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

[usmanbhutta]

@moizirfan bhai
generator ko open choke pe bhe set kr k dekha par wo us pe itna load nhe uthata aur vibrate krta hai bht tvalve se adjust kr k dekha par.....
pleeez koi solution?

[gastech]

@MoizIrfan bhai
generator ko open choke pe bhe set kr k dekha par wo us pe itna load nhe uthata aur vibrate krta hai bht tvalve se adjust kr k dekha par.....
pleeez koi solution?

i can't understand v well the generator situation from your question, but understand never ever use choke at NG or LPG
normally if its needed, it mean the gas kit faulty. or gas inlet hole (where the gas go into the carb.) is not at good place

the gas kit is very sensible thing that we use for convert NG/LPG for generators, so adjust it same way......

run your generator without load, and adjust the load adjustment
How to adjust it: tight (clockwise) the screw as much when you feel the generator become unstable , stop
and now open (counter clockwise) the screw 1 to 1.5 tern
now apply load and check. if its ok that good. but if you still feel not carry full load then open the load screw 1/2 tern (counter clock wise) and now check it i am sure if the valve gap and spark plug is perfect, its carry full load.

[afnan1112]

@moizirfan
today i connected petrol solenoid with ats but t2 relay is not latching as a result self motor doesnt run what should i do?

[jamil.from.pakistan]

https://hotfile.com/dl/152194353/42e271e/ATS_and_Change_over_circuit_diagram.zip.html

Helo PWs , i upload the ATS and change over circuit diagram on a new link , few days before i make a new ATS by following the circuit diagram which i upload previously and there i spoted a mistake in that circuit,,,,,,,,,,i match that diagram with the one i made with my hand on paper ,,,,,,,,,,,,,,there was a one connection error in it ,,,,,,,,any how i correct that diagram and upload it again with some good pic resolution,,,,,,,,,,,,,,now thats a final and error free ATS and change over switch circuit diagram

AGOODFRIEND or anyone else reading this post, CAN YOU PLEASE PLEASE PLEASE EMAIL ME THE UPDATED CIRCUIT DIAGRAM for the ATS that you made. It is no longer available on the website you listed. My email is syed.n.amjad@gmail.com

[MoizIrfan]

@afnan1112
Check connections. First delay circuit should latch after 3 self attempts roughly 30 seconds so as soon as it latches all things stops working. This does not drain battery .Check its time. U could have set it to 0 seconds.
Second delay circuit latches after 2 seconds. So when it does not latch petrol solenoid works and as soon as this delay circuit latches self engages. If all connections are proper.

[MoizIrfan]

@usmanbhutta
That's why I set gen at half choke and start on petrol. Then convert to gas. U using ats?

[afnan1112]

@afnan1112
Check connections. First delay circuit should latch after 3 self attempts roughly 30 seconds so as soon as it latches all things stops working. This does not drain battery .Check its time. U could have set it to 0 seconds.
Second delay circuit latches after 2 seconds. So when it does not latch petrol solenoid works and as soon as this delay circuit latches self engages. If all connections are proper.

now it is working connected relay separatly for solenoid.Do i also need to set my choke position to half?

[MoizIrfan]

now it is working connected relay separatly for solenoid.Do i also need to set my choke position to half?

I recommend choke to be TIED to half position so that it does not move due vibration. then adjust T valve accordingly and test by applying load.
At full choke gen will not be able to take that much load. Our gas pressure isn't that great that we can easily always run our gensets without choke. So the best possible solution i suggest is half choke. Otherwise ur choice.

[usmanbhutta]

@usmanbhutta
That's why I set gen at half choke and start on petrol. Then convert to gas. U using ats?

g bhai using ats
but only gas wala
direct gas se start krne wala, no gas solenoid valve

[afnan1112]

I recommend choke to be TIED to half position so that it does not move due vibration. then adjust T valve accordingly and test by applying load.
At full choke gen will not be able to take that much load. Our gas pressure isn't that great that we can easily always run our gensets without choke. So the best possible solution i suggest is half choke. Otherwise ur choice.

what appliances u run on your gen i mean how much load your gen can easily manage on gas

[MoizIrfan]

what appliances u run on your gen i mean how much load your gen can easily manage on gas

mine is 2.5 kva.
I run 4 fans, 2 exhaust fan,10 to 12 energy savers only & washing machine sometimes only.

[MoizIrfan]

g bhai using ats
but only gas wala
direct gas se start krne wala, no gas solenoid valve

so u are using ats without gas solenoid valve. u then must have modified the gas kit as agoodfriend suggested? if so first tie the choke in which ever position u feel gen runs good and takes the load. then adjust its screw(not T valve) such that u increase the gas required for starting. then once u are successful in that then adjust the T valve and check by giving load

if u haven't modified the gaskit like agoodfriend suggested the thats the reason u r unable to start the gen without choke

[ibrahim022]

pathaka sound on start, whereas i have changed spark plug 15 days back and gap is .40mm, any suggestion. what to check more.

[MoizIrfan]

pathaka sound on start, whereas i have changed spark plug 15 days back and gap is .40mm, any suggestion. what to check more.

check tappet plate for any wear and tear.

[ibrahim022]

one thing i mention to forgot, misfire is only when i have started my generator and some time, it shut down during conversion to natural gas and then when i have to give self to start again it misfires.what may be the reason

[MoizIrfan]

one thing i mention to forgot, misfire is only when i have started my generator and some time, it shut down during conversion to natural gas and then when i have to give self to start again it misfires.what may be the reason

i think ur valves seats or valves are giving up. get it checked.

[mtmoghul]

@agoodfriend

very informative and detailed thread about generator reparing / maintenance.
One can gain a good knowledge about generator / ATS from this thread.
Thnx for sharing your knowledge here.

[ibrahim022]

1 month back i got the head job done replace valve with steal one. the reason i got the head job done was the gasket leakege oil was leaking from gasket.so i had the head job done. what can be another reason

[MoizIrfan]

1 month back i got the head job done replace valve with steal one. the reason i got the head job done was the gasket leakege oil was leaking from gasket.so i had the head job done. what can be another reason

whenever u open up the head, check for play in piston. because it has happened in my relative's gen that valve stuck due bad rings in a new head after 1 month of use

[ibrahim022]

whenever i open head, the first thing i do is check for the play in piston, piston had no play absolutely. what do you say about carberator thing gen is running rich on petrol there will always be some fuel left in intake valve which will cause pathaka, correct me if i am wrong.