Generator starter problems

palmerjp wrote:

It all boiled down to the end on the pos cable being corroded internally. Alls up and working.

Thanks again to all for their assistance
Joe

Glad to help, and Thank YOU for the update. We're often left wondering.

Glad too, you didn't tear it apart for the starter. You did the basics first. That's always good.

FYI, we've had a number of cases recently cables were corroded inside factory terminals. Including OEM chassis battery cables. Easy to take them for granted and we should NOT.

palmerjp wrote:

Gjac wrote:

palmerjp wrote:

Gjac wrote:
It sounds to me like you have a corroded wire, loose connection, or low battery. I have the 5kcm21 genset, and had this problem. I had 12.4 v getting to the starter but it would not turn over, after cleaning and tightening all the connections I found that the pos wire on the battery was corroded inside the crimped terminal. I was getting voltage but very few amps.

Could this be the reason it will not run when using the start button unless I keep the button depressed but will run when I short the terminals.

To isolate this problem I would use your tow cars battery and jump it directly to the starter. If it starts and runs you know you have a connection problem or weak battery in the MH.

Looks like you may have hit the nail on the head. Batyery is good so I am going to clean all terminals. It will start and run when connected to external battery. It is a little hard to start bur messing with the choke gets it running,

Thanks a bunch to all
Joe

It all boiled down to the end on the pos cable being corroded internally. Alls up and working.

Thanks again to all for their assistance
Joe

Gjac wrote:

palmerjp wrote:

Gjac wrote:
It sounds to me like you have a corroded wire, loose connection, or low battery. I have the 5kcm21 genset, and had this problem. I had 12.4 v getting to the starter but it would not turn over, after cleaning and tightening all the connections I found that the pos wire on the battery was corroded inside the crimped terminal. I was getting voltage but very few amps.

Could this be the reason it will not run when using the start button unless I keep the button depressed but will run when I short the terminals.

To isolate this problem I would use your tow cars battery and jump it directly to the starter. If it starts and runs you know you have a connection problem or weak battery in the MH.

Looks like you may have hit the nail on the head. Batyery is good so I am going to clean all terminals. It will start and run when connected to external battery. It is a little hard to start bur messing with the choke gets it running,

Thanks a bunch to all
Joe

If it starts but doesn't run when the start switch is released, it could easily be a myriad of things- oil pressure, speed sensor, output voltage, bad main board, etc.
It's really best to get the service manual and fix it correctly, rather than jury rig something.

Service manual: http://www.uponrequest.com/Data/Kohler/tp5394%205CKMR1.pdf

palmerjp wrote:

Gjac wrote:
It sounds to me like you have a corroded wire, loose connection, or low battery. I have the 5kcm21 genset, and had this problem. I had 12.4 v getting to the starter but it would not turn over, after cleaning and tightening all the connections I found that the pos wire on the battery was corroded inside the crimped terminal. I was getting voltage but very few amps.

Could this be the reason it will not run when using the start button unless I keep the button depressed but will run when I short the terminals.

To isolate this problem I would use your tow cars battery and jump it directly to the starter. If it starts and runs you know you have a connection problem or weak battery in the MH.

Gjac wrote:
It sounds to me like you have a corroded wire, loose connection, or low battery. I have the 5kcm21 genset, and had this problem. I had 12.4 v getting to the starter but it would not turn over, after cleaning and tightening all the connections I found that the pos wire on the battery was corroded inside the crimped terminal. I was getting voltage but very few amps.

Could this be the reason it will not run when using the start button unless I keep the button depressed but will run when I short the terminals.

It sounds to me like you have a corroded wire, loose connection, or low battery. I have the 5kcm21 genset, and had this problem. I had 12.4 v getting to the starter but it would not turn over, after cleaning and tightening all the connections I found that the pos wire on the battery was corroded inside the crimped terminal. I was getting voltage but very few amps.

Thanks to everyone for the input.

I removed the whole contraption from the RV and connected it directly to a battery. When I press the start button it tries to start but will only run while the button is pressed. NOW, when I short out the top and third from top connectors on the starting plug, it will run and start with no problem with full A/C output. Is there anyway to bypass all of the start buttons and just install my own.
Also I still don't have battery power when I disconnect from my land power. are the two problems connected.

Thanks Again
Joe

palmerjp wrote:
why would the motor say confidant 5 if it is a 20 hp magnum.

Perhaps Kohler assigned that name to the GenSet. You say it's 5500W which is around 5KW which could inspire somebody to label it "5"

If the crankshaft is horizontal, it's not a Confidant ENGINE. At least according to Kohler's lookup.

Got enough info to go in after the Starter? If so, please go ahead and then let us know what you find.

palmerjp wrote:
why would the motor say confidant 5 if it is a 20 hp magnum. My starter just whines and doesn't engage.

Thanks for the info and assistance
Joe

The generator mfg can use any model engine they choose. If they had chosen a Kohler Command engine, you could name it a Confident Leader 5, lol.

Since the motive energy of the starter is all about the operation of the armature and you state that it spins, the best process has been suggested, remove it, clean and service the flywheel engagement mechanism. That is likely the only thing wrong with it.

It may behoove an owner to buy a new starter complete at $50 and keep the original, serviced starter, as a backup for emergencies. Your call.