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Only 2v on 220 outlet , brushes are still good , what next

My generator is only making 2v on the 220 outlet and I checked the brushes they are ok what else could make the voltage drop , Help me please I have no electricity . John

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Your voltage regulator is shot. Needs voltage regulator.

Posted on May 12, 2009

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My powermate 3500 generates 157 volts on all 120 outlets and 308 volts on the 220 outlet. What could cause that to happen. I've heard of generators not delivering enough voltage but never heard of one over...


the governor is not set properly, good job catching this issue. also check it under a load, if you still find the voltages too high, I recommend having it serviced.
setting the governor can be tricky.make sure you mark the shaft.

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How to test the electrical system of the generator for free


Ez test to determine if stator wiring is ok. This test works on generators that have two sets of 115v plugs and 220v plug. Use a 12v, 1amp ac power supply ( smaller ac power supply should work ok ). With generator not running, apply 12v to one of the 115v outlet plugs. Now verify 12v output voltage with meter at another 115v outlet on generator. Also verify that there is about twice the voltage at the 220 v outlet plug (should be about 20v - 24v) . If the adjoining 115 v outlet plug has no output or very little voltage or if the 220 volt plug has no output, most likely stator is damaged or breaker is off. If the stator is shorted voltage reading will be very low and power supply will heat up. If stator is open, there will be no voltage at second 115v plug or 220 v plug. If voltage is ok at the other outlet plugs as per test above then most likely problem is with voltage regulator, or brushes not making contact or armature winding open or just needs to be energized. Unplug the 12v power supply after test to prevent it from overheating. Most generators have two 115v windings that together power the 220v plug. When you energize one of the windings with the 12v power supply, the second 115v winding will be energized also and give you a voltage reading about equal to 12v. You will not damage the generator with this small voltage being input thru the plug. Good luck

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1 Answer

Coleman 3500 with subaru engine no power to outlets


Hello there.
I'm assuming that engine runs fine. if there's no power output then the AVR or carbon brushes are dead. remove the back cover of the alternator very carefully and look at the center to find the rotor rings and check if the plastic brush holder hasn't melt or heat deformed and make sure the brushes make good contact against the rotor rings. if everything's fine then the AVR is dead. The AVR is a crescent shaped plastic container similar to this one.
http://www.ebay.com/itm/Automatic-Voltage-Regulator-AVR-For-5KW-5-5KW-Single-Phase-Gasoline-Generator-/221461125389
replace it with any similar found on Ebay, just make sure that connectors and cables are similar in shape and number. Regards

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Generac 5500XL, model#09778-7 no output. Changed the power regulator board. No luck. Flashed the 120 plug with 12-30vdc from DC board. Nothing. Excited the brushes directly with DC board. Only got 2.36VDC...


Double check your brush istallation. positive side toward rotor bearing, if you put 12 vdc directly into brush pack and check with a meter at the 120 vac outlet and have low or no voltage, you may have no resistance in your rotor slip rings, excitor & main windings also need a resistance check. 12.6-16.7 ohms (rotor) 2.26-2.80 ohms (excitation) .26-.32/.28-.35 main or power windings. Note: unit running when appling 12 volts to brush pack. 2-5 second only, ( This test tells you the rotor & stotor are ok )

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1 Answer

5500 generator stopped producing eletric after


First check with the dealer and see if it is still under warranty. If it is not, make sure nothing is blocking the air flow around where the control modules are located. This could cause the voltage regulator and other electronic parts to overheat. Next check the brushes and make sure they are free of any dust or build up preventing them from making contact.

If everything is OK the next thing I would do is change the voltage regulator.

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take a look at the fuse...if it seemed burnt then replace it.
if not.
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.

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1 Answer

Coleman 5500 W/Yamaha MZ300 engine, runs great, no power produced


next is...brushes..
if they were fine check AVR

don't hesitate to write to me for further information:
sal_kh_sab@yahoo.com

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1 Answer

10,000 watt generator 220 plug doesn't work


Most generators have several circuits incorporated within the windings. There are usually two 115v windings, one or two windings that produce power and sensing voltage for the regulator that supplies power to the armature (produces magnetic force) and sometimes a 12v winding to supply power to charge the battery. The two 115v windings power one 115v plug each and together power the 220v plug. Each outlet has a breaker and or ground fault. Since the 115v plugs are working indicates that the 220v plug must have an open/broken wire or faulty breaker. Easy to check, however you must open cover to wiring compartment and trace wires. Should be easy fix. You do not have to start engine to find broken wire. Use ohm meter instead. With engine off, Insert probes into 115v plug and obtain ohm reading. Then insert probes into second 115v plug and obtain similar reading. Look for same reading at the 220v plug (remember 2 circuits of 115v, ground and neutral). Good luck with your repair and email if you have other question.

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1 Answer

Motor runs but have no power coming out of outlets of mygenerator


1 - Check the circuit breakers on the front of the panel where the outlets are located.
2 - Make sure the black molex plug on the back of the panel where the outlets are located is plugged in securely.
3 - Carefully take the plastic endbell off the generator ( you'll need a 7/16 inch wrench and socket) and look for broken or missing brushes, broken wires, etc.
4 - If you're not up for #3 take it to a good repair shop. :-)

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