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Portable generator outputfailure

I am writing this from New Jersey where our electrical service has been off since Monday. I would appreciate any information that would beat on the following problem . I am 75 years old and kind of chilly. In 2002 I bought a Coleman Powermate 5500n Endura portable generator 5500 watts, model PM0645500 that I expected would help me to deal with extended power outages, and last year in the case of Irene it functioned flawlessly. The unit had 24 hours total service when I started it on Monday after the power failed this time. It worked OK for about 10 hours and then the lights went off momentarily. About 30 minutes after this momentary failure the output voltage went to zero. And the operational display was blank. The motor starts and runs perfectly. Following instructions in the generator operations manual : I checked the brushes. They were OK I excited the generator but still no voltage approx 2 volts across 120V outputs In an attempt to deal with the problem I removed the operations panel screws and did not notice anything amiss. I loosened and inspected the rectifier board. There were no noticeable problems. i.e., the solder points appeared ok and the diodes looked normal. I checked all the connectors and they seemed to be securely fastened I checked the connectors in the plastic pouch adjacent to the low oil module and they all seemed secure I reassembled the panel and restarted the engine. The voltage came up to normal. You can imagine how happy I was. The frequency was a tad high 63 cycles persec but I reconnected the various devices and the generator operated normally under load for about 1 hour and then the output failed again. I rechecked all the connections and no improvement but the voltage output remains low 2 volts when the engine is running. I called Powermate tech serviceline 800-445-1805 and was put on hold for 15 minutes and then got a message due to high call volume they were dropping the connection. This happened twice. If anyone has any suggestions for repairing the problem I would appreciate it. If anyone has a service manual in computer readable form or even a circuit diagram that is appropriate to this generator I would appreciate receiving it as link or as an email attachment. My email is petegerster at Thank you

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  • Electrical S... Expert
  • 153 Answers

You need to run these tests in the video and come back to us with the results. Send your test results to us here:

Then we can tell you what the problem is :)

How to test your Electricity Generator AVR Brushes and Alternator on...

Posted on Feb 27, 2017


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SOURCE: I have freestanding Series 8 dishwasher. Lately during the filling cycle water hammer is occurring. How can this be resolved

A 6ya expert can help you resolve that issue over the phone in a minute or two.
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Posted on Jan 02, 2017

  • 169 Answers

SOURCE: coleman powermate pmo645500 wont produce


This could be one or more of just a few things, in order of ease to check:

1 - Not enough rpm from the engine. You need some way to measure Hz of the output from the generator. At no load it should be about 61.5 Hz, if it isn't you have to troubleshoot further to figure out why not.

2 - Dirty slip rings causing a lack of rotor current. Get an ohm meter and measure the rotor winding thru the brushes, if it's much greater than 30 ohms or so you need to clean the slip rings.

3 - a bad voltage regulator module. You can check the inputs and outputs, check that the wiring to the module isn't broken, and visually inspect it for damage. These are not inexpensive (ahem)

4 - rarely the stator wiring might be shorting to something in such a way as to load the generator even with nothing plugged in. You would likely also notice a distinct change in how the generator sounds if this were the case.

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Posted on Dec 06, 2008

  • 83 Answers

SOURCE: I have a Coleman Powermate 5000 / No power output

Two suggestions. One: check for voltage from the secondary coil wires (if it has one). Two: unless stated do not do this, I have always flashed the excitor circuit through the 120vac receptical. Give these a shoot and I hope it works for you.

Posted on Mar 30, 2009

stunt driver
  • 5 Answers

SOURCE: Checked capacitor, diodes and circuit breakers and

Make sure it is not the brush set.
There must be continuity from one slip ring to another.
If not, but rotor doesn't look burnt - check points where rotor wire is soldered to slip rings, or clear contact point on each side of wire and check continuity there, past slip rings and brushes. Big chance that wire came loose from slip ring.
Had such problem on my Champiion 3500
evern if burnt - rotor is easy to rewind at home, unlike stator.

Unless your model is Inverter type - there is AVR module.
But, unless your rotor has continuity - don't bother going further.

Posted on Jan 13, 2010

  • 1 Answer

SOURCE: No AC out put

After working on several of this style coleman generator,i have found that the lead wires in the windings that are soldered to where your brushes would contact tend to break.I don't know if it's a poor design or just a fluke,i would check to see if your getting continuity on the rotor and go from there.They seem to either "burn off" or just break.

Posted on Apr 02, 2010

  • 5603 Answers

SOURCE: Coleman Powermate Powerbase 4000 -no AC Need Field test procedur

Check the voltage sent to the field when running. It will probably be around 12 volts. You can try connecting a lantern battery BRIEFLY to the field to re-magnetize the field. Try bothe polarites.

Some have had a bad rectifier and one had a bad transformer that generaates the low voltage from the generated output. He had a broken wire from the winding to the wire from the transformer. He was able to reconnect the failed solder joint.

Posted on Apr 16, 2010

Testimonial: "Thanks for info. I had it solved. I found the 130uf 200V rated cap was bad. 12 volts to the brushed did re-energize the field, power is operating. TY"

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