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pstroke · 08-21-2007, 12:36 PM

Well, it was bound to happen. Almost 11K miles of trouble free traveling came to an abrupt end yesterday. While in route from vacation in Florida to home in Texas, my coach lost power and is sitting at the Spartan repair shop in Longview.

They put it on the computer before we left and it did not show any codes. So we load the family up in the Jeep and drove the 200 miles to the house. They said at least a week and a half before they could look at it. Hopefully, they are exaggerating.

Here is the entire story. While on I-20 with the cruise at 70, the coach started to slow down. I put the pedal to the floor but it continued to slow. Unable to keep it at highway speed, I was lucky enough to be at the rest stop just inside the Texas state line. I put a call into Newmar and was transferred to the Spartan rep Kent. He asked me to look for a loose intercooler hose or clogged air filter neither of which I could find. At this point, he could no longer help me find the cause and directed me to Spartan Roadside Assistance and even suggested that they could send out a mobile repair to my location.

Roadside assistance basically said they do not offer a mobile service. Since I was "safe" that my only options were to be towed to the nearest service center or drive there if I could make it. They then suggested I call Spartan customer service and find the nearest service center. After calling four times and leaving two messages, I was really beginning to doubt the decision to buy Spartan. Luckily, I had internet service and was able to find the closest shop in Bossier City. Tommy at Pegues-Hurst Motor Company was very helpful and tried to help further diagnose the problem over the phone. Since we had not received any "codes" on the chassis, we still could not determine the problem. Tommy indicated that it could be a fuel issue and to try changing the fuel filters. Their Longview branch had both filters in stock so we decide to try to get there.

The coach ran normal for a few miles after leaving the rest stop but then began to lose power again and we decided to try the back roads from Marshall to Longview. The coach continued to go from normal to dead all the way to Longview but we did finally make it.

We did change the fuel filters and try to make it home. It seemed all was well until we got to the interstate and back up to speed and she fell flat again. It appears that the motor is going into some sort of "limp" mode or d-rate mode to protect the motor but still no check engine light or codes show up in the ECM. When the motor is running normal, we see 30+ psi of boost from the turbo. When it goes flat, we see less than 5 psi.

So now, I can't use my $300K coach and worse yet, I will have to drive 400 miles round trip when it is fixed to pick it up.

I hope the fix is a simple one and we can put this behind us. I want to keep a positive attitude toward Newmar and Spartan through this ordeal. As all on this forum know, it stinks to break down on the side of the road in a "new" coach. I was fortunate that we were in safe area and had a toad to get us home but I did not sign up for this. We shall see.

Any other Mountain Master owner's had this happen? Any ideas? Thanks for letting me rant.

pstroke · 08-21-2007, 12:36 PM

Well, it was bound to happen. Almost 11K miles of trouble free traveling came to an abrupt end yesterday. While in route from vacation in Florida to home in Texas, my coach lost power and is sitting at the Spartan repair shop in Longview.

They put it on the computer before we left and it did not show any codes. So we load the family up in the Jeep and drove the 200 miles to the house. They said at least a week and a half before they could look at it. Hopefully, they are exaggerating.

Here is the entire story. While on I-20 with the cruise at 70, the coach started to slow down. I put the pedal to the floor but it continued to slow. Unable to keep it at highway speed, I was lucky enough to be at the rest stop just inside the Texas state line. I put a call into Newmar and was transferred to the Spartan rep Kent. He asked me to look for a loose intercooler hose or clogged air filter neither of which I could find. At this point, he could no longer help me find the cause and directed me to Spartan Roadside Assistance and even suggested that they could send out a mobile repair to my location.

Roadside assistance basically said they do not offer a mobile service. Since I was "safe" that my only options were to be towed to the nearest service center or drive there if I could make it. They then suggested I call Spartan customer service and find the nearest service center. After calling four times and leaving two messages, I was really beginning to doubt the decision to buy Spartan. Luckily, I had internet service and was able to find the closest shop in Bossier City. Tommy at Pegues-Hurst Motor Company was very helpful and tried to help further diagnose the problem over the phone. Since we had not received any "codes" on the chassis, we still could not determine the problem. Tommy indicated that it could be a fuel issue and to try changing the fuel filters. Their Longview branch had both filters in stock so we decide to try to get there.

The coach ran normal for a few miles after leaving the rest stop but then began to lose power again and we decided to try the back roads from Marshall to Longview. The coach continued to go from normal to dead all the way to Longview but we did finally make it.

We did change the fuel filters and try to make it home. It seemed all was well until we got to the interstate and back up to speed and she fell flat again. It appears that the motor is going into some sort of "limp" mode or d-rate mode to protect the motor but still no check engine light or codes show up in the ECM. When the motor is running normal, we see 30+ psi of boost from the turbo. When it goes flat, we see less than 5 psi.

So now, I can't use my $300K coach and worse yet, I will have to drive 400 miles round trip when it is fixed to pick it up.

I hope the fix is a simple one and we can put this behind us. I want to keep a positive attitude toward Newmar and Spartan through this ordeal. As all on this forum know, it stinks to break down on the side of the road in a "new" coach. I was fortunate that we were in safe area and had a toad to get us home but I did not sign up for this. We shall see.

Any other Mountain Master owner's had this happen? Any ideas? Thanks for letting me rant.

Dav5942 · 08-21-2007, 01:19 PM

Wow, not good! We have been able to get immediate service from two different Cummins dealers. You might give them a call. Would not wait the week 1/2. Keep us posted. Best of luck.
All Star

GaryKD · 08-21-2007, 01:52 PM

Dave is correct. This is not a Spartan problem. This is a Cummins problem. You have a good clue with the turbo information. Please let us know what the solution is.

Lug_Nut · 08-21-2007, 01:53 PM

I think the original diagnosis of a fuel problem is the issue. It may be contaminated fuel or a pump or line problem. This is in all lightlyhood a minor problem to correct. Check your water drain at the bottom of the fuel filter and drain it. If your fuel is good, it may very well be the lift pump.

Peter

Fillitup · 08-21-2007, 02:12 PM

I hope you have it at a Cummins shop. Where did you end up leaving it? Also sounds like a fuel delivery problem to me. Good luck and if you do this long enough - things like this can happen. Just read any forums (including Newmar IRV2) and you will find that it can happen to a 1 million dollar coach as well. It's just the nature of mechanical things. Sounds like you were having pretty good luck until this...Once again, I hope you have it at a Cummins store. I know you are having trouble, but it sure is a nice coach...

pstroke · 08-21-2007, 02:38 PM

Thanks to all the early responders.

The shop is Cummins certified. They work on everthing.

I will keep you posted. Thanks again.

jimandsue60 · 08-22-2007, 04:27 AM

My guess is a lift pump.

Jim

tmitchell · 08-22-2007, 06:09 AM

I had my 2004 DSDP go into limp mode once, it was a few years ago. The reason was, it was low on transmission fluid. My guess is that the tech didn't top off the fluid after the 5,000 mile initial filter change.

pstroke · 09-08-2007, 06:14 AM

Well, 2 weeks and about $850 later, we have our coach back. Drove to Longview on Tuesday afternoon and picked her up.

During the test drive, the diagnostics indicated "Ambient air density state" and this was causing the engine to go into a derate state. Apparently the air filter had some sort of restriction. They replaced the air filter and extensively road tested it and the problem could not be repeated. I guess 196 miles while in the shop would be considered extensive.

This first trip to the shop did also include her first oil change as well.

Also, while in there they performed two Spartan campaigns. One for the front brake line repositioning and the other for a newer campaign involving the bearings, seals and caps on the tag axle.

This overall has been a great learning experience. I suppose that 43,000 miles between my two coaches in the last 4 years and this was my first breakdown, I am lucky. I will keep a closer eye on the air filter restriction gauge and change out the filter when it gets closer to the red level.

Other than a few small warranty fixes that need to be done while back at the dealer, this has been an absolute great coach for the first 10 months of ownership. I hope one day to be able to afford to upgrade to the King Aire but until then, enjoying the heck out of the Dutch Star.

Thanks again to all those early responders. I did ask about the lift pump but was informed the lift pump only operates until the engine driven fuel pump takes over and then it shuts down.

Cruzer · 09-08-2007, 06:36 AM

I just saw this post and was going to recommend checking the air filter. If it gets overly restricted the engine ECM will sense that and you'll have exactly the symptoms you gave. Air filters really aren't designed to go X number of years. They are designed to go until they get plugged enough to cause restriction. Most filters are designed to be replaced when the filter's restriction (vacuum) is 15" over the baseline. Every coach is different due to variations in intake plumbing and filter sizes but when a new filter is installed you should note that reading. Then, when the number increases by 15, it's time to replace it.

For instance, my last coach had a baseline of 6" with a new filter. 6 + 15 = 21 so it should be replaced at 21" of restriction. Your's may vary by a few inches.

If you wind up going down a bunch of dirty roads that number can jump up fairly quick so it's important to keep an eye on it. I replaced one filter at 18" just before a trip on my 2004 Bus/Freightliner. Then had an issue where a Freightliner exhaust clamp loosened up and melted the filter element, giving it restriction real fast to the point where I saw the same things you did and the engine derated.