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

[MoizIrfan]

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.

my friend's camshaft spring got stuck. mechanic opened it and the plastic from oil gauge was stuck in bits and pieces on the cam spring.
so cleaned it and installed it back. working great now

[babarhailian]

Eventually I managed to bring that piece of junk to life. The issue was with tappets, they weren't nicely adjusted and were very loose and they were not able to open the valves. After three days of struggle, I eventually successfully overhauled an engine for first time. Engine is running great and seems to be quite in power. I'll post whatever pictures I have by tomorrow.

The teflon plastic camshaft seem to be very useful for noise reduction, the only noise in this engine comes from exhaust; which I'll try to reduce as much as possible; I'll search for some 4stroke rikshaw exhaust and give it a try.

Now I'll start searching an exhaust and a dynamo for this engine so that I may have a spare generator in a case my 7.5KVA fails sometime.

Thanks for all the help and suggestions; special thanks to @nabeelryk and @avionics...

[mtn.ubl.ali]

Eventually I managed to bring that piece of junk to life. The issue was with tappets, they weren't nicely adjusted and were very loose and they were not able to open the valves. After three days of struggle, I eventually successfully overhauled an engine for first time. Engine is running great and seems to be quite in power. I'll post whatever pictures I have by tomorrow.

The teflon plastic camshaft seem to be very useful for noise reduction, the only noise in this engine comes from exhaust; which I'll try to reduce as much as possible; I'll search for some 4stroke rikshaw exhaust and give it a try.

Now I'll start searching an exhaust and a dynamo for this engine so that I may have a spare generator in a case my 7.5KVA fails sometime.

Thanks for all the help and suggestions; special thanks to @nabeelryk and @avionics...

Good job babar i am happy for you at last the problem is sorted.I am also planning to overhaul my gen i will need your advice plzz anything there worth sharing plz do so and plzz tell m
us price of that plastic camshaft and its advantages and also should i change it as well ?

[dr3vil]

got 2 problems
when gen is switched off with a jerk 2 wires from avr to a black thing det disconncted and i i have to reconnect them
original clips were loose got new one same as car horn but not working fine as i think it needs little bit more wire in length
2nd prob is i am usign 10w 40 zic a oil in my loncin 2.5 kva now i think it has started to reduce oil
i got no vibrations no smoke in it but if i count hours its nearly 3000hrs running time approx
so should i go for 20w 50 oil in it
pls tappet cover has a mini leak it might also be the culprit
i am going to change tappet cover and switching oil to 20 50
which brand is good for this gen
advise

[nabeelryk]

got 2 problems
when gen is switched off with a jerk 2 wires from avr to a black thing det disconncted and i i have to reconnect them
original clips were loose got new one same as car horn but not working fine as i think it needs little bit more wire in length
2nd prob is i am usign 10w 40 zic a oil in my loncin 2.5 kva now i think it has started to reduce oil
i got no vibrations no smoke in it but if i count hours its nearly 3000hrs running time approx
so should i go for 20w 50 oil in it
pls tappet cover has a mini leak it might also be the culprit
i am going to change tappet cover and switching oil to 20 50
which brand is good for this gen
advise

well i am using 20 50 havoline in Honda (original) ep2500 and loncin 2500 since from purchase and changing at the interval of 75 hours.
soo far so good change the tappet seal.
we use gene average 7 to 8 hours daily.

[bakiz89]

Mein es forum par new hon mera generator ndl 2500 watt ka ha last night uski denmo side wali seal se oil leak hogya ha phle crankshafat wali side se leak hoa tha wo seal mein ne khud change kar li thi. ab denmo wali side khul nai rhi koi mari help kar de muje bta de yeh kase open hoga. tak ke mein eski seal change kar sakon

[dr3vil]

well i am using 20 50 havoline in Honda (original) ep2500 and loncin 2500 since from purchase and changing at the interval of 75 hours.
soo far so good change the tappet seal.
we use gene average 7 to 8 hours daily.

seal is changed but cover looks kinda bent to me from down side
we used gen too much 24/7 as load shedding is too mch in our area

[nabeelryk]

seal is changed but cover looks kinda bent to me from down side
we used gen too much 24/7 as load shedding is too mch in our area

24/7
you must be kidding dude
i know couple of generator operators of Govt institutes even thay dont use it 24/7 max 12 hours spell then 2 hours cool down, even those generators are water cooled.
i would love to know more about your gene if that air cooled gene is capable of 24/7 operation

[dr3vil]

24/7
you must be kidding dude
i know couple of generator operators of Govt institutes even thay dont use it 24/7 max 12 hours spell then 2 hours cool down, even those generators are water cooled.
i would love to know more about your gene if that air cooled gene is capable of 24/7 operation

lol no way i run it but its 1 hour break after 3 hours on running
now bijlli is ok as due to rains weather is better
but in ramadan we had to use gen all night

[MoizIrfan]

lol no way i run it but its 1 hour break after 3 hours on running
now bijlli is ok as due to rains weather is better
but in ramadan we had to use gen all night

I once forgot to switch on my ATS signal switch and my loncin 2.5 ran 2 days continuous and nobody realized. it worked like an ups the gen is on 3rd floor open to sky an we live in first floor so nobody realized. then after two days when load was suddenly transferred from kesc to gen then i realized.

[afnan1112]

@moizirfan
Cut off relay is not latching
I have removed relay of time delay circuid and connected wires from its 12v dc points to stabilizer relay

Sent from my IM-A850S using PW Forums mobile app

[MoizIrfan]

@MoizIrfan
Cut off relay is not latching
I have removed relay of time delay circuid and connected wires from its 12v dc points to stabilizer relay

Sent from my IM-A850S using PW Forums mobile app

remove the whole time delay circuit and directly connect the stablizer relay with 12vdc output from transformer,
Is your stablizer relay 12v dc or 220v AC?

[MoizIrfan]

@MoizIrfan
Cut off relay is not latching
I have removed relay of time delay circuid and connected wires from its 12v dc points to stabilizer relay

Sent from my IM-A850S using PW Forums mobile app

remove the whole time delay circuit and directly connect the stablizer relay with 12vdc output from transformer,
Is your stablizer relay 12v dc or 220v AC?

[nabeelryk]

I once forgot to switch on my ATS signal switch and my loncin 2.5 ran 2 days continuous and nobody realized. it worked like an ups the gen is on 3rd floor open to sky an we live in first floor so nobody realized. then after two days when load was suddenly transferred from kesc to gen then i realized.

in my case the oil alert kills the engine if its too hot
we use for 3 hours spell on daily bases than at-least 1 hour cool down, thats the reason i said 24/7 = kidding.

[afnan1112]

remove the whole time delay circuit and directly connect the stablizer relay with 12vdc output from transformer,
Is your stablizer relay 12v dc or 220v AC?

It works with 12v dc direct from transformer

Sent from my IM-A850S using PW Forums mobile app

[MoizIrfan]

It works with 12v dc direct from transformer

Sent from my IM-A850S using PWForums mobile app

Directly connect it with your 12v transformer which u are using in your Ats. No need for delay.

[afarooqi]

By mistake, I turned ON power switch (from KESC) while generator engine was OFF but its circuit breaker was ON. It made sound like burzzzzzzz. Would it have harmed alternator or any other electrical device inside generator?

[hasooboy]

By mistake, I turned ON power switch (from KESC) while generator engine was OFF but its circuit breaker was ON. It made sound like burzzzzzzz. Would it have harmed alternator or any other electrical device inside generator?

It would harmed the alternator for sure as it got return current from KESC.

[hasooboy]

I need a suggestion, should i go for KHOLER or Brigs and stratton in gas genset ??

[afarooqi]

It would harmed the alternator for sure as it got return current from KESC.

even if generator was not running ?