Question about Coleman Powermate Premium Plus 6250W Portable Generator

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No power out to plugs

Every thing is good breakers,board ,outlets etc. the stater and coils are a bit rusty, will this make it so there is no output

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  • sddennis2 Sep 06, 2008

    My unit is 3 years old and has about 30 hours of running time on it. The engine runs perfect but the generator stopped working. I pulled the 4 bolts to the brushes and they were clean and the 2 contact points on the disc are also clean. I put an ohm meter on the disc and got no reading. I did find a winding wire sitting in the plastic cover that the brushes are housed in. The generator is stored in a covered area and it has a cover that fits on it like a bbq cover. I'm not sure if one winding wire would completely stop the flow of electricity. Your suggestions please. My email address is: sddennis2@earthlink.net

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My answer:

I don't know how or where you stored your Genset there, but it the generator head got soaked with water and/or was subjected to constant moisture and/or worse case - saltwater exposure - then there's a 100% chance you have shorted out the windings and possibly burned out the stator!

There are a few things you can or should check on both the generator head and the engine if it has HIGH HOURS of runtime.

Namely the the BRUSHES on the generator head as I also don't know what normal LOAD you are putting on your Genset there, or have been putting on it previously, or at what RPM you are normally running the engine at - as to half throttle or full throttle setting??

The heavier the electrical LOAD the more heat the generator head had to dissipate as well. Is the generator venting clear and free from dust, dirt, and any obstructions?

I take it that it's most likely a Briggs & Stratton 4-stroke single cyl, or else it's a Honda 4-stroke single/twin cyl engine? Has it been serviced properly as well? Oil changes, air filter cleaned and/or changed out, fuel filter changed, Carb cleaned out periodically, etc etc etc.

These are just as critical so as not to burden the generator head output as well. If the generator head runs extremely HOT then you definitely have a problem there. Internal short, bad winding, etc.

Which brings me to the next point.

Since I take it that it has been running somewhat good up to now - I have a few ??'s as to how you have been running it recently, and how well it's been running generator-head wise?

Has the output voltage been really stable and clean up to this point or has it varied at lot?

Have you actually measured the AC output voltage with a good quality DVM set on the 200 volt AC scale? If so - what voltage was read? How stable was it - as to any notable variations?

Did you compare your DVM readings/findings to those listed in the Operator Manuals spec listed?

Btw - were any of the output outlets totally dead prior to the total output failure? Is so then it's not the breakers at fault. Not if the engine runs OK, and at the proper RPM settings as well.

Beings your Genset is probably an older model - it just indeed might have some high RUNTIME HOURS on it. If it does it just could very possibly be what sounds like to me (and I personally HAVE SEEN this happen myself firsthand) that the generator BRUSHES are nearly shot - as in almost worn out. Or in your case - TOTALLY GONE. If there is some brush length there, but not enough by spec then they may be getting way too hot - as from excessive current draw at point of contact, and thus the generator sensing circuitry itself is doing a complete electrical CUTOUT!!

An added protective Genset circuit feature in that the generator itself may indeed be linked to the engine as a type of REV LIMITER or CUTOUT on the Maintenance-free Magnetron® electronic ignition. Again - your operators or service manual should have a pretty good troubleshooting section in it unless you don't have that anymore or never got one if you bought it used to begin with.

If you unscrew & remove the Generator brushes, and they are indeed below the recommended length (or worse case they are indeed totally worn down) then that most likely is your problem right there. All rusting aside!

If you choose to replace the old brushes with new ones yourself - be very careful when seating the new ones - as to their insertion and cap retainer tightening. Never over-tighten those black plastic-like brush retainer screw caps - for if you break one (hard to get immediate replacements is why), or fracture one it could cause the Genset to fail under LOAD, and that very well could do some severe damage to the generator part itself. Take your time doing it, and be patient!!

It has to be one of the scenarios listed above, as I've covered every possible cause short of a broken or shorted wire somewhere - which in that case you will have to schematic trace and Ohm out wire to wire contacts. This being the least likely scenario from my experience.

Please post me a reply as to the found problem there, and the resolve to it by following my recommendations above. Also please rate my troubleshooting fix as well.

Keep me posted and I'll follow up as well.

Best regards,

Frank

Posted on Sep 04, 2008

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I have had the same problem three times. All three times I had to replace the bridge rectifier board. This was on a 2006 model. I contacted the manufacturer and they told me that yuo can overload the generator without tripping a breaker ie: using more watts than amps. This board is also very sensitive to moisture which could build up under a cover in humid areas. Good luck.

Posted on Mar 18, 2010

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