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Generator starter is not working

PT 10000 Generator

On our way home from Texas we used the generator to run AC a couple days in a row for maybe 3 hrs each day.  On the last day I pushed the button to start the generator and it did not start.  At a rest stop I tried it from the front end to see if there were fault lights.  Pushed the switch to start, pre heat comes on, fuel pump starts, engine running light is blinking but the starter motor does nothing.  Battery power is good, controls have power, no tripped circuit breakers that I can see.

It is in a quiet box on the 2001 so not easy to get at anything and the starter is on the back side of the Kubota engine.

I pulled the generator slide out after disconnecting the exhaust,  it comes out about 10", is that all there is?

I called PowerTech, waiting for a call back.  Any suggestions what to look for? I am hoping for a simple solution.  We are up to 374 hrs on the generator, mostly 1/2 hr every month it seems.
Roger Engdahl and Susan Green
2001 U320 3610 #5879 (Home2) - 2014 Jeep Cherokee or 2018 F150
Hastings, MN

Re: Generator starter is not working

Reply #1 –
Roger,

I have seen the little control wire to the start solenoid on the starter come loose causing a non start.  It is a PITA to get to where you can check it.  I have also seen one unit that the wire had gotten next to the exhaust and melted.  This would the the first thing that is simple to check then take a good look at the starter.

Mike
Pamela & Mike 97 U 320

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

Re: Generator starter is not working

Reply #2 –
Roger I was able to sit up in the area behind the generator when I replaced the fuel lines. Also you can unscrew the back panel and access from the rear. I don't know if the internal insulation will be a issue. Currently all my insulation is ripped out.
Scott

Re: Generator starter is not working

Reply #3 –
Look at the wires connecting to the ES52 controller, the one with the led lights.  Sometimes with the vibrations these can be loose.  There is also a Finder relay inside the box with the ES52 for the multiple switch (same one as the water pump) and 3 cube relays.  Any of these could be bad or have a loose or broken wire or unplugged.
When I moved the ES52 and relays to the side compartment I found a broken wire in the wiring loom that was causing my shutdown.
Forest & Cindy Olivier
1987 log cabin
2011 Roadtrek C210P
no longer 1999 36' U320 build #5522
2013 Rzr 570 & 2018 Ranger XP1000
2006 Lexus GX470
2011 Tahoe LT 4x4
Previous 1998 45' 2 slide Newell, 1993 39' Newell

Re: Generator starter is not working

Reply #4 –
Thanks for the rear access idea Scott, I though of that last night. Your quiet box is the same as mine. I am really hoping for a lose or broken wire.

Forest, do you have a wiring diagram?
Roger Engdahl and Susan Green
2001 U320 3610 #5879 (Home2) - 2014 Jeep Cherokee or 2018 F150
Hastings, MN

Re: Generator starter is not working

Reply #5 –
Quote from: Roger & Susan in Home2 –
Your quiet box is the same as mine.

Think I can only rate mine as a box since it's stripped clean. Curiously all the vents were covered over with soundproofing. Winter project
Scott

Re: Generator starter is not working

Reply #7 –
Howdy Roger, A print from '00, but the date on print inclusive to 09/12/01. Probably cover your coach.
Good luck, Dave A
Dave and Nancy Abel
'00 U320 36' WTFE  Build #5669
'10 Jeep Wrangler Unlimited Rubicon
Livingston, TX  SKP's Fulltiming

Re: Generator starter is not working

Reply #8 –
Thanks for the elect diagrams. Pouring rain for the last few days so this is on hold. Tomorrow.  It is a tight squeeze to get at wiring. No fun if you are wet.
Roger Engdahl and Susan Green
2001 U320 3610 #5879 (Home2) - 2014 Jeep Cherokee or 2018 F150
Hastings, MN

Re: Generator starter is not working

Reply #9 –
Quote from: Roger & Susan in Home2 –

I called PowerTech, waiting for a call back.  Any suggestions what to look for? I am hoping for a simple solution.  We are up to 374 hrs on the generator, mostly 1/2 hr every month it seems.

Good luck with that. Still waiting on a call back from last week for my generator questions.
Hope you get it sorted.
'99 U320 40 WTFE
Build #5462,
1500 Watts Solar 600 amp Victron lithium
2012 Jeep Grand Cherokee Overland Hemi
Instagram bobfnbw
Retired

Re: Generator starter is not working

Reply #10 –
Well I spent several hours working in very tight quarters to get the rear panel off the generator box, you have to take the top and the front off to get the back off and then there was no obvious way to get (or even see) the starter motor.  I put it all back together.

I tested all of the relays tha the all work. Preheat comes on, fuel pump pumps, but the starter does not engage.  And I noticed a fuel line was leaking right at the top of the loop towards the passenger's side rear of the generator. I already had some time scheduled with a mechanic and while there he fixed the fuel line.  He said he could see the starter through a round access hole in the bottom of the case so he stuck a long bar in there and gave the starter a couple whacks.  When he tried the generator it started, and again 5 or 6 more times.  I started and ran the generator on the way home.

I know where the hole is and I have something for the whacking if needed. I should consider replacing the starter ... after figuring out how to get to it.
Roger Engdahl and Susan Green
2001 U320 3610 #5879 (Home2) - 2014 Jeep Cherokee or 2018 F150
Hastings, MN

Re: Generator starter is not working

Reply #11 –
Mine was acting up would shut down and not restart. Ended up being the 15 Amp fuse in the holder on the front of the outside control panel. Fused was not blown but the twist in fuse holder was bad. Looked ok except that the fuse was tight in the holder and would lose contact when I would hit bumps in the road. Switch fuse holder with the 5 Amp and generator started right up. Might not be your problem but easy to check.
Larry
Larry & Debbie Town
2000 U320 4210 
Previous 88 GV
 

Re: Generator starter is not working

Reply #12 –
Mine was acting up would shut down and not restart. Ended up being the 15 Amp fuse in the holder on the front of the outside control panel. Fused was not blown but the twist in fuse holder was bad. Looked ok except that the fuse was tight in the holder and would lose contact when I would hit bumps in the road. Switch fuse holder with the 5 Amp and generator started right up. Might not be your problem but easy to check.
Larry
Larry & Debbie Town
2000 U320 4210 
Previous 88 GV