Generator repair/ re-exciting windings

[Chilly807]

It could just be a blown fuse on the voltage regulator or something like that.

We occasionally have to re-flash the field on the diesel generators we have at work, if they've sat for a while without running. Normally anything less than a year and they're fine.

Sean

 

[Soundguy]

I'm glad i have a brushless. have been able to let it set years at a time with no problems..

soundguy

 

[tommu56]

I'm glad i have a brushless. have been able to let it set years at a time with no problems..

soundguy

the brushless have the same thing in rotating field it uses the slip in the rotor to make the field and in my opinion harder to repair and work on becaus the rectifier and caps are spinning with the rotor

tom

 

[Soundguy]

have yet to have a problem with the 2 I use / have access to. I might be lucky.. but I do like the good results..

soundguy

 

[Halmar]

I've got a generator that I only use for power outages, so it is 20 years old but has very few hours. It quit putting out full power so I took it in and it needed a new capacitor. The repair guy said electronics parts have a finite life in years, so just sitting can make them go bad. My brother, who is an electrical engineer, said that all the military stuff his company makes has special protective coverings on electronic components to overcome this problem.

Long story short, maybe you just need an inexpensive component.

You're right, maybe it issomething cheapand easy to fix. I will look into it.

 

[Soundguy]

can't hurt... I just fixed a buddies lcd monitor with 3$ of capacitors from radio shack.. 4 lil ones in the PS module were completely shutting the unit down..

soundguy

 

[Travelover]

My circa 1972 whole house electronic air cleaner quit working a few years ago, but the owners manual had a schematic. I ordered all new diodes and capacitors from Mouser for about $50 and it has been working like a champ ever since. As long as you get the voltage and current specs right, it ain't rocket science. Now stuff with integrated chips are a different story, at least for me.

 

[Halmar]

My circa 1972 whole house electronic air cleaner quit working a few years ago, but the owners manual had a schematic. I ordered all new diodes and capacitors from Mouser for about $50 and it has been working like a champ ever since. As long as you get the voltage and current specs right, it ain't rocket science. Now stuff with integrated chips are a different story, at least for me.

My problem is that I have no manual or schematic. I know everything about the motor side, but not much about the electrical end.
Anybody have a schematic for an Arctic Cat AC 4000G2? I know it is a Suzuki motor but I don't know who makes the generator part.

 

[Travelover]

My problem is that I have no manual or schematic. I know everything about the motor side, but not much about the electrical end.
Anybody have a schematic for an Arctic Cat AC 4000G2? I know it is a Suzuki motor but I don't know who makes the generator part.

RepairManual.com - Official Arctic Cat 4000G2 Generator Shop Manual - 2255-802

$37 for a manual. I'd take it apart first and see if there are any components that can be tested - like capacitors, diodes, etc.

 

[Soundguy]

ditto that. I've found many problems by just simply taking things apart and looking for obvious issues... like broke wires.. blown fuses, burnt parts of the PCB.. etc.


soundguy

 

[F1520]

ditto that. I've found many problems by just simply taking things apart and looking for obvious issues... like broke wires.. blown fuses, burnt parts of the PCB.. etc.

+1 on looking around for the obvious. :thumbsup:

This has worked for me a bunch of times. Another thing to look for-- a capacitor with a slightly bulged top is usually bad. This can be subtle; it hardly looks like there's anything wrong with it.

A magnifying glass can be very helpful when checking out the components of a PCB.

 

[Soundguy]

bulged.. or wet around it where it vented..

soundguy

 

[Halmar]

bulged.. or wet around it where it vented..

soundguy

I started tearing it apart today and it looks like there are only brushes and what I believe is a regulator besides the fields and the armature. My guess is that it would have to be the regulator. What do you guys think? I also attached a picture of the parts.
Thanks,
Mark

 

[Soundguy]

no pic attached?

soundguy

 

[Travelover]

Looks like the circuit board is potted - you can't test individual components.

 

[Soundguy]

sweet.... gotta love that.. that takes a bite out of self repair..

soundguy

 

[Halmar]

sweet.... gotta love that.. that takes a bite out of self repair..

soundguy

The brushes are in terrible condition. The local auto electrical guy said he thinks the brushes could be the cause. Got new brushes in the holder now for $21.00. I will try it tomorrow. I hope so because the regulator costs from between $300.00-$380.00. Not willing to shell out that much cash without being certain.

 

[Soundguy]

yep.. try te cheap easy stuff first in a case like this where troubleshooting has been intentionally crippled by the manufacturer.

good luck

post back

soudnguy

 

[Travelover]

yep.. try te cheap easy stuff first in a case like this where troubleshooting has been intentionally crippled by the manufacturer.

good luck

post back

soudnguy

Actually potting the electronics protects them from vibration and moisture. Unfortunately, it also prevents any repair.

 

[Soundguy]

I know that some potting is needed in some places.. but I have surely seen some boards 100% potted so that you can't do anything on the component level.. I've also seen boards with scrubbed part numbers... also fun...

soudnguy