Generator Failure

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Generator Failure

May 28, 2018, 10:23:27 pm

Yesterday I started the generator and ran the air conditioners. Came back after an hour and generator was not running. Found a fault light on the dash. I reset the generator, started it and noticed blower was not running and no power inside on panel. Noticed a spot on gravel under generator over flow. Found expansion tank empty and radiator low. I assumed blower was not starting and it over heated. Today I filled the radiator and expansion tank started the generator, It started and ran for about 30 seconds. I was wondering if I was having a fuel issue. Restarted the generator it ran, I checked the rotation of the blower, engine bogged down like a load was connecting then smoke was coming from the generator compartment and engine shut off. Overcrank light came on. Smells like electrical. Don't know what was smoking. It's getting dark. Tomorrow we will pull generator out and look inside to see if I can see any burnt windings. I will also look inside the control box and look at the regulator. Don't know what's going on. Any help would be appreciated. I have the generator with the Isuzu engine. If you look at the picture the pancake looks new like it was changed by the previous owner. I looked through my manuals and I don't have the manual for my generator. Anyone knows the number for my unit I can download the manual from PowerTech.
Thanks, John M.

Re: Generator Failure

Reply #1 – May 29, 2018, 08:09:03 am

Mine quit several times and the problem was the voltage regulator, but when it did so the fan did not run as no volts being produced.
Then it overheated and shut down.
I have a copy of the manual I could send it to you, if that would help. I also have a '99 320 so I assume the same engine . I don't have information on the generating portion.

Re: Generator Failure

Reply #2 – May 29, 2018, 11:49:22 am

I called PowerTech and James told me that he thinks the generator is fried. We are trying to find the correct generator for my coach but I don't have my generator model number. Where can I find the number or does someone know the correct number? I tried giving him the number on the pancake in the picture but that didn't work. Help please!
John M

Re: Generator Failure

Reply #3 – May 29, 2018, 01:21:01 pm

Quote

Where can I find the number or does someone know the correct number?

John,
Here's my notes from our 99. Might help.
jor

Generator
Serial Number      ITA25DB90899EFT
Model Number:       PTS IDL10EFT

Power Technology Southeast, Inc.
Leesburg, Florida 34748

Engine
Isuzuu 3LD1
Family: SSZ1.5U6D2RA
Manufactured: 07/98
1,496 cc
Texaco ELC (pink)

Oil & Filters: February 25, 2012
Bought from Truck & Trailer Services
Oil:      PH2808 (LuberFiner)
      Mobil Delvac 1300, 15-40
Fuel:   FP588F (LuberFiner)
Air:       FIL2276 (LuberFiner)
         * used Fleetguard spare - AF-435KM)

Re: Generator Failure

Reply #4 – May 29, 2018, 01:25:52 pm

Jor,
Thanks for the help. That's what I needed. It seems that Marathon Electric supplies PowerTech the pancake for that generator and they no longer deal with Marathon so he would have to order it.
Thanks again. John M

Re: Generator Failure

Reply #5 – May 29, 2018, 02:45:21 pm

Someone here had a generator for sale? Just the electric part

Re: Generator Failure

Reply #6 – May 29, 2018, 03:23:04 pm

I'm always cynical when a tech tells me something has to be replaced in its entirety, but your description of the load and smoke sounds like he may be right. If it were bearings, I would expect to hear loud grinding sounds, but it could be the windings "welding" themselves to each other. It would be interesting to dismantle it and see what happened. If you do replace it, don't toss it to the curb. The salvage value on the copper and metal could be significant.
generator windings design - Bing images

Re: Generator Failure

Reply #7 – May 29, 2018, 05:00:47 pm

Call Foretravel They will have your part number for that generator. I have the the electrical part for an 8 KW Powertech. I believe that you have a 10 KW

Re: Generator Failure

Reply #8 – May 29, 2018, 05:15:07 pm

John,once you get it diagnosed if the windings are shot could you possibly wait til you get back to Fla and have powertech do the job?We will be in the area around the middle of June,could possibly take a look.

Re: Generator Failure

Reply #9 – May 29, 2018, 05:57:59 pm

Well it was an interesting day today. I went to the coach, pulled out the generator and opened the control box and found the regulator at the bottom of the box. My generator looks new as you can see from my previous pictures and it is standard procedure that when you change the generator you change the regulator. Whomever replaced the regulator only installed one screw at the corner of the regulator. It seems they could have overtighten the screw and cracked the plastic corner and with the generator rough whip lash starts it broken loose. I feel that overtime the heat sink melted into the the wire in the picture which goes to the top of breaker on line 1. I think that wire goes to the blower, not sure. Any way it finally shorted out and shorting out the heat sink to the box. I started the generator and measured voltage at the top of each breaker and I had 14.7 volts at each breaker. I am feeling lucky and think the pancake is still good. I'm going to order a new regulator and repair the broken wire and take it from there. Crossing my fingers on this job. I will try and order the regulator from Marathon Electric directly or search the internet for the best price.

Re: Generator Failure

Reply #10 – May 29, 2018, 07:30:57 pm

Well I found a Genuine Basler voltage regulator for $215. Power Tech wanted $354. There were other copycats for a lot less on Ebay but I didn't want to take my chances. Will be here on Friday. Crossing my fingers everything will be fine.
John M.

Basler AVC63-4 Voltage Regulator, Genuine AVR : Generator Parts, Generac,...

Re: Generator Failure

Reply #11 – May 29, 2018, 07:49:05 pm

John if it turns out to be a problem with the stator I have a good used 10 kw power tech stator.

Re: Generator Failure

Reply #12 – May 29, 2018, 08:29:41 pm

I am reminded of those damaging gen when they replaced regulator with some wire to be removed in regulator. Maybe someone can elaborate.

Re: Generator Failure

Reply #13 – May 29, 2018, 10:12:05 pm

Quote from: Jack Lewis – May 29, 2018, 08:29:41 pm

I am reminded of those damaging gen when they replaced regulator with some wire to be removed in regulator. Maybe someone can elaborate.

I was one of them.
How not to change voltage regulator in genset

Re: Generator Failure

Reply #14 – May 29, 2018, 11:17:44 pm

Here is my regulator current wiring setup. The regulator I am getting is the same exact one, so nothing should change am I correct?
John M

Re: Generator Failure

Reply #15 – May 30, 2018, 07:12:57 am

John,re-crimp or put new connectors on those wires,looking at your pictures,is your hour meter and some switches missing?The
hour meter is also missing on the 99 320 Bob just bought.Another thing to check is the rubber mounts,mine were all weak and
Bob's look worn the more worn they are the more vibration.The fronts can probably be changed in place the back would be harder.

Re: Generator Failure

Reply #16 – May 30, 2018, 10:34:23 pm

John, I had a similar problem several years ago on my coach. Because of the constant vibration and whiplash starts, I decided to move all the delicate items in the control box that is mounted on the generator itself into the forward port side locker, the generator radiator bay. The only components remaining in the box on the generator are the two 120volt circuit breakers. The new location is almost vibration free and has worked well for me.

Re: Generator Failure

Reply #17 – May 30, 2018, 10:47:13 pm

Richard,
I already have a secondary box in the generator blower bay. Someone before me moved everything except the regulator and breakers. I didn't know if I can move the regulator in their. The regulator has the heat sinks on it and I don't know how hot it gets. The original box on the generator has air flow going into it from the generator. I'm assuming it's to cool the regulator. Did you move your regulator in there.
John

Re: Generator Failure

Reply #18 – May 30, 2018, 11:11:20 pm

John, I moved the regulator and the two 12volt circuit breakers into that bay. I also noted the heat sink but thought that with the regulator removed from the generator bay, that heat might not be as much a problem. I guess it was just a gamble on my part but it has seemed to work out. I put them in their own metal box at the front outside portion of the bay away from the generator radiator. That was in March of 2010, so far so good.

Re: Generator Failure

Reply #19 – May 31, 2018, 11:22:32 am

If regulator heat is a concern when relocating it to the side bay it would be easy to mount a 120v pancake fan on the new box. Add a few vent holes to let the fan air flow out and power it from the 120v
feed to the generator cooling fan.

Re: Generator Failure

Reply #20 – June 04, 2018, 10:54:03 pm

I called PowerTech this morning before installing the regulator and this time I got Jeff in tech support. We went over the installation of the regulator. I installed the regulator and still nothing on the generator. He felt that the regulator short damaged the generator. He suggested I go to the nearest service center to have it checked out. I have an appointment next week. The service technician feels the shorted regulator could have damaged the stator. He will verify that when he looks at it next week. We will keep you informed.
John M.

Re: Generator Failure

Reply #21 – June 05, 2018, 12:19:49 am

Any tech should be able to use a multimeter and determine the conditions of the windings in a few minutes. Good luck. Fingers crossed you don't need a whole new generator end because of that fried regulator!

Re: Generator Failure

Reply #22 – June 05, 2018, 05:58:16 am

If a genny replacement will cost you big bucks, perhaps you could install a big solar system instead. I did this in two rigs:

1. Fleetwood Southwind: Installed solar and sold the genny.
2. U270: Installed 1.9KW solar: We only use the genny just to keep it exercised and for backup purposes. Would sell it for parts if it required a lot of repairs.

Benefits include:

- Less maintenance. No more oil, filter and coolant. Save time and money.
- Save diesel fuel. Save money.
- Better for the environment in terms of pollution and noise.

Re: Generator Failure

Reply #23 – June 14, 2018, 09:40:09 pm

Quote from: Tim – June 05, 2018, 05:58:16 am

If a genny replacement will cost you big bucks, perhaps you could install a big solar system instead. I did this in two rigs:

1. Fleetwood Southwind: Installed solar and sold the genny.
2. U270: Installed 1.9KW solar: We only use the genny just to keep it exercised and for backup purposes. Would sell it for parts if it required a lot of repairs.

Benefits include:

- Less maintenance. No more oil, filter and coolant. Save time and money.
- Save diesel fuel. Save money.
- Better for the environment in terms of pollution and noise.

Well I took the coach to the nearest Power Tech Service Center. The generator pancake is fried and needs to be replaced. The cost with parts and labor is going to be $4500. I'm really considering doing what Tim suggested and investing in a decent solar package for the coach. My batteries are very close to being replaced. So if I eliminated the generator I can scrap out the pancake for salvage, I have someone in construction interested in the Isuzu Engine. I don't know what would be a good price for the engine. Then I could probably use the generator compartment to store the new house batteries. I can run solar system on 4 new 8D batteries or switch over to 6 volt batteries. It would be nice to move the batteries over into the generator area. I could free up the current battery compartment for storage or keep the current batteries and add more. I could use the generator blower compartment to house the solar electronics and anything I need inside can be chased through the thermostat pillar behind the driver from the blower compartment. . I can also run the solar panel wires down from the roof through the same thermostat pillar into the blower compartment. These are just thoughts and ideas. I don't know what the cost is and if this is something I can do on my own. I was a aircraft electrician in the Air Force servicing the B-52 Bombers and KC-135 Tankers and I worked as a Tool and Die Maker for various companies. I'm not afraid to jump in and tackle any job. With some guidance I feel I can do the job. I would also look at installer recommendations.

Questions:
1. Can I truly survive without a generator with a great solar installation?
2. Can I use the generator and blower compartments to house the solar system?
3. Should I eliminate or keep the current battery location? It would be nice to have more storage on my 36 footer.
4. Would I need to also upgrade my current inverter or keep it along with my current battery system?

Thoughts, ideas and suggestions are welcome.

Thanks, John M.

Re: Generator Failure

Reply #24 – June 14, 2018, 09:58:30 pm

"Questions:
1. Can I truly survive without a generator with a great solar installation?

When we travel in hot weather we run the generator and roof airs. I wouldn't give that up myself.

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