The Replacement generator

This page has five pictures of the problems I found with the new generator. When I opened up the service door to have a look inside, the very first thing I saw was the nut off the engine mount laying in the bottom of the generator pan. After having so much trouble with the other generator, I decided to take this one apart and check to make sure it did not have the same problems as the other one. Am I glad I did! The following is a list of what I found. 

1. The nut was missing off the motor mount on the front side of the motor.

2. All but one of the nuts that secure the resonator box were very loose. In fact, three of them were not even tight enough to touch the plastic box. The others were finger tight. If this box had come loose from its mount, I feel that it would have let a lot of hot air into the resonator box. I doubt if this would be very good for the controller. It looks like Onan put the controller in the resonator box to help keep it cool.

3. The braided ground strap was installed just like the other generator. It rubs on the muffler and cuts in to it over time.

4. I took the grounds loose from the generator and controller to see if the star washers had cut through the paint of the frame. Last time this was the cause of the controller failure. The bolt that had the generator grounds looks like it made good contact; however,  the controller ground was not very good. In the picture you can see that it just started to cut into the paint, but not good like the generator grounds. I feel that this could have caused me more lost controllers. Circle number 1 is the controller ground point, number 2 is the generator winding's ground point.

5. I have no idea why the duct tape is on the vent for the generator. I pulled up one corner to see if the duct was damaged, but it looked ok.

6. The upper radiator hose and housing is cutting into the insulation. Already there is black off the radiator hose. I am wondering if over time this will rub a hole in the cooling hose and cause me a break down later on. The red area is from the hose and the green area is from the clamp and housing.

All of the above problems I found on the generator right out of the box. Some of these problems were the very same ones I found on the other generator.