Powertech generator: Sudden stopping problem...again

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Powertech generator: Sudden stopping problem...again

September 09, 2012, 08:22:42 am

In August I posted that our 8 kW Powertech generator suddenly quit while we were driving and running the house AC. I found low coolant level and added around 20+ ounces of 50/50 mix as recommended by James T. However, the sudden stopping after running approximately 30 minutes has happened again. The red fault light on the dash came on, but there were no fault lights on the generator. We are passing back through Idaho and slowly heading back to Nacogdoches. There is no Powertech service in Idaho. So, I called Jon Thompson at Gem State Generators. He came to our campground and checked the coolant level, the air filter, air flow around the radiator, and oil level. The generator started OK and was run under no load. He said heat related problems would result in a fault code on the generator. Naturally, no problems were found. His suggestion was to stop in at Jeff Peterson Generators in Salt Lake City and get the generator load tested. (He knows Jeff Peterson). There are two Powertech Generator dealers in Utah. (The one in Salt Lake City is not Jeff Peterson).
There are also two Powertech dealers in Nacogdoches: Encore RV and Genuine RV. And of course there is FOT and MOT. I like the idea of a load test and allowing the generator to reach operating temps.
Any other suggestions as to where I might take the generator to?
Thanks
Bob
2000 U270

Re: Powertech generator: Sudden stopping problem...again

Reply #1 – September 09, 2012, 08:44:17 am

Does the start up normal. & run ok for awhile, if so think fuel filter replacement. Otherwise low coolant, low oil pressure or loose / shorting wiring, fan working?
Dave M

Re: Powertech generator: Sudden stopping problem...again

Reply #2 – September 09, 2012, 08:53:36 am

Dave:
It starts and runs fine. After 30 minutes under AC load, it stops. Oil, oil filter, fuel filter, air fliter were changed in May at FOT. Thinking bad fuel, I had a new fuel filter installed in August. The fan pulls lots of air.
BobW

Re: Powertech generator: Sudden stopping problem...again

Reply #3 – September 09, 2012, 09:04:58 am

Good Morning Bob
This pass spring I decided to change the belts and hoses on my 10kw Powerteck and while I was disassembling I noticed the radiator was blocked up to some degree after I got it off I could see it was probably 30% stopped up with grit and the plastic from the insulation in the box, You might take a look as this is a possibility..

Re: Powertech generator: Sudden stopping problem...again

Reply #4 – September 09, 2012, 10:12:41 am

It still sounds like a fuel filter issue, some units have an additional fuel filter that most folks either dont remember or do not kow about, it is located underneath and between the generator and the fuel tank.
The complaint of running 30 minutes and stopping, let sit a few minutes and restart for another 30 min before it dies again. I would be looking for the 2nd filter and you are not the first or second to have this same issue.
Worth a look see
Dave M

Re: Powertech generator: Sudden stopping problem...again

Reply #5 – September 09, 2012, 10:33:30 am

Load test it yourself.

Run both roof air, electric floor heaters, etc.

Some electric lit pumps have a small filter that looks like a connector fitting.

Look for air being sucked into fuel lines.
Test by connecting a new hose from generator into your own temporary fuel supply tank.

Keep running it and whatever was the problem, may go away.

I don't think Encore or Genuine are the place for this problem.

Try tech Keith Risch at MOT.

Re: Powertech generator: Sudden stopping problem...again

Reply #6 – September 09, 2012, 11:18:56 am

Genuine RV is owned and run by Bob Morris and his brother where Bob is the service manager. Bob is the long time ex-service manager of Foretravel. He has forgotten more about Foretravels than most men know. Bob Morris is the man that trained Keith Risch, hence Keith's excellent service.

Although Bob is busy maintaining the towables that Genuine sells, he has worked on Foretravels there. Call to see if he can fit you into his schedule.

Re: Powertech generator: Sudden stopping problem...again

Reply #7 – September 09, 2012, 11:21:31 am

The next time you have it running maybe shoot the coolant lines with an IR thermometer, see what kind of temps you're running. As Barry says, you can load test it yourself with the AC units and microwave.

My money is on fuel problems though, bad filter, sucking air, failing fuel pump. Is the fuel pump the little square looking job or a cylindrical facet type?

Chuck

Re: Powertech generator: Sudden stopping problem...again

Reply #8 – September 09, 2012, 12:22:56 pm

I wonder if it could be a bad latching relay? I had to replace mine. It would die sometimes. I am dealing with major issues on my 8k as well at the moment. FOT has given me very poor service and I will most likely never use them again. Its a long story. I may post more later. I would try the others suggested before FOT.

Mark Z

Re: Powertech generator: Sudden stopping problem...again

Reply #9 – September 09, 2012, 06:33:19 pm

Regarding what Chuck said about the square fuel lift pump: We replaced our original square pump with a cylinder shaped 12-volt fuel pump. This pump is used to prime the system during pre-heat and works to pull fuel from fuel tank to supply the injector pumps.

Re: Powertech generator: Sudden stopping problem...again

Reply #10 – September 09, 2012, 06:52:51 pm

Inline fuel filter. ck it as it appears to just be an end to a hose going to electric pump. Had 99 and it was still original in 2009. It is so often overlooked, DAN

Re: Powertech generator: Sudden stopping problem...again

Reply #11 – September 09, 2012, 06:59:57 pm

To eliminate any fuel problem get a cheap on demand electric pump, 2 gals of diesel in a jug, and some fuel hose. Run some hose from the jug to the cheap (does not have to be a "for diesel" pump, a pump is a pump") pump, then some hose from the cheap pump to the fuel in at the 8k, thereby bypassing the existing pump and wire the cheap pump always on. Run the 8k for an hour if possible and then you KNOW it ain't fuel unless it would be the injector pump which I doubt. BONUS.........run the 8k for the hour on load and you'll know it's mileage.

Perhaps I said pump too many times.

Re: Powertech generator: Sudden stopping problem...again

Reply #12 – September 09, 2012, 07:08:52 pm

Quote

Inline fuel filter. ck it as it appears to just be an end to a hose going to electric pump. Had 99 and it was still original in 2009. It is so often overlooked, DAN

There's a photo of the inline fuel filter on Foreforums somewhere. That will help finding it on the generator.

It's about $2-$3 at Napa. I carry a spare.

best, paul

Re: Powertech generator: Sudden stopping problem...again

Reply #13 – September 09, 2012, 08:29:47 pm

We had similar problems and found a cracked fuel line. Replaced fuel line from tank to generator and solved it. No easy job; had to remove the propane tank and find a tiny fellow to get in there.

Re: Powertech generator: Sudden stopping problem...again

Reply #14 – September 09, 2012, 08:32:20 pm

I would not rule out the chance of cracked dried out fuel lines, as mentioned by Barry and Cindy..... Air leaking around my front 10 feet of generator fuel line hose junctions was my problem last year. Couple of big air bubbles will shut it down.

david

Re: Powertech generator: Sudden stopping problem...again

Reply #15 – September 10, 2012, 11:41:57 am

When our generator had to be pulled out to have a rotor wire repaired, we went through a series of problems and fixes before it would run long enough for me to drive around the block without turning back to the shop. They topped off the coolant, changed the oil, swapped out the oil pressure switch, swapped out the coolant temperature switch, bled the air out of the coolant, and finally solved the problem by changing the coolant level float/switch assembly (they, an auhtorized PowerTech shop, didn't even knowit existed until I showed it to them in the FT schematic.

Re: Powertech generator: Sudden stopping problem...again

Reply #16 – September 10, 2012, 11:43:43 am

Here is the fuel pump prefilter.

Mark Z

Re: Powertech generator: Sudden stopping problem...again

Reply #17 – September 10, 2012, 12:49:49 pm

That is NOT the filter used on all coach's. The filter in question is between the generator and the fuel tank, you can get to it from underneath, it is a Racor, same as the Aqua Hot Fitler.
It is the filter that lots of folks either forget or do not want to look for, either way it provides the exact same description as mentioned above when it gets stopped up from either water or trash.
Cheers
Dave M

Re: Powertech generator: Sudden stopping problem...again

Reply #18 – September 11, 2012, 12:44:23 am

I had a similar problem with an Isuzu powered Powertech 10 kw on my 1998 FT 320. The problem went away when I replaced the temperature sensor. Verify by pulling the single conductor from the sensor which is located on the back side of the block just below the thermostat housing. If the problem goes away it is either a faulty sensor or the temperature is running above 240 degrees F ( A fact that I learned from Powertech). If the problem does not go away, then look elsewhere. If you determine that it is the temp sensor, I can share some tips that may save some time.

Re: Powertech generator: Sudden stopping problem...again

Reply #19 – September 12, 2012, 08:58:36 pm

Thanks to all for your input. A service tech from Precision Power in Lawton, UT immediately found the Racor R12T, the fuel-water separator, and said that it looked like it has never been changed. (I had generator service at FOT in May 2012. They changed the oil, oil filter, air filter, and fuel filter. They evidently did not check the coolant level because I added about 30 oz last week). The tech also found a leak in the return fuel line. He ended up replacing about nine feet of fuel line.
He also found that the electrical box behind the generator was mounted about an inch too low. When the generator is pushed back in place, the electrical box made contact and crimped a fuel line entering the generator. It had lasted 103,000 miles without leaking, but it had been damaged. The box was raised and the fuel line was replaced. See attached pic.
The generator was then load tested using both overhead ACs and the electric water heater for over twenty minutes. His IR thermometer read 180 degrees on the generator. Since he had the heat gun out, I had him read the temps of the gray and silver paint on the front of the motorhome in the direct sun light. Gray = 157 degrees and silver = 127 degrees.
Bob
2000 U270

Re: Powertech generator: Sudden stopping problem...again

Reply #20 – September 13, 2012, 07:44:33 am

Hi Bob,
Nice follow up, glad they found the problem.
Rick

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