Bison BS-20KVA Manuel utilisateur
Safety Precautions
Please read this operation manual carefully, which is closely related to your personal safety. This
manual contains basic safety measures that must be adopted when maintaining your engines. Make
sure that manuals are matched with your engine model before reading.
◆Daily inspection items
Develop a good habit to inspect your engine and engine room with your eyes before turning on and
after shutting down the engine, which will help you to promptly discover leakages of fuel, lubricating
oil or coolant and any other abnormality that has occurred or will occur.
◆Refueling
There are dangers of fire risks or explosions for refueling. Smoking is forbidden and do shut down the
engine. Don’t overfill the fuel tank. Make sure that the cap of fuel tank is securely tightened. Only the
fuel recommended in this manual is allowed to use. Fuel in poor quality may easily result in abnormal
operation or shutdown of engine. Engine operating with poor fuel will lead to blockage of fuel pump
and will cause engine racing. Even worse, engine maybe destroyed and personal injuries maybe
caused.
◆Engine operation
Don’t operate the engine in a place where there are explosive substances or gases because not all the
electrical and mechanical components are properly protected to prevent sparks. It is dangerous to get
close to the engine under operation. Loose cloth, hair, fingers or falling tools may be caught up in
rotating parts, giving rise to serious personal injuries. In case that protective devices are not provided
at the time of engine delivery, you must equip all the rotating parts and hot surfaces with protective
devices to ensure personal safety.
◆Carbon monoxide poisoning
It is only allowed to operate the engine in a well-ventilated environment. If engine is running in an
enclosed space, proper ventilation must be ensured to discharge exhaust gas outdoors from engine
emission and crankcase. Lock the starting switch (Without starting switch lock for the instrument box,
the engine room must be locked or a lockable main switch must be used) to prevent that engine is
turned on by people without permission.
◆Maintenance and service
This manual includes instructions regarding how to perform general maintenance and services safely
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and correctly. Please read this manual carefully before you start with any work. You can obtain more
detailed information in this respect from your distributor. Do not proceed with any work you are not
certain about. Please contact with your distributors and ask them to extend help.
◆Fire and explosion
(1) Fuel and lubricating oil
All the types of fuel, most types of lubricating oil and many chemical products are flammable. Please
read and observe instructions marked on the packages. All the operations related to the fuel system
must be performed after the engine is cooled because fuel splashed on hot surfaces or electrical parts
may cause fire. All the rags immersed in fuel and lubricating oil as well as other flammable materials
must be safely stored in a fire-proofing place. Under certain conditions, rags immersed in the
lubricating oil may be ignited spontaneously. Smoking is strictly forbidden while filling fuel or
lubricating oil, or near the fuel station and inside the engine room.
(2) Spraying liquid for engine start
Don’t start the engine equipped with air preheat device (glow plug/starting heater) using spraying
liquids or equivalents. Otherwise explosion may occur inside the air intake manifold threatening
personal safety.
◆Hot surface and high-temperature liquid
There are dangers of scalding for people operating with high-temperature engines. Pay special
attention to hot surfaces, such as exhaust pipe, turbocharger, oil pan, supercharged air pipe, starting
heater, high-temperature cooling liquids, and high-temperature lubricating oil inside tubes.
◆Chemical products
Most types of chemical products, such as anti-freezing liquids, anti-rust agents, oil seal greases and
degreaser agents are harmful for people’s health. Please read and observe instructions marked on the
packages. Some chemical products, for example, oil seal greases are flammable and harmful for human
body once these substances are inhaled by people. Place chemical products and other hazardous
substances out of reach of children. Please dispose used and residual chemical products in accordance
with regulations for the benefits of environment protection.
◆Cooling system
Don’t open the cap of cooling liquid for high-temperature engines to avoid any scalding as a result of
spraying of steam or high-temperature cooling liquids. If you inevitably open the filling cap or switch
of cooling liquid or you must remove the cooling liquid tubes, please unscrew the cap slowly and
carefully to discharge the pressure before fully opening the filling cap. Pay attention that high-temperature
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cooling liquids may easily give rise to scalding.
◆Lubricating system
Don’t touch high-temperature lubricating oil with your skin to prevent any scalding. Make sure that
pressure has been discharged from the system before you start to work with the lubricating system.
Don’t start or operate the engine when the filling cap of lubricating oil is not closed to avoid the danger
of lubricating oil ejection.
◆Electric welding
Firstly, remove the battery positive and negative cable. Then, disconnect all the cables connecting to
the charging generator. The electric welding clamp must be fixed to the components to be welded while
approaching to the welding point as close as possible. Don’t fix the electric welding clamp on the
engine or have current go through any bearing. Once the welding task is completed, be sure to securely
connect the cables for charging generator and control module before connections of battery cables.
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Preface
BS-30KVA/BS-50KVA Series diesel engines are evolved and developed on the basis of
BS-30KVA/BS-50KVA Series vehicle diesel engines according to the requirements for
electricity-application diesel engines, including models of naturally aspirated types, supercharged
types and supercharged inter-cooling types. The power for this series of diesel engines is defined in
accordance with the ISO standard power specified in section 5.1.2 of GB/T 2820.2-2009
“Reciprocating internal combustion engine driven alternating current generating sets-Part2:
Engines”.This manual introduces various technical specifications, operation instructions and
maintenance methods for BS-30KVA/BS-50KVA Series diesel engines applicable for generator
sets.
Correct operation and maintenance are crucial for safety operation and long service life of diesel
engines. Please read this manual carefully before any operation. Operate and maintain diesel engines
in consistent with the requirements. Refer to part list and service manual for the adjustment, service
and spare part replacement of diesel engines.
Diesel engines you purchase may slightly differ with what has been listed in this manual due
to constant product improvement. For accurate information, please inform the factory of model,
delivery number (purchase order) and serial number marked on the nameplate whenever you want to
purchase the parts.
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Content
1.MAJOR TECHNICAL PARAMETERS OF DIESEL ENGINE
2.OUTLINE DRAWING OF DIESEL ENGINE
2.1 OUTLINE DRAWING OF 4DW81-23D, 4DW81-28D, 4DW91-29D AND 4DW91-38D
2.2 OUTLINE DRAWING OF 4DW92-35D AND 4DW92-42D
2.3 OUTLINE DRAWING OF 4DW93-42D AND 4DW93-50D
2.4 OUTLINE DRAWING OF 4DX21-45D AND 4DX21-53D
2.5 OUTLINE DRAWING OF 4DX22-50D AND 4DX22-60D
2.6 OUTLINE DRAWING OF 4DX23-65D
3.ENGINE MODELAND ITS DEFINITIONS
4.RATED POWER
5.THE OPERATING ENVIRONMENT OF DIESEL ENGINE
6.THE COOLING SYSTEM OF DIESEL ENGINE FOR GENERATORS
7.AIR INLETAND EXHAUST SYSTEM OF DIESEL ENGINE
8.THE FUEL SUPPLY SYSTEM OF DIESEL ENGINE
9.THE SPEED GOVERNING SYSTEM OF DIESEL ENGINE
10. ENGINE OPERATION
10.1 PREPARATION BEFORE ENGINE START
10.2 GETTING PREPARED BEFORE STARTING THE ENGINE
10.3 STARTING THE ENGINE
10.4 ENGINE OPERATION
10.5 ENGINE SHUT-DOWN
11. MAINTENANCE OF DIESEL ENGINE
12. TROUBLESHOOTING OF COMMON FAILURES
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(1) DIESEL ENGINE CANNOT BE STARTED PROPERLY
(2) ABNORMAL OIL PRESSURE
(3) SMOKE IN EXHAUST GAS
(4) INSUFFICIENT POWER
(5) ABNORMAL NOISE
(6) SEVERE VIBRATION
(7) ENGINE OVERHEAT
(8) EXCESSIVELY LARGE OIL CONSUMPTION
(9) SHARPLY INCREASE OF ENGINE SPEED
(10) SHUT-DOWN BY ITSELF
(11) ENGINE SPEED FLUCTUATED WITHIN A CERTAIN RANGE
APPENDIX 1 ALTITUDE AND AIR DENSITY
APPENDIX 2 POWER MODIFIED RATIO OF DIESEL ENGINE
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1
Chapter 1. Diesel Engine Data
Engine Model
Type
Aspiration
Cooling mode
Bore × Stroke (mm×mm)
Compression ratio
Displacement (L)
Dry weight
(basic configuration)(kg)
Prime power
(without fan)(kW)
Fuel system
Emission
Average effective pressure
(MPa)
Speed regulation rate in
steady state
Fuel supply advance angle
Valve clearance in cold state
(mm)
Lubricating oil capacity
(with filter) (L)
Lubricating oil consumption
(L/h)
Fuel consumption of prime
power (g/kW.h)
Fuel consumption ratio of
prime power (g/kW.h)
Permissible max. air intake
resistance (kPa)
Amount of exhaust emission
(m3/min)
Exhaust temperature after
turbine (℃)
Heat dissipation of exhaust
gas(kW)
Max. permissible back
pressure of exhaust pipe(kPa)
Air consumption (m3/min)
Applicable power station
(kW)
Max. Standby power (kW)
4DW81-23D 4DW91-29D 4DW92-35D 4DW92-39D 4DW93-42D
In-line, four-cylinder, four-stroke
Water-cooling
Naturally
aspirated Naturally
aspirated Supercharged Supercharged Supercharged
and inter-cooling
85×95
18:1
2.156
220
17
18.7
12
5%/3%
StageⅡ
0.63
17°CA±1°CA
0.3±0.03
7.8
0.04
4.08
240
1.6
3.7
4.7
470
16.0
6.7
90×100
18:1
2.545
220
21
23
16
5%/3%
StageⅡ
0.66
17°CA±1°CA
0.3±0.03
8
0.05
4.94
235
1.9
3.7
5.5
500
20.2
6.7
90×100
17.5:1
2.545
240
26
29
20
5%/3%
StageⅡ
0.82
17°CA±1°CA
0.3±0.03
8
0.05
5.98
230
2.2
3.7
6.4
450
21.0
6.7
90×100
17.5:1
2.545
240
29
32
22
3%
StageⅡ
0.91
17°CA±1°CA
0.3±0.03
8
0.05
6.67
230
2.5
3.7
7.1
460
23.9
6.7
90×100
17.5:1
2.545
240
31
34
24
5%/3%
StageⅡ
0.97
17°CA±1°CA
0.3±0.03
8
0.05
6.98
225
2.7
3.7
7.8
420
23.9
6.7
Mechanical/
electronic governor Mechanical/
electronic governor Mechanical/
electronic governor Mechanical/
electronic governor Mechanical/
electronic governor
1. Major technical parameters of diesel engine (1500rpm)
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