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Failed Generac 7kW 0058370 and Researching Solution

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13K views 73 replies 11 participants last post by  kingbellaus  
Check EBAY (continuously) for a replacement engine ... as others' generac's fall out with a stator/rotor failure, the engine will still be (reasonably) good. Your generac manuals will specify the engine type you want to search for (or set a search alert that notifies you).

The generac dealers want to sell new replacement engines, understandably, but at a year for resupply, perhaps the used market will help you. Not sure who will replace the engine for you, if you do find a (used) replacement ... w/o the field service manual, the replacement process might be tricky.

For example, I have a Generac 22kw model (7042) w/ a failed stator/rotor, but a reasonably good engine, and all kinds of ancillary parts around it ... will go onto EBAY for sale of parts as soon as I can get pics and such up.

You'll be waiting for a combination similar to mine ... stator/rotor failure on a model the same or close to yours with the same engine type, where the stator/rotor is just too expensive to fix ... so the rest will be parted out, via EBAY.

Hope this helps ...
 
Generac's model is "full support, by auth'd dealer" + propane + unknown thd + so-so reliability, so if playing in this open-frame generator arena, you'll periodically pay a base price of $2500 to $5000 every warranty period. Odds of a catastrophic failure (engine, stator/rotor, controller) seem to be at 2000 hours or so (or equivalent in years of age). Current warranty is up to 5 or 7 years, if you fully play in their support model (you are in an area covered by an auth'd dealer). They come to you and do the work. For this, you'll get a quiet machine, propane, full auto-start and other nifty features, and peace of mind.

Honda's model is "full support, by auth'd dealer" + inverter/generator (low thd) + reliability, so if playing in this arena, you'll periodically pay a base price of $5000 every warranty period (3 years?). Odds of a catastrophic failure (controller/gcu) seems to be at about 2500 hours, but the engine, stator/rotor seems to be further out; if you get the repairs done, the system will outlive its warranty. Current warranty is around 3 years? Gasoline only, so if you go propane, you'll mess with the warranty. No auto-start (w/o effort). You go to them (in most cases, you take the unit into a dealer), to get the work done; again, their reliability is a given (but to me, it only goes so far ... I think 2500 hours is not unreasonable, backed up by several threads on this site).

Duromax's model (what I use now, and I used to run a generac) is "self-support" + propane + 12% thd + so-so reliability, so if playing in this open-frame generator arena, you'll pay a base price of $1500 every warranty period. I purchase two right off the bat, so one is running, and the other is in near-standby mode; if one fails, it is easily repaired, and the other jumps right into duty, allowing for near 100% reliability (of power, when needed). Generators/parts are recycled, by becoming part of the stream of working units; add a unit when needed, part the failed unit out and feed back in. No auto-start. Nobody comes to you (unless you still have an old genny guy in your area), but that is ok, as it is easily DIY. Replace Duromax with any similar-class genny.

This is a long way around of saying you'll need to determine which arena you want to play in ... lots of variables (auto-start, fuel, support, warranty, who does the work, etc.) to consider, and everyone's use case is different. Honda's is not the same as Generac's, and neither are even close to the DIY model I use, but I get 100% reliability at a lessor cost than either of the other two; living rural, this seems to be the best fit for me. Nobody is coming in to work on my units, and I can't take them to anybody (few genny shops, these days). But, they are super easy to work on, and Duromax has the parts availability.

I'd stick w/ generac (replace your existing unit when you can), so you can keep the auto-start, full-service model, if you "don't want a failure" that you have to manage ... you just call the auth'd dealer; if the maintenance is being done (right), you'll likely not have a failure within the warranty period and/or the 2000 hour mark. Usually, it all just works.

Hope this helps ...
 
UPS's at our off-grid location never "clicked" (cut in and out) when we ran on the generac (THD somewhere between 5% and 15%, but hard to pin down); these ups's do click when on our 12%THD Duromax's. My thinking is that it isn't a THD problem, as much as it is a QOS due to amount of power ... the Generac at 22kw powered everything in sight, even when charging the off-grid batteries through the inverter ... this is a guess. The whole neighborhood glowed when that thing was running ...

In another note, my theory on gennies is that there seems to be some kind of curve of age/utilization (not just utilization alone), where these things have to be replaced within a given set of years or hours. I call this the "base" price, and every generator is different. In the case of your 7-yo generac ... that is old in terms of years/technology, even if it may not have a high run-time of hours. The base price unit has to be replaced every so often, just to keep up with technology/parts, and so on. Couple this with "warranty" of a given unit ... if the vendor won't warranty it for more than a couple of years, that probably correlates to how long you can keep it running (not more than a few years beyond it's warranty period). There are outliers, of course ... 10k hours, or 10 years or more of service.
 
I believe you are grid-tied? I'm off-grid, so I run solar/genny power thru a Magnum 4024 inverter/charger (solar via a midnite classic mppt) ... it takes care of charging our LiFePO4 battery bank; when not charging, then it feeds the house from the battery bank. The battery bank feeds the house for upwards of 24 hours or more, in between being topped off by solar, or charged by genny during non-solar times.

Is this what you are asking about?

It gets tricky if you are grid-tied, as all kinds of regulations come into play ... an electrician is almost certainly called for to sort through the wiring issues.

If grid-tied, you could get away with a inverter/charger and a battery bank, w/ no solar or mppt; when grid is on, the inverter/charger draws from that to top off the bank. when grid is down, inverter feeds the circuits, and genny is tied in at times to replenish the bank.

Hope this helps ...