Generac 75D Starting Issue Resolved

[zzjea]

Ever since I've owned this 2001 National Marlin (4 years), the Generac 7.5KW diesel generator has been hard to crank and occasionally would start. I had tried everything over several years including 3 starters and 2 solenoids. It turns out that by accident I discovered that the spacer for the starter motor was aluminum and was not permanently attached to the flange that held the motor. This spacer had oxidized to such an extent that the ground path from the starter was restricted and the starter drew excessive amps. It was a grounding issue but not where most everyone suspected. I thoroughly cleaned the spacer and flange, etc. and it cranks every time now. Am also using dielectric grease on all electric connections including the spacer.

I hope this will help someone who might have this setup. I cost me a lot of money and hours of effort.

[Randy125]

Wow great troubleshooting thanks.

[zzjea]

Originally Posted by Randy125

Wow great troubleshooting thanks.

I may use Ox-Gard on the aluminum flanges although it took 18 years for the oxidation to get this bad. If it wasn't so difficult to get the back mounting bolt in and out (starter motor), I definitely would put it on all the aluminum surfaces.


Thanks for the reply. I hope it helps someone else.

[twinboat]

No need to remove the starter, run a short ground cable from a easy accessible starter bolt to the engine block or generator ground point.

[AF Nomad]

I need to replace the drive belt Idler pulley and both belts on my Quietpact 75D. Where do you guys get your parts?

[bddadles]

Good info. Thanks.