Before putting a new Generator set into operation, the Generator set must be run in according to the technical instructions in the user manual for the diesel engine. Proper running in smoothens the surface of the moving parts and prolongs the life of the engine. For old Generator sets that haven’t been used for a long time,run-in shall also be conducted before retesting them. When running in the Generator sets, increase the engine speed and load on a gradual basis to ensure a good run-in result. Engine oil shall be watery at the beginning of run-in and then increase the viscosity gradually.
During the course of run-in, try not to let the Generator set operate at empty/low loads for long periods. Or it will cause the following results: decreased fuel efficiency, oil/diesel fuel spills from the exhaust pipe, carbon deposits on the piston and piston ring groove, incomplete combustion and fuel intrusion into the oil. Therefore the Generator set is not allowed to run at low load for more than 10 min. Backup Generator sets must run at full load for at least 4 hours every year to burn off the carbon deposits in the engine and exhaust system so that the carbon deposit will not impair the life and quality of moving engine parts.
Steps of Running In
a)Run the Generator set at no-load. Check the Generator set thoroughly as per methods aforementioned. If there is no abnormity, start the Generator set. Tune the engine speed to idling and let the engine run for 10 min. Check the oil pressure and listen to the running sound of the Generator set. Stop the engine.
b)Open the side cover of the cylinder block and feel with hand the temperature of the main bearing and the connection rod bearing. The temperature shall be no higher than 800℃ or such as your hand would get burnt. Monitor the conditions of all working parts. If all the parts have appropriate temperature and are in good condition, then proceed with the following step.
c)Raise the engine speed from idling to rated gradually. First, rev up the engine by 200r/min, let the engine run for 2 min and then repeat the revving until the engine reaches the rated velocity. Nevertheless, the total amount of time for the engine running at no-load shall not exceed 5-10 min. During run-in, the coolant temperature shall always maintain at between 75-800℃ and the oil temperature no higher than900℃.
d)Connect the Generator set to the load if everything is ok with the Generator set and the load is in conformity with the technical requirements. Increase the load in a step-by-step way while the Generator set runs at rated speed. First maintain the load at 25%, then raise it to 50% and then 80%. During run-in, check the oil level every 4 hours , replace lubricant, clean the oil pan and oil filter.
e)Check whether the main bearing screw cap, connection rod bearing screw cap, cylinder head screw cap, and fuel injection pump and injector screws are tightly fixed. Ensure that the valve clearance is right or adjust it when necessary.
Expected Performance after Run-ina)The Generator set can be started quickly without problems.
b)At rated load, the Generator set works stably, steadily with no strange noises.
c)When the load changes greatly and abruptly, the diesel engine can return to a stable rev as quickly as possible. When running at high velocity, the engine doesn’t get overrevved neither does the speed fluctuate. When running at a low velocity, the engine doesn’t extinguish neither would any of the cylinder cease working. The transition from one load to another is smooth and the color of the engine exhaust smoke is normal.
d)The temperature of the coolant and all lubricated parts is normal and the oil pressure is within expected level.
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