Troubleshooting Your Predator Generator Power Issue

Table of Contents

1. Introduction
2. The Background of the Predator Generator
3. The Issue with Power Generation
4. Testing the Health of the Stator
5. Checking the Resistance at the Brushes
6. Testing the Resistance of the Rotor
7. Identifying a Broken Wire on the Rotor
8. Disassembling the Generator for Repair
9. Separating the Rotor from the Engine
10. Conclusion

Introduction

Welcome back, guys! Today, I want to share with you my experience with a Predator generator that I recently brought home. This particular generator was listed for parts only and was priced at just $50. While the engine seemed to be in good condition, it had one major issue - it didn't generate any power at all. In this article, I'm going to take you through the process of troubleshooting this generator, step by step, to determine the point of failure. By sharing this information, I hope to help you if you ever find yourself dealing with a similar problem.

The Background of the Predator Generator

Before we dive into the troubleshooting process, let's first talk a bit about the Predator generator itself. The Predator generator is a popular choice among DIY enthusiasts and homeowners due to its affordability and reliability. It is known for its compact size, ease of use, and ability to provide power during emergencies or outdoor activities. However, like any other machine, the Predator generator can encounter issues that may affect its performance, such as the one we are going to address today - a complete lack of power generation.

The Issue with Power Generation

The person who sold me this generator purchased it brand new but never used it until a couple of years later. To their dismay, when they finally went to use it, they discovered that it didn't produce any power whatsoever. In an attempt to fix the issue, they replaced the AVR (Automatic Voltage Regulator), but unfortunately, it didn't solve the problem. The voltage measured at the outlets was only 2.5 volts out of the expected 120 volts, indicating a case of residual magnetism. This pointed to a possible problem with the rotor, brushes, AVR, or DPE winding. Since the AVR was already replaced, it seemed likely that the issue was terminal. However, before giving up on the generator and using it for spare parts, I decided to conduct a thorough investigation to pinpoint the exact point of failure.

Testing the Health of the Stator

The first step in our troubleshooting process is to check the health of the stator. This test is applicable to both brushed and brushless generators. In the case of this 240-volt generator, it has two 120-volt coils, both of which should be tested. To identify which coil is which, visual inspection is often sufficient. However, if you're unsure, it's best to test them all. The readings we're looking for should be around 1 ohm. While most generators of 5000 watts or above test at around half an ohm, this particular Predator generator, as well as several other brands of similar size, tend to be closer to 1 ohm. It's essential to check the resistance of your meter before conducting the test and subtract that from any reading you get. If the test results indicate a resistance close to 0.7 ohm on both legs, then the stator can be considered good.

Checking the Resistance at the Brushes

Next, we need to test the resistance at the brushes. To access the brushes, some wires may need to be moved out of the way. In this particular generator, the blue wire represents the positive side, while the yellow wire represents the negative side. It is crucial to note that since this is a DC circuit, polarity sensitivity should be taken into account. Generally, a good rotor should have a resistance between 7 and 70 ohms. If the resistance falls within this range, it is a positive sign. However, if the test results show no reading at all, it indicates a potential issue with either the brushes or the rotor.

Testing the Resistance of the Rotor

To further investigate the problem, we need to test the resistance of the rotor. The rotor is responsible for creating the magnetic field that induces voltage in the stator windings. It is crucial for this component to be in good condition for the generator to function correctly. Typically, a good rotor will have a resistance between 7 and 70 ohms. In our case, the rotor showed no resistance at all, suggesting either a broken wire or a faulty rotor. To confirm the exact cause, I decided to remove the brushes and directly test the slip rings.

Identifying a Broken Wire on the Rotor

Upon closer inspection, it became evident that there was a broken wire on the rotor. The wire, which connects to the slip ring, was corroded and severed just before entering the rotor. Unfortunately, due to the lack of sufficient good wire and the difficulty in peeling out the wires that were glued together, it was clear that the rotor was beyond repair.

Disassembling the Generator for Repair

Now that we have identified the problem but couldn't salvage the rotor, the next logical step is to disassemble the generator for repair. This process involves removing the end housing, stator, and eventually separating the rotor from the engine itself. Disassembling the generator allows for a more thorough assessment and presents an opportunity to salvage other functioning parts that can be reused for future projects.

Separating the Rotor from the Engine

Separating the rotor from the engine requires some additional steps. First, the cylinder is filled with rope to prevent the piston from moving. Then, by removing the bolt and using hydraulic pressure, the tapered shaft is carefully separated from the crank. This prevents any damage to the threads on the crank and ensures a smooth separation between the rotor and the engine.

Conclusion

In conclusion, while our initial attempt to repair the Predator generator's power generation issue proved to be unsuccessful, we were able to identify the root cause of the problem. The broken wire on the rotor ultimately rendered the generator non-functional. However, this experience has provided invaluable knowledge on how to troubleshoot and diagnose similar issues with generators. Furthermore, the generator can still serve as a valuable source for spare parts, including the engine, control panel, stator, frame, and fuel tank. With the information shared in this article, I hope to empower and assist others in their own generator repair endeavors.

Highlights

• Troubleshooting the power generation issue in a Predator generator
• Identifying a broken wire on the rotor as the cause of the problem
• Disassembling the generator to salvage functional parts
• Utilizing the knowledge gained to troubleshoot similar generator issues

FAQ

Q: Can a broken wire on the rotor be repaired? A: In most cases, a broken wire on the rotor is not easily repairable, making the rotor replacement necessary.

Q: Can I use aftermarket parts for the Predator generator? A: Yes, many aftermarket parts are available for the Predator generator, including engines and other components.

Q: How much does a new rotor for a Predator generator cost? A: The cost of a new rotor for a Predator generator can vary, but it's often more cost-effective to purchase a new generator altogether.

Q: Are there any common issues with Predator generators? A: While Predator generators are generally reliable, some common issues include power generation problems, engine starting issues, and fuel-related problems.

Q: Can I use the parts salvaged from a Predator generator in other generator models? A: Some parts may be compatible with other generator models, especially those that have similar specifications and components. However, it's always best to consult the manufacturer or an expert for compatibility confirmation.