zplugger
Model # SG0041891
Serial # 3613781

This is the third time it has gone bad,need to find out why going bad. Not sure if I checked the right terminals on voltage reg.but terminal 1 and 4 show 36 ohms is this high? Can I buy a service manual for this,living on SS so I have to try and fix stuff myself. Been a good generator for years but have this voltage reg problem in last 2. Any advice would be appreciated.
Thank You Larry
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BrentB
Probably help to clean the slip rings. I've seen them produce power up to 80 ohms, but you should read only 5.8 ohms on that model. Good idea to take the reading on 0 & 4 while you rotate the rotor. you are only getting the ohms value in one spot on the rings,and you are reading through the wiring harness and brushes. Check field boost on wires 0 and 4 from the PCB. The root cause may be low field boost not turning on the regulator. I have seen a new AVR fail after only a few weeks, and we cleaned the slip rings for the customer which allowed the old AVR to work again. Customer put the new one back in the box to save for later.
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zplugger
Thanks BrentB

Thanks for the response Brent, I'm very new to this but a quick learner. Not sure what slip rings are,is this what the brush rides on? What do you clean them with. Should I do a ohm test at the brush terminals for a true reading. Just want to make fixes before new regulator is installed. I do all the maintenance on this and its time to learn other things to maintain. There is nothing better then knowledge,and I thank you for sharing yours.My owners manual does not show a good breakdown on the brushes and slip rings.

Larry
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Canada_Guy
This procedure may apply to your unit:
[url]http://zillerstore.com/forums/showpost.php?p=29054&postcount=29[/url]
It's from page 3 of this post: [url]http://zillerstore.com/forums/showthread.php?t=3390[/url]
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You need to disassemble the left end of the generator enclosure to expose the generator end bell. You will need a harmonic balancer puller to get the fan off which can be tough. Take the brush holder out and clean it with Brake Kleen. Use a mirror to see the slip rings and I use a scotch brite pad (green) cut to about an 1.5 X 4 inch strip folded over a short piece of paint paddel to get it against the slip rings. Shut the gas off and crank it over while holding prssure on the paddle. you can use some brake kleen on the slip rings if they are greasy. Good Luck, Peddler
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Birken Vogt
This model should be a liquid cooled, so it should be easy to get in to the brushes, no fans or anything in the way.

Usually there are 4 brushes on this type so if it has high resistance more than one thing has to be wrong.

Instead of replacing with the same old 083048 / G083048 regulator, the updated finned 0F97190 will also work. I think the 083048 is still the old design with the square pot but maybe the OP can confirm?
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zplugger
Thanks everyone for the tips,it will be Sunday before I can take apart. It looks like two brush holders on this model,still not sure what the slip ring is,guessing where the brushes ride? If so that area looks dark and dirty. What is the best way to measure the ohms,should I take 0-4 off regulator and turn motor over?
Check field boost on wires 0 and 4 from the PCB ?? Does this mean right at the brushes,if so very easy to get at. This unit the whole side panel comes off for easy access.

Larry
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nrp3
Slip rings are where the brushes ride.
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Peddler
Do you have any unusual loads on this generator, like UPSs or other things that may cause Harmonic distortion? Hid lighting can cause problems as well or line reactors, capacitors that are supposed to save electricity. Anything that can cause excessive harmonic distortion can cause a VR to fail. Also how heavily loaded is the generator, is it close to it's maximum output?
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BrentB
zplugger;52346 wrote:
Thanks everyone for the tips,it will be Sunday before I can take apart. It looks like two brush holders on this model,still not sure what the slip ring is,guessing where the brushes ride? If so that area looks dark and dirty. What is the best way to measure the ohms,should I take 0-4 off regulator and turn motor over?
Check field boost on wires 0 and 4 from the PCB ?? Does this mean right at the brushes,if so very easy to get at. This unit the whole side panel comes off for easy access.

Larry


Unplug 0 & 4 from the PCB board going to the AVR. If that unit has an all in one plug on the AVR just unplug it there and read the field boost. I think you may have answered the question now that you said you see the slip rings and they look dirty. I bought a commutator stone from Grainger supply 8 years ago and am still using the same one to polish rings!
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zplugger
Just want to Thank everyone on helping me fix my generator. I cleaned the slip rings and spaced them to the center of ring. I set the new voltage regulator to 247 volts. Everything seems to be OK, just one question if I can.I took the 0 and 4 wire off the regulator to measure ohms, I get 1.8 ohms ? Is this a normal
reading. I think my biggest problem was not running the generator weekly,I had it off to save fuel.Now I see how important it is to do the weekly running,leaving the thing on auto for ever. I was just not thinking that it would cause problems,I change the oil and all filters yearly.Going to keep a eye on the slip rings when I change the oil. This thing is 16 years old and only 235 hours on it, hoping to get ten more years out of it. Having trouble finding parts for the 1.5 Mitsubishi engine, was thinking a new cap and rotor for it. I guess I just want to know is the 1.8 ohms sound right.

Thanks Larry
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78buckshot
You may have 18 ohms instead of 1.8, if you can get back to the slip rings and remove the brushes and measure resistance from ring to ring, also measure from each ring to ground- should be no continuity.
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zplugger
I checked my meter with a 5 ohm resistor, it read 5.0. Checked the o and 4 wires at regulator and read 1.8 Have to go hardware to get some small washer to space out brushes on slip rings.When I remove the brushes will read ohms between rings.
Larry
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78buckshot
Did you remove the zero and four from the AVR?
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zplugger
Yes, have not got to hardware yet for washers to space brushes but when I do will measure the rings.
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zplugger
I made it to hardware today,so I added 2 #6 flat washers behind the brush holder to make them ride in center. I checked the ohms between rings, 5.5 ohms and 6.1 at VR. So Im guessing this is OK? I will do a yearly check on 0&4 terminal when I change the oil. Is there a certain ohms reading I should stay under at all times? Again Thanks everyone for helping,I just got a little smarter in life.
Larry
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