Parts Generator? Or an Easy Fix (No Output)

I found this generator on Facebook Marketplace. According to the seller the engine runs perfectly but it doesn't have electricity. Worst case I can reuse the Yamaha MZ300 engine on something else. But before tearing this thing down lets find out what happened to the generator and see if it can be fixed.
Generator Model: PM0645500
Engine Model: Yamaha MZ300
Bridge Rectifier Board: 0063525SRV
Brushes: 0050439SRV
I use Harbor Freight Super Heavy Duty Degreaser in my ultrasonic cleaner.
Board Repair: • Generac/Pramac/Powerma...
Bassguitarist1985: / @bassguitarist1985
Visit My Amazon Store:
www.amazon.com...
Breakout Cord: amzn.to/3VVXM5G
Brushes: amzn.to/3Yrf6Bg
Kill A Watt: amzn.to/3Yq8VgL
Multimeter: amzn.to/3Wf8iEP
If you want to donate to the channel, you can use the KZbin "Super Thanks" feature.
#GeneratorRepair #SmallEngineRepair #SmallEngine #DIY #Fixed #Troubleshooting #HowTo #Powermate
0063525SRV, Alternator, Bad Capacitor, Breakout Cord, Bridge Rectifier, DPE. Diode Test, Engine Runs Fine, Fixed, Generator, Hertz, Hour Meter, How To, How-To, Insulation Test, MZ300, MZ360, No Output, No Power, Ohms, Powermate, Regulator, Repair, Resistance Test, Rotor, Short to Ground, Small Engine, Stator, Troubleshooting, Volts, Yamaha

[@21zit]

We have used the kzbin.infoUgkxOTeIs0vv4_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!

[@edmckinney8457]

James, I recently retired from a 45 year career in the Industrial Electrical field. During those years I've repaired or built the controls for many different power generation devices all the way up to Coal Fired Power generation facility's and large portable generators. It's a pleasure watching you do the work and knowing that people still exist with your work ethic. Keep those video's coming.

[@jcondon1]

Thanks. It nice to hear positive comments from experienced people. I am not trained in this and just learning what I can as I go.

[@johncourtneidge]

Yes!

[@johncourtneidge]

@@jcondon1 best way!

[@robertdavis6708]

I love to watch James videos. His diagnostic procedures are pure gold. I've been around some gifted electrical trouble shooters in my lifetime but none better than James Condon. He's taught me the proper way of ringing out a gen set.

[@haneyoakie14]

I have started to dabble in generators because James has taught me enough that I an willingly to try my hand. Thanks James!

[@jaizulic1770]

Hi James, you have inspired me to do my own projects I had a lawnmower engine that was seized. I’ve got it on seized and running. I’m only 12. Lol

[@jcondon1]

Very nice

[@r8118830]

There is a great deal to be learned on the internet Jai. James is a great teacher. You have the capacity to become a good engineer,

[@jaizulic1770]

@@r8118830 yeah

[@oldroscoe2590]

I like seeing this. Learn to fix things and you'll save a fortune and not feel helpless the rest of your life.

[@philliphall5198]

Wonderful to see you learn

[@Bassguitarist1985]

Awesome video James! Glad to see one of the rebuilt boards put to good use! Cheers for the channel mention!

[@jcondon1]

Thanks for you help saving this one.

[@philliphall5198]

You’ll make a good business deal for everyone

[@johncourtneidge]

And well done you!

[@Farm_fab]

Jim, diodes operate like a check valve for air or water. They also do reduce the voltage slightly. In some circuits, they are intentionly used as a voltage limiter.

[@markyoung7470]

Just another validation that James is the Master Generator Gru.Amazing job James I love your video's just packed full of information and your diagnostic procedures are spot on with great camera angles!

[@mrobi5797]

Thanks for all your great videos during the past year James. They really help me solving a few issues and learn more about generators. I want to take this opportunity to wish you and your family a great holiday and wish you the best for the coming new year. Look forward to more videos in 2023. Keep the good work. Cheers. Mario

[@jcondon1]

Thanks Mario. Wish you and your family a happy holiday as well.

[@kaboom4679]

I always love that James can make the distinction between " A problem " and , " THE problem " . The ability to make these distinctions is priceless when troubleshooting systems , be they electrical , electronic , or , mechanical .

[@dougs6460]

Well done, James. A rescued machine is cash in hand and much better than parts sitting on a shelf (which may, or may not find future use). Your knowledge, and resources (bassguitarist) are invaluable and saved the day, again!. I was wondering what happened to the lift stand, it will save your back in years to come.

[@hb0292]

Couldn’t tell if you checked the dip switches on the panel monitor to see if they were the same when you changed it. People love to move switches

[@frankvucolo6249]

Very nice video! That engine, alone, was worth the $140, but great that you were able to resolve the electronics.

[@chrisssmallengines7163]

It is great having a parts hoard , especially on discontinued parts . Great video as usual .

[@JRattheranch]

Ah! That's more like your usual video! Meticulous cleaning achieved! 🤔🤭🤭

[@Farm_fab]

Jim, did you ask Gary if he could test the digital display? This night be a minor problem as well.

[@Chris.Y.054]

That was my question as well. Jim, thanks for another great video.

[@aliabbadi9149]

You sir are a LEGEND, I absolutely love your videos, please keep them coming.

[@RustyNail5856]

Great video, Iam glad to see that you used your lift , it make's it a lot easier to work on the gen, you did not break you back. James , keep putting out the good videos. take care.

[@YukonHawk1]

Excellent teaching video. Love the way you do things, one step at a time. Great genny saved from the garbage heap

[@iandennis7836]

Another fix......Jim, you're my dealer when it comes to enjoyable videos and long may that continue. Have a great festive season from all of your English viewers .🎅

[@rickolson9011]

James, loved the electrical testing detail. You point out different “expectations” for reading with various generator “types”. Is there any place that you have documented what we should expect based us being able to discern “type” we are working on? Thanks so,much for all you do to educate us shade tree “sparkys”!

[@rodneymiddleton9624]

This is the first one in a long time that hasn't had a carb issue. Thanks!

[@jcondon1]

I was thinking the same thing!

[@jesterr7133]

What does it indicate when the ohm reading jump all over the place? I have a starter switch in a riding mower that is doing the same thing. It will start the mower, but the headlights do not turn on.It jumps all over the place at the headlight sockets with the switch in the on position, then drops to 0 when the engine starts. I have already replaced the sockets with used sockets that are known to be good. I connected them directly to a battery, and they worked fine. I think there is an issue with the starter switch.

[@FarmCraft101]

Thanks for all your videos. Filling a lot of little gaps in my knowledge. Is there any utility in checking across each individual diode while they are still installed?

[@ninaevans4501]

Hi James, Wishing you all a Merry Christmas and Safe and Prosperous New Year. Wayne & Nina (Ipswich, Suffolk, UK) 🎄🎄🎄🎄🎄💗💗💗💗👍👍👍👍😊😊😊😊😊

[@haneyoakie14]

Watching Jim and Gary and Kenny makes me understand that there I a lot I don’t know. Yet continuing to watch closes that gap. I love the clear explanations and the thought process as you go up the decision Tree. Merry Christmas

[@jefferycrites9722]

Thanks for your videos. I’ve watched most all of them. They greatly helped me to learn more about fixing mowers and generators. I’m retired and have time to look into fixing things. It keeps my brain working. That’s important when you you get older. Keep them coming God Bless You.

[@KaldekBoch]

I stay up late every Thursday hoping for a new video. Thanks again James!

[@christiantreldal1585]

The problem with the cap is the voltage. You have 135v * sqrt2 = 191v at that cap, and that is to close to max. You should use a 350v cap and it will last forever. The brand Nichicon are some of the best caps; but not when you abuse them.

[@philliphall5198]

Love how you clean them up and fix them Your very picky and I bet the kids walk a line Lololo. Merry Christmas

[@ericsexton6799]

I have several generators, some I have fixed , but no where near his level of expertise, that’s why I watch …….to learn

[@tonygriffiths2485]

Another pleasant journey, thanks. Will lookup Base Guitarist 1985 thanks for that tip to :)

[@er1073]

James good stuff here I had doubts of this possible working but according to what your tested I then realized it has good potential. You did not disappoint me again. Thanks James for your skills and wisdom. Ed

[@AntonioClaudioMichael]

Pretty good machine just needed a Capacitor and a hour meter and good to go Not bad At all sounds pretty good @James Condon

[@greghanlon2235]

Good fix James and 2 in a row without carb/fuel issues. You're on a roll!

[@sebastiannielsen]

I saw and the DIP switch settings were the same on both meters. When exchanging meters like this, always make sure the DIP switch setting are the same, because it tells the meter the full load capacity of the generator.

[@Darryl603]

Nice generator. I like the built in panel lights

[@philstreeter9703]

Great video James. Your troubleshooting skills are excellent.

[@oldroscoe2590]

I've drilled holes in cases when the capacitors were to "long". Might not be the best solution in this case but it works on garage door safety detectors, the ones with the infrared beams.

[@jcondon1]

I have done the same. Not elegant, but it works.

[@watermanone7567]

Very nice job James. I had a couple of these in my shop several years ago, and the rear bearings were bad and caused damage to the stator or rotor. As near as I can remember there was a recall or warrantee that repaired them, but that was many years ago. Thanks.

[@Ram14250]

Hi James. Good video. I had that same exact genset... bought it at Home Depot. I have since sold it, but it ran well. I mainly got rid of it because of it's "dirty power". I too saw over 130volts. I have since gone to a Honda EU2000 which does everything I need and is much, much quieter. The Powermate was fine in it's day... and saved me headaches at the time.

[@tuguybear930]

Maybe the over voltage knackered the capacitor.

[@ariedekker7350]

Thanks for this video, enjoyed watching it in the Netherlands.

[@robertmailhos8159]

No power at the business end oh no that's not a great thing but it is in the right place to get it fixed

[@robertmailhos8159]

Thank you for the heart young man and hopefully you are feeling better because of the case of the vid that invaded your house hold

[@woolval52]

After washing that down I now feel guilty about my generator being so dirty. I can hear her calling me to get out there and give her a bath! That looks brand new, nice job. Also on getting power from it again... yeah, that too.

[@larryreich2154]

James- I work in a Corporate setting outside Boston. Management is now delivering a "Safety Mention" before events- How are you protecting yourself against CO2 poisoning running the engines in your garage?- I realize that there are many things unseen by the camera. I don't hear a ventilation fan running either. I enjoy your weekly broadcasts, and I want them to continue with you in good health.- Thanks!

[@P_RO_]

He's got a CO alarm down there.

[@jcondon1]

I do not run a fan or edit a fan sound in like some others. But I do have ventilation and a multiple carbon monoxide detectors that display the PPM of carbon monoxide so I can keep an eye on things and they will alert if the levels are too high. I always shut the engine down as soon as they start moving. Some engines are very clean and others will put a lethal amount of CO in the air in less then a minute. Here are a few clips of what I have setup kzbin.info/www/bejne/Y6XEiGx3qrt4mLM kzbin.info/www/bejne/mHKQhqZjqrhgjNU Also have a CO2 monitor because I also run a propane heater in the winter and want to monitor those levels as well.

[@shawnmrfixitlee6478]

Saved another one James.. I always put a dab of fresh grease on the end cap needle bearing race . being a non sealed bearing they loose there grease over time..👍👍

[@jcondon1]

Good point. Thanks Shawn.

[@bobyehchaoyi]

This is the best channel for repairing generators on KZbin.

[@zzzdogutube]

Next time repair boards yourself. No sense in sending it out when it's capacitor and diode. You can test those yourself. Capacitors fail due to age , moisture and not necessarily due to any other reason. Thanks for the video.

[@erik_dk842]

It's a no-brainer to swap out capacitors.

[@mcu_nerd2163]

With a little practice, a decent iron/station such as a Hakko FX-888D or a Pinecil with a chisel tip, some solder wick and/or a sucker you can easily replace components like that bad capacitor yourself. Enjoyed the video.

[@oldsranch]

Always generating great content. Powerfully good info, currently very accurate! (no more dad jokes now)

[@dannyj5688]

Another great diagnostics and fix...Always look fwd to your Thursday video's....Keep up the good work... you are appreciated more than you probably realize!!!!

[@SamCanada1]

Thanks for the video 👍

[@deangentles4966]

Hi James always great sitting in your class A nice easy fix for you with all the parts at hand as always a great teacher thanks for sharing May I wish you and your family a Merry Christmas and happy new year from here in the UK

[@jcondon1]

Thanks Dean. Have a Merry Christmas yourself.

[@passenger6735]

Nice work. Its always better to test diodes out of circuit in a power supply as the capacitor is directly across the output. If you need to test a diode then with the meter on resistance, place the leads across a diode note the reading and then reverse the leads and note the reading again. The values should be high in one direction and low in the other direction. A diode is just a one direction valve. The actual parts in that unit cost cents to replace so it's worth having a go yourself. Just replace like for like.

[@jcondon1]

Definitely need to take out of circuit to find the exact issue. Was just testing the board as a whole and it failed.

[@lv_woodturner3899]

That engine just sounds so good. As you mentioned, it hardly felt the full 5000 W load. Shame the design does not have AVR. Another one saved from the parts bin or scrap yard. Well done. Dave.

[@jaizulic1770]

Hi

[@PickandFlip247]

Would it be possible to add an AVR as an upgrade or improvement?

[@jcondon1]

No OEM option, but could probably fit a universal AVR.

[@erik_dk842]

@@jcondon1 You should make a video about that

[@r8118830]

Lovely work James. I thought the broken ropes were indicative of something worse. If one or a couple of turns of one of the coils had become hot then it did not last long.

[@jcondon1]

The lacing was not burnt looking, so may have been vibration related instead of heat.

[@victorhernandez4373]

Ay the 18 minute mark James ask: what do you think, will it work? I was like, NO there is still half a video left… 😂 Good work as always

[@robertsimpson7113]

Would have been interesting to see what the onboard display read for output during the 3,000 watt and 5000 watt tests???

[@jed2055]

Got me in the whole way with this one. Good video mate. I leanrned a few things too I was thinking, just learn to solder and order parts in and you can fix those simple boards yourself. You will find that soldering big stuff like that is easy peasy. Also, it occurred to me that AC devices allow +_ 10% voltage. Well, they do here in Oz. So that would mean 120x10%=12volts above and below 120volts. So, 132vac top end and 108vac bottom end. This genset was at 111vac low end at "full load" which I would be happy with. It will pull more amps though, and get hotter in the stator (another reason to keep the load no more than 5000 Watts). As you said, without a VAR you get what you get. But, back on Facebook for $220-$250 for an easy fix is not bad at all.

[@Popeyes66]

You deserve more Subscribers James. I've put the word out to my Geeky Pals. Another excellent video,Your Excellency .

[@tubeDude48]

Jim, I was surprised you didn't clean the rotor where the brushes rub against. Or is just the way they look?

[@jcondon1]

It looked like someone had already cleaned them recently. Not very well though, probably should have cleaned them again while in there.

[@tubeDude48]

@@jcondon1 - After thought, right!? ;-)

[@MotoRestoFL]

Was your house built around ‘72? That lally column is telling. Gotta watch the bottom at the concrete. The thing rots out and it’s not always visible. Then floor above starts settling.

[@kpdvw]

impressed witht the Diode Test, simple but effective..Thank you James and a happy new year...!

[@PeterLawton]

Watching you clean the generator, I thought, "you should create a separate KZbin channel for ASMR content, you know, for mental health". Ahhhhhh.

[@M0UAW_IO83]

The LCD in the 'digitech' looks for all the world like a standard 2x16 'HD44780' compatible display, should cost very little to buy but you'd need to find someone who could remove the old part and solder in the new one.

[@viscache1]

I have a new (runs like a champ) 8500W Firman (Fireman?) generator that was overloaded. Now if I plug in one item (space heater or IPad charger) it generates and works. If I add one item to it (regardless how small) it simply stops delivering power. If I take one item off…it starts sending power. The amount of power usage of either item does not seem to be the issue…but only ONE. Any ideas?

[@GaryToland]

I just picked up a Coleman Powermate maxa 5000 ER for $100 it's a little older but it is brand new, never had gas in the tank or oil in the crankcase. Has the Tecumseh 10hp engine. Wanted to make a little extra money, but sold it to my sister for what I paid for it.

[@HUBBABUBBADOOPYDOOP]

Mother's makes a plastic sealant/protectant called "Back to black", and it's excellent for things like that red dashboard. It would rejuvenate & moisturize that oxidized, faded plastic, also making it water resistant. Do you ever clean and paint the unsightly, pitted & rusty mufflers that come with most of these neglected generators you repair? It's not just cosmetic. I'm not talking about disassembly, sandblast and powder coating- but a simple brush in situ, then spray of Rustoleum BBQ.

[@Dirtyharry70585]

Caps from China are notoriously, bad or cheaply made. Back in the early 90s and 2000s when CPU boards were being made by major manufacturers in China they were putting in capacitors that were using incorrect data to be created causing them to fail within a year Dell gateway. Even Apple had all the problems.

[@brianwood5220]

Great video James, almost an early Christmas Present (just needing a capacitor). Thanks for sharing. 🎅

[@zodzod9378]

Nice easy fix ! Just done my Dell computer 5 capacitors for £1 lol runs great ! Little john from the UK Have a great xmas love all the vids !!!

[@bobadam7021]

I'm sure you're aware James, but in the 2000s there was something called the capacitor plague. Chinese companies got the formula wrong for electrolytic caps and they failed in everything from TVs to Generators. I made some good money buying those devices and just swapping out caps. In fact I still have a plasma TV in my shop that I've had for about fifteen years that cost me less than $20 to repair.

[@Chuck_in_CT]

But you didn't show if the display was showing a load!... btw don't toss the old display. It just might be a connection problem between the LCD and the board

[@mikefooyc8237]

So it's $5 worth of parts that brought down the machine. Good thing they used simple diodes and capacitor without any potting or waterproof coating. No fancy ic chips. Replacing parts is easy. Change out the diodes too while you're replacing the caps, a 100 strip of diodes is dirt cheap. The display looks like it was cooked. Exposed to prolong heat or Sun.

[@BKD70]

Love those Yamaha MZ engines. Better than Honda. To me it looked as if the original brushes were not fully worn in... maybe this generator has very very few hours on it? Just wondering if you checked what the display was reading while under load. Is it reading correctly?

[@VenturiMotorWorks]

The display actually started working after you reset the GFCI half way through. I haven’t watched the whole video yet maybe you already know this.

[@tarstarkusz]

Capacitors block DC and let AC pass like it's not even there. In this case, it's probably there to smooth out the output. Diodes do not produce clean DC, they produce 1/2 wave AC. In some applications it's not big deal, but in others you want clean DC.

[@Jonas_Aa]

Could make your own PCB layout in eagle software and then order like 10 pcs for $1 per board from like pcbway or something and then populate it with components.

[@ManorZvi]

Display - compare the deep switch toggles between the good and non-functioning display. may be that was the problem.

[@XxTWMLxX]

I just got a whole home 15Kw generator. Here's hoping that after watching all your quality content I can actually fix or atleast diagnose any issue I have with it if/when they show up...

[@davevaneck6026]

May I suggest that you upgrade your multimeter to one from Fluke? - You will never look back. The sampling time on the cheaper multimeters is very slow, so you have to wait for the reading to settle down.

[@m9ovich785]

Thanks James. I am watching this on generator Power. Last nights Snow Storm took out My power. Mike M.

[@paulstaf]

You ought to disassemble the display and see if the LCD has "zebra" strips... you might be able to clean the board and get the display to work again.

[@fitter70]

Excellent video as usual. I learn something new every time I watch one of your videos. Thank you.

[@jayjudd6518]

I’m satisfied that you are a genius at what you do. Congratulations

[@johnfeeney4636]

Im interested to know why there was no AC output until the bridge rectifier was replaced as its for converting AC to DC?

[@artpatronforever]

Instead of trying to repair existing control modules made to fit inside the power head, your electronic technician friend could likely create a heavy duty upgrade universal replacement AVR and rectifier board installed in a small project case, built using over engineered parts that will never fail in service because anything controlled will burn up before those controller parts which won't be the weakest link in the system. My idea is instead of trying to repair those marginal duty control boards that are onboard, externally located heavy duty control boards would be an upgrade that would eliminate the failure mode for the original less capable factory supplied cheaper design. Another advantage is a genset that did not come stock with AVR would have that feature easily added as an upgrade when repaired, so it would actually be better than new after a regulator upgrade.

[@rayvoorhies7180]

Can the display be fixed? It's probably a IC chip that fails. Nice generator and it wasn't expensive to fix.

[@MitchEllis-dn9lf]

To very old memory electrolytic caps usually short out while standard caps usually burn open.

[@1SmittysGarage]

Great catch there! If only they was all this easy. But, don't be fooled by the term easy as what's easy to one is difficult to another. Anther great informational video in the books my friend! Blessings and respect!

[@tedheierman1181]

It looked like the display may have been working after you reset the GFCI outlet.

[@tomschmidt381]

Another fantastic repair video. I'm surprised a 120/240 volt genie only has a GFCI on one leg. I was confused by how many diodes were on the PCB. Watched Bassguitarist1985 and each diode is paralleled so that mystery solved. It may be worth opening up the bad meter and try reseating the LCD display.

[@kpdvw]

good repair, as for the broken lacing strands a bit of silicon RTV will take care of them, (notice that the stator with the lacing has not been dunked in varnish and baked solid)....

[@JOHN-wy2iv]

Over the last 20 years or so there have been bad electrolytic capacitors showing up in all kinds of electronic circuits. Typical visual signs are the base blown out so the capacitor leans to one side and the electrolyte leaking everywhere. The top of the capacitor may also be swollen. It wouldn't surprise me if there was a problem capacitor in the display unit as well.

[@malandphyls]

James, thankyou for your videos and merry Christmas to you and your family. Mal from new zealand

[@michaelprince5255]

Electrolytic caps blow all the time. If the generator sits for long periods of time without being run they absorb moisture and blow the next time you power them up. Repaired many a board with swollen capacitors. You should be able to test the board by cutting a lead to the bad cap.

[@NY411Info]

Nice find, easy money. I have never been a fan of that plastic case head unit, but I have connected a good amount of them for people in my area that bought them during the 98 ice storm. These were the only ones available. If you need power they at least work. Ya gotta do what ya gotta do.

[@Renville80]

You can check the individual diodes with the multimeter as well. You should see a voltage drop when the black lead is on the end of the diode with the band (and the red lead to the other end), but not when the leads are reversed. If you get a very low reading either way, the diode is shorted. On the display unit, is there a potentiometer? Sometimes the display contrast just needs to be readjusted, so I would double check that before condemning it.