Would you replace this generator?

[belfert]

I talked to Justin at Wrico and a new head is right about $2,000.  He originally was saying I should try to find a different regulator, but after I explained the head has brushes he said a new head is a better option.

After talking to Justin a second time it seems Powertech did everything on the cheap.  He said the head they used is cheap and he thinks they probably used a less expensive industrial engine instead of a generator ready engine.  I am contemplating if I just replace the whole generator, or take a gamble on a new head.

[belfert]

Can't the slip rings be cleaned or turned? Seems like there should be enough copper there to take a light cut and restore them.

I'm not convinced the issue is as simple as bad slip rings.  I would still have the issue of regulators that are easy to kill at $370 each.  I am going to look at the generator again this weekend.

I have an old email from Powertech that states if I disconnect the brushes from the regulator and apply 12 volts I should get 100 volts AC from the unit so I am going to try that.

[Jim Blackwood]

If the contact between the slip ring and brush is less than perfect you won't get full amperage and the voltage will drop under load. Often slip rings will get a groove worn in them and the corners of the new brushes are all that will hit until they run long enough to wear in. That will cut your output way down. Any foreign material on the rings can have the same effect. Before you go further you should check your brushes to see if there is a wear pattern showing full contact across the face.

Jim

[windtrader]

I'm not convinced the issue is as simple as bad slip rings.  I would still have the issue of regulators that are easy to kill at $370 each.  I am going to look at the generator again this weekend.

I have an old email from Powertech that states if I disconnect the brushes from the regulator and apply 12 volts I should get 100 volts AC from the unit so I am going to try that.

Brian, check PM.

[belfert]

I called a local truck repair place I have dealt with before and they will take the generator out for me with their forklift and put it on my trailer.  I can then work on it a lot easier.

[chessie4905]

Maybe one of these to do it. I imagine the fee build up would pay for it. They make a 2 ton version also for a little more money. On sale at times.
https://www.harborfreight.com/1-ton-capacity-foldable-shop-crane-61858.html?_br_psugg_q=engine+hoist

[dtcerrato]

We bought a 2 ton Delco Remy like new used similar to that HF for $150. Worked great on the transmission R&R.

[belfert]

I don't think an engine hoist would have enough clearance on top to lift the generator out of the bus.  I think I could spend no more than the cost of a engine hoist to have the generator taken in and out by a forklift.

I realized I have a guy with a skid loader coming by on Friday.  I am trying to find out if he has forks he can bring to get the generator out and into my garage.

[dtcerrato]

Engine cranes can be jerry rigged to pick up from underneath with some safety minded ingenuity.

[luvrbus]

Fork lift is the best way they were design for a fork lift,no way to use a lift than I have seen,that little CAT engine is every bit as good as a Kubota

[Busted Knuckle]

I don't think an engine hoist would have enough clearance on top to lift the generator out of the bus.  I think I could spend no more than the cost of a engine hoist to have the generator taken in and out by a forklift.

I realized I have a guy with a skid loader coming by on Friday.  I am trying to find out if he has forks he can bring to get the generator out and into my garage.

For future reference around here skid steers rent for around $200 a day w/ forks, bucket, auger or whatever attachments you desire. (1 attachment free w/rental an additional for an extra fee each)
  BK 

[belfert]

For future reference around here skid steers rent for around $200 a day w/ forks, bucket, auger or whatever attachments you desire. (1 attachment free w/rental an additional for an extra fee each)

That might be the best way to get the generator back in the bus after I work on it.  It looks like it would be right at $200 after taxes and fees.  I would need to use the bus to pick up the Bobcat.  For getting the generator out it makes sense to pay the extra $50 to $75 to have the guy do it who is already coming out for another project.

I am paying someone for the skid steer work on Friday instead of renting a skid steer because the project requires a really large skid steer.  The only place that rents a really large skid steer I could find in 2017 required the renter to supply a trailer.  This guy has a large skid steer that is big enough for the work.

[TomC]

I have a 10kw Powertech with a Marathon brushless alternator-big. I have 1,800 hours and zero problems. Brushless is the way to go. Good Luck, TomC

[belfert]

That's what we got - the 13K version and I couldn't have been happier with it.

Of course, if you're replacing the head you'll probably have to reconfigure the engine controls and auto shutdown for things like low oil pressure and high temp. I did those using Murphy Switchgauges.

It looks like the current engine controls should work so long as I feed load and neutral from the head to the ECU for voltage sensing. 

I talked to Wrico about getting the 10KW generator head.  My HP is slightly low for 10KW, but I hope I can get a bit more than 8KW out of it.  I need to pull my currrent head off to figure out the right SAE size to order.  The cost should be about 1/3 of a new generator.  I think it will cost me between $2,500 and $3,000 all in with some new wiring, misc parts, and costs to get the generator in and out of the bus with a forklift.

[luvrbus]

Speak with CAT and see if engine can be tuned for 10kw, it depends on the manufacture but most 8kw and 10kw heads are the same just a difference in engine hp