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Re: I have a Coleman Powermate portable gas 110 volt...
Check where is the plus and minus of the field.
Take a 12 V battery. Connect the minus to the field minus. Start the generator and just for a second connect the plus and disconnect. The voltage should build up. If not check the AVR.
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Your field has lost the residual magnetism. You need to flash the field. There are several ways to do this and the description is too long to write here. Best is to search google for flashing field generator. I would try the trick using a single speed drill motor first as it is a safe method. You must lock the drill on and it cannot be a type with a throttling trigger. Plug into the 110 receptacle and with breaker on give the drill a spin with your hand. This is with the generator running. More drastic steps using a battery need to be done with generator stopped.
Most likely the excitation DC circuit is broken or exciting rectifier (AVR if present) is damaged. If the field has been demagnetized it can be recharged by a 12 V battery, connected for a short time to +, - of the excitation winding, with engine running.
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.
Yes, polarity does matter. If you remove the front cover on the generator end you will see where the rings and brushes are located. The closest to you is positive and the ring that is towards the engine is negative. Trace those wires up into the control box and flash the genset there. The six volt battery is fine. I preferr 9 or 12 volt battery, so that I can produce a larger AC voltage.
To flash the excitor circuit on a coleman ( the generator is built by generac) you need a 12 volt battery. You quickly apply 12 volts via your 120vac recepticals. NO MORE THAN ONE OR TWO SECONDS! Then check you ac voltage. Most of the time the brushes are burnt up when voltage is low. Check the brushes first. You can access them by taking the end cap off of the generator via two to four screws. The brush holder is easy to spot, two wires leading to the front of the amature. Hope this solves your problem.
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.
Here is a simple test to check field and other wiring. With engine off apply 12v ac 1 amp to 110v outlet plug on generator. This will energize the field windings and should cause the armature to produce dc voltage at the brushes and produce a nice magnet. If there is a short in the field or broken wire or shorted capacitor there will be no dc reading at the brushes. . This test is the opposite of what actually occurs when the engine is running. That is the armature produces a magnet fed thru the windings, regulator and brushes. If dc voltage is present at the burshes, remove 12v ac and start engine to check for output. enjoy
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