New Generator

[mike_k]

Well I just picked up a 2.5 kva ex army/ military generator.

I'm very impressed, it's a really well built unit, and bigger and heavier than I thought from the photos!

This one is from the 1960s and powered by a licence built wisconsin engine built by Ronaldson and Tippett Ballarat. (long since gone, thanks accountants.)

A bit dark at the moment, I'll try to post some photos tomorrow.

I got the engine running, just needed some new cork fuel gaskets and a bit of a clean up - and it looks good, no smoke etc, and runs well in both the idle and run positions.

Unfortunately the power side doesn't work. The power meters are all dead, and both 120 and 240 volt sides have no output. I tried it a few times, and it did work once, but when I turned on one of the 240 volt socket switches it bogged down and then went back to no output.

I had a look inside the control box and to my very inexpert eyes, there is no obvious problem. A bit of a maze in there, but possibly fixable!

 All the wiring is fine, all connected and no spares, no burnt stuff on the 2 circuit boards no water ingress etc. Maybe some dry solder joints but nothing really bad, I might try to redo them next. All of the switches check out on the multi meter as does the cable between the generator and the control box.

So I need to call on the wide resources of REMLR.

Does anyone have a manual for one of these or a wiring diagram? I'm definitely not a sparky, but I could probably follow some test procedures if any are available.

Alternatively, has anyone seen any of these things anywhere else for sale? Maybe I can get away with a new control box, since I think that the generator and the motor are good.

The web is very quiet on these, I haven't had a lot of luck there either.

If anyone can help, I would very much appreciate it so this terrific bit of kit can come back to life.

I'll try to put up some photos tomorrow.

Cheers,

Mike.

[aussiegregmac]

First off,  be careful.   Does the brush cover come off the generator ??
Have a look at the brushes.  maybe worn down , bad wiring or dirty worn commutator.

Photo I.D. will be good once you take some photos.  Also, any makers marks or plates ??

Maybe also it needs a sparky to look at the operation.  At least you've got the motor going.
Now change the oil and clean the air filter.
Greg

[mike_k]

Thanks Greg, I know what you mean, I've only opened things up when it's not running.

Not a big fan of raw electricity myself!

I'll have a look at the generator tomorrow, hopefully the brushes etc are easy to get to.....

It would be great if that's all it is.

I've already changed the oil, and the stuff that came out didn't look too bad, the air filter was fairly good too. I'm much better at engines than the sparky stuff, which isn't saying much.

Cheers,

Mike.

[mike_k]

A quick update this morning, hopefully now with some photos....

Front view



Rear view



Generator End



Motor end



Control box



Magneto



And the placards,








Air cleaner stencil, does anyone recognise this?



Hope this works, first try at photobucket on this forum.


Looks like I made a mistake last night, the engine is actually licence built by Norton Villiers, not Ronaldson Tippett.

The placard with the instructions is a bit hacked around due to some in service repairs to the tinwork at the top of the engine.

I think it should say

GENERATOR 2.5 KVA 12 120 240 VOLT SINGLE PHASE but it is a bit hard to read.

The 141258 stencil is the engine number, and it looks like the DSN is 6115-66-021-1300.

From what I can see, it is missing something from the top of the frame (maybe a clip in box?), the recoil starter and the exhaust has 2 studs that probably take a flexy extentsion pipe.

Apart from that its all there, now I just need to get the electrical side going.

There is a removable cover on the end of the generator, so far I've got 1 of the 3 brass bolts out of the alloy casing....Hooray for dissimilar metals! more CRC, time and maybe a bit of careful local heat, I don't want to shear them if I can manage it....

Any info parts leads etc gratefully appreciated, I'll try to keep this updated as it goes on.

Cheers,

Mike.

[mike_k]

A quick update on the Genset....

I was very fortunate to be offered all of the manuals for this unit, which were invaluable.

Following the troubleshooting in the EMEI led to the discovery of some fairly dirty slip rings.

After cleaning them up, I was able to get the DC side running using the 'excitation' procedure.

Next was a dead short on the 240 volt side anytime any of the 3 socket switches were turned on.

Turned out that at least one of the capacitors fitted across the 240 volt sockets were faulty and causing the problem.

All three capacitors have been temporarily removed pending replacement, they do not affect the ops of the genset,as they are only for RF suppression.

Having fixed this fault, it now runs!

I've loaded it it up a fair bit and it is very stable. (also quite loud but who cares.)

Very satisfying to get it up and running, and many thanks to the kind person who took the time to send me the manuals.

Next is a bit of a tidy up, new paint, rust removal etc.

I'll try to retain the markings,especially the boomerang / lightning bolt on the air cleaner.

Does anyone know where I can get some numerical stencils made up for the engine number? They are 1 inch high.

Also I'm now on the lookout for a spares / toolbox to go on top of the frame and an exhaust extentsion as well. If anyone sees any bits out there, I'd appreciate a heads up.

I'm quietly hoping for a blackout sometime this weekend......

Cheers,

Mike.

[AGAS 5]

Does anyone know where I can get some numerical stencils made up for the engine number? They are 1 inch....

Try searching on ebay uk.

Pete

[mike_k]

Thanks Pete,

Just ordered some of the brass interlocking ones.

Should last me out!

Cheers,

Mike.

[IAN WILLIAMS]

Hi Mike,
            I have just read about your great find of a 2.5 kva military generator, I to have recentily acquired one the same as yours, mine has the tool box. I had trouble with my HT lead shorting to the cable shield, after fixing this problem and cleaning the fuel system the engine started and run quite well ,but a different story for the generator. After checking the condition of the brushers and slip rings which were in very good condition, I then removed the control box and found the capacitors across the 240volt outlets were badly cracked and broken so I removed them.  I replaced the control box and then started the engine and exited the fields and every thing worked, that was until the engine was stoped and restarted; now it fails to charge. I was wondering if it would be possible for me to obtain a copy of your manuals so I could trace the wiring circuit. I would be quite happy to pay for all costs. My engine is a Wisconstin model BKNDA serial number 6210883.

cheers, Ian.

[mike_k]

G'day Ian,

I'll send you a PM.

Cheers,

Mike.

[AGAS 5]

Hi Ian,

Welcome to REMLR !  It'd be nice to see pics or a vid of the generator once she's all sorted.

Cheers,

Pete

[derek76]

Hi
I also have one of these generators which I have fixed up.  I to could do with the manual that was talked about in the previous comments.

Derek

[derek76]

Pic of mine almost finished

[THE BOOGER]

Nice work

[mike_k]

Derek, that looks terrific.

I like the 'feet' you put on the base of the frame, I did something similar to mine.

Do you have all the parts for yours? I spent a fair while looking for the recoil starter and the toolbox for mine.

I'll send you a pm,

Cheers,

Mike.

[derek76]

Thanks Mike.  I have spent many hours pulling it apart and sanding it back thru multiple coats of badly aimed paint.
I am missing the tool box which I am very interested in seeing yours.  And I dont have the 240v gpo dust caps which I notice yours has.  I dont have the exhaust extension either.  I have put a carby kit thru it and new fuel lines.  New glass fuel sediment bowl. New fuel pump repair kit.  New spark plugs. I have a box of 6 from us out of an airplane. 
I bought a Q2 gasket kit for the engine also.  The piston and bore are in excellent condition it already has the oversized piston and re bore completed by the army.  All bits were dismantled sanded back reprimed and 3 coates of army lustreless. 
My pull start section took quite a while also.  Mine was very rusty.  I bought a new shroud from the states and refitted the pullstart mechanism to it.
I have the complete BKND parts book if u need.
I dont have any info on the generator portion though I would be interested to get it if u have any.
Mine never had the information plate stating revs and kva etc.  It just had the small rectangular one WISCONSIN made by ronaldson and tippett.  Model serial number
What is the correct rpm stamped on yours?
Please post some pics of yours.
I will find some pics during restoration and post them