Powerhouse Help

tinmanlsu

tinmanlsu

Member
I recently purchased a Powerhouse Generator. I took it apart, as well as the cutout, and cleaned it up. I wanted to test it before putting it on. I am pretty sure I put everything back exactly as it came off but I cant get any readings from anywhere while turning it with my Dewalt. I have searched through most of Tom's posts on Powerhouse, but cant find a jump in point to fit my situation. Any insight would be appreciated and Thank you!
 

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Slip a piece of paper between the adjustable brush and commutator, then connect a small battery charger (3 to 6 amp) positive cable to the case and negative cable to the adjustable brush. The field windings whould draw about 1 1/2 to 2 amps.

Remove the paper and connect the negative clip to the output stud, and the generator should spin slowly in the normal direction of rotation when driven by the engine.

Those brush wires look a little longer than normal, so make sure they don't rub on the rear cover. I've never seen insulation on any brush wires, but maybe these are homemade from something else.
 
Good Morning Mr Tom and Thanks for the immediate response! Do you ever sleep?

I tried what you said and the generator does spin slowly, with small but noticeable pulses, with the paper removed. But with the paper in, the charger was ******* all the way as if completely shorted..?..
 
Also check the twisted wires between the field coils to be sure you do not have an open. With a open the generator will not motor.

Ron
 
tinmanlsu said:
Good Morning Mr Tom and Thanks for the immediate response! Do you ever sleep?

I tried what you said and the generator does spin slowly, with small but noticeable pulses, with the paper removed. But with the paper in, the charger was ******* all the way as if completely shorted..?..
Click to expand...

It looks like the field wire is taped or spliced right near the case. Be sure that doesn't have a frayed wire touching the case. You have a short in the field somewhere, because it shouldn't draw more than a couple amps to run the field windings.
 
It was definitely covered some time ago, prior to me, and I looked but didn't see any bare spots on the wire. Externally this was a very nice piece but internally...lots of patches... I will pull the field out and see what I find...Thank you!
 
Before you pull the field coils, you might want to isolate the problem. You have 6 coils that each draw about 12 amps, if 6 in series draws 2 amps. So now you can remove the ground wire from the end of the coils. then connect the charger to the ground wire and middle of the 6 coils. You should draw about 4 amps if those 3 coils are good. That will eliminate them. Now try the same thing on the other side by connecting to the middle again and the adjustable wire. I suspect the trouble is on these three since you said it pegged the meter when all 6 were checked together. In fact after you unscrew the ground connection, just connect to the field adjustble wire and the ground wire and take a meter reading. If it shows about 2 amps, then you know the end coil with the adjustble field wire is the one grounding out.

The insulation tape may have broken down so the wire is touching the field pole or case.
 
I wasn't able to knock the field coil screws loose, so I took a break and started reexamining the wires. See the pics...one shows the crud that was the remains of a piece of plastic straw, electrical tape and very old cloth tape. I am going to try and reinsulate the bare wires and see what happens from there...If not, I will go with your next check out...and Thanks!
 

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Thank you Mr Tom!!
It appears that the short was in the field adjustable wire and/or the ground wire. I rewrapped both making sure they were tucked in and out of the way and all readings came up normal. I will try it in one of the cars tomorrow as I am over my limit of fun for today. Thanks again!!
 
I bought a bottle of "Liquid Tape" at Fleet Farm, and it works great for things like this. The ground wire won't need insulation, but the wire leading to the adjustable brush can remain flexible with two or three coats of liquid tape. About 15 minutes between each coat is usually good.
 
Yep Tom W. is the best source for powerhouse generator issues, he trouble shot 3 for me!
Thanks again Thomas and a very MERRY CHRISTMAS to you!
 
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