Originally Posted by Scotialaddie
Has anyone had problems with the magnets coming loose in a 7.5k genset?
You don't say what year/make/model of coach so that it can be narrowed down to a series that has has this issue. Mine was one of them. We have an '04 Itasca Horizon 36GD with the C-7 330HP CAT and, while we really don't know when it happened, it was found during investigation of other issues with the Gen Set.
Some folks were lucky enough, if you want to call it "lucky", for it to happen when the coach was under warranty. The fix on that is anywhere from about $800 up to around $1500, depending on all kinds of variables. When I found mine had done it, I was actually fixing other issues too so, I had to tear it down to a point that, I was accomplishing more than one fix at a time.
I got lucky when it came to replacing the rotor. I got a semi-new one from ebay that was off of an 8.0KW unit. It still cost me $200 shipped to my door step. Below are some pics of what kind of shrapnel you might see if yours has done the same action as mine and others. That magnet will explode since it's operating in literally thousandths of clearance between it and the stator.
It has no place to go when it dislodges from it's rotor body. So, it just grinds and shatters into multiple sized pieces and, due to the rotational centrifugal force, the pieces of it will end up sticking to anything metallic all over the inside of that generator housing/panels.
It's not a fun job to replace that rotor. Mine was waaaaaaay easier than many due to the fact that the gen is on a slide out tray. If yours is not, the gen will have to be dropped out the bottom and placed in a work area for semi-complete disassembly. I say semi because, you do have to literally take the genset about 1/2 way apart to gain access to that area.
Not to mention, when any of those magnets dislodge, there's about a 95% chance that there will be damage to the stator too. That's an $1100 dollar part alone. At least it was way back when I replaced it. Anyway, good luck on your repair. It's really interesting to get into that gen, that far.