7500 EXL putting out low voltage

[foutsboy]

Help.

I have a Generac 7500 EXL. Sits outside under porch, rarely used, quit putting out power. Tried flashing it..nothing. Just replaced the voltage regulator (#84132GS), now I get about 40 VAC output. Tried flashing it again using a 12volt car battery, plugged into the brushes with correct polarity. Same 40 VAC output when regulator plugged back in.
Note: when I supply the 12VDC to the brushes(while running), I get 120 VAC output at the receptacles. ALSO this unit has a 12 volt receptacle, and I only measure a couple VDC at the receptacle when running. I measured voltage at #2 and #6 wires when running, I get under 1 VDC. ANY suggestions?

[Wayne 440]

Check out this page, particularly post #3.

http://www.smokstak.com/forum/search...archid=1268156

Then sit back with your favorite beverage and decide if your set is worth fixing. It won't take too many Generac parts to equal the price of a new generator. My first guess is that the voltage regulator you installed (a) was not good when installed (b) is now bad like the first one because something else is "killing" the VR.

[foutsboy]

I appreciate the reply.
The fact that I get 120 VAC output when I supply 12VDC to the brushes, tells me the generator head is ok...right.?
Can anyone tell me what steps to take to troubleshoot this?
Thanks

[Wayne 440]

Does your diagram match this one?

http://bsintek.basco.com/BriggsDocum...GGMG_.IjhJvcv4

If so, your application of 12v to the field (wires 1 and 4) effectively bypassed any input from the "power regulator board" and "system control board"- or more correctly any input relating to output voltage regulation. If it made close to rated V when manually excited and smoke didn't boil out after 5 or 6 minutes the windings are probably OK. Without schematic diagrams for the boards and typical in/out voltage readings, about all you can do is replace both boards with "new" ones and hope they are good this time. The schematic shows an unfused 120 V input to the "system control board" (wire 11). IMHO, it is entirely possible for a failed component on the "system control board" to subsequently damage the "power regulator board"; aas I mentioned earlier parts get expensive quickly.

Take this for what it is worth, as free advice is usually worth that amount. I have little experience with Generac, most of it was both aggrevating and costly.