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

[nabeelryk]

Hi Guys hope you remembered me
I have having trouble with my governor setting, can someone help
my gene is always in full RPM even without load,looks like its gona explode .

[talhabinomar]

Get its tappets adjusted.
Check for the Gas Setting.

[makniazi]

nabeelryk adjust the governer as mentioned in this thread if that doesnt help the problem can be in governer gear and for that unfortunatly u neend to open the engine

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[nabeelryk]

nabeelryk adjust the governer as mentioned in this thread if that doesnt help the problem can be in governer gear and for that unfortunatly u neend to open the engine

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That's what I thought I did as mentioned on page 5 of this thread, no luck so far as I have overhaul my engine on last Friday so I am really not in a mood to redo it
is there any possibility that I can just open a half or some parts like dynamo and head only

[nabeelryk]

I have a question but it might not be relevant here but I'm still hoping someone will answer me. I have a Honda EP-3000 generator and want to sell it. How much can I get for it? It works completely fine and has got gas kit installed as well. It reduces oil though.

Dear same brand and model original we bought in 2008 and I overhauled it last Friday head replaced and piston oil rings replaces else is original and kick starter only no self so that's why we use this one as substitute for our main GENE. Do let me know what price do you get in market I get 10K

[sheikh_meister]

Dear same brand and model original we bought in 2008 and I overhauled it last Friday head replaced and piston oil rings replaces else is original and kick starter only no self so that's why we use this one as substitute for our main GENE. Do let me know what price do you get in market I get 10K

10K is peanuts yaar! I'd rather keep it instead. kam he ajaye ka kabhi

[nabeelryk]

10K is peanuts yaar! I'd rather keep it instead. kam he ajaye ka kabhi

yup that's why we are still keeping work fine in emergency situations like last Thursday our transformer explode like a bomb oil all over the road so no light for 16 to 18 hours, our main GENE was hot like a hell so I just over-hauled it on Thursday and on Friday evening our WAPDA grid was on fire so no electricity for almost 2 days that's when this baby came in handy we rolled both gene one after another like 8 hours main GEne 6 hours this HONDA (with RPM manually fixed at certain point using a quick fix I will show you that tomorrow ) then 8 hours and so on till the grid restored so my point is its better to keep it as emergency backup GENE

[nabeelryk]

here is view of my bed room's corner


recently I was having complains about battery drain in my previous ATS designs as case 2 and 3 both were using some battery so I redesigned to reduce battery consumption to avoid battery drain.


I am working on auto gas control using heat gun as I mentioned once upon a time last year in this thread that I am using heat gun to suck and provide stable gas to GENE work fine upto 5K GENE. so I am tring to finalize this auto gas control for more automation so far we have alternative solution for that but that's not reliable works 80% but still I am hungry for more as I am lazy enough to do 20% manually :')

[makniazi]

nabeelryk no bro for governer it needs to be opened

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[nabeelryk]

nabeelryk no bro for governer it needs to be opened

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then I believe my manual quick fix will be used until next over haul

[babarhailian]

yup that's why we are still keeping work fine in emergency situations like last Thursday our transformer explode like a bomb oil all over the road so no light for 16 to 18 hours, our main GENE was hot like a hell so I just over-hauled it on Thursday and on Friday evening our WAPDA grid was on fire so no electricity for almost 2 days that's when this baby came in handy we rolled both gene one after another like 8 hours main GEne 6 hours this HONDA (with RPM manually fixed at certain point using a quick fix I will show you that tomorrow ) then 8 hours and so on till the grid restored so my point is its better to keep it as emergency backup GENE

@nabeelryk Regarding your RPM issue, before opening the crankcase, you should first check your throttle butterfly at the carburetor; sometimes ng pipe or something else get in the way and restrict the movement of throttle butterfly which causes RPM to increase or decrease (In my case ng pipe was not letting the throttle butterfly to close the throttle plate). It's better to check all linkages and springs of governing system by manually moving governor arm and observing all components move freely. Hope you don't need to open the crankcase apart.

I have also read your post about automation of heatgun/airgun. I have recently installed a heatgun, and was wondering if I could automate the speed using some stepper motor, but I have zero knowledge of programming or PLC handling. Please do guide us about this interesting project. I'll also request you the 80% automation you have already done with your airgun. In my area ng pressure varies very frequently (sometimes I have to set the airgun speed to minimum and sometimes I have to raise it to number 7) so there is a lot of ng loss due to this variation.

Waiting for your reply.

[nabeelryk]

@nabeelryk Regarding your RPM issue, before opening the crankcase, you should first check your throttle butterfly at the carburetor; sometimes ng pipe or something else get in the way and restrict the movement of throttle butterfly which causes RPM to increase or decrease (In my case ng pipe was not letting the throttle butterfly to close the throttle plate). It's better to check all linkages and springs of governing system by manually moving governor arm and observing all components move freely. Hope you don't need to open the crankcase apart.

I have also read your post about automation of heatgun/airgun. I have recently installed a heatgun, and was wondering if I could automate the speed using some stepper motor, but I have zero knowledge of programming or PLC handling. Please do guide us about this interesting project. I'll also request you the 80% automation you have already done with your airgun. In my area ng pressure varies very frequently (sometimes I have to set the airgun speed to minimum and sometimes I have to raise it to number 7) so there is a lot of ng loss due to this variation.

Waiting for your reply.

well about governor I tried to move it manually governor and butterfly moves freely no friction so I guess the problem is with governor gears, well I don't need governor anymore I have quick fixed it and my fix is working fine for me so far.

well good to know I help someone, I do have quick fix for you if you just tell me your GENE and load.
well I am working on that automation its still in beta testing mode and as you know components like UC are costly so I would not recommend or share anything until I am sure that's gona work for you. I will share ASAP when I am done and I believe that will be soon.

I can share logic that I am using for this purpose may be that help you to understand the concept, the logic is RPM controls/effects frequency (Hz) so I am trying to ADC frequency, after that by using those values I am controlling heatgun current.

[babarhailian]

well about governor I tried to move it manually governor and butterfly moves freely no friction so I guess the problem is with governor gears, well I don't need governor anymore I have quick fixed it and my fix is working fine for me so far.

well good to know I help someone, I do have quick fix for you if you just tell me your GENE and load.
well I am working on that automation its still in beta testing mode and as you know components like UC are costly so I would not recommend or share anything until I am sure that's gona work for you. I will share ASAP when I am done and I believe that will be soon.

I can share logic that I am using for this purpose may be that help you to understand the concept, the logic is RPM controls/effects frequency (Hz) so I am trying to ADC frequency, after that by using those values I am controlling heatgun current.

I had that same logic in my mind for controlling heatgun as well as for making an electronic governor (which should be much more efficient than mechanical governor); the problem is that I can't figure out how to convert analog frequency to digital; I also purchased a HZ meter so that I may use it's display input signals; but again I lack programming knowledge. I have read somewhere that this simple automation can be done using PIC micro-controller; It would be of great help if you could guide us how to do it.

My normal load is about 1000 watts and when 1.5 ton AC is turned on, the load is 2400 watts. waiting for the quickfix

[nabeelryk]

I had that same logic in my mind for controlling heatgun as well as for making an electronic governor (which should be much more efficient than mechanical governor); the problem is that I can't figure out how to convert analog frequency to digital; I also purchased a HZ meter so that I may use it's display input signals; but again I lack programming knowledge. I have read somewhere that this simple automation can be done using PIC micro-controller; It would be of great help if you could guide us how to do it.

My normal load is about 1000 watts and when 1.5 ton AC is turned on, the load is 2400 watts. waiting for the quickfix

I prefer ATMEGA , PIC is very sensitive and even a voltage EMP can change the result, whereas ATMEGA is hardcore UC.

Here is your quick fix for gas adjustment.
1. place T joint in main and output pipe of heatgun and place a valve in center of both this valve will serve as direct valve.
2. before placing those T joints drill a hole on the link side, as you will see that T joint have 1 direct line and 1 attachment on side of it forming T joint, the hole in that attachment is narrow you have to wide it using drill.
3. after widening both T joint place them like shown in picture make sure you connect valve on T joint side and let the main broad way attached inline with heatgun (air Pump) on both side.
4. after placing valve you will notice that the overall pressure of heatgun is reduced when valve is open and in case of valve is closed the pressure will be full again.
5. the point is to rotate the gas so excessive gas should rotate on its on and resulting in no gas adjustment again and again. in case if full valve don't work for your try experimenting by closing it bit by bit.
6. make sure your gas is on full (7 or 1 ) which one is your higher.

[babarhailian]

I prefer ATMEGA , PIC is very sensitive and even a voltage EMP can change the result, whereas ATMEGA is hardcore UC.

Here is your quick fix for gas adjustment.
1. place T joint in main and output pipe of heatgun and place a valve in center of both this valve will serve as direct valve.
2. before placing those T joints drill a hole on the link side, as you will see that T joint have 1 direct line and 1 attachment on side of it forming T joint, the hole in that attachment is narrow you have to wide it using drill.
3. after widening both T joint place them like shown in picture make sure you connect valve on T joint side and let the main broad way attached inline with heatgun (air Pump) on both side.
4. after placing valve you will notice that the overall pressure of heatgun is reduced when valve is open and in case of valve is closed the pressure will be full again.
5. the point is to rotate the gas so excessive gas should rotate on its on and resulting in no gas adjustment again and again. in case if full valve don't work for your try experimenting by closing it bit by bit.
6. make sure your gas is on full (7 or 1 ) which one is your higher.

Thanks for your reply; are you sure that generator will not consume more ng this way? Is there any method to check how much gas generator is burning? I am doubtful that during good pressure time, keeping the airgun at full will force lots and lots of gas to generator, even with the bypass valve attached.

[nabeelryk]

Thanks for your reply; are you sure that generator will not consume more ng this way? Is there any method to check how much gas generator is burning? I am doubtful that during good pressure time, keeping the airgun at full will force lots and lots of gas to generator, even with the bypass valve attached.

well you can check you gas meter check reading in peak pressure and note down how much did it consumed and do the same for low pressure time. That's what I did and almost my every friend did the same we set gaspump twice, once before going to bed almost at 11 pm as pressure is full that time so we dust set the speed to 5 and in the moring we set it back to 7 (full). in my case that's automatically set using simple LDR that detect light and switch full or semi full mode. my friends do that manually as they are not lazy like me

[uqc]

dear all need an advise i have a 3 kva marquis gene looks like this

its is been in use for the last 2 years or so on natural gas.i dont know exact hours it has been ran.Now this gene has started eating oil.its engine oil has started reducing it self.
What i wana know is that is it the time for an engine overhaul?
what price normally overhauling for 3-3.5kva takes?
what i am getting rates is with genuine parts it will be 8k(with 1 year warranty) and with normal parts it will be 5k.
or shud i go for overhauling process or buy a new gene?as post overhaul experience has some fear factor whether it will work fine or not.

[babarhailian]

dear all need an advise i have a 3 kva marquis gene looks like this

its is been in use for the last 2 years or so on natural gas.i dont know exact hours it has been ran.Now this gene has started eating oil.its engine oil has started reducing it self.
What i wana know is that is it the time for an engine overhaul?
what price normally overhauling for 3-3.5kva takes?
what i am getting rates is with genuine parts it will be 8k(with 1 year warranty) and with normal parts it will be 5k.
or shud i go for overhauling process or buy a new gene?as post overhaul experience has some fear factor whether it will work fine or not.

Best option is to use it till it works; don't change the oil, just top-up some oil when required; when it stops working or starts eating lots and lots of oil; just go and buy original JD engine and replace the engine. it would cost you about 13k. Best solution & peace of mind, your gene will be as good as new.

[babarhailian]

well you can check you gas meter check reading in peak pressure and note down how much did it consumed and do the same for low pressure time. That's what I did and almost my every friend did the same we set gaspump twice, once before going to bed almost at 11 pm as pressure is full that time so we dust set the speed to 5 and in the moring we set it back to 7 (full). in my case that's automatically set using simple LDR that detect light and switch full or semi full mode. my friends do that manually as they are not lazy like me

Well it's fine in your case but in my case ng pressure is dependent on days of week as well as different times of day. In my city, CNG pumps are allowed to sale just Mondays and Thursdays so domestic pressure is almost nil on these days. I have to set the pump to almost full (just above number 7) to get the generator running. In rest of the week, pressure is very good; at cooking time I have to set it to number 2 or 3 but at night and other times of day I keep it even below number 1 (as low as the *** can be rotated anticlockwise). So pressure keeps on fluctuating.

[uqc]

Best option is to use it till it works; don't change the oil, just top-up some oil when required; when it stops working or starts eating lots and lots of oil; just go and buy original JD engine and replace the engine. it would cost you about 13k. Best solution & peace of mind, your gene will be as good as new.

Jd engine kahan se milega and who is gonna replace it? And for3kva is there any jd engine avail?