Not having any background info as to how old your model is or - TOTAL RUN HOURS unknown as well? - I can
only give you several possibilities
of what the electrical/electronics problem might be - even though I don't know the exact model
# and which engine you have on your Genset.
McCulloch, Coleman, and
many others as well do not mfr much of
anything inside the USA today - let alone factory service anything they
sell, but like with many other USA companies out there today they
do private label out to a lot of mfg vendors (mostly in China btw),
and the Genset gas engines are numerous to say the least. From Briggs
& Stratton to
Honda to Subaru and so forth...not to mention the generator heads as well. Again - all made in China.
I also don't know what normal LOAD you are putting on your Genset
there, or have been putting on it previously, or at what
RPM you are normally running the engine at - as to half throttle or
setting?? The heavier the electrical LOAD the more heat the generator
head had to dissipate as well. Is the generator venting clear and free
from dust, dirt, and any obstructions? I take it that it's most likely
a Briggs & Stratton 4-stroke single
cyl, or else it's a Honda 4-stroke single/twin cyl engine?
Has the gas engine always been serviced properly as to scheduled fuel
filter changes, oil changes, air cleaner maintenance, etc? These are
just as critical so as not to burden the generator head output as well.
If the generator head runs extremely HOT then you definitely have a
problem there. Internal short, bad winding, etc.
Which brings me to the next point.
Since I take it that it has been running good up to now - I have a
few ??'s as to how you have been running it recently, and how well it's been running generator-head wise?
Has the output voltage been really stable and clean up to this point or has it varied at lot?
Have you actually measured the AC output voltage with a good quality
DVM set on the 200 volt AC scale? If so - what voltage was read? How
stable was it - as to any notable variations?
Did you compare your DVM readings/findings to those listed in the Operator Manuals spec listed?
Btw - are all the output outlets totally dead? Is so then it's not the
breakers at fault. Not if the engine runs OK, and at the proper RPM
settings as well.
your Genset is probably an older model - it just indeed
might have some high RUNTIME HOURS on it. If it does it just could very
be what sounds like to me (and I personally HAVE SEEN this
happen myself firsthand) that the generator brushes are nearly shot
- as in almost worn out. Or in your case - TOTALLY GONE. If there is
some brush length there, but not enough by spec then they may be
getting too too hot - as from
excessive current draw at point of contact, and thus the generator
sensing circuitry itself is doing a complete electrical CUTOUT!!
An added protective Genset circuit feature in that the generator itself
may indeed be linked to the engine as a type of REV LIMITER or CUTOUT on the Maintenance-free Magnetron® electronic ignition.
Again - your operators or service manual should have a pretty good
troubleshooting section in it unless you don't have that anymore or
never got one if you bought it used to begin with.
If you unscrew & remove the Generator brushes, and they are indeed
below the recommended length (or worse case they are indeed totally
worn down) then that most likely is your problem right there.
If you choose to replace the old brushes with new ones yourself - be
very careful when seating the new ones - as to their insertion and cap
retainer tightening. Never over-tighten those black plastic-like brush
retainer screw caps - for if you break one (hard to get immediate
replacements is why), or fracture one it could cause the Genset to fail
under LOAD, and that very well could do some severe damage to the
generator part itself. Take your time doing it, and be patient!!
It has to be one of the scenarios listed above, as I've covered every
possible cause short of a broken or shorted wire somewhere - which in that case
you will have to schematic trace and Ohm out wire to wire contacts.
This being the least likely scenario from my experience.
Please post me a reply as to the found problem there, and the resolve
to it by following my recommendations above. Also please rate my
troubleshooting fix as well.
Keep me posted and I'll follow up as well.
Sep 02, 2008 |
McCulloch Electrical Supplies