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Topic: Generator problems again (Read 606 times) previous topic - next topic

Generator problems again

My Powertech 10 KW has been working well, until now.  Started up and died very quickly.  I got the red fault light inside but no fault lights on the generator. I tried it several times, got it to run almost 12 minutes once, then died- sounded like fuel starvation.  I changed fuel filters, tried it again, similar results over many tries.  Had it run almost an hour total when I add up all the 5 minutes, 2 minutes, etc, changed fuel filters again.  No joy.  Roland helped me take out the fuel pressure solenoid, zip tie it up and plug the hole where the solenoid was.  We could see very quickly after starting the generator the green run light would go off and the solenoid would push out the rod which would cut the generator off.  No fault lights.  Even then the generator would grumble to a halt.

We got a new piece of fuel hose and hooked it on the suction side of the fuel pump to test it- no joy.  Replaced the original fuel line and tested some more, still cannot get it to stay running long and do not think it is fuel with changing 2 sets of filters so soon.

Conclusion- something electrical is telling the fuel solenoid to shut off early- no idea why.
And something else is causing the generator to grumble to a stop - no idea why.

We will be in Yuma tomorrow- anyone there have any ideas or recommend a good tech or shop?  I am at a lost with this and reluctant to keep trying to by pass the faults as I read that they are safety devices and I could cause an expensive repair by running it when the fault says not to.

Your help and ideas are always appreciated..              ^.^d
Ted & Karen
2001 U270 36' - sold after 12 years full timing

Re: Generator problems again

Reply #1 –
Try checking all wire connections in and around the generator, there are some 2 and 3 wire conections where the wire from one end
may have pulled out of the connector.What about a bad oil pressure shutdown?
96 U270 BUILD 4810
85 380SL
Drummonds TN.

Re: Generator problems again

Reply #2 –
Oil pressure switch is a common failure item - and signals fuel solonoid to close.
Dan - Full timing since 2009
2003 U320 40' Tag 2 slide

Re: Generator problems again

Reply #3 –
oil pressure switch was just replaced in September along with the fuel pressure solenoid.  I looked for loose wires but haven't found anything that stands out to me.    Thanks
Ted & Karen
2001 U270 36' - sold after 12 years full timing

Re: Generator problems again

Reply #4 –
It won't hurt to jump the oil solenoid to see if it is the problem. As long as the oiling system is working, no knocks or other noises. The other option is to read continuity across the solenoid after the engine starts to see if a connection continues until after the engine shuts off.
1999 40 ft. U-320 wtfe build 5563 Chuck & Lynda's "Rollin' Inn"  2030 watts solar
prev. mh's 71 GMC 5 yrs. 73 Pace Setter 1 yr. 78 Vogue 5 yrs 81 FTX 40ft all electric 18 yrs. 1996 Monaco Signature 3 yrs.
2014 Grand Cherokee Overland
Dream as if you will live forever. Live as if you will die today.  James Dean

Re: Generator problems again

Reply #5 –
Worst case, limp to "Q" and we can help you there.
96 U270 BUILD 4810
85 380SL
Drummonds TN.

Re: Generator problems again

Reply #6 –
To confirm a consistent supply of fuel, I temporarily replaced the short section of fuel hose after the fuel filter with a piece of clear tubing.  It made it easy to see bubbles in the fuel supply.  The source of my issue a previous owner spliced in a short section of 3/8 supply line using a 5/16 fitting which was allowing air to enter the supply side.
40ft 1997 U320

Re: Generator problems again

Reply #7 –
Unplug the water temperature sending unit on the back side of  engine. If it runs unplugged, it's the sending unit. Wire just plugs on the end of the unit.
The selected media item is not currently available.
Lynn & Marilyn Sickel
Tollville, AR
1997  U320  40'
2021 Chevrolet Silverado pickup
Motorcader  17257

Re: Generator problems again

Reply #8 –
If the electric fuel pump is on the edge of failing, that is also a possibility. Good to see if the pump is still getting juice after the engine stops. If air is getting into the system, leaving the "T" handled valve partially open will allow any air bubbles to go back to the tank while the generator is running. The electric pump does not produce enough pressure to open the relief valve back to the tank and the air can build up until the injection pump is starved for fuel.

I installed a temp gauge and fuel pressure gauge on the generator engine so I could eliminate some possibilities.

Pierce
Pierce and Gaylie Stewart
'93 U300/36 WTBI
Detroit 6V-92TA Jake
1140 watts on the roof
SBFD (ret)

Re: Generator problems again

Reply #9 –
I once had a similar fault caused by the coolant level float switch. It had no fault light. Just wired in.
Tom Lang K6PG (originally  KC6UEC)
and Diane Lang
2003 38 U295 build 6209
2016 Jeep Grand Cherokee Summit Ecodiesel
still have tow-ready 2006 Acura MDX 
Temple City, California
Motorcade 16681 California Chapter President
SKP 16663 member of SKP Park of the Sierra, Coarsegold California
FMCA F071251
Retired electrical and electronic engineer

Re: Generator problems again

Reply #10 –
Is it producing electricity?
Tom Lang K6PG (originally  KC6UEC)
and Diane Lang
2003 38 U295 build 6209
2016 Jeep Grand Cherokee Summit Ecodiesel
still have tow-ready 2006 Acura MDX 
Temple City, California
Motorcade 16681 California Chapter President
SKP 16663 member of SKP Park of the Sierra, Coarsegold California
FMCA F071251
Retired electrical and electronic engineer

Re: Generator problems again

Reply #11 –
Ted,

You might try to swap out the 2 relays on the  ES-52 to see if the problem changes. Here is a link to see I am talking about and what you will be looking for.  Stubborn Powertech Generator

Mike
Pamela & Mike 97 U 320

"It's not what happens to you, but how you react to it that matters."

Re: Generator problems again

Reply #12 –
When mine was playing those games it ended up being the ES52.
Bruce, Linda, and Macy
Zoey RIP 1/20/19
1999 U295 40' build #5400
2017 silver Jeep Wrangler, 1260 watts of solar on top
Moving around the country

Re: Generator problems again

Reply #13 –
Low coolant will also cause the no run. Mine did the same thing. It was low  coolant. Pull the rad cap and physically inspect the level in the rad. It turned out to be the solder connection was faulty and slowly lost coolant till it would start. Run a few minutes and stop.
Good luck,
Safe Travels
Dave
2001 U320 40ft
Build #5867
2003 Tracker
VE7DOD

Re: Generator problems again

Reply #14 –
Quote from: Dave Dunington –
Low coolant will also cause the no run. Mine did the same thing. It was low  coolant. Pull the rad cap and physically inspect the level in the rad. It turned out to be the solder connection was faulty and slowly lost coolant till it would start. Run a few minutes and stop.
Good luck,
Safe Travels
Dave
And if it is low coolant, there is a specific procedure to "burp" it (at least on our 2003 U320).  Procedure for bleeding the coolant system on Powertech Generators



I  had this problem after OTM drained and refilled our generator coolant a couple of years ago.  A air pocket trapped in the system would turn to steam, overheat the sensor, and shut the generator down.  The burp procedure fixed it.

" It turned out to be the solder connection was faulty".  I also suspected the solder connection. I used 2 part JB Weld epoxy around the neck after wire brushing first.  Still holding strong more than 2 years later.


Dan - Full timing since 2009
2003 U320 40' Tag 2 slide
 

Re: Generator problems again

Reply #15 –
Mine was running anywhere from 5 minutes to 10 hours, changed the ES52 and knock on wood no problems so far


Keith
The selected media item is not currently available.Keith & Jo
2003 U320T 4025 PBBS Designer series
Build 6203    Cummins 500hp
2000 U320 4010 WTFE / Build 5762 —Sold—
Motorcade #18070   
Pasadena, Texas
2015 Jeep Wrangler Sahara-Sunset Orange pearl coat
Don't argue with a fool, people watching might not be able to tell the difference.