Biomass Gasifier

STARTING THE ENGINE

PREPARATION FOR STARTING

1. Check the radiator water level

2. Check the engine sump oil level
3. Ensure that the gasifier plant is already started
4. Check that the starter battery is fully charged and all electrical
connections are properly made and that all circuits are in order.

Under warm conditions it is only necessary to engage starter motor by

turning the ignition type key to the position at the same time adjusting the
the engine speed control. As soon as the engine starts, release the starter
switch or button. Always ensure that the flywheel and starter pinion have
stopped rotating before attempting to re-engage the starter motor,
otherwise the starter ring or pinion gear or both may be damaged.

TO STOP THE ENGINE

To stop the engine, it is enough to close the gas inlet valve to the engine
slowly. The moment gas supply cut the engine comes to halt.

1
Biomass Gasifier
GENERAL INSTRUCTIONS

The biogas engine once started with full preparation, it will run
continuously without any interruption. As long as the gas is supplied to the
engine at its rated quantity, it will work without stoppage.
For a smooth run of the engine please ensure
 That the correct kind of lubricating oil is used.
 That the lube oil is clean without any contamination
 That the correct air- gas mixture is set
 All the filters in both lube and biogas is clean and without
any blockage.

LUBRICATION
 Use correct and recommended type of lubricating oil

 Wrong kind of lube oil will create problem

 Do not mix different brands or grades of lube oils
 Do not use the lubricant oil that is kept in its container for a
longer period
 Be sure that there is no water particles or dirt present in the lube
oil

CHANGING THE LUBRICATION OIL

 For changing the lubricating oil, please refer to the Maintenance
Schedules
 When refilling the sump, fill to the ‘FULL’ mark on the dip stick,
ensuring the engine is in perfect level
 Do not over fill the lubricating oil
LEAKAGES

2
Biomass Gasifier
Make a regular habit, at least once in a week, of wiping the
engine over, paying particular attention on oil pipe unions, joints in
the crank case etc., to check for leakage.
If found any leak, take immediate steps for arresting the leak.

VALVE ROCKER LUBRICATION

Every 500 hrs of operation, take off the cylinder head cover
and with the engine running see that the oil is oozing slowly from the
edges of the rocker arm bearings.
If it is not and the bearings seem dry, clean all oil pipes to and
from the camshaft reducer which is on the offside of the engine.

ENGINE MAIN FUEL - BIOGAS

The engine is specially designed to use the gas which is
coming out of the adjoining gasifier unit. Do not use any other fuel
other than it is designed.
Even though, all measures have been taken to supply pure gas
to the engine from the gasifier unit, watch out the gas supplied
accordingly.
Do not attempt to operate the engine with other type of fuel.

SPARK IGNITION SYSTEM

The engine is fitted with specially designed spark ignition
system suitable for igniting the incoming biogas. The firing order is
so arranged to minimize engine wobbling and to utilize maximum
power from the engine.

AIR AND GAS SYSTEM

3
Biomass Gasifier
The air fuel (Biogas) setting to the engine is set for the smooth
operation of the engine. Donot alter the company setting. Always
ensure that the proper setting of the air fuel ratio is intact during the
operation.

DIFFICULT IN STARTING
Given good compression, a quick turn over, and adequate gas
supply the engine should start immediately. If it does not, there
could be three things to look into:
1. If the battery is down and will not turn the
starter motor quickly enough, then the remedy
is to replace the battery with a new one.
2. If the battery is ok, then check the gas supply,
there should not be any block or hurdles in the
free flow of gas to the engine. Also check for
the quality of the gas, a quick and steady fire in
the flare unit will ensure the quality of the gas.
3. Timing: In case, the above two checks are
found to be all right, then there may be
possibility of trouble in the timing of the
ignition. This can be set right by a qualified and
trained engine mechanic only.

TESTING OF FAULTY SPARK IGNITION SYSTEM

REPLACING A SPARK PLUG

HINTS ON RUNNING

4
Biomass Gasifier
When emptying the water system the radiator must also be drained.
Where a pressurized radiator filler cap is fitted, this should be removed
before draining the cooling system.
Check the level of the water in the radiator every morning. If the
engine over heats, because of shortage of water, some of the parts may get
damaged.
Moreover, if the water boils, steam pockets may form in the cylinder
head causing local heating and perhaps a crack.
Do not under any circumstances continue to run the engine with the
water boiling. The result may be heavy down time and unnecessary
expenditure.
Do not continue to run the engine if there is knocking. In such
condition adjust the main gas line valve to the engine gently and maintain
the operation smoothly.
Do not run the engine with air cleaner removed.
Keep wipe the engine at regular intervals. This is good because, any
oil leak can be found immediately. Do not operate the engine when oil leak
is detected.
Do not alter the air fuel ratio setting. This will lead to decrease the
efficiency of the operation.

AIR FILTER MAINTENANCE

The time period for cleaning the air filter depends on operating
conditions. Therefore, if possible, maintain a clean surrounding to avoid
dust and other sources which are likely to choke the air filter. However,
periodic cleaning of the filter fabric is very much essential for the efficient
operation of the engine.
The correct maintenance of the air filter will greatly assist in
reducing bore wear, thereby extending the life of the engine.

5
Biomass Gasifier
FROST PRECAUTIONS
Precautions against damage by frost should be taken if the engine is
to be left exposed to inclement weather either by adequately draining the
water system or where this is not convenient, an anti freeze of reputable
make and incorporating a suitable corrosion inhibitor may be used.
Should it be your regular policy to protect the engines from frost
damage by adding anti freeze to the cooling system, it is advisable that the
manufacturers of the relevant mixture be contacted to ascertain whether
their products are suitable for this engine. Also ensure that the products
will not have any harmful effects on the cooling system generally.
When draining the water circulation system, it is not enough merely
to open the radiator drain tap. The one on the cylinder block must also be
opened.
Where a pressurized filler cap is fitted, this should be removed
before draining the cooling system.
When the engine is drained, the water pump is also drained but the
rotation of the pump may be prevented by the locking of the impellor by ice
due to the pump drain hole being blocked by sediment or the locking of the
seal through the freezing of globules of moisture between the seal and the
gland.
Operators are therefore advised to take these precautions when
operating in temperatures below freezing point:
1. Before starting the engine turn the fan and water pump by
hand; this will indicate if freezing has taken place. If freezing
has taken place, this should be cleared.
2. If it is impossible to turn the pump by hand, the radiator and
engine should be filled with warm water.
3. To avoid this trouble it is advisable when all water has been
drained, run the engine for a few seconds at idling speed,
thus dispersing any moisture remaining in the pump.

6
Biomass Gasifier
After an anti freeze solution has been used, the cooling system should be
thoroughly flushed in accordance with the manufacture’s instructions
before refilling with normal coolant.

DOs
 KEEP THE ENGINE CLEAN
 Keep this book where it is conveniently accessible.
 Pay special attention to the lubrication system
 Use only approved grades of lubricating oil
 Use only genuine spares
 Keep all bolts and nuts tight
 Examine engine oil level at the sump daily, replenish
if necessary
 Completely change engine oil in accordance with
‘Periodical Attentions’
 Renew element in lubricating oil filter in accordance
with ‘Periodical Attentions’
 Check oil flow to rocker arms and examine the valve
springs in accordance with ‘Periodical Attentions’
 Keep a check on the temperature of the cooling
water. It should not be allowed to boil. The best
temperature is 77 degree C. If a pressurized radiator
filler cap is fitted, the temp can be allowed to go upto
88 degree C.
 Attend immediately if any oil or fuel gas is detected
 Check tappet clearance from time to time with warm
engine (it should be around 0.25 mm)
 Keep essential spare parts in store
 Drain radiator and cylinder block if engine is being
left idle in frosty weather

7
Biomass Gasifier
 Ensure that the pressurized radiator filler cap is
removed before draining the cooling system
 Close these drain cocks and refill with water before
attempting to restart next morning.
 When in doubt, read this Hand book.

DON’Ts
 Do not neglect the routine attentions specified in
‘Periodical Attentions’
 Do not race the engine in neutral
 Do not run the engine unless the gauge ‘Shows Oil
Pressure’
 Do not unnecessarily interfere with any adjustments
 Do not continue to run the engine if the cooling water
boils
 Do not forget to keep the fan belt adjusted
 Do not omit to wipe the engine over regularly with a
clean rag to check for oil leaks.
 Do not alter the air fuel setting arrangement
 Do not subject the engine to continuous over loading
 Do not guess or assume about the trouble, always
ask for help from M/s.Aruna Electrical Works.

8
Biomass Gasifier
PERIODICAL ATTENTIONS
POST DELIVERY CHECKOVER
The following general check over of the engine be carried out after
the first 25 hours of service. The same procedure may be well suited for a
engine which is in operative for a long period.
1. Drain lubricating oil sump and refill upto the full mark on the
dipstick with new clean oil.
2. Renew the lubricating oil filter element.
3. Check external nuts for tightness.
4. Check cylinder head holding down nuts and set screws for
correct torque tension (9.68 kg m).
5. Check and adjust tappet clearance (0.25 mm in hot condition).
6. Check for lubricating oil leaks and rectify if necessary.
7. Check cooling system for leaks and inspect radiator water level.
8. Check fan belt tension.
9. Carry out test to check general performance of engine.
10. Check engine mounting bolts for tightness.
11. Check and if necessary adjust slow running speed.

9
Biomass Gasifier
PERIODICAL ATTENTIONS
PRESERVATION OF LAID UP ENGINES
For certain reasons, the engine is not going to be operated for
a long period, the following precautions to be adopted:
1. Thoroughly clean all the external parts of the engine.
2. Where a preservative fuel is to be used, drain fuel system
and refill with preservative fluid.
3. Run the engine until well warmed through. Stop the engine
and drain the lubricating oil from the sump.
4. Drain water from the radiator and engine cylinder block.
5. Renew full flow filter element.
6. Clean out engine breather.
7. Fill sump to correct level with clean new lubricating oil or
with a suitable preservative fluid.
8. Remove spark plug and spray into cylinder bores 150 ml of
lubricating oil divided between the cylinders.
9. Replace spark plugs and turn engine slowly over
compressions.
10. Remove air cleaner and any intake pipe which may be fitted
between the air cleaner and inlet manifold. Carefully seal
manifold orifice with waterproofed adhesive tape or some
other suitable medium.
11. Remove exhaust pipe and seal opening in manifolds.
12. Disconnect battery and store in fully charged conditions.
Before storing the battery, terminals should be treated to
prevent corrosion.

10
Biomass Gasifier
PRESERVATION PROCEDUR FOR
SPARK PLUG IGNITION SYSTEM
(to be given)

PERIODICAL ATTENTIONS
DAILY OR EVERY 8 HOURS (WHICHEVER COMES FIRST)
 Check coolant level
 Check sump oil level
 In extreme dust conditions, clean air filter
EVERY 250 HOURS
 Drain and renew lubricating oil
 Renew lubricating oil filter element
 Check drive belt tension
 Clean oil bath air cleaner
 Clean water trap (if fitted)
 Check engine for leakage of oil and water
EVERY 500 HOURS
 Check hoses and clips
 Check spark plugs
 Examine valve springs and tappet clearance
 Inspect valve rocker shaft assembly for lubrication
 Clean and treat battery terminals
EVERY 1000 HOURS
 Inspect commutator and brushes of dynamo
 Flush radiator with clean water
EVERY 2,400 HOURS
 Arrange for examination and service of proprietary
equipment i.e., Starter motor, dynamo, etc.,

11
Biomass Gasifier
MAINTENANCE OF SPARK IGNITION SYSTEM
(TO BE GIVEN)
TO CHECK TAPPET CLEARANCE
Rotate the crank shaft until the valves of No 1 Cylinder are rocking (inlet
valve opening and exhaust valve closing)
Check and adjust clearances as necessary on Nos 4 and 6 valves
Turn crankshaft one revolution (360) and repeat for Nos 1,2,3 and 5 valves
Tappet clearances for both inlet and exhaust should be set to 0.3 mm cold.
With the engine running at fast idling, check that the oil flow to the rocker
assembly is satisfactory.

12
Biomass Gasifier

F A U L T P O S S I B L E C A U S E
Low cranking speed 1, 2, 3, 4.
5,6,7,8, 9, 10, 12, 13, 14., 15, 16, 17, 18, 19, 20, 22, 31, 32, 33
Will not start
Difficult starting 5,7,8, 9, 10, 11, 12, 13, 14, 15, 116, 18, 19,20,21,22, 24, 29, 31, 32, 33

Lack of power 8, 9,10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32, 33

Misfiring 8, 9,10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 30, 32

Blue white exhaust 4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45, 57

Knocking 9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 35, 36, 45, 46, 60

Erratic running 7, 8, 9,10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 57

Vibration 13, 14, 20, 23, 25, 26, 27, 29, 30, 33, 45, 48, 49

Over heating 11, 13, 14, 16, 18, 19, 24, 25, 45, 47, 50, 51, 52, 53,54,55, 58

More Crankcase Pressure 25, 31, 33, 34, 45, 56

Poor Compression 11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 60

Starts and stops 10, 11, 12

13
Biomass Gasifier
KEY TO FAULT DIAGNOSIS CHART
1. Battery capacity low
2. Bad electrical connections
3. Faulty starter motor
4. Incorrect grade of lubrication oil
5. Low cranking speed
6. No incoming gas supply
7. Faulty stop control operation
8. Blocked gas line
9. Faulty spark plug
10. Choked gas filter
11. Restriction in air cleaner
12. Improper mixing of gas and air
13. Faulty ignition
14. Incorrect type of spark plug
15. Incorrect use of cold start equipment

14
Biomass Gasifier
19. Incorrect valve timing
20. Poor compression
21.
22. Week mixer of gas
23.
24. Exhaust pipe restriction
25. Cylinder head gasket leaking
26. Over heating
27. Cold running
28. Incorrect tappet adjustment
29. Sticking valves
30.
31. Worn cylinder bores
32. Pitted valve and seats
33. Broken, worn or sticking piston rings
34. Worn valves stems and guides
35. Over filled air cleaner or use of incorrect grade of oil
36. Worn or damaged bearings
37. Insufficient oil sump
38. Inaccurate gauge
39.
40. Pressure relief valve sticking open
41. Pressure relief valve sticking close
42. Broken relief valve spring
43. Faulty suction pipe
44. Choked air filter
45. Piston seizure/ Pick up
46. Incorrect

15