Guardian 10kW, "Click" then no start, sporadic!

[Chuckolicious]

Hey y'all,

Model 005241.

Perfect maintenance record.

18 months ago I would sometimes check my generator and find the Overspeed/No RPM if flashing red light lit.

I'd hit manual start, it would start right up.

This was super sporadic.

Then one time, when I found it this way, I hit manual start, it made one distinct click, pause for a second, then another distinct click, and the red light went on. Switched to off, then manual again, and it started right up.

I replaced the battery even though it tested fine and was only 2 years old.

Problem came and went still.

Got a service guy. He found that one of the terminal connections on the starter relay seemed loose. He could wiggle it and sort of replicate the problem. So he replaced it and it "seemed" to fix it, though he did say if it came back to replace the Power Relay. He knew I was a power user, so showed me it and it was clearly and easy swap. I ordered one just to have on hand.

Over the next 15 months, it happened a handful of times, but still totally sporadic. Would go months no problem, then come back, then go away.

Yesterday lost power and was not home. Check camera and sure enough it had not started up. Luckily my neighbor was around, she switched to Off, then back to Auto, and it started right up and ran through the outage perfectly.

Today I finally said screw it and replaced the Power Relay.

First attempt at a manual start: CLICK-PAUSE-CLICK, no start, red light. Off, then Manual, started right up. 10 starts in a row, no problem, then got it to do it twice, here is the video. Video begins with a good start and run, then a click, then a good start, then a click.



UGH!!! Any suggestions on what to try next?

[UnknownOverlord]

Check your battery connections are tight and corrosion free first.

[Chuckolicious]

Yep, battery terminals like new.

[Handyman02]

Check the wire connections on the starter for corrosion.

[Chris]

That 'clunk' sounds louder than just the starter relay, and makes me think that was the starter solenoid energizing on the starter. If so, the starter may be failing... Like others mentioned, check all of the connections before condemning the starter. This would be the new replacement for it: https://shop.gentekpower.com/products/g ... 0kw-and-up