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bringing a diesel generator back to life

sewerzuk

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Oct 28, 2008
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149
Location
Oregon Coast
I made up this video of one of my 15kW 3 phase diesel generator sets; this one has been sitting for quite a few years. I go through a reasonably thorough pre-start/repair procedure. Thought there might be a few people here who like to see that first startup...I know I always enjoy hearing an old engine come back to life!

 
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m151

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Jul 23, 2011
Messages
62
I enjoyed the video, do you ever have to re-energize the field
if the generator has been sitting a long time? I have read
that some military units have a built in switch to make this
easier. If I leave my 30k kohler sitting for more than a couple
of months I have to flash the field and I don't really know the
proper way to do this (brush type). Any suggestions ?
 

CaseyJoes.

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Apr 2, 2011
Messages
482
Location
Strasburg, PA & Eastern Shore Maryland
I also enjoyed the video!
I have heard that you can flash the field on a small generator by plugging in a drill and with the engine running, pull the trigger and spin the chuck by hand. The small amount of current generated will flash the coil. I am not sure how large of a generator this will work with though.
 
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sewerzuk

Well-known member
Joined
Oct 28, 2008
Messages
149
Location
Oregon Coast
I enjoyed the video, do you ever have to re-energize the field
if the generator has been sitting a long time? I have read
that some military units have a built in switch to make this
easier. If I leave my 30k kohler sitting for more than a couple
of months I have to flash the field and I don't really know the
proper way to do this (brush type). Any suggestions ?

The MEP generators flash the field during each startup; whenever the start switch is in the start position, 24v is applied to the field coils. So nope, no need to flash the field!

I have had to do this on a few smaller generators; a 9v battery applied for just a few seconds works fine.
I have never heard of or tried the drill method...but it sounds reasonable. You're sort of flashing the wrong part of the generator, but if it causes current to flow and builds a magnetic field, I would guess that it works. I've often wondered if passing a powerful magnet by the generator while it is running would accomplish a field flash.
Think I'll try it the next time I run into one...

edit: every set I have had to field flash with the 9v battery uses the rotor as the field, so I just pop the inspection cover off of the end of the generator, fire it up, and briefly touch the leads of the battery across the brushes. Common sense should apply here...if you accidentally flash the HV side of the generator and it begins producing power, you will suddenly begin holding an exploding battery!
 
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GoBlue

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May 10, 2011
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1,070
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Under a car...swearing
What a great video! What do you do with these once they are up and running? Sell them i assume, but who typically buys them? Commercial...residential etc?
 
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sewerzuk

Well-known member
Joined
Oct 28, 2008
Messages
149
Location
Oregon Coast
What a great video! What do you do with these once they are up and running? Sell them i assume, but who typically buys them? Commercial...residential etc?

I put them up for sale one at a time; I have sold about 20 of them in the last couple of years. It's really just a hobby that pays me a few $$...I have a "real" job, but I really enjoy bringing neglected equipment back to life.

I have sold generators to a wide range of people; small businesses, a fishing camp in Alaska, jobsite temporary power for a concrete company, a couple of restaurants, and a few houses and shops with high power demand. A couple of people have purchased them for backup power and for adding 3 phase to their garage without having to build a phase converter or pay the power company for new service. I used one for a few years to power my lathe and Bridgeport (although I got a deal on a phase converter so I no longer use the generator for my 3 phase needs).
This year I even rented a couple of the sets out; one of them was for a blacksmith's convention. They needed power for some large 3 phase machinery.
I use one exactly like the one in the video for backup power for my house and shop...it's nice to be able to run everything (dryer, oven, etc.) without worrying about overloading the generator. I am planning on setting mine up with auto start in the next few months; that way my wife doesn't have to go outside to start the generator when the power goes out.
 

Provincial

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Joined
Sep 21, 2011
Messages
6,871
Location
Near Salem, OR
I have an old belly-mount 15KW 3-phase set that powered a reefer unit on a semi. I used it to power a shop because I couldn't justify the $25,000 the power company wanted to extend the three phase service. It has a little Perkins 4.108 engine and a Lima generator. I ran it for five years 60-80 hours a week.

Although I tried to keep a load on it at all times with metal halide lights, etc., eventually it wet-stacked and started pumping oil out the exhaust. I tried to find a replacement engine, but had no luck and bought a new Perkins-powered 20KW set. Three days later one of the vendors I had contacted called back and said that he had checked out a 4.108 he had and it started and ran perfectly. I could buy it for $350. Despite having spent 20X that on the new set, I jumped on the deal.

Interestingly, the setup is from a Carrier Transcold reefer. My genset has an odd bolt pattern for the bell housing and flywheel. I determined that the engine I bought was directly mounted to the refrigeration compressor, and has the same bolt patterns. The only difference between the two engines is that the generator powerplant has no "kick down" provision when the load is off, and the RPM is set on the governor by two set screws that lock the control arm in a fixed position. I think Carrier only wanted to stock one engine and the generators were designed to fit the compressor power plant.

My needs have changed an now I wish I could get 120/240 single phase out of this set, but the generator windings are 3-phase only.
 
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RM209

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Joined
Apr 17, 2009
Messages
892
Location
MD
Excellent video; very thorough. Looks like you were trained as a generator tech in a previous life.

Thanks,
RM209
 
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sewerzuk

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Joined
Oct 28, 2008
Messages
149
Location
Oregon Coast
Uploaded part 2 last night; in this second video, I perform a series of operational checks and tests that uncover a few additional problems. I make all of the repairs, and at the end of the video the set is ready for a full load test.

 
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