Generator Head Installation - How to Install a Generator Stator and Rotor
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- เผยแพร่เมื่อ 20 พ.ค. 2020
- Part 2: Bought this generator used, advertised as good engine but no power output. After troubleshooting the power output in the first video I discovered that the DPE winding was bad. I purchase a new generator head and will show you how to install it..
Part 1: • Troubleshooting Genera...
Generator Model# HU40500G
OEM Generator Head# 310227059
Alt Generator Head# 310227016
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You gotta love USPS! My postmaster has said that she doesn't believe her letter carriers can even read!
Nothing better than watching a man working when he knows what he's doing. Great job!!
Thanks
I just put that same head on an old obsolete Generac 7000exl. I had to machine a taper adapter from the old rotor. It works great.
Once you have the motor running at 3600 or 1800rpm for 60hz, adjust the tiny brass screw on the back of the avr to get your voltage closer to the 110v you want in America.
The engine sounds like it's surging a little, take the emulsion tube and idle jet(generally a little black plastic plug on engines like that ) out of the carb and clean them, the main jet will come out to release the emulsion tube, clean that too.
Use a throttle body cleaner that foams and goes goey to soak them, then wash with a solvent.
Nice score on the generators, it's a great way to learn things. I've commented on a couple of videos looking for information regarding the avr wiring but think I've discovered the original notes i made when I learned how to test them.
I can add the information if it's useful to you.
Cheers!!
I really like your videos. I have been picking up generators for free or next to nothing and fixing them. The latest was a 7500 watt briggs for free and a $14 set of brushes fixed it. I really like your rope trick. Learn something new everyday.
Nice. It is hard to find them for free around here.
You would think by 2015 all generator manufactures would know, exhaust heat shields should be standard unless there is a 3+ inch air gap between muffler and gen. head. Great video, you rock!!!
Thanks
HEY THANK YOU SO MUCH FOR MAKING THE FULL VIDEO AND NOT WHIMPING OUT AFTER THE FIRST VIDEO!! ALOT OF PEOPLE WOULD HAVE THROWN IT IN THE GARBAGE OR SCRAPED IT!!! Thank you soooo much for completing it all the way!!!
Those power heads can be stripped down, cleaned, and re-wound in a electric motor shop. There is one in town here, about 4 miles North of me. They specialize in rewinding motors & generators ect.
Wish we had one here. I've called everybody inna 150 miles radius and nobody will touch a armature, and if thay do thay want 1200. To do it.
@@foodforthought73 I'm not sure how much S & W charges to do this. I'm sure it depends on the size of the unit.
@@lestergillis8171 ya. It's just a standard 4500 wat gen head on a Hobart welder generator, the armature
Definitely a lost art like getting your wheel cylinders bored, sleeved, honed and good to go for another ten-fifteen years.
you or great at what you do thanks have fun
James Condon I got a free Duro Max 10,000 watt dual fuel pretty sure engine blew pull cord and I sounds like marbles coming from the engine and cant feel compression with the plug out. I called Duro Max replacement engine 486.00 to the door I never swapped engines on a generator I am going to try my first one this weekend watching your videos gave me more confidence.
Good luck. Take your time and take plenty of pictures. The most critical part will be removing the wiring and getting the powerhead off without damaging it.
@@jcondon1 Yes little nervous about removing the powerhead.
Thanks for the video, it was very informative. I understood your caution about connecting the white wires at first, but I knew you didn't realize the stator power windings were isolated. I continued watching to see if you figured it out, and of course you did, followed by an excellent explanation. I really appreciate your time and effort making the videos, I am learning quite a bit from them. I've done valve lash, carb rebuilds, but never messed with the power head. Thank you !
Glad you got something out of it. Most people stop at the engine side of things.
New to the channel, like how you work clean and organized, most of all you talk when you need to talk not mindless tribble. Looking forward to all previous and future videos. Cheers from Canada
Thanks!
Hurrah and thank-you again!
Your channel is going to blow up. Keep doing what you are doing.
Thanks. Been blowing up recently. 5k subs in 28 days! Yikes.
@@jcondon1 The matrix has found you...
Your video is really helpful
Thank you
Nice video… so much education in practicality
Hand tighten the stator bolt at first. Fully torque the stator, after you installed he windings housing. The rear bearing fitment helps with perpendicularity issues for assembly balancing. The engine's taper end will better align with the stator shaft during the torque down. It could develop unwanted run-out otherwise, and possibly vibrate.
I think you mean rotor, not stator. Rotor is the rotating part, stator is the stationary section around the rotor.
Mate you are one clever fella it's great to watch you in action keep it up thanks
You sure make Hardwork look easy. I enjoyed every minute of the video.
Thank you so much 😊
That's fine you've got the whole pieced 'parcel' on vid! USPS should pay the repairs... I hope.
Now I know what my slip rings should read, hopefully good since I have an identical PH on a another gen. Stater looks fairly easy to swap out. Great we'll done video, scoured you tube looking for answers!
Most bond to ground for construction purposes, in case of an osha inspection. Unfortunately it can cause gfci issues if using in a household emergency power situation
THATS OUR AWARD WINNING USPS SERVICE FOR YOU.
Ah yes, was not their best moment. To be fair though, it was packaged very poorly.
Love your video.
I'm would run it with load for a half hour first, with 4000w loads
Nice work, great video! Thanks for sharing.
Thanks for watching!
Brilliant video, thank you from the UK.
Thanks
Fantastic work. I need to get you to rebuild my 2005 Subaru powered generator.
Really awesome job. Super slouth finding the missing capacity. Loved how you highlighted the spring jumping off🤣🤣. Once you replaced the carb it purred like a kitten 😸. Great catch at the end connecting the oil sensor.👍 Funny you mentioned the sustained winds over 40mph with gusts over 70. Our power went out Christmas morning at 3:30 am and was out for 19 hours. The Predator 6500 I picked up ran like a top. March can't come soon enough when the standby gets installed. Anyway keep up the great work. I learn something new every time. Happy New Year.
Our power was flickering all day, but managed to stay on somehow. A lot were without power on Christmas Day.
nice repair, thank you
You bet
Very nice
Thank you good work
Very good video thanks for the info !!!. i just bought a westinghouse 7000 watt gen with remote start it is one sweet gen i love it !
Your name should be James Concise, keep up the great work!
Thanks
Great vid...and yes definitely needs the shield!
Great video!
Excellent
Great content...I have to say to everyone though that I have found almost all homelife products inferior to defective from brand new.sooo...we ve got that going for us.thankyou..
Homelite not homelife
The air intake of the stator is 1/4" from the muffler, thereby pulling hot air into the stator windings. Thrrow the muffler over your shoulder, and just fabricate an elbow, to direct exhaust outward. Now there's plenty of room for a heat shield.....
Good Eye!
I'm a newer subscriper to your channel and I would like to said your videos are very informative.. So I would like to thank you for this..
Thanks
Nice video, thanks :)
some times a good motor shop can rewind those burnt up fields cheaper than you can buy one depends on where you live
soo... your repair videos are awesome.. especially for someone like me, who uses Gens, a lot.. also.. i built a smelter furnace.. from youtube.. lmao.. and a nice project you can do, is casting and melting of your scrap.. look into it..u must have a lot of scrap lying around..
Thank you for the information. They may have thought that the air is coming out of the generator head at front, or that is what it looked like, not east to know for sure from what little I could see. They may have thought that the air coming out would stop the heat from the muffler from damaging the generator. But that is just a thought from someone that didn't get a good look at the generator fan. I would put a R next to the place that got the red wire. I don't like trusting my memory where the wires go I also sometimes take a photo with my phone. Getting older and if it is a week or two before I can put it back together, I don't want to make a mistake. In school they told us to always mark where the wires go and it just stuck with me. Also learned the right handed motor rule, and left handed generator rule. But the way I learned it I can't tell on here. THANKS
Well, I am glad I record all of this because I find myself watching the video at time to remember how it should be put back together.
Good video. I’ve got to do this to my rigid 6500. Repair place said my stator is short circuited but I see nothing visable
Awesome job
Thanks
I just picked up an all power 6000 watt model APG3009N for 375 run like new mint condition about 10 yrs old
nice video thank you
Thanks
Good content
Thanks
Would it had been possible to inject the 4 volts ac the avr w/e needed externally, and see what output the generator can do?
don't get me wrong you make great ilusttrative videos I am a good follower of you. it justify for video purposes thank you very much
I don't know if you could see it but the terminal block had --L1 and L something else on it. Would that be line or load ?
That little lock ring on the bearing was giving me fits. I tried again and I found that one side of the bearing has the groove deeper. If you spin it around it sits flush!
27:00 time . Make a heat shroud, and bolt/screw it to whatever is handy there, to separate housing from muffler, directing any air flow OUT and AWAY.....
Thanks!
Great thought process in your videos.
Thanks! I really appreciate it.
Should the center bolt be jumping around in that bearing like that ?
How do I identify the sense and excite connections on the generator end? The avr replacement i got doesn't have the same plug type, I've identified the sense pair and excite pair on the avr but I don't know how to match them with the 4 wires on the generator end!!
Intresting seeing TTI on that new motor, considering TTI is a tool company that own ryobi, milwaukee, empire, dirt devil, and other brands. Wonder what a tool company is doing making generator motor parts
I think you’re right. These generators are failing because the stator is getting too hot from the muffler.
They may also be failing because the winding are probably aluminum clad with copper instead of solid copper.
Muffler Comment: My recommendation is to get a 90 degree connect from the flange to the head pointing out and away. This will move the muffler away from the generator housing and eliminate your overheating and destruction of your outer winding which are in very close proximity of the muffler as it exists without this modification.
I did a video on a powerboss generator that had the muffler above the stator (actually a car muffler, that I return removed and set back to OEM). I thought that was strange at first given nobody else is doing that, but it makes things a lot cooler. Am working on one now that has sever vapor lock issues. Would be nice is manufacturers would give thought to the details.
brush holder not on right. . .What happens is the AVR wants to compare the 120 volts or a
tap off the 120 to use as a reference point for the excitation. so if this reference voltage is
a bit on the hi side it will tell the AVR to reduce excitation to the field or if on the low side,
it will tell the AVR to up the excitation to the rotor.
James, Great videos! I'm working on my first generator its a Dayton 5u934a 5000 watt. I don't know much about them but the I got the engine running and it put out no power. So I figured it was the 50uf 450v capacitor that was bad and replaced that. Now it puts out 123 volts but have not checked the 220 connection yet. What test should I run before I deem the generator safe. Thanks for your help,
Not much on the electrical side other then checking the wire insulation. On the engine side you should check the speed. Because it is a generator you can test the hertz either with a Kill-A-Watt device (sold at Home Depot) or some multi-meters can check the frequency. Should be at 61.5 hertz under no load. Also you can test the RPM with an induction tachometer. That will work on any engine. Also test under a 3000 watt load to make sure the hertz stay around above 58 hertz. Ideally between 59-60. If too low, then that could indicate a top end issue on the engine.
@@jcondon1 Thanks for the response. I also worked on a coleman 1850 watt
sorry today and it seems to not have very clean output. I connected a drill and a angle grinder to it and it seemed to vary anywhere from 110 v down to 90 volts as I was running the 2 tools. Are these things very safe to run your equipment on?
That was a great video. I often wondered how the generator came apart. I did not see you install the right hand screw to the brush holder? Maybe I missed that but I didn't see it when you put the rear cover on for the last time? You probably already know this that the air is drawn in from the back side, through the cover toward the engine? No air is sucked in from the engine to the generator. Just the same, the heat shield is a real good idea. I have a Generac and it has a heat shield to shield the generator. Thanks again for a helpful video!
There is only one screw to hold the brushes on. The right side only has a tab to hold it in place.
@@jcondon1 I was wondering about that but I could not see it clearly. That video was the very first of your work that I even saw. I have had a lot of experience working with my own generators that supply all my power at my camp. Between one diesel and one gas generator I have produced over 16 thousand run hours of power over the years. I guess I thought you were kind of new at this until I discovered your volume of work and I can say that I am truly impressed! Thanks for being here. Terry
So, did the heat shield line up with the old stater where it was burned?
That Generator should run entire House with well, I have same 1 runs everything even outside spot lights
NICE !!
Thanks!!
@@jcondon1 Hey How Hot Should A Stater Get On A New Champion 100592 Generator ? Should It Be Cool Enough To Lay My Hand On It After Running 5 Hours ?
Heat Shield: Simply adding a heat shield will reduce the heat transmission slightly (minor reduction), however, moving the muffler away greatly reduces the head transmission. Note: Heat radiates radially outward, so the closer the muffler is to the generator the greater the heat transmission.
John Mauthner
... worked on gen sets for over 20 years and just retired. I can tell you the heat shield saves quite a bit... somewhere around 100 degrees cooler, but mostly after you shut the engine off, which is when the engine cooling air stops. Basically the "after boil" heat is what kills the winding insulation. The other aspect is that most people have no clue as to what 5 Kw can power and they are easy to overload with fridges, freezers, well pumps, etc. Of course an overload usually toasts the main windings, not the DPE winding.
Heat on half of it changed the resistance of electron flow creating even more heat. Just think how super conductors have to be very cold to work.
James, I cannot find a more current video to ask this question.
Please share some O-scope screen shots comparing the 'trash level" of a regular
generator as compared to the newer INVERTER models now being produced.
I am going to make that video in a couple months.
I recently completed the install of my Generator inlet box/off-grid connection. I successfully ran the A/C and essentials, but feeling a little sketchy about today’s high-tech, digital TVs and the like. Granted, the transformer/rectifier circuits do a good bit of filtering....
TTI made the whole head or just the AVR? Never mind, I see that they did but they only make a chainsaw at this time. No more lite in Homelite.
James can you do a video and talk to us about how people burn up these generators. What are some of the ways that we need to avoid. the do's and dont's ..
When you buy a power head how do you know the crankshaft taper of the engine will match the power head? I can't believe the taper is standard with all manufacturers.
On the 5000-8000 watt generators there are two types of standard tapered shafts. There are some odd ones on older machines and an occasional odd one in newer machines.
Nice video. What kind of paint did you used to paint the muffler?
I use Rustoleum. In the past have used the grill/bbq paint, but find that it looks a little chalky. More recently have been using Rustoleum high heat paint.
So to get 240v out of this to charge your Tesla or run your house dryer you would have to come off the hots on each side and both neutrals hooked together in one plug. Right?
Yes, that is essentially what the 240 outlet does.
Another good demonstration. Talking about heat shield why some of those are painted black instead of shiny finish?
No reason that I know of.
@@jcondon1 I saw heat shield for fuel tank are shiny finished, should the generator shield be the same?
Should the bolt be replaced ?? Now days most bolts are one time use.
What size metal rods do you use?
Why is armature bolt turning so crooked , is it loose or just drilled crooked ? Great video , to bad we receive packages in the mail in that condition .!
The hole where the bolt goes in the armature is always larger then the bolt. It is nearly impossible to keep the bolt centered when torquing it down.
Why did you take the head apart and then re assemble? You can put the stator and rotor on all in one piece and not have to worry about the bearing or do any damage sliding the stator over.. great videos by the way!!
I think it could be put on as one piece. But is easier and safer to do in two steps.
great vid James , i'm working on a yamaha gen ,, refreshing it ,,,,,,,,,,,cheers
James, I am in a similar situation with a 15 year old Black Max generator. The engine is a 13 horse Honda, and he old burnt out generator that I want to replace is a 6500 watt Powermate PM0496750. Any ideas on where to find a new unit that will bolt up to my engine? I have it all stripped down to the bell housing now, just looking for parts.
BTW, those are some great generator repair videos you have been putting out. New subscriber here!
I would check out the Ryobi parts for their 5500 watt generator. It was very affordable. Used a Ryobi stator and rotor on this powermate and managed to get it to work. th-cam.com/video/OT2etRMdTVc/w-d-xo.html. Otherwise the power heads fir the Generac GP5500, GP6500 and GP7500 would probably work, but much more expensive.
I’ve been watching your vids. I have a snapper gen 5600/8600. Briggs motor. My stator windings are burned as you showed on a very similar unit in another vid. Unfortunately they no longer make the stator. Can I use another brand or different head all together as long as it’s similar in size and power ?
Yes. That is a common setup. You could probably use a generator head from any other similar sized generator with a Briggs and Stratton engine. The biggest issue might be the wiring. Most Briggs stators are wired into a proprietary plug that runs from the stator to the outlets. Ideally you would find one with the same plug. Otherwise you would have to do some cutting and soldering to connect the stator to you existing outlets. You might want to check out this video th-cam.com/video/kWSKi07JxXc/w-d-xo.html. And this one th-cam.com/video/tX1sSLhNSio/w-d-xo.html
James Condon thank you very much for replying. My stator is technically discontinued but I’ve found a few 5500s online that are the same setup..... not really worth the investment of repairing unfortunately . I can buy the same generator in mint shape for the price of the stator. I reckon I can part it out.
James Condon hey man. I found a guy local throwing away a power head from a generator very similar to mine. Troy-bilt 5500 vs my snapper 5600. I replaced it mine with his. Worked perfectly. Your videos were very helpful. Thank you for that.
I wonder if that heat shield being missing dident have something to do with the melt down in the gen cause ill bet it was hot as hell !!!!
I am sure it did.
@@jcondon1 And you say this is chronic; you've seen it on 2 previous units. Did you bother to contact the manufacturer? Is there a recall or safety bulletin?
i have a predator 7000/8500 and the end bracket broke by the mounts and the generator head end fell/dropped while it was running and it damaged both rotor and stator-both SHOT thanks to watching your vid,-
i ohmed them out. So been looking for a suitable replacement Gen head but not find any sources, can you or anyone help point me in the right direction THANK YOU! GREAT informative video BTW !!!!!
1st I have to say I love your videos you do excellent work excellent work and teaching, The problem I have that I need help with need help with is that I'm getting half the voltage I should have both on the 120 legs and 240 side, I have power but only half what should be there. What do you think? Also what is the green and yellow ground wire, By the way I'm working on a predator 4375
I would suspect a problem with the AVR. Could also be the brushes or maybe an issue in the stator. Would start with replacing the AVR. If the issue is with the stator, then not much can be done with that.
I see you didnt use any anti seize, do you not recommend using that on the shaft?
Do not think that would be a good idea. The rotor is a friction fit. Do not want anything that can act as a lubricant.
I have been wondering about that. I have seen a blk/red blue and wht hookt so the wht wire
was the neutral so one coil had a blk an red other coil had a blue an wht. The wht being hookt
to the red and 240 came off the blk and blue and 120 from wht to blk or blue. the blk an blue
being the HOT legs with a bigger breaker and the bigger brkrs hookt to the 240 v socket and 2
20 amp or 15 amp brkrs to the 120 volt receps.
If you expect people to read what you've written, write properly.
We were given the power of intricate communication for a reason, let's not regress back to stone age grunts and screeches.
One would think it prudent to run a meter test on the new unit before going into the disassembly process.......
Your hook up is good but did you notice that the roter shaft bolt is wobbeling?
That is normal on these. The ID of the bearing is larger then the bolt. Recently have been building a should on the bolt with electrical tape to help center it.
Where did you get one of these power heads
Wow the usps is actual shite
You need a Royal Mail, the slightest Nick on the packaging and the refund you the whole parcel.
Do you have any idea about how much efficiency for such alternator? Is it 50% or close to 90%
Sorry do not know that information.
Wonder amazing more and more
Please give winding diagram and connection diagram
You could use a pice of tin for a heat shield and save 30 bucks good video
Yes, have done that also. This shield used to be a lot cheaper. Has doubled in price recently.
Hi James , this video is awesome.
Where site you use for a buy a replacement, I need a stator for a Briggs statton generator 8500 watts
Thanks for your help.
santos bobe what is the generator model number? I have priced out Briggs before and remember the price being very high.
James Condon i know but need it
James Condon the model is 030663
The main sites I use are PartsTree, Jack's Small Engine and Sears Parts Direct. I took a quick look online and it does not appear that the stator is available.
James Condon very thankful👍🏻
Can you tell us where we can find part numbers for generator stators and rotors? There is a generator for sale listed as not producing power and I want to see what a stator and rotor would cost for it.
What brand is the generator? Usually the model number is on the generator frame or the stator. Usually they start at $300 to $1000 if available.
@@jcondon1 It's a DuroMax DS12000EH. The seller is asking $400 but I think that is too much for a generator that doesn't produce electricity. If the generator head isn't too expensive I would follow the steps you've shown us multiple times in your videos to get it working and if that doesn't work then replace it if not too costly.
@@TheTechnoSpark duromax generators new are not very expensive. $400 is almost the working price. Would not pay more then $100. Also not sure if Duromax supplies parts like that. Possible a Ryobi or Generac power head would fit, but would need modification.
@@jcondon1 Thank you. I greatly appreciate your feedback.
Great video. Can you show me how to adjust the governer ?
On what type of engine?
@@jcondon1 on the generator you just fixed.
@@alfypierri8022 there is literally a screw right there to adjust the speed. If you cant see/find that you should step back from the generator before you fry yourself.
I have that same generator without the heat shield. Can I ask where you ordered it and what the part number was? Thanks
The part number is 638539002. I think I got it from Part Tree. If you google that number there are plenty of places that sell it.
James Condon Thank you very much James for that helpful information. I agree with your assessment that having it is better than nothing. I would preferably avoid repeating your experience despite having your excellent video as a guide!
You should put on a new bell head in case the old one is crack
My rotor isnt rubbing when i turn the motor over at all but when i start it the thing rubs and throws sparks . Still has voltage but only when it runs will it rub.. like its a magnetic force pulling it.. annoying.. i dunno how to fix that.. rotor goes in straight, torque to same thing.. but its just weird..
Hi, is there a way to use a generator head with other engine using a belt system?
I habe ben triyng but the rotor keeps touching the stator.
Srry for bad english
Not possible without some fabrication because the engine side of the rotor need the engine tapered shaft to center things.
Ok, thanks
Go to 29:01 on your videos time. Is that a crack in the housing just to the right and slightly below your finger?
Just a casting mark