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Old 07-10-2019, 04:11 PM   #1
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07 Newmar Essex 12.5kw generator shuts down

Generator shuts down while traveling on the road with the AC on as a load. It appears I have lost the muffler to my generator. Oil/coolant is fine. Good airflow below generator (will suck a paper plate out of my hand and there is a steady flow of exhaust out off the exhaust pipe.

The exhaust pipe; however, appears to be twisted and there is evidence something was attached to the pipe and a hanger... I assume the muffler fell off. Anybody know if I am supposed to have a muffler and if so a link to replace it while traveling. As always, Thanks!
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Old 07-10-2019, 04:26 PM   #2
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That twisted pipe does not look healthy. Here is my muffler setup. Any muffler shop that you can park in will fix that pretty easily.

PS. A Jeep is a better vehicle for serious off-roading!

PPS. Don't do that to the Aquahot muffler!!!
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Old 07-10-2019, 04:43 PM   #3
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Generator shuts down while traveling on the road with the AC on as a load. It appears I have lost the muffler to my generator. Oil/coolant is fine. Good airflow below generator (will suck a paper plate out of my hand and there is a steady flow of exhaust out off the exhaust pipe.

The exhaust pipe; however, appears to be twisted and there is evidence something was attached to the pipe and a hanger... I assume the muffler fell off. Anybody know if I am supposed to have a muffler and if so a link to replace it while traveling. As always, Thanks!
Attachment 252822

The parts book doesn't show anything past the flexpipe. I assume the pipe is fabricated for a specific chassis. As mentioned, a decent muffler shop could make one. Or, you could likely piece something together from the "universal" stuff at Advance Auto or similar. I picked up enough pieces to rebuild my HydroHot exhaust for about $20.
BTW, the muffler is not missing .... it's inside the "big box" ahead of the flexpipe. That mangled piece was probably an elbow with a straight pipe clamped to it.
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Old 07-10-2019, 05:31 PM   #4
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Thanks! I took the twisted pipe off. Two bolts, it has a gasket, not connected to the silver pipe. Pic is worth a thousand words. Glad to know it wasn’t the muffler!
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Old 07-10-2019, 05:59 PM   #5
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Thanks! I took the twisted pipe off. Two bolts, it has a gasket, not connected to the silver pipe. Pic is worth a thousand words. Glad to know it wasn’t the muffler!

As mentioned ... don't do that to the HydroHot pipe .... no fun at all. And it's surprisingly easy to catch that pipe on an obstacle.
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Old 07-11-2019, 03:32 PM   #6
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Thanks again AzSkier, bruceisla... et al; You guys are awesome! Repair: Had the flange elbow heated and straightened out. Could not find 1” generator tail pipe anywhere (muffler shops, Cummins, RV repair etc) so replaced it with standard 1 ˝ exhaust pipe. Muffler shop made a 90 degree bend in the pipe for a perfect fit. Drilled and added a screw on the connection between 1” flange elbow and the 1 ˝” tail pipe. Used two clamps and one hanger total cost $40. 30 minutes to install.
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Old 07-11-2019, 03:34 PM   #7
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Thanks again AzSkier, bruceisla... et al; You guys are awesome! Repair: Had the flange elbow heated and straightened out. Could not find 1” generator tail pipe anywhere (muffler shops, Cummins, RV repair etc) so replaced it with standard 1 ˝ exhaust pipe. Muffler shop made a 90 degree bend in the pipe for a perfect fit. Drilled and added a screw on the connection between 1” flange elbow and the 1 ˝” tail pipe. Used two clamps and one hanger total cost $40. 30 minutes to install.


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Old 07-11-2019, 04:31 PM   #8
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Sweet !!! Did that fix the shutdown?
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Old 07-11-2019, 05:44 PM   #9
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I think the shut down was due to the twisted flange elbow (not providing good exhaust flow). Works perfectly now while stationary. We are back on the road Saturday and will see then how she does moving.
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Old 07-11-2019, 05:59 PM   #10
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Not too complain too much, but My picture did not show the very end. The very end of the exhaust pipe has a curved, chrome tip.

Like this one.
https://www.ebay.com/i/253354097103?...hoC4KUQAvD_BwE


This is an Essex we are working on... Nothing but the best for Any Ole Joe!
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Old 07-20-2019, 01:12 PM   #11
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ID:	253959 Thanks for the link... job is now complete! Generator works perfectly on the road. I always stay on the hard stands, so was confused how this could happened. I now believe the muffler hanger failed and allowed the pipe to hit the ground while the motorhome was moving. Thanks again to all!
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Old 07-21-2019, 04:49 PM   #12
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Many more ESSEX stuff by same two people found in this link that will lead you to the ESSEX THREAD.
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