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

[nabeelryk]

@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

WAO nice info thanks dude never though there would be difference as i have always worked in DC environment weather its robotics or electronics , now i have to study wikipedia for power factor
thanks again

[MoizIrfan]

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.

will get hold of these. i am planning for new bolts with these washers. lets see

[MoizIrfan]

Use a longer bolt and a nut

I am planning to use new bolts same size. otherwise long ones, if still unsuccessful then will be adding a nut to it

[MoizIrfan]

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

good idea

[MoizIrfan]

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

i get it. thanks

[OmRON]

@nabeelryk

pf is some phase shift in alternating current. In DC it is always =1 , that what W=V*A*1 is ignorable.

But in AC it holds true in few application where there is inductive load. like motors , transformers, wire wound applications.

It is again =1 if ac load is resistive like old incandescent light bulbs, sodium tubes.

DC motors are always more efficient than AC motors, thats why whole railway system in world use DC motors.

Every generator can handle more resistive load like 1000VA generator can light 10 bulbs of 100W each easily, But when it comes to motor loads it will hardly managed to tackle 660Watts of Motors ( fans , compressors , fridge , ac etc).

Thats why when you buy new generator, shopkeepers are happy to show you a test of 1KVA sodium tube load on 1 KVA generator ( 8000VA generator = they will light up 8 Sodium tube of 8000VA). While on back home its always struggling with your 2500 Watt 1.5 ton Ac.

Hope it will be informative for some of members,

OmRON

[nabeelryk]

change NG kit spring using Honda 125 timing spring

how can i change NG kit builtin spring with HONDA timing spring ?
the builtin spring is just about size of 1 inch whereas honda timing spring is almost 2.5 inches in size do i have to cut it about the size of builtin spring or just place it as it is in the NG kit. ?

[afnan1112]

@babarhailian
if I do this mod then I don't need gas solenoid valve or do I?

[mtn.ubl.ali]

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.

now the question is that i tried doing all this but no use the thing is that the button u are telling me about how i use that is when i want to start the gen on gas i push it 2 or 3 times after that gen start easily thing is that when the gen is running on gas of i push that button gas supply kind of cuts off so how is it possible that when it is open all the time by sticking a pin it gen can work i m no one to question u plzz its just that i dnt get how its possible.

[babarhailian]

@babarhailian
if I do this mod then I don't need gas solenoid valve or do I?

In my case, I am not using a solenoid and there isn't a substantial amount of Gas being lost; you may use a solenoid if you like; there would definitely be a minor gas leak, but if your generator is happy with up to 1 inch of flame and it is not in a concealed place, I don't think there is any need of using solenoid.

[babarhailian]

now the question is that i tried doing all this but no use the thing is that the button u are telling me about how i use that is when i want to start the gen on gas i push it 2 or 3 times after that gen start easily thing is that when the gen is running on gas of i push that button gas supply kind of cuts off so how is it possible that when it is open all the time by sticking a pin it gen can work i m no one to question u plzz its just that i dnt get how its possible.

The function of this button is that when you push it, a large amount of gas passes through the kit all the way to the carburetor. It by no way cuts the gas; your generator starts dying upon pushing that button because it releases too much gas for the generator to handle and it starts dying.

If you have done the trick just check if there is a flame at kit's out put when you lit a match. If there is no flame, then tighten the a couple more screws of that button. You need to have at least half or one inch flame at Kit's output port. Don't worry the flame won't got in the kit

There is a small plate under that button inside the kit, pressing that button pushes that plate and releases gas to generator which is required for generator to start; after starting, generator starts sucking gas by itself as required. If you do this modification, the button will continuously press the plate a very little bit and there would be a very small amount of gas going out of kit all the time, that would be enough for the generator to start. I am using this trick from first day and I have received a very reasonable gas bill.

You can experiment on it; just remove the gas out pipe from your kit lit a match near the opening and press that button there would be a lot of fire, the more the fire the more you press the button. be careful don't keep your hand in front or above the opening.

[babarhailian]

now the question is that i tried doing all this but no use the thing is that the button u are telling me about how i use that is when i want to start the gen on gas i push it 2 or 3 times after that gen start easily thing is that when the gen is running on gas of i push that button gas supply kind of cuts off so how is it possible that when it is open all the time by sticking a pin it gen can work i m no one to question u plzz its just that i dnt get how its possible.

Please not that it wouldn't be open all the time; you should never fully tighten the button back to it's place; JUST TIGHTEN IT TWO OR THREE THREADS (CHOORI'S) this way button will be slightly pressed all the time and generator will start and run like a charm; you'll tighten the button more to increase the flame and loosen it to decrease the flame.

[mtn.ubl.ali]

Please not that it wouldn't be open all the time; you should never fully tighten the button back to it's place; JUST TIGHTEN IT TWO OR THREE THREADS (CHOORI'S) this way button will be slightly pressed all the time and generator will start and run like a charm; you'll tighten the button more to increase the flame and loosen it to decrease the flame.

on more thing i dont know if u hve tried or not if u push the button while already gen is running on gas it shuts down why is that

[babarhailian]

on more thing i dont know if u hve tried or not if u push the button while already gen is running on gas it shuts down why is that

It is because fully pressing that button releases too much gas for generator to handle and it dies. I already mentioned in above reply that if you fully press that button and lit a match near gas output port, there will be about 1 foot of flame. generator can't handle that much gas while running.

[mtn.ubl.ali]

you are a gem thanks alot brother Allah bless you i will try it tonight once again and keep you posted with the results.

[babarhailian]

you are a gem thanks alot brother Allah bless you i will try it tonight once again and keep you posted with the results.

Thanks brother, do let me know about the result.

[OmRON]

@nabeelryk

Its on ebay. I can't remember its dimensions but it slightly bigger than the voltmeter on the generator. I have seen this fitted into some Chinese generators ( low brands ). But it can display Volts, Frequency, Amps and Hour meter. Functions are all good.

[mtn.ubl.ali]

Thanks brother, do let me know about the result.

well by the grace of Allah and with the help of star i would say all is well.i found out one thing onstead of pressing the button all the way i pressed it half way through this way it can be screwed firmly in its orognal place and i didnt had to use tape as well in the end credit goes to you a job well done.

Now coming to the more technical part which i have zero know how about is making ATS i need your experties in this matter as well plzz.one thing i should be telling u is that i live in small town kabirwala its 13 kms from khanewal and 60 +kms from multan.

[babarhailian]

well by the grace of Allah and with the help of star i would say all is well.i found out one thing onstead of pressing the button all the way i pressed it half way through this way it can be screwed firmly in its orognal place and i didnt had to use tape as well in the end credit goes to you a job well done.

Now coming to the more technical part which i have zero know how about is making ATS i need your experties in this matter as well plzz.one thing i should be telling u is that i live in small town kabirwala its 13 kms from khanewal and 60 +kms from multan.

That's great, all is well that end's well. You don't need to follow the instruction line by line; whatever works for you is the perfect thing.

But make sure about one thing which is very important; remove the outlet pipe from kit, lit fire at output port and check the flame; it shouldn't be too much. it should be at maximum 3 or 4 inches. A bigger flame would cost you a lot in terms of gas bills. If the flame is too large then try unscrewing the button and the flame would reduce it is not necessary to keep the button at its original place; Just keep the minimum flame that makes your generator start on first self.

About ATS, I hope you'll find most of the stuff in Kabirwala; I'll send you a list of required things with Photos; check them in your market and tell me what is available and what is not.

[mtn.ubl.ali]

@babar you are rite i did rechecked the flame after reading your reply just to make sure its not more than 2/3 inches i also shut the gas handel upon shutting the gen down just till i dont have ATS.well waiting for the detials i m cant wait to start the project.