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Old 08-14-2016, 06:37 PM   #1561
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Today: Found new bearing at auto parts store (National bearing #6205ZZ). Made tool to remove the rotor and successfully did just that. Seeing I don't have a large shop press, this is going to the local machine shop tomorrow for the bearing install.

New bearing is ready.jpg
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Old 08-14-2016, 06:56 PM   #1562
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Originally Posted by aja8888 View Post
Today: Found new bearing at auto parts store (National bearing #6205ZZ). Made tool to remove the rotor and successfully did just that. Seeing I don't have a large shop press, this is going to the local machine shop tomorrow for the bearing install.

Attachment 24501
Is there a simple way to know how healthy the rotor/stator windings are (overall resistance check, etc). I hate to knock on doors if there's likely to be a monster behind one, but while you've got everything apart, if a re-winding is needed and not too costly, maybe this is the time to do it?

Apologies if that is a dumb question.
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Old 08-14-2016, 07:13 PM   #1563
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Is there a simple way to know how healthy the rotor/stator windings are (overall resistance check, etc). I hate to knock on doors if there's likely to be a monster behind one, but while you've got everything apart, if a re-winding is needed and not too costly, maybe this is the time to do it?

Apologies if that is a dumb question.
Not a dumb question at all. The old manual I found has a series of electrical tests that can be done with a multimeter. Mostly looking for shorts and opens. There are also some resistance (ohm) values that are part of the test of the stator and rotor.
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Old 08-14-2016, 07:15 PM   #1564
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That winding looks good to me, not burned (no dark varnish), slip rings look good too. Replace the brushes of course.
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Old 08-14-2016, 08:13 PM   #1565
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That winding looks good to me, not burned (no dark varnish), slip rings look good too. Replace the brushes of course.
If I can find some correct brushes, I will replace them. This is a 20+ year old generator.
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Old 08-15-2016, 05:16 PM   #1566
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Today I got the new bearing pressed on at a local machine shop ($10 fee). I also ordered a new brush set and air cleaner element. I also partially assembled the generator and associated wiring. Waiting on brushes now.
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Old 08-20-2016, 06:34 PM   #1567
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New brushes are in and the odds and ends from previous maintenance events (missing bolts, loose wires, split hose ends, etc) have been sorted out. We mounted the unit on the shelf plate and it is ready to be installed. That will happen tomorrow afternoon with pictures.

IMG_20160820_183858.jpg

IMG_20160820_183933.jpg

IMG_20160820_183946.jpg

IMG_20160820_183956.jpg
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Old 08-20-2016, 10:22 PM   #1568
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I guess it takes additional work if the generator is to make a test run before installation. It would give me a warm and fuzzy feeling. I don't know how much of a hassle to mount and dismount the generator.
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Old 08-20-2016, 11:12 PM   #1569
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I guess it takes additional work if the generator is to make a test run before installation. It would give me a warm and fuzzy feeling. I don't know how much of a hassle to mount and dismount the generator.
It's not practical to try to set it up for a test run outside of the RV as I have no load wiring to attach, no fuel tank, and a 12V battery would need to be wired. It is not too hard to jack it up with my floor jack and slide it into place in the RV and tie in a few wires and plugs, the gasoline line and the load wiring.

Our plan is to bring the RV to my house tomorrow afternoon and install it then give it a whirl. I don't anticipate any problems as long as the new brushes seat with no problems and I didn't re-wire anything wrong ().
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Old 08-21-2016, 02:42 PM   #1570
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Just be careful not to let any of the magic smoke out.
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Old 08-21-2016, 04:58 PM   #1571
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Generator is installed. It fits in a framed location a bit back from the driver's door side. It took two of us about two hours to work it in place with a floor jack and then hook up the fuel line, load wiring, accessory plugs, air cleaner and misc bolts and fasteners. She started right up and was not running smooth until I adjusted the carburetor (it needs to be rebuilt). But I did get it running pretty smoothly and the generator side works as it should. Here's a few pics of the end of the project:

IMG_20160821_155230.jpg

Generator installed and running (above)

IMG_20160821_161827.jpg

IMG_20160821_161857.jpg
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Old 08-21-2016, 05:04 PM   #1572
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Thanks. I love project follow-ups.
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Old 08-21-2016, 05:13 PM   #1573
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Nice job!
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Old 08-21-2016, 05:47 PM   #1574
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Nice job!
Thanks!

I just totaled up the parts cost and it was $89.12 for the following:

New ball bearing,
New brush set,
New Air Filter element,
3 foot threaded rod (7/16" dia, coarse thread) - make a tool for rotor removal,
One 9/16" dia X 2" long bolt - Use with rod above,
4 quarts 10W 30 Motor oil/new oil filter,
One tube of Permatex form-a-gasket for the install of the intake manifold.

Labor to press old bearing off and new one on was $10 at a local machine shop.

So we have around $100 into the repair. Not bad, given a new generator is around $4250 installed.
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Old 08-21-2016, 06:00 PM   #1575
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Thanks!

......So we have around $100 into the repair. Not bad, given a new generator is around $4250 installed.

Plus the lunches that you failed to note down ....
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Old 08-21-2016, 06:05 PM   #1576
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FIL had a new counter installed, but didn't pay for the sink hookup, then he fell doing the sink.
So I went over and installed the sink strainers, taps, new garbage disposal, a new filtered water tap along with some new shut off and braided water lines.
A nice 5 hour family event.
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Old 08-21-2016, 06:06 PM   #1577
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Plus the lunches that you failed to note down ....
Yeah, there were few of them. But we would have had lunch anyway.
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Old 08-21-2016, 06:08 PM   #1578
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FIL had a new counter installed, but didn't pay for the sink hookup, then he fell doing the sink.
So I went over and installed the sink strainers, taps, new garbage disposal, a new filtered water tap along with some new shut off and braided water lines.
A nice 5 hour family event.
Lots of under counter work there! I'll bet FIL was pleased.
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Old 08-21-2016, 06:21 PM   #1579
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Lots of under counter work there! I'll bet FIL was pleased.
Yep, here is a good tip for under the counter work.

My Aunt had a very low stool about 2.5 ->3 ft long , I put that up to the entrance of the counter with a padding on top if it. Then lying on the floor stuck under the counter was not painful or awkward.

I really thought the idea was stupid at first, but now I know it's a great idea.
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Old 08-22-2016, 06:04 AM   #1580
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Congrats aj8888, that is superb save for the old gen set.
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