Generac GP7500E - No Power Output (Stator/Rotor Swap)

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This is another one of Jason's generators. He was told that it had a good engine and made power but needed the fuel system cleaned up to run. Once running he saw that it did not make power. He asked me to take a look and see what I could do. With any luck its an easy fix.
Generator Model: GP7500E - 0059432
Below are links to the 4 videos in this GP7500e series. Each video is a complete standalone video. They build on each other and make more sense if watch in order.
Part 1: (this video)
Part 2: Another Generac Generator Not Producing Power - Can We Fix It? • Another Generac Genera...
Part 3: Generac Engine Rebuild - Wiped Camshaft Lobe • Generac Engine Rebuild...
Part 4: Generac Engine Swap - Worn Engine/Down on Power • Generac Engine Swap an...
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#GeneratorRepair #SmallEngineRepair #SmallEngine #DIY #Fixed #Troubleshooting #HowTo #Generac
AVR, Alternator, Bad Camshaft, Bad Rotor, Bad Stator, Borescope, Broken Brushes, Broken Wire, Clean Slip Rings, Down on Power, Fixed, Flooded Engine, GP5000, GP5500, GP6500E, GP7500E, GP8000, Generac, Generator, Hertz, How To, How-To, Install Generator Head, L1 L2, Load Test Fail, Load Test, No Output, No Power, Oil Contamination, Power Head Swap, Powerhead Swap, Remove Rotor, Repair, Set Engine Speed, Small Engine, THD, Total Harmonic Distortion, Troubleshooting, Volts, Worn Camshaft

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Опубликовано:

24 май 2023

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Комментарии : 327

@brewster3987 Год назад

Jim, ~8 minutes in: "This should be an easy fix"... me, looking at the 56 minute video length, "Ummm...." 🤣😂😁

@YukonHawk1 Год назад

I did the samething😂😂😂😂😂

@MrHugawa Год назад

lol, get out of my head

@timdwyer8004 Год назад

Exact same thing!! 😂

@wesley00042 Год назад

Note to self: when buying a used generator, bring a bunch of space heaters to test the health of the engine first.

@danbenson5319 Год назад

Probably not the worst idea.

@evilredBoris 7 месяцев назад

I think you mean the stator right?

@fcdrummer1806 6 месяцев назад

@@evilredBorisThe power head is driven by the engine. If the engine is down on power it could stall under load. If the stator was not healthy it would either not power up at all or a leg would work and the other one won’t.

@ecaparts Год назад

Good find! I would imagine most shops wouldn’t have load tested more than a small load and shipped it out the door. I have learned a lot from your videos! Thank you for taking the time to help others!

@williambennon7532 Год назад

While that amount of oil contamination is extreme, it does show how important clean oil is for the longevity of these filterless small engines. Absolutely love your videos and appreciate your expert editing. Would love to see more repair videos on small non-Honda suitcase generators. Keep up the good work!

@sgtbrown4273 Год назад

Awesome like always ! I spend my internet time listening to James Condon down in Antarctic at McMurdo station. its 2330 here and the best thing on TV is generator repair! 😁 keep safe brother, cant wait to show you the generators we have to service for the science crew down here. Your channel has helped as well as inspired us to be better technicians.

@ickipoo Год назад

I can't wait for you to show us either!

@XPFTP Год назад

have james or others send you broke down gens. repair them there sign them. sell them . own a genny thats been to the south pole.. hahhaha

@kd5byb Год назад

McMurdo station has to be the coolest watching location I've ever seen in a RU-vid comment! Respect! :)

@Channel-gz9hm Год назад

They got you guys the MuskNet down there yet?

@ickipoo Год назад

@@Channel-gz9hm I suspect that won't be practical until Elon has the inter-satellite laser comms working. At the moment, they can only provide coverage when the satellite can see a ground station and I don't think the ground stations in Australia are close enough.

@2packs4sure Год назад

Oh man I wish that generator could talk,,, it's obviously got one hell of a story to tell !!

@gutsngorrrr Год назад

Wow, your friend got punted a real lemon there.someone knew what they were getting rid of there. But that's the gamble you take when buying stuff like this.

@mikehotchkiss8975 Год назад

All that rust may indicate a flood damaged machine. Cleaned up nicely by the previous owner. Thanks man

@goatmaster3387 7 месяцев назад

I don't think there is a more reassuring and relaxing voice to listen to while watching repair videos.

@beaubrummelmotorizedbicycles Год назад

I did notice during the video, that the engines side cover had an excess amount of orange RTV sealant on the gasket, leading me to believe the side cover has been off at some point recently. It does look like the engine has had water infiltration. Never a good sign when you hear tinkling noises when the oil hits the pan. Great video, I have learned some good knowledge about a generator. Thanks for doing these videos they are very well done.

@davidparsons5513 Год назад

That was a very good and interesting final few minutes! You'd never imagine the internals could look that way.

@generessler6282 Год назад

My dad was an industrial mechanic for most of his days. Whenever we worked on engines together, he constantly talked about cleanliness and how any dirt would mix with oil to effectively make grinding compound. Looks like exactly what he was talking about 😊. My job was always scrubbing parts, so this was inspiration.

@jimthannum7151 Год назад

Your videos are so interesting, educational, and constructive with your clear and precise dialogue. I am so fortunate to have found your channel. Great job!!

@jcondon1 Год назад

Thanks Jim

@charlesmisiak4926 Год назад

You always leave me amazed and at a loss for words with the work and care you put into these machines. I would have NO problem buying a generator that you have worked on.

@TheBen003 Год назад

James this is the reason why when I get ready to buy a generator I would rather buy one from you because someone that takes the time to do it right and takes pride in their work does not go unnoticed. I would dearly love to buy a generator from you sometime in the future only if you autograph it for me. Thank you and please keep up the good work I watch all your videos and try not to miss any.

@1DouglasBurney 8 месяцев назад

Wow! A whole hell of a lot work to find a double lemon. Thanks for showing all of it. It makes me think about analysis before dumping major parts in a project. A bore scope is on my shopping list. ............. This video does help me! ...........

@samuel_towle Год назад

@9:30 A friend of mine had a Generac 5500 that stopped making power and it also had no continuity through the slip rings. I found the rotor winding was broken at the slip ring terminal likely due to combination of vibration and rotation fatiguing the wire (Like you describe @21:27). There was no epoxy / RTV or anything to prevent the wire from moving. Luckily, I was able to strip and solder the end of the winding back on the terminal. It's been working fine for about three years now. Bit of bad luck with the engine.

@AW-Services Год назад

Wow we are in for a treat

@sgtbrown4273 Год назад

awesome!!!!!! 😆

@theconnectedcamper Год назад

What you NEVER want to hear when you open the oil drain! Great capture of that audio, but an unfortunate situation. James - your work, attention to detail, dedication to saving these machines, and soothing voice all come together in an awesome fashion. You inspire me to be more diligent in my reassembly of my machines and to not be so proud that I can get mine put together with less hardware than the factory ;)

@ParrotHead1809 Год назад

This vid was like a master class in generator repair; from the power head to the engine. Love the channel!

@carl-gunnarhillefors7612 Год назад

Yet another enginuity and correction of a faulty generator! Well done!

@1pcfred Год назад

A U-boat captain was running this generator. Dive, dive, dive!

@Dugie555 6 месяцев назад

Thanks for the very methodical and meticulous diagnosis and explanation! It bites that this generator need/needed a lot of work and parts; it goes to show that you never know what you’ll get until you try and work on it. 👏 P.S.- That oil change…. Oof..

@richardphelan8414 Год назад

I have learned a lot about small engine repair watching your Videos

@gonzaleznadia2 11 месяцев назад

We have used the ru-vid.comUgkxOTeIs0vv4_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!

@emylrmm Год назад

Beautifully done James!

@zrkn1 Год назад

I love your current test bed, never a dull moment. A bore scope is a miraculous tool in this case wow. Someone got burnt on this deal. Sometimes another bad carb would be welcome, ouch. Excellent video JC!!

@mygardenofthings Год назад

Many thanks for extra footage, excellent video as always 👍

@watermanone7567 Год назад

Very nice diagnosis Jim. thanks for the video.

@jamesmcmanamy4704 Год назад

Another great analysis by JC.

@Barracuda48082 Год назад

I just bought one at a local Menards, storms knocked out power here in Michigan, 7150watts run, 8000 watts surge, and as usual, utility was restored as we fired up the new unit and a 800 watt load..ha

@MitchEllis-dn9lf Месяц назад

Good catch on the camshaft. And measurement technique

@butler386 Год назад

Oh dear what a bummer. That is typically what would happen to me. Great diagnosis. Thanks for the video.

@jg6142 Год назад

Very good detective work Jim!

@johnnybgoode6466 Год назад

well done James - lets see you work your wonders on Jason's machine later on in the year - Jason will be a bit disappointed that he has been mislead by the previous seller. excellent video again James.

@rodneymiddleton9624 Год назад

Great diagnosis!!! Thanks Jim!!!

@carlbelken4478 Год назад

I enjoy your videos. I like how you just calmly explain things with no drama like there is on other channels.

@philstreeter9703 Год назад

Great video. I learn something every video. Thanks for sharing.

@thomasstewart9368 Год назад

That was a unexpected ending to a well done video...thanks 👍

@loucinci3922 Год назад

Very interesting. Enjoyed that troubleshooting. Thanks for sharing

@Tom-In-Ga Год назад

Another first for James Condon. At 4:45, the worlds first Gen-Cam.😁

@hieyeque1 Год назад

I guess it might be a good idea to inspect the oil from the get-go. If you had seen that from the start, it might have been a different story.

@jeffbotkin1405 Год назад

Spot on Jim . I would have probably gone down a whole different path and checked the breakers and wiring first. Then the brushes and AVR. Glad you found the problem so quickly. Just junk.

@pyro_chip8287 Год назад

Just found your channel, its amazing. Im an amateur small Engine mechanic myself. Truly enjoy your videos. Just subbed

@jeanbaptistevallee4500 Год назад

Thank`s James!

@ayozhek1898 Год назад

That is an unusual one, suprised it ran as well as it did. Another great video, thanks James.

@jcondon1 Год назад

It ran pretty well without a load.

@deangentles4966 Год назад

Hi James always love watching you work mate Great detection on your part thanks for sharing

@jcondon1 Год назад

Thanks Dean

@jonminer9891 Год назад

Hi, James. A disappointing surprise. Oh well. I was happy when you put away the razor and got out the snips! Thanks for sharing! Stay Healthy!

@YukonHawk1 Год назад

That genny definitely took a midnight swim😂😂

@methods-SE Год назад

I already love the story before listening to the whole thing

@mrpetit2 Год назад

Interesting ending! What a lemon! Awesome video for sure 👍

@jeffgrant6914 Год назад

Good video 👍 James

@MrJmattr3 Год назад

Great content as usual!

@nederlandhiker2 Год назад

Excellent video. Thanks

@Sev_Auk Год назад

That was an interesting one James. That thing was definitely "mistreated with extreme prejudice" at some point :) Thanks as always for the videos. Cheers, Sev

@Mikelp73 Год назад

Super nice amp clamp/meter. Super neat, anyway.

@garbleduser Год назад

Toenail clippers are the fastest tool to use for circumcising overzealous insulation tubing on electrical connectors.

@thesilentonevictor Год назад

When you know your job the result is spectacular

@geoffreyhall7843 Год назад

Happy Friday, James. FYI, could definitely hear the pebbles hitting the drain pan. Boroscope (sp.?) pictures stunningly clear! Surprised the engine didn't sound like a cat fight w or w/out loads.. Love your content. Surprised you don't have way-more viewers. Looking forward to the engine replace (rebuild,,,, I couldn't imagine the work!).

@jcondon1 Год назад

The engine sounded a little off without a load. Was thinking it has a clogged spark arrestor or maybe a bad bearing. Never imagined how bad it was.

@GerardRusso Год назад

another great video with a twist

@peterwalker7869 Год назад

Someone was in there before you. First sign, missing stator bolt, second, there was numbering on the terminal block. Never seen that before when you open up a generator. Third, broken brushes because the yanked the stator off without first removing the brushes. Forth, no broken fan bits inside.

@tchads_57 Год назад

As you noted, someone had already been inside the machine and had to know that it was under water. Selling this to your friend was IMO, ripping him off. 🤬 Nice video on how to check the power head.

@ddblairco Год назад

thank you james

@Georgeolddrones Год назад

Brilliant love your videos more please George in England Uk 🇬🇧🙏🇺🇸👍

@davidblake6889 Год назад

Thanks James for all your great videos. I know the engine on this unit is done for, but I would love to see a full tear down, as well as the rebuild of the generator when a suitable engine becomes available. It would be interesting to know what caused the damage, and what the bits of junk in the oil are. BTW, the audio caught the sound of the 'bits' hitting the tray really well when you emptied the oil.

@jcondon1 Год назад

I plan to do a tear down once I locate a suitable replacement engine. For now, much easier to keep it all together.

@richardhawkins6612 Год назад

@@jcondon1 Hello James. I have a GP7500E with probably around 250 hours on it and it needs a stator/rotor assembly, but the engine runs great. I haven't decided what I'm going to do with it yet but it sounds like my engine could be a possible candidate for replacing yours. If there is a way I can get in touch with you please let me know and I'll contact you to discuss it. Regards Richard

@Jameson4327 Год назад

I’m sure you will get up and running again. I’ll be waiting for your next video

@AdamMaszynotwor Год назад

Good job my friend:)

@eamonnmckeown6770 Год назад

Good stuff. I picked up a Guardian Generator 45822 which I think I remember is produced by Generac. It's a future project and the story was that the carb might just need cleaned. It didn't start after winter storage. A govdeals DPR purchase. Not sure if any of this video will apply directly but cool video nonetheless.

@anthonysimonhough9691 Год назад

Very interesting thanks for the movie

@wjodf8067 Год назад

What a mess Good job as always

@michaeltarasenkoop2389 Год назад

I worked on some equipment from I think Germany that green wire was a hot leg with blue also hot rather black and white and red ! In our country !

@wildefox1478 Год назад

Like you said, can't win them all, it's unfortunate the inside of that engine is in such bad shape and the camshaft is shot but I'm sure you'll find a replacement engine to fix that generator. Nice work as always James!

@jcondon1 Год назад

I will find an engine at some point.

@jcondon1 Год назад

I will find an engine at some point.

@iantyler4045 Год назад

Just goes to show that just because it sounds okay doesn't mean it is. Good thing your eagle eye picked up the valve opening issue. Most people would have said "There you go it's running and producing power".

@benkanobe7500 Год назад

I was only able to find the white/translucent zip ties with the bolt hole which I think do not have the photon/UV protection the black ones do. If you ever get a spare moment it would be great if you provided a link in your Amazon Store to the black ones. They are also used on boats for holding wiring harnesses along the length of the hull and such.

@dwightelvey645 Год назад

Hi James: you do enough generators, it might be worth making a growler. Finding opens is relatively easy with an ohm meter but detecting shorts can be more difficult. As a kid, we used to use what is called a growler to test armatures from car generators to test for shorts. On a stater you need an inside device rather than an outside one. My thinking is you could use a rotor as the inside coil. Most seem to have about 24 volts. I'd think a Variac ( adjustable auto transformer ) or a fixed 24 volt transformer would likely work. Anyway, it would be worth experimenting with. Just my thoughts. The other way might be to use an AC current meter and use the rotor in the motor. One could use the auto transformer and bring the voltage up to some level of AC current.

@mjg263 Год назад

Very interesting analysis! I’m surprised there’s no sign of mud / water contamination inside the power head in between the windings. I wonder if that had something to do with the fan blowing apart too.

@dennissmith8199 Год назад

The lack of apparent damage to the inside of the fan housing is interesting to me. If the fan came apart while running, there would have been damage to that area. It's almost like someone put the bad rotor and stator on knowing they were bad.

@martin4787 Год назад

I agree Dennis

@TopCat2021 Год назад

Good catch

@andybonneau9209 Год назад

Great explanation of how the connections are configured.

@robertmailhos8159 Год назад

I saw a video on a Kawasaki belt driven generator on AJ restoration that was the first time I saw a belt driven generation power machine 👍👍

@MazichMusic Год назад

Bruce recently had a belt drive Honda on his channel.

@richb4099 Год назад

I don't work on portables much but did have a Generac with major engine issues with very low hours.....Engine was self destructing......Very poor quality machines and trust me I just spent time trying to fix a Generac 6.5 RV unit and said never again!! Generacrap is a better name for them....

@richb4099 Год назад

I forgot to mention I’ve seen the Made in China base Generac portable 5.5’s more than once with very few hours and burned up brushes. 50 hours or less.

@tbas1972 Год назад

Did you see all the black soot on the top of the adapter plate? Looks like it was a light show In there, I'm guessing they took it apart and saw that and put it back together, seeing as the brushes were broken, I've forget to take them off the put the end cover back on and heard a crack, woups, great fix and great video

@redneckbryon Год назад

After seeing the overall condition of the bottom, I'm surprised it ran as good as it did.

@larrycleeton Год назад

I had a feeling at the beginning based on corrosion on some bolts that this gen set was out in the rain at least.

@peterouellette3874 Год назад

That was a bummer, nice job James

@kpdvw Год назад

Bummer, James...!

@dzidaolek88 Год назад

Dziękujemy.

@jcondon1 Год назад

Thanks Aleksander

@stiggywatts4258 Год назад

Another brilliant video. Thanks James.

@franksando635 Год назад

I enjoy watching your videos 👍🏆

@RiverratGoRVing Год назад

James, your knowledge supercedes your ability to diagnose the main problem. And your garage/work shop is almost every man dream to have with the tools to diagnose the problem. Keep posting as your post help all DYIers that try and make it live longer. Michael

@jimato01 Год назад

As you've said "you cant win them all !"

@paulstewart5788 Год назад

I really enjoy your videos. I was wondering what brand oil you recommend. I understand oil is oil but I’m curious

@johnmolnar2957 Год назад

some definitely was in there, even spray painted the stator to make it look better

@lintonthomas9826 Год назад

Hi, as for the stator u can carry it to a motor repair shops and get it rewind.

@NikeHM69 Год назад

As soon as I saw that red RTV all over the engine block I knew that this was going to be a basket case.

@anthonytriolo3643 Год назад

You should be using lacing cord ,with heat the tie wrap could pop and back to square one.

@standodge7687 Год назад

anyone else's wife come banging on the bathroom door after 45 minutes yelling "you still alive in there"

@er1073 Год назад

It was too good to be true it did look very promising but looks are deceiving and the bonus is low quality H2O. Thanks James good stuff to bad your friend got taken like the dishonesty in some people. Ed in Stafford Virginia.

@stevendufresne9994 Год назад

Great Video Thanks James Always learning something new from your Videos!!👍👍

@michaelkennedy2528 Год назад

Meant to ask a while back but forgot. Are the rotor bolts that hold the rotor to the engine tapered shaft torque to yield and need replacing each time?, or are they reusable? With those being so long, stretching could be a very real problem, even with just the 30ish foot pounds of torque. Thanks, enjoy the videos a lot.