Generator Low Voltage - Fixed
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- čas přidán 28. 10. 2020
- A subscriber dropped off his generator which was in storage for 5+ years. He fixed the fuel problems only to find out that the generator was only generating 35 volts! After a little work, was able to fix the issue and it makes 120 volts again.
Generator Model# 030471-01
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#GeneratorRepair #SmallEngineRepair #SmallEngine #DIY #Fixed #Troubleshooting #HowTo
There are those who swap parts until it works. Mr Condon is a forensic pathologist when it comes to repairing generators and engines. Not only does he identify what failed, but why it failed and he explains it well. The "why it failed" keeps generators coming back for a repair of the same problem. I hope I don't have to but if my generator fails, I might just be able to repair it now.
Very informative video. Thanks for covering all of the bases without making it boring as hell and really appreciate you not playing some horrible "music" which seems to be the newest trend.
I have that very generator. I ran it pretty regularly for 1/2 hour a week as recommended for more than two years and just out of warranty, @90h it developed a stuck intake valve and bent a pushrod. No kidding, it was maybe the second time I ever pulled the cord to start it -- normally used the starter. I took the head off today, broke the plastic lever the remote choke cable attaches to DOH! I freed up the stuck valve, cleaned up the head -- there is evidence of rust in the intake tract and blow by on the bottom of the head -- two head bolts were very snug, two others were less so. TONS of carbon and sticky stuff around the exhaust valve. Tommorrow is reassembly day. Wish me luck! Excellent video -- helped this guy! Oh yeah, my engine does not look exactly like this, the markings on the valve cover are different, and it is a different shape.
Edit - it is running in the yard, it now has 91h on it! Only one part left over. :( groan.
This video is very comprehensive
from diagnostic to testing to treatment and rationale behind the approach. James you are an amazing man and very natural teacher. Thanks for putting this video really informative. Anothet amazing video from James MD ( Machine Doctor)
We have used the czcams.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!
Great detailed troubleshooting and explanations as always, James! Good catch on the wear mark on the governor arm too. Always more challenging to follow the repair efforts of others in my opinion. You should have an extra happy subscriber who gets that generator back running right, tuned right AND making power as it should!
Thanks Eric!
Adjusting the potentiometer on the AVR was the takeaway on this vid for me. So simple. So obvious. And I never considered it.
Question about that arm setting and adjustment ‘room’ on the throttle adjustment: what if you moved it to the fourth hole? Wouldn’t it give you more threads on that bolt?
Would it make sense to put a drop of a thread locker on that throttle bolt to keep it from moving in or out?
Thanks for your videos. Familiarization of all the different engines is really eye opening. And comforting.
Excellent video! It's always a treat to see a true mechanic at work. Full knowledge of the machine and testing/ investigating instead of guessing/part changing. After several months on loan I got my Powermate generator with Honda motor back. Upon starting and checking it over I found it was only supplying 103v. After watching this video I dove right in and after checking resistance at all the locations mentioned, inspection of brushes and cleaning the slip rings, it moved to 106v. Upon inspecting the AVR made by GTDK I found an adjustment screw on the front. After two adjustments to complete 3 full turns, it now supplies 119.8v. This style AVR doesn't require removal of the AVR to adjust it.
Thanks, I learned a lot...
very helpful video! I learned a lot. Turns out my issue was just dirty slip rings, diagnosed them, cleaned them, and now she's back in action without spending a penny all thanks to this video.
You will definitely have a happy customer when they get that back my friend.
Jim, thanks for your content. I also appreciate your observation on dirty slip rings causing the AVR to work harder and possibly fail. Great maintenance tip. Jim
I wish this James was my neighbor...there would be nothing we couldn't fix...I am a beekeeper, naturalist, gardener, carpenter, plumber, electrician, and all around if it needs fixed I normally figure it out
I was just thinking that. Need a brainy neighbour
Wow!! Now I think about it, I have several small engines, n watching these videos helps me understand the relationship between r.p.m, frequency and voltage, thanks, informative vids, keep em coming. 👨🔧🤷♂️🙈🤦♂️
Awesome video. Never been into a gas generator and am gonna tackle mine with this video in hand.
Enjoying the videos, I'm about to get started on third generator. My second one I did I found the carb jet under the needle for the float. Keep the videos coming
EXCELLENT repair and very educational. Thanks much and it is always good to win.
Outstanding job explaining and showing. This single video answered all my questions regarding the problems I’m having with my generator.
This video is gold! So much info here, and I have the same generator so now I know exactly where everything is adjusted.
James.....great job on this generator. I just finished watching (for the second time) the Yamaha ef6000 fix. What a great genny that is. The more I watch the more I learn. Take care.
Thanks! That is a good generator.
When I clean slip rings, I pull the plugs so the engine is not compressing, and use a variable speed drill to spin the shaft while I hold the scotch brite on the rings. A little bit of Nu-Trol contact cleaner also helps.
Great fix James , ENJOYED !
Doc, ye did it again. Very good diagnostic lesson for me.
James you do such a great job. I always enjoy your videos. I have learned a great deal from you. Thank you
Glad to hear it
What a great video with excellent results. Good advice too. Thank you
Thanks so much James, I had absolutely no idea the AVR was adjustable, I'm currently working on one with low voltage even after cleaning the slip rings, adjusting the AVR may likely solve the low voltage issue. Again, another great video, thanks for all the help!!!
Hi James, I very much enjoy your videos, and the valuable instruction provided by your methodical approach to troubleshooting Generator Issues.
I have used the information contained to make several repairs, and perform maintenance for my friends, and client's generators. Thank you for sharing your vast experience with us here on YT.
Great video. You don't watch it you don't learn.
Who needs a Haynes workshop manual when we have James Condon video's. Saying that do you guy's have Haynes workshop manuals in the states? I live about 4 miles from where Haynes manuals are printed here in the UK. Maybe one day we could have a James Condon video on what tools you have and maybe your workshop. Would love to see you invest in a scissor lift table James or your back will remind you as you get older. Great video.
I have that same engine and head setup on my Troy-Bilt. Engine is noisy as hell but seems to have plenty of power. I converted to Propane which makes storage so much nicer for me. Thanks for the video!
what kit did you use?
@@martinoelec4552 Motor Snorkel from US Carburetion. motorsnorkel dot com.
love the video.. stumbled upon this for adjustment of governor and frequency. Happen to have the exact same generator.. Use it for music festivals and dance events running a very large PA system and nightclub lighting etc on stages for several hundred people.. Added a 50 amp SPA breaker panel on the side, new #6 wiring to the inside and a Range plug on it. Over 12 years of use and almost 1200 hours on it.. This generator is pretty much bullet proof! Still runs like a champ with minimal work (mainly just minor engine work) think its time to check the brushes and clean the slip rings.. Thanks!
Very good vid. Your the kind of Tech I would like to have working on my truck!
Thank you James .....Great troubleshooting !
Nice job of explaining everything you had to do on this generator. I used to work in a factory with a lot of DC motors and one thing we did to clean up commutators was to put fine emery cloth under the brushes and turn the motor over. I'm not sure if there is room to do it on these small generator slip rings, but you might want to try it sometime if you haven't already.
That would probably work better. The space is tight, buy will give it a try next time.
Another great video James! It’s something Briggs makes a Honda clone. But that’s the way it goes!
.p
I’ve learned a lot about repairing small engines from Mustie1 but I am now learning A LOT from you on the power head of gensets. I am quite proficient at electrics and electronics in general but have always shied away from the power end of gensets. After watching your trouble shooting process over and over I am getting much more comfortable as I do with small engines going through “the Mustie1” process. Really great stuff from you. When I can say out loud what I think you will try next then I am getting there!! Thanks for great videos of real time trouble shooting.
Was always strong on the power head side. The engine side, I owe Mustie1 and Taryl.
Super super video. You are so helpful to so many of us. You have very good grammar and diction; thus your dialogue helps with the video so much. Thank you again.
James good show, I got a generator that runs but no power, haven’t got to looking at it yet. After watching a lot of your videos I am ready to jump in, thanks.
I'll never get tired of these. Such a chill format and nice seeing these get fixed rather than scrapped. That engine had Briggs stamping on it. Did Briggs at one point source Honda clones or is the whole thing a mis-matched clone of a Briggs generator?
i have a duel fuel champion. checked oil because i watch your chan. thanks runs great. Never had to use it in emergency but start it every 3 or 4 months. putting it under load. tx.
Thankyou. I learned so much. How to adjust voltage and frequency on the generator. Location of wiring etc. Excellent. Thank you
It is like a hunt.. Someone was in here before me. great line !!!!!! Nice work. You nailed it.
Thanks Bruce!
I have been binge watching your channel and every time you start the video with "Hey guys, welcome back" you kind of sound like a villain greeting his victim for a second time lol!
Excellent process!
One heck of an educational video!!! I certainly learned a lot. Thank you James... :-)
Nice job on getting all the setting correct.
On the cleanup, you use water and a green pad. Water may induce future rusting. I suggest WD and fine steel wool as an alternate.
This has worked well for me on chrome and shiny parts and precludes the intrusion of water induced rust.
Just a suggestion on what has worked for me in the past.
Thanks for sharing.
Thanks. I normally use WD40, but in this case was not sure if it was a good idea given the temperature the exhaust runs at.
Good stuff man. Really glad i found your channel. You do a great job explaining what and why you are doing things which is super helpful.
Thanks
Happy to announce that this got my generator running again! All that’s left (after getting a kill-a-watt) is adjust the RPMs and maybe a good carburetor cleaning.
Excellent video. I really appreciate you sharing your work. Inspires me to do some additional checks on my generator to ensure it continues to run well and be reliable.
The important thing is to run the carb dry and change the gas out at least once a year if not twice.
Excellent video! Learned a lot. Thanks
One of the other generator mechanics, I can't remember who used a pencil eracer to clean the slip rings, the idea being it wouldn't remove any material from the ring or risk damaging the windings, as always great job
That would work (I think)
Make the cover for the exhaust out of stainless steel to make it look new good resell feature !
My Briggs & Stratton ignition just clicks when I turn the key and it isn't the battery.. I'll keep on watching your videos just in case you make a video about this issue.. Your A to Z approach on explaining got me hooked.. Thank you..
Nice fix, thanks for the video.
another great video! thanks James!
Glad you enjoyed it
Another really great video....Great to learn from the 'master'!
Awesome video. I now have a clue on what to check on my generator.
I’m a Castrol Edge fan too 👍
Gracias por este espectacular demostración de el trabajo de un generador fue como volver al curso técnico pero con teoría y practica juntos. me aclaro muchas dudas Eres un campeón)
Gracias
I like your diagnostic process, 😃😃😃 Thanks
Thanks for this video. I learned a ton about generators
great work..learning a lot..keep it going...
All of these portable generators need inline fuel filters installed bout $5:00 and a bit of fuel line to hook up. The pilot jets holes are very small and it takes one fuel station to ruin your evening. Have the same gen and if worked awesome till one fill of fuel. Had to clean carb twice,.and put filter on. fine brass grindings from pump vanes in bowl. Cheers good work James!
Well because they basically only run full speed the jet hole isn't that small it's pretty big , at least compared to a more elaborate engine with idle Jets to plug up. And you typically remove it directly from the bottom of the carburetor bowl so it's real easy too access and clean. A fuel filter is not a bad idea but it is mass that will shake around on a flimsy plastic fuel line. Bigger problem for carburetor pluggage comes from fuel turning to varnish.
If you're not going to run your generator often stabilize your fuel, running the bowl dry then draining it before storage is a good idea
Haha I got the pun. Generator just a little shocking. Great testing. If I watch another 7 or 8 thousand maybe I will understand how to test these things. Governor spring was an excellent discovery as well. Thanks for the video. One more happy customer.
Thanks for watching!
James, I own one of these as our main backup generator, and cannot tell you how much I just learned from watching this! I have tried to watch as many of your videos as possible and will continue, but this one hit real close to home!
I'm assuming that AVR = Automatic Voltage Regulator? When I first got this unit, I was reluctant to use it to power up our new furnace with all of its electronics during power failures because I was unsure of how clean the power actually was. I read that only inverter generators (which this is not) would be acceptable. I used a scope meter on it while running a hair dryer to see what it looked like and was surprised to see a decent sine wave output! Eventually, I had to pucker up my butt and try it! LOL No issues!
I did experience a failure of the fuel solenoid back when it was still under warranty and they replaced the whole carburetor. I have since only had to replace the battery. I try to exercise it every month or two. I noticed that you check the oil level without screwing in the dipstick? Checked the manual and they agree! Great video!
A lot of great information in this video. I found this video because I am looking to buy a used generator and wanted to know what trouble spots to check out and how to test it before I buy it and/or fix it if I do. Wow! You didn't disappoint!
If you want a trouble free generator, then Honda is the way to go. With a little care, it will last. Most others are similar. As long as it has an oil sensor and an AVR then it is a good generator. The other thing to consider is parts support. Most Chinese engines are not branded and difficult to find parts for. Vendors like Ryobi, Briggs and Generac use Chinese engines and they also sell the engine parts. A lot of others do not. Also like any generator that has a name brand engine on it like Honda, Yamaha, Subaru and Briggs.
@@jcondon1 Thanks. Ended up with a Honda. Oil sensor- check! AVR- nope. it's a Cyclo-Converter model. Found a great deal.
@@marceld6061 even better. An inverter is better then an AVR.
hi james i enjoyed being in your class today ,another great video mate
Thanks Dean!
Another excellent video, Thanks for sharing.
Thanks!
Great video, you take the time to get the action in the shots :) with all the gennys that you repair I’m surprised you haven’t built a Load bank :)
Thought about it. Just easier to carry around the little heaters.
I learned a lot today in class 😎
Thanks
Excellent video! Your skills, style and the information you present are all incredible. I learned so much from just this one video...Thank you! By the way, your voice is very easy on the ears - sounds exactly like the narration in Zeitgeist; was that you?
Nice job as always
That was some very useful information thanks 👍👍
I'm going to have to get me one of those devices that reads the voltage and frequency like you use.
@marthale7 can you buy one of those kilowatt meters at a electrical supply house?
Excellent vids 👍🏽 I have one of these it performs well, I'm not a fan of the hose out of the gas cap, prevents me from just placing a piece of plywood on top of it to shelter it during a storm. I will have to build a simple shed for it instead.
Also they tend to kink cutting off the vent.
Glad you are doing these videos, I'm pretty good on engines and carbs, but the electronics not so much. My son has a friend who wants me to work on a couple of generators, because I fixed a couple for him before that only had carb and wrong spark plug issues. Now I might take a look at the others. I'm pretty crippled up with arthritis and worn out knees so I take it slow and steady now days. Good therapy to fix things if I can.
Definitely take it slow. Not only for your body, but at times it is good to step away when things are not going as planned. Definitely good therapy.
Picked up a champion 7500 today and it only makes 75-85 volts. It's enough to make my angle grinder turn at half power. It has a handy built in hz and voltage meter all in one with the hour meter
Hi James, I'm a new subscriber to your channel. Its obvious much of the work that you do on these generators is from neglect. Would you be willing to make a video showing us all how to properly maintain generators and how to store them for long term? Thanks so much.
See what I mean how delicate the parts on the gen are so delicate just touching the wires off the brushes could destroy the gen Or the carburetor parts ! Make them more heavy duty ! So they can stand the vibration and wear en tair.
Very good video, I really like your content overall. I have a fascination for generators, I find them interesting and I like fixing them. Looking forward to the next vid!
Thank you very much!
Alas I'm not as odd as my wife says I am. Generator collector is a thing!
@@worthcounty4317 Absolutely! I have 3 myself ;)
I am a fan of compressed air, my air compressor is my go to, for cleaning and dusting.
Be extremely careful with compressed air. Dust in a generator does not usually kill it but if you blow the wingdings and not clean all the chunks completely it's a recipe for disaster. Just from experience.
Great video!
Great video. Thank you.
49 ohms not bad for the old brushes makes sense why the brushes were bouncing all over the place because the avr was so low on voltage it was over working
Don't say juice. But I think you are correct that the AVR would probably be putting out higher voltage to overcome the higher resistance of dirty slip rings. It could be that running the AVR at (max?) output for a long time could burn it out. BTW I love your videos. I must have watched 30 of them. I need to do a bit of maintenance on my own generators, and I feel a whole lot more confident doing that now thanks to your vidoes!
Following now! Will try this with my generator that seems to not power lights....it has been kept outside with a cover and not much use to it
Thanks for the video,
I LIKE YOUR HONESTY
Always interesting James i have learnt a lot on generators thank you
You are impressive
You explain your action well, and when you are wrong you admit it
That was a really good video! Thank you!
Nice Vid's James,
thanks
Thanks for this awsome Video. This is great info
Great Work...Please define "Stator" & Field for perfection...Clarification.
When you’re in a ‘state’ of confusion , always check your ‘ governor’ . ha ha he he ,,,,,,,,,helps me remember this stuff.
Hey James, great videos, with excellent trouble shooting! Looking through your videos for something similar on a portable genny with a servo throttle governor and similar issues, hunting and low voltage with no success? Keep up the good work!
Is it an inverter generator? The only ones have have worked on with servo governor control are inverter generators. 3 of the 4 where carburetor related. czcams.com/play/PLoj6DvbhMTzsUU5RHD652cjiohLrnQ-US.html
@@jcondon1 No it's not an inverter, older big portable generac. 17,500 running and 22,500 surge watts. It has a servo motor to control the throttle. I had the carburetor all apart, looked very good but did a clean up and blew everything out while I was in there. Pretty obvious that someone has had it apart, lots of weird stuff, including the start/stop switch installed upside down? I have it apart to check the valve clearance and then going to see if I can sort it out. Other than the surging it seems to start and run well but voltage is a bit low, 112, 113 on both sides. Thanks for getting back to me,!
WD -40 works good to remove the rust. good upload thanks
Interesting choice of words at the end there “just a little shocking”
As soon as I saw an electrolytic cap on the AVR - that would be the 1st thing I would change in an older unit. Cheap as chips to replace.
Hello James. Just a quick note to say hi and thanks for all your great videos and very helpful and informative advice on generators small and big, old engines and all the other items that you fix. Please keep the great videos coming and thanks again. Jonny
Ps, I have a few issues with B& S vanguard v twin engines and single engines on pro max generators. Anyway too shrink wrap the internals in the main box without dismantling it! We suffer from wires chaffing and coming lose!!
Thanks again 👍👍
To do that without dismantling could use some like these two products
www.cabletiesandmore.com/spiral-wrap-standard?pid=329&gclid=CjwKCAjw0On8BRAgEiwAincsHM8pYRNT9k7qRW7jV5uxjIdg8HW8Vm52UIcciDmFGWSDWTh8XajyKBoCyzoQAvD_BwE
www.cabletiesandmore.com/black-wire-loom-tubing?pid=232&gclid=CjwKCAjw0On8BRAgEiwAincsHOdC44FHpUhhuadYVJ6pA9N-Ibt3AJA7EEbqJ2zFGu_yBUtGsb69dRoC0FUQAvD_BwE
Awesome, thanks. Maybe that engine is a Mitsubishi? Just an idea? I really appreciate your help and assistance and please keep your awesome videos coming up. Take care bud and thanks 😀
Thanks for your assistance James
Dr. James Condon....at your service!! Not feeling well, little generator? I fix you up!!
lol
Just found this from a search. Thank you, this was very helpful. My generator is different, but this helps me know where to look. No idea what your other vids cover, but I'll subscribe because of the great job on this video. Thanks again!
You should look up a CR950. It is basically a predator 212 with a few minor changes
Awesome video