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Old 03-02-2021, 10:19 PM   #1
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Generator Issues Please help

Hello all, Iím in need of some help. I have A 2005 American Eagle 40L with a Powertech 8k generator with 640 hours. It has been serviced on a regular basis. How ever several times I have gone to shut off the Gen and it would grind like it was trying to be started I would eventually get it shut off by waiting or going to the actual generator and shutting it off at the unit. A couple months back on one of our trips I woke up and turned the gen on with the switch next to my bed. I happened to fall back to sleep. When I woke up a hour later the gen was off and wouldnít restart. Turns out it fried a starter. So I had The starter rebuilt and installed it. Since rebuilding it when you turn it on it will run for a couple minutes and then The starter tries to start it again and makes a horrible grinding noise. So I had a gen repair man out and he thought it was a sticking relay so we replaced all the relays and the switch on the gen and inside switches on the Dash and bedroom and it still tries to start on its own. I can Tap the switch very lightly like Iím gonna shut it off and the grinding stops for about 10 seconds and then starts grinding again. I have Disconnected the auto gen board in the control panel and it still does it. The only way we have been able to get it to stop is by disconnecting the plug on the side of the gen that leads to the dash and back bedroom switch. It puts out power like itís suppose to but I cant slide the nose cone out each time to start the gen. Anyone else have this issue or suggestions or ideas Thanks for the help
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Old 03-03-2021, 04:29 AM   #2
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Probably insulation on wiring somewhere allowing two wires to touch together as if you were trying to start the generator.
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Old 03-03-2021, 06:14 AM   #3
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Quote:
Originally Posted by Azrv001 View Post
Hello all, Iím in need of some help. I have A 2005 American Eagle 40L with a Powertech 8k generator with 640 hours. It has been serviced on a regular basis. How ever several times I have gone to shut off the Gen and it would grind like it was trying to be started I would eventually get it shut off by waiting or going to the actual generator and shutting it off at the unit. A couple months back on one of our trips I woke up and turned the gen on with the switch next to my bed. I happened to fall back to sleep. When I woke up a hour later the gen was off and wouldnít restart. Turns out it fried a starter. So I had The starter rebuilt and installed it. Since rebuilding it when you turn it on it will run for a couple minutes and then The starter tries to start it again and makes a horrible grinding noise. So I had a gen repair man out and he thought it was a sticking relay so we replaced all the relays and the switch on the gen and inside switches on the Dash and bedroom and it still tries to start on its own. [B]I can Tap the switch very lightly like Iím gonna shut it off and the grinding stops for about 10 seconds and then starts grinding again.[/B] I have Disconnected the auto gen board in the control panel and it still does it. The only way we have been able to get it to stop is by disconnecting the plug on the side of the gen that leads to the dash and back bedroom switch. It puts out power like itís suppose to but I cant slide the nose cone out each time to start the gen. Anyone else have this issue or suggestions or ideas Thanks for the help
If tapping the switch makes the grinding stop for about 10 seconds.... then that is likely the problem. Suggest you replace the switch.
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Old 03-03-2021, 06:18 AM   #4
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If tapping the switch makes the grinding stop for about 10 seconds.... then that is likely the problem. Suggest you replace the switch.
Ok.... I now see where the switch was replaced.
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Old 03-03-2021, 06:38 AM   #5
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Take pictures of all of your generator switches inside.

Then disconnect all but one. Have someone at the generator ready to pull the plug apart that stops the nonsense so you don't damage another generator.

Without a schematic it makes it a bit difficult to suggest any voltage readings but if you are handy with a voltmeter/ohmmeter I would suggest getting some readings on the switches so we can reverse engineer how it operates.

It sounds like shorted wires but a switch can do it as well. I understand you have replaced the switches but having them all out at first will help with confidence in troubleshooting.

The "command" to start or stop may be just a "logic" high or low signal being sent to a control board. That is, is is highly unlikely the switches run directly to any relays without that signal being sent through some electronic control.

What I mean by the logic high or low is that it may take a very very low current to cause the generator to trigger the starter.

If there is any "leakage" going on in a connector do to water entry or just one strand of wire being eaten it could cause your issue.

A voltmeter could catch it but an ohmeter might be the better choice. Get some reading with the harness plugged and unplugged at the generator where disconnecting it stops the nonsense.

For safety if possible find the starter relay wire (the light one) that controls the starter, not the battery feed that passes through the relay. And install your own jumper wire that you can extend out to a safe location where you can mount a switch temporarily.

Once you start the generator you can flip the switch so the starter cannot be engaged and also have a place to connect a meter or test light which would be even better/quicker. The test light would come on if you connect to the control voltage side of the switch when the thing is trying to start again. With this disconnect you can take measurements on the switches and follow the wires.

You could build your own wired in test light with a long wire so it could be dragged to any location.

At this point if you are not comfortable with this you have to follow every inch of that control cable, no matter how many bruises or bumps you get. I like a head lamp and often do it after dark. The shadows and bright light during the day can cause you to overlook something. Your phone camera is very handy it tight spots.

You may have to become familiar with a "signal tracer" as well.

Good hunting and thanks for listening if you are still with me.
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Old 03-03-2021, 07:57 AM   #6
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Hi ! Welcome to IRV2! We're sure glad you joined us!

I agree with Fred's assessment! It sounds like the switch to me.

I would suggest that you create a signature showing the make and model of your RV. It will help folks to answer questions you may have in the future.

Good luck, happy trails, and God bless!
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Old 03-03-2021, 09:59 AM   #7
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I have replaced all the switches, Im assuming it has to be some wires that are touching somewhere. I will dig into the electrical and see what happens. Thanks for your help

Chad
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