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

[mtn.ubl.ali]

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.

Thanks for the suggestion but i want to save money as well stablizer will be quite expensive dont you think so?

[mtn.ubl.ali]

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.

babar tell me the signs of it plzz when one needs to change valves plzz.

[nabeelryk]

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.

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

use a hot boiling water to clean the terminals just open the terminals and place them in the bath Mug full of hot boiling water, and pore that hot boiling water on battery terminals also that will clean them easily, to farther protect them place them back and tight them as much as possible and cover them like insulating with grease.

keep checking the battery water , for charging battery the charger must not be more then 1/10th of the battery power. In my case i used charging card of homage ups easily available in market cost me 1200. stable charging all you need to do is just couple the clippers to the battery as it is and plug the charger into 220 AC.

you can use gas pipe for insulation that was my quick fix working from couple of years

[nabeelryk]

Thanks for the suggestion but i want to save money as well stablizer will be quite expensive dont you think so?

not worth than your fridge compressor
and mess of timer, transformer and relay to do the job

[mtn.ubl.ali]

not worth than your fridge compressor
and mess of timer, transformer and relay to do the job

understood will do that cheers

[OmRON]

@mtn.ubl.ali

Emergency generator what we have mostly use a method to splash oil inside crankcase "Its called DIRECT SPLASH". The connected rod has a pointed edge whose job is to splash or spread engine OIL inside crankcase to all the components.

Cars use a different methods which is known as force Feeding Engine OIL inside the crankcase. Force feeding applications have OIL filter too. Newer car engines have another technology which is known as Extreme force feeding.

You can find this information on BRIGG and STRATTON website.

Oil filter continously filter the oil and remove small impurities in the oil.

[babarhailian]

@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

Thanks for detailed reply; about charging, I believe, the issue is that as you mentioned it would need 2 to 3 hours for gen to charge the battery so that it may crank; power fails here for one hour in one go and when it comes back I crank the gen for 3 to 4 times which causes the battery to drain again.

About starting problem, again you were absolutely right; the problem was in ht coil wire. I insulated it with the petrol pipe that I once bought to copy Moiz's petrol starting tweak but never did it because my gen used to start with very little leak. That worked very well as insulator and gen is now starting first rope pull. Idea of using suigas pipe by @nabeelryk seems very effective will use it now. I'll use recoil unless I check charging by letting the gen charge the battery for at least 4 hours.

Hats off for OmRON; thanks Nabeel

[babarhailian]

babar tell me the signs of it plzz when one needs to change valves plzz.

There could be more than one symptoms like blast type sounds from air filter side, missing, engine running on low power e.t.c; we may be able to share our experience and help you in a better way if you post the exact problem that your engine is encountering.

[mtn.ubl.ali]

There could be more than one symptoms like blast type sounds from air filter side, missing, engine running on low power e.t.c; we may be able to share our experience and help you in a better way if you post the exact problem that your engine is encountering.

well the thing is gen is fine on thing is there though is it normal for one to increase the speed of gen i mean if its on low speed it does not take the load of fridge it dies is it suppose to increase the speed automatically ? if i increase the speed than it takes the load fine when i switch the fridge on it does shows that it is taking the load the rpm drops bhut within a second stabilize is it normal?

[afnan1112]

@moizirfan
Which point of this relay is normally open,normally close and common?
And which points of time delay circuit i should connect with it??

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[MoizIrfan]

@MoizIrfan
Which point of this relay is normally open,normally close and common?
And which points of time delay circuit i should connect with it??

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the two screws at front are normally close (NC) & normally open (NO).
the one at back side is common.
the two screws at bottom are its 12v dc supply which will come from time delay

[afnan1112]

@moizirfan
which points of time delay will power this relay

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[babarhailian]

well the thing is gen is fine on thing is there though is it normal for one to increase the speed of gen i mean if its on low speed it does not take the load of fridge it dies is it suppose to increase the speed automatically ? if i increase the speed than it takes the load fine when i switch the fridge on it does shows that it is taking the load the rpm drops bhut within a second stabilize is it normal?

It is all normal; just adjust your engine RPM with full load and keep it there. These generators adjust there RPM to some extent by themselves. Also adjust your tappets when engine is cold; intake tappet at 0.1mm and exhaust at 0.15. Hope that will help.

[mtn.ubl.ali]

It is all normal; just adjust your engine RPM with full load and keep it there. These generators adjust there RPM to some extent by themselves. Also adjust your tappets when engine is cold; intake tappet at 0.1mm and exhaust at 0.15. Hope that will help.

which one is which intake and exhaust tappet?

[nabeelryk]

which one is which intake and exhaust tappet?

well one on exhaust side is exhaust tappet and the other on carb side is intake tappet.

left (exhaust) right (intake)

[mtn.ubl.ali]

well one on exhaust side is exhaust tappet and the other on carb side is intake tappet.

left (exhaust) right (intake)

I am sorry after reading your reply i was happy and felt very dumb.

[mtn.ubl.ali]

can someone from multan guide where one can buy feeler guage plzz.and also as the name is feeler guage how to adjust the tappets what will be the feeling when the guage is passed through the tappets?

[babarhailian]

can someone from multan guide where one can buy feeler guage plzz.and also as the name is feeler guage how to adjust the tappets what will be the feeling when the guage is passed through the tappets?

There will be some market where they sell peter engines and generators e.t.c; In that market you'll find some shops named "XYZ mills store" selling screw wrenches, spanners, pillars, and all the tools relating to repairs; these shops have feeler gauges.

To adjust the tappet, first make sure your engine is at compression stroke; the easiest way is to remove the spark plug, put a screwdriver in the plug hole then slowly pull the rope, screwdriver will start coming out, when it is at top most position just stop pulling, your piston will be at compression stroke.
Now loosen the tappet (put a No. 13 ring spanner (ring pana) at lower nut and hold it with one hand, then another No.8 or 10 ring spanner on the upper nut and unscrew it a little bit) put the feeler gauge under the tappet tighten the lower long nut and keep moving the gauge up and down, when you feel little drag like feeler gauge is moving but not freely, tighten the upper nut; once again move the feeler gauge to confirm (sometimes tightening the upper nut makes the tappet too tight) just make sure that you can move the feeler gauge without applying a lot of force. You are done...

[babarhailian]

@MoizIrfan
which points of time delay will power this relay

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12V DC points, as mentioned by Moiz will power the relay.

[avionics]

AoA
I am running into a problem with my 2.5 kva Honda clone gen. It starts fine on NG (idle screw adjustment done) but when nominal load is put on it dies. I changed complete head including tappet valves etc. engine is not taking load.

1 observation of I leave it for idle running for atleast a minute then at times it takes load. I don't put load more than 1000 watts.. suggestions required

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