Do other diesel generators require constant repairs and parts like my Powertech generator? Since 2010 I don't think I have made a single trip without a generator problem. I was practically buying brush assemblies by the case for a time I had so many issues with brushes. I don't understand how a generator with 1250 hours is broken all the time. I had to work on the brushes at least a dozen different times.
I have spent about $1 per hour on replacing parts. On my last trip an idler pulley seized up. It cost me $700 to order parts. $400 for the idler pulley plus $300 for new motor mounts. I asked Powertech why the fan hub part of the idler pulley assembly was hitting the shroud and they said the motor mounts need replacement too.
I have had so many problems I always bring a backup generator now. I just bought a used Yamaha 4500 watt inverter generator for this purpose. I strongly considered buying a new diesel generator, but the new ones with enclosure are longer due to the brushless generator head and won't fit.
I will probably put a hex on mine by saying this,but I wish every thing on my 94 Prevost CC was as dependable as the Powertech generator .To be honest ,I really don't know how they last any time at all given the fact that they provide such poor ventilation .Mine is in a sealed compartment with a 14x14 dust filter feeding the genset from underneath the bus.
The generator is a 2010 model? What kw? If it is actually a lot older, the mounts may have deteoriated. Is the shroud not adjustable?How heavy do you load it? Have you talked to the guy that sells a lot of them about your issues? I don't remember his name, but it's mentioned frequently. In the several years I've been on the forum, I don't recall many issues. Many, many more issues with Webasto furnaces. I recall people prefer the models with brushless generator section. I recall Cliff and some others mentioning that.
Quote from: chessie4905 on April 25, 2018, 04:37:43 PM
The generator is a 2010 model? What kw? If it is actually a lot older, the mounts may have deteoriated. Is the shroud not adjustable?How heavy do you load it? Have you talked to the guy that sells a lot of them about your issues? I don't remember his name, but it's mentioned frequently. In the several years I've been on the forum, I don't recall many issues. Many, many more issues with Webasto furnaces. I recall people prefer the models with brushless generator section. I recall Cliff and some others mentioning that.
No, it is a 2006 8KW model, but it started having trouble in 2010. I was having problems with the generator not always producing enough voltage in 2010 and I had to replace the voltage regulator in 2011. My brush problems started in 2011 or 2012. At first they were stuck and not making contact. We were able to pull them out and get them to make contact again. I ordered several sets of brush assemblies when I got home. The brush problem was really bad in 2013. I had to repair the brushes three or four times on a July trip and I spent about 8 hours fixing the brushes on my September trip. We bought a package of small terminals at Menards and that whole package got used up and had to buy another package. One of the brush assemblies the spade terminal broke from working on it so much! Finally, in 2014 I spent over $700 on a slide assembly from Powertech to make it easier to work on the brushes. I double checked the brushes in 2014 and no further brush issues since then. No issues I recall in 2015 or 2016, but in 2017 the idler pulley for the radiator fan failed causing the belt to shred. Luckily, it failed in a way that the blower fan was still spinning due to the goofy design Powertech uses for the belts.
Jeff at Powertech said it is normal at 1,250 hours to need to replace the motor mounts. The mounts were probably really needed before 1,000 hours. It is crazy to me that I have to spend $300 on motor mounts every 750 to 1000 hours. That would be like having to replace the motor mounts in your bus every 45,000 to 60,000 miles.
I am almost on a first name basis with the technical support guy at Powertech due to all my issues. The shroud is not adjustable up and down per him and I see no adjustment either. He is almost certain the rubber motor mounts are bad.
I can't picture how the mounts are made, but could you use big body washers to shim them back up to original height? Or grind a little metal from shroud for more fan clearance? At 8 kw, do you usually draw close to maximum from it, say running the roof airs?
Regarding the brush issue, are you sure the brushes you used to replace the worn/ bad ones were correct? I looked online for Powertech issues on various forums. Found problems but none about mounts or brushes.
The 8kw PT generator does seem to give problems I have had to to replace oil sensors,bearing and brushes on quite a few over the last 10 years ,is your a Cat or Kubota powered ?,seems like the mounts PT used on the Cat engines don't last very long
Mine is the Cat version. It isn't the PT, but rather the 8CSI. It is probably similar, but I have the sound enclosure. I believe I need an oil sensor too as occasionally the oil pressure is coming up on start, but the generates shuts down with a low oil pressure alert. As far as Bob's idea about shimming the motor mounts I already ordered the new mounts. I asked Jeff at Powertech about trimming the metal and he said I could, but I would probably end up hitting again if I didn't replace the mounts.
I am almost certain the replacement brushes are correct. They sure look the same. The first set of brushes got stuck and we got them moving again, but eventually they cracked from going in and out several times. The second set of brushes the spade terminal eventually broke off from going in and out several times. The wire to the brush assembly broke several times and a new spade terminal had to be installed. The third set has been in there for a few years now and I am pretty sure I have a spare set yet.
I need 8KW for three roof airs and everything else. Occasionally, the voltage will drop low enough with three roof airs going that the roof airs will stall. If I turn one off the voltage comes back up and the other two start back up. I know it isn't good for the roof airs. Jeff at Powertech says I probably need another new regulator, but I haven't shelled out another $200 as I am not convinced. I usually just don't run all three to get around the problem.
Maybe 8 Kw is not quite enough for what you are running, 12 Kw would be more appropriate. Higher altitudes would reduce your power a bit, and put you in a bind if you did not have reserve capacity. The air intake location is also critical for cooling. Sometimes everything works well while parked, but when on the road if the air intake is in a low pressure area, cooling will suffer and might lead to engine shut-down from overheating.
Just a heads up. I've been very pleased with my Yamaha inverter generator in general but if I don't run it about once a month the carb soon cruds up and the thing runs poorly. Using fuel stabilizer helps some but there is still some wicking in the jets that leaves a deposit behind to eventually make the genny run way too lean and makes it hard to start particularly at higher (5ooo') elevations. --I'm talking about a gas genny of course. Jack
Quote from: oltrunt on April 25, 2018, 08:56:16 PM
Just a heads up. I've been very pleased with my Yamaha inverter generator in general but if I don't run it about once a month the carb soon cruds up and the thing runs poorly. Using fuel stabilizer helps some but there is still some wicking in the jets that leaves a deposit behind to eventually make the genny run way too lean and makes it hard to start particularly at higher (5ooo') elevations. --I'm talking about a gas genny of course. Jack
Try shutting the fuel off and let the carb run dry.
Quote from: DoubleEagle on April 25, 2018, 07:51:51 PM
Maybe 8 Kw is not quite enough for what you are running, 12 Kw would be more appropriate. Higher altitudes would reduce your power a bit, and put you in a bind if you did not have reserve capacity. The air intake location is also critical for cooling. Sometimes everything works well while parked, but when on the road if the air intake is in a low pressure area, cooling will suffer and might lead to engine shut-down from overheating.
The generator cools just fine parked or cruising down the road. Overheating is a problem I have never had. The radiator was actually quite plugged with debris and still cooling fine.
I likely would have gone to 10 KW knowing what I know now. I only planned on two roof airs when I bought the generator, but I had to add a third roof air to cool the front adequately.
On gas units run corn free gas.
belfert, cut your losses, get this one functional and sell it, start again with a bigger one?
Once you get a hate on for a piece of critical equipment, it ruins the entire busnut experience?
X2 - same for my little Yamaha.
Close off the fuel to turn it off, and with religious fervour, fuel stabilizer properly rationed into every drop of gasoline.
Every small gasoline engine I have gets the same. Put fuel conditioner into the empty jerry cans before heading for the gas pumps, job done.
My small engine mechanic hates that he told me this trick...
Happy coaching!
Buswarrior
I have a truck driver friend that had a 8kw on his truck. When the brush type alternator failed, he replaced it with a brushless from Powertech. When he sold his truck, it had over 23,000 hours on it with only minor maintenance on it.
Mine is a 10,000 watt Powertech with a large brushless Marathon alternator on it. I have about 2,100 hours on it have done only oil changes on it. Course it is a 1993 model with minimal electronics and mostly relays. I would suggest you change the alternator to brushless. Good Luck, TomC
I would also consider on selling it and moving up to a 10 or 12 kw brushless model. I don't think many of them like working near max capacity in very hot weather unless cooling is optimal. Sorta like the engine.
My 10kw Powertech generator uses a Kubota. It has been relatively trouble-free. I did have to replace the fan belt and that proved to be quite an ordeal because this generator is in a soundproof box, and the whole unit had to be removed from the bus in order to access the belt. Ouch.
Mike in GA
I talked to Powertech about replacing the brushed head with brushless. They said it can't be done because I have the sound enclosure and the brushless heads are three inches longer.
I unfortunately don't have the $5,000 to $7,000 to buy a new generator. Also, the new 8KW brushless generators are at least 3" longer and the 10kW are even longer. I only have an inch or two to spare to be able to slide the unit out for service.
I wonder if Wrico could put together a made-up unit that will fit your available space?
Maybe a pleasant surprise at the other end of. A phone call?
Happy coaching!
Buswarrior
Wrico made up a 12kw custom unit for me (not listed on their site). What it is a Kubota 1305 3 cylinder with a 13kw alternator head derated to 12kw. I'm remote mounting the radiator with a really powerful, but low amp draw pusher fan with variable speed that Dick provided. The whole generator is right at 36" long. Good Luck, TomC
If your engine was more reliable, I'd recommend just replacing the generator head with a new one from Wrico. The new ones they have are smaller than many of the older, and it's much less a hit on the budget to do it this way. I did this on our 4106 - we kept the Perkins diesel and replaced the Kohler 12.5kw with a Mecc Alte 13kw. Wrico was able to supply with an adapter ring and flex plate to fit on the old engine as a bolt-on operation. If you are still having reliability problems with the engine in yours though, this may not be a good option.
There is nothing wrong with the reliability of his Cat engine I seen those running strong with 20,000 hours,Powertech recommends the head bearing be checked or replaced at 2000 hours which I think is stupid they could have used a better bearing IMO
The engine has pretty much been problem free. The issue is all the stuff added by Powertech around the engine.
Jeff at Powertech said not to worry about the generator head bearing until 5,000 hours. I ordered the bearing a few years back when I ordered brushes. I had read some place that 1,000 hours was a good point at which to replace the bearing. I might just replace the bearing when I replace the motor mounts.
In that case, I'd call Wrico on Monday and see what they have that will fit. I spent about $2600 for the 13kw head including shipping to Wisconsin. They did a great job getting the mounting set so it bolted on with no problems. The generator heads they sell produce clean and accurate electrical output. The only thing I had to do after mounting was to create a new set of fail-safe controls. I used a Murphy switch gauge setup to do that.
Powertech had a rash of bearing failures a few years ago lol some didn't make it a 100 hours.You have the 8k now have some one run the numbers for the HP on the little engine most all the time the power head is 8K to 10K and only a HP change is needed to make it a 10kw generator if you need more watts
I know I'm the greenhorn here, but an earlier comment you mentioned the generator someimes dropping voltage while running the three roof airs.
Have you thought about adding a hybrid inverter like a Victron or Magnasine , one of these could help boost your power and lighten the load on the generator.
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I like the idea of seeing if I could get a brushless head to fit. It looks like Mecc Alte has a head that would fit in the existing space. Even better if I could get 10 KW with the same engine.
I don't have the money or time before I leave on a trip on May 13th, but maybe I could do something before my September trip.
Hey Jack, I run twin Honda EU 3000is gennies with the parallel cable kit. They work absolutely flawlessly and have well over 1000 trouble free hours on them. To keep the crud and varnish from setting in, I dump a can of sea foam into their fuel tanks about an hour or so before we are done using the gennies for a while...run them hard with the sea foam and then shut them down. A year later, they will start just fine.
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