Evil PT 10 generator

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Evil PT 10 generator

June 25, 2011, 09:49:50 pm

Does anyone know where the auto start controller is located in a 99 U295? Gen (PT10) runs no telling how long then shuts down with low oil light blinking on the ES52 controller. It will fire right back up may run fine for extended times or shut down. Low O/P SW and wiring have been checked (new O/P from PT as well) also 80PSI hot, fuel lines and pump all good, all elect grounds clean and checked. I want take the auto start out of the system before I replace the ES52. Been messing with this thing for a while, time to fix it it's hot down here.

Re: Evil PT 10 generator

Reply #1 – June 25, 2011, 09:58:12 pm

Howdy Bruce,
On our '00 U320 with PT10, the auto controller is located under the center dash. This is the top with the cupholders, just lift it up, and mounted vertically on the front side.
Good Luck, Dave Abel

Re: Evil PT 10 generator

Reply #2 – June 25, 2011, 10:10:15 pm

Would highly recommend replacing your FUEL filter between the genset and the tank, not the filter on the genset, but the one between. This has caused very similar issues as you describe when it gets nearly plugged up with dirt/trash.

Re: Evil PT 10 generator

Reply #3 – June 26, 2011, 12:19:27 am

Think Dave may have hit it on the head. Sediment or algae can collect in the filter blocking it. When the generator shuts down, the particles are no longer held against the filter material and fall to the bottom only to gradually block it again once the generator is running again. Had this happen with algae on a lot of small primary filters in MB diesels. If you pull the filter between the tank and generator (usually called the primary filter) and it is black inside, it's algae. Once inside your tank, it doesn't go away without a fight.

Fueling from above ground tanks increases the chance of algae as does having vented fuel tanks in your RV. Moisture can get in when the fuel level is down and moisture laden air gets in. Algae can grow in the interface between the water and fuel, especially in warm conditions. If your fuel tank releases pressure when you unscrew the cap when warm or cold, you have less change of getting moisture in the tank. Boats really have this problem operating in high humidity conditions all the time.

Any generator that shuts down for no apparent reason and then restarts a short time later would have fuel contamination as number one on the usual suspects list.

Auto parts stores and truck stops have the stuff to kill it. Once dead, the filters still have to collect it.

Re: Evil PT 10 generator

Reply #4 – June 26, 2011, 09:33:57 am

Dave do you have any Idea where this filter may be located? I am aware of the algae issue if fuel and tanks are not properly cared for. I can see the lines from the gen to where they go to the fuel tank, the only possable place is at the fuel tank which will take some doing to get to. The generator doesn't seam to be starving for fuel (had that problem already, bad transfer pump) when it shuts off or restarts.

Re: Evil PT 10 generator

Reply #5 – June 26, 2011, 10:44:48 am

Are you home, Bruce? If so, you are only 45 miles from the factory... I stopped by their repair shop once - Its a nice shop about a half mile from the factory. The guy there is ultra knowledgeable.

Power Technology Southeast Inc
2810 W Main St
Leesburg, FL 34748
(352) 315-1670

Re: Evil PT 10 generator

Reply #6 – June 26, 2011, 10:46:27 am

On my 01 320, it is the same filter as used on the Aqua Hot, the one for the generator is located behind the generator, lay on ground and look behind the generator, there is a fuel line with the filter midway between tank bulkhead and the generator.
Yes, as mentioned, have seen this exact issue on a 03 320, run while stop, low oil light, restart all good for while and repeats again and again until the filter was replaced OK?

Re: Evil PT 10 generator

Reply #7 – June 26, 2011, 08:53:44 pm

Unplugged the auto start module, gen still shut down. Tomorrow I will run a hose to a separate fuel source (gallon jug) and see what happends that should eliminate all fuel lines and filters.

Re: Evil PT 10 generator

Reply #8 – June 26, 2011, 09:08:28 pm

Quote from: Pierce & Gaylie Stewart – June 26, 2011, 12:19:27 am

Think Dave may have hit it on the head. Sediment or algae can collect in the filter blocking it. When the generator shuts down, the particles are no longer held against the filter material and fall to the bottom only to gradually block it again once the generator is running again.

Auto parts stores and truck stops have the stuff to kill it. Once dead, the filters still have to collect it.

I agree. Ours was acting fuel-starved last year. Both filters replaced and some Lucasoil Bio-Medic in the tank and it's running much better.

Michelle

Re: Evil PT 10 generator

Reply #9 – June 26, 2011, 10:04:28 pm

I change mine every time I change the main filter on the genset. I guess I am anal but I also run it a lot too. Dave is pretty sharp on gensets.

Re: Evil PT 10 generator

Reply #10 – June 27, 2011, 10:02:13 am

Thanks for this info. I'm having a similar problem. Will try the solution mentioned.

Re: Evil PT 10 generator

Reply #11 – June 27, 2011, 11:13:19 am

I don't think there's a pre-filter on Bruce's genny, just a strainer at the fuel pump inlet. I added a big strainer before my new pump with a sight glass.

Re: Evil PT 10 generator

Reply #12 – June 27, 2011, 09:06:24 pm

Hooked gen fuel pump to a gallon jug of fuel via clear plastic line. Fuel pump picked up fuel quickly, gen started and died 2 times low oil press light blinking, then ran 20 min. Hooked it back to fuel line it ran 30 min until I shut it down. Looks like a call to P/T to find out how to bypass the low oil circuit in the control board without bypassing the high temp shut down. Not that I'm cheap it,s just against me nature to go buying parts just to see it that's it.

Re: Evil PT 10 generator

Reply #13 – June 27, 2011, 11:57:23 pm

bbeane, It is starting to sound like a wire rubbing (shorting) on a ground somewhere. I Must assume you are not running the fuel through the same fuel filter, but a new clean filter and still have the oil pressure issue.

Just for giggles, it is common for a low oil pressure fault to show up when there is a problem with the running of engine, and it stops, THEN the oil fault shows up. SO is it the chicken or the egg first ?

I think you are saying the generator is running great, good power and it just shuts down on low oil pressure or erratic oil pressure, if that is the case, yes it is either one or more of the following.

1- Bad / erratic oil pressure switch
2- Bad ES-52 (DynaGen)
3- Erratic grounding of the oil pressure switch wire
4- Low oil level or wrong oil viscosity (15W-40) recommended
5- As noted by another issue, does the generator go dead before it shuts down on oil.
6- Does oil light come on before engine stops or after engine stops ?

Not too many possibilities here.
Cheers

Re: Evil PT 10 generator

Reply #14 – June 28, 2011, 06:12:38 am

Dave M, New O/P SW from P/T, new wire from ES52 to op SW, 15-40 Rotella T, fuel filter is new, oil pressure is 80 psi on a new mechanical gauge W/engine running at operating temp. I have also visually checked to wiring harness inside the controll box and tightened all connections. Low oil pressure lite comes on blinking after gen shuts off. Up until then gen is running fine pulling a load (both A/C's). I am about to think I have eliminated the mechanical issues.

Re: Evil PT 10 generator

Reply #15 – June 28, 2011, 06:52:46 am

bbeane, Good info, Now for the one nagging issue and it is important.
DID the blinking oil light come on BEFORE the engine stopped
OR did the light come on after it stopped ?
Again the facts here are important and worlds apart in what the problem is.
I know it is a pain keeping an eye on the display and staying awake but still needed to know.
You could simply start throwing parts at it until it fixes its self, but being like me, hate paying for un needed items
The ES-52 module run in the low $200 area and it surely could be the problem, but after you replace it and still have the same issue, revert back to the above, what happened first red light or engine stop.

Re: Evil PT 10 generator

Reply #16 – June 28, 2011, 07:59:23 am

Changed primary fuel filter on Kubota engine for Power Tech.
Unit now stays running after first start up.
Thanks for the very useful info, for I was about to start throwing parts at it.

Re: Evil PT 10 generator

Reply #17 – June 28, 2011, 08:15:58 am

Dave, I'll watch it again, and see when the light comes on but I believe it's after shut down. I understand the chicken and egg deal, however the Genny has only 1500 hrs on it and 80 psi on a mechanical gauge with engine hot running, stranger things have happended but I don't anticipate internal issues given the durability of these engines. BTW the fuel system is clean with no alage issues and full of biocide treated fuel always.

Re: Evil PT 10 generator

Reply #18 – June 28, 2011, 04:24:21 pm

bbeane, Good info. Now since you suggest the light comes on after shutdown, this indicates the engine is stopping for some reason other than low oil pressure. It is common for the low oil light to light if the engine fails during a run time, like a loose wire to the fuel solenoid, bad fuel (we covered this), bad relay contacts, overload-stalling engine. IF the light came on then the engine stopped, now that is clearly an oil issue.
Sure could be a DynaGen ES-52 issue, I have not seen this same event with one, but there is always room for learning.
Think somewhere you mentioned loosing antifreeze when it stopped, makes me wonder if the hi temp and lo oil switch's are reversed. Lo Oil to terminal #2 and HiTemp terminal #3. Check the wiring, Anything is possible, why a good wiring diagram and a reliable test meter are real wonderful tools.
Not a biggie either way, just a pain in the butt, I can promise you when you find it you will remember it.

Re: Evil PT 10 generator

Reply #19 – June 28, 2011, 05:35:04 pm

Bruce, this could be a long shot, when the coach is dark at night, check the fault lite on the dash, and see if it has faint red glow, if so you have a bad ES52, if you have to change the
ES52 DO NOT go number for number, go nomenclature for nomenclature as the new replacements are numbered different.

Re: Evil PT 10 generator

Reply #20 – June 28, 2011, 08:54:56 pm

Dave M no coolant issues coolant temp 160 after extended run at 95 degrees. I'm going to check the latching relay, run relay, and fuel relay, and connections. May just replace all three when I get the #s off of them I should be able to find the locally for cheap with co discount. I agree with you once I find it, I will have gained a bunch if education about the generator for the next go around.

Re: Evil PT 10 generator

Reply #21 – June 29, 2011, 06:12:31 am

Bruce, I had a similar problem with my 2003 - 320. Generator would die for no apparent reason; sometimes it would run for 1/2 hour, sometimes 10 minutes, sometimes 5 seconds. After the generator would die (iluminate a fault light on the dash), I would go to the generator, reset and restart. I called Powerteck and they told me that if no warning lights were on the generator control panel, it was probably a fuel delivery problem or the shut-off coil. While in my driveway, I ran the generator until it died, approximately 5 min., immediately removed the fuel hose to the injection pump restarted the generator, and observed fuel delivery, more than adequate, as this generator uses less than a 1/2 gal per hour at fuel load. I reattached the hose, started generator and found that with the correct twist or movement on the shut-off coil, the generator would die. I could not find a replacement plug so I removed the coil, cut back the plastic to gain access to the little terminals and carefully soldered 2 - 6 in pigtails of fine-stranded 14 guage. I made a dam with aluminum tape around the plastic housing to contain JB Kwik epoxey to protect the soldered terminals and hard-wired with wire-nuts 3 inches back of original plug. I have been on the road twice, ran the generator for approx. 12 hrs., no problems. Hope this helps, good luck.

Gregory S
2003 Designer

Re: Evil PT 10 generator

Reply #22 – June 29, 2011, 11:19:35 am

Thanks Gregory, thats where I going next along with the relays.

Re: Evil PT 10 generator

Reply #23 – July 11, 2011, 09:16:48 pm

Ordered a new ES 52 controller from Parts for Techs well see what happends after we get installed.

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