Help With Coleman Powermate Generator

[D45]

I picked up a VERY gently used Coleman PowerMate MAXA ER 5000W generator today, for $60

5 gallon poly gas tank, Tecumseh 10HP cast iron sleeve motor, low oil sensor.
It has four 110v outlets and one 220v twist lock outlet. Its a nice machine with good features.

Changed the oil, air filter, fuel filter, and spark plug

The only issue...........it is not making voltage

I took the brushes out and they are over 5/8" long with a ton of material remaining, and seem to be in great shape. So I don't think the brushes need replacing

Inside the mounting area for the brushes is a round cylinder, which I believe to be some sort of capacitor? Could this be the faulty?

Its a Teapo capacitor and costs $20ish on Amazon or $12ish on Ebay

#0034819.01

Anything else I can do or check to find a solution for the machine not generating power?

 

[kelpaso1]

Look up "Re-flashing a generator". Usually needs to be done if they sit for too long unused. Can be done with a corded drill. EDIT: be quick to release your hand from the chuck when it starts up

 

[Justin James]

kelpaso is correct. The capacitor may be bad, but if the unit sat for any length of time we always start with a "field flash" of the alternator. What you will be doing is sending 12v through the brushes directly to the rotor. Is is polarity sensitive so you must determine what brush is P and which is N.

 

[Lightning rod]

if you have time, this guy does a great job at diagnosing and repairing generators

reflashing with a drill has never worked well for me
I prefer to use a 12v battery across the brushes to start the reflash
both methods covered on the YT channel - just have to find them

 

[D45]

The generator was used in the fall of 2020 and stopped producing voltage

I am going to try installing a new Teapo capacitor first

 

[Jking24]

I picked up a VERY gently used Coleman PowerMate MAXA ER 5000W generator today, for $60

5 gallon poly gas tank, Tecumseh 10HP cast iron sleeve motor, low oil sensor.
It has four 110v outlets and one 220v twist lock outlet. Its a nice machine with good features.

Changed the oil, air filter, fuel filter, and spark plug

The only issue...........it is not making voltage

I took the brushes out and they are over 5/8" long with a ton of material remaining, and seem to be in great shape. So I don't think the brushes need replacing

Inside the mounting area for the brushes is a round cylinder, which I believe to be some sort of capacitor? Could this be the faulty?

Its a Teapo capacitor and costs $20ish on Amazon or $12ish on Ebay

#0034819.01

Anything else I can do or check to find a solution for the machine not generating power?

I'm not a generator tech by any means but it's not likely the capacitor. They usually lose the rectifier/ voltage regulator box. If you Google it their are plenty of videos that walk you through how to check voltages. If I remember correctly most generators have a low voltage side that charges the feild for the high voltage side so you need to figure out what your missing first as far as inputs and outputs

 

[D45]

I looked at the parts schematics and don't see a voltage regulator or rectifier

 

[Lightning rod]

Rectifier might be on the brush assembly as 4 black cylindrical parts (diodes)
If not on the brush assembly , there still has to be a rectifier to feed DC to the rotor brush’s
Not all gen sets have regulators
I have not been able to find an electrical schematic for your model
Only a parts breakdown
If you have the electrical schematic, can you post it?

 

[theoldwizard1]

Re-flash first !

You can power the brushes directly from a car battery after disconnecting the other wires. If you still get no output you likely have a bad rotor or stator.

 

[Lightning rod]

also , I will mention , that if a capacitor is present, the design of this generator may NOT
have brushes or rectifiers if it is a brushless rotor design

thats why it is important to identify what design you have

if you have a brushless rotor design, then the capacitor will affect the output voltage 100%

reflashing the capacitor is done differently In this case

 

[D45]

I hope the attached files work

 

[D45]

Generator def has brushes and a Teapo capacitor

 

[D45]

Model: PM0525312.17

Capacitor P/N: 0034819.01

Stator 5.0Km 60Hz P/N: S0055635

Diode Assembly P/N: 0006006
I dont see this part anywhere on mine

https://www.manualslib.com/manual/134032/Powermate-Maxa-Er-Pm0525302-17.html?page=6#manual


https://www.searspartsdirect.com/model/3093e6figb-000214/coleman-pm052531217-generator-parts

 

[D45]

Nice breakdown

https://arkansas-ope.com/parts_pm0524000-5000.pdf

https://www.arkansas-ope.com/parts_pm0525302.17.pdf

 

[D45]

Well the new capacitor was installed and did not fix the issue

Looks like I will try the "flash" technique

Will a small lawn/garden battery from my riding mower work?

 

[larry_g]

Model: PM0525312.17

Capacitor P/N: 0034819.01

Stator 5.0Km 60Hz P/N: S0055635

Diode Assembly P/N: 0006006
I dont see this part anywhere on mine

https://www.manualslib.com/manual/134032/Powermate-Maxa-Er-Pm0525302-17.html?page=6#manual


https://www.searspartsdirect.com/model/3093e6figb-000214/coleman-pm052531217-generator-parts

In your third picture above the diodes are at the end of the bar at the bottom of the housing and have a yellow wire connected to them.

I just went through a generator problem and documented it here, https://www.garagejournal.com/forum/showthread.php?t=477507 Mine is a bit different but the manuals linked to have some theory of operation and troubleshooting in them that may help you. https://redirect.viglink.com/?forma...www.manualslib.com/manual/76...page=23#manual

lg
no neat sig line

 

[D45]

In your third picture above the diodes are at the end of the bar at the bottom of the housing and have a yellow wire connected to them.

I do not have any diodes at the end of the bar

 

[gungatim]

I do not have any diodes at the end of the bar

LGR

 

[Boilerhouse]

I have a 3500W Coleman Powermate Generator and have had to reflash it a few times, although not for the last several years since i am now smarter about properly shutting it down. Anyways, the manual says to use a 6 volt battery to reflash, and that is what I have always used.

 

[D45]

I did find the diodes, I was thinking small diodes like from a circuit board

I took both off and cleaned the contacts on the diode tabs and also on the wiring connectors.........a little surface rust

I also found a broken wire inside the generator........supposed to have two wires soldered on to the disk. One was broken. I soldered the two together and still no power.

I then found an old cord from a vacuum and plugged it into the generator. Powered up the motor and used the other end of the vacuum cord on my 12v riding mower battery.

BINGO!!! I now have power in all the outlets and it seems to be functioning as it should

When in doubt, flash it first!!!

I never heard of such a thing before

 

[gungatim]

LGR!

 

[D45]

Started up again today

Still producing voltage