Introduces the troubleshooting methods of pancake generator
This troubleshooting guide addresses common causes of very low or no output voltage in Marathon capacitor regulated pancake generators, specifically models 201CSA5411 (6kW) and 201CSA5420 (8kW). The document outlines a systematic diagnostic process involving six main components: the main stator winding, main rotor winding, excitation winding, capacitor, diode, and surge suppressor. It provides detailed instructions for testing these components using digital or analog multimeters to identify failures that require component replacement or generator replacement.
| Model 201CSA5411 Output | 6kW |
|---|---|
| Model 201CSA5420 Output | 8 kW |
| Main Stator Winding Resistance | .3 to .7 Ohms |
| Excitation Winding Resistance | 1.0 to 2.5 ohms |
| Diode Forward Resistance | under 100 Ohms |
| Diode Reverse Resistance | over 30,000 ohms |
You will need a good multi-meter (such as a Fluke), a ratchet set, a set of screwdrivers, and a soldering iron.
Common causes include a failed capacitor, failed main stator or excitation windings, a failed diode, a failed surge suppressor, or a loss of residual magnetic field.
No, failed main stator or excitation windings cannot be repaired and the generator must be replaced.
You can use a 12V battery to flash the field statically or use a 120V field flash through the service receptacle.