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10K Powertech

Has anyone had a complete failure  of the generator end to not produce voltage, excluding mechanical failure? I had the voltage regulator and end bearing replaced 100 hours ago 2(years). Did the checks per Jeff at PT. About 6 mos ago voltage would just drop out intermittently then run fine. I just can't imagine the rotor and windings going south on 1800 hour HD generator. This is a brushless unit. I'm kind of thinking it needs to be externally excited again, they had to do that when the bearing was replaced.
Bruce, Linda, and Macy
Zoey RIP 1/20/19
1999 U295 40' build #5400
2017 silver Jeep Wrangler, 1260 watts of solar on top
Moving around the country

Re: 10K Powertech

Reply #1 –
The symptoms point to the regulator. Jeff had me check the voltage when mine wasn't making power at the back of one of the main breakers. If it had a certain voltage the regulator was at fault under the head was bad. I didn't write down the number but mine was 9 volts and the regulator was at fault. Even though the regulator is only a year old you might ask Jeff how to test it. I don't recall anything about exciting the head when I changed mine. I think that has to do with dc voltage systems but could be wrong.
1999 40 ft. U-320 wtfe build 5563 Chuck & Lynda's "Rollin' Inn"  2030 watts solar
prev. mh's 71 GMC 5 yrs. 73 Pace Setter 1 yr. 78 Vogue 5 yrs 81 FTX 40ft all electric 18 yrs. 1996 Monaco Signature 3 yrs.
2014 Grand Cherokee Overland
Dream as if you will live forever. Live as if you will die today.  James Dean

Re: 10K Powertech

Reply #2 –
I had an electrical end brake just where the wire goes into the crimp and the generator
quit. It happened twice. The first time I bought the voltage regulator and the second time
I had to old regulator out when I found the broken wire so I put the new regulator in.
Pull on the wires and see if they come apart. Your coach is the same year as mine.
Peter and Frieda Morin
1999 36ft. U320 Foretravel
Build # 5436
1998 Suzuki Sidekick Sport

Re: 10K Powertech

Reply #3 –
Chuck, I did talk to Jeff should be 4-9 volts. Mine is 1 volt. But going to have to do a bit more checking before I replace the generator end $$$$$,  if one can be found. When the Pt dealer replaced the bearing 2 years ago the had to externally excite the generator.
Bruce, Linda, and Macy
Zoey RIP 1/20/19
1999 U295 40' build #5400
2017 silver Jeep Wrangler, 1260 watts of solar on top
Moving around the country

Re: 10K Powertech

Reply #4 –
Peter's issue would make more sense than a failed regulator at this point.
1999 40 ft. U-320 wtfe build 5563 Chuck & Lynda's "Rollin' Inn"  2030 watts solar
prev. mh's 71 GMC 5 yrs. 73 Pace Setter 1 yr. 78 Vogue 5 yrs 81 FTX 40ft all electric 18 yrs. 1996 Monaco Signature 3 yrs.
2014 Grand Cherokee Overland
Dream as if you will live forever. Live as if you will die today.  James Dean

Re: 10K Powertech

Reply #5 –
Quote from: craneman –
Peter's issue would make more sense than a failed regulator at this point.
I'm going to try to find a real live generator guy to check it out. I'm currently wrestling a bunch of check engine codes that don't make any sense. Got a guy with Cummins scan tool coming Monday to see what's up
Bruce, Linda, and Macy
Zoey RIP 1/20/19
1999 U295 40' build #5400
2017 silver Jeep Wrangler, 1260 watts of solar on top
Moving around the country

Re: 10K Powertech

Reply #6 –
This happened 3 years ago,

Quote from: Dave & Danette –
Just wanted to share what we found on our 10kw Powertech generator. Back in February while at the King of Hammers race in Johnson Valley California our generator shut down from an overheat condition while we were away. Generator ran fine but no fan and no power output. Luckily we had a portable generator to get us through the week.We finally had time to do some troubleshooting on it a couple weeks ago. Found 5v at transfer switch and fan. When we pulled the end off the generator we found the end bearing a little tight and rough to spin. The Exciter Rotor had made contact with the Exciter Stator. Going through all the troubleshooting steps and ohming everything out we found the Stator was bad. Rotor looked fine luckily.

After a conversation with Jeff at Powertech, we ordered the parts (Stator & End Bearing) and replaced them this morning. Fired up the generator and all is well (Whew and WooHoo)! We really dodged a bullit on this one. According to Jeff the Exciter Stator is the only replaceable part other than electronics. If that didn't work we would have to replace the whole generator head. Total repair was $570.41 parts and shipping. Was a fairly easy repair, even with no knowledge or experience with generators. 

Thanks to Barry's Beamalarm site for the manual and troubleshooting guide. And to the Foretravel forum and related posts and info. I felt comfortable enough to tackle the job. I wish I had took pictures and documented the process but in reality it was a simple straight forward remove and replace. Once we saw the damage it was pretty obvious what happened. Hope this info can help someone in the future.
Dave & Danette
2005 Foretravel U270, 3620 PBLW, Build #6331
2018 Jeep Grand Cherokee
2017 Can-Am Maverick X3 RR
2016 Polaris Turbo RZR
Motorcade #17839

Re: 10K Powertech

Reply #7 –
Quote from: bbeane –
I'm going to try to find a real live generator guy to check it out. I'm currently wrestling a bunch of check engine codes that don't make any sense. Got a guy with Cummins scan tool coming Monday to see what's up

Good call. If we worked these problems everyday it would be one thing. The big items are always in the back of my mind. Hope it works out for the better. If I had to replace I actually might look at going all solar. And those aluminum silicone batteries Peter got are quite intriguing. I HATE BATTERIES, but might be a better way to go? Please keep us updated🤞
Scott

Re: 10K Powertech

Reply #8 –
Bruce.......
Where are you measuring the voltage at when you say it just "drops out" ?

If you are losing voltage at the "line side" of the generator breaker and it is changing from 120 to 0 volts (or 1volt as you stated) then that sounds more like a loose connection or a failing regulator (less likely). If you are measuring voltage anywhere else, then more components come into play. 

I just changed our end bearing and newer voltage regulator without having to excite the coils.
Justin & Cathy Byrd
1995 U280 "Old Faithful"
36' Build #4673
C8.3 Cummins
Allison MD3060R 6 speed - retarder
Powertech 10KW  4cyl Kubota

Re: 10K Powertech

Reply #9 –
Justin, the voltage was measured at the line side of the main breaker, per Jeff at PT should be 4-9 volts. Then that would indicate a voltage regulator.  I am tempted to try a new regulator though.
Bruce, Linda, and Macy
Zoey RIP 1/20/19
1999 U295 40' build #5400
2017 silver Jeep Wrangler, 1260 watts of solar on top
Moving around the country

Re: 10K Powertech

Reply #10 –
If you haven't done so.... I would certainly check all connections at the voltage regulator. If it's a AVC63-4 it has four wires with spade connections.

Also check the connections on the grounded stud where the T2 and T4 stator along with the E1 exciter lleads are connected.
(1/4 -20 stud with multiple wires) at least that's what ours has. If yours is 120v only it should be using the E1 and E4 exciter coil leads.


Don't rule out a loose connection until all are checked in the junction box.

Hope it's a simple fix for you. These are robust generators.
Justin & Cathy Byrd
1995 U280 "Old Faithful"
36' Build #4673
C8.3 Cummins
Allison MD3060R 6 speed - retarder
Powertech 10KW  4cyl Kubota

Re: 10K Powertech

Reply #11 –
Thanks for the info Justin, I'm going to try to dig into it in the morning
Bruce, Linda, and Macy
Zoey RIP 1/20/19
1999 U295 40' build #5400
2017 silver Jeep Wrangler, 1260 watts of solar on top
Moving around the country

Re: 10K Powertech

Reply #12 –
Upon further inspection no broken/ loose wires in the control/voltage regulator. 1 volt at the line side of the main breaker. Looks like it may be terminal.

But got to recover from a 4K ECM repair 1st.
Bruce, Linda, and Macy
Zoey RIP 1/20/19
1999 U295 40' build #5400
2017 silver Jeep Wrangler, 1260 watts of solar on top
Moving around the country

Re: 10K Powertech

Reply #13 –
ECM repair at ECM King is $1000 to $1200.
Rudy Legett
2003 U320 4010 ISM 450 hp
2001 U320 4220 ISM 450 hp
1995 U320 M11 400 hp
1990 Granvilla 300 hp 3208T
Aqua Hot Service Houston and Southeast Texas

Re: 10K Powertech

Reply #14 –
Quote from: Rudy –
ECM repair at ECM King is $1000 to $1200.
Talked to the folks at ECM King they couldn't do my ECM/ CPL #. Nice folks though.
Bruce, Linda, and Macy
Zoey RIP 1/20/19
1999 U295 40' build #5400
2017 silver Jeep Wrangler, 1260 watts of solar on top
Moving around the country

Re: 10K Powertech

Reply #15 –
Bruce about 3 years ago the same thing happened to me. Mine fortunately was wires that had seen better days. Once I replace the connectors it worked okay again. Two years later than I had to replace the breaker and was going to replace the voltage regulator to but didn't need to do that. Also replace the end bearing as well and all four motor mounts. Changing out my end bearing was not easy. These powertechs are different engines and different configurations interiorly as to whether the bearing is easy to get to or a little bit harder. Mine was to harder kind. At the time. I thought if the generator head was toast I might just go with more solar and additional lithium batteries. Luckily it was not. I hope you figure it out and it doesn't cost you. Would it potentially could.
Bob
'99 U320 40 WTFE
Build #5462,
1500 Watts Solar 600 amp Victron lithium
2012 Jeep Grand Cherokee Overland Hemi
Instagram bobfnbw
Retired

Re: 10K Powertech

Reply #16 –
Bruce
Do you have a schematic for your gen-set? If yours is like mine........?..... make sure you can read continuity thru the 4 amp breaker that connects L1 to wire #4, Wire 4 is the voltage sense to the regulator. 1 volt does sound low but it wouldnt matter if the 4 amp breaker is tripped, open or just not making good contact.

Just a thought, yours may be different but it may be worth checking, maybe use a temporary jumper around the breaker just for a short test to see if you get voltage.
Justin & Cathy Byrd
1995 U280 "Old Faithful"
36' Build #4673
C8.3 Cummins
Allison MD3060R 6 speed - retarder
Powertech 10KW  4cyl Kubota

Re: 10K Powertech

Reply #17 –
Yes I use the schematic on PTs web site. I'll give that a try. Thanks
Bruce, Linda, and Macy
Zoey RIP 1/20/19
1999 U295 40' build #5400
2017 silver Jeep Wrangler, 1260 watts of solar on top
Moving around the country
 

Re: 10K Powertech

Reply #18 –
Wishing you the best in a cheap fix Bruce!  Scott (DSD) and I, mostly him, replaced the end bearing on our 10k and it was not fun, but doable.  Of course ours is in a box, which makes it much more time consuming.  I did have to replace the board while in Florida and just down the road from PowerTech, so had John come over and replace the unit.
Joe & Dottie Allen
Sold!  December 2023.      2000 U320; build # 5645
Our coach " Maxine"
Motorcade #  15922;  Escapee 150950; FMCA F330833; Boondockers Welcome;  Harvest Hosts;  Thousand Trails
'98 U320 from 2000-'06
USAF '62-'66

"Do not spoil what you have by desiring what you have not; remember that what you now have was once among the things you only hoped for." ―Epicurus