How to Check Intake System of Diesel Generator Set

The methods for checking the intake system of a diesel generator are as follows.

Check for cracks or perforations in the hose, soft movement of the clamp, tighten or replace if found, to ensure that the intake system does not leak.

Check and maintain intercooler

Use the naked eye to check the inlet air cooler for cracks, perforations, or other damage to the air chamber, pipes, radiators, etc.

Check the air filter

When the air filter resistance exceeds the following values, the air filter element shall be replaced.

Supercharged and supercharged intercooled type: 6.2KPA;

Natural suction: 5.0Kpa.

Note: air filter resistance should be checked when the diesel engine is calibrated.

If the air filter is equipped with a maintenance indicator, check periodically, and replace the air filter element if the red flag 2 has risen to the inspection port position.

After replacing the air filter element, press the button switch on the end of the maintenance indicator to reset it.

Warning: do not allow the operation of diesel generator sets without air filters. Otherwise, it is easy to cause early wear and tear of diesel generator set.

Fault diagnosis analysis of intake and exhaust system of diesel generator set.

The intake system of the diesel generator set is equipped with dry air filter and air filter and air resistance indicator, with exhaust gas turbocharger, full intake and guaranteed performance. Pules dry exhaust pipe is used in the exhaust system of diesel generator set, which can make full use of exhaust energy and give full play to engine performance. In addition, the genset is equipped with a diameter of 127mm exhaust elbow and exhaust bellows, easy to connect. Therefore, the intake and exhaust system of diesel generator sets is very important to ensure the performance of the generator. So how to diagnose and analyze the intake and exhaust system of diesel generator.

Air entering the unit cylinder should be kept clean (if the air enters the cylinder with dust and dirt, it will cause early wear and tear of the cylinder sleeve, piston ring, and also damage the valve rod and duct. Larger waste can also damage the blades of the turbocharger. Therefore, diesel generator units should be equipped with intake air filters.

1. Intake air leakage of diesel generator set

1) Too much air intake resistance causes black smoke and power reduction (air filter can be blown three times with compressed air and will have to be replaced later).

2) Too much smoke or lower power of turbocharged diesel engine may be due to loosening of pressure section of intake pipe or serious leakage of rubber pipe.

3) Air leakage in the intake system, in addition to inspection with the naked eye, but also with soap foam in the possible leak to check.

2. Diesel generator exhaust part fault

Check exhaust leakage, gasket leakage, exhaust pipe, silencer resistance of exhaust pipe and supercharger. The increase of exhaust leakage and resistance will lead to the decrease of turbocharger speed, the reduction of air volume, the decrease of intake pressure, the increase of exhaust smoke and the decrease of power. Leakage of exhaust gas usually detects leakage sound or can be seen that high temperature gas discolors the material near the leak. If the exhaust is blocked, the turbocharger can not work effectively, so the factor of power reduction caused by exhaust resistance cannot be ignored.

1) The breakdown of supercharger reduces its supercharging efficiency and causes the decrease of diesel engine power and the increase of smoke.

2) Diesel generator oil supplies the supercharger with bearings and provides some cooling with its working oil pressure through the tubing. The return pipe is connected to the bottom of the middle shell of the supercharger, and the oil goes back to the diesel fuel pan along the return pipe. Seal rings are arranged at both ends of the rotor part of the supercharger. The main role of the seal ring is to prevent exhaust and pressurized air intake supercharger in the middle shell. Oil leakage from the seal ring is rare, but it can still occur.

If the pressure of the crankcase is too high, it will hinder the return of the turbocharger and fill the oil with the middle shell. The oil will pass through the compressor seal ring and blow into the cylinder of the diesel engine with the pressurized air.

If the return tube of the supercharger is blocked or damaged, the oil pressure in the middle shell will rise and the oil will flow along the seal to the compressor or turbine inlet vortex shell.

High intake and exhaust resistance creates a vacuum between the compressor and the supercharger housing, causing the sealing ring to leak oil.

Check: the above problem can be removed turbine exhaust pipe and compressor outlet pipe, check for oil leaking from the seal ring.

3) A leak in the intake and exhaust system of a generator set makes additional noise (usually a very sharp whistle).