Question about Coleman Powermate Premium Plus 6250W Portable Generator
I have a Coleman Powermate generator Model PM 0525305 Ser# 96171339
that is maybe a couple of years old,have not used it maybe 40 hours at most.I started it up a couple of days it ran find for about 30 minutes then
all of a sudden it started running faster,check it and found ON/OFF switch
had somehow went from the On postion to half way between ON/OFF and it will not move,to ON or OFF,it did cut off by the choke.I tried to call Coleman but I understand they are out of business.Can someone tell me
caused this problem and will a new switch solve the problem?
This a fairly common problem & easy fix with the Powermates, and other Gensets in the same class - made in you know where - China.
I seriously doubt if the Ignition Coil had anything to do with the failure of the KILL switch, as by how it's wired in the Genset circuit unless maybe you failed to fully set it to the ON position, and then in that case you may have had some "arc over" internally at that switch contact point to Gnd - prematurely causing a bit of engine surging - as that like which happens just before an engine runs out of gas.
If your Genset has a 3-wire connector harness coming off that ON/OFF switch then most likely there are only 3 wires connected to the back of that switch. One single wire (most likely GRN in color) goes to an/the Engine Block GROUND bolt somewhere - easy to follow.
The other 2 wires will be the same color (every Genset is a bit different so my schematic only says they are #18 with no color stated - possibly WHT though ??), and one of those 2 wires goes to the #1 pin of that 3-wire harness connector, which in turn is WHT in color on the other side of that 3-wire harness connector pin #1, and goes back to the Control Board inside the Front Panel Box. The other #18 switch wire goes to the Ignition Coil Primary side. Lets hope it's just a bad switch and not a bad Control Board.
Most likely the switch contacts inside just burned out from heat breakdown, as when you go to shut off the Genset - by turning it to OFF - the switch has to take the Ignition Coil Primary voltage/current and basically SHORTS it to Ground thus collapsing the Ignition Coil by robbing the Primary excitation voltage. It's bound to fail if it's a "cheap switch design" to begin with. AND - we all know about cheap Made in China stuff now don't we?
Just so you know - you are not the only one in this same Genset boat - as there are tons of people out there with far worse Powermate problems then just a simple switch problem like you have there. Count your blessings!
You are right about Powermate being out of business though, but not all hope is lost there either when you read everything farther below - as to factory service and parts for your Genset.
I know it's a little long, but the info farther below may be of future help to you later down the road - so copy and print it out for later reference just in case you have other Powermate Genset issues or this site goes down as well....hahahaha.....just kidding.
If you choose to contact the PRAMAC people about getting a new switch, and repairing the Genset yourself here are a couple options for you. If their factory replacement part is outrageously high in price - then you have another option.
If you are handy with a good soldering iron and some good 60/40 Kester solder and acid flux all you have to get is a good ON-OFF single-pole single-throw (only 2 wire connection points for the wires) toggle switch rated at 120 VAC or 12-24 VDC, and at least 10-15 amps rated, and just do it yourself. $5 part worst case!!
DO NOT use a Momentary switch type - as then someone could start the Genset inadvertently - esp if you have smaller kids around!!
Just make sure you get a good solder connection on the wires and the switch tabs, and make sure you tin both the wires and the switch tabs first to get good results. If the switch doesn't fit the old hole perfectly you may have to do a bit of modification work there.
Sorry - I can't help you out there. Make sure you mark the switch as to ON & OFF - unless you find one with a metal ON-OFF backplate like some come with - as there is no right or wrong way here. It's either one way or the other depending on how you mount the switch to personal preference. Right - Left or Up - Down.
Test the switch first before final mounting by firing the Gennie in whichever is the ON position so you know which is which, and make sure it kills the Gennie when you flip the switch in the opposite direction. That's is all there is to it. You're done!!
Hopefully like I said before the Ignition Coil is OK and so to is the Control Board otherwise I know I'll be hearing back from you soon.
Please post me a reply as to finding this solution being the best resolve to your Genset problem there by following my recommendations above. Also please rate my troubleshooting fix as well.
Keep me posted and I'll follow up as well.
Posted on Sep 09, 2008
Dosen't this model have a Tecumseh engine ? If so you should be able to get engine parts including
the kill switch from them.
Posted on Sep 15, 2008
When using the 220 volts to run a pump, it trips out after about a minute. It doesn't trip the pumps breaker and the pump runs good with another generator. It may have been putting out less power ? What do I need to replace?
Posted on Jul 11, 2010
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