Blown Generator Engine Swap
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- เผยแพร่เมื่อ 9 ก.ย. 2020
- Recently picked up a Briggs and Stratton Storm Responder generator that was run low on oil and the connectng rod broke. I will pull the blown engine and install a similar 10 HP Briggs engine to repower the generator.
There are three other videos related to the original engine that was pulled of this generator.
Part 1: • Generator Engine Rebui...
Part 2: • Storm Responder Genera...
Part 3: • Generator Engine Rebui...
Part 4: • Will It Make Power Aga...
Blown Engine Model# 21T212-0116-G1 Code: 110106YD
Replacement Engine Model# 204412-0163-L1 Code: 060328YD
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#GeneratorRepair #SmallEngineRepair #SmallEngine #DIY #Fixed #Troubleshooting #HowTo
It is a rarity on YT these days to find content this good with as many subs as you have without being bombarded by ads and pushing for paid subscriptions for "upgraded / exclusive" content or to purchase merchandise etc.(not hating on anyone who does btw) I know it takes time to produce and edit these videos not to mention the time it takes to troubleshoot and fix these things, hopefully you make a little back on the resale of these items and the satisfaction of repairing them youself is priceless in itself, keep up the good work!👍👍😎😎
Thanks. Yes make a little selling the equipment. Not into all that other stuff. I have a day job that pays the bills. Maybe someday will have to add that stuff, but ok for now. Editing and filming takes much longer then just fixing the machine.
When Hurricane Ike came through Houston, our power was off for 16 days. I ran one of these generators almost continuously to run the house and one 10K BTU window AC. Ran flawlessly and used surprisingly little gas. Changed the oil at the end of each week due to the runtime a couple of times. No issues otherwise.
They are a solid generator/engine. Just need to check the oil. They do not have low oil sensors.
@@jcondon1 It amazes me that in an otherwise robust design, there's no low oil sensor. Judging by your channel, low oil issues are the end of many otherwise good engines in these units.
Outta
David Wood that is the main problem with these generators. Otherwise very solid, wish they would have included the sensor.
I run my predator 1800 4to 8 hours a day, I change oil the first week of each month. It's been 4 months and it runs great. The oil isn't to bad either. I think with a filter I could go 2 months between changes.
I used to fear and avoid anything to do with the powerhead side of a generator. You have taught me enough that I would attempt to troubleshoot and repair one myself now. Much appreciated!
There is no harm in trying, especially if it is already broken.
James, thank you so much for your videos.
I love working on my own machines, but I often rush or cut corners.
These videos are therapeutic for me.
It's very nice to see someone with patience and knowledge who actually fixes problems, even little ones, instead of "band-aids" them.
Keep up the good work.
A note (that you probably already know) on torque when using a thread locker:
You'll often see "wet" and "dry" torque values based on whether you have any lubricant on a fastener.
"Wet" values are typically 80% of "dry" values.
Thread locker acts as a lubricant when first applied, so you should actually reference "wet" values.
So if a torque spec for a dry bolt says "25ft-lbs", and you add thread locker, you should only go to 20ft-lbs (80%).
Most of the specs I've seen only list one value, and that value is based on whether they suggest the fastener being wet or dry, so this really only applies to self-prescribed thread locker.
But, it's something I've learned fairly recently, and it might explain the old bell housing bolts being torqued to 25, but you only feeling comfortable going to 20 when reinstalling.
Thanks. I try. You are correct on the wet vs dry values. Never knew the 80% rule. That will be helpful in future builds. Thanks.
@@jcondon1
80% isn’t a “rule”
SAE, ASTM, and the various fastener society people have specs for lubricated fastener torque reductions depending on application.
Some fasteners are 50% derated torque spec. As you said, with aluminum torque is probably worthy of extra attention.
I have the same engine on one of my generators and I am extremely glad that it does have the oil sensor
I recently had two of these generators come through the shop. One had a blown rod because he ran it out of oil. The other one had a broken crankshaft which was a surprise for me. I actually had a good crankshaft in stock that I took off another engine that I had converted to a straight shaft. It was an easy fix.
But the one that blew the rod out the side of the block was completely destroyed inside. It ended up being cheaper to source another engine and install it. I chose a 9 HP Briggs and Stratton Vanguard because it was the only engine I could find with a tapered shaft. With some modifications to the engine mounts and muffler, it worked perfectly fine.
Low oil is this engines weakness. Working on one right now that ran out of oil and broke the rod. No hole in the case so hoping it can be rebuilt.
@@jcondon1 You should be able to. A new connecting rod and clean up the crankshaft and your back in business. Hopefully it didn’t smash into the camshaft.
@@Omegadoomship I have an extra camshaft and crankshaft. The real wildcard will be the condition of the cylinder and crankcase.
@@jcondon1 If you don’t see a hole in the crankcase there’s a good bet the damage would be insignificant. But you never know what carnage you’ll see until you take it apart.
Thanks for the video!
Awesome, have the exact same engine and I wound up pulling out to review since I didn't document in my folders. Was reviewing what engines I have to potentially swap in a made in the U.S. engine into the Champion 4000W gen that came with an All-Power 196cc I'm guessing GX Honda clone that isn't starting easily. Thanks for sharing... neat watching.
Yet another excellent and detailed video! I didn't realize it until just a few days ago, but your 9/26/19 video on a Kohler head gasket was a perfect resource for doing my own back in the spring. Then pandemic boredom has had me fixing and flipping small engine equipment all summer. Your videos, and those of many others, have been invaluable resources! Many thanks for your time effort and attention to detail!
Thanks for the comment!
Very nice generator. Thanks for all your tips, I really appreciate how thorough you are.
Thanks
Thanks for the new vid James. I had been going cold turkey, having consumed all the your content in one huge video fest. A 48 minute 56 second fix will do me fine.
Nice
Great information. I had the same model in perfect condition but blew the engine after the storm running engine for about 20 consecutive days. We believe it blew due to low oil. Swapped engine with a Honda engine.
Thanks for the time taken to make and upload this video James, Removal procedure and double-checking torques during removal shows excellent experience and will probably save someone from stripping the castings. I agree that the centering of the fixing bolt seems like un-finished design business (Not your Issue) but would suggest that the amount of movement could be reduced by the addition of an external threaded reduction bush with a washer on the outer end.
GREAT VIDEO AND WELL EXPLAINED . NICE JOB .
Great fix
Good to see ya bro another sweet video
Very nice job, thanks for the awesome video! Next time I see one of these storm responders for a reasonable price I’m going to jump on it. I passed up a nice one for 200 bucks on “half price day” at an estate sale last summer, don’t know what I was thinking!
It is a good generator, just check the oil and it will run well...
It would have been nice to see blown engine disassembled.
🙂🙂🙂👍👍👍
You will see that this Thursday!
That was a good repair. I fixed one that was an old harbor freight 900 wat. and then My neighbor asks me to look at his chines wong jone do or something like that. I got it to running good but it kept putting out to my watts. I'm not too good with that end of the generators so I sent him to a friend and he refuses to work on it.
I can't blame him. LOL
Thank you for another great video!
Thanks
Excellent work! Might I make a suggestion? I use tie wraps with an eyelet made into the female end for just such an occasion of your securing that connection. As often as I use them now for wire maintenance in general, I can’t go without. Too easy for running a harness, just screw it to whatever/wherever, just grip and zip the bundle, thread then cut the tail... itsa nice tight bundle every time, it’s quick and looks great too😉 Anyway, thanks for taking us along, I learned something new today so that’s a good thing... thank you✌🏼😷
Thanks. Will get some.
Shrapnel is no bueno.
Well done, sir.
18:28 3/8” drive Carlisle allen sockets at Napa are halfway decent and would make that better- even use the little cordless impact to get them out.
You really need to invest in a simple map gas torch for your stuck bolts....saves a WORLD of headaches.
I was at a go kart track where the karts were supplied and I blew up the engine on one. The rod flew through the side of the block like you mentioned usually happens. It didn't run out of oil. I don't know why the rod failed because I didn't stick around very long after the race ended, lol.
First off thanks for the vid. Always good and I'm definitely sub to you. I'm a home remodeler and pretty good with my hands when it comes to any house or commercial related and the basic that I've taught myself but at a loss on this small engine so I checked my ego and listened to my girlfriend and came to TH-cam and you.
So here is my question and quick breakdown what I've already tried.
I really need your help. My mower won't run and don't have money for a new one. I've checked spark and my air filter and checked oil and checked tension on cables all the basics and will start no matter how much I try pulling...However if I put a little starter fluid or gasoline directly in the carb it'll start and run till it burns up that gas so about 30 seconds and Quince event Lee the exact same thing is happening to my work van right now but I think it's probably my fuel pump in my van but not positive yet. I checked all the fuel lines none of them are broke or cracked or disconnected so I was thinking about buying a carb kit for it? If the owner of this channel would respond to me that would be awesome or if anybody else in the comments section might know I would be extremely grateful for anybody's suggestions or tips thank you.
Hand impact might be good for the hex bolt loosening.
Very good
Thank you for your great vidios!
I,m enjoying your videos friend, i sure am learning a lot about generators and small engines
Glad to hear it
The first time the engine was started, the gas tank was STILL off!
Where was the gas coming from to run the engine?
Thanks James for these great videos' all thease tips of tourqe settings are eye opening, I enjoy your videos very much. on the subject of The Storm Responders, they seem to be cheaply built. shame a recognised company name like Briggs are doing this. I had a AKSA 3000 with a Briggs back in 98' that used to work at least 8 Hours a day up to 2006. Oil changes each 40 hours in abouve 47c Tempreture weather. served me well.
Not sure what brand FEMA gives out. But I would guess that many of these frequent flyer basic models were given out after storms. Hence why the owners treat them like crap. Here in Florida, people beg the government for them, then sell the never used generator. Gotta love it. Any free generator given out by the government should be painted bright orange to let people know the owner got it free of charge.
I actually think these are well built, a good design an do recommend them. Just gotta check the oil because most of them do not have a low oil sensor.
Hey James, congratulations on your success on your viewership! Keep up the good work!!
My son and I yesterday built a good standby generator from two dead ones - I'd show pictures if I could. PM me if you want details. Between the two of them: 1 wrecked engine, 1 seriously damaged armature from a spun bearing, and 1 shorted stator. You've been entertaining as hell. Your tip about using hydraulic pressure to pop (and I mean that) the armature off the crankshaft came in real handy - worked so very well.
I hope this becomes a thing for you and you follow what is clearly your passion. Best of luck to you, sir.
Nice! Good work!
Nice job!
Thanks!
Great video, Briggs and Stratton really should've put a low oil sensor on that engine because a lot of people probably just run their generator without ever checking the oil.
Yes, most generators fail when the power head goes out. These normal fail due to a lack of oil.
My dad was religious about changing and checking his generator oil. Never really used any.
Didn’t do due diligence this last fall. Early this winter: power outage. Fires up generator. Few minutes later it threw a rod. No oil in it. None. Surprise!
James have you ever considered a lift work table for the shop so you don't have to be working bent over all the time. The one I have really saves a lot of wear and tear on the back.
Yes, been considering one. Trying to use my bench more when possible. A lift table is something I will add. Was only making one or two videos a month so it was not a big deal. But since I've been home after Corona hit, been working on a lot more stuff.
James ,Just a tip instead of using a larger bolt to remove the rotor I use a one smaller in diameter this way when it pops it's still in the threads . keep them coming !! Best on utube !
You could, tried it once and bent the rod but it worked.
some people cant even do SIMPLE maintenance checks your gain , good repair
Thanks
So clean no oil monitor
Ive noticed when you check the Hz you normally load it with around 3,000 watt of load. You want it to be just above 60, what if when you actually are using it to power your house and your using the full capacity , say 6,000 watts. having checked its Hz at 3,000, are you still ok to be around 60 Hz at 6,000, or should you try to adjust it for a larger load.
I am just aiming for the middle load at 60. It will be higher with no load and lower with a load. But generally hertz are fine anywhere between 58 and 62 hertz. If there is an engine issue then you would see it at half load. Meaning if it goes from 62 hertz with no load and 58 hertz at half load then you know you will have a problem at higher loads and must dig deeper into the issue.
Awesome! Thank u...
Where do you find all these "need-fixed" generators? I like rebuilding such things, but never found any for free or cheap enough to buy and repair... Thumbs Up!
I can't speak for him. But in areas that face storms every year (florida) generators are purchased or given away by FEMA by the thousands. And when they sit and junk fuel destroys the carburetor, people sell them in huge numbers- usually cheap. I mostly see them on neighborhood websites like Nextdoor. Probably 10 listed in my neighborhood right now. Good luck.
Facebook marketplace or craigs list usually has a lot of them.
Gary Mucher I don’t see any of theses either it’s a east coast thing and a big city thing
I’m in oregon we don’t Have that many storms or power outages so generators are used on Rv and taken care of
We maintain them right along with out quads or side by side toys
I found this one on facebook marketplace. They are hard to find and sell fast. But, If I can find one at $100 or less then I will grab it. Think it is more common where I am then in other areas.
it blows me away how many people blow up their small engines because they don't do the most basic of things, which is to check/recheck the oil.
Where do you find all these Generators ?? I have been looking on marketplace for weeks and only found one that was broke. Have you ever done pressure washers or stripped them for motors (assuming side shaft).
Did one pressure washer video. Pump was bad. Fixed the engine, but nobody wanted the engine. Was asking $20. It was a vertical shaft though. Have not bought one since.
Thanks
Sir do you have any info on replacing the governor on that engine
I think mine is bad. It does not turn when you rev the engine
Thanks
I have not had to replace one yet. But next week I will rebuild the blown engine. You can see the governor in that video. Not many parts to it. Also make sure your throttle plate is not stuck first.
I hope you set the voltage up a bit before you finished.
great videos very instructional, I got a question recently after hurricane Isaiah a friend of mine blue the engine on a generator exactly like the one you made this video, so gave it to me for free, it looks brand new so I was thinking to try to rebuild the engine especially because I cant hear anything rattling inside, the question is where do I get all the specs , torque, clearance, etc? or if you have a video where you are rebuilding an engine like this can you share the link please.
Next week I publish a video rebuilding this engine.
James Condon thank you I will be waiting to watch it
Hi James I hope everything is going well with you. About this project I got the same exact situation as you publish in the video, the problem I have now is where do I get parts? Do you have a website or do you sale parts? I need the piston, connecting rod and gaskets
THANK you in advance for your advice
I could use a frame from one of those 3k ish china generators if you got one laying around. Got it behind my garage and use it several times a week. The frame is rusted away. basically a motor and head laying on the ground lol.
Good Job
Thanks
Ahh, just when I needed it!
Just a thought, but does applying thread locker to the bolt act as a lubricant that might give improper torque setting?
It does
My generator has the same engine but maybe a few years earlier. Has low oil shut off. Starts first pull every time.
Tank has fuel shut off, I always turn off the fuel and let it run till it empty’s the carb.
It does need a good carb clean/replace cause I need part choke
A cleaning should fix it. They are good engines. Nice that you have the sensor. It should last you a long time.
Why wouldn't a person use some emery cloth before joining the two together? Your videos are very detailed and complete. Thank you.
On the shaft? Generally I leave that alone. It is a friction fit. Do not want to make it too smooth.
A very interesting & informative video, thank you for sharing you videos with us. I have a Briggs & Stratton generator but the armature doesn't have a bolt going through the centre of it, have you any idea how it comes off, many thanks.
Every generator I have worked on has a bolt. Someone must have removed it. You should replace it. The armature is a friction fit. Without the bolt, eventually the crankshaft will start spinning in the armature and ruin the generator.
@@jcondon1 Hello James, thank you for your reply, the armature shaft is solid, all it has on the bearing end is just the centre from when it was manufactured. I am wondering if it is screwed onto the crankshaft. Thank you once again.
I can't help it, I love a good generator video
Thanks
great fix James , ENJOYED !!
Thanks
Cool clips
I like your videos 👍
Thanks!
Powerhorse model166113 at 7250 running watts has 5 volts going to the brush-set from the
AVR. Champion gen# 465963500 watts 7.5 volts to the brushes. TroyBilt 5500 7.5 from a
rectifier bridge on back of brush-holder, wires come from exciter coils in the st8or. These gens
are running just fine. I put the field voltages here to help people know what they should have
when working on these gen-sets. When I get more gens working, I'll post what I find out.
James, is it possible to purchase a low oil sensor and install it on an engine without complications?
You probably could, but I have never had to open one up that has an oil sensor so not sure if it can be installed or not in one that does not have one.
Sometimes there is a plastic plug where the oil sensor wire would exit. On those you probably could add something. Others have the casting for it, but it is not drilled out. Either way you would have to open up the engine to install it. I once saw a Briggs that had the oil sensor screwed into the oil fill. That looked like an add on that would be easy to install, but not sure what the part number is on that.
Great information, i happen to be working on a Power Boss with the same briggs engine. It would pass as a twin generator.
Can you use an engine with a straight crankshaft? What do you do to connect the generator head?
Must be a tapered shaft with these types of generator heads.
@@jcondon1 OK, thanks for the reply! That explains why I can’t find some sort of adapter. I suppose I’ll have to make one myself.
James, is your birthday coming up soon? I think you need to make a few suggestions that some extra tools would be a lovely present!! LOL
I got a Coleman powermate that needs an engine could I replace it with one of these? Or perhaps a Honda
Not sure on about that. Have never removed a powermate generator head. Would suspect that you could.
Rance here, James you have done another great informative video that was a pleasure to view & learn... Good job! !
Thanks
Does u now the thread size and pitch for rotor puller
James, with the holes in the governor bracket, you shouldn't need to bend the other bracket to compensate.
Those holes on the governor bracket adjust the governor sensitivity (and spring tension). Generally you do not want to change the sensitivity or the governor may not respond properly under load.
I saw what you did there, lol thanks for the extra effort on torque specs :)
Will you take apart the blown engine on video?
Yes, next week
Regarding no oil in the engine.
Engines from the factory sent out without oil.
Customers has to fill the oil, it says in the user manual.
what number of screw did you use to remove the rotor
Obviously very little use and well kept. Makes one wonder why it was run out of oil and destroyed itself?
It was pretty hot when it happened. May have used the wrong grade oil. And/or never checked it. Not sure.
Great job, I love any videos on this model generator because I own the same one.
I have 4 more in the queue. Picked up another that ran out of oil and one that had valve issues.
James Condon awesome, can’t wait for more videos!
James Condon anxiously awaiting another video especially on Storm Responders.
By unscrewing the rotor bolt with the torque wrench, you are not messing up the calibration of the torque wrench? I would use a breaker bar for that.
Did not know better at the time. Yes , use a breaker bar or impact for removal.
@@jcondon1 You inspired me to pick up a generator and start repairing it. Thank you for that. It is a Champion 76533(free) with stuck governor arm, and bad battery. I have also picked up a Coleman Powermate 5000 Gen Pro($60). This one, most likely has a dirty carb, since it starts with starter fluid. Thank you for all your videos, I'm learning a lot from them. The drought here in LA is getting scary, so I just want to be prepared.
just a side note, give the bolts a smack with a good hammer it will help...good work by the way im learning loads.
Thanks
Good evening James, I just happened upon your channel and decided to subscribe. You are covering the exact same generator I have, and I can tell from the video, that your generator above is indeed equipped with all the same parts and specs as mine. Yours is a Briggs and Stratton generator, and mine is a Troy-Bilt, which for all intensive purposes is a Briggs and Stratton unit with a different name. So my question for you, if I may ask, is what is the series or model number for this 10 horsepower Briggs and Stratton engine as such? I have been all over the Internet for the past week looking for that information and hit nothing but dead ends. My generator was a curb find and the previous owner already started to disassemble the engine. Because of that, I do not have the model or series for this engine. My piston is seized at close to dead bottom center, so I have no room to make it move further downward if I could. I will need to buy a replacement block and piston, but all else in the engine looks good. All that to ask, what is the model or series number for this engine?
Your help is appreciated, and I definitely appreciate all the work you have done and the level of detail in your videos. Keep up the great work!
These a made like a lot of Fords: lots of orphan parts. There should be a serial number plate…
But basically any similar motor could fit- there’s tapered fits on the shaft that could be different but basically only two as far as I can tell, or some have a non-tapered shaft.
I have three generators out by the shop right now- one is a blown motor, the other is a neglected motor with compression but a bad carb, the third runs but no electricity output.
I think the neglected motor will take the carb from the otherwise pristine blown motor and give me a running generator. As long as the shafts are both the same.
Get Milwaukee m18 3/8 impact and you will able to spin those rotor bolts right out without messing around with rope or strap around the flywheel.
True, but still need to lock it up when installing the rotor and torquing to 23 ft lbs.
Perfect...
How long did it take you to swap the engines out?
Work to hard, and torque wrench happy. On this small stuff everything d is rent call for the clicker. Just snug to tight simple! I yank engines apart the only thing really get the clicker is mains, and rods. Everything else gets the Ahgua dughah treatment.
Wait a minute,wait a minute. I won’t be able to achieve rem sleep until you fix that muffler bolt you broke. 🙀
Have you ever used a piston stop instead of rope to save time ?🔧
No. Considered buying one. It would save a lot of time. Just do not like the idea of applying that much on the spark plug threads. I know others use it without issue so may try one.
Did the previous owner have a story as to what happened to it? Almost looks like it my have never been run much if any, i.e. they never put oil in it.
So many folks with power equipment never check/change the oil, and these motors all burn a little. Over time they end up like this... they hold less then a qt most of the time so less the $3 once a year (oil change) probably would save 1000’s of machines a year.
He was just running it after a storm for several days until he ran out of oil. No oil sensor and did not think to check the oil level. They all consume a little oil even when healthy. You can get away with that on a lawn mower for example because you only use it one or two hours a week. You can easily put 200 plus hours on a generator after one storm. Got a few Briggs videos coming up. This was one of two I picked up recently that ran out of oil.
That is the connecting rod...or was
I really enjoy your videos, but I have to suggest that you invest in a decent hydraulic lift bench/table. HFT's has them and they are fairly inexpensive. Just looking out for your knees .....
I plan on getting one. Do not do this for a living and up until recently was only fixing a couple a month.
You are a very clever man? Wish I was as good as you? Top job nice one loving your videos please keep them coming stay safe dude
I have a brand new champion 5500 generator that thru a rod . is it worth putting a new motor on it
Probably not a new motor. Maybe a used Honda clone in the 388-420cc range.
Why did the low oil switch not shut the engine down?
The storm responder generators do not have one. Most Briggs 10 HP engines omit that.
@@jcondon1 Interesting, looks like a blk wire from blower housing going
up the side and I guess it is going over to engine run switch then? seems
the engine would have been saved if it had a low oil switch. I found that my Troybilt 5500 uses no AVR but a full-wave rectifier on the back of the brushes holder. part 91825GS available thru home depot and B&S also seen on another
make of generator being worked on. James, a big thanks for doing these vidz!
Do you sell detonators? I live in Vietnam
jim set the valves before changing any thing else on settings!!
i would to have changed the oil before a run up..
also clean the spark screen on the muffler before run up.
also to center the gen head main bolt on the bearing use tape on the bolt to get it to center.
Kens small engines. He mentioned u several times on his live video Check him out Kens small engines. Live video every Sunday morning @8am eastern time
Where did you gain all of your knowledge?
The interweb and a little bit of reading. Some trial and error.
Used power Equipment + OHV = Valve Adjustment automatically
What's the name of that type of shaft on that motor?
Tapered shaft
인기 급상승이라고 해서 눌러봤어요
틀어놓고 잠들어볼게요
Small engines are not for everyone.
How much do you sell your generators for?
It varies, but this one will go for about $450.
To center bolt loosen slightly and tap to center
That gets it closer. Would be nice if the bolt had a shoulder to center it.
How many generators do you have that's yours
I have two. Honda EU6500 and a Yamaha EF2000is.
@@jcondon1 I'm looking for a quality, small 2000 generator. Would you recommend the Yamaha as I'm a huge Yamaha product fan?
thank you very much in advance
You should get an Amazon affiliate and list the parts and tools you use. You get a few pennies from each purchase. If not that then links in the video description.
ShooterReadyStandBy yes was looking into that this week. There is one in the works.