Alfaowl
Any ideas how to stop ignition coil wires from breaking on QT02515ANSX units? We have had over 20 instances where the wiring to the plug on ignition coils breaks sometimes at the plug sometimes as far as an inch from the plug, there is extreme vibration at the coils and wires break into, even as often as every two or three hours.
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Hodgy
Alfaowl;37064 wrote:
Any ideas how to stop ignition coil wires from breaking on QT02515ANSX units? We have had over 20 instances where the wiring to the plug on ignition coils breaks sometimes at the plug sometimes as far as an inch from the plug, there is extreme vibration at the coils and wires break into, even as often as every two or three hours.



Are you talking about the high tension wire between the coil and spark plug ?



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BrentB
High quality conducitive silicone grease on the connection. Less heat on the conductor means less stress due to less temp changes (heating and cooling during stress)
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Alfaowl
The wire break is in the 12 volt wires feeding the ignition coils, upon further inspection we have learned that the protective shield that covers these wires is actually rubbing the wiring in two. We also have had screws and rivets that hold the coils to the bracket are breaking. There is extreme vibration on the bracket.
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Peddler
You have had this on multiple units? Could it be a bad balance job on the rotor? Peddler
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redman
According to Generac, this can't happen, but I will tell you what I found.
I have had 2 of these over the years, that you couldn't set a coffee cup on, it would shake it right off, both I had to change the rotor and stator on, finally went bad, from all the vibration in them.
If you look at the drawings on my it, was drawings 0A9348, mine was missing the bolt and lock washer #20 / 053557 / #21 lock washer 051769.
This bolt was suppose to hold the fan and ring gear assembly to the rotor, only thing in there was the key way, and the flex plate pushes against it, so there was no way for it come off.
After replacing it {rotor and stator} exactly back the way it came off, I still had same vibration, but now it was producing voltage, tech. told me to check that bolt to see if it came loose, I said what bolt, then I got the drawings, and there is a bolt, ordered, it took all back apart, put bolt in, tight to spec, put back together, never a vibration again.
Not saying this is your problem, but both of the generators I took apart were same way, neither one of them had that bolt and lock washer in them.
Thanks, Mike
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redman
they also sent the wrong new flex plate and bolts to go with it.
That's 3 days I wont ever fore get.
Thanks, Mike
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redman
Never had the spark plug wire problem, you are talking about, will look a lot closer at them in the future.
Have never put a set of wires on a liquid cooled, that I can remember, interesting.
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Hodgy
Alfaowl;37080 wrote:
The wire break is in the 12 volt wires feeding the ignition coils, upon further inspection we have learned that the protective shield that covers these wires is actually rubbing the wiring in two. We also have had screws and rivets that hold the coils to the bracket are breaking. There is extreme vibration on the bracket.




So this a coil on plug system, right ?

Are the 12 volt wires solid or braided ?

If this engine is used in other industrial applications, I wonder what the experience is with wires breaking ?

Must be some vibration to do this damage.



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Alfaowl
Thanks so much Pedddler and Redman, I think you have definitely given me a place to start looking, that would explain the vibration which is causing the problem, as far as the wires that are breaking, they are the wires feeding the ignition coils not the plug wires themselves but I know that this is due to the vibration and not wire failure itself. We have had this failure on approximately 15 separate units, most units have had multiple failures within two to three days. We still have some of these units running on their fifth day of ice storm failure since 12-26-2015, we had just came out of a six day ice storm on 11-26-2015 so we have been slammed. I have multiple units in my shop to start tearing down when I get a chance. If your guess is right it would also explain the flex plate failures I have had on several of these same units, as I said I have not had time to tear these units down, we have done swap outs with spares and went on for now. I will let you know what I find. Again thanks it might be a light at the end of a tunnel.
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Peddler
With that many failures many of which I would think are still under warranty the factory should be able to shed some light on this problem. I don't think there could be that many out of balance rotors in the country unless they had a bad batch. The pictures above are of the 1.5 liter Mitsubishi engine not the 1.5 Chery which is not in the same league. I do everything I can to sell around the Chery engines both the 1.6 in the older units or the 1.5 that they have been selling for a couple years. Sometimes cheaper just not better. Peddler
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78buckshot
I have to agree with you Peddler, most of the time nowadays cheaper is not better.
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Alfaowl
I was able to tear one of the units down yesterday, the bolt holding the flywheel to the rotor was in place and tight, the flex plate appears to be ok, thinking possibly bad batch of rotors or flywheels because we do have several other units of the same model that have not been affected, I talked to Generac service one day last week and he told me to send in pictures, they had not had this complaint before. I am waiting on a reply. For now we have stripped back the plastic loom off of the wiring to stop rubbing and taped the coils tight to the bracket, to dampen vibration, since my last post we have had to two of our swap out units that were new, rub into the wires in less than 48 hours of run time.
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redman
My mistake Alfawol, I read this in the wee hours of am and replied, and should have noticed model number better.
Peddler, you are right again, about engine family.
Last one I done in the QTO line was a QTO2724ANAX, that was August 2015, tech. told me then they thought they had a flywheel balance problem on some units, but it was too soon to tell, and that was "off the record", but they didn't hesitate to ship me a new flywheel and flex plate, to replace.
I can image with the out of balance "vibration" I had with an 1800 rpm, how bad it must be on 3600 rpm. Did you notice any flywheel teeth broke off, have had to replace a lot of starters on new units last couple of years, just stripping the teeth right off flywheel.
Have pictures but they are too large to up-load.
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Namvet34
redman;37152 wrote:

Have pictures but they are too large to up-load.


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If you want to send them to me Mike, I'll resize them for you you and send them back. You have my email address.

Regards,

Gene

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Skip Douglas SkipD
redman;37152 wrote:
Have pictures but they are too large to up-load.
I can tweak images for anyone who needs that done as well. Just PM me to get hooked up.
Skip Douglas
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patmurphey
Photobucket.com is a free website where you can upload photos. When you copy a direct link from your library there, the photo will be automatically sized for use in a forum.

It works for any size photos.
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redman
Thanks Guys, haven't figured out why if I take a photo with my cell phone, its too big to up-load, take it with my camera, its ok. Is there a simple program that can be downloaded to fix these pictures on my end.
Thanks, Mike
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Namvet34
redman;37158 wrote:
Thanks Guys, haven't figured out why if I take a photo with my cell phone, its too big to up-load, take it with my camera, its ok. Is there a simple program that can be downloaded to fix these pictures on my end.
Thanks, Mike


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Yes, Mike.

The program I use is called FastStone Photo Resizer. It's free for home users.

Here's the link:

[url]http://www.faststone.org/FSResizerDetail.htm[/url]

Good luck,

Gene

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Skip Douglas SkipD
patmurphey;37157 wrote:
Photobucket.com is a free website where you can upload photos. When you copy a direct link from your library there, the photo will be automatically sized for use in a forum.
One needs to make sure that the maximum size is no more than 1024 pixels in either direction, though. Otherwise folks have to scroll even to see the text.
Skip Douglas
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patmurphey
SkipD;37161 wrote:
One needs to make sure that the maximum size is no more than 1024 pixels in either direction, though. Otherwise folks have to scroll even to see the text.


Right, photobucket.com copied links are automatically sized correctly, no editing required..
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Alfaowl
Thanks again redman, haven't had teeth stripped off of flywheels but have lost several rpm sensors and flex plates, also have several QT030ANSX units that have vibration problems also, but not as serious. Just wondering if the larger rotors might be dampening the vibration a little better. May be grasping at straws here but I did check and both units use the same flywheel.
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