Troubleshooting Generator With No Power Output - AVR and Brush Replacement - Flashing the Field

Part 1: Bought this generator used, advertised as good engine but no power output. Will go though common methods of troubleshooting to determine the cause of the failure and fix if possible.

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Generator Model# HU40500G
OEM Generator Head# 310227059
Alt Generator Head# 310227016

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#GeneratorRepair #SmallEngineRepair #SmallEngine #DIY #Fixed #Troubleshooting #HowTo

[tomporter]

as an electrician i am always asked to look at broken generators but i have always said no because i wasn't too sure what to look for. now with your great video i am a lot more confident now

[puckthisdiscsmith]

Typically I look for the shortest videos bc my patience doesn't allow me to listen to people that like to hear themselves talk, lol. For some reason, probably bc I was desperate I watched this entire video. Thank you for being straight to the point and explaining things so well! I got my generator running again😊

[dennisburns]

I really enjoy watching you troubleshoot and repair generators! My wife and I are getting ready to buy a backup generator - probably a Honda EU7000iS to ensure we have clean power. Most are saying that all non-inverter generators produce dirty power. Our gas stove, refrigerator, well control panel all have sensitive circuits and I'm afraid they'll be destroyed by a non-inverter model. Is this a huge risk and have you heard of lots of people damaging their appliances from using dirty power? I'm guessing, there are a few million "dirty power" generators out there waiting to back up homes with sensitive equipment. If it's really an issue, the generator manufacturers should have a warning label indicating what their generators should and should not power.

[jimwillson]

James thanks for these videos! I bought a China Generator (DS4000s) as a backup. It will likely sit for years before I use it. After I bought it understanding it will need some spare parts I selected brushes and an AVR. The spare AVR arrived with the mounting tabs broke off. I disassembled (took the potting out) the broken AVR and discovered a few things that people should understand. First, the circuit board and workmanship were kind of substandard. Second, the AVR maintains the adjustable voltage (via the pot on the AVR) by using a MOSFET. The part nobody’s talking about is the MOSFET gets hot (the nature of a MOSFET) but it's incased in the potting material. Really kind of a bad idea, it will fail if it gets too hot and it will. Compound the heat issue with the fact they run the MOSFET close to max, using full load it won't last forever. All said and done my generator is rated to run just under 30 AMPs continues load. I think running it at 80% (20AMPS or so) of rated load will keep the AVR and windings healthy. Just wanted to share the discovery, the AVR was really difficult to take apart! I do want this generator to work when I need it. So:
Drain the fuel bowl, I’m taking it off.
Drain the fuel tank
Check the oil before start-up (for fuel and level)
Pick some good spares
Know how the thing works!
Thanks!!!

[musterklammer]

Dear JamesCondon, after looking your Reapairguide, I was able to repair my "Briggs and Stratton 2100 Sprint" Generator. After looking to all parts and testing the resistance of the coils, I laid 12 Volt to the anker. I did clean up the brushes, because there was one of them not complete looking outside. After that, the Generator was making Energy like nothing has been wrong before. Many thanks, so I could rescue the machine from taking it to a junkyard. All the best to you and MANY THANKS

[shaneweatherall]

This is the most well explained video I've seen so far on the obscure cause of a generators death. That was a lot better then the readings are wrong so lets just declare it dead. Please do some more generator videos James. The video was really helpful.

[ShogunAutoworks]

You just gave a lot of guys familiar with small engines but not generators an amazing opportunity to fix and flip, or do repairs around the community to help prepare those who have generators stored up but not a lot of money to just buy new ones every single storm. Thanks man I have one here that's nice but same issue.

[CHRISINMCNEILL]

You done a great job of keeping it simple and step by step. No fluff intro to your video is a big plus in my book!

[thomassecurename]

James this is the best in-depth I’ve seen. Thorough on steps and test results. Correct test equipment. Great explanation. Thoughtful analysis. My opinion you clearly show details on a power head that fails. Too many other vids show what’s good/right of which there is no comparison. Thumbs up, Tom.

[halcobb]

In my youth I was a repair man at a local Black and Decker repair center. We used commutator seating/cleaning sticks to treat brushes that weren't making good contact. They're available commercially. Hold against the commutator / slip rings while armature is spinning and brushes are installed to make them seat and conduct well.

[michaelstreck]

This was the first video of yours that I watched. Then I watched pretty much every other video you've published over the course of a week. Just got my generator back in action this morning thanks to you! Thank you so much! Great educational channel!

[krkmofet]

Absolutely selfless contribution to human knowledge. Bravo

[johnnyortiz]

This video saved me $750 ! I went through all of what you did and ended up getting power ! All done by hand, too. Thank you so much for your content !!!

[thomasgibson]

Me too. He should be teaching small engine repair and generator repair at the local community college!!! I want to hang out with this guy fie a weekend to absorb his brilliance.

[ericvaughn]

Just watched this one AGAIN before going to assess a unit for sale with no power tomorrow morning. Thanks again for the level of detail and clarity that you provide in ALL of your videos James!

[tonyfremont]

I've got that same radio shack meter. It still works fine. Thanks for making these videos. I repair small engines on the side, but generators were something I had little clue about. I have a lot of DC electronics experience, but AC motors, alternators and generators were pretty foreign to me, until I discovered you and Jeremy Fielding (I think that's his name).

[richarddovala]

Jim been watching for a while I have been a auto/heavy duty truck mechanic for 43 years and I have learned so much from you, as far as I am concerned you are the BEST, Thanks just a real treasure watching and learning!

[budgillett]

I know nothing about these generators but this helped me learn a little. I’m excited to watch more! You have a great voice and are so great to listen to! Thank you, sir.

[josephgiustiniani]

This is great. I want to see when there is a hopeless case. When all the tests lead to the fact that it is now just a parts donor. Yes, I want to fix the generators that come into my shop, but at some point, you get one of these. Then it's a matter of telling the owner. He/she can now decide how to proceed. Thank you again for the great info you share.

[davidmelhuish]

In the UK there is a vast difference between your grid and ours. It is so good to see this from both sides very educational.This is good so I watch with great interest.