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

[OmRON]

@MoizIrfan
Thats cool brother, I think 36 Hrs fairly good interval for a generator which has 2200 Hrs long run. Now question arises which OIL , Company and Grade you have used on it. What Interval you used to changed at?

[afnan1112]

@moizirfan
I have 14 point 12v relay not 220v relay so i will power it with transformer having its input coming from gen and output connected to point no: 6 and 7
For R3 iwill use another transformer connected to wapda
^^^^^^^^^^
Is that right to do?

[nabeelryk]

Tell me the one you have used in over-haul + Some good brand referral. My mechanic says he will use Japanese and Taiwanese parts in Chinese generator. Which is like a joke to me.

Hope to hear from you,

OmRON

dear your mechanic is bluffing and cheating, if you can disassemble and reassemble that is easy and already briefly explained that would be good for you, if you cant than buy a new engine BRO your mechanic knows your worth so he will make sure that your gene keep troubling you so that he can charge you alot and after that buy your gene as your well wisher saying "tension na lain main rakh lata hun bhai k kaam nai ana to kis k kaam ana hai hum ny. ap new lay lo yeh mujhay baach do" as he knows what he has done would fix the self caused problem and resale that to someone and heavy price.

i have been through all this so i know their mentality. At one time we felt him as a part of our routine and part of our family almost couple of visit in a month. all this came to end when me and my bro over haul honda ep2500 and that one is working from last 2 years about 4 or 5 hours daily working time. just adjusted tappets and oil change or plug change nothing more and no more visit

[nabeelryk]

@moizirfan
I have 14 point 12v relay not 220v relay so i will power it with transformer having its input coming from gen and output connected to point no: 6 and 7
For R3 iwill use another transformer connected to wapda
^^^^^^^^^^
Is that right to do?

you will create a lot of mess using all that , just vist your nearest shop and do ask him for replacement.

[nabeelryk]

Finally after 10 days of continuous testing and experimenting my ats is ready to rock and roll
although its on bread board but still working like a charm
addition of another function.
POWER SAVER only 10 mile Amp at ideal mode

[mtn.ubl.ali]

@omron btother i read your post liked very much upon going through question arised in my mind.Suppose i want to overhaul my 2.5kva gen i have no help besides my own self it means i wont be able to do it bcoz i dont have a helping hand ? secondly mech told me that to increase the life on gen i should always ovrfill the oil bcoz unlike car engine its not leveled is it true thirdly what to do to stop oil coming out of the blow pipe going from tappet cover into air intake

[babarhailian]

@MoizIrfan
I have 14 point 12v relay not 220v relay so i will power it with transformer having its input coming from gen and output connected to point no: 6 and 7
For R3 iwill use another transformer connected to wapda
^^^^^^^^^^
Is that right to do?

@afnan1112 you have an other alternative; you may use your gen12V to power the relay. This will perform exactly the same function as "gen 220V+transformer+diode bridge rectifier"

[babarhailian]

@OmRON btother i read your post liked very much upon going through question arised in my mind.Suppose i want to overhaul my 2.5kva gen i have no help besides my own self it means i wont be able to do it bcoz i dont have a helping hand ? secondly mech told me that to increase the life on gen i should always ovrfill the oil bcoz unlike car engine its not leveled is it true thirdly what to do to stop oil coming out of the blow pipe going from tappet cover into air intake

@mtn.ubl.ali
For overhauling, you won't need a helping hand all the time except for a couple of tasks like when you have to free the dynamo from engine, you need someone to pick the engine vertically and you'll have to hammer the bolt at exhaust side in the center of dynamo.

Secondly overfilling the oil is equally hazardous as under-filling; overfilling will cause your crank case to break the seals and oil will start dripping out of your crankcase joints; you cannot put new seals without opening up the engine. Oil should be filled up to the first thread (Choori) of oil gauge socket from bottom.

Dripping oil from breather pipe to air filter is default problem of these Chinese machines, you can't completely get rid of it; @agoodfriend installed valve seals in one of his posts but in my case that didn't help either; you'll have to live with this problem.

[babarhailian]

Finally after 10 days of continuous testing and experimenting my ats is ready to rock and roll
although its on bread board but still working like a charm
addition of another function.
POWER SAVER only 10 mile Amp at ideal mode

@nabeelryk

This project possess a great deal of interest for all of us enthusiasts; it would be of great help and knowledge for all if you could manage uploading some schematic of the circuit with mention of part names and numbers.

Personally I know how to print a circuit board; if you could just post a schematic, many of us may benefit from this multifunction dream homemade ATS; and would also be an asset to the forum for future visitors.

[MoizIrfan]

@MoizIrfan
Thats cool brother, I think 36 Hrs fairly good interval for a generator which has 2200 Hrs long run. Now question arises which OIL , Company and Grade you have used on it. What Interval you used to changed at?

i used havoline 20w50 as suggested by agoodfriend from day one in intervals of 60 hours. sometimes more than 60 hours

[MoizIrfan]

@MoizIrfan
I have 14 point 12v relay not 220v relay so i will power it with transformer having its input coming from gen and output connected to point no: 6 and 7
For R3 iwill use another transformer connected to wapda
^^^^^^^^^^
Is that right to do?

as suggested by nabeelryk replace it with a 220v one.
for r3 also add another 14 point 220v relay. by this u won't be needing another transformer. simpler the better.

[mtn.ubl.ali]

@mtn.ubl.ali
For overhauling, you won't need a helping hand all the time except for a couple of tasks like when you have to free the dynamo from engine, you need someone to pick the engine vertically and you'll have to hammer the bolt at exhaust side in the center of dynamo.

Secondly overfilling the oil is equally hazardous as under-filling; overfilling will cause your crank case to break the seals and oil will start dripping out of your crankcase joints; you cannot put new seals without opening up the engine. Oil should be filled up to the first thread (Choori) of oil gauge socket from bottom.

Dripping oil from breather pipe to air filter is default problem of these Chinese machines, you can't completely get rid of it; @agoodfriend installed valve seals in one of his posts but in my case that didn't help either; you'll have to live with this problem.

Thanks babar like always you always here to help respect you for that.So one thing need to ask i.e what can i open in gen that doesnt require me to open the denmo.i mean is it possible for me to change piston and rings plus valves .and also how should i make a timer i want to put the timer in between the plug of my fridge and the current supply socket the idea is to turn the fridge on after five minutes of gen giving supply to lights and fans at the moment i am doung it manually.

[babarhailian]

Thanks babar like always you always here to help respect you for that.So one thing need to ask i.e what can i open in gen that doesnt require me to open the denmo.i mean is it possible for me to change piston and rings plus valves .and also how should i make a timer i want to put the timer in between the plug of my fridge and the current supply socket the idea is to turn the fridge on after five minutes of gen giving supply to lights and fans at the moment i am doung it manually.

You can change the valves without any hassle but if you want a ring/piston replacement, you'll need to take the engine and dynamo out of frame, detach the dynamo and then open crank case (Engine block); to change valves, you just need open up four nuts of the head read first four or five pages of this forum; agoodfriend has beautifully described everything with pictures.

To make timer, you just need a 1- small 12Volt transformer, 2- four diodes or a rectifier and 3- the single variable timer that you found in your city when you were searching for the stuff to make ATS.

[babarhailian]

Generator won't start
@all

Need some help/Advice. My generator's 12V out gone dead a couple of days back, gen charges the battery but (may be battery has gone old enough or something else) after about two hours of running the generator, battery gets able to crank the engine twice or three times at max.

Moreover from the day it's 12V out gone dead, it wasn't starting on first crank; usually took four to five attempts; by tonight, I had to pull the choke and pull the rope for about 5 times to get it started; now it doesn't start at all. Pulling the rope doesn't feel like generator is switched off, it attempts but doesn't picks up.

I have tried changing the spark plug, checked the spark which was sound enough, checked tappets (exhaust tappet was very tight) and adjusted them. Need any suggestion advice about what else could be the problem.

[OmRON]

@nabeelryk

The ATS relays or Contactors will eat nearly 15W - 20W on wapda. You are talking about your PCB broad consumption ( 10 milli-amps?

[yasir_khan]

Very informative. . Subscribed

Sent from my GT-I9300 using Xparent Blue Tapatalk 2

[nabeelryk]

@omron btother i read your post liked very much upon going through question arised in my mind.Suppose i want to overhaul my 2.5kva gen i have no help besides my own self it means i wont be able to do it bcoz i dont have a helping hand ? secondly mech told me that to increase the life on gen i should always ovrfill the oil bcoz unlike car engine its not leveled is it true thirdly what to do to stop oil coming out of the blow pipe going from tappet cover into air intake

your mechanic sucks dude these engines are designed for this purpose so they have mentioned and placed oil gauge what you think the designer is fool or or out of mind ?
if you will over fill as the word describes over means that more than required or limit the over oil will blow out from tappet head seal or may b chases seal so dont listen to those mechanics there are just trained not qualified.

[nabeelryk]

Thanks babar like always you always here to help respect you for that.So one thing need to ask i.e what can i open in gen that doesnt require me to open the denmo.i mean is it possible for me to change piston and rings plus valves .and also how should i make a timer i want to put the timer in between the plug of my fridge and the current supply socket the idea is to turn the fridge on after five minutes of gen giving supply to lights and fans at the moment i am doung it manually.

dude just buy a stabilizer for fridge and ask him to set its timer to 5 min.
that will save your compressor from low voltage also.

[nabeelryk]

@nabeelryk

The ATS relays or Contactors will eat nearly 15W - 20W on wapda. You are talking about your PCB broad consumption ( 10 milli-amps?

dear i mentioned as IDEAL MODE and load on battery not mains or gene 220
i will notice that tonight how much it load on gene or main 220

@nabeelryk

This project possess a great deal of interest for all of us enthusiasts; it would be of great help and knowledge for all if you could manage uploading some schematic of the circuit with mention of part names and numbers.

Personally I know how to print a circuit board; if you could just post a schematic, many of us may benefit from this multifunction dream homemade ATS; and would also be an asset to the forum for future visitors.

bro i am working on PCB i will post the PCB design and parts list so every one can buy that stuff and print that picture on PCB and some soldering and everything is good to go.

[OmRON]

@babarhailian
aOa,

Here is what I want to tell you,
http://www.greenpower.cn/image/service/6-Common%20Spare%20Part%20List.pdf

Open it up and on page 2 see entire right. Its the charge coil, It is under the flywheel. Its JOB is to charge battery at maximum 8.3A @12 Volts. If your battery is too low on charge, You can crank it only after 2 or 3 hours of generator working, but that will die soon as well. A classical symptom. Remove the battery take to shop or charge is for 4 - 5 Hours on UPS charger with opened lids. Put water if needed. Battery terminals must be cleaned with green AXE blade from the inner round and the area where wires meet. And it should be very tight on battery and wire.

Take battery terminals cleaning and tightness very seriously.

I Still believe that wire of your HT coil need a Thick Sleeve, Its hard to explain here everything by words. That black wire is mostly bad. I have observed it in nights with many generators. They leak current with other metal parts.

Voltage of specific higher frequency really jump through the cable insulator from outside, to metal parts and living things.

Chinese generators have this manufacturing fault. Their insulator of the cable is so bad. Copper wire strands are not always in the middle of the insulator, Some-times they are close to the rubber some time more than adequately far.

If you get Heat-Shrinks of the same size, Tape the wire and put that heat shrink on that wire from one end to the other. It will never happen again in generator life time. or change that prescribed wire with the known Quality one.

OmRON