Question about Coleman Powermate Powermate 5000W Generator

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Powermate PM0435001 Runs no power out

Hey guys, GREAT SITE you have here.
Here is what happened, we were running for about 2 days with a never used 2 year old Powermate 5000, I was monitoring the amp draw through out the day and it would average around 11 amps on both legs that was until someone decided to turn on the DRYER "2 pole 30", well needless to say that is what brought me here.
I have dissembled the end bell and removed the circuit board and have done a lot of inspection of it and nothing shows signs of damage "cap is not swollen nor do the diodes show any type of discoloration" the board itself looks and SMELLS brand new.
One thing I found that does not seem to make sense to me is if I hold the rotor by using a wrench on the end bolt and then grab the windings behind the slip rings I am able to rotate the windings of the rotor, my question is could that be the problem or is this normal ?
I have checked the windings and this is what I found, 34 ohm across the slip rings, 0 ohms to the shaft and also the stator.
While reading through different posts I see where some people need to flash the unit with a battery in order to get output voltage, exactly what does that do, charge the cap, magnetize the windings, just curious ?
Last question, how do you go about testing the cap, does it have to be removed or is there a way to do it while soldered to the board ?
Thanks in advance to any that respond.

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I worked at a tool rental center while going to college learned a few tricks trouble shooting generators. To test the circuit board apply 12 - 14 volts AC to the small two pin connector and read output at the leads to the brushes, you should get about the same or more voltage but DC. Capacitor should be removed to test properly if you suspect failure. It should read to 95 % of stated valve (Most caps for this gen are 470uf and will swell when failed). The armature should not slip on the shaft of the engine, you might remove the armature and check for damage or windings may not be fused to shaft. The armature is generally difficult to remove. We would remove the bolt and insert a hard steel shaft that would slip past the threaded part of the engine crank. Carefully Impact the shaft with heavy blow (use caution when hitting steel with hammer and do not miss.) It may be safer to remove the stator when you do this. Flashing the gen is generally only necessary when the gen has lost its residual magnetism. (If not used for a long period of time) To flash a gen we would use a small ac power supply 12 - 16 volt ac less than 1 amp, any small thrift store power supply will do and attach to a short piece of scrap male pigtale. Plug in the power supply to wall outlet and the short pigtale into the 115v outlet of the generator with the engine not running. (Some people will do this with engine running but not necessary) You will hear a slight hum in the stator. The stator will actually cause the armature to produce a magnet and voltage will be present across the commutator rings. Remove after a minute and the armature will regain its residual magnetism. This method will also test one of the 115v windings of the stator. If the winding is open there will be no voltage at the commutator rings. Good luck , enjoy.

Posted on Dec 17, 2008

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