240D engine to be used for a Generator (info needed) - PeachParts Mercedes-Benz Forum

80's old school · #1 02-11-2009, 12:03 PM

I live on the Gulf coast and have been wanting to build a large standby generator. Now I have located where I can get 15,20,or 25 KW heads.

My question is, what would be the best way to couple the engine to the generator head? I will mount the engine, radiator, fuel tank, and generator head on a skid. I am trying to create the most cost effective way to couple the two.

BTW, the engine is an automatic transmission engine.

jt20 · #2 02-11-2009, 02:11 PM

is the stock trans too much of a loss for you? Determine the most optimal RPM range based off someone's dyno sheet and find the corresponding gear through trial runs kW output.

jt20 · #3 02-11-2009, 03:16 PM

http://www.peachparts.com/shopforum/sitemap/t-102511.html

MBNRA · #4 02-11-2009, 04:15 PM

I don't mean to dampen your enthusiasm, but vehicle engines are not the best type of engine for this! They are meant to provide varying RPM's and power levels and will not hold one constant RPM and be governed well connected to a GenSet. I would seriously look into a Perkins, Yanmar or Hatz. I would look into a Hatz. There are really durable air cooled diesels and this company has been around since the turn of the last century! They make excellent diesels for industrial power service and this is what you are trying to do. I honestly do not think that a 240D engine will do the trick for you if it came out of a car.

What you need is something in the 30 to 42 horsepower range. If you have the time, I would also recommend a Listeroid engine for your project! They are much better on fuel and easy to start by hand! There have been successful Listeroid homemade gensets that deliver amazing results for very little fuel and these are designed to run for long periods at a time and handle varying loads better than a lot of others and no governor is necessary because of their design.

Try this link for some ideas: http://www.listeroid.com/

This link is to a great site called UtterPower and their CD on Lister Engines is worth the $20 bucks alone for offering real practical guidance for the Home Do it your selfer who wants to build a genset. This site and the links at both are worth a read!

http://www.utterpower.com/ Good luck and let us know hiow it turns out!

Stevo · #5 02-11-2009, 08:26 PM

That Listeroid would be the "ideal" stationery gen set, but as a second option I would look for a marine unit out of a fish boat or yacht, someone thats up grading for more KW. One shouldn't be hard to find around a large port.

47dodge · #6 02-11-2009, 08:29 PM

what is your source for generator heads?, and are they 1800 rpms? I have several "Thermo-King" engines, that did have generaters on them and am looking for a 15kw head.

47dodge · #7 02-11-2009, 08:41 PM

Although there are other engines built for generating, I see no real reason that the 240d engine would be not suited, other then not having a governer. You really would need to adapt one to the engine. But other then that you are well within the rated power, and rated duty. I can understand using what one has on hand if it will work, rather then looking for the "right" engine. Depending on the rpm's of the generater a direct drive without the transmission would be best. Do stay away from belt drives, unless side load from the belts are taken by bearings other then the engine. In other words use a short piece of drive shaft to a pulley with a bearing on each side of the pulley to take the load.

jt20 · #8 02-11-2009, 09:37 PM

Quote:

Originally Posted by 80's old school

I live on the Gulf coast and have been wanting to build a large standby generator. Now I have located where I can get 15,20,or 25 KW heads.

My question is, what would be the best way to couple the engine to the generator head? I will mount the engine, radiator, fuel tank, and generator head on a skid. I am trying to create the most cost effective way to couple the two.

BTW, the engine is an automatic transmission engine.

It seems everyone except 47Dodge missed this crucial statement.

As long as this isn't going to be providing energy for a small village, I see no reason to believe that the costs incurred by fabbing some 'perfect' transmission will become overshadowed by the net difference in fuel costs to operate on a lesser transmission such as the stock one you already have.

I would be very surprised if a simple collection of rubber intermediaries and a shaft (as mentioned) could not replace the entire trans.

lutzTD · #9 02-11-2009, 10:14 PM

seems like you could rig the cruise control to be a governor, all those parts are already there

strelnik · #10 02-17-2009, 11:13 PM

Quote:

Originally Posted by lutzTD

seems like you could rig the cruise control to be a governor, all those parts are already there

The 240D originally came with a Bowden cable arrangement to act as a high idle at start up to speed up bring the engine to full operating temp. It is vert easy to bring that engine to that speed by just adjusting nthe point where the cable connects.

Alternately you could increase the overall basic speed of the vehicle by changing the fuel delivery on the injection pump itself.

I can't imagine this would be necessary but under extreme conditions you could ensure fast start up by heating the engine using the block heater and starting almost at 1500 rpm, then going the rest of the way to 1800 rpm shortly therafter, assuming that your genset had its own lube set-up so that it is not adversely affected by friction as the engine speeds up to its "cruising" rpm for the genset.

Then all you would need is your post production equipment, such as voltage regulator, fuse box, plug ins to the mains etc, etc.

Many DB engines have had multiple uses (especially the OM 636, OM 516, 616, M121 and M180) and the 240s were used for trawler-type constant-speed marine applications in Europe. I am sure the fuel inj pump and governor set up were different but I think this engine would work fine for your application if it could power a trawler.

babymog · #11 02-11-2009, 10:14 PM

The transmission can't be used without a way to compensate for the slip in the torque converter, which would really complicate the governor. You will need a direct-drive.

1800rpm should be fine for that engine.

80's old school · #12 02-12-2009, 10:06 AM

I was planning on using a simple Audiovox cruise control system. Run the engine until you get 60 cycles per minute and then set the cruise. When the load changes (increases) the cruise will still keep the RPM constant to power the generator.

Yes I agree there might be other engines more suited to this but hey, I have a ragged out 240D that was just given to me. Besides.....we are all car guys or tinkerers....are'nt we?? I would be so cool to have a Mercedes diesel generator!!

The Generator heads can be purchased online ebay. Just type in generator head.

kalpol · #13 02-16-2009, 03:17 PM

Quote:

Originally Posted by 80's old school

I was planning on using a simple Audiovox cruise control system. Run the engine until you get 60 cycles per minute and then set the cruise. When the load changes (increases) the cruise will still keep the RPM constant to power the generator.

I don't know anything about the injection pumps / governors but isn't there a test in the manual to test the governor on the pump (if that's where it is) - the wide open throttle test or something shouldn't exceed X rpms? So, seems like you could just screw down on the governor and lock open the throttle all the way to keep it at whatever RPM you decide you want.

80's old school · #14 02-16-2009, 03:20 PM

[quote=kalpol;2112231]I don't know anything about the injection pumps / governors but isn't there a test in the manual to test the governor on the pump (if that's where it is) - the wide open throttle test or something shouldn't exceed X rpms? So, seems like you could just screw down on the governor and lock open the throttle all the way to keep it at whatever RPM you decide you want.[/quot

That would be sweet if you could do that!!! Somehow I just don't think it will be that simple.