Chicago Electric Generator (Part 1) - No Power

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A local subscriber gave me this Chicago Electric generator. It looks like it has had a hard life and has stopped making power. Will it make power again? Lets figure out what happened and with any luck, get it working again.
Chicago Electric Generator (Part 2) - Repower and Upgrade: • Chicago Electric Gener...
Generator Model: 98838
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AVR, Alternator, Automatic Voltage Regulator, Bad Powerhead, Chicago Electric, Diagnostics, Engine Runs But No Power, Fixed, Flickering Light, Generator, Ground Fault, Hertz, How To, How to remove generator rotor, How-To, Insulation Test, Load Test, Low Voltage, No Output, No Power, Ohms, Puller, Repair, Rotor Test, Small Engine, Stator Test, Troubleshooting, Volts

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30 сен 2024

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Комментарии : 298

@nnan0001 Год назад

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 Год назад

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

@nozzledrich Год назад

Start playing cowboys and generators!!

@dljones61 Год назад

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 👨‍🔧

@EastCoastScott Год назад

I don't understand why or how people spend the kind of money they do on these items only to leave the outside and no regard about their condition

@adobedoug2564 Год назад

Possible that it was inside until it stopped working.

@CrimeVid Год назад

People buy ‘em for a possible emergency, happens once in ten years, don’t maintain, move it outside !

@randykinnamon93 Год назад

@@adobedoug2564 ki i8

@endtimeawakening5557 Год назад

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 Год назад

Thanks!

@alext8828 Год назад

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.

@inspector1794 Год назад

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.

@anthonysummy6944 Год назад

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_ Год назад

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

@markmoran9716 Год назад

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.

@redneckbryon Год назад

I know it might be a waste of time, but I would reinstall the original router and see what happens. There might’ve been some dirt that fell out and you just didn’t notice it.

@craigdreisbach5956 Год назад

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 Год назад

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

@billsmith5166 Год назад

@@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 Год назад

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

@RiverratGoRVing Год назад

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.

@DeadKoby Год назад

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.

@jesterr7133 Год назад

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.

@CuddleTrouble Год назад

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

@kpdvw Год назад

take the rotor out and bake it dry inside your oven, let cool, measure resistance to ground and try it again...!

@alantorrance6153 Год назад

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.

@Bulletman426 Год назад

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

@PabloDiablo682 Год назад

I don't understand why someone would buy a generator, and they ain't cheap, and then store it outside.

@jcondon1 Год назад

You and me both. It looked a lot older then it was.

@vilefly Год назад

Ah. You had just discovered the most annoying of electrical problems: THE CAPACITIVE SHORT. You noticed how it acted like a capacitor for a moment when you were measuring it? The resistance climbed until it was out of range? Yeah. Big hint. The worst part about a capacitive short is that it blocks DC, but lets AC voltage right on through. So, when the circuit twitches or alternates (during regulation) it shorts the rotor. What is also annoying is that it is so easy to fix with spray on lacquer or a bit of silicone. Just make sure it can handle being vibrated with repeating its performance later on. Welcome to automotive diagnostics 201.

@Tom-In-Ga Год назад

Enjoy your vacation. Looking forward to part 2?

@jesterr7133 Год назад

This one isn't salvageable, but it will make a good parts machine. I has a good engine, tank, stator, and many other small parts that you can use on something else. I wouldn't waste that nice Predator frame on this one, especially since it doesn't have the same rating. That would be a lot of time and effort for a machine that wouldn't bring much money.

@kpdvw Год назад

I saw pinched insulation on the stator terminals.....

@paulravitsky2898 Год назад

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!

@daemoncan2364 Год назад

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.

@jameshedrick605 Год назад

It's amazing how much someone pays for a generator just to leave it outside. Yeah I leave mine outside but i keep it on my porch under a water proof riding mower cover. The fuel that came out of that looked like what came out of my gas powered air compressor that I bought last week from a friend that needed money to get parts to fix his generator

@gonzo_the_great1675 3 месяца назад

Late to this party. But the short to ground was only tested (at leaso on camera) with the brushes/avr connected. A rogue reading?

@jesterr7133 Год назад

Wow. That machine has been severely neglected. I thought it was an antique machine at first glance.

@HwSystems Год назад

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

@lesr5737 Год назад

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

@robertmorin6495 Год назад

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.

@spencerwood1142 Год назад

Once again some quality content. Love the videos!!

@cjsebes Год назад

I don't think you need to use the Predator frame. That fuel tank and old frame just need a little TLC with some rattle cans and a rubber bushing for the vent.

@d1bergman Год назад

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.

@KrissBartlett Год назад

couldent you put some lacquer over that bad bit there like the green stuff you need to ultralight it for 20 seconds to harden over that where the wires were showing ?just asking ?

@davidhollfelder9940 Год назад

On the rotor, remove the 2 bolted plates in the middle, and check for poor insulation. Aha you went and did that later …😊

@tomhill9027 Год назад

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

@jayjudd6518 Год назад

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.

@sebastiannielsen Год назад

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 Год назад

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

@sebastiannielsen Год назад

@@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.

@vg3430 Год назад

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 Год назад

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 Год назад

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

@jcondon1 Год назад

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.

@jonminer9891 Год назад

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

@waynec3121 Год назад

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

@Red1red1MC Год назад

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.

@GusbidsBids Год назад

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.

@louisbigelow1866 Год назад

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

@jesterr7133 Год назад

I had a 2000 watt generator given to me. I was told it was a working machine, but when I went to pick it up, I found out that it has never even been out of the original box. It has never been used, but has been sitting in the original packaging on the floor of a relative's garage for an unknown number of years. The box is beginning to decompose. Given that this machine has been sitting for an unknown number of years with no oil in it, are there any additional precautions that I should take beyond the normal break in procedures for a new machine? The production date on the machine is 03/15/2005, so I am assuming that it has been sitting for 17 years. It is a Buffalo Tools brand, and appears to be a Honda clone of some type.

@jcondon1 Год назад

I would pull the plug before the first stat and put oil in the cylinder. Leave the plug out and fill the engine to the normal level of oil and rotate the engine clockwise with a drill to splash it all around. You will have to remove the starter recoil to access the flywheel bolt to rotate the engine.

@cptyler150 Год назад

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

@harryheaton1185 Год назад

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 Год назад

I'm with you mate, bit obvious.

@jcondon1 Год назад

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.

@philliphall5198 Год назад

Thank You for information and advice Really enjoy watching

@donaldelrod9172 Год назад

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

@Ram14250 Год назад

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

@P_RO_ Год назад

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.

@Jammer.1 Год назад

I'd just repaint the old frame & save the preditor for a better swap !

@artpatronforever Год назад

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.

@aerotro Год назад

@jcondon1 me again I have seen situations of oil conductive contaminants causing shorts, might I suggest washing the shorted area with IPA Alcohol, this will not harm the windings or coating on them, then WD 40, use a soft brush to agitate the area then clean and replace the metal plates also you could add some black tape to the insulation on the plates, and use the mega to check for high voltage arcing, you could save the rotor.

@johnhershey4010 Год назад

Hay James is that blue Generator a Harber Fright Brand

@philliphall5198 Год назад

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

@wildefox1478 Год назад

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

@georgelewis8904 Год назад

I think parts, your video is interesting thanks.

@CombatDoc54 Год назад

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

@XxTWMLxX Год назад

Could you of pulled the 3 fan bolts and swapped the fan from the bad rotor to the good one? Or would it of changed its length?

@JohnSmith-yv6eq Год назад

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

@reneenelsen7416 Год назад

Thank you for sharing your content. Much appreciated 👍

@MARKE911 Год назад

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.

@brewster3987 Год назад

Bwahaha 23:00 "I think definitely maybe on at least one of those"... Now there's commitment for ya 🤣🤣🤣 Edit: OK well, you weren't wrong... 👍

@rayburn157 Год назад

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

@garbleduser Год назад

This is why we coevolved with the shellac beetle.

@TomsLife9 Год назад

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

@JohnSmith-yv6eq Год назад

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

@hardyschlegel1048 Год назад

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.

@loucinci3922 Год назад

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

@GaryToland Год назад

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

@hpda44 Год назад

You’re still working on the floor! What gives?

@JohnSmith-yv6eq Год назад

Showing the viewers that it can be done on the ground if you don't have a bench?

@charlesmiles9115 Год назад

😛😛❤❤❤❤🦾🦾🦴🦴👍👍👍👍👍👍👍

@kyawhtin6949 8 месяцев назад

Hello, Where can I buy the power heads for the generator. I have on B & S 50 Amp stand by generator generating only 140 Volts instead of 230 volts. Model 354447 type 0122-E1 code 00031411. Thks

@GNX157 Год назад

One of the white wires had its shrink tubing extended down onto the terminal post area, which you identified as a problem in another video. How come you didn’t do anything about it on this machine?

@NY411Info Год назад

Chicago Electric is a Predator anyway. Harbor Freight just changed the name to Predator because it sounds cool. Hey, what do you have for a Genny? Oh, its a Chicago Electric. Umm ok. What do you have? I have a Predator See sounds better...lol.

@gd2329j Год назад

Someone's been in this unit so expect anything & inspect everything ….. As this generators been manhandled the phasing could be backwards . When you get MΩ remember it could just be damp in the windings ! Put the thing somewhere nice & warm for a couple of days . When testing for power always tests for 220 volts ….

@budzillasohoski9858 5 месяцев назад

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!

@georgebond6429 Год назад

fan bottoming out, Em, question would the fan from the damaged one not fit the other rotor? Yes I'm guessing

@JohnSmith-yv6eq Год назад

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

@georgebond6429 Год назад

@@JohnSmith-yv6eq Ah you said the dimensions was correct but I see what you mean😪

@HappilyHomicidalHooligan Год назад

Strip the frame, clean it up and give it, the tank and panels a fresh paint job and it might become worth it to stick that new power head in it... Especially if you can get rid of the rust on the Control Panel and replace the stickers... EDIT: If you've got a 9,000 WATT Power Head the Chicago engine can drive, than the Predator Frame makes sense...it's labels and Control Panel are already set up for it and nothing needs to be changed...

@philliphall5198 Год назад

Where is the flunk meter ???

@SNeal5966 Год назад

Wow they had Generators on the Chicago Electric name too? That's crazy! Now the name is "Predator" from Harbor Freight. The direct pipeline of Chinese junk to the usa!

@pepethefrog7193 Год назад

The megaohm connection is probably carbon powder from the brushes. Give the sliprings isolator a clean and this should be gone.

@P_RO_ Год назад

Doesn't explain why the short stopped with the removal of the plates. But otherwise yeah- I can see that happening.

@johnnybgoode6466 Год назад

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.

@ericblackwood1286 Год назад

Is there any way to replace the bushings in a generator

@HappilyHomicidalHooligan Год назад

When rinsing the tanks out, why wast expensive gas? Shouldn't some rubbing alcohol from the Dollar Store work just as well?

@ron827 Год назад

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.

@ranga2050 Год назад

The climbing resistance ground fault SCREAMS capacitive connection. I am willing to bet you have some kinda oxide corrosion layer between the windings and ground somewhere that's damaged the insulation. Try a meter on capacitive mode and see what you get compared to a healthy one.

@johnmckee7937 Год назад

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

@mikekrening7327 Год назад

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!

@daryelljeffries7861 4 месяца назад

If you wrap electrical tape around the pliers it won't damage threads and it will give you more friction. I learned this from taking speedometer cables out of rental vehicles to keep milage lower for costs. Please don't report me to rental agencies 😂. No I don't do it anymore and haven't since 1976.

@er1073 Год назад

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

@somerandomguy3868 Год назад

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

@mikeprociuk988 Год назад

It appears someone took the neutral/ground bond off so they could hook it up to their house panel without a transfer switch.

@vincyman80 2 месяца назад

I have a generac generator GP1800 only runs with the choke on and not on off. Once I turn it to off it stars stutter and smoke a lil then shuts off. What do you think is my problem?

@dawn1berlitz Год назад

you might be able to touch it back up with a fresh coat of paint and some screws from harbor freight or a true value nuts and bolts that is assuming the parts your trying will work

@gaetansimard1594 Год назад

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 Год назад

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

@SeekingTheLoveThatGodMeans7648 Год назад

What a pity that the proposed replacement rotor "almost" worked except for the slightly different configuration of its fan end. If you'd had the casting in which the replacement rotor's fan end fit, maybe that could have done it.

@ericwuichner8168 Год назад

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

@alfredocuomo1546 Год назад

It looked like the wires on the block had the insulation covering the eyelets but I'll wait to the end of the video to see if thats the issue for no power.

@SoundzRite Год назад

A Hipot tester would find this problem immediately by causing a low power arc at the fault point. Hipot testers are used by industrial manufactures to qualify their products for CE conformity. I worked at a manufacturer that was required to test every unit. I found and repaired many defects on the floor due to sloppy assembly. These testers are pricey but you may be able to rent, borrow or buy a used one at auction.

@Renville80 Год назад

Use the continuity setting on the multimeter, the next position clockwise. It will give a beep if there is a low resistance path.

@benjaminbenji1355 Год назад

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..