coach.Not on a slide. Anyway about 9 that night it was running great and the total bill for labor and all the parts was $2,600. Been running great every since.
Yes Onan new about the bad glue they used but, no help of any kind.
Good luck

[FIRE_UP]

Jim,
Onan knew of this problem a while ago. I don't know if there was ever any recall or any notice of any kind sent out but, for some, it happened while still under warranty. For me, on our '04 Itasca Horizon 36GD with the C-7 330 CAT and 7.5QD diesel gen, it lost one magnet and some minor damage to the stator. In the pictures below you'll see what it looks like when it decides to grenade. I had other issues for which was the reason I tore mine down for repair.

I got real lucky because at the time of tear down, I found an 8,000 watt rotor, in perfect condition on ebay for way less than half the price of a new one. When one or more of those magnets decides to go into outer space via centrifugal force, it's not a pretty picture. It looks like the insides of your generator grew "Hair" (as in little fuzzy dark gray stuff stuck to everything that's metallic inside that case. I'd say that the preliminary estimate is fairly close. It quite possibly will go up as they get in there and find more damage. You'll just have to wait and see. Sorry for your issues, while this is not an every day thing with the 7.5, it's happened to many. I've coached a few who wanted to do the tear down themselves. Good luck.
Scott