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Re: generator went out. no power at all
You need to check the resistance of the rotor, should be over 5 ohms and under 20 ohms. The voltage going to the brushes is DC voltage, not output voltage. You should see at least 10 to 60 volts dc at the brushes. If there is no dc voltage at the brushes then your voltage regulation circuit is bad or your stator is not providing the voltage to your voltage regulator. Also, make sure your rings are cleaned and your brushes have a good length and that they sit right on the rings. Clean the rings with 150 to 200 grit emory cloth until you see the copper shine.
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A couple of things would be worth checking into. Of course, I'd pretend that you checked the output fuse or circuit breaker? If you can check for voltage directly from the stator or armature and check the results. Nothing? If it has them, could be brushes. Also, if it's a fuse, don't just do a visual...check it with a test light or multi-tester of some sort.
I need a model number for your ENGINE not the whole generator. I believe this is a case of the engine not running fast enough. I.e governor adjustment will be necessary. Respond with an Engine model number and I will stll you how to adjust the governor speed.
This is GENERIC but the Governor arm has a spring that connects to a speed plate. The speed plate has a stand off screw and nut used for speed adjustment and a center nut for securing the speed plate in a fixed position. The Steps are to slightly loosen the center nut and the locking nut on the speed adjustment screw. Start the unit with a meter reading output power voltage (use extension wire for meter) Then turn the speed increase screw in to increase speed. When you reach 122-123 VAC stop. The reason you adjust it to 122-123 VAC is because voltage will drop as the generator provides power loads
Tighten the screw lock nut while running if possible and tighten the center nut on the speed plate to secure it in place. Check voltage again.
If you generator is running at normal speed and you have low voltage output... most of the time the Capacitor is failing. If the capacitor is failing the magnetic field in the armature and stator collapse under above average loads causing HUGE voltage swings.
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.
take a look at the fuse...if it seemed burnt then replace it.
then check the breaker...try connectting your voltmeter directly to the wire that goes into the breaker(directly to the +) and the other side to the regular (-).
if it read 220 volts then the breaker is down...so replace it...or you can use the outlet directly.
however if it didn't read any voltage,
then you should check the brushes...they are right next to the AVR module...(the two wires that come out of the AVR are connected to the brushes)
if the brushes are shattered or if there is no connection between each brush and it's connector then replace the brushes..
but if they seemed fine.then your problem is with the wires...trace every wire and check for continuity.
the problem has to be one of the things i mentioned.
Check for any blown fuse and replace. It can be traced directly from the output lines.
Check field excitation. The field excitation is
supplied by the battery to the excitation coil through a pair of carbon
brushes. If the brushes are worn out, no excitation field is supplied
and no output is generated. Replace carbon brush if found worn-out.
Use an analog multitester to check the continuity of the carbon brush and the field coil.
To flash fields the genset has to have rings and brushes. The ring towards the bearing or towards you is positive and the back ring is negative. The rings and brushes are on the rotor, which is the part that spins on the generator end. Place a volt meter on the outlet, start the genset, with a 12V battery apply the positive to the front ring and the negative to the back ring. The voltage should climb up to about 50 - 100Volts or more. If this happens then you will need a Voltage regulator. If voltage does not climb up, then check the rings and brushes. Make sure the brushes have a good length and that they touch the rings and make sure the rings have a shiny copper color to them, if they're black clean them with emory cloth until there is a nice copper color and try flashing the gen again. If nothing happens then you need a new generator end or new generator, which ever you prefer. Make sure to use rubber gloves when flashing and look out for rotating parts.
Remove front cover on the genset and you will see the brushes and rings. Clean the rings if black with emory cloth and inspect brushes. Flash the fields by apply a 12V battery to the brushes. the brush closest to you or the bearing is connected to the positive side of battery and the back brush is negative. You have to do this with genset running. You should notice your voltage climb up to over 50Vac maybe even over 100Vac. Make sure to use rubber gloves when flashing fields and keep hands away from rotating parts. if voltage does increase when flashing the the voltage regulator is shot. If voltage does not climb then you will need a new genset or generator end.
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.