I have a 5500Watt BSI550 generator that lost AC while in use. It's only putting out about 5VAC. I Tried several other capacitors and even without a cap it's still putting out about 5VAC right at the stator leads. What can cause this?

check the voltage reulator for output voltage
this regulator allows voltage to the alternator windings to generate power and without that voltage there is no generator ac out put
talk with a genset repair shop for a better diagnosis and quote

The pin hole is to allow air into the tank. without the hole it would not be able to pull fuel from the tank

Sounds like the generator unit (sometimes called the generator head) has overheated and melted the insulation in the windings. This is the same as an electric motor "burning out", and if this is the case, then the generator is toast. If you happened to notice that the lights or fans were getting dim or slowing down before the breaker tripped (without the gas engine slowing down) then this is most likely the case and you generator is toast. But if the output just suddenly quit, then it is possible that some smaller electrical component has failed. In any case, it's not something external that you can easily reset or replace. Sorry for the bad news.

You need a Champion RC12YC it takes a 5/8 Spark Plug wrench

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Hi and welcome to FixYa, I am Kelly

The BSI550 came in 4 model types 0, 1, 2, and 3.

Types 2 and 3 are brushless. I am assuming this is a brushless generator and the following list of parts can cause the unit to suddenly stop working.

1. Capacitor(s) This unit has _ capacitors
Usually when capacitors fail on a brushless generator you first start noticing that when there is a load introduced that voltage changes dramatically. However they can just up and quit.
2. Diode pack
3. Wiring from the capacitor to the stator is damaged.
4. The Varistor in the rotor has failed (this fails because of a short in the rotor)
5. Rotor short or open
6 Stator winding short or open.

My years of experience with brushless generators is the 2 most common failures (other than wiring that happens alot) are the Rotor and the capacitors in that order. Rotors fail out of the blue... capacitors usually do not. Take a look inside the control panel. If you notice that the bottom of the the end cap enclosure looks like someone dripped candle wax in it you most likely have a failed capacitor. I probe the capacitor(s) with one terminal removed watching for a brief spike in resistance on the meter and then it drifts to infinity EACH time the meter leads are reversed. (Good result usually). After that is is on to wiring, Rotor and stator resistance tests.

Parts:
http://www.ereplacementparts.com/images/Porter_Cable/BSI550-W_TYPE_0.pdf

Thanks for choosing FixYa,
Kelly

the capacitor is gone, that is why your Generator is not putting out AC

One sure thing is you better find a competent service guy.

It sounds like you have lost excitation to the field of the alternator. Without documentation I can't tell if this is a brushless type or brush type rotor.

In either case, the excitation needs to be restored. On a brushless type, either lack of residual magnetic flux to start the buildup of the field OR failure of the rotating diode(s) can be the problem.

In a brush version, investigate "flashing" the field on Google or trace out why there is no voltage to the field. Possible things for this are failed transformer, failed rectifier, blown protective fuse and or wiring.

here is the link to download the manual you're looking for
http://www.briggsandstratton.com/pdf/owners_manual/101/1933_0_om-Domestic.pdf

Hi,
If the generator hasn't been used for awhile the rotor may have lost it's magnetism. All you need is to re-excite it. There are several websites that explain how to do this. It's a good place to start.
Erick

The burn spot on the display tube is normal.

Check for dc voltage to the display first and last pins should be (-20v to -30vDC) to ground.Then check for ac voltage across the first an last pins of the display should be (3v to 5vAC)
If you are missing them check for open fuses or resistors often on a board on the main transformer. But there are several other possibilities (shorted diode, transistor, capacitor or open resistor).
Only a couple of times have I seen a new display fix it.
Always look for bad solder connections on the display.

As for replacement parts I dont know if they sell to the public or only to service centers.