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

[sharyyyyyyy]

To my experience i faced these issues when I wired ats directly to gen self solenoid and petrol/gas solenoid which tend to drain the battery over a short time period. Then i added two six point relays and taped them on the generator frame. Both gets signal from ATS. one relay operates self solenoid while other gas/petrol solenoid. Now my ats is trouble free. By removing your self solenoid wire test your ATS if its working great then do the mod which i have done

thanks for your reply..much appreciated

in my case i have ats at distance and my generator is gas/petrol of apprx 15kw custom made. battery is new but not used much...yes long wire is used to connect both things. kindly let me know things to do, to diagnose the issue.??

[ab6666]

aoa all today me and a friend converted his generator to self start the generator was in the store room for about 2 years it is an old 2.5kva gen the parts changed were
1)Carburetor as the old one was faulty the new one was for 300 gas pipe fitting 150 total costed rs 450
2)Added valve seals Rs 32
3)New NG kit Rs 350
4)Starter Motor (self) Rs 1400
5)Flywheel Rs 1000
6)Charging Coil Rs 300
7)Battery 30amp Rs 1800
8)Deno Spark plug Rs 120
9)Flywheel cover Rs.350
10)Oil Rs.250
Total for converting to self start Rs.4850
Total with conversion and other parts Rs.6050
After adjusting the tappets and plug the engine that was at rest for last 2 years started on petrol on first self now the problem is that later i noticed that it does not have an avr and its dynamo is different than the gensets these days the avr of the new 2.5 kva gen can't be installed in it is there any external avr that can be installed with it ?
Regards

Can u plzz tell me bro that why chinese generator dont have valve seals? Plz help me bro waiting for ur reply!

[makniazi]

ab6666 well its just cost cutting nothing else honda clone engine (chinese) manufacturers do this to lower the production cost its a thing must have it reduces oil consumption

[ab6666]

ab6666 well its just cost cutting nothing else honda clone engine (chinese) manufacturers do this to lower the production cost its a thing must have it reduces oil consumption

But the valve seals are not so costy that they can affect production cost?

[makniazi]

ab6666 well it can they dont produce one or two gen sets

[babarhailian]

I think your governor gharari not working inside the crankcase.
As for the choke. this can be due low gas pressure

@moizirfan I have changed the governor gear but still facing problem. The only major issue is that I turn on my 1.5 ton AC, and set frequency to 48 Hz, but when the AC trips, frequency goes up to 70 Hz; and vice versa if I adjust frequency to 50 Hz without AC, it drops to 35 or even some times gen dies when AC starts. See picture of worn out governor gear below

[babarhailian]

thanks for your reply..much appreciated

in my case i have ats at distance and my generator is gas/petrol of apprx 15kw custom made. battery is new but not used much...yes long wire is used to connect both things. kindly let me know things to do, to diagnose the issue.??

Try charging your battery to full. You can do it by taking your battery to a shop and get it charged or you may like to manually ignite your generator and leave it running for three or four hours to charge the battery; when you are sure that battery is fully charged then try using ATS.

[ab6666]

But the valve seals are not so costy that they can affect production cost?

Plz reply bro!

[babarhailian]

Plz reply bro!

Dear! they are not so costly but when they have to manufacture like 5000 units, they'll save 5000*50 250,000 in rupees. So that makes sense; moreover Valve seals are not mandatory for generator to be operational. There are a lot of generators, including mine (Although I am facing RPM issues these days but not related to valve seals), working very well without Valve seals so they don't bother to include it; after all they are selling these things for a just a fraction of original Honda genset price; so we should expect minimum and only necessary components in these Chinese generators.

If you are still a lot concerned about valve seals, you may get after market ones from any good generator parts shop and install them (procedure has already been mentioned somewhere in this forum by the moderator).
Hope that answers your questions.

[capricon2]

Plz reply bro!

ap na to tension main dal diya suba shop pa ja k generator ka head open kr k dkhu ga whether they have valve seals or not

[sharyyyyyyy]

Try charging your battery to full. You can do it by taking your battery to a shop and get it charged or you may like to manually ignite your generator and leave it running for three or four hours to charge the battery; when you are sure that battery is fully charged then try using ATS.

ok will give a try but this does not seem the permanent solution to that if whole system is consuming more power than it should..
thanks for reply..

[sharyyyyyyy]

To my experience i faced these issues when I wired ats directly to gen self solenoid and petrol/gas solenoid which tend to drain the battery over a short time period. Then i added two six point relays and taped them on the generator frame. Both gets signal from ATS. one relay operates self solenoid while other gas/petrol solenoid. Now my ats is trouble free. By removing your self solenoid wire test your ATS if its working great then do the mod which i have done

where are you bro. plz help

[makniazi]

sharyyyyyyy i had the same problem battery was getting drained because of gas solenoid for that what i did was modified the circuit in way that as soon as gen starts gas solenoid is shifted to gen 12v output

[lse1]

Dear All,

We have a 20 Kva generator, coupled with a 1.8 engine. Its been running fine for 3 years.

Now I am thinking of getting an 8-10 kva generator, made from 660 or 1000 CC engine by the same guy. What kind of NG consumption per hour should I expect? this is for our smaller house, so want to keep NG bill to a minimum, so please do give suggestions. Dont want to buy chienese or other gensets, as my experience with the local generator has been very good so far, thanks to an expert mechanic

[OmRON]

@lse1
Dear what is your monthly gas bill with 20KVA generator, if you pls tell us how much gas units its consuming in one hour @ how much KVA load, It will help us to answer the question.

OmRON

[OmRON]

Hi
from picture both governors looks different, You should find same like before. focus on the middle spindle, on new one its round while on previous one its flat part facing down. For your new governor I think you have to find new arm if you have a plan to keep new one inside, I suggest go and find 100 percent identical part and problem will be solved.

[ab6666]

Dear! they are not so costly but when they have to manufacture like 5000 units, they'll save 5000*50 250,000 in rupees. So that makes sense; moreover Valve seals are not mandatory for generator to be operational. There are a lot of generators, including mine (Although I am facing RPM issues these days but not related to valve seals), working very well without Valve seals so they don't bother to include it; after all they are selling these things for a just a fraction of original Honda genset price; so we should expect minimum and only necessary components in these Chinese generators.

If you are still a lot concerned about valve seals, you may get after market ones from any good generator parts shop and install them (procedure has already been mentioned somewhere in this forum by the moderator).
Hope that answers your questions.

Thanx bro for such a detailed answer. Thanx alot!

[babarhailian]

Hi
from picture both governors looks different, You should find same like before. focus on the middle spindle, on new one its round while on previous one its flat part facing down. For your new governor I think you have to find new arm if you have a plan to keep new one inside, I suggest go and find 100 percent identical part and problem will be solved.

I would definitely admire your observation @omron. Governor gears were, however, identical; there is probably some specific light angle which is making the old one look flat; they both were round (just checked the old one after your email).

Any how real culprit was the carburetor; a few months ago my gen's engine fan broke at night and it got overheated causing a lot of plastic parts to melt; carburetor's throttle knob also melted and was not moving the way governor was trying to move it. Today I replaced the carburetor and everything is fine now.

One thing which is bothering me is that I have to fully choke the engine for starting; once it starts, it can run on half choke. NG pressure in my area is very good; what could be the reason that I need to use choke. Any help/idea?

[dmszack]

hey guys... bn long i guess..
hows everyone doing? hope all good..
alot of new stuff.. good to see you all..

Dear @hanimughal bro,

I have read your all posts in this thread and you look very familiar with generators, I have some chinese brand generator of 2.5KVA which doesnt performs very well, it never starts directly on gas(Patakhay Marta hai) and now it doesnt even not start on Petrol. It's not used since 1 year. Will you please help me in this regard. Some mechanic told me to get my Carburetor changed.

[makniazi]

dmszack get the carburetor cleaned+ idle adjustment in your gas kit+ tappet setting intake 0.10 mm exhaust 0.15 mm+ original spark plug with gap of 0.4 mm