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I have found a 2mm slab of carbon fiber on Amazon for pretty cheap so I am going to order new diodes and try to fab the ring out of the carbon fiber. I have read some white papers about carbon fiber becoming conductive in high magnetic fields with high voltage but I have seen it used in electric...

That is a handy drawing! Thank you!

And just for some history before everything went to hell, I would run this once a month and put my whole house load on it every other month. It did get hit by lighting (not running) but obviously that was not the only thing that happened. Mine also looks like loose bolts causes a chain reaction...

Sooooooooo,......... Looky, Looky, Looky what I found with the help of Kurt Klopp and the TM tests. It appears at first glance that my windings are ok, but nicked the paint for sure. I will have to repair the wires that come out to the diode assembly as two of them got ripped.

I have a two ton hoist and mine is mounted the same way, on a trailer, my engine hoist will go right in there over the generator housing, I tried it today, but hopefully I don't need to pull it all the way. Did you test the windings to see if they are damaged? Or are they obviously cut?

I know they make thread lock up to 600 degrees, I am not sure it would get that hot in that area unless the bearing failed. I will be posting my tragic findings at the end :-(

There is a video on Youtube of a guy pulling the diode plate and the generator out and having the generator rebuilt and fixing the diode plate himself. I image it can be rebuilt fairly simply if you fabricate the mounting plate.

Hi, Yes, that is a very good point, however I have been down that road as well, lol. It does not matter how long you hold it down you get no voltage. I have seen that some people had a problem where they had voltage when they held the switch over but it would go away when they went back to run...

Hi, Yes, I work on industrial mechanical/electrical machinery for a living so I have scopes and meters and analyzers galore! lol. I don't however work with generators so this is a learning experience but I like it. I do have frequency at the service outlet and can adjust it with the freq pot...

Hi, Sorry for the delay I was out of town. I don't necessary think I have a governor problem. I have no Freq and and no Voltage so I am following the TM troubleshooting again and this is one of the first test. A little history,,, after going through it this set ran fine for about a year. Then...

Hi all, I have a question about a test in the maintenance manual, TM 9-6115-643-24 Section 4.2.1 test B. I will try to add a screen shot. This test is testing for voltage between terminal 19 and 20 on A5. The test states after hooking up the leads...... "then move the master switch to START...

Follow up, I was able to resolve this issue with a new A5 Governor controller. The transistors that control the voltage to the solenoid failed. Everything else on it was good. So now the overspeed is fixed, the genset is running good, I can control the speed with the freq dial, however I still...

I just found the data sheet online, it looks like it draws 2.5A in steady state with 12V. So with 6V it would draw 5-6A so might be normal in this test. Lets see how the battery does.

So back at it, I am finally home and went over all the wires in the area, none are damaged, or burned, and all ohm out well, took all the harnesses apart near there to inspect each wire. Also after putting the A1 back it is clear that the burn area is under the A1 where there are no wires on my...

Hi all, Finally got back home and started in on the generator. I was about to put the regulator back into the machine and found this burn mark on the back panel, not sure how I did not see it before. I took pictures of the back panel, and the back of the regulator. The burn mark is about 2.5cm...

On thing I did not recall what the result was anyways, was to put 24V on the controller terminal 3 directly from the battery and see if somehow it was dropping power from S2 when it went to run.

Sorry, been out on the road forever and still out but did want to respond. One of the tests in the TM is to test the R2 pot wiper input to the controller. It goes from 10ohms to almost 5k pretty linearly. it is also 5k on the ends. Is there anything else to test with it?

Hi GuyFang, Thanks for the reply, I am not sure if I am not being clear or I mis-understand what you are saying. The generator starts, and runs, but only at full throttle. The controller is not controlling anything. Just puts battery voltage to the actuator at pins 9 and 10. The TM says it...

Update, I have checked all the connections I can get to, removed all the relays, tapped them, tested them, put them back, did the testing for the Woodward controller again and it passes all the tests in the TM. I have reset the pickup transducer about 10 times, I have 2.8VAC now at the...