Generator Low Voltage - Fixed

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

[danburch]

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.

[reypanelo]

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)

[Wingnut_Stickman]

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.

[ericvaughn]

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!

[sergiopinto]

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...

[davidreynolds]

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.

[jamarney]

Your videos are the most informative and very easy to learn from . You are a top notch tech and wonderful teacher

[ChrisfromKeyfarm]

My generator was only making 30 volts . I watched this video got on eBay ordered an AVR installed it today and it's fixed, thank you

[hurtinalbertan]

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.

[shelydued]

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.

[MeoIngenuity]

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!

[alanstant]

You will definitely have a happy customer when they get that back my friend.

[YukonHawk]

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.

[michaelbegay]

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. 👨‍🔧🤷‍♂️🙈🤦‍♂️

[billiamc]

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

[phbrinsden]

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.

[Kuzzzzman]

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!!!

[johnshea]

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.

[TheFarinelli]

Outstanding job explaining and showing. This single video answered all my questions regarding the problems I’m having with my generator.

[paulmoffat]

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.