DeVibiss PowerBack Generator - Running Poorly - Valve Issues and Clone Carb Fail

A subscriber donated this 3000 watt Powerback. The carburetor is missing pieces, compression is low, voltage is low and the engine is stuck. Will it run?
Generator Model# CGTP3000
Tecumseh Engine Model# OHH60-71129C
Tecumseh Carburetor# 640135A
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[@Lovinflyindrones2022]

I’m glad u left everything in the video where the carburetors did not work. That’s real life besides editing it out of the video. Thanks

[@rthistlethwaite3430]

Thanks for sharing.

[@davecc0000]

Extra credit, James, for taking the effort to preserve the original stickers/labels. It adds value to the engine (per "curb appeal"--that first glance, gut feeling "Would I pay $xx for this genny?").

[@AntonioClaudioMichael]

Very cool of your neighbor to bring it back to you and very cool donation for our entertainment

[@radneys57]

So glad to see you found the valve issue .I have a tecumseh engine that is doing the same thing runs fine for a few seconds when cold then starts misfiring. I am going to set the valve lash and retest!

[@ImnotChuck.]

Hi James. I was the Product Manager at DeVilbiss for several years (probably during the time when your generator was built.) I am impressed with your knowledge of generators and small engines, and with your determination to get things right. As to the genhead, you are correct; it is of very high quality. In addition, the laminations in the stator are skewed, which helps to ensure an extremely low THD. Although I can't say for sure, I suspect that it is actually a 4kw head, and if I am right, you could attach a 7.5 or 8 hp engine and get another 500 to 1000 watts. An 8hp Honda GX or a 7.5hp Briggs Vanguard would be a good choice. Thanks for your video.

[@jcondon1]

Thanks! I try to get them right as possible. The DeVilbiss generator heads are very good. Not sure I have ever seen one that does not make power. Many manufactures make a generator head that can handle a range of power and just throw different HP engines on them.

[@ImnotChuck.]

@@jcondon1 Brushless genheads sometimes have to be "flashed" if they have not been run in a long time. You probably know that and maybe have a video about it. It's an interesting process.

[@robb8235]

drill two holes though the frame each side.... pass the ubolt through the frame. Great job refurbishing it !!!

[@jaimesmith6459]

I have the same exact engine generator setup on a different style frame it's a porter cable, rated at 3250 watt. I bought it brand new and the only problem I have had with it is that the fuel tank cracked from vibration and I had to replace it. It has always been stored inside and in a heated environment after being run out of gas. I also have bought 2 new Honda generators. A EU6500is and a EU2200i, which have been trouble free. Maintenance is everything! I really enjoy your channel. I also work on small engines and have learned a lot from watching you. God Bless you and have a Merry Christmas!

[@SeeSaw72]

My dad owned a 68 VW Beetle and I ended up adjusting the valves every six months to keep them from burning up. How many generator owners have actually adjusted their valves. I agree that most generators are not run daily. Your videos are an inspiration for all DIY small engine repairs. Keep them coming.

[@jwsystems]

James, that was a great video saving an generator that most would have written off, I hate the disposable mindset. I watched in disbelief how you can take a rusty, beat up generator, spend a little TLC on it and bring it back to life and make it look really good with a bit of cleaning and paint. I appreciate anyone who saves a neglected piece equipment on principle and brings it back to becoming useful. You have one of my favorite small engine channels, I fix small engines on the side such as riding mowers, 2 cycle and push mowers, you have motivated me to mess with generators which in the past have always scared me off due to the technical nature of trouble shooting. Thanks for the great content. Have a great Christmas and for us all to have a better New Year.

[@jcondon1]

Glad I could help. It is a common thing that most small engine guys run the other way on the electrical side of things. Have a Merry Christmas!

[@giggiddy]

You outdid yourself on this one. Noticing the additional hole in the main jet passageway was something most would have never noticed. It actually looked like it belonged there. Great catch!

[@patturk7408]

If you look up "trim clip pliers/panel clip pliers" you will find a tool that repurposes for removing fuel lines, or many types of flexible/rubber lines from fittings. In fact it became the major use of those pliers. Plus you can also use it to remove car trim panels just in case. Really like your content.

[@Lovinflyindrones2022]

You remind me of Bruce Pender always neat and clean. !!! That’s good

[@rstephe]

Thanks Eric for donating something for us to learn from.

[@RustyNail5856]

James. you work wonders. made and old one look new again and run as well also. great job.

[@graymodeler]

You could open the main jet a smidgeon with a Micromark modelers drill set.. Not supposed to do it but a good experiment that would work.

[@sureshkumarc.k6534]

Whoo a new video by the king of generators

[@KensSmallEngineRepair]

We say Mr. Generator!!! He is the man!!!!

[@sureshkumarc.k6534]

@@KensSmallEngineRepair YEAH he is like the clone of mustie

[@matthewhoffman9242]

Got to love when the fuel line will spin freely on the fuel barb but absolutely refuses to come off the barb

[@DaveGagliardi]

The way you added the wheels was brilliant... I have a harbor freight genset with tiny wheels that I've always wanted to put larger wheels on... your method has given me the needed inspiration to do it. Thank you for the great videos!

[@jcondon1]

Thanks

[@Bulletman426]

Excellent work James. Really great seeing you bring back a rusty, broken down gen and make it come alive again. You have such a good mindset

[@tonyz2897]

That carb looks very similar to the one on my push mower with a Tecumseh engine. When it needed replacement, I found a clone version with mixture screws instead of fixed jets. It's nice to be able to dial in the mixture yourself instead of relying on luck to get one that's jetted correctly.

[@jcondon1]

I agree. Adjustable jets would make it so easy to fix carburetors when not running well.

[@AntonioClaudioMichael]

Nice from 33 psi of compression to 70psi always amazes me working on motors how much simple valve adjustment makes

[@davidclement6253]

Rust-oleum makes a clip on handle/spray adapter that is not expensive. Makes it much easier to get a smooth layer of paint. I am a little surprised that even with OEM carb it hunts and surges. Still an air leak? Good job of restoring a beast.

[@TK4619]

I have that same generator, Had chronic issues with it , gave up on that tecumseh engine and found a briggs and stratton model that fit as a perfect replacement.

[@AntonioClaudioMichael]

Defenitly still sounds like it's struggling with the carb but it's working well on power output with the valves adjusted @29:50 @James Condon

[@harveyellis6758]

Great videos. I have learned a lot over past couple of weeks. One tip when using multimeter with a rotary switch > turn off the meter when switching mode from AC voltage to Hz. There is a chance of creating a voltage arc between contacts within the rotary switch, when switching modes and having high voltage AC is on the probes. I know this from experience and destroying a good meter.

[@electricboyo]

This video proves that having the ***correct*** valve clearance can make a huge improvement in engine performance and horsepower.

[@calvinkirk1638]

That was a tricky one with all those carb. trials but good thing that you are familiar with them so that you could pin point the engine running problem. And now it is a great looking unit that someone could make good use of!

[@Savage-lx5yj]

I picked one of these generators up at a yard sale this summer. It is a beast, runs like a champ! I added a nice exhaust system off of a Yamaha dirt bike, works well. Nice and quiet! Definitely worth the repair! I put the P3 in rice when it got wet, fixes the moisture issue.

[@w2dmw]

When I suspect an intake leak, I spray ether around flanges, and other possible sources. It really was a great help, when I couldn't find a leak.....

[@watermanone7567]

Great job James. I had a similar Tecumseh that would not run right and finallly found that the gasket from the carb to the engine block was missing on the far end of the intake manifold. Someone took it out and left it out and it was sucking air. When I put a gasket in it, it ran like a top. Tanks for the video's.

[@jcondon1]

I was wondering the same thing. The connection looked undisturbed, but should probably take a look to be sure.

[@DeadKoby]

That's the kind of generator that defines "bare bones".... No big tank, not a bunch of outlets. Likely marketed for a job site, to run tools in short bursts. That's a decent engine for its time.

[@ericblackwood1286]

Thanks I have the same generator and that fuel line was the worst so we relocated it and got new carberater so now. It runs great

[@RMJUDGE]

WOW! What a simple machine.

[@CARLOSTREUIL]

Great video. A guy on a car restoration channel calls a paint job a Craigs List Rebuild. Thanks for sharing.

[@buckchase1]

Here in Maine, when we fix something like this and make it right, we call it "fluffing it out". James fluffed out that generator.

[@KensSmallEngineRepair]

Who gets free generators and someone to deliver them free from eight hours away send some of that Luck my way James have a great holiday!!!

[@shalashaskasaiz]

Making parts like a Boss 💪, Merry Christmas Mr James.

[@benjaminclarke6870]

you are brilliant again in your ratio of info to visual, but shout out to say i appreciate your level of minimum standard you hold. professional my friend.

[@FeralPreacher]

Merry Christmas James. Nice catch on the carb issues, now you have more spares. Thanks for sharing.

[@AntonioClaudioMichael]

Wow got replacement carb in the mail installed and it's doing the same thing at the beginning the very first carb did this is the 3rd carb and still issues very intriguing 🤔 @39:20 @James Condon

[@butler386]

Man that one was a naughty little fellow. Between mal-adjusted valves and goofy carburetor problems this one was difficult to get fixed and running well. But kept with it and got it fixed to work another day. Excellent fix and repair to make a good little generator for someone. Good job Generator Man.

[@jcondon1]

Thanks. This one was a lot or work, but it was free so worth the extra effort.

[@johncourtneidge]

Very nice! I like your new bending toy! For preference I favoured the blue paint and a wipe over the plastic parts (tank and air box). Your persisence is legendary! Thanks to Eric and Joe also!

[@PeterLawton]

Just FYI: The trade name is misspelled in the video title. Great job fixing up that generator, by the way!

[@Jim-ie6uf]

Great way to spend Christmas Eve, Thanks Jim. Merry Christmas.

[@ThePheonix2009]

Finally found the answer. It has to have two diodes and a rectifier. Sometimes it is hard to find stuff on the web.

[@michaelhuey4187]

Way to go JAMES! I REALLY enjoy your videos. It’s really nice to see a young guy take the time and make the effort to bring something that most people would just scrap, not only back to life, but then make it something that anyone would be happy to own and use. Keep up the good work👍

[@jcondon1]

Thanks! I enjoy the challenge.

[@jeep146]

I fixed a similar one. These are great in the middle of the night as the neighbors can hear it for miles. After awhile you can just hear the motor and tell if it is surging or is at the right RPM. Often you find the carb full of old fuel. Most times inside the carb the fuel has turned to sludge and is not easily cleaned.

[@brancarr1]

Great video as always! Merry Christmas Mr.Condon.

[@jcondon1]

Happy holidays!

[@Me11oIngenuity]

You did great! Happy Holidays!

[@jcondon1]

Same to you

[@AntonioClaudioMichael]

Red paint came out nice

[@er1073]

Great job as usual. Thank you for sharing your video with us Merry Christmas and Happy New Year Ed

[@AntonioClaudioMichael]

Nice Eastwood bending tool love getting new tools

[@musicwiz40]

Its kinda mind blowing that you don't have a welder. Being as talented as you are. I just bought my first welder a week or so ago and oh my gosh is it awesome to have!! You'll definitely benefit from having one.

[@jcondon1]

I now have everything, but the welder. Looking forward to getting one.

[@musicwiz40]

@@jcondon1 oh it will totally change your workflow. Its so awesome to have! I keep thinking I have everything lol. Until I need something like a tap and dye set and boom off to the store I go again lol!

[@Lovinflyindrones2022]

I wish u would’ve given us the heads up when u were using the grinder to cut the handle off. That was all in our eyes!!!!! Lol

[@patbarrett9263]

you made it a lot further with that Tecumseh than I ever did. I hate working on those things. I usually put in some repair time then pitch them.

[@MrSmitty6969]

A Tubing bender, you could seal the tube & freeze water in the oil dipstick tube then bend it with the frozen water in it to about 35-40 Degrees then you could use the other frame with bigger fuel tank !!!! Smitty

[@andrewgrace4410]

Nice clean up James 😊

[@ericvaughn1126]

I could not have scripted a better progression or outcome for a donor unit! As always, very fun and educational to watch. Such a bummer that 2 clones and a modified OEM carb didn't run right for sure. Great mods by moving and tweaking hardware from that Troy-Bilt frame. Love the new bar bender, wheel mounts and red paint too! No tire dressing!? 😉 Thanks for delivering an early Christmas gift to your regulars and have a Merry Christmas, James. Hope the winter brings you power outages so you can move rehabbed units to make room for more!

[@jcondon1]

They are forecasting 40 Mph sustained winds tonight with gusts up to 70. Might be moving some equipment Christmas Day. Have a good Christmas Eric and thanks for making this one possible.

[@ericvaughn1126]

@@jcondon1 Wow! Yeah it sounds like you will be open for business on Christmas day! Good luck and you're welcome. Was my pleasure and special thanks to Joey for literally being the middle man too.

[@lestergillis8171]

I recognize the logo on the bender. Eastwood does NOT skimp on their tools. They are TOP NOTCH.

[@martinkennard1669]

I enjoy your videos. You have a calm and concise voice. You need to get yourself a small MIG welder to repair small things. Build brackets etc. I'm a retired machine designer and spend my time on garden tractors, small engines, art welding and a little fabrication. Have a great New Year.

[@jcondon1]

Thanks. Actually just picked up a used 240v one. Need to do some wiring, get a tank of gas and a cart. It will make an appearance at some point.

[@AntonioClaudioMichael]

Never seen the 120v plugs on the cover of the power head before very interesting 🤔 🤯

[@jcondon1]

I lot of older ones have that.

[@AntonioClaudioMichael]

@@jcondon1 very neet I live in a dry desert state don't see generators much here other then on store shelves

[@geyser3445]

Excellent detailed video.

[@KensSmallEngineRepair]

Just an FYI the lower HP Tecumseh carbs had pressed-in brass emulsion tubes. Happy Holidays James! Stay safe!

[@m.brillon8808]

Merry Christmas James and Family. Thank You for all the great videos of this year. Plus keeping me entertained in these trying times.

[@jcondon1]

Happy holidays!

[@FeloniousDream]

Just picked one up for $50. Last week I got a 2006 Mitsubishi 5800 making power.

[@terrystover7365]

Really enjoy your videos and your trouble shooting methods. You're good!!

[@mikimikemike1]

Thank you I feel I can start a generator repair business now .

[@jayyoung5423]

Great job, that was enjoyable.

[@jcondon1]

Thank you very much!

[@dmaverick2396]

Great vid! I need to learn to weld. It would come in handy. I like when you customize stuff and make it work.

[@jcondon1]

Thanks 👍

[@Mike95inNJ]

Yet again another kick ass video. I learn a little more on each one. Great work as always.🤘

[@jcondon1]

Thanks!!

[@benrobles752]

I have had the same experience with clone carburetors.

[@FatTailFishing]

Another nice build James! Merry Christmas 🎄 🎅

[@jcondon1]

Thanks, you too!

[@YukonHawk1]

Another awesome video. Great job figuring out the carb mystery. Brilliant paint job also. They definitely don't build them like that anymore 😁🎄🎄🎄🌲🌲🌲

[@brendahall7483]

Merry Christmas! Try putting your Kil-a-Watt meter into a plastic bag of rice for a day or two; it really works to dry out electronics effectively. Good Luck!

[@jcondon1]

It is working again. Bought a backup just in case.

[@jimdavenport4484]

Great video James 👍

[@CajunGreenMan]

Another way to remove grips like the ones on the handles is to use a screwdriver to pry it up enough to get a blow gun from an air compressor under it, then hit the air. That inflates the grip enough it usually comes right off with no struggle or force. Those grips might have been a harder plastic than typical motorcycle grips, so it might not have worked as well. Looks like you got the Eastwood 4 inch bender. They make good stuff. There are metal brakes that are made to work in the same way on a bench vise, but I'm not sure yours is sturdy enough for those. Keep up the great work!

[@rancelynch6514]

Very good learning video. Hey the Harbor Freight down here on the Ms Gulf Coast had Kill a Watt for $25. In retrospect it's good that the other frame did not fit, because I don't believe the engine had a oil sensor which could spell disaster should the engine use more oil than thought. Either way it's always wise to check the oil level slot in these situations..... enjoyed the video..Merry Christmas to you and your family..

[@shinhostergroup]

I know that feeling when you buy a clone carb and the old one works better than the new one.

[@itsallfabrication]

Thanks for sharing. That was a bit of a tough one.

[@hondajdmtyper201]

Well done James buddy happy Christmas 🎄 👍

[@hectorarroyo2285]

Good job!!!... merry Christmas Mr. James!!!

[@shawnmrfixitlee6478]

Great save James . ENJOYED !!

[@jcondon1]

Thanks

[@charlesk8897]

Fun video, just need to admiral the tires;-) LOL Thanks!

[@PoopyPants-1955]

Merry Christmas James 🎄🎁 Hope Santa brings you a sleigh 🛷 Filled with broken generators.

[@JF32304]

Hahaha 😂😂😂😂

[@fire44x]

About time you got some tools keep struggling a lift up cart bench to save you on the floor working

[@MsDave64]

That's what I am talking about. Fine job, looks nice and runs good. On your little bender for the flat bar stock. To find out the correct locations for the center of bend there are formulas for set back and bend allowance and you need a K factor chart that goes with that for use on any other degree of bend other than 90°. For 90° the K factor is 1:: SB= K(T+R) For the Bend Allowance the formula for 90° is: BA= (2 πR + 1/2 T) ÷ 4. You may be interested in trying or researching that. Bending metal was part of my job for 50 years, before I retired. For each bend remove 2 set backs and replace it with one Bend allowance. R= Radius of bend T= Thickness of material Center of bend is located at 1/2 of the material allowed for the bend. The rest fof the material would be the 3 flat sections of your U channel. The #4 in the bend allowance formula was used because 90° is 1/4th of 360°.

[@jcondon1]

Thanks I will check that out. Was surprised the bender did not offer any guidance with that. Seems like I would need to know that to get consistent repeatable results. Thanks.

[@MsDave64]

Back in the late 80s I was the lead Mechanic in Eastern Airlines Fabrication shop at our home base in Miami. I use to teach those formulas to our crew so they could make flat pattern drawings that were used to make aircraft parts. @@jcondon1I am glad if it helped you in any way.

[@deangentles4966]

hi james i like this gene i think it has character, its from the old school and will be a round for a long time to come ,good job mate i hope it went to a good home

[@jcondon1]

Still have it. Not sure people want an old machine. But that it ok. Have plans for it in a future video.

[@deangentles4966]

@@jcondon1 i always think the old genes are the best ,they are always well made and last a lot longer then the new ones

[@larrykelly2838]

Great job Doc.

[@mjg263]

Great work James! That was kind of an oddball there, both in the gen head and the engine. Those last generation Tecumseh OHV engines were great when setup for snowblower duty where they can run rich but they seem kind of fiddly when setup for general use. Between the tight EPA regulations and the same bare bones carb design that they’ve used for decades it seems kind of hard to get them dialed in just right. Looks and runs super!

[@w2dmw]

When putting an engine back in service, put some berryman's #12 carb and fuel system cleaner. Works well to ckean out crud and varnish..

[@michaeltarasenkoop2389]

You would think that with all the vibration on the engine they would make things on the carburetor a bit more beefier to withstand the vibration parts a bit more able to withstand the wear and tear ! Also the windings on the stator ? A lot heavier so they don’t break down the insulation on the windings ! Great show !

[@DallasAya]

Wrap string around the axil shaft and frame and put epoxy or fiberglass resin on it. Wipe the rusty parts in cooking oil. bake them in the oven or don't. Works great on mufflers. What have you learned on Champion 1200 80 cc rigs. I got one I think it's great.

[@WJCTechyman]

You're like Mustie1 but focusing primarily on generators. Nice informative videos.

[@shotguncamaro1214]

James, Just a warning. Anything electrical you buy from Harbor freight " YOU OWN IT, NO MATTER WHAT". Meaning if you buy it take it home and it doesnt work, there ARE NO REFUNDS. I bought a scan tool (not a cheap one) TOOK IT HOME PLUGGED IT IN, AND NOTHING, I WENT RIGHT BACK THEY SAID SORRY no refunds ON ELECTRICAL, AFTER A LONG FIGHT THEY DID TAKE IT BACK, BUT IT COST ME 25 % to return it. So I get nothintg electrical from them. Just some advice. Get stuff like that at a real store, where you can return it if needed.

[@jesterr7133]

I haven't seen many generators with Tecumsehs in them. This one should be interesting.

[@obviouslytwo4u]

The dipstick modification was possible. Option 1. Cut the metal dip strip and measure it correctly and then attached to a plastic dipstick. Option 2. Purchase a 3D printer and print a new dipstick, Option 3 Find a bolt that fits the hole drill the middle of the bolt out and then epoxy resin the metal dipstick in the bolt. Option 4 Smash a hole in the crankcase and glue a piece of plexiglass as oil viewing window

[@oldcarnocar]

Tecumseh ALWAYS a pain to get running right

[@earlwest7351]

You can also use a pipe or tubing cutter if you have one handy.

[@mattyal9347]

Good job!

[@lawnmowerdude]

I really like those engines.