How to test your Electricity Generator's AVR, Brushes and Alternator on a Brushed Alternator
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- เผยแพร่เมื่อ 20 ต.ค. 2011
- When your electricity Generator stops producing power or fluctuates, you need to know how to test the Alternator to find what has failed. This video will show you how to do this. Send us your results, and we can tell you which part you need. Contact us via our website generatorguru.com/ask-the-guru/
**If your generator has a Brushless Alternator with a Capacitor, please ignore the Brushes step of the testing."
This test was invented by our Founder and is called "The Beagley Testing Technique." With this test you can find out what has failed in the alternator. By default you can discount faults in the alternator allowing you to determine if the AVR or Capacitor has failed. Normally you need an expensive tool to test AVRs and Capacitors at such a high voltage. With this testing technique you can do this with a standard multi-metre!
If you have any questions please email us through your local Generator Guru website.
We are always happy to help. We also sell 1,000,000 generator parts and pro tools on our website with quick shipping.
www.GeneratorGuru.com
The information contained in our videos and on our websites are designed as a guide only, for assisting Repair Professionals. This does not replace professional training. By using our information you are agreeing to our T&Cs: generatorguru.com/t-c/ - แนวปฏิบัติและการใช้ชีวิต
We thank you for your interest in our help videos. Unfortunately, due to limitations in TH-cams comment sections, we are unable to quickly
answer questions in the comments. Please feel free to contact us directly here: www.generatorguru.com/need-help/
PLEASE NOTE: You cannot test the AVR without a very expensive piece of kit called a Megga meter. This is why you need to do these tests to make sure there is no other problems in the Alternator. This will discount any other problems leaving the only possibility being the AVR.
you need to show,or tell,what happens when certain items blow. . my geni reved up. trying to find out why. the shop said,its chinese,buy another. there not interested. its remote start,key,pull,3.500 w. inverter. i have an old subaru,10 yrs,still going,but noisy as hell. 5kva. need a more portable geni. so bought the inverter.small suitcase size.
I have never commented on any of the hundreds (if not thousands) of TH-cam videos I've watched, but I am beyond grateful for this. I promised a client of mine that I would fix his generator, which I've never done before. More than 5 hours and many YT videos later, I still hadn't figured out the issue. The brushes were shot, everything else had continuity. Replaced the brushes, but still no power. You are the ONLY person I found that pointed out that the positive wire always goes on the left side of the brushes. I just hooked them up how they were before (another shop tried to repair). All of a sudden, IT WORKED!!! So, thank you so much for your help. Very grateful for you.
💯
I am so glad we could help! If you need any other info we have an interactive help centre which can help you fix most generator issues: generatorguru.com/need-help/>Engineering
this is actually helpful. every other video I've been finding requires jumper cables to test the AVR. didn't think about testing the generator itself.
Thank you a thousand times!! You were very instructive in every phase of showing how to properly troubleshoot a generator. You even took the time to show the proper settings on the multimeter for anyone who needed help. Your a blessing. GOD bless you.
Thank you so much! This video saved me weeks of ordering parts, dropping them in and finding out they didn’t fix it. You are the best!
Thank you so much for your Comment! I have patted my team on the back and passed your thoughtful thanks onto them. We really appreciate you letting us know.
Would you be able to leave a review for us on trustpilot? We have recently signed up with them and would like to spread the word and help save more Generators. If you could be so kind, please leave a review via this page uk.trustpilot.com/review/generatorguru.com
Thanks again for your feedback!!
Straight to the point and a very good guide for generator troubleshooting. You have earned a sub!
Thanks brother.. Very well explained.. Great effort.. You saved my generator from selling lol
Subscribed your channel 👍
Thank You! Finally a video on fixing a generator with brushes that makes sense. I am finally now able to narrow down what the actual problem is. It is the AVR. Thank you again for the awesome video.
Generator Guru back in the early 70s, I was taught by my grandfather, how to rebuild generators, alternators and starters, with the simplest tools available, close to 50 years I've only had to replace one generator to an alternator, switching over a 1960 Ford F-100 Excellent video, really enjoyed it.
Hi Dale
Thank you for the comment, I would love to hear more about it, a lot of people get stuck with the lesser known or unbranded generators as many rewind companies do not want to touch them so charge high prices for repairs to push people away and many people find themselves with a unit that is no use to anyone but not worth the repair costs
This has been the best instructional video I have found on you tube. Thank you for taking the time to demonstrate the testing. Now I have a question not really covered. I have 4.7 v to both the R1R2 and L1 L2 and 0v on R1L1 but I only am getting 1.7v across the brushes. The surface that the brushes are riding on are smooth. I thought these were grooved. I am looking forward to your expertise on this.
Gary
Thanks for the feedback! R1 and L1 should be 0 vac if you have a voltage changeover switch and set it to the lowest setting. These results indicate you need a new AVR. The AVR should bring up the rotor to 5vac also if you run it for 20 mins without load to stabilize the magnetic field. Your brushes will be smooth where they connect to the rotor, but be sure they have enough play in them to make a good connection. If you are still having any trouble please let us know and we will be happy to advise you further. :)
Sorry I should have added that I have already replaced the AVR. This unit has only been used a short time. brushes are not even worn in yet.So are you saying I should run it 20 minutes with the new AVR? one last question. This John Deere 6200 watt runs wide open all the time. Is that normal?
Generator Guru sir i changed the Generator AVR but the voltage is still not stable ..when i start some things on it becomes decreasing voltage from 220 to 195..
i think the AVR frequency is not set... how i set that frequency
The diodes on your rotor have blown. Check to see if they are accessible (usually on the end of the rotor or the fan end) if so replace them. If they are "in" the rotor you can take the rotor and windings to your local "motor rewind" company and they can rebuild it for you. But worth calling g a few companies as price varies greatly!
Thanks to you and this tutorial my generator works again. Greetings from Holland.
That was a very well explained and informative video. It removes some of the mystery about what's inside the alternator, and teaches the ordinary lamer some basic troubleshooting tips. Thank you.
nice one
Hi from Romania,
very informative your video.
Thanks
Hey man. Thank you. You made my day. I didn't loose magnetism, just had to change the avr (because i mistakenly connect the public power source to my generator. Turned the thing into a motor in a flash ruining my avr in the process. . That's a awesome guy you got there. (the black cutie) Thanks a lot
We DO want the test in volts (AC. v~). I keep getting emails saying otherwise, but we are doing a different test.
Hi, Generator is outputting around 3.5- 4V on the brushes and 4 - 5 V on the L1, L2, R1, R2 and when I tested the L1 - R1 I was also getting 4 V but im only getting 8V on the 230V output on the generator. what could this error be?
Excellent video. I learned so much and learned how to diagnose my generator properly... Thanks generatorguru!!
Excellent video and obviously you know what your doing and gave great advise. Thanks for sharing.
Thank you! Very informative.
Great video Generator Guru! You got a new subscriber! Thank you!
A great video, easy to follow. Please keep them coming
Very explicit and concise. You're the best.bless you
I find it interesting that people who really understand what they are doing make great simple instructors. No complicated garble that the watcher doesn’t understand anyway.
Thanks! *blush
Outstanding video, very helpful Thank you.
hi from argentina, your video was very helpful to me, you explain very well all the trobleshooting, thumb up for you, thanks
Woow im going to check my Generator !! Thanks for the video!
Thank you,
With your help I located the brushes on the Hyundai 7000 and cleaned them so it works again.
Genpower were useless and argued over warranty times so much for the platinum warranty!
Kind regards
Andy
Thank you for your feedback! We pride ourselves on "Good old-fashioned customer care!"We strive every day to save generators and other machinery from being scrapped due to parts not being available. It helps every-ones pockets and prevents tons of CO2 being added to our ecosystem!
this is the first video i have seen on generators having a problem with mine and youre the best so far fully understand everything
Thank you for the feedback!
I agree that this is the best instructional video. Might want to do it for companies and get paid for it.
Fantastic video, cheers mate!
Followed your tests and ended up replacing AVR .Bingo, fixed it.$17 .Thanks
Nice work!
Thank you for the guide! Very helpful
So nice video..thanks teacher..i continue following you from República Dominicana..
Great vid very informative thanks:)
Great video.. now I’m headed out to the shop to use what I just learned on a generator. Thank You
Glad we could help
Excellent video ,very profecional !!!!
thanks mate, wish you nothing but the best, your a champ.
hi, my brother very good i like this video, congratulations from Venezuela !!!!!!!!!
Thanks Generator Guru!
Very good demo. Nice, clear explanation. I thought I might mention though - that the rotor is not "otherwise known as the stator". The part you call "the windings" are the stationary part of the generator - the stator. The rotating part of a generator or a motor is the rotor - whether it has windings, permanent magnets or a squirrel cage structure.
Hi Ralph
Thanks for getting in touch! A few people have pointed it out over the years, a bit of a slip of the tongue we didn't spot until after we had posted the video, it used to have a little tag at that point in the video apologising but youtube seems to have dropped the captions off and won't let us replace them as its convinced they are still there!
Good info, thank you..
Top vid , cheers mate . Very informative.
Glad you enjoyed it
Usted tiene un excelente canal, muchas gracias por compartir,
Saludos desde Veracruz México.
Gracias por sus amables comentarios.
Thank you for your kind feedback.
Very good explanation of the fault, will serve me much thanks
Always happy to help!
Fantastic explanation,
Was your voltage changeover switch on the lowest setting? If so you windings need replacing. L1 & R1 should = 0v ac
What's that you say? Ahhh! Now I can hear you. I have to remember not to test my AVR on a windy day I guess...THANK YOU!! very content rich. Love that.
Stephen,
Thanks for getting in touch.
Yes, we find on some computers the sound works perfectly, and on others it is impossible to hear. If you have any questions please contact us www.generatorguru.com/need-help/.
We have in planning stage, a new version of this video and a poster for step by step instructions.
Thanks for your feedback! Hope it was helpful even with the sound quality. :)
Thanks, Good video.
really good video
Thank you for the video
The was a great job bud
Saludos, excelente tus explicaciones,muy buen video.atentamente José María García Yamin
Caracas, Venezuela.
Thank you your feedback is greatly appreciated
Gracias, sus comentarios son muy apreciados
Thank you very much for you concern. Appreciated....
Cheers bruv.. Nice one
Thanks for sharing!
Our pleasure!
thanks for video
Thanks from Dennis at Northern Tool and Equipment Pompano Beach Fla. Hi Jenny.!!
Excellent video. I would have appreciated better close-up shots but I think it was good enough to give me the general idea.
Hey thanks for the info We will try to rectify this in future. :)
(PS. sorry about the delay in answering, for some reason TH-cam sent this question to the "junk" folder. We apologise for the inconvenience.)
nice video. The only technicality I see is your explanation of a rotor and stator, two distinctly different parts. Keep up the great work! This was a very informative video!
Yeah I got nervous during filming. I did add a note over it on youtube, just after I uploaded the video, to say I got them mixed up but over the years it seems to have disappeared with all the updates that TH-cam have done. Thanks for pointing it out. I will try to get that reinstated. :)
Helpful video. Thanks for sharing.
Glad it was helpful!
Very usefull video, thanks a lot for your teachings.
You are welcome
That is the rectifier. You can find the replacement on our website.
Sure drop us an email on the site, there is a link there for sending an email.
Hope I'll never need it but nicely done and helpful video...
Excelente explicación, sencillo y concreto
Thanks! If you need any further help or parts, please visit us at www.generatorguru.com. :)
Can you please clarify what the n v v u represent. Also which generator (make and model) do you have?
Your rectifier is reading a bit high. I would suggest replacing it.
I learned a lot, thanks.
Glad it was helpful! We are always happy to help. :)
Great video
Glad you enjoyed it
I had a loose terminal on a new duromax 8500 which fried the avr.. They sent a new one but it was only putting out 109 volts on both sides . The avr had an small adjusting screw and I turned it and adjusted it to 120 . Works perfect now.. Thanks for the video
Ummmm.... you should not be adjusting that screw! They are set at the factory and now you have just changed the hertz output!!! That is not good!!!!!
IF IT HAD CORRECT VOLTAGE BEFORE THE AVR BLEW - Run the test in this video and follow relevant steps below.
IF GENERATOR IS COMPLETELY BRAND NEW:
Best to set it back to 109 then adjust the speed by the top screw on the carb. Use voltmeter to set to the correct voltage.
Before you do that. be sure good fuel flow is coming from the tank as the Petcock has a filter behind it which might be blocked.
IF GENERATOR HAS RUN FOR MORE THAN 1 HOUR:
If you were getting low power and it is NOT totally brand new, but has some running time on it, this is what you need to check:
1) it needs servicing. (1st service best done at 50 hours as loads of metal shaving are produced as it settles in) - see th-cam.com/video/ioAgCqPhUfg/w-d-xo.html
2) The engine has settled in and valves need resetting. This needs doing after about 1st 50 hours - see valve setting on our website and follow this video: th-cam.com/video/mYrdnPVmaDs/w-d-xo.html
If you need more help please contact us on generatorguru.com/need-help/ and we can assign you an engineer. :)
The generator is running at 60 to 61 hertz. This was tested with an Ideal sure tester
Thank you for your excellent and most helpful video. I tested my Firman 4550/3650 and the results were not what I was hoping for. Across the brushes 13.28 L1/2 .38 R1/2 .34 and I didn’t bother measuring L1/R1. Please confirm my worst nightmare about this generator. Thank you again for sharing your time and knowledge.
Sorry! The rotor diode has blown. If you can see it on the end of the rotor you can remove and replace, or take it to a motor rewind shop and ask if they can change it for you. :)
@@Generatorguru thank you. Have a merry Christmas.
Muy buen video.
thanks for you help realy nice of you
Thanks for the video, this is one of the better, more informative videos on this subject! The service manual for my EB6500SX is about $150, USED, so, you might have saved me that money!
Glad it helped
thanks for your video helped me alot.I repllace avr on my generator brushes are find but .dont have power .
Then how did the video help you at all then I dont understand really
Hi Amber, Are you getting any reading across R1 and L1?
Probably 1 of the most helpful and easy to understand videos I've seen. Especially as I'm trying to diagnose my genny which has stopped producing power. I've tried the drill technique and I've tried the flash with a battery after disconnecting the avr. Neither have worked. Tho the genny did produce power for the few seconds I flashed it with the battery. So now I'm wondering if the avr is fried as we noticed water in the extension lead that was plugged into it. So I'm thinking that has sorted out the avr to protect the alternator like you just mentioned it should!
For fault finding or technical advice, feel free to contact us using the link below
www.generatorguru.com/need-help/
This will allow our engineers to review your query and give you the best possible advice!
Que bien por la traduccion al español seguire en contacto
Thanks for the informative video. I am an experienced motorcycle mechanic, but wasn't sure what to look for in testing why my xp4400e generator was only producing 40 volts at the outlets. The tests you prescribed here showed all within normal operating parameters, is it your opinion that my AVR has quit?
Thanks again!
Generator guru gave me more help with my hyundai generator that the importers of the generator.
So happy we could help! Thanks for the feedback!
@@Generatorguru How are you with hyundai diesel engine parts?
Great video! I am working on a generac gp5500 with no output. I get 1.7 volts from the recepticales. Following your video I tested the brushes (0 volts) L1 1.7 volts, L2 1.7 volts and L1-R1 1.7 volts. Pretty much every where I am getting 1.7 volts. With only my positive lead on the brushes I am getting 15 volts but as soon as I connect the neg lead my meter (fluke 88) drops to 0Volts. Any ideas? I tried to use the drill technique with no luck - All my readings do not match any of your suggested readings. Sounding to me like my alternator is not creating any power what so ever?
David
If you have a capacitor then you need to have a look at my video for Brushless Generator Testing.
You cannot fit an AVR unit to a brushless alternator without replacing the whole alternator and wiring system. It would be cheaper to buy an new generator, and a lot less hassle!
Hope this helps!
Does it have 2 poles on the windings (i.e. L1 and L2 And R1 and R2). If so then one of your windings sound like they have broken. Test the continuity on each set to see if one has snapped.
Well you need to run this video to get the results for the readings.
In respect to the engine not starting, sounds like it needs a service. Change the oil and fuel (over 6 months it will be stale) and clean off the spark plug. Chances are that will fix your starting and may even fix the electricity problem if the thickened oil id keeping the engine revs low.
Hope this helps.
Good footage and really helpful. I have just tested my generator that wont give power. Across the brushes 4.8 volts. L1 and L2 11.3 volts. R1 and R2 2.2 volts. R1 and L1 7.8 volts. Just need to work out now what that actually does mean 😀
You alternator has blown. Sorry! You need to either replace it or take it to a motor rewind company to see if they can fix it for you. :(
Yes we want the test reading in Volts AC (V~) please
Muchas gracias.
Happy to help!
Verry good !!!! thanks s lot , mam
Always happy to help! FYI... We also have loads more info on repairs and maintenance on your website if you ever need it. :) www.generatorguru.com/need-help/
Thank You for the video.
It could be that the floater in the carb is stuck. I suggest a good clean, and inspection of the whole carb. If there is old or dirty fuel it will allow to much fuel through to the engine.
The only other thing it will be is a governor problem, but this is very rare.
thank u generator guru
Cooper pipe freeze spray works too. But make sure you wear gloves, especially when spraying down the bolthole. Don't want to freeze your fingers. :)
Very helpfull. I have a DG6, it looks like I have to remove the muffler first to access the end of the Alternator.
Thanks for your help.
David from NZ
If you have the super-silent version, You might be able to find the Capacitor (or AVR in some models) from the back panel held on by the 10mm bolts (some models only). If not you will have to remove the exhaust... sorry.
+Rick Saffery
You cannot test the AVR without a very expensive piece of kit called a Megga meter. This is why you need to do these tests to make sure there is no other problems in the Alternator. This will discount any other problems leaving the only possibility being the AVR.
Generator Guru my UST 2300 reads 145-190 vac and HZ reads 75-79 time to scrap it?
John,
These are the results without the AVR attached during testing? If not please test without it attached, if so, then follow the next step.
If the hertz are that high then we would be questioning the speed of the engine. First, check the Governor Rod and all springs are in good order (especially the one over the rod to the top of the carb as a little play in the spring will greatly affect this.) Also, service the engine to be sure that nothing has gunked up the governor which sits inside the engine as this adjusts the speed.
In North America, you want 60hz (50hz for European or Auz regions) so you need to slow down the engine if neither of the above is the case. On your generator, you can do this with the screw at the top of the carb. Turn slowly anticlockwise until you get the desired Hz. If this does not work you will need to replace the governor inside the engine.
If you need parts we hold them for your generator. You can buy online on www.generatorguru.com/
What were the readings as set out in the video?
Hi. Great video. Very informative. Im trying to repair a generator very similar to the 1 in the video. i think it is probably the avr but when i test the voltages with the avr disconnected i get 1-2 volts between L1 and R1. is that anything to be concerned about or not. all other voltages are 3-4 volts
Thanks you ,Gracias.
Cheers :)
What test results were you getting?
Thank you!
You're welcome!