I have a honda generator em2500x serial ezcn1084497. The generator produces only some voltage. ie will run a drill however if I load it up it with more voltage it stops generating completely. I turn off the motor and turn it back on and it starts generating again. I have taken the generator apart and have checked the brushes and stator and rotor and they appear to be ok. I am wondering if the the voltage regulator is done. It is expensive to replace and if that isn't the problem I am stuck with the part. Is there a check I can make to see if the voltage regulator is functioning properly Thanks firstname.lastname@example.org
Re: I have a honda generator em2500x voltage problem
Cummins P2200, 2KWatt, it starts fine, but after a couple of minutes, it gives quite high voltage output, meter needle goes beyond 300v, engine speed seems high since throttle is increased, indicator light on generator also becomes bright, after a minute or so, things come to normal, sometimes takes few minutes to come to normal, situation is same, with/without output load. this happens within initial 15 minutes after startup, afterward everything is normal.
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Re: I have a honda generator em2500x voltage problem
My E2500 did this. Turned out to be dirt in the brush holders causing the brushes to have less pressure in the slip rings. Stopping and restarting joggled the brushes to make better contact until they wore down again. Pull your brushes and make sure they slide easily in your holders. Also you may need to replace them if they are worn too much or clean the slip rings. Good luck. Doing your own repairs is fun.... especially when they work.
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The EU3000 series generators are inverter generators. The generator features an alternator, which produced high-voltage, multi-phase AC power. This power is converted to DC power and then converted back to AC. This process is controlled by a microprocessor and is necessary to provide stable, consistent power capable of running equipment sensitive to power surges. This type of generator provides higher fuel efficiency and lower operational noise ratings in a lighter model than home and work generators produced by Honda.
EU3000i Handi Specifications
The Honda EU3000i Handi is a 3,000-watt inverter generator that features wheels, folding handle and a recessed convenience light. The engine is a Honda GX160, which features a 163-cc displacement. The AC output is 120 volts, with an average rating of 2,600 watts and a maximum production of 3,000 watts. There are three receptacles to include a 20A, 125-volt duplex and a 30A, 125-volt locking plug. The DC output is 12 volts and 100 watts. The EU3000i can hold 1.56 gallons of unleaded fuel, which will provide consumers with 3.6 hours of run time at 25 percent load for 7.7 hours.
The AC waveform may cause your meter to read inaccurately. You would need to use a TRUE RMS meter to accurately read the voltage.
The siple meters actually read the AVERAGE voltage and then are calibrated to mulltiply it by the "form factor" for a sine wave. OFTEN these generators don't produce a clean sine wave. A square-ish wave will read higher on the garden variety meters.
Compare the brightness of a lamp comparing to when run on your utility.
The frequency depends on engine speed ... yours is running a bit fast...check it under at least half load and if off, adjust the govenor slightly.
Voltage regulator, rotor, or stator are at fault here. Flash the fields F1 and F2 to see if you can produce voltage. Flashing consists of connecting positive from a battery (9V or 12Vdc) to F1 and negative to F2 while genset is running. If voltage increases, then you will need a voltage regulator. If voltage does not increase, then you will need a new generator end.
You'll need to test to see if you are getting voltage from the brushes. This is a live test so, using something like alligator clips or such on the metal bracket of the brushes for your volt meter is a good idea. Simply start your generator with the volt meter leads attached to the the brush holders or exposed electrical connection to the brushes and see if they are producing electricity (120vac or greater). No voltage then it's your brushes, field, or stator. If they are good check the output of the voltage regulator. If it to does not kick down any voltage above 120 then it's your problem.
Note most cheap generators do not have a voltage regulator. All generators depend on the correct engine rpm to achieve normal voltage. 3600 rpm is the correct speed on a two pole generator to produce 110 to 125vac and 60hz (normally found on gas generators). 1800 rpm is the correct speed for four pole generators (normally found on diesel generators). You may set your rpms slightly higher to ensure that it's maintained underload ie 3750 for gas. Diesels usually have very good governors and don't need to be set higher.
If you need troubleshooting help for your Honda or other portable generator there's nothing better than a handy schematic. This detailed diagram will help you troubleshoot your portable generator. In publications or online you may find a variety of schematics for Honda or other portable generators.
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Honda generators are very reliable and are easy to adjust. The best way to check for proper output is to use a meter that can check cycles and voltage. Set meter to htz or freq and adjust the engine governor to 60 cycles. When the engine is turning 3600 rpm it is at max power and the generator may be producing ac voltage ranging from 115 to 125 at 60 cycles. When you draw power from the generator the engine governor will try to overcome the stress and maintain 3600 rpm. The engine must be well maintained to produce full power. Service oil, filter, plug and valve adjustment. Some engines have a spark arrester installed in the muffler that may become blocked with carbon. If engine is producing full power and voltage/amps is low then check brushes, capacitors, and/ or voltage regulator. Most problems occur when too much power is requested from rated generator. Example, trying to connect an 1800 watt air compressor to generator. The compressor may draw double the stated wattage upon starting and cycling. For longest generator life, It is best to use only 75% of rated output. On an 1800 watt generator use max wattage 1350. If you actually need to use 1800 watts then the best generator would be a 2500 watt. enjoy