Splitting Harbor Freight 15k PTO Generator

[sacu]

Last year my 10+ yrs old Harbor Freight 15k pto generator started leaking oil. The only thing I could say was “It had to be the inner pto seal”. Not knowing to much about these things I figured 3 things could happen. I could buy a new one, try to fix it, or try to fix it breaking it and then buy a new one.

Let’s start by saying the manual and the parts diagram are total crap. Getting parts from Harbor Freight has been terrible and I’m still waiting for parts I order 6 months ago but the seals are on Ebay. So here's my not so professional recommendation of how to do it with some pics for clarity.

Drain the pto oil.

Remove the 4 bolts and remove the louvered end cover.

I would recommend removing the 2 bolts (image 2) that hold the brushes in part and moving them out of the way, I didn’t do this and broke the plastic mount piece and had to fabricate a new piece because my rotor and bearings pulled out with the pto gear box, (image 0).

There is a large bolt running through the rotor shaft remove it (image 2). This is what holds the rotor to the pto gear box. It’s just a taper fit on the end of the shaft (image 4). Hint: You could damage your brushes if you don’t and also pull out the whole rotor J.

Brace the generator up and remove the 2 fwd mounts

Remove the 4 bolts that hold the generator ends to the stator housing.

Carefully remove the front generator end with the pto gear box. The generator end is soft cast aluminum and dents very easily if you use a persuader “ aka: hammer “. Once off you know have access to the inner oil seal (image3). Mine was very badly dry rotted and cracked (image 1).

I choose not to remove the generator end from the pto gear box because I was worried about an alignment issues getting it back together. Hope this helps someone out there.

 

[bmaverick]

I've seen many gensets up on FB and CList that need some work to get them running. I wonder if the issues are getting parts and the lack of documentation.

Glad you were brave enough, thought things thru and took the task at hand.

Some of these name brand gensets come with a 3 year to 5 year warranty. What good is it when there are no parts in the supply chain to fix them. Box stores can get complete gensets to sell, but nothing in the support supply chain to be had. Plus, the newer units are with CA carbs and other emission items that are very unique to those engines. It's so frustrating.

 

[seijirou]

I'm curious as I can't really tell from the instructions or any reviews. Does this generator supply 240v or 120v according to the switch? Or does it supply both simultaneously and the switch determines which is being displayed on the little monitor?

 

[arto98607]

Last year my 10+ yrs old Harbor Freight 15k pto generator started leaking oil. The only thing I could say was “It had to be the inner pto seal”. Not knowing to much about these things I figured 3 things could happen. I could buy a new one, try to fix it, or try to fix it breaking it and then buy a new one.

Let’s start by saying the manual and the parts diagram are total crap. Getting parts from Harbor Freight has been terrible and I’m still waiting for parts I order 6 months ago but the seals are on Ebay. So here's my not so professional recommendation of how to do it with some pics for clarity.

Drain the pto oil.

Remove the 4 bolts and remove the louvered end cover.

I would recommend removing the 2 bolts (image 2) that hold the brushes in part and moving them out of the way, I didn’t do this and broke the plastic mount piece and had to fabricate a new piece because my rotor and bearings pulled out with the pto gear box, (image 0).

There is a large bolt running through the rotor shaft remove it (image 2). This is what holds the rotor to the pto gear box. It’s just a taper fit on the end of the shaft (image 4). Hint: You could damage your brushes if you don’t and also pull out the whole rotor J.

Brace the generator up and remove the 2 fwd mounts

Remove the 4 bolts that hold the generator ends to the stator housing.

Carefully remove the front generator end with the pto gear box. The generator end is soft cast aluminum and dents very easily if you use a persuader “ aka: hammer “. Once off you know have access to the inner oil seal (image3). Mine was very badly dry rotted and cracked (image 1).

I choose not to remove the generator end from the pto gear box because I was worried about an alignment issues getting it back together. Hope this helps someone out there.

Enclosed is their current $1999.99 model 15 kW PTO generator assembly drawing - is this the same as you have?

Looks like a generic 35x72x8 seal should fit.

 

[duffer]

I'm curious as I can't really tell from the instructions or any reviews. Does this generator supply 240v or 120v according to the switch? Or does it supply both simultaneously and the switch determines which is being displayed on the little monitor?

My portable generator always reads out the voltage it's producing, and it usually reads 240'ish. The individual plugs (with independent breakers) adjust the voltage accordingly at the receptacle (at least on mine)

 

[seijirou]

My portable generator always reads out the voltage it's producing, and it usually reads 240'ish. The individual plugs (with independent breakers) adjust the voltage accordingly at the receptacle (at least on mine)

Is yours the HF unit? The HF unit has a toggle switch between 240 and 120, which is why I ask. Most generators will do both at the same time. Most generators also don't have that switch.

 

[sacu]

It looks the same. Your parts break down is a little bit different then mine but,,, My manual also claims to be a 35x72x8 seal but my inner seal was a 30x72x10. I believe the manual has the to p/n's reversed for the seals. It also doesn't show the bolt that goes through the rotor shaft and mine doesn't show the bushes or hardware that they attach to.

I do have the HF model. On mine the one thing in noticed it that the 240/120 switch controls the display and the plugs. On 240 it reads 240 volts/60 cycles and you can only uses the 50 amp plug. On 120 it read 120 volts/60 cycles the 2 20 amp outlets work. I can't operate 240 and 120 volt at the same time on my unit, it might be some kind of safety so you don't overload it. I never used any of the other outlets.

HF does have some parts but my first order was for the inner and outer seals, I got the 35x72x8 seal and a bearing. My second order was for the 30x72x10 seal and got a another bearing. My third order still on back order but the seals were easily found on ebay. I'm sure a good bearing shop could get them. HF was addressing the issue with their stock and sending out the wrong parts. As for the extra parts I'm just going to keep them, I might need them I might not.

The only other thing that happened is the hours meter reset so I don't have an accurate hour count any more. I don't think that's a big deal seeing that it had less then 50 hrs on it.

 

[seijirou]

I do have the HF model. On mine the one thing in noticed it that the 240/120 switch controls the display and the plugs. On 240 it reads 240 volts/60 cycles and you can only uses the 50 amp plug. On 120 it read 120 volts/60 cycles the 2 20 amp outlets work. I can't operate 240 and 120 volt at the same time on my unit, it might be some kind of safety so you don't overload it. I never used any of the other outlets.

Thank you! I had a feeling that was the case. I have one on order, we'll see if I like it. If not I'll sell it and get an IMD.

HF made a little whoopsie this weekend and their 25% off Monday only coupon worked on this generator, so I can get what I paid right back if it isn't going to work for me.