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Idle control comes into play when there is no power draw forcing the engine to idle with an electro magent. If you feel that the electro magnet is interfering with governor, temp remove the wire to the solenoid. Usually the idle control will not effect how the engine /gen output power. An overloaded condition will cause the engine the go the full throttle as the internal governor of the engine will try to maintain 3600 rpm. Overloaded condition will greatly shorten the life of the generator/engine. Try to use only about 80 % of rated power. Large motors can draw three times running amps. A compressor using 12 to 18 amps to run can draw over 40 amps to start.
If your generator could handle the load in the past, check the engine for loss of power, or the generator for faulty voltage regulator or capacitors out of range. Easy to check. Connect digital volt meter to plug /load and look at volt reading while running with no load and loaded. Voltage should stay between 110 to 120 under load and with no load (unless goes into idle mode). Good luck
High no-load voltage Capacitor with high capacity
Check and replace.
Low no-load voltage Speed to low Check and adjust rpm
Faulty rotary diodes Check and replace
Breakdown in windings Check winding resistance
Capacitor with low capacity Check and replace.
Proper no-load but low loaded voltage Capacitor with low capacity Check and replace.
if wires are connected start with the Diodes first electronics parts stores will have these in stock as well as cheeper.
hope this helps
Are you sure your gen.set is Coleman. The 5000 W gensets of Coleman as far as I know do not have auto idling. If your has, check this:
If by the same load it was accelerated ones (before) you may have problem with current measuring circuit.
Try does it run up with bigger load. It may not go up with loads less than 100 W. It has a big hystheresis on droping down (at less than,about 50 W) and running up (at more than 100 - 150 W).
If this can not help you give some more details in testimonials field in order to give you more instructions.
If generator has idle control circuit on it already, then it makes job easy. You just need to add on a solenoid that pulls the governor to a slower setting. When the control circuit engages due to no load, then solenoid is engaged, governor position is altered.
Much easier to buy parts from your local distributor to finish the task. No machining, usually more economical vs. reinventing the wheel.
Your RPM's are too high. There is no voltage regulator in coleman generators (generator is actually made by generac) and is 100% dependent on engine speed. There is a screw under the tank when your looking in from the recoil side. It controls the governor arm. Screw it in and it incresses the rpm, out decrease. Plug something in that draws a decent load while setting the rpms since you want it to put out 120 and 240 underload. Your idle voltage does not matter.
Both the Hz and the voltage will be wrong if the engine speed is low. You need to use either a DMM with a HZ function to set the engine speed so that you get 61.5 Hz at no load, or use a tachometer to set the no load speed to 3750 rpm.
Get a DMM that can measure frequency (Hz), then check that with no load and the idle control set to off the frequency is 61.5 Hz - If it isn't you have to troubleshoot why it isn't and correct it. You should also check the idle control mechanism if there is one on the generator, with it on the generator should start up at regular speed, then slow to idle speed, then rev back up to regular speed when you draw current from the generator. To check it use the DMM to measure the speed at startup ( should be 61.5 Hz), when it idles down (about 37 Hz), when you're drawing power from any other outlet ( pretty close to 60 Hz). If the generator has idled down and you shut off the idle control it should rev back up immediately.
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