Re: I have no ac power output, but motor runs fine!
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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A couple of things would be worth checking into. Of course, I'd pretend that you checked the output fuse or circuit breaker? If you can check for voltage directly from the stator or armature and check the results. Nothing? If it has them, could be brushes. Also, if it's a fuse, don't just do a visual...check it with a test light or multi-tester of some sort.
The input to your treadmill is about 120 volts Ac. The output from the board will be about 30 Ac. Almost nothing on there will be measured in DC. Your particular issue is your motor controller. It needs to be replaced.
Check the voltage sent to the field when running. It will probably be around 12 volts. You can try connecting a lantern battery BRIEFLY to the field to re-magnetize the field. Try bothe polarites.
Some have had a bad rectifier and one had a bad transformer that generaates the low voltage from the generated output. He had a broken wire from the winding to the wire from the transformer. He was able to reconnect the failed solder joint.
After working on several of this style coleman generator,i have found that the lead wires in the windings that are soldered to where your brushes would contact tend to break.I don't know if it's a poor design or just a fluke,i would check to see if your getting continuity on the rotor and go from there.They seem to either "burn off" or just break.
Make sure that the alternator is being turned by the engine--sometimes the mechanical coupling fails. Check for a tripped breaker/blown fuse. Beyond checking for bad brushes (if used), you will need a wiring diagram and an AC/DC voltmeter/ohmmeter to chase out any troubles in the alternator. Be aware of voltages up to 230 volts can be found inside even if there is no output.
Try replacing the capacitor. You can buy it from http://www.jackssmallengines.com/do_it_home.html. When you pull off the power end of the generator look at the diodes also. If they look toasted replace them as well
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