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Generac 5250 with a 8 hp Honda engine. Runs fine, no output

Generac 5250 with a 8 hp Honda engine. Runs fine, no output, brushes look good. I field flashed the unit using a 12 volt battery, still no output.

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Take a resistance reading across the brushes with and Ohm meter. (not running) You should read a low resistance. If you have no resistance across the brushes then then either the brushes are not mating with the armature or the the armature is open.
IF you have resistance then the AVR (Automatic Voltage Regulator) in the endcap has failed. With the engine running and the Brush block disconnected you should have 4 - 12 VDC on the two wires going to the brush block. No voltage = bad AVR.

Thanks for choosing FixYa.

Kelly

Posted on Jul 30, 2010

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Try putting 12 volts across the commutator at the brushes. Ust a low current battery nor a car storage battery.

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  1. Check for any blown fuse and replace. It can be traced directly from the output lines.
  2. 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.
  3. Use an analog multitester to check the continuity of the carbon brush and the field coil.

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This sound like a loss of residual magnetism in the generator. The field will need to be "flashed".This is also known as re-exciting the field of the generator.
The Coleman manual gives these steps:
1Use a 6 Volt lantern batters (dry cell) or a 12 Volt automotive battery.
2.Disconnect all loads from generator.
3. Remove the brush cover (that's the rectangular plastic cover on the end of the generator.)
4. Plug a lamp or light into the generator before starting the engine. The light will illuminlate when ?Voltage has returned.
5. Start the engine with no load connected to the generator.
6. Attach the "-" lead of the battery to the negative brush. Very briefly touch the "+" lead of the battery to the positive brush. Remove as soon as Voltage builds up.

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if you dont have the field excitation then you'll never get any AC no matter how your motor runs..field excitation comes in two types..one is by pole magnets and two is by field coils connected to a battery..

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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.

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Flash the fields. Remove front cover from the generator end. You will see the brushes and rings on the rotor. The ring closest to you is positive and the ring closest to the rotor windings is negative. With a 12 volt batttery and the generator running, place the positive side of the battery to the ring towards you and negative to the back ring. Make sure to use jumpers and keep fingers away from rotating parts and don't get zapped. You should see output voltage increase. If it does, your voltage regulator is bad, if it doesn't your generator end is bad.

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It is possible that your voltage regulator is shot but before purchasing the volt regulator try flashing the fields first and make sure the brushes and rings are clean.

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It is possible that your voltage regulator is shot but before purchasing the volt regulator try flashing the fields first and make sure the brushes and rings are clean.

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It is possible that your voltage regulator is shot but before purchasing the volt regulator try flashing the fields first and make sure the brushes and rings are clean.

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