MEP - 803A: No crank issue

[Arachnid223]

The generator was working fine when we turned it off to go to lunch. On return, it won't crank. We have voltage to 1-8 at S1, but none of the lights on the control panel work. When turning to a position other than OFF, all voltage drops at S1.

CB1, emergency shutoff, and fuses have been diagnosed and not the issue. Any ideas? I'm leaning towards needing a new S1 switch.

 

[Light in the Dark]

Does it crank from the dead crank switch? Whats your battery voltage at now?

 

[Arachnid223]

Does it crank from the dead crank switch? Whats your battery voltage at now?

No, it does not. Both batteries are reading 12.64v and it's around 25v at the panel.

 

[Light in the Dark]

The dead crank has nothing to do with the S1, so I think this warrants further evaluation. Perhaps your batteries have surface voltage, but fail under load. I would yank them out and have an auto parts store load test them. Your alternator might not be producing sufficient voltage to charge them up. The TMs have a whole section on troubleshooting this exact issue. If you don't have a copy of them, you should download them ASAP from here: https://www.steelsoldiers.com/threa...-generator-set-additional-information.213028/

 

[2Pbfeet]

No, it does not. Both batteries are reading 12.64v and it's around 25v at the panel.

The great thing about the dead crank switch is that it cuts out so many potential causes. Can you hear even the solenoid on the starter engaging? (A click when trying the dead crank switch) If you hear a click, but no spin, I would follow @Light in the Dark's advice and pull the batteries for load testing.

All the best,

2Pbfeet

 

[Arachnid223]

The dead crank has nothing to do with the S1, so I think this warrants further evaluation. Perhaps your batteries have surface voltage, but fail under load. I would yank them out and have an auto parts store load test them. Your alternator might not be producing sufficient voltage to charge them up. The TMs have a whole section on troubleshooting this exact issue. If you don't have a copy of them, you should download them ASAP from here: https://www.steelsoldiers.com/threa...-generator-set-additional-information.213028/

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I do have the TMs. Went through as much of it as we could with the time we had. Using a NATO cable, we have the same results. Shouldn't that bypass the batteries and start it then? In a last ditch effort, we crossed the starter and it turned over, but wouldn't catch.

 

[Light in the Dark]

If you jump the starter it will spin, but that doesn't open the fuel shutoff solenoid, or any of the other startup functionality... it just spins the engine over.

Those TM steps are listed in a particular order, for a particular reason. I would go through them one by one and confirm before moving forward.

 

[Light in the Dark]

The fact that your dead crank switch isn't doing what its supposed to, is a red flag.

 

[Guyfang]

Go through the T/S steps. Tell us what you find. That way we know in what direction you need to start looking at. And yes, the fact that S10 will not roll the motor over is a big fat red flag.