When mine died completely back in February, it was a connector on the starter solenoid
which had corroded and fell off. It's inside the casing, on the opposite side from the
exhaust system and tailpipe. If you're standing behind and looking at my van, it would be
towards the front and on the left side.
Anyway, they had to drop the genset and remove the green cover to get at it. The service
guy was able to solder a new blade on the old solenoid, and replaced the wire. Fixed!!!
He said one of the biggest problems is that folks just don't run their gensets enough to heat
them up and get rid of the condensation which forms inside the cover, which was probably
what caused my corrosion problem. In this case, heat is a good thing!
Heat isn't always a good thing, though.
I owned a '73 Mustang Convertible, 351C, 4 barrel, headers, mags, air shocks in the rear end,
all the goodies I could add. It was canary yellow, with the Mach 1 stripe/decal kit in black.
A real beauty!!!!
It was the "trade-in" for my first camper van
back in the late 70s. In hindsight, I should never have let her go.
For a while, I had the same problem with it, that your genset seems to have. It would start
fine when cold, but eventually, if I turned it off and then tried to restart it, it wouldn't turn over
or sounded like the battery was near dead. If I let it sit for a while and cool down, and then
tried it, it fired right up.
One time when it happened, I popped the hood and was checking the battery for a loose cable
connection. I jiggled the wire to the starter motor, and my friend turned the key, and it fired up,
but it stalled. I tried jiggling it again then put some tension on it, and we tried again and it
fired up and kept running. Getting down underneath it, I could see that the cable connection was
slightly loose on the starter motor casing.
Well, it seems that when the engine was cold, the threaded bolt/post on the starter motor
was fully expanded, and the standard nut holding the eyelet connector on the battery cable
in place was tight. Engine starting was no problem.
However, when the engine heated up (the starter was close to the exhaust pipe) either the post/bolt
would also get hot, and contract just enough, or the nut also heated up and expanded just enough,
that the connection got loose and electrical connectivity was lost.
The fix was adding a locking nut to keep the battery cable tightly connected to the starter motor.
MORAL: Nuts and bolts expand and contract when exposed to extreme temperature changes,
and can loosen, resulting in a loss of electrical connectivity.
Is there any chance the connections from the battery are loosened when your genset has run for a
while and heated up? Maybe you need to check all your cable connections for a loose one, after it's run
for a while. I'd start with the connections at the auxilliary battery(s) and work towards the ones at the
Sorry for the long story,