The ebay generator restoration thread
Discussion
I'm back
Not posted on here for a while as not had any thing interesting/different to work on.
New project collected today, It's a Honda E4000 V-twin diesel generator which I think dates from the late 60s/early 70s... Bodywork needs a bit of TLC as it fell off the back of a lorry!
Will get some more pictures/ info up when I get a chance.
To be continued...
Not posted on here for a while as not had any thing interesting/different to work on.
New project collected today, It's a Honda E4000 V-twin diesel generator which I think dates from the late 60s/early 70s... Bodywork needs a bit of TLC as it fell off the back of a lorry!
Will get some more pictures/ info up when I get a chance.
To be continued...
)Blue32 said:
I'm back
If you're all suffering generator withdrawl symptoms, there's a whole channel for you to gorge on, https://www.youtube.com/channel/UCr_GXW2Y56hOpGchX...
shtu said:
Blue32 said:
I'm back
If you're all suffering generator withdrawl symptoms, there's a whole channel for you to gorge on, https://www.youtube.com/channel/UCr_GXW2Y56hOpGchX...
https://www.youtube.com/user/SmallEngineMechanic
Harrison Bergeron said:
shtu said:
Blue32 said:
I'm back
If you're all suffering generator withdrawl symptoms, there's a whole channel for you to gorge on, https://www.youtube.com/channel/UCr_GXW2Y56hOpGchX...
https://www.youtube.com/user/SmallEngineMechanic
Now had a chance to have a bit more of a look and had it running for a short while. So far we have learnt its very heavy and not very quiet, but looks like it works (volt meter indicated 200v). There is about 1/3 tank of fuel which i think is either kerosene/heating oil or red diesel, it's a little bit smokey which i think is from the air cleaner which is an oil bath type, so when it fell over its likely the oil from the air cleaner got into the intake. Oh and did I mention its very heavy
Hopefully it doesn't need any parts as so far I have not been able to find anything for it, not even a manual. Fortunately the previous owner has found both the generator and engine manuals and is sending them to me (couldn't find them when I collected it), so hopefully I might be able to find some part numbers to search on.
The engine is a GD90 and I think is 400cc and develops around 9hp from what limited information I have found so far. I found some references to the engines been used on custom motorbikes.
Anyway some photos:
You can see the top cover is a bit bent, but should be reasonably easy to straighten out
Cover removed, all looks ok, just need a clean
Fuel filler is a a bit bent though
Side of engine with oil fill and drain. Found the oil filter is behind the cover where the red bullet connector is
Handy wiring schematic inside control unit
Old school components
The main damage looks to be on the fan cover where a chunk if the casting has broken away
When we had it running the fan was making a grinding noise where it was rubbing against the inside of the cover
With the cover removed we could see where the fan blades were rubbing
Rub marks in inside of cover, you can also see where it is slightly raised where the cover was pushed in from when it fell off the lorry..
After some gentle persuasion with a rubber mallet no more rubbing and i definitely didn't crack the cover
Just need to straighten out the intake grill, which we removed for the test run as the mesh was getting caught in the fan.
Next I started checking the alternator, when i removed the cover i was greeted with loads of mouse droppings, pine needles and seed husks
The slip rings which apply power to the rotor were in need of a clean, probably the reason it only indicated 200v on the test run
Looking better after a clean, but could probably do with a bit more cleaning.
Looks like the mice who made it a home for a while had a bit of a chew on the insulation on the wires
Plan is to try and release the wires and slip some heat shrink sleeving over the damaged sections.
Finished off by air-lining the alternator cover filter mesh, everyone loves a 50/50
Oh and also need to fix the terminal block
Fortunately all the broken bits were in the bottom of the alternator cover, so hopefully with some careful application of super glue it should be back on one piece.
I'm near certain that's the same model my mate had, bought it at an auction cheaply, said to be not working, he brought to me to get the engine running, we could only get a fluctuating voltage from it 150-200v.
Because of the weight we never took it out of his pick up, plan was to have a look at the generator another day.
Unfortunately someone broke into his garage one night and stole the truck, along with the generator, police found the vehicle some days later severely damaged but the generator wasn't with it.
Because of the weight we never took it out of his pick up, plan was to have a look at the generator another day.
Unfortunately someone broke into his garage one night and stole the truck, along with the generator, police found the vehicle some days later severely damaged but the generator wasn't with it.
dhutch said:
Probably fell out! You dont live near to each other do you? Could be the same unit.,.. 
Hope not, the seller i got it from had photos of the original manuals in the listing (which hopefully are on the way to me now he has found them) so pretty sure it doesn't have a suspect past at least I hope not
Looking at the stickers on the cover it looks like it lived in Sevenoaks
Origin Unknown said:
There doesn't appear to be an hour meter on it so I don't suppose you have an idea what sort of life it's led? Even so, I'd say that was in very good condition given it's ~50 years old!
Nope no hour meter, so no idea how much use it's had. Was thinking of adding one as I need to add a box or something with UK style socket, as it currently has 2 American style sockets. The engine oil is very black and thin so hasn't been changed for a while, data plate says SAE30 oil so just looking for a decent equivalent. The drive belts to the alternator don't appear to have much wear either.
I spent some time rocking the flywheel back and forth to see if I could feel any play in the crank and rods etc which would indicate wear.
Couldn't hear/feel any play so that's a good sign, as with pretty much every other machine I have worked on so far there has always been a little bit of play which you can hear/feel by rocking flywheel back and forth
Someone has been in the back of the alternator before me as you can see from the broken terminal block and rounded off screw. Apart from the obvious damage all the metalwork is in really good condition, there is some minor surface rust in places with the worst on the chrome heat shield on the exhaust.
I think it just needs a good clean and service and it will probably work quite happily for another 50 or so years...
First job is to repair the damaged wiring and run it up with a load to make sure its working correctly before deciding how deep to dig into it. All the rubber hoses in the fuel system are rock hard so could do with replacing. The valve adjustment probably wants checking but until I can get a manual I have no idea what the setting should be.
spikeyhead said:
How big is that broken terminal block? I might have something equivalent here.
Thanks, it's probably 6-7cm long will get some measurements/ better photos when i next working on it. Edit
patched it up with superglue and measured it, its around 10.5 cm long 25mm wide, fixings look to be 90mm centers
Edited by Blue32 on Tuesday 25th January 16:49
Blue32 said:
spikeyhead said:
How big is that broken terminal block? I might have something equivalent here.
Thanks, it's probably 6-7cm long will get some measurements/ better photos when i next working on it. Edit
patched it up with superglue and measured it, its around 10.5 cm long 25mm wide, fixings look to be 90mm centers
Edited by Blue32 on Tuesday 25th January 16:49
spikeyhead said:
bugger, I got rid of the box they were in a couple of months ago.
Oh well thanks for checking. Hopefully the superglue will hold...I did find a potential replacement, it looks very similar to the terminal block in the back of the EX5500 alternator which is still available but it's nearly £50!
and the original keys
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