Discover the hidden problems of the Coleman Powermate generator!

Table of Contents:

1. Introduction
2. Initial Assessment of the Generator
3. Cleaning and Testing the Generator
4. Removing the Carburetor for Cleaning
5. Inspecting and Cleaning the Carburetor Components
6. Reassembling the Carburetor
7. Adjusting the Engine Speed
8. Installing New Air Filters
9. Adding Wheels for Mobility
10. Customizing the Generator with Handles and Feet
11. Final Assessment and Conclusion

Introduction

Welcome back, everyone! Today I have an exciting project to share with you. I recently acquired a Coleman generator with a 5,000-watt capacity. As you can see, it's quite dirty, but I believe that with a little cleaning, it will look much better. This generator was left behind by the previous owners of the house where the seller had just moved in, and he didn't know much about its condition. However, he was only asking twenty dollars for it, so I couldn't resist the opportunity. In this article, I will take you through the process of cleaning and repairing the generator to get it back in working order. So let's get started!

Initial Assessment of the Generator

Before diving into the cleaning process, it's essential to assess the generator's overall condition and performance. The seller mentioned that it runs but not very well. To confirm this, I decided to start it up and check a few critical components. I pulled the cord to check for compression and inspected the governor arm to ensure that the throttle plate wasn't stuck. Thankfully, everything seemed to be in order. After checking the oil level and determining it to be sufficient, I attempted to start the generator. To my surprise, it started right up and produced power. This was already a good sign compared to other generators I have encountered in the past. However, there were still some issues with the carburetor and a rattling noise from the frame. So, the next step is to address these issues and perform a thorough cleaning of the generator.

Cleaning and Testing the Generator

Cleaning the generator is an essential step to not only improve its appearance but also ensure its optimal functioning. To begin, I drained the fuel tank as a precautionary measure, as I had no idea how old the fuel was. Normally, I don't power wash generators, but in this case, I decided to make an exception due to the generator's condition. After draining the tank and removing it, I power washed the generator to remove dirt and grime. Although it's still not perfectly clean, it's a significant improvement from its initial state.

The next focus is the carburetor, which is often a culprit when it comes to engine performance issues. Removing the carburetor can be a bit more involved than usual due to the presence of a choke lever bracket. After carefully disassembling the necessary parts, including the plastic piece and bracket, I was able to access the carburetor. Surprisingly, the carburetor came off quite easily, indicating that it might have been recently removed and improperly reinstalled.

Removing the Carburetor for Cleaning

Whenever cleaning a carburetor, it's crucial to drain the bowl and inspect the components for any signs of clogging or damage. I cracked the drain on the bowl, and fortunately, some debris came out, but there was no water, which is a positive sign. The main jet appeared to be clear, and there was no visible clogging. Carefully inspecting the bowl, I noticed some rust, but it didn't seem to originate from the carburetor. The fuel tank is made of plastic, making it difficult to determine the source of the rust. Overall, the carburetor seemed to be in decent condition, but cleaning it is still necessary for optimal performance.

Inspecting and Cleaning the Carburetor Components

To begin the cleaning process, I decided to use an ultrasonic cleaner. Before proceeding, I drained the bowl and ensured that the fuel valve wasn't stuck. The ultrasonic cleaner effectively removed the dirt and grime, leaving the carburetor ready for reassembly. I inspected the various components, such as the pilot jet and emotion tube, for any signs of clogging or damage. The pilot jet, in particular, appeared to be partially blocked, which could explain the running issues experienced earlier. Overall, the cleaning process was successful, and the carburetor components looked much better.

Reassembling the Carburetor

With the cleaning complete, I began reassembling the carburetor, taking care to ensure that all parts were properly aligned and secured. The main jet was tightened, but I refrained from forcing it to avoid potential damage. Although there was some concern about the plastic needle in the ultrasonic cleaner solution, I decided to leave it in place to avoid any potential issues. With everything in place, I attached the carburetor back onto the generator, making sure it was securely fastened.

Adjusting the Engine Speed

Now that the carburetor is cleaned and installed, it's time to address the engine speed. It was running a bit slow, so I adjusted the throttle to bring it to the correct speed. There are two set screws that control the high and low-speed set points. By backing them off slightly and adjusting the throttle, I was able to achieve the desired engine speed. After making the necessary adjustments, I tightened the set screws to secure the throttle in place.

Installing New Air Filters

Another important aspect of ensuring the generator's optimal performance is having clean air filters. The existing filters were dirty and needed replacement. I purchased new air filters and installed them, providing improved airflow to the engine. This simple step greatly contributes to the generator's overall efficiency and longevity.

Adding Wheels for Mobility

To enhance the generator's mobility, I decided to add wheels to make it easier to move around. I had spare eight-inch wheels available, similar to the ones used on another generator I own. The challenge was creating a suitable bracket to attach the wheels securely. After some experimentation, I found a stainless steel bracket at the hardware store that would work perfectly. I drilled holes in the frame and attached the wheels using the bracket. This addition greatly enhances the portability and convenience of the generator.

Customizing the Generator with Handles and Feet

In addition to the wheels, I wanted to further customize the generator by adding handles and feet. I happened to have two pieces from a disassembled elevated bed that were perfect for this purpose. These sturdy pieces, when attached to the generator, serve as both handles and feet, making it easy to lift and stabilize the generator. I drilled holes in the frame and secured the customized handles and feet in place. This not only enhances the generator's functionality but also adds a unique touch to its overall design.

Final Assessment and Conclusion

After completing all the necessary repairs, cleaning, and customization, it's time for a final assessment of the generator. The engine now runs perfectly, both under load and unloaded, with no significant issues. The filters have been replaced, ensuring optimal performance and clean airflow. The addition of wheels, handles, and feet has made the generator more mobile and convenient to use in any situation. Despite its improved functionality, the generator may still require some additional cleaning due to its previous condition. However, it is now in much better shape and ready for use.

In conclusion, this project demonstrates the potential of refurbishing and restoring old generators. With a little cleaning, troubleshooting, and customization, it's possible to bring these machines back to life and extend their useful lifespan. Whether you're looking to save money by repairing a generator yourself or simply enjoy hands-on projects, restoring generators can be a rewarding endeavor.