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Parts Generator? Or an Easy Fix (No Output)
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- เผยแพร่เมื่อ 14 ธ.ค. 2022
- I found this generator on Facebook Marketplace. According to the seller the engine runs perfectly but it doesn't have electricity. Worst case I can reuse the Yamaha MZ300 engine on something else. But before tearing this thing down lets find out what happened to the generator and see if it can be fixed.
Generator Model: PM0645500
Engine Model: Yamaha MZ300
Bridge Rectifier Board: 0063525SRV
Brushes: 0050439SRV
I use Harbor Freight Super Heavy Duty Degreaser in my ultrasonic cleaner.
Board Repair: • Generac/Pramac/Powerma...
Bassguitarist1985: / @bassguitarist1985
Visit My Amazon Store:
www.amazon.com...
Breakout Cord: amzn.to/3VVXM5G
Brushes: amzn.to/3Yrf6Bg
Kill A Watt: amzn.to/3Yq8VgL
Multimeter: amzn.to/3Wf8iEP
If you want to donate to the channel, you can use the TH-cam "Super Thanks" feature.
#GeneratorRepair #SmallEngineRepair #SmallEngine #DIY #Fixed #Troubleshooting #HowTo #Powermate
0063525SRV, Alternator, Bad Capacitor, Breakout Cord, Bridge Rectifier, DPE. Diode Test, Engine Runs Fine, Fixed, Generator, Hertz, Hour Meter, How To, How-To, Insulation Test, MZ300, MZ360, No Output, No Power, Ohms, Powermate, Regulator, Repair, Resistance Test, Rotor, Short to Ground, Small Engine, Stator, Troubleshooting, Volts, Yamaha
James, I recently retired from a 45 year career in the Industrial Electrical field. During those years I've repaired or built the controls for many different power generation devices all the way up to Coal Fired Power generation facility's and large portable generators. It's a pleasure watching you do the work and knowing that people still exist with your work ethic. Keep those video's coming.
Thanks. It nice to hear positive comments from experienced people. I am not trained in this and just learning what I can as I go.
Yes!
@@jcondon1 best way!
I love to watch James videos. His diagnostic procedures are pure gold. I've been around some gifted electrical trouble shooters in my lifetime but none better than James Condon. He's taught me the proper way of ringing out a gen set.
I have started to dabble in generators because James has taught me enough that I an willingly to try my hand. Thanks James!
Awesome video James! Glad to see one of the rebuilt boards put to good use! Cheers for the channel mention!
Thanks for you help saving this one.
You’ll make a good business deal for everyone
And well done you!
We have used the th-cam.com/users/postUgkxOTeIs0vv4_9B5hsmnLsk9r930uDQLu_Y for probably 30 hours with our camper and it’s been great! The noise level is really only noticeable when running the AC and other appliances like the microwave, hair dryer, or coffee pot. It’s not huge like other ones and it has wheels so even at 90lbs, I can move it!
Hi James, you have inspired me to do my own projects I had a lawnmower engine that was seized. I’ve got it on seized and running. I’m only 12. Lol
Very nice
There is a great deal to be learned on the internet Jai. James is a great teacher. You have the capacity to become a good engineer,
@@r8118830 yeah
I like seeing this. Learn to fix things and you'll save a fortune and not feel helpless the rest of your life.
Wonderful to see you learn
I always love that James can make the distinction between " A problem " and , " THE problem " .
The ability to make these distinctions is priceless when troubleshooting systems , be they electrical , electronic , or , mechanical .
Just another validation that James is the Master Generator Gru.Amazing job James I love your video's just packed full of information and your diagnostic procedures are spot on with great camera angles!
This is the best channel for repairing generators on TH-cam.
Big shout out to the person that donated the lift to you sir , he couldn't have had it donated to a better person than you Mr James, definitely a back saver.
Love your videos 👌
It is great having a parts hoard , especially on discontinued parts . Great video as usual .
Jim, diodes operate like a check valve for air or water. They also do reduce the voltage slightly. In some circuits, they are intentionly used as a voltage limiter.
After washing that down I now feel guilty about my generator being so dirty. I can hear her calling me to get out there and give her a bath! That looks brand new, nice job. Also on getting power from it again... yeah, that too.
Another fix......Jim, you're my dealer when it comes to enjoyable videos and long may that continue. Have a great festive season from all of your English viewers .🎅
This is the first one in a long time that hasn't had a carb issue. Thanks!
I was thinking the same thing!
Well done, James. A rescued machine is cash in hand and much better than parts sitting on a shelf (which may, or may not find future use). Your knowledge, and resources (bassguitarist) are invaluable and saved the day, again!. I was wondering what happened to the lift stand, it will save your back in years to come.
Very nice video! That engine, alone, was worth the $140, but great that you were able to resolve the electronics.
James- I work in a Corporate setting outside Boston. Management is now delivering a "Safety Mention" before events- How are you protecting yourself against CO2 poisoning running the engines in your garage?- I realize that there are many things unseen by the camera. I don't hear a ventilation fan running either. I enjoy your weekly broadcasts, and I want them to continue with you in good health.- Thanks!
He's got a CO alarm down there.
I do not run a fan or edit a fan sound in like some others. But I do have ventilation and a multiple carbon monoxide detectors that display the PPM of carbon monoxide so I can keep an eye on things and they will alert if the levels are too high. I always shut the engine down as soon as they start moving. Some engines are very clean and others will put a lethal amount of CO in the air in less then a minute. Here are a few clips of what I have setup th-cam.com/video/-taW9AuVEbQ/w-d-xo.html th-cam.com/video/bA-Us-uS-Vs/w-d-xo.html Also have a CO2 monitor because I also run a propane heater in the winter and want to monitor those levels as well.
Thanks for all your great videos during the past year James. They really help me solving a few issues and learn more about generators. I want to take this opportunity to wish you and your family a great holiday and wish you the best for the coming new year. Look forward to more videos in 2023. Keep the good work. Cheers.
Mario
Thanks Mario. Wish you and your family a happy holiday as well.
Good fix James and 2 in a row without carb/fuel issues. You're on a roll!
Thanks for your videos. I’ve watched most all of them. They greatly helped me to learn more about fixing mowers and generators. I’m retired and have time to look into fixing things. It keeps my brain working. That’s important when you you get older. Keep them coming God Bless You.
I stay up late every Thursday hoping for a new video. Thanks again James!
Great video, Iam glad to see that you used your lift , it make's it a lot easier to work on the gen, you did not break you back. James , keep putting out the good videos. take care.
Couldn’t tell if you checked the dip switches on the panel monitor to see if they were the same when you changed it. People love to move switches
Watching Jim and Gary and Kenny makes me understand that there I a lot I don’t know. Yet continuing to watch closes that gap. I love the clear explanations and the thought process as you go up the decision Tree. Merry Christmas
You sir are a LEGEND, I absolutely love your videos, please keep them coming.
I saw and the DIP switch settings were the same on both meters. When exchanging meters like this, always make sure the DIP switch setting are the same, because it tells the meter the full load capacity of the generator.
I just got a whole home 15Kw generator. Here's hoping that after watching all your quality content I can actually fix or atleast diagnose any issue I have with it if/when they show up...
Excellent teaching video. Love the way you do things, one step at a time. Great genny saved from the garbage heap
James, loved the electrical testing detail. You point out different “expectations” for reading with various generator “types”. Is there any place that you have documented what we should expect based us being able to discern “type” we are working on? Thanks so,much for all you do to educate us shade tree “sparkys”!
Nice generator. I like the built in panel lights
I've drilled holes in cases when the capacitors were to "long". Might not be the best solution in this case but it works on garage door safety detectors, the ones with the infrared beams.
I have done the same. Not elegant, but it works.
Love how you clean them up and fix them
Your very picky and I bet the kids walk a line
Lololo. Merry Christmas
That engine just sounds so good. As you mentioned, it hardly felt the full 5000 W load. Shame the design does not have AVR.
Another one saved from the parts bin or scrap yard. Well done.
Dave.
Thank you for all your wisdom over the past few years Jim!
Thanks Justin!
Love to watch James videos, but great to fall asleep with to take a nice nap
I have to say, I love the design of this generator. The plastic looks beefy, although aesthetically, "constrictive" in my opinion. The tires are robust-looking. And the oil drain channel, that one is a nice feature. Thanks for the video. Glad you brought this one back to life.
Saved another one James.. I always put a dab of fresh grease on the end cap needle bearing race . being a non sealed bearing they loose there grease over time..👍👍
Good point. Thanks Shawn.
James good stuff here I had doubts of this possible working but according to what your tested I then realized it has good potential. You did not disappoint me again. Thanks James for your skills and wisdom. Ed
Thanks James.
I am watching this on generator Power. Last nights Snow Storm took out My power.
Mike M.
Great video James. Your troubleshooting skills are excellent.
Nice find, easy money. I have never been a fan of that plastic case head unit, but I have connected a good amount of them for people in my area that bought them during the 98 ice storm. These were the only ones available. If you need power they at least work. Ya gotta do what ya gotta do.
I’m satisfied that you are a genius at what you do. Congratulations
James always says not tto pruchase a gen set with a bad power head then of course he does purchase it and then rips it apart So glad you are using the back saving lift and off that generator goes to work a well or a furnace/boiler or a refrigerator or a sump pump as in we need power back NOW !
I'm sure you're aware James, but in the 2000s there was something called the capacitor plague. Chinese companies got the formula wrong for electrolytic caps and they failed in everything from TVs to Generators. I made some good money buying those devices and just swapping out caps. In fact I still have a plasma TV in my shop that I've had for about fifteen years that cost me less than $20 to repair.
Fabulous fix and now you have another great generator
Jim, did you ask Gary if he could test the digital display? This night be a minor problem as well.
That was my question as well. Jim, thanks for another great video.
Very nice job James. I had a couple of these in my shop several years ago, and the rear bearings were bad and caused damage to the stator or rotor. As near as I can remember there was a recall or warrantee that repaired them, but that was many years ago. Thanks.
With a little practice, a decent iron/station such as a Hakko FX-888D or a Pinecil with a chisel tip, some solder wick and/or a sucker you can easily replace components like that bad capacitor yourself. Enjoyed the video.
greatgrandma here ,, seriously love watching your videos - most guys don't like yuh watchin them work or maybe the questions .....anyways watched a million of your videos and fixed a locked up ( pb blaster for days and gentle persuasion) , dinked with a old nikki ( at least a doz times ) and swapped out a rectifier board & brushes ( think 1 of the brushes had a broken or burnt wire ) LOW A BEHOLD after a month of occasional dinkin and plenty videos ................the dang thing works and now makes POWAH !! haha freaked me out when light actually came on !!!! and after carbs last soak in ultrasonical ( yeah all the cool kids have 'm sooooo got me one ) had the dangdest time for it not to leak ...........no clue why motor smoothed out too ?...............changed the oil twice get the pb blaster , rust and gas out........ that oughta be dandy now and put a new gas shut off after rinsing out idk gravel from plastic gas tank (the old one was rusted shut or prolly open since the oil smelled like gas and was thin). Bought me a killawatt today hahaha.....JUST CURIOUS i hope it makes good numbers but believe me i'm just a monkey see monkey do old lady -don't understand the magic -just did stuff you taught me ........ PLAN now is run a tank of gas thru it with some stabil till it runs out ......... if my luck holds ! You always say thanks for watching and hope it helped someone ........... DUDE this was beyond a help !! ding dong here's yuh dinner MIRACLE...........thankyou soooooooo much.
its an old powermate 5500/6200 and can't find motor identification on 10hp briggs WHERE THE HECK IS IT
and where the heck you find those diagrams
Thanks for this video, enjoyed watching it in the Netherlands.
Great catch there! If only they was all this easy. But, don't be fooled by the term easy as what's easy to one is difficult to another. Anther great informational video in the books my friend! Blessings and respect!
This is just fantastic - if only there were repair places I could trust, with your knowledge, and could repair it in a few weeks at least! I bought a Champion 201035 10,000/9000. Had an old powermate from Katrina days, and a smaller Champion 4000/3500. When I got the electric start 201035 running I also got the other 2 running. SUCCESS!!! As it got colder only the new one will crank. And yesterday the rooe snapped as I tried cranking the smaller Champion. Soo, your videos are amazing. And I just sit with 2 dead generators because it's all above me. Guess I'll get Champion on tge phone and search yiutube on how to replace the pull rope. Thanks for the great videos.
Most small engine shops can handle the engine side without issue. But it does take them a while to fix as they are swamped in work. Some of my repairs take multiple months mostly waiting on parts.
Another pleasant journey, thanks. Will lookup Base Guitarist 1985 thanks for that tip to :)
Got me in the whole way with this one. Good video mate. I leanrned a few things too
I was thinking, just learn to solder and order parts in and you can fix those simple boards yourself. You will find that soldering big stuff like that is easy peasy.
Also, it occurred to me that AC devices allow +_ 10% voltage. Well, they do here in Oz. So that would mean 120x10%=12volts above and below 120volts.
So, 132vac top end and 108vac bottom end. This genset was at 111vac low end at "full load" which I would be happy with. It will pull more amps though, and get hotter in the stator (another reason to keep the load no more than 5000 Watts).
As you said, without a VAR you get what you get. But, back on Facebook for $220-$250 for an easy fix is not bad at all.
Ay the 18 minute mark James ask: what do you think, will it work?
I was like, NO there is still half a video left… 😂
Good work as always
The problem with the cap is the voltage. You have 135v * sqrt2 = 191v at that cap, and that is to close to max. You should use a 350v cap and it will last forever. The brand Nichicon are some of the best caps; but not when you abuse them.
WooHoo, love that lift! Great investment, for your repair biz and the videos.
Hi James. Good video. I had that same exact genset... bought it at Home Depot. I have since sold it, but it ran well. I mainly got rid of it because of it's "dirty power". I too saw over 130volts. I have since gone to a Honda EU2000 which does everything I need and is much, much quieter. The Powermate was fine in it's day... and saved me headaches at the time.
Another great diagnostics and fix...Always look fwd to your Thursday video's....Keep up the good work... you are appreciated more than you probably realize!!!!
good repair, as for the broken lacing strands a bit of silicon RTV will take care of them,
(notice that the stator with the lacing has not been dunked in varnish and baked solid)....
Hi James always great sitting in your class A nice easy fix for you with all the parts at hand as always a great teacher thanks for sharing May I wish you and your family a Merry Christmas and happy new year from here in the UK
Thanks Dean. Have a Merry Christmas yourself.
Nice work. Its always better to test diodes out of circuit in a power supply as the capacitor is directly across the output. If you need to test a diode then with the meter on resistance, place the leads across a diode note the reading and then reverse the leads and note the reading again. The values should be high in one direction and low in the other direction. A diode is just a one direction valve. The actual parts in that unit cost cents to replace so it's worth having a go yourself. Just replace like for like.
Definitely need to take out of circuit to find the exact issue. Was just testing the board as a whole and it failed.
Another fantastic repair video. I'm surprised a 120/240 volt genie only has a GFCI on one leg. I was confused by how many diodes were on the PCB. Watched Bassguitarist1985 and each diode is paralleled so that mystery solved.
It may be worth opening up the bad meter and try reseating the LCD display.
Excellent video as usual. I learn something new every time I watch one of your videos. Thank you.
As an electrician I know all gfi breakers has to have power for the test button to work. It is not a circuit breaker. It only trips if it detects power to ground. So you don't get shocked.
You are totally correct about that air filter box that piece they left out of there is meant to be a spacer and serves as a seal for the back side of that filter and should be in there
Really love watching James videos. He puts a lot of passion into the work he does it.
Lovely work James. I thought the broken ropes were indicative of something worse. If one or a couple of turns of one of the coils had become hot then it did not last long.
The lacing was not burnt looking, so may have been vibration related instead of heat.
That's awesome it was a very simple easy fix to get it making power again, just a bad rectifier, excellent work as always James!
I learned a lot from these videos about generators.
I just picked up a Coleman Powermate maxa 5000 ER for $100 it's a little older but it is brand new, never had gas in the tank or oil in the crankcase. Has the Tecumseh 10hp engine. Wanted to make a little extra money, but sold it to my sister for what I paid for it.
One thing to remember it that a GFCI won't reset if there's no power going to it. Hope that helps others that are looking at that problem
You deserve more Subscribers James.
I've put the word out to my Geeky Pals.
Another excellent video,Your Excellency .
Hi James,
Wishing you all a Merry Christmas and Safe and Prosperous New Year.
Wayne & Nina (Ipswich, Suffolk, UK)
🎄🎄🎄🎄🎄💗💗💗💗👍👍👍👍😊😊😊😊😊
Again, entirely excellent! Thank-you!
impressed witht the Diode Test, simple but effective..Thank you James and a happy new year...!
There are some automotive reconditioning rubbing compounds you could use on generators like this with fades plastic components to restore the color nearly to new condition.
Superlative work as always. Pleasure and relaxing to watch.👍🏻👍🏻👍🏻👍🏻👍🏻👏🏻👏🏻👏🏻👏🏻👏🏻⭐️⭐️⭐️⭐️⭐️✅✅✅✅✅
Just started watching your videos, and I want to thank you for the time and effort you put into them. I like how calm you stay and how thorough you are when you repair a generator. I was pretty impressed with the bore scope video and ordered one for myself.
Think they are low on stock now.
Thank you James. Great video
Great video James, almost an early Christmas Present (just needing a capacitor). Thanks for sharing. 🎅
Love the unit having a light over the plugs and control board.
Excellent repair james
This is the first video that the carburetor and fuel tank didn’t have to be cleaned. I just love your videos, and I’ve learned a lot. Merry Christmas, and a happy new year!
Reason is plastic tank
I have a plastic tank on one 12 year old. Never need nothing but metal tank one. Carb and clean tank every year
Thanks, you too
Excelent job Mr. James!!! Great job diagnosis in this board... have nice day!!!!😁
Always generating great content. Powerfully good info, currently very accurate! (no more dad jokes now)
You can check the individual diodes with the multimeter as well. You should see a voltage drop when the black lead is on the end of the diode with the band (and the red lead to the other end), but not when the leads are reversed. If you get a very low reading either way, the diode is shorted. On the display unit, is there a potentiometer? Sometimes the display contrast just needs to be readjusted, so I would double check that before condemning it.
Dang! Didn’t have to rebuild the carb? Crazy! Thanks!
Good catch 👍 This is the first time I remember where he hasn't done something to the carb!
James, you clean up these gennies like they were used cars on the lot LoL
Great video and troubleshooting. Amazing how a few inexpensive parts cause it to fail.
That's a good-looking piece, another great job James
Thanks for sharing your knowledge.👍
Excellent find and fix!
Nice one! Glad you were able to make a few smallish replacements & come out in profit.
Excellent save as always
Another great video. I have no idea when that generator was manufactured, but I can't help but wonder if that bad cap was part of the capacitor plague.
Another great job! Easy fix!
You made the generator look and run like new,, Who ever had it before took good care of it,, I hope that you can find an inverter generator to work on once in awhile,, I have worked on my inverter generator some but you need to be a surgeon to get to anything on the inside of it,, Lol,, :-)
Great job James loved it 👍
Thanks for the vid James.