Bad Fuel / Down on Power - Powermate Generator Sitting for Years

This generator was used for a few times when new then put away for 14 years with fuel in the tank. The prior owner noticed the problem after the fuel tank bushing failed and starting leaking the bad fuel onto the floor. Can the carburetor and fuel tank be saved? Will the generator run and make power?
Generator Model: PM0545007
Engine Model: 204412-0156-E2
Engine Code: 031014
Teapo Capacitor: 034819.01 220uF 200V.HD 85/C + - 3 %
I use Harbor Freight Super Heavy Duty Degreaser in my ultrasonic cleaner.
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#GeneratorRepair #SmallEngineRepair #SmallEngine #DIY #Fixed #Troubleshooting #HowTo #Powermate
Bad Fuel, Bad Gas, Bad Gasoline, Bad Petrol, Capacitor, Carburetor Cleaning, Dirty Carburetor, Fixed, Fuel Valve Install, Generator, Governor Droop, Governor Spring, Hertz, How To Clean a Carburetor, How To, How-To, Leaking Tank, Leaking, Load Test, Low Voltage, Powermate, Residual Magnetism, Running Lean, Small Engine, Surging, Tank Bushing, Troubleshooting, Ultrasonic Cleaner, Volts

[@sn0w_gel597]

looks like James is even for a moth a bright light❤️ 20:07

[@beezalbub7325]

1st lol. keep these great videos coming. You mentioned the old capacitor did not have a polarity marking, I respectfully disagree. At time 37:29 you can clearly see the label indicating the tab with a pattern is the negative.

[@jcondon1]

I eventually found it

[@jeanbaptistevallee4500]

I`m way old and I no longer have a place to try and fix up stuff that was cheap, that I could never afford if it wasn`t broken. But by golly, I can watch and sort of re-live "Those thrilling days of Yesterday!" Thanks again for a good morning!

[@rancelynch6514]

Yes, I feel the same you do…. Living vicariously thru someone else….feels like I need to wash my hands after watching his videos ! !

[@erik_dk842]

Reality TV for sane people

[@BIG.STEVE13]

Hi Jim got a tip for cleaning your fuel tanks put some kitchen paper in tank and blow it round inside the the tank you can get it in places you can't reach and great videos

[@ninaevans4501]

You repair them, check them, and clean them. You are a man who thinks the same as me and my other half (Wayne). Sorted to perfection (as far as you can). Loving you and your vids. Nina Evans & Wayne Brill (Ipswich, Suffolk, UK)❤️❤️❤️❤️❤️👍👍👍👍👍

[@johnclamshellsp1969]

Good morning James. Always great videos and thank you.

[@danburch9989]

It's been several years, but I believe the markings on the label is positioned on the side closest to the negative terminal of the capacitor. The positive terminal is furthest away from the markings. It appears the "-negative" along with the green dot annotaton on the label follows that convention.

[@FirstSuiGeneris]

Glad to see you got one of those fuel pumps. I use them for all kind of things and have about five of them, one for oil, def, fuel, and gas. Then one for a back up. They save the back and messes!

[@bjusticeforever]

James, nice job. I recently had to solder a cap onto one of these boards. I wanted to tell you about the Powermate I just finished (a Subaru Robin EX30) that had a Chinese carb that ran rich with no-load. I rebuilt, then eventually replaced the carb with another Chinese knock-off and it did the same thing as the Chinese carb I pulled off. Buying a $160 original carb wasn't an option for me, so I bought another, and it did the same thing as the first two. I ended up filling in the pilot-jet with JB Weld and reducing the original .026" jet down to .018". I'm thinking about making a video and posting it. It runs PERFECTLY now. I had seen a previous video of yours where you commented you had a box full of Chinese knock-offs for this particular motor. I hope this helps you out. I know you've helped me before!

[@michaelschumacher3702]

I'm jumping the gun, but my go-to for cleaning a plastic tank like that is TSP - Trisidium Phosphate - from the paint department. Not sure if we can buy it here in NY, but I manage go pick it up elsewhere from time time to time. It gets cigarette tar off walls and mixed with very hot water, it floats all kinds of varnish off small engine parts.

[@MitchEllis-dn9lf]

AND, James is GONNA CLEAN IT

[@DeadKoby]

Fine work as always. Nice to see something different than the usual China generators that are mostly the same other than color and name. The plastic fuel tank was a blessing, as the inside won't go to rust.

[@blahblahblahblah2933]

Nice fix. A few notes: Big electrolytic caps typically have way worse tolerances. Something like +/- 20% is typical over their life (checked a couple of datasheets from TEAPO and I believe that's true of those series). Those caps can also fail due to their ESR increasing without major loss of capacitance.

[@ickipoo]

I believe a high ESR can also make the capacitance read higher than it actually is.

[@chrishartley1210]

The ESR typically increases as the capacitor begins to fail, this in turn causes increased internal temperature which usually finishes the failure process. I'm not sure of the purpose of generating a DC voltage here, is it something related to the governor?

[@jeremydewolfe8026]

Don’t forget bench testing a cap just barely on edge of spec is one way to check for obvious failures but also a dynamic inline running test using voltage and simple multiplication math may show issues not present in testing caps out of circuit! I see how this could be slightly more dangerous but only about as dangerous as adjusting the pot on a running generator with an avr.

[@chrishartley1210]

@@jeremydewolfe8026 I considered that option, but on this generator it would have involved dismantling to access the capacitor, attaching wires, reassembling, testing, then repeating to remove the wires. Probably not worthwhile in this case considering that the capacitor was bulged and the capacitors are not expensive.

[@r8118830]

@@chrishartley1210 The DC voltage feeds DC current into the brushes which powers the rotor. Earlier versions of this generator had a PCB with 4 pairs of diodes and the electrolytic capacitor mounted on its surface. I recall James sending some of these boards for repair to Bassguitarist1985. The firm has since realised that the whole board could be replaced entirely by a separately mounted capacitor and a separatedly mounted GBPC style full wave bridge rectifier.

[@floridadave224]

When it looked like IAN was headed our way I dragged out the generator that hadn't been used since hurricane IRMA. Of course it wouldn't start so started watching your videos. I didn't know anything about generators but learned to pull the carburetor, clean it and put it back together. It ran for a couple minutes then would stop. Then I learned the gas cap is what vents the gas tank. Took the cap off to see if that solved the problem....Bingo! Fortunately we ended up not needing it. Wish i had a way to donate it to the people in SW Florida that really need it.

[@jcondon1]

Glad you got it running and did not need it. Nothing worse then being in a situation where you need it and it does not work.

[@adnacraigo6590]

I have learned a lot from your persistant troubleshooting.

[@MrTonyPiscatelle]

Another great job James, You have a good eye for detail and it definitely pays off.

[@v-g-z3689]

I´m very surprised to see such a 60´s Power-Products style fuel valve on a generator that modern.

[@alfredocuomo1546]

capacitors are one of the most common failures in electronic equipment, their capacitance is most important, followed by it's Break down voltage and then it's ESR value but if there is any Bulging or leakage it must be replaced no matter what. Also you can always replace a capacitor with a equal to or higher voltage rating. Nice video as always Jim.

[@thepubliceye]

I have two feet of 3/16 welded chain I put in rusted/dirty tanks and shake, it really makes a difference.

[@MrPatdeeee]

I dare say that less than 10% of mechanic's; would've ever spent such time with ernest that you had. You kind Sir are a "cut" above. A person to be respected to the nth of degree. Thank you. May Jesus bless you and yours always.

[@freddyrosenberg9288]

I have one of those ultrasonic cleaners. The electronic ontrols go bad real quick and then you can't use the heat or the clean. I bypassed those with a mechanical GE timer and it is still working.

[@petethehandyman9185]

Great job sir! I have had one of those for 20 years and it has gotten me through many hurricane seasons! They are so very reliable as long as you take care of the carb! I wonder how many of those were made ?

[@davidwelling9471]

Needs an adjustable carb. I have a Coleman with same problem that adjustment on bottom of carb fixed.

[@detroitredneckdetroitredne6674]

Hello from Detroit Michigan brother thank you for sharing your knowledge and expertise

[@hanksbud2544]

Thank you James.

[@gregsappington9991]

Thanks for showing everything you do. I have 5 generators and have learned a lot from you!!!!

[@billiehydrick6417]

I really appreciate watching you and learning more about generators repairs and service experience

[@chucktrotter9699]

10.6.22 James, another fantastic repair video. I did not see you check the valves.

[@bobmehlfelder1823]

James, I think when you ran the generator the first time, maybe you should've left the original settings. Seeing how much of a load pulls the engine down the voltages would probably be correct as the engine stabilizes. By adjusting the speed you allowed the generator to drop the voltages too low under load!!!!

[@jcondon1]

True. Some engines are set at 63 hertz from the factory. But the voltage and hertz were a little too high. And that will only increase as the engine warms up.

[@bobmehlfelder1823]

@@jcondon1 How much of an increase are we talking?! With a 5000 watt load after a sufficient warmup the voltage and frequency would return to normal??!! Your best bet would be to put the engine back to original specs and TRY the load drop then. Do it on the side and see if what I'm saying will work.

[@user-smalltownAK]

..the lack of permanent magnet in generator by design, after significant time spend new-unused in-the-box, and never started since bought..(?) With a spare genset such as this, how to energize the device and make it work..? This generator likely is 10HP 5000 Watt; but memory fades, so can't be certain; and it is over 110 miles one way, distant.. Still has the factory break-in oil, and power cable, etc in the kit! An out of town cabin, is where the unit is stored. Bad weather and distance plus wintery mix extreme snowfall then subzero, slow efforts to head out remote in midwinter.. The generator from Home Depot in Anchorage, was one of two, got one for a neighbor who ran theirs in the Kenai Mountains, south of urban AK. Two miles south of Moose Pass, where I grew up.. Thank you for your video and tenacious repair skills; at least you have a warm dry place to repair stuff out of the weather.🙂 PS: Probably will have to rescue it, and hope the lack of 'permanent generator magnet' is not critical or costly to overcome..!🌻❄

[@kpdvw]

chalk another one up for the Generator Wizard....!

[@Bassguitarist1985]

Nichicon is my favorite brand of capacitor. Tolerance is likely +/-20% for that electrolytic cap. Its only smoothing the rectified DC as a passive filter.

[@crisprtalk6963]

"It earned an oil change" Pretty sure I heard the generator let out a gasp of relief at that point.

[@davidjones1393]

THKS

[@watermanone7567]

NIce find, Nice fix Jim. Thanks for the video.

[@AntonioClaudioMichael]

Wow with a 5000 watt load it dripped drastically on voltage yikes 😬 😳 not good @James Condon

[@emyrjones2717]

Hi James, You mention in several of your videos that there are no AVR's fitted to the generator. Is it possible to retrofit an AVR, and have you done so? I would be most interested to know. I really enjoy your work.

[@AntonioClaudioMichael]

Cleaned up pretty nice Cleaned csrb it runs amazing looks like it had never been used with how clean that exhaust is @James Condon

[@paulravitsky2898]

Not sure if it's me or is that handle upside down? I'm having the same issues with chinesium "rubber" parts. Great job!

[@throwbo]

While you were in there you should have re-greased the bearing in the end cap. Those end caps are plastic and if the bearing overheats it will melt its seat and that's the end of the gen because the end caps are NLA.

[@brianr101010]

Just a question. Wouldn't "blowing out" all the dust and sawdust from inside the power head help it stay cooler and allow the internal components to last longer and also make less likely dirt and trash could bridge across the circuit causing a short inside the head?

[@steveobrien8792]

I really want to thank you for your videos. I started watching about a week ago, after doing some maintenance on my Rigid zero gravity MZ360. I've learned a lot in just the week and have been able to use this info on other small engines as well. My Mother had been complaining that her Lawn mower was getting harder to pull start. I would have never thought that adjusting the valves would fix this problem until I watched one of your videos where you explained the pressure release mechanism. I was able to fix her lawn mower in a short amount of time. I have my generator stored away after hurricane Ian but when I get it out again I'm going to check the valves on it as well because I've noticed it getting a little harder to turn over as well.

[@AntonioClaudioMichael]

Sometimes Nock off parts like gaskets that come in a multipack are junk and oem is best @James Condon

[@AntonioClaudioMichael]

Capacitor helped a little bit bringing the voltage back up to 111 volts but didn't do much

[@ricklavictoire4806]

I had a small comment on the petcock grommet replaced in the tank. I have bought some of these aftermarket grommets and they are not super tight fit. They seem fine but if your generator is exposed to extreme cold I have seen them start to leak. Seems like the component material is not a pliable as the original.

[@megason2]

Niki carbs are the worst I hate that walboro quit making carbs for small engines

[@moody326]

You most definitely helped me. Thank you 🙏

[@GhettoWagon]

I picked one of these out of the garbage Same powermate 2006 era. All it needed was the Nikki Carb cleaned and all the O rings on it were shot. Fuel line and Fuel shut off too. I Call it RUSTY.. It was sitting outside it looked like for a little but its not terrible.. Looks low use they abandoned it when the carb was gacked,. Anyway, It makes about 130volts and 61hz with really no load just 1 light bulb, It will not start a CFL bulb which is strange Maybe because of the 130 volts. at low load Is that Normal for these? The Brushes look new on it I have not removed the back of the alternator yet . Plan is to keep it as a spare next time a storm rips through here Ill just try to rent it to someone Cant sell them here in FL over 400-500 listings depending on the day for generators and the prices are pretty low. I'm not selling it for $150. :)

[@davidfoulk3078]

I’ve always had really good luck using clear lacquer thinner when cleaning a plastic gas tank. As usual another “out of the park” repair!

[@delynnaddams8774]

Anyone have the valve gap values for a 4000 dual fuel Sportsman gen? Always helpful and great videos,, thanks

[@KensSmallEngineRepair]

I set these at 0.006/0.008 intake and 0.007/0.009 exhaust (Cold).

[@GuysPlayingWithTools]

Old gas beats another carb... One day *everyone* will realize you have to drain the gas if it's going to sit for a while.

[@ronaldlapointe1219]

Dear James, I discovered on KZbin your videos and I am very delighted to see your way of solving the problems that are offered to you. I like your analyzes and your solutions and especially not to throw away and replace...it's like a second chance for these sometimes very expensive machines...thank you and I now I’m a new subscriber to you! 👍

[@er1073]

Attention to detail like you always show in your videos helps a lot. That carb was far from being cleaned. This sitting for 14 years really turned out pretty good. Thanks James. Ed

[@warrend114]

Your channel has become my favorite channel to watch without a doubt. I would love to know how you find all these obscure parts though.

[@KensSmallEngineRepair]

I always get cockeyed when I rebuild one of these carbs as the float seems to be set too high in its un-adjustable position (when viewed held upside-down), I always think it will flood out but it never does. Nice work Jim.

[@jcondon1]

Thanks Ken

[@dennisolsson3119]

The capacitor should not be charged if the brushes are even remotely fine, because the rotor continuously discharges it. Same with a brushless where it has a winding in parallel with it. Still... Better safe than sorry, but I would not hold you not shorting it against you.

[@LeewardStudios]

James I had a diesel mechanic show me a trick with ultrasonic cleaners. Put water in the cleaner but put parts with diluted cleaning solution in a zip lock bag. Then place that in the ultrasonic. He used it to keep bolts and parts organized while cleaning. Also keeps the sonic cleaner neat and saves the time having to clean it out of sludge, dirt etc. I have done this cleaning brass “freedom seeds” of differing caliber to help keep things organized. The ultrasonic energy goes right through the plastic bag and does not affect the cleaning at all.

[@colingraham1065]

Another great save! With a tank that gross would you ever consider using degreasing fluids or some other solvents to remove the 'varnish'?

[@jcondon1]

Yes, would not hurt.

[@commercialelectrician133]

Great video

[@mcg6762]

A bulging cap has probably failed with high ESR. The capacitance can still be good, sometimes even over spec. An ESR meter is recommended.

[@gordonwilloughby8793]

A full wave rectifier like that typically has 4 diodes. If one fails it works as a half wave rectifier producing pulsating dc because it only conducts when the ac goes in one direction. I believe it might still work but would produce less power.

[@r8118830]

If one of the diodes went short circuit then the full ac waveform would feed through it. The effect of that depends on what it is feeding.

[@gordonwilloughby8793]

​@@r8118830 You are correct and now that you mention it I remember a time when I replaced a diode shorted out in a reverse connection protection circuit in a CB radio. I believe it shorted when it was corrected backwards. I have seen diodes become open in full wave rectifiers so It could happen either way.

[@vk4uh96]

Another great video diagnostic success. Two suggestions to think about. About failing capacitors. The test that I suggest is to measure the ESR (Equivalent Resistance Series) not just the capacity in uF. Needs a different test meter but cheap to get. Low ESR is good, rising ESR is sign of failure. Bad caps often read normal capacity on a simple multimeter but ESR goes up so they dont work as they should. Also bridge rectifiers can fail - but still work. They contain 4 diodes connected in a square. If one fails they still produce DC on load for the field coil but at a lower voltage. Easy to test all four diodes in the block with the multimeter you already have there

[@MitchEllis-dn9lf]

Most brushed generators with full bridge rectifier have very small(capacitance unknown) capacitors on the full bridge rectifier

[@covinhas87]

Where do you guys get the technical sheets with torques and ohm values? I just got a supposedly working generator from marketplace, the engine works great, but the overload light is always on and it doesn't have any power on the 230v sockets. I also noticed the 12v dc outlet is reading 24v or so on the multimeter. The AVR is a big square box, completely different from those on your videos. Generator is a SHX2000 with a honda GX100 engine. Any hints of what may be the problem or how to troubleshoot it?

[@RobertKohut]

The word "Negative" and "cross hatch symbol" printed on the original cap might be a clue... LOL... 🙂 @37:27

[@rainmanrays]

I really wish you would write a general repair book on generators. Because I would read it.

[@felixcardona8509]

Hi James.. very interesting video..!! any recommendation, looking to buy ultrasonic cleaner for occasional use..

[@hugh007]

What? Chinese parts, like gaskets, won't resist gasoline? I'm shocked. Like the NEW starter I put in my truck just over a year ago: now intermittent. Great job. thanks.

[@theeagle4540]

Just want to say enjoy all of your videos and have a question. Having a problem with an Onan generator 5500 Marquis gold, starts with start button but dies when you release button. Any suggestions on where to look for the problem the oil sending units has been replaced. Could bad brushes in the generator head cause this problem? Thanks

[@rancelynch6514]

I really appreciate your generator fixit videos. With me I’ve always had a mental struggle with which is preferable…capacitor or AVR generator heads. In my life time I remember house electrical appliances first rated at 110 volts then 115 volts now 120 volts. So it was confusing to me when I would hear you be satisfied with a voltage reading less than 120v but still try to get the cycles/sec as close to 60 as possible. Now I can say cycles more critical.

[@tomcroley7084]

Excellent video, you are a Master Mechanic. I have one of these. What about adding a filter between the tank and carb? All inputs welcome. Thx

[@mikerossman9863]

I bought the same Gen for $50, put $95 in it and it runs like a champ. Powers my camper with ease and use it at the property. I have it mounted on a small single axel trailer with a old truck tool box with all the ext cords, splitters, daisy chains and adapters. Uses a bit of oil but that to be expected. Keep a few tools on hand in the box along with oil and fuel additive when I plan to store it for an extended length of time. Always fires up first pull can’t ask for more from it.

[@r8118830]

Very nice job James. The generator was in very good condition. I dont think that it was left out in the rain because there was not any rust.

[@dantyler6907]

Weirdly satisfying to watch... Learned a lot!

[@ShainAndrews]

36:33 You literally showed the label LOL. If the foil doesn't explicitly say negative, the post closest to the print is going to be negative. Honestly I don't remember ever seeing a capacitor absent any polarity indicators.

[@davidcooner3249]

A neighbor put the exact same generator on the curb. I got it cleaned the tank and put an Amazon replacement carburetor on it it runs and makes power. I think it needs adjustments as well. Watching your video was very helpful to me.

[@jamesbruce1183]

A capacitor can test pretty good under the low voltage of your test meter but not work well under actual voltage. The larger capacitance of the new capacitor will make the DC voltage a little higher and more steady so that may explain the better voltage regulation from no load to full load. ESR (effective series resistance) is not measured with your meter either. The old capacitor having the base puffed out is a giveaway to it being failed. It's a built in safety to prevent a rupture of the case.

[@christophermarshall5765]

This is why I turn the fuel off & run the carby dry. If the fuel in the tank becomes stale, I simply remove the fuel hose from the carby, & drain the tank.

[@RWebster325]

Have one very similar to this one. Carb definitely needs a rebuild. Power head works but have not fully tested it yet like here, but it probably does need a new cap as well. The carb on this one is different than the one on mine, and mine has electric start as well. It appears to have the same engine though. This video and one other with a similar configuration but different engine has helped tremendously. Thanks.

[@keithsilva6330]

Just a suggestion...Sppend the money on the oil neext time prior to testing... 14 yrs is just way beyond old, it breaks-down like gasoline but not as notiicable.

[@timgarner6768]

Thorough. Meticulous. Wonderful approach.

[@MitchEllis-dn9lf]

Acetone might be a better choice for you with so little that you can give on hazardous cleanup day. Acetone can be left open to the atmosphere to evaporate and all you be left with will what doesn’t evaporate, no fire around as acetone is very flammable and the vapors even more so.

[@Rorschach1024]

per NEC code. when should you ground the genset frame through the ground lug? anybody know?

[@pesto88]

You said the the guy selling it “wasn’t sure where to go from there”. Doesn’t he watch your videos? That’s a violation 😂

[@shadowpotatoe9482]

Decent generator, not sure the govener system is good enough to hook to your house and run sensative electronics but it works. The huge dip when it first sees a load and the kinda galloping when the load is taken off quickly is not what I would want for anything electronic. Although it may not act the same in that use case

[@YukonHawk1]

What model ultrasonic cleaner did you get? I know in your last video the old one bought the farm😁

[@jcondon1]

I am using this one now a.co/d/d8PLrcT

[@YukonHawk1]

@@jcondon1 Nice one. Great video as well.

[@haneyoakie14]

@@jcondon1 did you get the 6 liter version? My Harbor Freight one is starting to act wonky. Daughters got it for me for Christmas almost two years ago. I might be in the market for one soon.

[@frogfoot198]

What's the cleaning spray you use to clean your small engines with? Seems to work well. Thanks.

[@MitchEllis-dn9lf]

Have you ever tried LA’s Awesome cleaner available at dollar tree in your ultrasonic cleaner. It’s an excellent degreaser and mild solvent.

[@MaXpeedingRods_Coop]

Hey sir, we enjoy your great & fair contents ! Could we work something great out for fans ?❤

[@demetriosa7646]

I don’t understand why generators stopped the plastic tanks. They last much longer and never any rust issues

[@Firecul]

TBF the old capacitor did say on the label that the hashed side is negative @37:30. Typically there would be a stripe at the negative also which is potentially an indication here but it could also be this one just got lucky and ended up in the right place depending on how cheaply it was made.

[@jesterr7133]

Lol. You only have to touch a charged capacitor one time, and it is a mistake that you certainly will not make twice. Ask me how I know.

[@wildefox1478]

That generator was in pretty good condition and only needed some minor repairs, nice work as always James!

[@andrewgrace4410]

Very nice troubleshooting James, good find 😊

[@MitchEllis-dn9lf]

Looks like harbor freight got in more of the old formula heavy duty degreaser you use in the ultra sonic cleaner. ???? 13:52

[@jerryhouston5400]

Wouldn’t it be more practical to run a pressure washer wand and clean the tank better without waisting the gas ??

[@artpatronforever]

Xylene is a good solvent for fuel varnish, also for carbonized oil sludge

[@forestsantos9828]

It's also great for removing most glues

[@wallaceloper637]

Well, I find a good fuel tank, and a better carburetor, and changing all the fuel lines wish me luck. just saying

[@AZVIDS]

Great fix and clear explanations👍👍👍

[@jayjudd6518]

Interesting one. Good outcome even thought I saw surprised.