60A Gen Issue

[gcbennet]

After doing some maintenance on the cables going to my 60A I discovered the terminal protective cover was inadvertently making contact through a break in the pos eyelet plastic shielding. This caused the gen to whine and get hot. I realized something was amiss after about 5 or 10 seconds of operation but I fear it may have done some damage to the gen. On startup the gauge needle now goes midway through the green then slowly creeps up to the line. I'm not knowledgable on the inner workings of the gen so I'm wondering if what I did caused potentially catastrophic damage to the unit?

 

[Monkeyboyarmy]

What's your voltage at the batteries now with it running?

 

[gcbennet]

I metered the gen and it's still putting out 28.5 V. Unfortunately the S3 sh*t the bed once again and drained the batteries again over night. Something is intermittently clunking the S3 and draining the batteries and I'm wondering at this point if the gen is responsible.
I pulled, cleaned, and did a resistance check on all of the GP's as well. They all show 2 to 2.4 ohms.

 

[Retiredwarhorses]

Your problem is not the EESS, its a symptom of something else. Have you replaced the engine harness yet?

 

[gcbennet]

Yes, new engine harness has been installed because the old one was age cracked and corroding. New gp's that all metered fine, and both starter and gen are new as well. The 60A gen is a rebuild from TNJ and the starter is what I suspect is a Chinese clone from Woolfer. I wouldn't mind upgrading the gen to the 200A if the current 60A is indeed the culprit, but I'm not sure what that involves.

 

[Retiredwarhorses]

Did this issue arise after adding any of the abov parts?

as far as 200amp comversion...you just need the gen and the conversion kit.
its a simple upgrade...the kits are all over epay.

 

[gcbennet]

When the first S3 box I installed died I replaced it and took the opportunity to replace the starter while I was at it. At that point I also discovered the engine harness was all corroded and needed replacing as well. On the truck's first post maint test run the gen overheated so I replaced it with the TNJ rebuild. The funny thing is the truck worked fine for a few months before the new S3 started becoming problematic.

 

[gcbennet]

I've seen on other posts both in here and on the G about how the 60A gens have been blamed for killing the batteries with power off. I'm still educating myself on humvee electrics, so with all things being equal if my 60A is the culprit is it conceivable that the issues with the S3 box are a side effect of this?

 

[gcbennet]

Curious question: if I were to disconnect the gen and starter and reconnect them one at a time to isolate them from the system to troubleshoot if one of them is indeed the source of the power draw and S3 clunking, would this work? Or is the system all tied together to the point where they're symbiotic?