Help! Generator has no output

Hello, I have an "obsolete" (no longer supported) Coleman powermate OHV 1600. There is no documentation for this unit online whatsoever. I need it to run my grinder so I can finish restoring my VW Beetle.

The generator runs good but it doesn't produce any voltage. I hook up 13VDC to the brushes and it will produce AC, but as soon as I remove the voltage, the AC immediately stops.

I replaced the capacitor, and now the AC will output when it is first started for a fraction of a second then stop.

I am thinking it is maybe the voltage regulator? The heavy gauge wiring output (I don;t have the outlet panel) has one black wire, one white wire (That have the 120V output) and two heavy gauge orange wires. Maybe the orange wires are for the 12VDC output, if it had one? Or maybe they are for a circuit breaker, or some other regulatory circuitry? With them not connected it does still produce 120 VAC only when I put 13VDC into the brushes.

The regulator is completely sealed, and has 4 wires. One wire goes to one of the brushes, another wire goes to the capacitor, another wire goes to the ground, and the last wire connects to the harness as it goes into the generator head.

I did some inspecting and discovered that the 4 wire harness going to the electronics in the head goes to two smaller gauge wire loops in the stator coils. The two coils are connected in the middle, or center tap, with the other outputs going to the connector, for a total of 3 connections to the harness that connects to the electronics. the 4th wire going to the harness is the same as the heavy gauge black 120VAC output (hot?).

Can anyone help me?

 

This may help you.

Generator Parts

Is this a 5000 watt gen?

Mike NJ

 

Yes, that actually did answer a few questions I had, thank you. No, it is a 1600 watt unit (1400 rated).

I de-potted the potted regulator and found that the large transistor had blown up, and some other components had also blown up.

Unfortunately I cannot get another regulator.

Any ideas on what I could do? The regulator says "S505" on the PCB. I might try replacing individual components but they may be impossible. On one component that has 4 leads, 3 small on the bottom, one large on top, it is blown up and only 5Z is visible on the bottom, and maybe the beginning of an "S" on the top. Then there are two larger units that came unsoldered marked 1GZ then 6.C, and they have a polarizing mark so they are a diode or a capacitor. I am leaning towards diode. Finally, there is the large transistor that is using the metal casing as a heat sink. it is marked D1795 D07 or 007 JAPAN 50 then B C E. (Base Collector Emitter)

 

Here are some pictures of the components:

 

I believe when the capacitor fails it caused the diodes to blow. They are the diodes you show.


I will look for parts for you.

Thats the AVR you took apart?

I need to check. Do you have a model # of the generator?

Mike NJ

 

Yes sir, it is the AVR. The model is OHV 1600, and tradesman and Coleman Powermate both put their name on it. The engine is a Suzuki H120A. If I can replace those components that would be great. The only other component is the one that is missing the corner, and reads 5Z on it. It may hve blown when I flashed the field coils, I believe I accidentally reversed the polarity.

 

I dont think thats the actual model #..


Mike NJ