Generator Engine Overhauling & ATS Dedicated Thread ( Advice , DIY, Repair ,Install)

[babarhailian]

To all brothers if any one can guide me or post pics for the mod of ng kit plzz i want to start my 2.5 kva gen on gas it will be a dream come true for me bcoz the only few days it does start on gas is when mech do the tappet setting after that again need to give petrol for starting.

If your NG Kit has a push button on it's back side top, then it would be very easy, otherwise you'll have to open up your kit and drill a hole like agoodfriend mentioned in earlier posts; let me know if it has a push button that you usually push before starting it.

[MoizIrfan]

Hi! Just change the tappet cover oil gaskit and then see, if they are loose again and the threads are good then put a small spring washer under each bolt and tight them. I hope this solves your problem.

replaced the tappet cover & its gaskit. still they are becoming loose. whats a difference between a normal washer and a spring washer??

[MoizIrfan]

sir ad same issue
i then replaced the bolts with bigger churrri
like one with 11no churri on my gen
problem solved

ok will be doing it. thanks alot
Shall i insert the 11mm bolt. it will make its threads by itself???

[MoizIrfan]

@MoizIrfan use bolts of different size thread or you can hand tap it or you can use nut/bolt on tappet cover what ever suits you

yes will be replace the bolts.
which one is easy nut & bolt or using 11 size bolts.??
i suppose i will have to drill to nut and bolt installation

[Thunderbolt]

Ok Moiz making new threads is the last option and under conditions when threads get worn or slip. One option is get new bolts of the same size. You asked what is a spring washer. This is a spring washer.I hope this solves your problem. Secondly tight the bolts with socket set.

[ToxicDevil]

Use a longer bolt and a nut

[babarhailian]

@ALL
i am facing an issue of loose tappet cover bolts. i tight them but after one day they become loose again, then again i tight them again they become loose after one day. wired

That really is a very annoying issue; no one wants to change his generators head just because they are out of threads for bolts. the same happened to my 7.5 KVA; it just has one large nut in the center of tappet cover. The mechanic came with an oversized nut but it didn't just fit in, he had to make new threads with the help of a drill-bit, that worked perfect but when I removed the tappet cover a few times, the new nut also failed to get tight.

Now I am using a copper wire (the one that is inside a TV transmission cable) in the hole; but it would only fit if the nuts are quite loose; you may cut four pieces of copper wire and flatten their ends a little with a hammer or something like that and insert the pieces in all the four holes so that their flattened ends are a little bit out of holes, then place the tappet cover and carefully put the nuts in so that they may not crush the wire and rather go in along with the wire. to tighten the nuts, you should first give the nut a little stroke by hammer then tighten it a couple of turns preferably by GOTI, and repeat the same till all the nuts are fully tightened; this surely works but you'll have to insert new wires everytime you'll open up the tappet cover.

[dr3vil]

ok will be doing it. thanks alot
Shall i insert the 11mm bolt. it will make its threads by itself???

sir try different bolts in them
i did that and made threads in it self
but try out different set of bolts in even 10mm as some bolts have thick currri even though they are 10mm
im sure u getting my point

[dr3vil]

well i think thats working Amp, you must check its surge Amp.
as u mentioned Loncin gene,
i am using loncin from april 2012 working fine, loncin is rated 2.2 Kv Max thats 10 Amp on 220, they have just calculated it according to petrol and circuit breaker.
loncin is pre-loaded with 10 Amp breaker and when its operating on GAS its output is max 7.5 Amp so i guess u may overload you gene, so would be better if you check surge rating of your AC, in simple words "starting AMP of AC when compressor starts"
best of luck.

sir mine is old shape genn
and i opend the dynamo cover and i could see copper windng and 2.5KVA written plus mine came with 11amp breaker and i also have one heavy duty breaker 16amps lying around
and iwrote 7.5 etc but its less as it works fine on that jd 2.5kva we tested

[mtn.ubl.ali]

yes it does have that button which i use b4 starting up the gen

[OmRON]

@babarhailian

Yes your hour-meter need watch cell replaced, Its a plain hour meter. These days plenty of stuff you can buy, A new type of red LED letter Hour meter , Volt meter , Hz Meter and Amp Meter All in one is available in 600 Rs from Brandeth Road Lahore. I have see very few new generators come with that fitted.

This is also sold as New DB Gadget. It is oddly unpleasant looking but do the JOB.

[babarhailian]

yes it does have that button which i use b4 starting up the gen

Then you are almost done with the modification; I'll post step-by-step procedure with pics; may be in a while or at the most by tomorrow. Plus you have to adjust your spark plug's gap to 0.4mm and adjust the tappets, if you haven't already done it.

[nabeelryk]

ok will be doing it. thanks alot
Shall i insert the 11mm bolt. it will make its threads by itself???

no you have to drill a hole and place oversized(that is 11 in your case) thread in it.

[babarhailian]

@babarhailian

Yes your hour-meter need watch cell replaced, Its a plain hour meter. These days plenty of stuff you can buy, A new type of red LED letter Hour meter , Volt meter , Hz Meter and Amp Meter All in one is available in 600 Rs from Brandeth Road Lahore. I have see very few new generators come with that fitted.

This is also sold as New DB Gadget. It is oddly unpleasant looking but do the JOB.

Thanks OmRon, I'll ask someone in Lahore to buy from Brandreth Road and send me that thing in pic; It seems quite useful. About the factory fitted meter in my generator, I checked it's battery with multi-meter and it was producing the voltage rated on it; could there be any other issue with that meter?

[nabeelryk]

sir mine is old shape genn
and i opend the dynamo cover and i could see copper windng and 2.5KVA written plus mine came with 11amp breaker and i also have one heavy duty breaker 16amps lying around
and iwrote 7.5 etc but its less as it works fine on that jd 2.5kva we tested

dude you dont get the point, and you are miss calculating

The power P in watts (W) is equal to the current I in amps ( A), times the voltage V in volts (V):
P(W) = I( A) x V(V)
So watts are equal to amps times volts:
watt = amp x volt
or
W = A x V
for example if your AC is running on 240 volts MAIN supply with 7 amp load then watts=A x V; w= 240 x 7 = 1680
and as generators are rated according to petrol power your gene is 11(amp)* 195(volts) =2145 watts capable, now the point is as your gene is on gas so will lose some power due to difference of octane levels.
normally dropout
HONDA ep2500 (2.5 max power 2.2 Kv Max load) dropout rate 1.5AMP
JD 3500 (2.5 max power 2.2 Kv Max load) dropout 2.5 Amp
lincon 3500 (2.5 max power 2.2 max load) dropout 2.5 Amp

so when gene is running on its peak load dropouts voltage also in my case voltage drops to 195 if i run Mitsubishi split AC.
normally dropout to 205 volts.

so i guess your gene will dropout to (11-2.5 amp) x (195) = 1658
and 1658 is < your required load 1680.

best way to calculate is put and amp meter and volt meter and start ac and note down volts and amps of both starting and running condition.
then use Amp and volt meter to calculate dropout of gene.

BTW never witnessed and heard about 11 Amp breaker
10 15 20 Amp breakers normally available in market.

[OmRON]

@babarhailian

You can search this meter from Sultan Ka Khu, There are used parts market, There are old electrical stuff vendors, They also have lots leftovers in brand new and in Boxed.
It should not cost you more than 600 Rs. Sub kuch china ka hae na aaj kel.

If battery is OK then hour meter has some problem, You can take that out and show that to some WATCH Repair Shop. It can be fixed, Plus you can also buy one new.

[nabeelryk]

@babarhailian

A new type of red LED letter Hour meter , Volt meter , Hz Meter and Amp Meter All in one is available in 600 Rs from Brandeth Road Lahore.
This is also sold as New DB Gadget. It is oddly unpleasant looking but do the JOB.

i would love to know more about its size (dimensions) and functions.

[babarhailian]

yes it does have that button which i use b4 starting up the gen

1- Detach your kit from generator (no need to remove pipes)

This is what your kit should look like

2- You have to unscrew this button from its base

Unscrewing (It should come out by bare hand)

Button removed

Looks like this

Pressing the button makes it look like this

3- Stick a needle at the base of button and press both button and needle at once (you have to insert the needle with the button so that the button won't come out and make sure it is permanently pressed)

4- Wrap squash tape on the threads on the base of button so that when you reinstall it, it may not move with vibrations even if it is fixed with just a couple of turns in it's hole.

5- Cut the excess tape hanging beneath the threads by scissors.

Should look like this

Put it back in hole and just give it a couple of turns to tighten it (DO NOT FULLY TIGHTEN IT; NOT MORE THAN TWO TURNS)

Fix the kit back

The button will now look like this from side

Remove the pipe going to carburetor and lit a fire at opening. there should be a small flame, you can increase the flame by turning the button clockwise and reduce it by turning it anti. keep about half an inch of flame and fix the pipe back. Now start your generator, but make sure to adjust the Spark plug gap and adjust tappet before it. If your gen start on first crank, then pray for me; if it doesn't then try increasing the flame a little bit more, your generator shouldn't demand a flame of more than 2 to 3 inches.

Best of Luck; Now you'll be ready to make an ATS; believe it that ATS thing is worth your time, money and effort.

[OmRON]

@nabeelryk
DC Power.
The power P in watts (W) is equal to the current I in amps ( A), times the voltage V in volts (V):
P(W) = I( A) x V(V)

Power Calculation in AC is different,

P(W)= I( A) x V(V) x p.f =================> pf is power factor it can be normally between 1.0 - 0.5.

Good appliances and good generators have pf close to 1 like ( .9 , .85, .8), If in commercial set uo pf is found below .75, a heavy fine is imposed on user by wapda.

Generators are very bad in pf section, they hardly have .8 power factor if they are good. That brings down 1658*.8 = 1326.4 watts at NG.

Hope that helps

[babarhailian]

@babarhailian

You can search this meter from Sultan Ka Khu, There are used parts market, There are old electrical stuff vendors, They also have lots leftovers in brand new and in Boxed.
It should not cost you more than 600 Rs. Sub kuch china ka hae na aaj kel.

If battery is OK then hour meter has some problem, You can take that out and show that to some WATCH Repair Shop. It can be fixed, Plus you can also buy one new.

I live in Sargodha these days and in local electronics market, they have such meter but they sell it in Rs. 1500; I have some friends in Lahore; I'll ask them to find one from Brandreth Road.