Powermate PM0496500.02 No voltage output

You need a manual so you can check the rpm, brush gear, circuit and check the rotor is receiving enough current to produce the rated output.

It isn't really a good idea to use a portable on "modern home elctronics" the way the regulate the voltage is not a s tight as a digital AVR found on permanent home generators. While this voltage is not uncommon, I would not recommend it

Not sure what you mean "high voltage rpm power generator out", however many people have asked how to adjust the engine for proper voltage output. On generators with~out a voltage regulator, I adjust the engine RPM by using a digital voltage meter that has a Hz setting. Adjust the governor untill the meter displays 60 Hz. With the geneator producing 60 cycles, I know that the engine is turning 3600 rpm (the engine produces max hp when it is turning 3600 rpm). At this point, read the voltage output to verify that the range is between 115 ~ 120. On generators with a voltage regulator, verify/adjust that generator is producing 60 cycles then adjust voltage by turning screw at the regulator (some regulators are sealed with potting compound and can not be adjusted). If your power demands are not that great and you appliance can operate at 50 cycles, adjust governor as needed. Lowering to 50 cycles will also reduce output voltage. Good luck

I think you have a problem with the Automatic Voltage Regulator. I have ordered one from the New Company that purchased Powermate. It solved my problem.

chek brushes...if they seemed ok then replace AVR card

The voltage regulator controls the output. You will need to check that first.

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Stator resistances should be around .5 ohms. This may look like a short to you. Unhook the regulator from the field brushes and put 12 volts on the field winding. you should get output to partially light a bulb..maybe 60 volts. Remember to use 12 volts dc on the fields and don't reverse the polarity.
If there is output then the avr(voltage regulator) is probably bad. If there is no voltage then check the resistance on the brush contacts. through the bushes and field. Maybe around 25 ohms. Your generator manual can give the exact ranges. No resistance then clean the brushes and slip rings and check again. No resistance...take reading on the slip rings. No resistance...open field...bad rotor. Good luck....keep posting until problem is resolved.

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.

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.

I looked at your parts blow up and noticed that you generator has a brush pack and a voltage regulator. Here are a couple of tips that may help you determine which part is at fault. Obtain a 12 - 16 volt ac power supply of about 1 amp and same voltage DC power supply. I find these at a thrift store and are used to power phones or door bell etc usually about 2 to 3 dollars each. This size power supply is relatively harmless and will not shock you or damage your generator. Remove the brush pack and set aside. You are going to apply 12-16v AC voltage into the 115v plug of your generator. You should hear a very slight hum in the stator if the winding is not open or shorted. Assuming that the 115v winding is ok, there should be voltage at the commutator rings and the armature should actually be making a magnet force. You can turn the armature slightly and actually vary the voltage at the rings. If you are getting voltage at the rings then winding and armature are progably ok. Remove the AC power supply and replace the brush pack. Next use the 12-16v DC 1 amp power supply (paying attention to polarity) to replace the voltage regulator. Disconnect the voltage regulator from the brushes and use the DC power supply to power the armature thru the brush pack and start the engine. You should get some low voltage at the 115v outlet and more important some ac voltage at the leads that power the voltage regulator. If no output at the leads to regulator then winding is open or short, if ac is present then regulator is most likely fault. Good luck, hope this helps, enjoy.