We have CAT Generator 465 kw since last 2 days we are not able to solve the problem,when starting the engine RPM is normal but no output voltage,we check already the diode and AVR & winding but still the same problem.. Regards, Andy

REDUX 1.
Why in the world post an engine and NO car told, yes 2002
DEAD WRONG IT HAS BOTH.!! VIN F TOO.

the CMP and CPK sensors both must be good and cam actually turns and cam timing in spec or the ECU cuts spark then cuts fuel..



cmp goes to icm and icm to pcm.2002 Ecotec 2.2 DOHC. no VIN F IS 2.4L AND VASTLY DIFFER\ENT

I GUESS this car. # below Cavalier.
2002 Chevrolet Cavalier 140 hp (104 kW) @ 5600 rpm 150 ft?lb (203 N?m) @ 4400 rpm 10.0:1

SEEMS i GUESSED RIGHT , TOP OF LIST, AND NOW VIN F TOLD.

2003-2005 150 ft?lb (203 N?m) @ 4000 rpm link
2005-2006 Chevrolet Cobalt 145 hp (108 kW) @ 5600 rpm 155 ft?lb (210 N?m) @ 4000 rpm 10.0:1 link
2006 Chevrolet HHR 143 hp (107 kW) @ 5600 rpm 150 ft?lb (203 N?m) @ 4000 rpm 10.0:1
2004 Chevrolet Malibu 145 hp (108 kW) @ 5600 rpm 155 ft?lb (210 N?m) @ 4000 rpm 10.0:1
2005-2006 144 hp (107 kW) @ 5600 rpm link
2002-2004 Oldsmobile Alero 140 hp (104 kW) @ 5600 rpm 150 ft?lb (203 N?m) @ 4000 rpm 10.0:1
2002 Pontiac Grand Am 140 hp (104 kW) @ 5600 rpm 150 ft?lb (203 N?m) @ 4400 rpm 10.0:1
2003-2005 150 ft?lb (203 N?m) @ 4000 rpm link
2002 Pontiac Sunfire 140 hp (104 kW) @ 5600 rpm 150 ft?lb (203 N?m) @ 4400 rpm 10.0:1
2003-2005 150 ft?lb (203 N?m) @ 4000 rpm link
2005-2006 Pontiac Pursuit/G5 145 hp (108 kW) @ 5600 rpm 155 ft?lb (210 N?m) @ 4000 rpm 10.0:1
2000 Saturn L-Series 137 hp (102 kW) @ 5800 rpm 135 ft?lb (183 N?m) @ 4400 rpm 9.5:1
2001-2003 135 hp (101 kW) @ 5200 rpm 142 ft?lb (193 N?m) @ 4400 rpm
2004 140 hp (104 kW) @ 5600 rpm 150 ft?lb (203 N?m) @ 4000 rpm
2003-2006 Saturn Ion 140 hp (104 kW) @ 5800 rpm 145 ft?lb (197 N?m) @ 4400 rpm 10.0:1 link
2002-2005 Saturn Vue 143 hp (107 kW) @ 5400 rpm 152 ft?lb (206 N?m) @ 4000 rpm 10.0:1 link
2006 143 hp (107 kW) @ 5600 rpm
2007 144 hp (107 kW) @ 5600 rpm
2001-2005 Opel Speedster / Vauxhall VX220 147 hp (110 kW) @ 5800 rpm 150 ft?lb (203 N?m) @ 4000 rpm
2001-2006 Holden Astra (TS) 147 hp (110 kW) @ 5800 rpm 150 ft?lb (203 N?m) @ 4000 rpm


THIS IS THE 2.2L NOT 2.4L SO NOW i HAVE BOTH PRESENTED

Service the engine then check the engine speed. Engine speed affects output. :)

Output voltage is based on 3600 rpm @ 60Hz. Sounds like your generator is over speeding slightly. Put a Frequency meter on the output of the generator and tune it to 61.5 Hz, that will get your generator in the 3600 RPM range.

I answered this twice already?

Not sure what you mean "high voltage rpm power generator out", however many people have asked how to adjust the engine for proper voltage output. On generators with~out a voltage regulator, I adjust the engine RPM by using a digital voltage meter that has a Hz setting. Adjust the governor untill the meter displays 60 Hz. With the geneator producing 60 cycles, I know that the engine is turning 3600 rpm (the engine produces max hp when it is turning 3600 rpm). At this point, read the voltage output to verify that the range is between 115 ~ 120. On generators with a voltage regulator, verify/adjust that generator is producing 60 cycles then adjust voltage by turning screw at the regulator (some regulators are sealed with potting compound and can not be adjusted). If your power demands are not that great and you appliance can operate at 50 cycles, adjust governor as needed. Lowering to 50 cycles will also reduce output voltage. Good luck

Sounds like a short in one of the windings to me. Can you verify that the engine rpm is not exceeding specs? If you can modify the engine speed Id say slow it down and see what the voltage read is.

Here are a a few possibilities to look at:

1) Bad connection at the outlets themselves (loose wire) regarding neutral, hot wires.

2) Bad Excitation Capacitor. The Exc. Cap. is responsible for energizing the field wiring of the alternator. If the field is not energized, there will not be a magnetic field developed, therefore, no electrical output.

3) Open Field / Stator winding. If Field winding is open, no magnetic field will be developed. If Stator winding is open, no voltage will be induced.

4) Generator speed is too slow. If the RPMs of the engine are too slow, the output of the alternator will fail as well. Note that from normal speed, voltage output will occur but at reducing frequency until ouput ceases altogether, usually at about 47Hz. If your alternator is a 2 pole, engine speed should be 3600 rpm nominal. If alternator is a 4 pole (most aren't), engine speed would need to be about 1800 rpm nominal.

5) Generator speed too fast. If RPMs are too fast, output may fail as well. See above.

6) Excitation Fuse has blown. There is sometimes a fuse in the excitation circuit. To check this, you will likely need to pull the end housing off the alternator. Pay attention to bearings / bushings.

chek brushes...if they seemed ok then replace AVR card

You'll need to test to see if you are getting voltage from the brushes. This is a live test so, using something like alligator clips or such on the metal bracket of the brushes for your volt meter is a good idea. Simply start your generator with the volt meter leads attached to the the brush holders or exposed electrical connection to the brushes and see if they are producing electricity (120vac or greater). No voltage then it's your brushes, field, or stator. If they are good check the output of the voltage regulator. If it to does not kick down any voltage above 120 then it's your problem.

Note most cheap generators do not have a voltage regulator. All generators depend on the correct engine rpm to achieve normal voltage. 3600 rpm is the correct speed on a two pole generator to produce 110 to 125vac and 60hz (normally found on gas generators). 1800 rpm is the correct speed for four pole generators (normally found on diesel generators). You may set your rpms slightly higher to ensure that it's maintained underload ie 3750 for gas. Diesels usually have very good governors and don't need to be set higher.

Most generators use a flyball type governor within the engine to control rpm; also there is a voltage regulator that tries to maintain voltage at about 115v. The voltage regulator varies the voltage to the armature increasing /adjusting magnetic force. Use a meter with htz or freq setting to adjust engine governor to 60 cycles. When the generator is producing 60 cycles, the engine should be turning 3600 rpm, max power range. At 3600 rpm the voltage should be 115 to 120 volts. Loading the generator will cause governor to try to maintain 3600 rpm. Check engine manual for proper adjustment of gonvernor and linkage. The governor mech should last the life of the engine, however governor system does wear out. Expensive repair. enjoy