Generator Head Installation - How to Install a Generator Stator and Rotor

Part 2: Bought this generator used, advertised as good engine but no power output. After troubleshooting the power output in the first video I discovered that the DPE winding was bad. I purchase a new generator head and will show you how to install it..
Part 1: • Troubleshooting Genera...
Generator Model# HU40500G
OEM Generator Head# 310227059
Alt Generator Head# 310227016
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#GeneratorRepair #SmallEngineRepair #SmallEngine #DIY #Fixed #Troubleshooting #HowTo

[@billybadass601]

HEY THANK YOU SO MUCH FOR MAKING THE FULL VIDEO AND NOT WHIMPING OUT AFTER THE FIRST VIDEO!! ALOT OF PEOPLE WOULD HAVE THROWN IT IN THE GARBAGE OR SCRAPED IT!!! Thank you soooo much for completing it all the way!!!

[@livefreehobbies4326]

I really like your videos. I have been picking up generators for free or next to nothing and fixing them. The latest was a 7500 watt briggs for free and a $14 set of brushes fixed it. I really like your rope trick. Learn something new everyday.

[@jcondon1]

Nice. It is hard to find them for free around here.

[@petersack5074]

One, could also remove the pull starter - and make method, of STOPPING it from turning - ....

[@tedtedness184]

You would think by 2015 all generator manufactures would know, exhaust heat shields should be standard unless there is a 3+ inch air gap between muffler and gen. head. Great video, you rock!!!

[@jcondon1]

Thanks

[@renejackson7652]

I just put that same head on an old obsolete Generac 7000exl. I had to machine a taper adapter from the old rotor. It works great.

[@MileyonDisney]

You gotta love USPS! My postmaster has said that she doesn't believe her letter carriers can even read!

[@daverose8772]

Hand tighten the stator bolt at first. Fully torque the stator, after you installed he windings housing. The rear bearing fitment helps with perpendicularity issues for assembly balancing. The engine's taper end will better align with the stator shaft during the torque down. It could develop unwanted run-out otherwise, and possibly vibrate.

[@chrisharkin3741]

I think you mean rotor, not stator. Rotor is the rotating part, stator is the stationary section around the rotor.

[@w2dmw]

The air intake of the stator is 1/4" from the muffler, thereby pulling hot air into the stator windings. Thrrow the muffler over your shoulder, and just fabricate an elbow, to direct exhaust outward. Now there's plenty of room for a heat shield.....

[@bigdognance]

Good Eye!

[@robertmartin5167]

Love your video. I'm would run it with load for a half hour first, with 4000w loads

[@robertpiver6280]

Great content...I have to say to everyone though that I have found almost all homelife products inferior to defective from brand new.sooo...we ve got that going for us.thankyou..

[@robertpiver6280]

Homelite not homelife

[@mcarroll598]

I think you’re right. These generators are failing because the stator is getting too hot from the muffler.

[@pmaint1]

They may also be failing because the winding are probably aluminum clad with copper instead of solid copper.

[@aaronemery738]

I'm a newer subscriper to your channel and I would like to said your videos are very informative.. So I would like to thank you for this..

[@jcondon1]

Thanks

[@chevynomad4507]

Should the bolt be replaced ?? Now days most bolts are one time use.

[@Maine307]

soo... your repair videos are awesome.. especially for someone like me, who uses Gens, a lot.. also.. i built a smelter furnace.. from youtube.. lmao.. and a nice project you can do, is casting and melting of your scrap.. look into it..u must have a lot of scrap lying around..

[@Alec9821]

Wow the usps is actual shite You need a Royal Mail, the slightest Nick on the packaging and the refund you the whole parcel.

[@tahanlaoboy]

Very nice

[@1DouglasBurney]

Thanks!

[@1DouglasBurney]

Great thought process in your videos.

[@jcondon1]

Thanks! I really appreciate it.

[@richardbaker3621]

When you buy a power head how do you know the crankshaft taper of the engine will match the power head? I can't believe the taper is standard with all manufacturers.

[@jcondon1]

On the 5000-8000 watt generators there are two types of standard tapered shafts. There are some odd ones on older machines and an occasional odd one in newer machines.

[@bushratbeachbum]

How do I identify the sense and excite connections on the generator end? The avr replacement i got doesn't have the same plug type, I've identified the sense pair and excite pair on the avr but I don't know how to match them with the 4 wires on the generator end!!

[@raymondgarafano8604]

brush holder not on right. . .What happens is the AVR wants to compare the 120 volts or a tap off the 120 to use as a reference point for the excitation. so if this reference voltage is a bit on the hi side it will tell the AVR to reduce excitation to the field or if on the low side, it will tell the AVR to up the excitation to the rotor.

[@dcrickerson7611]

Nice work, great video! Thanks for sharing.

[@jcondon1]

Thanks for watching!

[@ES-iv6wb]

Great video!

[@teddysgunshop2318]

Awesome job

[@jcondon1]

Thanks

[@teddysgunshop2318]

I just picked up an all power 6000 watt model APG3009N for 375 run like new mint condition about 10 yrs old

[@charlesbowen3944]

You could use a pice of tin for a heat shield and save 30 bucks good video

[@jcondon1]

Yes, have done that also. This shield used to be a lot cheaper. Has doubled in price recently.

[@meesiphht2769]

So, did the heat shield line up with the old stater where it was burned?

[@FernandoDIY]

nice video thank you

[@jcondon1]

Thanks

[@wjdsr64]

1st I have to say I love your videos you do excellent work excellent work and teaching, The problem I have that I need help with need help with is that I'm getting half the voltage I should have both on the 120 legs and 240 side, I have power but only half what should be there. What do you think? Also what is the green and yellow ground wire, By the way I'm working on a predator 4375

[@jcondon1]

I would suspect a problem with the AVR. Could also be the brushes or maybe an issue in the stator. Would start with replacing the AVR. If the issue is with the stator, then not much can be done with that.

[@Juanre889]

Hi, is there a way to use a generator head with other engine using a belt system? I habe ben triyng but the rotor keeps touching the stator. Srry for bad english

[@jcondon1]

Not possible without some fabrication because the engine side of the rotor need the engine tapered shaft to center things.

[@Juanre889]

Ok, thanks

[@billkrause4585]

I'd say 25% of the parts I received are damaged or junk like the Craftsman Ratchet Wrench Set I received made with plastic parts, it's display package was previous cut into (Used item) and contained a broken wrench. You have to be very careful what you buy, or it's poorly packaged for shipment.

[@barthanes1]

That looked like all of your 3/8" drive extensions.

[@jcondon1]

Pretty much

[@johnmauthner8857]

Generator design comment: The new generator should be designed to attach to the gasoline motor as a single manufactured unit. This eliminates the need to dismantle the entire new generator for installation and thereby eliminates potential damage to the new unit.

[@rupe53]

John Mauthner ... these are in an assembled fashion to aid in shipping with less damage. In order to mate the assembly to the engine block you must tear it down because the mounting bolts are inside the housing. Almost every gen set made in the last 5 decades is like this.

[@michaelbegay9573]

Guess somebody went "POSTAL" on that item, n yeah, don't let the magic smoke escape the wires, that's how it really works. 😳😂💁‍♂️🤷‍♂️🤦‍♂️🙈

[@jcondon1]

It's hard to get that magic smoke back in.

[@Ecksterphono]

Go to 29:01 on your videos time. Is that a crack in the housing just to the right and slightly below your finger?

[@jcondon1]

Just a casting mark

[@BlondieSL]

I'm nosy, so why was it all beat up on the porch? Was it the USPS person not taking care or did someone try to rob it?? I only ask because here, where I am, when I order something, I have stuff delivered to a "drop off" location, never at home. Too many thieves around here. LOL

[@davidbradley3074]

You can have the generator rewound. It is done all the time.

[@jcondon1]

I looked into that once, but the cost was much higher then purchasing a replacement.

[@TheNARF86]

This tipe of starors can be a pain in the ass to rewind . if they burn up really bad there is no way to pull a schematic of it. Happens to me a few times,thath even the rotor may need rewind ....hell even the AVR gets damaged .that gives you a cost of repairing from around $ 300 to $ 400 So in my opinion.those 200 bucks were really well spent. Good luck dude ( sorry for my bad english )

[@danielsmith8659]

I’ve been watching your vids. I have a snapper gen 5600/8600. Briggs motor. My stator windings are burned as you showed on a very similar unit in another vid. Unfortunately they no longer make the stator. Can I use another brand or different head all together as long as it’s similar in size and power ?

[@jcondon1]

Yes. That is a common setup. You could probably use a generator head from any other similar sized generator with a Briggs and Stratton engine. The biggest issue might be the wiring. Most Briggs stators are wired into a proprietary plug that runs from the stator to the outlets. Ideally you would find one with the same plug. Otherwise you would have to do some cutting and soldering to connect the stator to you existing outlets. You might want to check out this video kzbin.info/www/bejne/oYi2fJxmbK-rjsU. And this one kzbin.info/www/bejne/qomUpIaCnbOGn9E

[@danielsmith8659]

James Condon thank you very much for replying. My stator is technically discontinued but I’ve found a few 5500s online that are the same setup..... not really worth the investment of repairing unfortunately . I can buy the same generator in mint shape for the price of the stator. I reckon I can part it out.

[@danielsmith8659]

James Condon hey man. I found a guy local throwing away a power head from a generator very similar to mine. Troy-bilt 5500 vs my snapper 5600. I replaced it mine with his. Worked perfectly. Your videos were very helpful. Thank you for that.

[@TheTechnoSpark]

Can you tell us where we can find part numbers for generator stators and rotors? There is a generator for sale listed as not producing power and I want to see what a stator and rotor would cost for it.

[@jcondon1]

What brand is the generator? Usually the model number is on the generator frame or the stator. Usually they start at $300 to $1000 if available.

[@TheTechnoSpark]

@@jcondon1 It's a DuroMax DS12000EH. The seller is asking $400 but I think that is too much for a generator that doesn't produce electricity. If the generator head isn't too expensive I would follow the steps you've shown us multiple times in your videos to get it working and if that doesn't work then replace it if not too costly.

[@jcondon1]

@@TheTechnoSpark duromax generators new are not very expensive. $400 is almost the working price. Would not pay more then $100. Also not sure if Duromax supplies parts like that. Possible a Ryobi or Generac power head would fit, but would need modification.

[@TheTechnoSpark]

@@jcondon1 Thank you. I greatly appreciate your feedback.

[@raymondgarafano8604]

I have been wondering about that. I have seen a blk/red blue and wht hookt so the wht wire was the neutral so one coil had a blk an red other coil had a blue an wht. The wht being hookt to the red and 240 came off the blk and blue and 120 from wht to blk or blue. the blk an blue being the HOT legs with a bigger breaker and the bigger brkrs hookt to the 240 v socket and 2 20 amp or 15 amp brkrs to the 120 volt receps.

[@bushratbeachbum]

If you expect people to read what you've written, write properly. We were given the power of intricate communication for a reason, let's not regress back to stone age grunts and screeches.

[@busterv333]

I have a generator that is pulsing about ever half min it throw enough electric to turn a drill about a turn any ideals what causing this

[@jcondon1]

What is the model number? Would first look at the AVR if it has one or the capacitor if a brushless model. Almost sounds like the system is trying to power up based on a capacitor charging. Also could be a brush issue. You should also check the ohms on all the stator coils and the rotor.

[@peterclark6290]

Is there a logical reason why the rotor doesn't use a key to establish itself on the crankshaft? Harder to install of course (alignment) and arguably unnecessary in a throw-away society.

[@jamesmnoblesjr9062]

Shame.Most gens are 30amp 1Phase. Will watch your other video with a 30

[@allensnook7760]

Awsome job on the repair,dont know how you kept a cool head when you shelled out 300.00 clams and they delivered that package in such horrible shape.albiet only minor damage but i would have been ripping someones ass for that.snookie pa.(i know violence solves nothing!!!!)

[@mouhsinesimo6540]

Hollo

[@MrMax31kk]

Engine muffler is too small also insulation not available at main stator and rotor-also you are not calibrate aver through veritable at aver unit-

[@stevemash3066]

These manufacturers no they screw up by no adding something as small as a heat shield but wort recall anything.. Dont buy a Husky.

[@ATOMSHAMRADIO]

Thier you going again never assume

[@YukonHawk1]

It didn't help matters as the person who packed that gen head did a crappy job. Then the post office was the final nail.

[@jcondon1]

Packing was very poor.

[@kauinoa2250]

I see that he forgot the key stock

[@rupe53]

KAU INOA ... there is no keyway. These are tapered shaft.

[@PaulHigginbothamSr]

I do not like to produce pain in others but the guys who threw around this head like this need ten lashes with a 6 foot horse lash. At least. There is no excuse for this behavior. It has to do with Americans not responsible for their actions. This is not excusable behavior and shows very very low mentality by whoever did this.

[@jcondon1]

I agree. But it worked out well with the price discount due to the damage.

[@NETWizzJbirk]

$1000 for a generator head? That entire thing new was probably not more than $600

[@MrBugsier5]

150 euro here in europe...

[@josephpuchel6497]

OMG

[@philipbucheit233]

I totally thought the same thing. But the rotor looks 3 time as big as my 6500 watt 10hp brigs generator. So it’s prob 15000 surge 10000 watt windings. That’s a big ma a jam a lol

[@lestergillis8171]

Those power heads can be stripped down, cleaned, and re-wound in a electric motor shop. There is one in town here, about 4 miles North of me. They specialize in rewinding motors & generators ect.

[@foodforthought73]

Wish we had one here. I've called everybody inna 150 miles radius and nobody will touch a armature, and if thay do thay want 1200. To do it.

[@lestergillis8171]

@@foodforthought73 I'm not sure how much S & W charges to do this. I'm sure it depends on the size of the unit.

[@foodforthought73]

@@lestergillis8171 ya. It's just a standard 4500 wat gen head on a Hobart welder generator, the armature

[@tihspidtherekciltilc5469]

Definitely a lost art like getting your wheel cylinders bored, sleeved, honed and good to go for another ten-fifteen years.

[@100kwatt_Neville_Goddard]

Where do you look up your parts? I need a complete head for a 9000 Predator.

[@TheNemosdaddy]

Most bond to ground for construction purposes, in case of an osha inspection. Unfortunately it can cause gfci issues if using in a household emergency power situation

[@adamasz54]

That's fine you've got the whole pieced 'parcel' on vid! USPS should pay the repairs... I hope.

[@TheFritz423]

Your channel is going to blow up. Keep doing what you are doing.

[@jcondon1]

Thanks. Been blowing up recently. 5k subs in 28 days! Yikes.

[@TheFritz423]

@@jcondon1 The matrix has found you...

[@johnmichaeltoimoy4047]

Your video is really helpful Thank you

[@TheBig3802redone]

Don't like all you folks trashing the USPS.. Maybe you are not old enough to remember when that was the only way you could receive anything, not like today where you can just run to the local Walmart and get it or maybe you don't live out in the country where you don't have that convenience.... If you grew up without email and internet you might understand what I saying

[@thepubliceye]

TTI made the whole head or just the AVR? Never mind, I see that they did but they only make a chainsaw at this time. No more lite in Homelite.

[@Z-Ack]

My rotor isnt rubbing when i turn the motor over at all but when i start it the thing rubs and throws sparks . Still has voltage but only when it runs will it rub.. like its a magnetic force pulling it.. annoying.. i dunno how to fix that.. rotor goes in straight, torque to same thing.. but its just weird..

[@pl747]

Do you know of anyone that makes a stub shaft and/or bearing plate to use old generator heads and make them belt driven?

[@Craig1967]

Thanks for the video, it was very informative. I understood your caution about connecting the white wires at first, but I knew you didn't realize the stator power windings were isolated. I continued watching to see if you figured it out, and of course you did, followed by an excellent explanation. I really appreciate your time and effort making the videos, I am learning quite a bit from them. I've done valve lash, carb rebuilds, but never messed with the power head. Thank you !

[@jcondon1]

Glad you got something out of it. Most people stop at the engine side of things.

[@dff409hobie5]

New to the channel, like how you work clean and organized, most of all you talk when you need to talk not mindless tribble. Looking forward to all previous and future videos. Cheers from Canada

[@jcondon1]

Thanks!

[@TheNewenglandboys]

Good video. I’ve got to do this to my rigid 6500. Repair place said my stator is short circuited but I see nothing visable

[@brianbloom1799]

That Generator should run entire House with well, I have same 1 runs everything even outside spot lights

[@rafaelaguilar5967]

Nothing better than watching a man working when he knows what he's doing. Great job!!

[@jcondon1]

Thanks

[@rudeboz5486]

ha ha can fix the gen but says end cover is beyond repair ! use a small wooden mallet on it

[@jcondon1]

I thought about it, but I had a perfectly good one sitting around.

[@robertsimpson7113]

One would think it prudent to run a meter test on the new unit before going into the disassembly process.......

[@jbgaud]

at 13:24, the back cover on the right, looks like a very suprized face crying for help.

[@j.l.daltoin2238]

some times a good motor shop can rewind those burnt up fields cheaper than you can buy one depends on where you live

[@raymondj8768]

Very good video thanks for the info !!!. i just bought a westinghouse 7000 watt gen with remote start it is one sweet gen i love it !

[@RonOrtman]

Should the center bolt be jumping around in that bearing like that ?

[@YukonHawk1]

Really awesome job. Super slouth finding the missing capacity. Loved how you highlighted the spring jumping off🤣🤣. Once you replaced the carb it purred like a kitten 😸. Great catch at the end connecting the oil sensor.👍 Funny you mentioned the sustained winds over 40mph with gusts over 70. Our power went out Christmas morning at 3:30 am and was out for 19 hours. The Predator 6500 I picked up ran like a top. March can't come soon enough when the standby gets installed. Anyway keep up the great work. I learn something new every time. Happy New Year.

[@jcondon1]

Our power was flickering all day, but managed to stay on somehow. A lot were without power on Christmas Day.

[@johnclarke6647]

They say Trump is stupid because of his criticism of the USPS. I ordered a set of suspension rods for our whirlpool washer and they took 16 days to travel 200 miles and were sent priority mail, which is supposed to give two days service. I side with Trump, the postal service sucks.

[@jcondon1]

I have had issues, but to be fair it was packaged very poorly.

[@bushratbeachbum]

We say he's stupid because he is stupid. Nothing to do with the postal service in your country.

[@twofeathers6540]

you or great at what you do thanks have fun

[@rohanhibbert1095]

I am trying to sources a generator head for a duromax xp5500e generator, can anyone direct me, where to start

[@jcondon1]

Do not think Duromax supplies parts. It looks like a Honda clone. You could probably fit it with a Ryobi stator as I did in the video link below, but there most likely will be complications including stator length, wiring differences and maybe an issue with the exhaust mounting. kzbin.info/www/bejne/hYWVlqeIgsmHjMU

[@randa743]

i have a predator 7000/8500 and the end bracket broke by the mounts and the generator head end fell/dropped while it was running and it damaged both rotor and stator-both SHOT thanks to watching your vid,- i ohmed them out. So been looking for a suitable replacement Gen head but not find any sources, can you or anyone help point me in the right direction THANK YOU! GREAT informative video BTW !!!!!

[@ronaldfain4541]

You should put on a new bell head in case the old one is crack

[@wvairgunssportsman8886]

Can you help me find one like that or messenger me so I can show you what mine is. Mine looks like that one but it's a generac portable 6250/5000 the armature is bad. I can't find the alternator parts.

[@jcondon1]

Take a look at this video. kzbin.info/www/bejne/hYWVlqeIgsmHjMU In the description are the part numbers I used for the rotor and stator. Might work on the Generac. Not an easy job for several reasons. Differences in wiring and the length of the stator will cause a ripple effect.

[@wvairgunssportsman8886]

@@jcondon1 I watched it. I'll try to find the link

[@wvairgunssportsman8886]

How do I find the correct stator and brushs and rotor. For mine thou. Model 0055771 Centurian 6250 peak 5000 watt. Serial 5404945A 120/240 Amp 41.7/20.8 Or can I just order the homelight one. I'm kind of confused with this

[@bushratbeachbum]

Once you have the motor running at 3600 or 1800rpm for 60hz, adjust the tiny brass screw on the back of the avr to get your voltage closer to the 110v you want in America. The engine sounds like it's surging a little, take the emulsion tube and idle jet(generally a little black plastic plug on engines like that ) out of the carb and clean them, the main jet will come out to release the emulsion tube, clean that too. Use a throttle body cleaner that foams and goes goey to soak them, then wash with a solvent. Nice score on the generators, it's a great way to learn things. I've commented on a couple of videos looking for information regarding the avr wiring but think I've discovered the original notes i made when I learned how to test them. I can add the information if it's useful to you. Cheers!!

[@mafosa8519]

hows the power on that head? anyone scope one yet?

[@dwmacneill]

Trust the United States Postal Service!

[@tanavasahamed3067]

Sir now little bit of connection more I need wire connection

[@gene2200]

Now I know what my slip rings should read, hopefully good since I have an identical PH on a another gen. Stater looks fairly easy to swap out. Great we'll done video, scoured you tube looking for answers!

[@the1spyderryder]

Your hook up is good but did you notice that the roter shaft bolt is wobbeling?

[@jcondon1]

That is normal on these. The ID of the bearing is larger then the bolt. Recently have been building a should on the bolt with electrical tape to help center it.

[@petersack5074]

27:00 time . Make a heat shroud, and bolt/screw it to whatever is handy there, to separate housing from muffler, directing any air flow OUT and AWAY.....

[@nathanielstuckey3354]

Where did you get one of these power heads

[@chinengsung8561]

Nice video… so much education in practicality

[@Farkus339]

Looking for parts for a champion generator head and can't find them online anywhere. Any suggestions?

[@jcondon1]

What is the Champion model number? How many cc's is the engine and what parts do you need? Most likely you can use honda clone 212cc parts or 420 cc parts.

[@Farkus339]

@@jcondon1 it's a 46517 3500-4000 watt 196cc. It needs that gen head repair like you did in this video and I can't seem to locate the parts online.

[@edwardmyers1746]

Intresting seeing TTI on that new motor, considering TTI is a tool company that own ryobi, milwaukee, empire, dirt devil, and other brands. Wonder what a tool company is doing making generator motor parts

[@WallStreet749]

James can you do a video and talk to us about how people burn up these generators. What are some of the ways that we need to avoid. the do's and dont's ..

[@tubergonz]

That little lock ring on the bearing was giving me fits. I tried again and I found that one side of the bearing has the groove deeper. If you spin it around it sits flush!

[@francisboudreaux3880]

You sure make Hardwork look easy. I enjoyed every minute of the video.

[@jcondon1]

Thank you so much 😊

[@brandonbarr2784]

Heat on half of it changed the resistance of electron flow creating even more heat. Just think how super conductors have to be very cold to work.

[@johncourtneidge]

Hurrah and thank-you again!

[@wilsonalvarez912]

don't get me wrong you make great ilusttrative videos I am a good follower of you. it justify for video purposes thank you very much

[@ThePheonix2009]

I don't know if you could see it but the terminal block had --L1 and L something else on it. Would that be line or load ?

[@turboimport95]

Would it had been possible to inject the 4 volts ac the avr w/e needed externally, and see what output the generator can do?

[@chrismoore9997]

Fantastic work. I need to get you to rebuild my 2005 Subaru powered generator.

[@alifarhat5523]

For that price the windig is most likely not copper but copper coated aluminum wires.

[@stratoman5504]

lots of run out on the bolt that goes through the center of the rotor

[@jcondon1]

Unfortunately that is how they are made. The bolts is much smaller then the shaft and impossible to center. Recently have been building a shoulder with tape. That get it much more where it should be.

[@billmonroe8826]

United States Postal Service. Says it all!