Question about McCulloch 13HP 338 Cc Portable Generator # FG6000MK

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No AC output on a FG6000MK genset

Genset runs fine, puts out minimal AC volts. What should the windings read with an ohmmeter? What is the best way to flash the field on these units if needed?

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Go see this post I did.

Posted on Dec 05, 2008

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You need to remove the cover where the outlets are at and measure the voltage before the breaker. There are no fuses on the output side of the genset only breakers. If breaker is fine but still no output, try flashing the fields with a 12 volt battery. If voltage increases then your voltage regulator is bad.

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1. Does the generator stay running when you start it the first time?

2. What color is the housing on this generator? Try to get the model number and serial number.

If the genset is shutting down on the first try, then your probably not creating voltage. However, if this is an older unit then the genset may stay running although no voltage is created. Place a volt meter on the genset to check for output voltage.

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Generators


My answer:

Not much in your original ? to go by as far as any history background of the Genset - if it indeed is a Powermate? Is it? And if so - is it already USED or is it BRAND NEW right out of the box - like many others here who I've already helped out and solved their problem(s)?

If this Genset is USED how many hours are on it. Try to be as accurate as you can - if known? Also - If this is not YOUR originally purchased Genset, but rather bought 2nd hand - did it work right when you first bought it?

Is so BRAND NEW or even USED - then I minds well tell you this first (if you don't already know this). After which I have some tech troubleshooting ??'s I need answered so I can pinpoint the problem.


As you are now hopefully but painfully aware - Powermate has gone totally Bankrupt, and is no longer in business as of this past year or so.

There is hope though - as I state below in the previous Footnote I posted to many having similar problems.

Previous Footnote: It's too late now for all those out there that unfortunately bought these now still Brand New "unserviceable" Powermate units that won't start for whatever, whether still Brand New "NIB", or whether taken out of the box and still not used, and are now seeking some kind of service on them (btw it's a sign of the present day GOP ran economic woes we are in AND it will only get worse - CHINA is going on the very same downward skid right now thanks to you know who - W!). If you buy anything today "made in China" - esp their cheap knockoff Gensets - you better be making a GOOD buying decision - otherwise you will be in the very same situation you are in now with your Powermate Gensets - as China is starting to collapse from within just like this USA economy of ours has been doing for the last 5-6 years to no end! All politics aside as well - as blame is put where it is deserved in my books and we can only blame YOU KNOW WHO! Sorry but true!

NOW -

Any inventory stock of their (Powermate) Gensets - that were once formerly sold in the USA & Canada - have been totally liquidated out to a company in Georgia I was told, and it was said to be true.

I was able to get this NEW added info through another source said to be VERY accurate btw - so hopefully it is.

That Company's name is PRAMAC, and their address and phone # info is:

PRAMAC INDUSTRIES, Inc.

* Regional head office:

1100 Cobb Parkway North C
30062 Marietta, Georgia

Phone: 770-218-5430
Fax : 770 218 2810

or:

* International sales office:

10100 NW 116 Way, Suite 10
33178 Medley, Florida

Phone: 305-888-9911
Fax : 305-888-3711

Site info:

PRAMAC Global Gateway

BUT -

Before you blame me for any possible incorrect Powermate info posted above in regards to that PRAMAC Co, or their contact info - read the GOOD NEWS below first, unless the BRAND NEW part doesn't apply to you here.

The GOOD NEWS is that I spoke with a very close contact inside Home Depot (not saying who so don't even ask), and that person gave me some very GOOD NEWS for those that act on it NOW!

Not tomorrow - Not next week - Not next month - and certainly NOT NEXT YEAR!

DO IT RIGHT NOW!!

I spoke with my Home Depot Corp contact today (using your "not starting" dilemma - as my own - to get a response) to see if anything could be done from their point of view and here's what I was told to do.

What I was told is that if I (you) bring in my (your) ORIGINAL HOME DEPOT CASH REGISTER DATED RECEIPT and speak to the (whichever Home Depot store applies here) Home Depot Store Manager there, and explain to them that the brand new never used Powermate Genset they sold me (you in this case) won't start - they would send your Genset out to their local Genset Service Vendor FREE OF CHARGE BTW, and hopefully get it started for you.

Anything more then that - you would be on your own if it was damaged by you or someone else that tried using it improperly.


NOW - as for your Genset there and the OVER-VOLTAGE condition you say you are experiencing.

I guess my first ? is - Which volt meter are you reading?

The one on your Genset possibly, or from a known Good Quality & good working hand-held DVM meter? If your AC panel meter is defective then that is not going to help matters at all. If your Genset control board is shot most likely something caused that condition from an electrical/electronics standpoint either on the board itself inside the "front panel control box" or else inside the "Gennie power head".

Usually an OVER-VOLTAGE condition occurs when a modification has been done to the Genset, such as say a new (or possibly a bigger wattage) replacement "Gennie power head" that is not rated properly to your engine speed (which btw should be ~ 3600 RPM max). Did you make any such modifications to your stock Genset recently?

If not - then we need to make sure you are getting the proper AC output measurements using a known good DVM meter set to the AC scale and either on 400 or 1000 volts depending on your meter's settings. Hopefully you're not using one of those defunct $3 cheapy Harbor Freight Tools meters either?

With the Genset running at normal idle what voltages are you reading at the 120VAC & the 240VAC outlets - from HOT to NEUTRAL only? Low - High - Sporadic - what? Be precise here - very important!

If you increase the Genset speed up to 1/2 Load speed what voltages are you now reading as well? Try not to run at Full Speed if indeed something had smoked inside the Control Panel such as the Control Board. Check that board out first for signs of damage. Does it look OK?

If this Genset has had HIGH HOURS of run-time on it have you check the "brushes" and/or "slip rings" on the ROTOR it as of yet? If it has brushes are they within factory spec? Are the SLIP RINGS clean and not arched and dirty looking? If the latter is found to be true then the SLIP RINGS need to be cleaned and polished bright again!! Very important!!

If the end plate (cover plate) is taken off (if you feel capable to do this yourself) is the inside fairly clean inside and around the SLIP RINGS & BRUSHES area? Do you smell any BURNT smell inside? If so then possibly either the STATOR or the ROTOR has gone bad! If not take an air hose and thoroughly blow out all the carbon dust & dirt and replace the "end plate" securely.

Unless it's a BRUSHLESS type Genset you have (which I doubt) then the problem possibly lies within the "power head".

Let me know what you find now that you know what to look for?

Based on that we can look still further is it's not covered above.

Best regards to all with the same problems, and hope I helped you out 100% - all political humor/truth aside.

Please post me a reply as to finding this solution being the best resolve to your Powermate 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.

Best regards,

Frank

Sep 08, 2008 | Coleman Powermate Powermate 5000W...

1 Answer

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My answer:

Not having any background info as to how old your model is or - TOTAL RUN HOURS unknown as well? - I can only give you several possibilities of what the electrical/electronics problem might be - even though I don't know the exact model # and which engine you have on your Genset.

McCulloch, Coleman, and many others as well do not mfr much of anything inside the USA today - let alone factory service anything they sell, but like with many other USA companies out there today they do private label out to a lot of mfg vendors (mostly in China btw), and the Genset gas engines are numerous to say the least. From Briggs & Stratton to Honda to Subaru and so forth...not to mention the generator heads as well. Again - all made in China.

I also don't know what normal LOAD you are putting on your Genset there, or have been putting on it previously, or at what RPM you are normally running the engine at - as to half throttle or full throttle setting?? The heavier the electrical LOAD the more heat the generator head had to dissipate as well. Is the generator venting clear and free from dust, dirt, and any obstructions? I take it that it's most likely a Briggs & Stratton 4-stroke single cyl, or else it's a Honda 4-stroke single/twin cyl engine?

Has the gas engine always been serviced properly as to scheduled fuel filter changes, oil changes, air cleaner maintenance, etc? These are just as critical so as not to burden the generator head output as well. If the generator head runs extremely HOT then you definitely have a problem there. Internal short, bad winding, etc.

Which brings me to the next point.

Since I take it that it has been running good up to now - I have a few ??'s as to how you have been running it recently, and how well it's been running generator-head wise?

Has the output voltage been really stable and clean up to this point or has it varied at lot?

Have you actually measured the AC output voltage with a good quality DVM set on the 200 volt AC scale? If so - what voltage was read? How stable was it - as to any notable variations?

Did you compare your DVM readings/findings to those listed in the Operator Manuals spec listed?

Btw - are all the output outlets totally dead? Is so then it's not the breakers at fault. Not if the engine runs OK, and at the proper RPM settings as well.

Beings your Genset is probably an older model - it just indeed might have some high RUNTIME HOURS on it. If it does it just could very possibly be what sounds like to me (and I personally HAVE SEEN this happen myself firsthand) that the generator brushes are nearly shot - as in almost worn out. Or in your case - TOTALLY GONE. If there is some brush length there, but not enough by spec then they may be getting too too hot - as from excessive current draw at point of contact, and thus the generator sensing circuitry itself is doing a complete electrical CUTOUT!!

An added protective Genset circuit feature in that the generator itself may indeed be linked to the engine as a type of REV LIMITER or CUTOUT on the Maintenance-free Magnetron® electronic ignition. Again - your operators or service manual should have a pretty good troubleshooting section in it unless you don't have that anymore or never got one if you bought it used to begin with.

If you unscrew & remove the Generator brushes, and they are indeed below the recommended length (or worse case they are indeed totally worn down) then that most likely is your problem right there.

If you choose to replace the old brushes with new ones yourself - be very careful when seating the new ones - as to their insertion and cap retainer tightening. Never over-tighten those black plastic-like brush retainer screw caps - for if you break one (hard to get immediate replacements is why), or fracture one it could cause the Genset to fail under LOAD, and that very well could do some severe damage to the generator part itself. Take your time doing it, and be patient!!

It has to be one of the scenarios listed above, as I've covered every possible cause short of a broken or shorted wire somewhere - which in that case you will have to schematic trace and Ohm out wire to wire contacts. This being the least likely scenario from my experience.

Please post me a reply as to the found problem there, and the resolve to it by following my recommendations above. Also please rate my troubleshooting fix as well.

Keep me posted and I'll follow up as well.

Best regards,

Frank

Sep 02, 2008 | McCulloch Power Generators

2 Answers

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My answer:

I don't know how or where you stored your Genset there, but it the generator head got soaked with water and/or was subjected to constant moisture and/or worse case - saltwater exposure - then there's a 100% chance you have shorted out the windings and possibly burned out the stator!

There are a few things you can or should check on both the generator head and the engine if it has HIGH HOURS of runtime.

Namely the the BRUSHES on the generator head as I also don't know what normal LOAD you are putting on your Genset there, or have been putting on it previously, or at what RPM you are normally running the engine at - as to half throttle or full throttle setting??

The heavier the electrical LOAD the more heat the generator head had to dissipate as well. Is the generator venting clear and free from dust, dirt, and any obstructions?

I take it that it's most likely a Briggs & Stratton 4-stroke single cyl, or else it's a Honda 4-stroke single/twin cyl engine? Has it been serviced properly as well? Oil changes, air filter cleaned and/or changed out, fuel filter changed, Carb cleaned out periodically, etc etc etc.

These are just as critical so as not to burden the generator head output as well. If the generator head runs extremely HOT then you definitely have a problem there. Internal short, bad winding, etc.

Which brings me to the next point.

Since I take it that it has been running somewhat good up to now - I have a few ??'s as to how you have been running it recently, and how well it's been running generator-head wise?

Has the output voltage been really stable and clean up to this point or has it varied at lot?

Have you actually measured the AC output voltage with a good quality DVM set on the 200 volt AC scale? If so - what voltage was read? How stable was it - as to any notable variations?

Did you compare your DVM readings/findings to those listed in the Operator Manuals spec listed?

Btw - were any of the output outlets totally dead prior to the total output failure? Is so then it's not the breakers at fault. Not if the engine runs OK, and at the proper RPM settings as well.

Beings your Genset is probably an older model - it just indeed might have some high RUNTIME HOURS on it. If it does it just could very possibly be what sounds like to me (and I personally HAVE SEEN this happen myself firsthand) that the generator BRUSHES are nearly shot - as in almost worn out. Or in your case - TOTALLY GONE. If there is some brush length there, but not enough by spec then they may be getting way too hot - as from excessive current draw at point of contact, and thus the generator sensing circuitry itself is doing a complete electrical CUTOUT!!

An added protective Genset circuit feature in that the generator itself may indeed be linked to the engine as a type of REV LIMITER or CUTOUT on the Maintenance-free Magnetron® electronic ignition. Again - your operators or service manual should have a pretty good troubleshooting section in it unless you don't have that anymore or never got one if you bought it used to begin with.

If you unscrew & remove the Generator brushes, and they are indeed below the recommended length (or worse case they are indeed totally worn down) then that most likely is your problem right there. All rusting aside!

If you choose to replace the old brushes with new ones yourself - be very careful when seating the new ones - as to their insertion and cap retainer tightening. Never over-tighten those black plastic-like brush retainer screw caps - for if you break one (hard to get immediate replacements is why), or fracture one it could cause the Genset to fail under LOAD, and that very well could do some severe damage to the generator part itself. Take your time doing it, and be patient!!

It has to be one of the scenarios listed above, as I've covered every possible cause short of a broken or shorted wire somewhere - which in that case you will have to schematic trace and Ohm out wire to wire contacts. This being the least likely scenario from my experience.

Please post me a reply as to the found problem there, and the resolve to it by following my recommendations above. Also please rate my troubleshooting fix as well.

Keep me posted and I'll follow up as well.

Best regards,

Frank

Aug 27, 2008 | Coleman Powermate Premium Plus 6250W...

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