Generator quits after starting

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Generator quits after starting

November 14, 2022, 07:54:45 pm

Hi everyone,
I have a 10k powertech with close to 4000 hrs.
Last service was in August and I've put about 20 hrs without an issue.

I started it the other day and it ran perfectly for about 40 min then it stopped while we were driving.
About 10 minutes later we arrived at our destination. No lights on the panel so I reset it and it started again and ran for about 5-10 min and stopped.
On the third time I heard a click and no start.

I pulled both glass fuses from the front and one broke when I pulled it out. Some corrosion was noted on the fuse cap.

Both fuses replaced and the generator started again but quits working very quickly now.

I pulled the generator out after removing the exhaust, slide stop. While under the coach I noticed some weeping from one of the coolant lines.

I opened up the control box on top.
I did not see anything unusual but did not take any readings since I don't have the service manual. It is a tight space with the front access door on the coach.

I thought I might have some air in the lines from the weeping of the hoses so today I opened both valves and ran the generator but it stopped real fast. I will probably disconnect both lines and bleed as per directions found here to see if anything changes. The surge tank was also checked and it was full.

I searched for the service manual but the link was dead. I have the owners manual.
I did not find the service manual at the powertech website.

Thanks for you input.

Re: Generator quits after starting

Reply #1 – November 14, 2022, 08:30:40 pm

Frank,

You didn't say if you had an overheat indicator on your ES-52 module. If you don't have an overheating indicator you are barking up the wrong tree. Now you may have a failing fuel relay on the ES-52 and that don't have a failing indicator. If this repair place tells you that you need a module for $300 or $400 bucks decline and start by installing a new relay for 5 or 6 bucks. I'm tied up with an upcoming surgery for my mother this week or I would see if you could swing by with you in the area so we could have a troubleshooting session.

Mike

Re: Generator quits after starting

Reply #2 – November 14, 2022, 08:35:32 pm

I had the same thing happen. It was air in the system due to millions of tiny cracks in the generator supply hose. I had changed the filter, etc but no joy. Easy job to replace the supply line on a U300 and if your ducks are in a row, you can change it out in 30 minutes. I put a pressure gauge on the output of the secondary filter and a temp gauge. See my old post for photos and how to do it. You don't have to slide out to change the hose. Later coaches may require more work.

I just used a gallon fuel can and bypassed the supply line to make sure it was the problem. Very easy to do. This will eliminate fuel as your stoppage.

Pierce

Re: Generator quits after starting

Reply #3 – November 14, 2022, 08:58:27 pm

Hi Mike,
No overheating indicated on the panel ES-52.
I guess the relay is in the ES-52. What does it look like?
Unfortunately when I took the cover off the other day I did not take any pictures.
I just got to Propman's (Al & Tauna's) a couple of hrs ago.

Thanks

Re: Generator quits after starting

Reply #4 – November 14, 2022, 09:00:03 pm

Pierce,
Will check fuel lines tomorrow.
Thanks

Re: Generator quits after starting

Reply #5 – November 14, 2022, 09:23:53 pm

Quote from: Lt403 – November 14, 2022, 08:58:27 pm

I guess the relay is in the ES-52. What does it look like?

Here you go with part numbers
Generator intermitten self shut down
You may find a couple of other pics.by searching ES-52 under my post.

Mike

Re: Generator quits after starting

Reply #6 – November 14, 2022, 09:35:48 pm

Thanks Mike,
Just to make sure this is the ES-52

Re: Generator quits after starting

Reply #7 – November 15, 2022, 12:36:11 am

had same issues and it was low coolant .

Re: Generator quits after starting

Reply #8 – November 15, 2022, 06:54:45 am

Frank,

Those indicator lights on the right side of the pic is part of the ES-52. The pic. I referenced shows the backside. After you finish with checking the water like you mentioned and the fuel lines then pull the cover off of the control box and look around for a loose connection on all the wiring. Do the easy first before taking the ES-52 out as it is a pain to get it reinstalled due to how/where it is mounted. The 2 Philips screws that you see is what mounts the ES-52 to the faceplate.

By the way which power unit do you have Kubota, Isuzu, Perkins? With your year it could be any one as all were used along those years.

Mike

Re: Generator quits after starting

Reply #9 – November 15, 2022, 07:31:23 am

Same issue- fan belt on Benny water pump broke- would send it to overtemp without any lights. Squirrel cage fan still ran. Fan belt is real thin and fortunately had one on hand

Re: Generator quits after starting

Reply #10 – November 15, 2022, 09:21:27 am

Good morning

Mike. I have the kubota. Will pull generator out and look inside the es52 for loose wires. Will post pics .

Danilaprepeliac. Will recheck coolant level,

Ernie. Belt for water pump is still there.

Thanks again for input

Re: Generator quits after starting

Reply #11 – November 15, 2022, 12:17:32 pm

I started the generator this morning and it ran for about nine minutes before it shut down.
Here are some pictures

Re: Generator quits after starting

Reply #12 – November 15, 2022, 12:45:15 pm

I had exactly the same issues on tge 2000 295 we had. Checked all the above mentioned items plus replaced the relays in control box, still stopped after a while. I spoke to Tech and he suggested taking an air line to all parts inside box on genset as dirt has been the culprit many times. Did as told and it ran like a top, no more stopping abruptly. In your pictures pull out the white relay and give it a good blow out as that fixed mine.
Johnh

Re: Generator quits after starting

Reply #13 – November 15, 2022, 12:48:19 pm

Thanks John

Re: Generator quits after starting

Reply #14 – November 15, 2022, 01:40:18 pm

When we had the similar problem it was a very loose belt and the idler pulley hadn't been turning in so long that it froze up.

Next time it happened it because the geny radiator was really , really dirty. Hosed it out and no more issues.
Embarrassed that my regular maintenance did not catch either issue. I've got to up my game.

Re: Generator quits after starting

Reply #15 – November 15, 2022, 03:37:18 pm

Well,
Removed both relays from the ES 52 and checked with multimeter. Both relays clicked and both relays had continuity with electric apply.
Also changed the fuel filter.

Started Generator up and ran for Six minutes before it shut down.

It seems that the fuel pump continues to run for a few seconds after the engine has shut down then stops.

Re: Generator quits after starting

Reply #16 – November 15, 2022, 03:38:44 pm

I had the same issue and it was the latching relay. Also check all connections.

Re: Generator quits after starting

Reply #17 – November 15, 2022, 04:08:19 pm

Hi Bob,
When your radiator was dirty were you getting an over temp light Or any other indicating light

Re: Generator quits after starting

Reply #18 – November 15, 2022, 05:39:33 pm

PS- my belt was still on water pump, but was a bit stretched. There is no way to tighten the belt except a new one- crummy design.

Re: Generator quits after starting

Reply #19 – November 15, 2022, 05:46:55 pm

'99 was the last year of the adjustable belt. I had to call Jeff as I couldn't believe that the 2000 wasn't adjustable.

Re: Generator quits after starting

Reply #20 – November 15, 2022, 08:03:13 pm

Don't know how old my belt is for the water pump but I will look at it closer tomorrow along with the big white relay.

Ran out of time today

Re: Generator quits after starting

Reply #21 – November 15, 2022, 08:57:44 pm

I have had a lot of little issues with my power tech kabota. Reading thru all of the posts and suggestions a lot point to overheat but you say no light so I assume the 120v fan for the radiator is coming on. If so then it will probably be fuel problem.

Kabota has a fuel selonoid or cut off, or shut down selonoid all different names but the same thing. 12v opens fuel supply to the injection system and no power it shuts off. One of the mini relays in es52 controls this. Mine was bad sending power but not enough current to hold the selonoid open. Over heats the windings and then shuts down. I had to replace selonoid also most kabota dealers stock this part common failure 100 bucks I believe it was.

You can put your hand on it when running and if is hot to touch it could be your problem.

My 2 cents
Alan

Re: Generator quits after starting

Reply #22 – November 15, 2022, 11:48:58 pm

Thanks Alan,
The fan is running. I actually replaced fan motor and capacitor right after the big freeze in Texas last year
I ordered a few relays for the es52 earlier today. I was planning on swapping them out just in case. Should arrive in a day or two.

Re: Generator quits after starting

Reply #23 – November 18, 2022, 01:35:44 pm

Swapped out both relays this morning on the ES-52 .

No change, generator still shuts down after a few minutes.

Re: Generator quits after starting

Reply #24 – November 18, 2022, 02:17:16 pm

Frank. Unfortunately our 95 didn't come with any indicator lights.
If memory serves it would run about 15 to 20 min before shut down.
I really need to run some gages for water and oil.

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