Chicago Electric Generator (Part 1) - No Power

[@nnan0001]

Watching your videos is like taking a class in generator repair. I find myself looking for old broken generators so I can "play James". It is fun and oddly satisfying to see one come back to life.

[@bionicman6969]

Right on Jasper, to me it's beautifully satisfying, lol.

[@nozzledrich]

Start playing cowboys and generators!!

[@dljones61]

Even worse for me, I bought a new one because I’m a guy and we like all things motors and now a year later I’m thinking I need one for backup for the backup 👨‍🔧

[@endtimeawakening5557]

This channel is priceless! Don't worry that the content is too long because some of us would rather see the full explanation as opposed to the modern summation. Attention spans have diminished in the modern era with all of the electronic pollution going into your eyes, ears, etc. It's refreshing to find content that's thorough and professional. Thanks for sharing on your channel James, it's very much appreciated! God bless!

[@jcondon1]

Thanks!

[@alext8828]

I'm not sure what the attraction is. I think it's the analysis and the calm attitude. It's inspiring. I get disgusted sometimes with my projects. James inspires me to take it easy and don't worry. Good stuff.

[@anthonysummy6944]

James, don't waste that nice Predator frame on this 5kw genset. Wait for a more suitable 7.5kw (ish) genset for the Predator. Keep the Chicago Electric intact, such as it is, and hope for a rotor that fits. That's my opinion, for what it's worth. BTW, IMO, you're right on point with the likelihood of that rotor having a pinched wire, causing intermittent leakage to ground. In the world of an electrician, water getting into an electrical environment causing corrosion, is a very common cause of ground-leakage. (That's exactly why GFCI's exist!) Again, IMO and for what it's worth, if the rotor leaked to ground once, it will do it again, even if the leak APPEARS to be fixed. The rotor is simply not reliable, and shouldn't be used. Another great video.

[@P_RO_]

I wouldn't trust it without a re-winding.

[@richardphelan8414]

Watching you work on Carbs ,has taken away my hesitation of working them Thank you for that

[@inspector1794]

I've only worked on a couple of generators but one of those had a similar issue as this one, the rotor winding was grounded. I found the slip rings shorted to ground. I isolated it by unsoldering the wires from the slip rings. I was surprised that replacement slip rings were available and replaced them. With the old slip rings out, I found a carbon track from the inside of slip ring to the rotor shaft. Thanks for sharing your work, I find it very interesting to follow along.

[@CuddleTrouble]

Thanks for taking the rotor to the bench, I was extremely curious as to what was causing the ground.

[@HwSystems]

It would be great to see more inverter generator. Thanks for the videos!

[@somerandomguy3868]

Always good to see you get to the root of the issue

[@RiverratGoRVing]

Have a good a safe vacation. As always, your posts are very informative and helpful for us DYI Tinkers as we try and keep the equipment alive.

[@jonminer9891]

Hi, James. I don't trust the rings. Thanks for sharing! Stay healthy!

[@Red1red1MC]

I recently bought one of these chicago electric generators. Mine is only a 3500 watt, and it was a lot rougher than this one. Only 30 bucks! I spruced it back up with new paint and some new parts. Couple of custom decals of my own choice, and it's like no other. Really great little machine.

[@CombatDoc54]

I'm 70 years old. If I had you as a shop teacher, I would have stayed in school.

[@waynec3121]

Enjoy your vacation we will be waiting the outcome of the two generators

[@markmoran9716]

Great Video as always. It always amazes me on how thorough you are in troubleshooting and repair. We always know that any generator you repair is as close to perfect as possible.

[@loucinci3922]

good show. It is not always a happy ending. Excellent troubleshooting. Thanks for sharing

[@philliphall5198]

What I like about generator is I can stand up and work plus there easy and not really oily or dirty

[@Bulletman426]

Another fine video Jim. I’ve done my fair share of working on Generators and still learn a bit from your videos. Thank you for taking the time and sharing them with us

[@AnwarKhan-dw8cj]

enjoy your vacation james have a good one

[@rayburn157]

Instant relief seeing the hose pliers being used. Also great for removing spark plug boots.

[@gaetansimard1594]

Always new details that makes the job different….Always amaze to check your video. If I ever have problem with my generator but I will know were to look if it happened. Your Chanel is the best one. I had a power black-out from December 23 until January first where I live. My small inverter 2000W generator hold-on. But I bought a 8000W and will have a transfer switch installed so next time no extension cord every where and…the water pump working. Tks

[@JohnSmith-yv6eq]

Did you do an oil change during the runtime? Which 2000watt inverter brand/model?

[@spettro9]

You always find the issue and smooth it out. Videos like yours are therapy for me. Grazie.

[@johnnybgoode6466]

Part 2 will be interesting with what you have opted for by way of frame etc - well done again James and have a great break with the family.

[@tomhill9027]

James, greetings from Boston! Thanks for all the effort you put into making these videos. I've been watching and learning alot from them. Looks like another subscriber beat me to sending you the fuel line pliers! Tom

[@GaryToland]

Another great video, James. Enjoy your vacation and hopefully without bad weather disruption.

[@philliphall5198]

Thank You for information and advice Really enjoy watching

[@tristanschaper281]

Phenomenal electrical troubleshooting and diagnostics!!! Have a great vacation!!

[@d1bergman]

Good video to see one that is in this kind of shape. I would suggest trying to use this rotor. I would put the plate back with minimum torque measure again to make sure the ground is gone. I might also try to use a small piece of insulation between the plate and the mounting area where the short is located. I think it would work fine. Worth a try.

[@brianwood5220]

I do hope you enjoyed your vacation. It will be waiting when you return. Thanks for sharing.

[@budzillasohoski9858]

I own this exact generator. I went to start it one day, used some starting fluid…long story short it caught on fire and by the time I got it out, it was pretty much a loss. The fire only damaged the engine side of the unit. The generator head was pretty much unscathed minus the control panel. Anyway, I’ve had it for years and found it to be beyond reliable so I went on Marketplace and found the same one but it wouldn’t put out any power. I got it for 80 bucks. My plan was just to swap the generator rotor and stator over from my old one (which I did, using your video.) but I ended up finding and fixing the fault in the bad one (broken wire right at the solder point) so now I have a spare. Thanks so much for your help!

[@MARKE911]

I really enjoy your videos, you are one of my top favorite channels. I like how you prove or find the issues when possible. I don't work on or plan to work on generators. I'm really fascinated in your knowledge and expertise on everything.

[@jesterr7133]

Thank you for sharing this. Generators are not extremely common in my neck of the woods, and I have never worked on one. I have learned so much from watching your videos. I am actually going to pick up my first one in a few minutes. It is being given to me, and is supposed to be a working machine, but I feel confident that I can make the necessary repairs if I need to. I really look forward to your videos every week. You are very good at what you do.

[@Ram14250]

Good Video James! Look forward to "part 2" if there is one.

[@peterouellette3874]

Have a good time and stay safe

[@paulravitsky2898]

I don't know James, that oil fill looks factree to me! Good call on the rotor. The only question I have is where the rotor wires are soldered to the ship rings. I can't tell if that is dirty fish paper or rusty metal under the connections. You may want to check there. Happy vacationing!

[@watermanone7567]

NIce video, have a great vacation.

[@deangentles4966]

Hi James always great watching your videos Thanks for sharing have a nice break mate

[@wildefox1478]

Pretty interesting the intermittent ground you discovered on that rotor, great work as always James and looking forward to part 2!

[@ericwuichner8168]

I just love your videos. I watch them to learn and to wind down after a long day. Your production recipe is just perfect.

[@presmak0542]

Enjoy your vacation,stay safe!!

[@martyb3783]

Very interesting. Enjoy your vacation!

[@spencerwood1142]

Once again some quality content. Love the videos!!

[@hardyschlegel1048]

I would look for carbon around the slip rings, give them a thorough wash, and retest with your megger to get an accurate look at what is happening. If you crank your megger consistently for 30 seconds to a minute and your reading drops and picks back up iraticaly, you have moisture in the windings. Love your videos. Thanks for sharing.

[@landiahillfarm6590]

love the new exit audio [sputtering engine and dog bark!]

[@SilliestSmurfEver]

Me too👍

[@1SmittysGarage]

Oh man, that was a real head scratcher for sure! Another great video in the books! Blessings and respect!

[@donwp]

Oh, I so wanted to see you unwind that rotor and show us it's secrets. Still more video to go though. It's so interesting about the high resistance, and possibly inconsistent ground. The way the power came up when the engine was not running is so interesting. Back to it...

[@johnmckee7937]

James Great Video as always! Have a great vacation. Maybe do a short video sometime showing us your spares.

[@NY411Info]

Have a great Vacation, thanks for your time.

[@reneenelsen7416]

Thank you for sharing your content. Much appreciated 👍

[@craigdreisbach5956]

Great video James. I'm wondering if you could transfer the plastic rotar fan from the bad Chicago Electric rotar to the replacement one by removing the metal fan on the replacement and use an interior shaft bushing/shim to match the rate of taper that is needed in order to avoid end fan interference. Just a thought. Kind Regards. Craig

[@JohnSmith-yv6eq]

James Condon 4 hours ago I could, but then the good rotor would not be the correct length.

[@billsmith5166]

@@JohnSmith-yv6eq It's so strange that they would look identical, be the same overall length, and yet make the shaft substantially shorter. It would be interesting to know the wattage and engine on the parted generator. Thanks for the video!

[@adnacraigo6590]

You read my mind about those plates on the rotor. To me that looked like the most probable place for the ground fault.

[@michaelschumacher3702]

Nice work! I'd love to see you slip something like credit card stock next to those windings and see if the fault to ground doesn't disappear when the plates are reinstalled. Enjoy your well-deserved vacation.

[@papergatorzfedducca7998]

New subscriber!! 🔥🔥🔥 I have this same machine for free because it didn’t work. This will be my guide!!

[@ron827]

Good work as usual. I find it hard to understand why some people spend good money and then leave generators, motorcycles and riding mowers outside in the weather. I guess it is true, common senses is not a flower that blooms in everyone's garden. If an engine uses excessive oil, putting an extension on the filler hole to gain more capacity is not a good idea. When probing the wire coils under the plate for resistance to ground, you may need an analog meter because some DMMs have a slow reaction time. A DDM with a continuity tone may also work because the reaction time is faster.

[@arthurbiringer5676]

Great video, I’ll bet you can repair the rotor.

[@thepubliceye]

If that thing comes back to life it is a testament to Harboro Freight generators.

[@hamop3]

No a testament to James Condon 😊

[@RustyNail5856]

Great video.

[@F3ND1MUS]

Great work the channel is interesting and informative very entertaining and enjoyable

[@jcondon1]

Thanks

[@georgelequin5070]

Great channel James! I’ve learned much,thanks!😁👍

[@GusbidsBids]

Not sure if you have considered taking the old rotor to a electrical motor repair shop or what the cost would be. The rotor looks fairly simple to rewind. I have used that type of service for some exotic foreign made motors installed in industrial equipment and cost was less than new. Might be worth a look and allow you to have a complete gen set.

[@alantorrance6153]

A 14.56 the insulation on an earth lead is pinched on the lug interfering with the position of the fixing nut. As was recently shown when fixing another "bad" generator, this can cause bad contacts. A close, careful visual inspection of all that is showing can reveal many types of problems and help in the remedy.

[@artpatronforever]

A couple of tests I was thinking could be useful is check resistance at the brushes through the rotor with brushes unplugged, and the bridge rectifier should also be checked.

[@GuysPlayingWithTools]

Good vid James.

[@georgelewis8904]

I think parts, your video is interesting thanks.

[@andrewgrace4410]

Thanks James 😊

[@texascottonfarmer]

👌👌👍👍 Thanks for the video.

[@davidwilles8577]

I would have thought a new coat of paint on the old frame and tank and a good clean up of the engine will have it looking as good as new and save all the trouble of messing around trying to fit it all on the Predator frame. The fuel tank is still good and just the paint has faded and with it looking nice again the value goes up. Hope you enjoyed your vacation.

[@daryelljeffries7861]

One of the best filters is a pants leg from a pair of blue jeans. Wrap a wire tightly around the end and you have a great filter for debris

[@er1073]

I can't believe that people spend money like this and destroy what they bought by leaving it out in the elements like this? Well James I have no doubts that you will persevere in this it might not look too pretty when its done but it will function once again. Thanks. Ed

[@vg3430]

James…any chance you can put together a spreadsheet with your known good resistance values for the different components of different sized/types of generators? Thanks for the consideration and all the great videos!

[@heyitsjay22]

James always gives the values of the stator .2-.5 ohms and he also explicitly states the values for the rotor both through the brushes and direct from the slip rings. The sense windings are similarly described. A spreadsheet would have to have many different values for different sizes of generators. I think a spreadsheet would be a great homework project you could share.

[@gd2329j]

@@heyitsjay22 James is using ballpark numbers ! He is looking for opens , shorts or connections that shouldn't exist .

[@jcondon1]

It would be a short list. Most Honda clones in the 5000-8000 watt range are between 0.3 and 0.5 ohms on the stator for each leg and the rotor between 40-70 ohms. Brushes should add very little resistance if the slip rings are clean. Some do not fit this mold and in that case I try to find the specs or just look for anything obvious like burnt wires, open circuit or really high or low resistance numbers.

[@ericblackwood1286]

Is there any way to replace the bushings in a generator

[@TomsLife9]

at 44:00, would swapping the fans potentially work?

[@JohnSmith-yv6eq]

James Condon 4 hours ago I could, but then the good rotor would not be the correct length.

[@RSi-tf3jx]

Hi James I’ve been enjoying to seeing how gently you treat the tools and fasteners when removing them. That shows skill and understanding doing something you love to do. I need your advice to recommend what you think is a good generator 5000W output and reliable. Thanks Man

[@daveschroedersworkshop4479]

Great video James! I thought you would try swapping the fans around on the rotors though. Looked like they had the same bolt pattern.

[@benjaminbenji1355]

Hi james I love watching all your videos and I have a question for you Have you ever considered working on diesel generators also would enjoy watching you work on those thank you..

[@cptyler150]

Put some Mylar tape over those ends where you took the plates off. On both sides put a couple layers on. Then bolt it back up and measure it again

[@AZVIDS]

Love these videos! Learned a lot, thanks👍👍👍

[@harryheaton1185]

Have you try to remove the fan blade and switching them around.looks like the one with aluminum fan has a plastic shim..I'd try and switching the fan blades

[@jp-um2fr]

I'm with you mate, bit obvious.

[@jcondon1]

Might be possible to move the fan. The issue is that the taper on the shaft starts higher up which means the replacement rotor is actually shorter by 1/4". That will cause poor alignment of the ball bearing on the end housing and brush alignment will be a show stopper.

[@daemoncan2364]

Great vid. I'd be inclined to take an analog multimeter, connect one lead to the slip ring, and the other to a piece of braided copper or solder wick with the end frayed out. Then sweep it across the windings in the suspect area. Just to satisfy my curiosity. Hacking thru multiple layers of varnish & wire is grueling.

[@andyhamilton8940]

Could you switch those fans for the clearance issue?

[@sebastiannielsen]

If you remove fan (both plastic fan and metal fan) isn't it a insert there? It looks like both rotors are compatible, but theres a tapered adapter/insert on the old rotor - that is to make it conpatible with engines with shorter axles - that could be moved to the new rotor. You would see it if you remove both fans.

[@JohnSmith-yv6eq]

James Condon 4 hours ago I could, but then the good rotor would not be the correct length.

[@sebastiannielsen]

@@JohnSmith-yv6eq You should not PERMANENTLY remove the fans, but remove them to look under. I suspect on the bad rotor, that theres an adapter/insert, which looks like a tapered steel corn with a tapered hole in it. And by moving this adapter to the good rotor, the good rotor would become good length.

[@louisbigelow1866]

Doesn't this generator also have the too much insulation issue hey you were showing with the storm responders?

[@robertmorin6495]

Nice bit of sleuthing there James. Are you sure you don't want to try a repair on that ground fault? How about leaving the plate off or isolating with rubber or plastic? Anyway, fun riding along with you.

[@mjg263]

Great video! I wonder if the fans can be exchanged, maybe that rotor can still be used. What an odd fault, you’d think there would be some kind of evidence somewhere!

[@JohnSmith-yv6eq]

James Condon 4 hours ago I could, but then the good rotor would not be the correct length.

[@allynbroderick]

Thank you for the video, but I'm wondering if you could you have changed the fan on the rotors?

[@jcondon1]

I could, but then the good rotor would not be the correct length.

[@Captionmarvelous]

I wonder if the plastic fan is interchangeable with the metal one on the good rotor and give you the clearances you need?

[@JohnSmith-yv6eq]

James Condon 4 hours ago I could, but then the good rotor would not be the correct length.

[@johnhershey4010]

Hay James is that blue Generator a Harber Fright Brand

[@JohnRoesner]

Is there a link to the hose pliers?

[@P_RO_]

Could be centrifugal force on a winding causing the short. Barely touches (very high resistance) when still but better contact (less resistance) while spinning. I've seen car generators and alternators do that- very rare but it does happen.

[@jameslarson6555]

A good shop vac with a smaller diameter crevice device might be a good addition to your arsenal.

[@mikekrening7327]

Have you ever tried to rewind a rotor? Also I would be glad to cut you a bushing on my lathe so the other rotor would work. Thanks for the videos!

[@donaldelrod9172]

checking the engines specs should give you the shaft taper(sae) dimensions.

[@SupangiAja]

Makasih ilmu bermanfaat

[@manualdidact]

You mentioned that the old bearing was "crunchy" -- could this have been a leakage path at some point, possibly with arcing inside the bearing? Also, is it possible to swap fans on the rotors? If the design of the fan is the only difference, would moving the plastic fan to the good rotor (replacing the metal fan) allow the good rotor to fit? Or is the difference somewhere else?

[@TomsLife9]

ah you beat me to the fan idea!

[@JohnSmith-yv6eq]

James Condon 4 hours ago I could, but then the good rotor would not be the correct length.

[@petepeterson4540]

@@TomsLife9 John Smith 24 minutes ago James Condon 4 hours ago I could, but then the good rotor would not be the correct length.

[@bobminchin]

It looks like the plastic fan might fit in place of the metal one on the good rotor. Worth a try? Bob

[@JohnSmith-yv6eq]

James Condon 4 hours ago I could, but then the good rotor would not be the correct length.

[@DeadKoby]

The intermittent shorts can be truly frustrating....... in my electronics background... when moisture gets into paper, paper becomes a bit acidic and conducts. My thought would be to replace the paper, re-install the plates and then check again.

[@lesr5737]

Do you have a video out there that is and other totally for beginners where you show a slip ring excetera and other components. Or have you written a book with the illustrations or I can order a book from Amazon

[@budthomason8890]

The shrink rap on the quick connecter and the material sleaves are insulating on the head power block?

[@justgetrinthere]

I think your on the right track taking and making a nicer unit work I wonder if you could put inline instead of having to change breakers Unless you already have the breakers

[@danbrookshire5628]

Hope you’re still able to fix the rotor.

[@jayjudd6518]

Another scratch you head one. The problems on generators are many. My guess is they never last long if used a lot. Good thing this country has reliable electricity.