My water cooled Diesel genset project

Hi;
New guy here.
Thought that some of you might be interested in my
22hp water cooled 10KW diesel generator project.
My Diesel genset page
Regards
My87tj

Welcome.

Very nice looking project. Appreciate you sharing it with us.

Egon [img]/forums/images/icons/grin.gif[/img] [img]/forums/images/icons/grin.gif[/img]

[img]/forums/images/icons/tongue.gif[/img] A very worthy project. I wish my emergency power plans were that far along. All I have so far is a "critical loads" panel which collects all of the critical loads so that when the day comes and we DO have a gen set we can just add the transfer switch and go. [img]/forums/images/icons/tongue.gif[/img] Just one comment on the setup in the photos......... The frame has no provision to prevent "wracking" (twisting), and since this is a portable unit, the frame will assume whatever shape the surface that it sets on has, and if it isn't sitting on a pool table, the frame may wrack (twist) and then the drive coupling moves side-to-side. There will never BE a shaft alignment per se. it will change as you roll the unit. Some mitigation of the tendency to wrack (twist) is possible if the unit were made as a THREE-WHEELER since a three wheel carriage is level on any plane. [img]/forums/images/icons/tongue.gif[/img] I've set up a gazillion stationary engines for driving pumps and gen sets, and I have used channel iron many times. Those installations were, however, lagged down and grouted to a concrete floor. [img]/forums/images/icons/tongue.gif[/img]

Hi guys;
Thanks for looking and comments.
The castors are for moving and storing the generator.
I am thinking of using PT 4x4's with rubber on top and
sitting(using a floor jack) the generator on them while running.
Regards
My98tj

And the water cooled part is what? Maybe a tank above the diesel and beside the fuel tank?

Is that a hand crank for starting, in addition to the electric starter?

I suspect you have plans to cover the flywheel and the starter ring for safety?

Great project coming together.

Hi Beenthere;
The water hopper is a red tank next to the fuel tank.
Neither tank is very large and will probably be replaced by
external units when I make a permanent installation.
This motor uses a hand crank(no electrical system needed)
or I can use the electric starter.
I am thinking of using expanded metal mesh to cover the moving parts.It is not much use if the large flywheel grenades,but it will keep me from getting wrapped up in it.
My98TJ

Does that crank connect through to the flywheel? or is it geared to the crankshaft on the 'end' it is shown? Nice feature to have both, at least for an emergency. Do you have to crank pretty fast to get it hand-started?
I couldn't find much descriptive literature or information on that engine.
Yes, I was thinking of your not getting wrapped up in the flywheel, not that it will 'fly apart' while running.
I think Yanmar has a one-cyl diesel. Wonder if these are similar?

I'm curious to as how much you have invested in this setup ?

Hi;
The hand crank appears to not be in line with the drive shaft.
I have an image of my costs at the bottom of the page.
Regards
My98tj

How does this unit cool itself? [img]/forums/images/icons/tongue.gif[/img] Is this a reprise of the turn-of-the-century (the last one not this one) setup where the one-lungers had a water pot on top that the water just boiled out of? The theory being that it takes what....540 kilocalories per gram to make water into steam or cause evaporation or some such thing? I just can't remember right now [img]/forums/images/icons/crazy.gif[/img] I jest hate working with Lovejoy couplings [img]/forums/images/icons/crazy.gif[/img] .....not enough movement and too difficult to line up. [img]/forums/images/icons/frown.gif[/img] A WOODS is my favorite [img]/forums/images/icons/crazy.gif[/img] I LIKE the idea of the intake flapper! [img]/forums/images/icons/cool.gif[/img] Now THAT is a good idea. [img]/forums/images/icons/cool.gif[/img] We've used all of the usual engine protection systems, but none will protect your diesel from sniffing a NATURAL GAS LEAK or a PROPANE LEAK and going into RPM Neverland. [img]/forums/images/icons/shocked.gif[/img] An exhaust flapper would if it was set for overspeed. [img]/forums/images/icons/cool.gif[/img]

One definite reliable means of slowing/stopping a diesel is to block its air input. It even helps you hold the stopper in place till it dies. This is one of the few good ways to stop a diesel that is running on its own lubricating oil fumes (or a leak).

I like diesels fine, especially in our previous Mercedes Benz type autos and our Dodge Ram but personally prefer propane for backup generators, especially fixed ones that aren't going to be moved a lot. I find them more compatible for short runs with fewer maint concerns.

[img]/forums/images/icons/smile.gif[/img] Pat [img]/forums/images/icons/smile.gif[/img]

Yes it is hopper cooled.
I agree with the propane for short runs.
The last 2 outages lasted for a week each,this summer.
I do not want a large propane tank in the yard and the amount
of propane needed for 24x7 for a week or more is a lot of expensive fuel. There was still a lot of diesel available after the
gas pumps were empty this summer.I also want to use this diesel for other projects.
My98tj

[img]/forums/images/icons/tongue.gif[/img] Propane would be our choice as well, but mainly because we have tanks of it sitting here already for the furnaces in the house and in the shop. If we did have a diesel set we would need to figure out how to "rotate" the diesel so the tank stays fresh, and right now we don't have a diesel tractor, only a gasser. I don't know HOW these big outfits can store genset diesel for long periods of time and not have it go bad? Hospitals run the generators weekly for about an hour at 70% load or thereabouts so that does use some fuel. I tested a genset once that used THIRTY-FIVE GALLONS PER HOUR during the test run. It was a 16V-92 detroit; that's sixteen cylinders at 92 cubic inches per jug.....over 24 liters of Screaming Jimmy. [img]/forums/images/icons/crazy.gif[/img]

My neighbor has a China diesel gen set, model CJ195M, #22726. Seems to resemble your set up. He became the owner when purchased the home and never started it. Looks almost new. It has no apparent start switch, glow plug, nor gauges or owners manual. It has a fairly complete set of spare parts. It has a battery attached. How do you start it? Is this unit reliable? Thanks for any help.

How about some pics of your neighbors genset ?
How long ago did he buy the house ?
If it was a looong time then I would replace the fuel.
Is it water cooled ? If so then check the coolant level.
I hand crank mine,but it has a starter too.
There should be a decompression lever near the fuel injector.
engage the decompression lever,adjust the throttle to about 1/3
open and either hit the starter or hand crank it with vigor [img]/forums/images/icons/cool.gif[/img]
It is probably very reliable.
If the fuel tank is empty then you will probably have to loosen
a banjo bolt near the fuel pump and get the air out of the line.
My98TJ

Thank you for prompt response. Very interested in pursuing this project. Will try and get picture. Engine date is 1986. Not water cooled. Can't locate starter button. Where do I look? Also, don't know location of hand crank. I would service engine prior to attempt starting, i.e. change out fuel, check fuel filter, oil etc. Set up was operational, but not used in many years. Has had very little use. All components look as new. Where can I find an owners manual for similar one cylinder China diesel gen set. Thank you for your help.

I have sent to a personal message(log in to read it).
Here is a great web site related to this topic.
Utterpower.com great home power project site
My98tj

[img]/forums/images/icons/tongue.gif[/img] That is some website! [img]/forums/images/icons/crazy.gif[/img] I just have to wonder, however, about how they are mitigating the noise and vibration from these one-cylinder diesels? [img]/forums/images/icons/crazy.gif[/img] We pumped water for years with a Witte, A Petter, and one other single cyl that I cannot remember the name of, and it was a good thing that the installations were a long way from the farmstead. [img]/forums/images/icons/crazy.gif[/img] You could hear those engines beating away for well over a mile on a summer evening. [img]/forums/images/icons/tongue.gif[/img] One of these single cylinder diesels might make a day-long power outage seem like a week. Of course you'd most likely not be running continuously and that would give your ears and nerves a much-needed break. [img]/forums/images/icons/crazy.gif[/img]

Dave, the first time we drove to Alaska (1972), it seemed that every time we stopped for gas, we'd hear one of those old single cylinder diesels way out in the woods. Of course at first I didn't know what it was until I noticed so many of them and had to ask. Now I don't know for sure that the two guys I asked were being completely honest instead of pulling a tourist's leg, but they said it ran continuously and when I asked how long it would last, they claimed theirs had been running for many years non-stop. With that pow. . .pow. . .pow, I figured they had to be the slowest turning diesels I ever heard of.

Thank you for information. I will stay in contact. The electrical hook up must mean it has some variety of starter/glow plug switch. Got to get it started! Thanks again.

[img]/forums/images/icons/tongue.gif[/img] Gen sets can rack up an incredible number of hours. One of our pumps had about an eight-foot circle around it pretty well oiled from blow-by and oil leakage. Those units ran just about continuously from April to late September. Everything in those engines is so overbuilt that there seems to be very little wear from stress. We never DID overhaul one; they became obsolete before they wore out. [img]/forums/images/icons/crazy.gif[/img]

Whenever you get your genset put back together after the painting, etc.. How about some kind of mpg of it running so we can hear and see this beast under power?

I look forward to putting one together myself soon, before the next hurrican season arrives!

Zbadone;
I have an old(read that non-digital)camcorder.Others have also
asked about a video of the running genset. I will see what I can
do.
It's a small world. I am also interested in casting alum(lost foam). I have seen your casting photos and posts for a long time on the net.
Regards
Ourfarm

Dos;
I have sent you a personal message with a solenoid photo link.
Regards
My98TJ

My98tj. Thank you for very useful photo. Check your personal message.

Good news on my China desiel/gen set. Replaced all filters, cleaned fuel tank, etc. Hooked up momentary switch per your diagram. First attempt at starting and it fired off! Like you say, it does make a bit of noise. Ran it for about three hours. Water filled hopper produced steam. Gen set is 8.5 kw. If run at half load, what kind of fuel consumption? Original fuel tank looks like about 2.5 galllons. Thank you so much for your help.

Hi;
That's great news.
I have not run mine enough yet to check consumption,but
others with similar setup all report 0.125 gallons/KWH.
I am interested in the experiences to have with it.
Regards
My98TJ