7.1 Introduction of Engine
7.1.1 General provisions: this diesel engine is the source of dynamic of the generator set. It is an industrial heavy diesel internal-combustion engine, featuring reliable performance and high efficiency. It is specially designed for generator, extremely applicable to promote generator.
This machine is four-stroke internal-combustion engine and equipped with perfect necessary accessories and provided with reliable dynamic. The detailed descriptions of the diesel engine and relevant equipment are listed in Manual for Diesel Engine. This chapter just simply describes main systems and how they are connected to the generator.
Perform normal maintenance of the diesel engine according to the requirements of Manual for Diesel Engine, which ensures the diesel engine will run reliably.
7.1.2 Cooling system: the cooling system of diesel engine only contain a radiator, a highly efficient propelling movement fan, a mechanic drive pump and thermostat. Fan belongs to the propelling movement type; it propels air into the radiator. This device can cool the heat on the surface of the diesel engine and alternator while the internal heat of the generator is cooled by the internal water recycles of the radiator. Thermostat makes the internal cooling liquid of the diesel engine constant to be the most efficient working temperature at the machine set. Notes: the air circulation the generator room is crucial to the cooling of the machine. Therefore, the installation instruction specified in section 4.7 will ensure the satisfied running of the generator.
7.1.3 Speed control of diesel engine: as for the speed controller of diesel engine, the mechanical or electronic equipment can be used to stabilize the speed of diesel engine to be adapted to the changes of load. For the speed of diesel engine has direct relationship with the output frequency of the alternator, any changes in the speed of diesel engine will influence the output frequency of the power.
Speed controller control the speed of diesel engine and fuel consumption. When load is added to the alternator, the speed controller will add oil to the diesel engine. When the load is decreased, the speed controller will reduce the fuel flow.
7.1.4 Fuel system: the fuel system of the diesel engine of the medium-and small-power generator set can selectively match an oil tank at the bottom at the chassis of the machine set according to the customer’s requirements. The oil mass of this oil tank is sufficient to supply oil the generator to run for 4-8 hours under the full load. This oil tank at the chassis can be connected to a big oil tank to manually or automatically transport oil. The complete oil transportation system has already be specified in the section 4.9, please refer to it. For there is no oil tank at the chassis of the bigger generator set, it is required to install a separated oil tank nearby to transport oil to the diesel engine.
7.1.5 Smoke extraction system: the one of functions of the smoke extraction system is to reduce noise and exhaust the waste smoke to a place, where damages are not caused. As for the smaller type generator set, the smoke exhaust silencer and pipe are directly installed in the diesel engine. As for the larger type generator set, the smoke exhaust silencer is separated to provide the users with the place convenient for installation.
7.1.6 Start-assisted method: using diethyl ether to start auxiliary is not suggested to for it will shorten the service life of the generator.
7.2 Maintenance of Generator
Manual for Diesel Engine provides detailed data and also includes comprehensive guidance in discovery and searching of the faults.
7.3 Maintenance of Radiator
7.3.1 Notes: the corrosive radiator might be the cause for the faults for the air in the water will accelerate corrosion. It is necessary to keep the pipe joint from leaked, and add water from the top of the radiator regularly to ventilate air and keep “no air” inside the system.
The radiator shall not be at the sate of drawing off the water for it will accelerate corrosion. As for the generator set not working, the water should be completely released or filled up. If possible, use the distilled water or natural soft water and added the appropriate amount of anti-rust additive.
Cooling liquid of the radiator, generally speaking, is vey hot and under pressure. It is allowed to clear up the radiator or dismantle the pipe when the cooling liquid is not cooled. Don’t let the radiator work or open the protective cover of the fan when the fan is running.
7.3.2 External cleaning: in the dusty or dirty environment, the seam of the radiator might be obstructed by objects such as: scrapes and insects, etc. but this will influence the efficiency of the radiator. The elimination of these deposits can be eliminated through spray rinsing with cleaning agent and hot water under low pressure, and inject the steam or water to the fan from the front of the radiator. The injection in the reverse direction will only force the dirty substances into the center. It is necessary to keep out the diesel engine and alternator in case of adopting this method. The stubborn deposits can not be eliminated by taking the aforementioned methods. However, the radiator can be dismantled to be immersed in the water containing soda for about 20 minutes, and the washed with hot water.
7.3.3 Internal cleaning: the hard water pouring method is selected due to the water leakage of the joint or the generator runs for a period of time without using rust inhibitor, then the system might be obstructed by the scale deposits.
Scale deposits can be eliminated according to the following procedures:
1. Drain the water from the radiation system, and then dismantle the pipe from the place, where it is connected with the diesel engine.
2. Prepare 4% rust-inhibiting acid solution and clean water, pour the acid liquor into the water, and be sure not to do reversely.
3. Wait for several minutes until it is mixed, and then heat the solution up to 49℃ (120℉), which is the highest point and should not higher.
4. Pour the solution into the pipe through the filtering cap or a branch slowly, and then it will be boiled with a lot of bubbles. When the chemical reaction is over, fill the radiator with the heated solution.
5. Let the solution stay in the system for several minutes, and place the solution into the original vessel from pipe at the bottom or the outlet.
6. Check the interior of the water tank. If there is scale deposit, then enhance the acid solution to 8% according to the aforementioned procedure.
7. After elimination of scale deposit, perform the reaction of neutralized acid liquor according to the following procedures: fill the vessel up with the clean water, heat it up to the boiling point and add washing soda crystals according to the following proportion: 500mg soda shall be matched with 20kg water (1 pound is matched with 4 gallon of water), pour the solution into the radiator, and then let it flow back to the original vessel.
8. Use the aforementioned method to wash the radiator for times, and finally after filling it up to let it stay inside the radiator for at least 1 hour, then hot clean water to clean it after drainage out.
9. Before re-installation and usage of radiator, use the water under double normal working pressure to test whether there is leakage. Sometimes, the water leakage occurs after elimination of scale deposit.
10. Before running, the cooling liquid should be added with corrosion inhibitor and proper amount of condensing agent.
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