Burnt out Sargent EM40 unit

Cockers

Cockers

Joined
Jul 15, 2015
Posts
183
Likes collected
302
Location
Isleham Cambridgeshire
Funster No
37,170
MH
Autotrail Dakota
Exp
Since 2012
Well our road trip has come to an unexpected halt Today travelled down through France and into Spain driving passed Albox on the E-15 A-7 heading toward Almeria and smelt the dreaded electrical burning smell and smoke started coming from the drivers side footwell, we had a very quick stop and switched everything off.
contacted Sargent and explained what had happened, explained the earth wires from the vehicle battery in side had melted and burnt out. I asked if if they could send me a new unit which I’m waiting to find out if they will send a unit to Spain. Strangely they said I would need a new EM40 unit and the repair wiring harness, i found it strange they have a repair harness to hand, which makes me feel there has been a problem with their wiring. I asked if it’s happened a lot to be told a few have had this issue.
really interested if anyone else has had the problem. And if anyone know of anywhere in Spain that may be able to assist.
by unplugging everything from the unit I can still drive the van but nothing is working in the hab area. The van is an Autotrail Dakota 2015.

1808B7C0-D441-4BB9-8CA1-60C48DA30891.jpeg
 
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My EM40 has melted recently.

20241005_114112.jpg


Nothing from Sargent, yet. They have EM41 at £194.34 inc post. Apuljack do indeed seem to have a superior product but they want £199.14 inc £8.34 (yes £8.34) for snail mail! So there is not a lot in it really and I'd probably go for the Apuljack as it seems better and will be easy to retrofit.
 
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Cockers said:
Well our road trip has come to an unexpected halt Today travelled down through France and into Spain driving passed Albox on the E-15 A-7 heading toward Almeria and smelt the dreaded electrical burning smell and smoke started coming from the drivers side footwell, we had a very quick stop and switched everything off.
contacted Sargent and explained what had happened, explained the earth wires from the vehicle battery in side had melted and burnt out. I asked if if they could send me a new unit which I’m waiting to find out if they will send a unit to Spain. Strangely they said I would need a new EM40 unit and the repair wiring harness, i found it strange they have a repair harness to hand, which makes me feel there has been a problem with their wiring. I asked if it’s happened a lot to be told a few have had this issue.
really interested if anyone else has had the problem. And if anyone know of anywhere in Spain that may be able to assist.
by unplugging everything from the unit I can still drive the van but nothing is working in the hab area. The van is an Autotrail Dakota 2015.

View attachment 753393
Click to expand...
Ours is a 2014 Tracker
Mitch
 
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Andacami said:
My EM40 has melted recently.

View attachment 961981

Nothing from Sargent, yet. They have EM41 at £194.34 inc post. Apuljack do indeed seem to have a superior product but they want £199.14 inc £8.34 (yes £8.34) for snail mail! So there is not a lot in it really and I'd probably go for the Apuljack as it seems better and will be easy to retrofit.
Click to expand...
Thanks for the info
Mitch
 
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Andacami said:
My EM40 has melted recently.

View attachment 961981

Nothing from Sargent, yet. They have EM41 at £194.34 inc post. Apuljack do indeed seem to have a superior product but they want £199.14 inc £8.34 (yes £8.34) for snail mail! So there is not a lot in it really and I'd probably go for the Apuljack as it seems better and will be easy to retrofit.
Click to expand...
Make sure when you fit the new em unit that you disconnect both the hab and van battery’s as I had my one change under Autotrail recall 6 weeks ago and they have blown my media centre along with with the satnav and reversing camera not working.
This is a on going problem I am having with both Autotrail and Sargent to who is going to fix my Motorhome, trying to get someone to respond to me is very frustrating from both parties.
The reason I say disconnect both battery’s is the instructions sent with the new unit only specifies to only disconnected the hab battery, there lies the problem they have created a feed back when cutting cables and refitting the new unit, seeing the unit is a interface between van and Motorhome.
This is my take on this ongoing Saga till I am told differently.
Hope it all goes well for you.
What year is your Motorhome as auto trail no there is a problem with this unit.

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Don’t be surprised that Sargent have spares - they make the wiring harnesses for AT and Swifts along with others that use Sargent
 
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2017 AS Corinium Duo on a Boxer.

I disconnected both hab and vehicle feeds as a matter of course. It was a simple fit but DO pay attention to stripping the wires to the stated length and DO ensure they are all firmly and fully seated.

The Appuljack unit is clearly a better product, (but I'm still grumpy about the postage).
 
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plug said:
Make sure when you fit the new em unit that you disconnect both the hab and van battery’s as I had my one change under Autotrail recall 6 weeks ago and they have blown my media centre along with with the satnav and reversing camera not working.
This is a on going problem I am having with both Autotrail and Sargent to who is going to fix my Motorhome, trying to get someone to respond to me is very frustrating from both parties.
The reason I say disconnect both battery’s is the instructions sent with the new unit only specifies to only disconnected the hab battery, there lies the problem they have created a feed back when cutting cables and refitting the new unit, seeing the unit is a interface between van and Motorhome.
This is my take on this ongoing Saga till I am told differently.
Hope it all goes well for you.
What year is your Motorhome as auto trail no there is a problem with this unit.
Click to expand...
Bloody and I thought I had problems, good luck.
Mitch
 
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I replaced my fridge PCB under Thetford warranty and as stated previously installed the Appuljack myself. I had the recall letter so wrote to customer services at AT and asked for some compensation for inconvenience even though I’d fitted an Appuljack. I received a payment of £100 also they have advised I get the new EM41 unit installed as well.
A lad on the Autotrail Facebook page had it done within 2 weeks by going to the AT factory directly.
I have spoken to my dealer who moaned “Do you know how many Auto Trails I’ve sold? It’s going to take years to sort out” So I said “You have made a lot of profit then? Not really my problem” …Tumbleweed.
Anyway my local AT warranted repair centre in Northwich said they will replace if I want, they just need to order it so I will make the decision whilst down here in Spain as the Appuljack is working fine.
 
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EM40 all running cool at the moment so I will just keep an eye on it. But no side marker lights so won’t drive in the dark.. Good luck with yours. Ours is 2014 🙁
Mitch

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Mick and Ruth said:
I replaced my fridge PCB under Thetford warranty and as stated previously installed the Appuljack myself. I had the recall letter so wrote to customer services at AT and asked for some compensation for inconvenience even though I’d fitted an Appuljack. I received a payment of £100 also they have advised I get the new EM41 unit installed as well.
A lad on the Autotrail Facebook page had it done within 2 weeks by going to the AT factory directly.
I have spoken to my dealer who moaned “Do you know how many Auto Trails I’ve sold? It’s going to take years to sort out” So I said “You have made a lot of profit then? Not really my problem” …Tumbleweed.
Anyway my local AT warranted repair centre in Northwich said they will replace if I want, they just need to order it so I will make the decision whilst down here in Spain as the Appuljack is working fine.
Click to expand...
Appuljack ?????
Mitch
 
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Al n Val said:
hi Mick

it’s a very common issue especially on Autotrails, I know quite a few owners had exactly the same issue. I’d urge you to also check the harness between the 3 stage charger and Sargent unit, a completely different issue but once again very common and melted everything 😟

Same thing, crap connectors and inferior capacity carryring cabling, if they charged us another £10 and used quality components this would never happen.

Hope you get sorted soon mate

Al
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MitchandJenny said:
EM40 all running cool at the moment so I will just keep an eye on it. But no side marker lights so won’t drive in the dark.. Good luck with yours. Ours is 2014 🙁
Mitch
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when you get the chance unscrew the em unit and check your connections as that is one of the things that gone wrong when the em unit starts playing up.
John
 
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MitchandJenny said:
Appuljack ?????
Mitch
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Yes mate my EM40 went down in Ireland I paid Sargeant to send a replacement one as I knew appuljacks was in production and as soon as that was released took the Sargent replacement one out (2 months old) as couldn’t trust it and stuck Appuljack one in

AE EM40 High Current/Upgraded Control Module | Apuljack Electronics

The AE EM40 is designed to replace the original Sargent unit. The unit acts as the vehicle interface for Sargent systems. The original EM40 can have issues with
www.apuljackelectronics.co.uk www.apuljackelectronics.co.uk
 
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Mick and Ruth said:
Yes mate my EM40 went down in Ireland I paid Sargeant to send a replacement one as I knew appuljacks was in production and as soon as that was released took the Sargent replacement one out (2 months old) as couldn’t trust it and stuck Appuljack one in

AE EM40 High Current/Upgraded Control Module | Apuljack Electronics

The AE EM40 is designed to replace the original Sargent unit. The unit acts as the vehicle interface for Sargent systems. The original EM40 can have issues with
www.apuljackelectronics.co.uk www.apuljackelectronics.co.uk
Click to expand...
Nice one Mick. Thanks for replying and well done. After removing the 4 screws How did you get the box out of the floor. ??
Mitch
 
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MitchandJenny said:
Nice one Mick. Thanks for replying and well done. After removing the 4 screws How did you get the box out of the floor. ??
Mitch
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It lifts straight out mate a bit tight for the sake of an extra cpl of mm of cable, just pull the connectors out and connect them into Applejacks . I’m crap with anything like that but did it in about 15 mins very easy.
 
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Mick and Ruth said:
It lifts straight out mate a bit tight for the sake of an extra cpl of mm of cable, just pull the connectors out and connect them into Applejacks . I’m crap with anything like that but did it in about 15 mins very easy.
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My box only just lift about 5mm 🤬
Mitch
 
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I haven’t got a replacement yet I just wanted ”eyes on” to establish the fault and see any burn marks etc.
Mitch

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The smaller Fridges need to be on a 20 amp D+ fuse, the taller N4000 series need to be on a 25 amp fuse as per Thetfords installation manual (page 11).

It's the same issue with the EM55 and the original batches of it's replacement EM56. Newer boards supplied by Sargent now have the 25 amp fuse fitted. There's a huge recall on all of them. For the EM55 issue over on the F Line FB Group we even reported it to the DVSA who then investigated.

Don't leave it too long as the thermal runaway issue with the wiring has the potential to knock out your rear lights, omnistep & towing electrics.
 
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Thanks Jonno all information is valid and I am gathering all I can mate.
I don’t want to prize the box out of the floor, but even with all 4 screws out it will not lift up. 🤬
I am not clever, but although old I did spend nearly 50 years in the vehicle technician game so not tooo thick 🙄.
Mitch.
 
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The wires would have been put on the back before it’s put in place so it must come out

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Just sent a reply Email to AEL Technical.
They say my EM40 box doesn’t have a buzzer. 😤
I will see what they say.
Mitch
 
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Terry said:
The wires would have been put on the back before it’s put in place so it must come out
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I agree with your logic Terry. I suspect after it’s installed they clip the cables and harness to the inside of the B pillar so I will have another look tomorrow. Made it Spanish border today, will
glare at it again tomorrow.
Mitch
 
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On the ones we fitted in new conversions we pulled the wires back behind cupboards😉 Then we stopped using Sargent because they always gave trouble. Paul used to have to take them to bits and solder wires etc and he came to the conclusion they were made up with a main board that’s cobbled to another bit of board instead of making 1 board ie as the board needed more stuff working on the van they simply added to main board to make things work -shite in his opinion - sounds like they are still cobbling bits that are not upto the job 😳😉
 
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