Instructions to Do Diesel Generator Set Commissioning

Diesel engine unsealing

In order to prevent the diesel engine from rusting, when the product leaves the factory, both inside and outside is sealed with oil. Therefore, after the new unit is installed and meets the installation requirements, it must be unsealed before it can start. Otherwise, it will cause the danger. So it should be taken seriously.

The steps to remove the oil seal are as follows:

1) Heating the diesel above 45 ℃ to 56 ℃for cleaning and removing the external anti-rust oil.

2) Heating water aover 90 ℃, then continuously pouring water through the water jacket outlet, flowing out from the plug assy Irain (or water pump inlet) on the side of the cylinder body, continuously for 2--3 hours, and rolling the crankshaft discontinuously to make the anti-proof oil of piston top, cylinder liner surface and elsewhere dissolves and flows out.

3) Clean the oil sump with clean diesel oil and replace it with new oil.

Cooling and fuel system, fuel injection speed regulation system, water pump and starting drive system should be cleaned and checked in accordance with the requirements of the instructions, and sufficient clean cooling water should be added, starting batteries should be fully charged, and preparations should be made for the start up of the machine.

Inspection before the genset has a test

1. Inspection procedures

1) Check whether the surface of the unit is clean. The anchor nut, flywheel screw and other moving parts are not loosened. It must be fastened if any problems found.

2) Check whether the clearance of each part is correct, especially check the intake & exhaust valve clearance to make sure it meets the requirements.

3) Put each cylinder in the pressure reducing position, rotate the crankshaft to check if there is any abnormal sound in the operating sound of the cylinder parts, and whether the crankshaft rotates freely. At the same time, pump the engine oil into the friction surface. Then, close the pressure - reducing device, shake the crankshaft, and check the cylinder for air leakage. If the crankshaft is very difficult to shake, it indicates that the compression is normal.

4) Check fuel supply system, steps are as follows:

① Check whether the venthole on the fuel tank cover is smooth and clean if there is dirt in the hole. Whether the diesel added meets the required brand number, whetehr oil mass is adequate, and turn on the oil circuit switch.

② Open the mechanism of decompressor to shake the crankshaft. If each cylinder has a clear injection sound, it indicates that the injection is good. Whereas, there may be air in the oil line. This moment, you should rotate the fuel filter and injection pump air bleed screw to eliminate the air in the oil line.

③Check whether there is oil leakage in the oil pipe and joint, and deal with the problems in time if found.

5) Check water cooling system, procedures are as follows:

①Check whether the cooling water in the tank is sufficient. If the water is insufficient, clean soft water should be added.

②Check whether there is water leakage in the joint pipe and solve the problem in time.

③Check that the impeller rotation of the cooling water pump is flexible and the belt is tight and appropriate. When checking whether the belt is tight, push the middle of the driving belt. It is suitable if the driving belt is pressed down 10-15mm.

6) Check lubricating system

①Check the oil pipe and pipe joints for oil leakage and solve the problem in time

②Check the oil mass of the oil pan, draw out the oil dipstick next to the crankcase, observe whether the height of the oil surface is in accordance with the rules, otherwise, add oil to the diesel engine, add No.8 or 11 engine oil in winter, and add No.14 oil in summer. Check again, if found that the oil surface height is above the normal, should be carefully analyzed the reasons for the increase in oil, usually there are three reasons.

a. Add too much oil

b. Diesel oil leaks into the crankcase and dilutes the oil.

c. The cooling water leaked into the oil.

7) Check starting system

a. First, check whether the specific gravity of starting system is within the range of 1.240 ~ 1.280. If the specific gravity is less than 1.180, it indicates that the battery power is insufficient.

b. Check whether the power line is correct.

c. Check whether there is contamination or oxidation on the battery terminal, it should be cleaned up.

d. Check whether the electric contact of starting motor and electro-magnetic control is good.