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

[hanimughal]

@sharo53
no dude thats not normal at all...
if iam not wrong ur not even using ur genny on ng right?
and its misfiring even on petrol? its taking too much load thats why ur circuit breaker is tripping,agoodfriend was using 1.5ton split with 1ton on his 6.5kva and on ng
well change in sound is like normal jus a bit like thoda sa load lia ho but not thaa thaa lol

[ToxicDevil]

This is my NG kit/carb.
There is nothing serviceable in it. Just two diaphragms and holes which I cleaned some days back.

This is how much the throttle is open when only 3 fans and 60-80 Watt worth energy savers are on.

Now if I use my hand to open the throttle to even to full the RPM increases and Engine speeds up without shutting down or anything. But if I turn on a couple of fans and the TV the throttle gets fully open and genny dies.

[Sharo53]

@sharo53
no dude thats not normal at all...
if iam not wrong ur not even using ur genny on ng right?
and its misfiring even on petrol? its taking too much load thats why ur circuit breaker is tripping,agoodfriend was using 1.5ton split with 1ton on his 6.5kva and on ng
well change in sound is like normal jus a bit like thoda sa load lia ho but not thaa thaa lol

yeah im not using Ng it is on petrol from day one...
dont know why the is it miss firing
what should i do know... it is 60 hours used, first oil change was done at 20hours

thaa thaa karnay k baad awaz bhari ho jati ha load wali...
aur jb band karta hon generator ko tb b engine band honai k baad zor say THAA karta ha kbi kbi...
ak dafa to mera "TARAH" nikal gaya tha hahahahaha.......

[agoodfriend]

yup...
our model is the best one..
hows jlt working?all good?
btw guru on other thread of power generators..
check what this guy wrote:
i need some suggestion.
i have loncin 2.5 gen.yesterday i tried to run my 1 ton mitsu hvy duty ac on it and to my surprise it runs without giveing any big jhatka to generator.its consuming 1200 watts and genrtr runs fine.i runs ac for 1 hours on gen.gen was showing 200 volts out put during that.should i keep runing ac on generator or should i stop for sake of ac or genrtr??genrtr is on GAS.

and i asked him to make a video for me...
check this out...
06062012006.mp4 - YouTube

JLT is working fine and these days its in use for atleast 10 hours a day ,,,,,,,,,,,,,i have seen this clip ,,,,,,,,,,,,,its shows 5 to 6 amp on clamp meter ,,,,,,,,,,means around 1000 to 1200 watts,,,,,,,,,,,,,,thats the rated power input of that AC ,,,,,,,,,,,,,,and the rated power of generator is 2500 Watts , means he can put more load on generator once he switches on the AC first ,,,,,,,,,,,,,,,the full load current of AC is may be around 1500 to 1600 watts ( it may be written on its label ) ,,,,,,,,,,,,,,and the full load mean peak power of generator is around 2800 Watts,,,,,,,,,,,,in theory this generator must runs this AC and i think is it doing so,,,,,,,,,,,,,,,during starting AC runs on its max load as both the starting and running winding of compressor works at the same time ,,,,,,,,,but it happens only for first few seconds of starting and the starting winding of compressor cuts off once the comp motor reaches its working RPM ,,,,,,,,,,,,
i havent try my 1 ton AC on 2.5 Kw generator but i am sure it can support it,,,,,,,,,,,,,

[agoodfriend]

well this kit is faulty as burnt during usage, i was trying to repair it. well the transformer i detached as i needed for my ats. still trying to figure out,replaced so burnt parts.
i have a problem relating generator output voltage.
it started to produce 300v with speed is higher than usual. Whenever we started it its on high speed relatively higher than previous on no load, then we put some load on it and its noise lessen with the load. few days, this thing kept on going. today i experienced that the voltage is dropped and came down to 180 volts, also generator was working like with very few load instead of the all appliances were working which normally work over generators. fans, tube lights , energy savers, two water cooler ( Lahori one), few tvs . Generator is Green power with 5 KVA.

Then I checked the AVR , it was some how deshapped from the center , and capacitor is also looking like over heated. so i replaced the AVR. after attaching it with generator, i adjusted the voltage with the tiny screw to 220v.

but the generator noise is still like its on low load, instead of all appliances were running . then i moved towards the speed adjustment screw , which was a the lowest level of speed setting , i cannot be able to decrease the speed from that.

what is the possible cause of speed enhancement?

ONE general question?
does the load causes the speed to up or down? like when we put more load, it communicates this to generator through governor and ultimately speed increases and stables the voltage?

yes load can drop the engine RMP and governor is there to stabalize the engine RPM ,,,,,,,,,,,,,,after changing the AVR now you need Hz meter to adjust the engine RPM with load on ,,,,,,,,,,i usually connect a 1000watt iron with gen output and then adjusts the RPM ,,,,,,,,,,,

[agoodfriend]

Anyone having any idea about TRICOM generator sets onf 2.5-6.0kva .. They claim that their genrators are factory fitted GAS runners and they dont ask you to run even 1 hour on petrol... no need at all... still no ring burns etc

green power is batter,,,,,,,,,,,,or just buy any petrol generator and convert it on NG with local made kit,,,,,,,

[agoodfriend]

From a few days my generator on moderate load feels like its suffocating. Throttle is almost half to three quarter open on moderate load and on a little more load it gets full open and generator dies.
Without load even if I rev the generator to full throttle there is no problem.

What could be the reason?? I changed the spark plugs.

engine valves are leaking either because of tight tappets or worn off valve head,,,,,,,,,,,check tappets clearance and adjust it,,,,,,,,,,,if you wont do that then exhaust valve will be totally worn off

[agoodfriend]

guys i want to know any one using 1.5ton split unit on generator?
whats to change in sound of generator?
when i turn ON 1.5ton ac on my 6.5Kva generator a sound like "gun fire" come from generator sound like a loud "THAA" lol is it norml?

and just right now when turned the ac ON generator sound like "THAA THA THA" and then its curcuit breaker tripped...

what you mean by THA THA ,,,,,,,,,,?,,,,,,firing from exhaust ?..........or some mechanical sound ,,,,,,,,,,,,,,,,,,i guess its a mechanical sound produce by denmo armature ,,,,,,,,,,,,its bearing bush is lose and its hitting with the stator ,,,,,,,,,,once it happes on my generator ,,,,,,

[noumanzia]

yes load can drop the engine RMP and governor is there to stabalize the engine RPM ,,,,,,,,,,,,,,after changing the AVR now you need Hz meter to adjust the engine RPM with load on ,,,,,,,,,,i usually connect a 1000watt iron with gen output and then adjusts the RPM ,,,,,,,,,,,

Can i get ur mobile number , please sms me at 0321-5373188

[agoodfriend]

This is my NG kit/carb.
There is nothing serviceable in it. Just two diaphragms and holes which I cleaned some days back.

This is how much the throttle is open when only 3 fans and 60-80 Watt worth energy savers are on.

Now if I use my hand to open the throttle to even to full the RPM increases and Engine speeds up without shutting down or anything. But if I turn on a couple of fans and the TV the throttle gets fully open and genny dies.

is it also giving starting problem ?
well dont open this carb/gas kit ,,,,,,,if its starting the generator then there will be no issue in it ,,,,,,,,,,,,,,,,,
start the generator with out load and pull the throttel lever to increase the RPM ................just check that whether the engine RPM increase or it start suffocating ?,,,,,,,,if its so then the problem is in the leak valves ,,,,,,,,,,,,,may be solve with just tappet adjustment or in extreme case you may need to replace the valves,,,,,,,,,,,,,,

from this pic it seems its 2.5 Kw genertor

[agoodfriend]

yeah im not using Ng it is on petrol from day one...
dont know why the is it miss firing
what should i do know... it is 60 hours used, first oil change was done at 20hours

thaa thaa karnay k baad awaz bhari ho jati ha load wali...
aur jb band karta hon generator ko tb b engine band honai k baad zor say THAA karta ha kbi kbi...
ak dafa to mera "TARAH" nikal gaya tha hahahahaha.......

whats the condition of spark plug ,,,,,,,,,you using its original spark plug ?
check another thing,,,,,,,,,,,,the exhaut may be leaking for some were ,,,,,,,,,check pic ,,,,,,,,,,,start the engine and put your hand near it,,,,,,,,you will feel extreme hot gases leaking from there ,,,,,,,,,,,,and also that tha tha ,,,,,,,,,,conform this,,,,,,,,,,

[agoodfriend]

dear check this carb,,,,,,,,its the same one which i show you before ,,,,,,,,,,,,i think its working fine on this guy generator,,,,,,,,,

[ToxicDevil]

is it also giving starting problem ?
well dont open this carb/gas kit ,,,,,,,if its starting the generator then there will be no issue in it ,,,,,,,,,,,,,,,,,
start the generator with out load and pull the throttle lever to increase the RPM ................just check that whether the engine RPM increase or it start suffocating ?,,,,,,,,if its so then the problem is in the leak valves ,,,,,,,,,,,,,may be solve with just tappet adjustment or in extreme case you may need to replace the valves,,,,,,,,,,,,,,

from this pic it seems its 2.5 Kw genertor

Carb is good.
Without load the RPM increases and suffocation is only on load.
One more thing that the generator is consuming oil. NO SMOKE but oil is also leaking from tappet cover.

[5555]

today i palnned to overhaul my generator as it was decresing oil as well as loss in power after opening i find out only rings need to be changed there was a little play in connecting rodso got it fixed.... the main problem was in head to got it overhauled as well will be fitting back tommorow my self attaching some pics

[ToxicDevil]

To open valves you have to use valve spring compressor tool. Whats the cost of that.
And of T shaped rod and feeler gauges?

[amirhasan]

today i palnned to overhaul my generator as it was decresing oil as well as loss in power after opening i find out only rings need to be changed there was a little play in connecting rodso got it fixed.... the main problem was in head to got it overhauled as well will be fitting back tommorow my self attaching some pics

astakhfar , yaa sab kaa sab kis kaam pa lag giya haan

[5555]

To open valves you have to use valve spring compressor tool. Whats the cost of that.
And of T shaped rod and feeler gauges?

i am getting the head done from mechanic and will fit back my self
t-rods worth 120 each

[5555]

astakhfar , yaa sab kaa sab kis kaam pa lag giya haan

daikh lo bus

[amirhasan]

daikh lo bus

bus nahi truck

[makecrazy]

in normal condition when i start generator i put off all lights fans and tvs and when generator started then i start putting load by starting fan lights and tv .... this is what told my generator wala and technician ....

By using ATS .. can this senairio can me accomplish .... how to apply load slowly .. when kesc gone generator start by ATS and lights fans & tv will start automatically all together and this will apply huge load all of sudden to generator ... am i right ?