How to Clean a Diesel Generator Set?

As an essential backup power supply device, diesel generator sets play an irreplaceable role in many situations. Whether it is industrial production, commercial operation, or emergency backup, the stable operation of diesel generator sets is directly related to the smooth progress of work. However, many users often neglect the cleaning and maintenance of the generator sets during use, which leads to frequent equipment failures and shortened service life. In fact, keeping diesel generator sets clean is one of the key factors to ensure their efficient and stable operation. In this guide, we will focus on the importance of cleaning diesel generator sets, the causes of common dirt, and specific cleaning methods.

Although the cleaning of diesel generator sets may seem simple, it has a profound impact on the performance and life of the equipment. Whether it is external oil stains and dust or internal carbon deposits and scale, these seemingly insignificant dirt can become potential hazards to the normal operation of the generator set if not cleaned in time.

The cleaning of the external components and casing of diesel generator sets should not be overlooked. Oil stains, dust, and moisture can not only corrode the surface of the components and reduce their service life, but also affect the heat dissipation effect of the equipment. More importantly, a clean external surface makes it easier for operators to promptly detect potential faults such as cracks and damage to the components. For example, if the surface of the components is covered with thick oil stains and dust, even if there are cracks, they are difficult to detect in the first place, which may lead to further expansion of the fault and even cause serious safety accidents.

Cleaning the inside of diesel generator sets is crucial. It involves removing carbon deposits from the combustion chamber and exhaust pipe, and cleaning scale from the cooling water passages.

Carbon deposits in the combustion chamber are common. They form due to incomplete diesel combustion or lubricating oil entering the combustion chamber. Poor combustion can be caused by low cylinder temperature, insufficient compression, or faulty fuel injectors. Lubricating oil can enter through gaps between the piston and cylinder wall, or between the valve and guide. If the piston ring is damaged or the cylinder wall is scored, oil enters more quickly. Excessive carbon deposits can degrade combustion efficiency and, in severe cases, cause the piston to stick. Regular cleaning is essential for normal operation.

Scale in the cooling water passages is also a significant issue. Minerals in the cooling water can deposit on the inner walls, reducing cooling efficiency and causing overheating. To prevent this, use qualified fresh water or antifreeze and clean the passages regularly.

During the use of diesel generator sets, various types of dirt will inevitably be generated. The formation of these dirt is closely related to the operating environment of the equipment, the way it is used, and the frequency of maintenance.

During the use of diesel generator sets, scale will be generated in the water tank. The formation of scale is mainly due to the following reasons: First, there will be some loss of coolant in the cooling system during use, which needs to be replenished in time. If users do not add coolant or distilled water, but directly add hard water, the calcium and magnesium ions in hard water will easily react with the inorganic salt components in ordinary coolant to form scale. Secondly, silica scale mainly comes from the silicates in inorganic coolant. Metal scale is mainly composed of iron scale and tin solder scale. Iron scale is formed by the reaction of inorganic salts in ordinary inorganic coolant with iron metal on the cylinder body, and the protective film formed by the reaction is consumed and falls off. Tin solder scale is a loose precipitate formed by the strong oxidizing inorganic salt corrosion inhibitor, which intensifies the "flowering" of tin solder. Therefore, to avoid the formation of scale, users should choose qualified coolant or distilled water when replenishing coolant, instead of using tap water directly.

Carbon deposits are a kind of hard, strongly adhesive, and poor heat-conducting substances. With the extension of the use time of diesel generator sets, carbon deposits will gradually accumulate in the combustion chamber, piston top, and intake and exhaust passages. The formation of carbon deposits not only hinders the heat dissipation of the combustion chamber and piston, but also reduces the volume of the combustion chamber, making the engine work more violently. If carbon deposits adhere to the intake and exhaust valves and their passages, it will lead to poor exhaust and insufficient intake. If carbon deposits form on the nozzle of the fuel injector, it will block the nozzle and cause poor fuel atomization. Therefore, regular removal of carbon deposits is an important part of ensuring the normal operation of diesel generator sets.

To ensure the efficient operation of diesel generator sets and extend their service life, it is crucial to adopt the correct cleaning methods.

Enclosure Cleaning: Use an air compressor gun to blow away the dust on the surface of the enclosure. This method can effectively remove surface dust and avoid scratching the enclosure during subsequent wiping. Gently wipe with a damp cloth to remove stubborn stains. For some difficult-to-remove stains, a special cleaning agent can be used for further cleaning. However, it is important to avoid using hard brushes to prevent scratching the surface of the enclosure.

Air Filter Cleaning: Regularly inspect and clean or replace the air filter. If the filter is clogged, it can be blown with compressed air or lightly tapped to remove dust. For washable filters, they should be handled according to the manufacturer's instructions. During the cleaning process, ensure that the engine is not running to prevent dust from being raised inside the filter.

Lubricating Oil Filter Cleaning: Clean the inner and outer surfaces of the lubricating oil filter and check for any damage or deformation. If damage to the filter is found, it should be replaced in time. When cleaning the filter, do not use solvents as they may damage the filter material.

Radiator Cleaning: Remove dust and debris from the surface of the radiator and check for any leaks in the water tank. When cleaning the cooling system, pay attention to the temperature to avoid burns.

Exhaust Pipe Cleaning: Use compressed air to blow away dust and carbon deposits from the exhaust pipe. If necessary, a cleaning agent can be used for cleaning, but attention should be paid to whether the material of the exhaust pipe is corrosion-resistant. If the exhaust pipe is at a high temperature, wait for it to cool down before cleaning.

Chemical Cleaning Method: First, prepare a cleaning solution with 30 kilograms of water, 2.5 kilograms of caustic soda, and 0.6 kilograms of kerosene, and pour it into the water tank. Then start the diesel engine and run it at medium speed for about 10 minutes before turning it off. After 10 to 12 hours, restart the diesel engine, run it at medium speed for about 10 minutes, turn it off, and drain the cleaning solution. Add clean cooling water and start the diesel engine to clean itself at medium speed. Repeat this process 2 to 3 times to thoroughly remove the scale.

Physical Cleaning Method: Drain the cooling water from the cooling water tank, remove the radiator inlet and outlet pipes, cylinder head outlet pipe, and thermostat, and then reinstall the cylinder outlet pipe. Use clear water with a pressure not exceeding 3kgf/cm² to flush the water jacket from the cylinder head outlet pipe, expelling the scale until the water coming out of the water pump is no longer turbid. Flush water into the radiator outlet pipe to expel the scale until the water coming out of the water inlet is no longer turbid.

Chemical Cleaning Method: Prepare a chemical solution in proportion, heat the solution to 95-100°C, and then soak the parts in it for about 60 minutes. After the carbon deposits are fully softened, use a brush to remove the carbon deposits from the parts, and finally rinse with hot water and dry with compressed air.

Physical Cleaning Method: After removing the cylinder head, valves, and intake and exhaust pipes, first soften the carbon deposits with kerosene, and then remove the softened carbon deposits with a wooden scraper. After cleaning, rinse thoroughly with diesel or gasoline. When removing carbon deposits from the cylinder body cylinder opening and piston top without removing the piston, place the piston at the top dead center position, and apply a layer of lubricating grease in the gap between the piston and the cylinder wall to prevent carbon deposits from falling into the gap, and then proceed with scraping. Try not to use metal scrapers during scraping to avoid damaging the surface of the parts. Be especially careful with aluminum alloy parts. If a scratch is made and not treated, it will become a new center for carbon deposit growth after assembly and use, and the growth rate will be much faster than before. Therefore, if a scratch is made, it can be polished smooth with sandpaper. After scraping the piston top and cylinder opening, remove the carbon deposits and lubricating grease together and clean them thoroughly.

When cleaning diesel generator sets, although the cleaning method is important, some details and precautions should not be overlooked. These precautions can ensure the safety and effectiveness of the cleaning work and avoid unnecessary damage to the equipment.

• Safety First: Before starting the cleaning work, make sure that the diesel generator set has completely stopped running and the power supply has been cut off. This is to prevent accidents during the cleaning process and ensure the personal safety of the operators.
• Use Appropriate Cleaning Tools and Materials: Different parts require different cleaning tools and materials. For example, for the cleaning of the enclosure surface, soft cloth and special cleaning agents should be used; for the cleaning of internal parts, appropriate chemical solutions or physical methods should be chosen according to the material of the parts. Avoid using hard brushes or unsuitable solvents to prevent damage to the parts.
• Regular Inspection and Cleaning: Cleaning should not be a one-time event, but should be carried out regularly. Regularly inspecting the various parts of the diesel generator set and promptly removing dirt can effectively extend the service life of the equipment and improve its operating efficiency.
• Follow the Manufacturer's Instructions: During the cleaning process, strictly follow the instructions provided by the manufacturer. Different models of diesel generator sets may have different cleaning requirements and precautions. Therefore, before starting the cleaning work, carefully read and understand the manufacturer's instructions.

Keeping diesel generator sets clean is one of the key factors to ensure their efficient and stable operation. By regularly cleaning the external and internal parts of the generator set, the corrosion of the equipment by dirt can be effectively reduced, the heat dissipation effect of the equipment can be improved, and the service life of the equipment can be extended. During the cleaning process, users should pay attention to choosing appropriate cleaning tools and materials, follow the manufacturer's instructions, and ensure the safety and effectiveness of the cleaning work. It is hoped that the introduction of this article can help users better manage and maintain diesel generator sets, ensuring that they remain in good operating condition during use.