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

[nabeelryk]

want to ask if it is normal to see smoke coming out of blow pipe and in that smoke i can smell engine oil kind of burnning what is the solution? today due to vibration the governer arm of my 2.5 kva gen had a hole the hole in which the race thingy goes in not the small spring but the thick one the first hole was cut due to vibration so i loosen the screw and took it off and got it weld after i fixed it back a new problem started now the gen takes full throtel and does not come to the point where its stable and the sound of gen is like its suffocating i started to pull the governer arm slowly towards me and it got stable i dont understand what is the problem now so for the time being i have to stick a thick piece of paper behind the carbaretor the point where it regulates the race and now it is working fine but of corse its only for the time being i will not be sleeping till the sehri time and will be working on my gen any ideas please for me that can help will be great .

as i think you have welded that part ,
it seems like the spring is tightened and that is the reason try stratching the spring to make it long enough if you have some space in adjustment nut then use that to loose the spring.
if it was working fine before than must not be any fallen issue, give it a shot and do let us know.
Regards Nabeel

[nabeelryk]

Do you mean i have to open up the engine ? or the same way i took it off ? and how to remove the petrol tank i have tried but dont know how to its just four screws after that it does not comes of i can move it but it just dont come off

you need to remove all four screws then unplug the fuel pipe and slide the tank from panel side towards opposite side and pick it up.

[nabeelryk]

want to ask if it is normal to see smoke coming out of blow pipe and in that smoke i can smell engine oil kind of burnning what is the solution? today due to vibration the governer arm of my 2.5 kva gen had a hole the hole in which the race thingy goes in not the small spring but the thick one the first hole was cut due to vibration so i loosen the screw and took it off and got it weld after i fixed it back a new problem started now the gen takes full throtel and does not come to the point where its stable and the sound of gen is like its suffocating i started to pull the governor arm slowly towards me and it got stable i dont understand what is the problem now so for the time being i have to stick a thick piece of paper behind the carburetor the point where it regulates the race and now it is working fine but of corse its only for the time being i will not be sleeping till the sehri time and will be working on my gen any ideas please for me that can help will be great .

thats not normal and in my opinion your piston rings are down.

[mtn.ubl.ali]

well i removed the petrol tank and checked the governer arm it was okay there is a pin that stops the arm from faling inside the crank case so thank God it is okay.after fixing everything back now the gen is okay but now a new thing its just not takong the load of fridge whenever i want to put the load on it it just takes the full throtel and suffocates than i have to manually pull the governer arm towards me and than it runs okay its not normal i know that i gave it to the mech now consulted few friends and after researching i found a good mech gave it to him and explained everything and also about the white smoke coming out of breathet pipe will update as soon as i get the gen back about the problem according to me just need good tunning but lets see.

[doctor]

Does Loncin 7600DDC charge the battery automatically through the wires that supply current to its ignition???

[doctor]

An idiot mechanic repaired our Tiger Four Stroke generator as it was leaking engine oil.Now when I checked it whether its working or not, its giving problem.It starts but shuts down by itself just after a minute before putting load of lights over it.Whats he reason?Gas pressure is fine.

[doctor]

Try adjusting your tappets; buy a feeler gauge would cost you about 250 (A real sensible investment). Adjust intake tappet at 1.0mm and exhaust at 1.5mm; I hope your hard rope problem will be solved.

For Installing electric start, got the page suggested.

I would suggest Loncin; It's price and quality, both are reasonable.

Thanks for the reply.Keeping in view the suggestion,I bought Loncin 7600DDC.

Can you elaborate further where the tappets of Honda EM 3000 generator are located?If possible with pictures?I shall be grateful.I sent it to a mechanic but its useless and the kick start is still very hard, rather impossible...He charged Rs.1300 but the problem is still there and the mechanic says its engine is hard and this and that you know what to expect from these mechanics(their foolish suggestions and reasoning).And as for as the Ignition start is concerned, I consulted a few mechanics but they say that its impossible to install ignition in Honda EM3000.Please advise.

[babarhailian]

An idiot mechanic repaired our Tiger Four Stroke generator as it was leaking engine oil.Now when I checked it whether its working or not, its giving problem.It starts but shuts down by itself just after a minute before putting load of lights over it.Whats he reason?Gas pressure is fine.

Your oil sensor seems to be the culprit; either your engine is low of oil or the sensor may be giving false reading; first check your engine oil level, if it is fine, then remove the oil sensor wire; this wire comes from within the engine through a large bolt near oil inlet and below starter motor. disconnect this wire from the square shaped device to which it is going; then give it a try.

[babarhailian]

Thanks for the reply.Keeping in view the suggestion,I bought Loncin 7600DDC.

Can you elaborate further where the tappets of Honda EM 3000 generator are located?If possible with pictures?I shall be grateful.I sent it to a mechanic but its useless and the kick start is still very hard, rather impossible...He charged Rs.1300 but the problem is still there and the mechanic says its engine is hard and this and that you know what to expect from these mechanics(their foolish suggestions and reasoning).And as for as the Ignition start is concerned, I consulted a few mechanics but they say that its impossible to install ignition in Honda EM3000.Please advise.

Tappets are located under a cover below the spark plug; unscrew the four bolts in the corners of the silver cover just below the spark plug you'll see something like this

Picture courtesy: agoodfriend from page 4 of this thread

get your engine to compression stroke (remove spark plug put a screwdriver in the plug hole and slow pull the starter rope when the screwdriver comes at the top most position, your engine will be at compression stroke) make sure to hold the screw driver with one hand in the center of hole and let it come out when piston pushes it; if you leave the screwdriver tinted in the hold, it may get stuck as piston comes up. once you get the piston at desired position then place the feeler gauge under each tappet arm as shown in picture above; For intake (right) side, it should be 0.1 mm and for exhaust (left), it should be 0.15 mm. To achieve this clearance, use a 14mm ring spanner to hold the lower nut and unscrew upper nut. Adjust the tappet by screwing or unscrewing lower nut, when desired clearance is achieved, tighten the upper nut and reconfirm once again after tightening the 10 mm nut.

[babarhailian]

@babarhailian

No no you should not use 7/36 cable at all. These are design to carry maximum 600V from them. And their insulator ( plastic is also very weak). You got me wrong.

You have to use same cable same style and for same purpose, Spark plug cable. You can find from Car Auto store in red or blue color. If you can't get it from Part store, Choose some car electrician and he will arrange it for you from his JUNK.

Rest is sleeve, You have two sleeves already. One is on new one and one is on old one. Remove that and put it on. But before that just give a nice cover of Tape ( HT tape is preferable, You can get it from a shop who sell HT stuff, Its normally an electrical store which deals in factory stuff). But try normal one first for experiment. Sometimes it works.

Don't spend anymore money on it, first test it. Make nice twist joints. you should see copper wire almost edge level and twist is tight. On both ends HT coil and spark plug holder.

Well One Bad new is here, In last summer I have bought a SWAN generator for a specific purpose. It gave us real tuff time. Same problem like yours. Failing Exhaust Tappet, Someone told me a hack for that which worked for 2 months for me. Just remove the plug and put 1 - 2 spoons of oil in it. It will start on first try. But it last for a couple of hours.

When that oil completely burns and clear off, It came to similar position of no starting. It used to do it almost every 3rd or 4th day when it refused to start. Then finally I got head new Tappet seals. Mine was also exhaust seal. A normal motor cycle mechanic opened its head and sent the stuff to Motor Cycle turner. Its working nicely now.

The Oil trick can make you delay the work after EID. Seal will always tight after 3 - 4 days of normal use.

Speak to you soon and will exchange more ideas.

The problem was there with the exhaust valve guide; it managed to come up from its place and was freely wandering around in its hole. This was the thing that made me change the head earlier when I got the engine overhauled as well; I bought new head with every thing already fitted in and I thought that I made a wise decision but now I am feeling it was a worst decision; they have used pathetically poor material in that ready-made head. I went to turner and requested him to repair the head, he fixed the guide and replaced the valves which were like destroyed from the corners and were leaking like hell; this time he used valves from some used Japanese car, which seem high quality stuff.

Any how, engine is now running fine and ATS back to operation with its full power; hope this charm lasts for some time.

Thanks for all the help once again.

Now a days I am working on a engine which I got as a gift from a friend; it is a JD 3500 engine that he bought two years back; now it was like decreasing pressure (that's what mechanic told him) and he replaced the engine with a new JD3500 engine. I got the old one, replaced its rings and cam shaft with a teflon plastic one, installed a new carb, fitted everything and gave it a test; it didn't start and rope was too hard; although crank rotates but when I pulled it whole the engine used to come up like a bag as well.

[mtn.ubl.ali]

First of all Eid mubarak to all my brothers be blessed.
Now first of all update i have big issue with my gen well took it to the mech all that needed to be done was tunning including tappet adjustment so he did that now one big issue that i am facing is its quite noisy and the issue is crank its in bad condition i can hear it moving i feel bad for my gen i have decided to overhaul my gen in winter as its still have 50% life in it so will use that completely and than change the piston rings and crank whatever thats needed to be changed will change my self fingures crossed.I have read good friends post throughly and agree with him that all we need to do is open it and ofcorse i will be giving the parts to kharadiya and than just assembel back its easy will be sharing my experince with you all hope all will end good.please advice me that i should be doing or any suggestion.

[nabeelryk]

EiD Mubarak to everyone
may Allah bless us and everyone peace and happiness.
155 hours (in ramzan) + UPS 4hours * 29 = 116 toal 271 hours / 29 = 9.30 hours loadshading in ramzan

[doctor]

@ babarhailian

Thanks for the reply.I already asked this question in this thread.Do you know whether Loncin7600DDC charges the battery automatically or not when it is operational??

[babarhailian]

@ babarhailian

Thanks for the reply.I already asked this question in this thread.Do you know whether Loncin7600DDC charges the battery automatically or not when it is operational??

I haven't personally seen that generator, however from model number (77600) it seems that this generator is 6.5 KVA or near somewhere. If it is the case, then it must have electrical start and charging system. Anyhow irrespective of output power, if the generator came with a self start option, it must have a charging coil as well; if it is only recoil (rope) start, then it is less likely to have charging coil. you can check for charging coil just under the flywheel, even if you don't want to remove flywheel, just check if a wire comes out from flywheel case (the colored casing between crankcase and recoil rope case) that wire is coming from charging coil and shows that your generator is equipped with battery charging system.

[Thunderbolt]

Hi! EID GREETINGS to forum members and to All PakWheelers. Have a joyous and happy Eid.

[babarhailian]

AOA and Eid Mubarak to All members,

These days I have been working on a JD3500 engine that I got from a friend; he bought this engine two years back (don't know exact hours) and replaced it now with a similar one because this engine was now lacking power. I took it home and opened it apart, it just need rings and valves replacement. I replaced both, changed camshaft with a Teflon plastic one to reduce crankcase noise and added a carby, fixed everything back and tested it.

The Problem:

It's rope was too hard to be pulled smoothly to start the engine. The rope pull was normal to half the rope length but after that it was too hard that I had to apply full force to rotate the crank. I removed spark plug and again tested; this time engine was rotating very smooth.

Then I reopened the crankcase and tried the old camshaft but to no avail. Just to mention that I adjusted timing mark on camshaft with one on the crankshaft gear. I tried to figure out the mechanism and found that engine is not behaving illogically;

• Crankshaft turns twice with one turn of cam; this way there are two up-down cycles of piston with one complete turn of camshaft.
• In first up-down piston cycle, camshaft opens intake and exhaust valves respectively but in second up-down cycle no valve is opened; this causes lot of pressure in cylinder and combustion chamber and piston gets kind of stuck.

In the second up-down piston cycle, when camshaft doesn't open any of the valves, when I tried force rotating the crank, air in cylinder and combustion chamber found nowhere to go and hence was forced to leak inside the crankcase making audible sound and engine almost unable to rotate.

It would be of great help if some member may advise upon this issue. I remember @makniazi once overhauled the engine, can you suggest anything about this problem?

[nabeelryk]

AOA and Eid Mubarak to All members,

Eid Mubarak Bro

[nabeelryk]

AOA and Eid Mubarak to All members,

- Crankshaft turns twice with one turn of cam; this way there are two up-down cycles of piston with one complete turn of camshaft.
- In first up-down piston cycle, camshaft opens intake and exhaust valves respectively but in second up-down cycle no valve is opened; this causes lot of pressure in cylinder and combustion chamber and piston gets kind of stuck.

In the second up-down piston cycle, when camshaft doesn't open any of the valves, when I tried force rotating the crank, air in cylinder and combustion chamber found nowhere to go and hence was forced to leak inside the crankcase making audible sound and engine almost unable to rotate.

It would be of great help if some member may advise upon this issue. I remember @makniazi once overhauled the engine, can you suggest anything about this problem?

The four strokes refer to intake, compression, combustion (power) and exhaust strokes that occur during two crankshaft rotations per power cycle.
(among some automotive enthusiasts names these respectively the "suck," "squeeze," "bang" and "blow" strokes.)
The cycle begins at Top Dead Centre (TDC), when the piston is farthest away from the axis of the crankshaft. A stroke refers to the full travel of the piston from Top Dead Centre (TDC) to Bottom Dead Centre (BDC).

INTAKE stroke: on the intake or induction stroke of the piston, the piston descends from the top of the cylinder to the bottom of the cylinder, increasing the volume of the cylinder. A mixture of fuel and air, or just air in a diesel engine, is forced by atmospheric (or greater) pressure into the cylinder through the intake port. The intake valve(s) then closes. The volume of air/fuel mixture that is drawn into the cylinder, relative to the maximum volume of the cylinder, is called the volumetric efficiency of the engine.

COMPRESSION stroke: with both intake and exhaust valves closed, the piston returns to the top of the cylinder compressing the air or fuel-air mixture into the combustion chamber of the cylinder head. During the compression stroke the temperature of the air or fuel-air mixture rises by several hundred degrees.

POWER stroke: this is the start of the second revolution of the cycle. While the piston is close to Top Dead Centre, the compressed air?fuel mixture in a gasoline engine is ignited, usually by a spark plug, or fuel is injected into a diesel engine, which ignites due to the heat generated in the air during the compression stroke. The resulting pressure from the combustion of the compressed fuel-air mixture forces the piston back down toward bottom dead centre.

EXHAUST stroke: during the exhaust stroke, the piston once again returns to top dead centre while the exhaust valve is open. This action expels the spent fuel-air mixture through the exhaust valve(s).

[babarhailian]

The four strokes refer to intake, compression, combustion (power) and exhaust strokes that occur during two crankshaft rotations per power cycle.
(among some automotive enthusiasts names these respectively the "suck," "squeeze," "bang" and "blow" strokes.)
The cycle begins at Top Dead Centre (TDC), when the piston is farthest away from the axis of the crankshaft. A stroke refers to the full travel of the piston from Top Dead Centre (TDC) to Bottom Dead Centre (BDC).

INTAKE stroke: on the intake or induction stroke of the piston, the piston descends from the top of the cylinder to the bottom of the cylinder, increasing the volume of the cylinder. A mixture of fuel and air, or just air in a diesel engine, is forced by atmospheric (or greater) pressure into the cylinder through the intake port. The intake valve(s) then closes. The volume of air/fuel mixture that is drawn into the cylinder, relative to the maximum volume of the cylinder, is called the volumetric efficiency of the engine.

COMPRESSION stroke: with both intake and exhaust valves closed, the piston returns to the top of the cylinder compressing the air or fuel-air mixture into the combustion chamber of the cylinder head. During the compression stroke the temperature of the air or fuel-air mixture rises by several hundred degrees.

POWER stroke: this is the start of the second revolution of the cycle. While the piston is close to Top Dead Centre, the compressed air?fuel mixture in a gasoline engine is ignited, usually by a spark plug, or fuel is injected into a diesel engine, which ignites due to the heat generated in the air during the compression stroke. The resulting pressure from the combustion of the compressed fuel-air mixture forces the piston back down toward bottom dead centre.

EXHAUST stroke: during the exhaust stroke, the piston once again returns to top dead centre while the exhaust valve is open. This action expels the spent fuel-air mixture through the exhaust valve(s).

Very informative post!

I was concerned about compression and power strokes, since there is no ventilation (from valves) in these two strokes; I was wondering how would the engine move in these strokes at startup. I searched it and found that on the camshaft, there is a decompression mechanism (a spring in the base of shaft) that allows slight opening of exhaust valve during power stroke during startup; once the engine starts, this mechanism deactivates due to centrifugal force and engine starts behaving like as shown in your gif image above.

My issue has been resolved; it was just because of loose tappets, valves were not opening and causing a locked engine. I readjusted the tappets and all is fine now.

[avionics]

There's a spring on the cam gear. The purpose of this spring is to lift the push valve at the time of start up for easy Smooth rotation. Once engine is started our cam shaft rotation attains significant speed then the work of these springs finishes. infact the spring moves outwards.

In my opinion you need to change your cam gear.