Brushless powermate (Black Max) Brand New Unit but never put out power

I looked at your parts blow up and noticed that you generator has a brush pack and a voltage regulator. Here are a couple of tips that may help you determine which part is at fault. Obtain a 12 - 16 volt ac power supply of about 1 amp and same voltage DC power supply. I find these at a thrift store and are used to power phones or door bell etc usually about 2 to 3 dollars each. This size power supply is relatively harmless and will not shock you or damage your generator. Remove the brush pack and set aside. You are going to apply 12-16v AC voltage into the 115v plug of your generator. You should hear a very slight hum in the stator if the winding is not open or shorted. Assuming that the 115v winding is ok, there should be voltage at the commutator rings and the armature should actually be making a magnet force. You can turn the armature slightly and actually vary the voltage at the rings. If you are getting voltage at the rings then winding and armature are progably ok. Remove the AC power supply and replace the brush pack. Next use the 12-16v DC 1 amp power supply (paying attention to polarity) to replace the voltage regulator. Disconnect the voltage regulator from the brushes and use the DC power supply to power the armature thru the brush pack and start the engine. You should get some low voltage at the 115v outlet and more important some ac voltage at the leads that power the voltage regulator. If no output at the leads to regulator then winding is open or short, if ac is present then regulator is most likely fault. Good luck, hope this helps, enjoy.

Hi,
I'm not sure what the reverse drill method you mention is but here is what to look at based on the documentation from the powermate website.

The main parts of this thing are:
1) The prime mover - We'll take it as given that the engine works OK for now.
2) The output panel - Check for tripped/broken circuit breakers, loose broken wires.
3) The rotor - Visually inspect the end you can get at for burned wiring, look at the diodes and movs mounted "inside" the end of the plastic bobbin the rotor windings wrap around.
4) The VR module - Kidney shaped plastic thing mounted on the support for the end of the rotor shaft. Check for obvious damage (take out the 2 screws and look underneath it too), look closely at the wiring in the plug for this module sometimes wires/pins get pulled out of the plastic connector, check the stator windings connected to the module with an ohm meter shouldn't be open.
5) The stator - Check all the windings with an ohm meter, visually inspect for burned/broken windings.

The VR module is why you "don't need to flash" this generator, unfortunately other than substituting a known good one there isn't an easy way for you to check this part.

If you've checked everything over and don't have any other alternative you might want to try the procedure I talk about here.

Carl