Honda generator

[Mdean16]

Hi everyone,

I am looking for some help with two gas powered portable generators and understanding how they work so i can troubleshoot and fix them.

The first one is a Honda EB5000X that produces no power at all. I disconnected the AVR from the brushes and while running I’m seeing 60V at the brushes.

While trying to figure out the Honda unit I made an error in judgement and decided to compare the voltages to my working Generac gas generator. After disconnecting the AVR and checking voltage while running that unit now only produces 7V at the outlet plugs with everything back together.

Any help or insight would be appreciated


Thanks
Matt

 

[alfredeneuman]

Hi everyone,

After disconnecting the AVR and checking voltage while running that unit now only produces 7V at the outlet plugs with everything back together.
Thanks
Matt

If you're checking the voltage with a digital meter it may be showing "ghost voltage" and it may not have any true voltage at all.

 

[Showkey]

Shop manual for the HONDA would be real handy...........there are exact test procedures with expected values.

 

[Mdean16]

Thats great, any idea where I can find the shop manual? I found a regular owners manual but it didn’t go that detailed.

Thanks




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[Showkey]

Thats great, any idea where I can find the shop manual? I found a regular owners manual but it didn’t go that detailed.

Thanks




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Honda EB4000 EB5000 EB6500 Generator Service Repair Shop Manual

https://publications.powerequipment.honda.com/power-equipment

 

[theoldwizard1]

You are thinking backwards ! On any AC generator (which technically should be called an alternator; but car alternator make DC; are you confused yet ?) the brushes that ride on the slip rings are the INPUT to the rotating FIELD. DC power is applied to the brushes/slip rings.

You may have heard of "flashing" an AC generator ? This because if there is not battery to "excite" the field when it first starts up, the generator is relying on residual magnetism in the field to "boot strap" itself. If that residual magnetism "fades" the field must be flashed. Flashing is just momentarily supplying DC across the brushes.

Most inverter generators use rare earth permanent magnets. They actually create a high voltage (300V?), high frequency (much greater than 60Hz) that is converted to DC and the 120V @ 60Hz is "synthesized".

DC motors/generator have brushes that ride on a commutator.

Brushless DC motors are a whole different animal. Sort of a first cousin to permanent magnet AC generators.

 

[Mdean16]

So I made some progress.

The Generac ended up being a bent pin on the AVR. Now the Generac is back up and running.

The Honda I disassembled and found what I think is burn marks on the stator.


Looks like I’ll have to find a stator replacement now.




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[Mdean16]

Looking for some additional help guys.

I have a new stator in and the generator back assembled and running.

The only problem left is it seems to run a little too fast. Under no load i have about 68 hz and 140vac on the 110/120 outlets. Once loaded it sits closer to 120 but the frequency stays high.

When I adjust the screw for the speed governor I can get it close to 60hz/120v but then it dies under load.

My thought is that i need to slow the engine down but then increase the fuel the engine is getting at the lower speed by adjusting that linkage.

Before i go messing with that, does that seem correct or should i approach this differently?

Thanks


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[p_mori7]

The engine needs to be turning exactly 3600RPM to produce 60HZ. Voltage can vary a little but should be right around 120V. Up to 125V or so is not a problem. You may have a carburetor adjustment / cleaning issue to deal with.

 

[p_mori7]

Also check the governor linkage is properly assembled in case somebody before you monkeyed around with it. This guys illustrates it fairly well in this video:

 

[Bretny]

Are you sure your not adjusting the carb when you should be adjusting the govenor?

 

[Mdean16]

Thanks for the help.

I ended up cleaning the carburetor, slowing down the throttle speed and was able to get it to the right frequency without dying under load.

Thanks!


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[p_mori7]

Thanks for the help.

I ended up cleaning the carburetor, slowing down the throttle speed and was able to get it to the right frequency without dying under load.

Thanks!


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Excellent !