Proper operation is necessary to ensure the longevity of your diesel generators. When you neglect the standard procedures, you pay in repairs and safety hazards. However, you shouldn’t have to as the procedures are pretty straightforward. In this guide, we’ll provide a detailed daily startup and shutdown routine. It will help ensure optimal operational efficiency.

Essential Pre-Startup Preparation for Diesel Generators

The pre-startup preparation entails all the steps to take before switching it on.

Check the Engines fluid’s level

• Before you turn on the engine, check if the cooling water or antifreeze in the radiator is sufficient. If it is not, fill it up.
• Pull the oil dipstick to check if the lubricating oil is enough. If not, top it up to the specified “full at rest” mark on the dipstick.
• Confirm that the fuel in the engine is sufficient for the scheduled on-time. Add fuel if it’s missing.

Look for Leaks

Move around the generator unit and look out for breaks and tears. Check for any puddles of fluids on the  ground. Inspect the hoses for crack/loose clamps. A small leak can become a major problem when the generator starts running.

Other Considerations

• Check the air filter indicator, and replace the filter if indicated.  Keep the window shutter and fresh air intake shutters of the radiator open.
• Check if the emergency stop button is pressed.
• Inspect the battery’s electrolyte levels for batteries that need maintenance. If the electrolyte is lacking, top it up with pure water till it is 1cm over the separator.
• Ensure the electrical field is as it should. Inspect the battery connection cables. Tighten the loose terminals and ensure they are all clean.
• Check the radiator air exit hood. Remove any blockage to ensure the air freely flows out.

Step-by-Step Diesel Generator Startup Process

Once you are sure that the preparation is good to go, it is time to get to the startup sequence. The approach here varies depending on the type of generator – automatic or manual.

Manual Startup

• Turn the circuit breaker to the off position.
• Switch the engine on, either with the key or tapping run or start on the control panel.
• Listen to the starter motor pick up and release the switch once it does.

Note: Don’t crank up the engine “hold on to the switch” for more than 10 seconds to preserve the starter.

Warm-up Sequence

Don’t turn on the engine under load. Let the diesel engine run idly for 3 to 5 minutes (at approx. 700 RPM) before you add electrical load. This time allows the oil to reach the desired temperature for proper running. Note, increase the warm-up time by a few minutes during the colder months.

Watch the Gauge

Immediately the generator starts, watch the oil pressure closely. The pressure should rise within 15 seconds of the startup time. Plus, inspect the frequency (in HZ) and voltage (in V) on the control panel. It helps ensure they match the rated specifications.

Safely Connecting Electrical Load to Generator

Remember, it is crucial to never start the diesel engine with the load already connected.

• Switch on the main circuit breaker.
• After, gradually switch on the distribution panels.

Monitoring Generator Performance During Operation

Once the generator starts working, you don’t simply walk away and abandon the machine. Instead you need to also do period checks.

• Listen for unusual knocking or vibration sounds.
• What is the smoke’s colour by the exhaust? Is it black or white? The colour indicates the state of the engine.
• Ensure the engine’s coolant temperature stays intact in the green zone.

Proper Diesel Generator Shutdown Procedure

Stopping a working generator is just as important as starting it. Here is a breakdown:

Remove the Load

• Take off the loads before turning off the generator. You can do this by switching off the load via the distribution panel as the first step.
• Then, switch off the generator’s main circuit breaker. Do not shut down the engine while it is powering equipment. This habit would cost you your alternator (AVR).

Cooldown Procedure

Let the engine stay idle for about 5 minutes without load. This process allows the pistons and turbocharger to cool off evenly. Otherwise, you risk your engine having internal warping and oil carbonization.

Finally, turn the off switch or turn the key to put the generator to rest. The engine turns off and you are confident that it has taken minimal changes.

How to Approach Emergency Shutdowns?

Choose an emergency shutdown when an operational generator imposes a threat to the equipment.

Press the conspicuous “Emergency Stop” button to instantly stop the engine. This step cuts fuel to the engine instantly, which kills it. Ensure you steer clear of using this method for regular shutdowns. This process skips the cooling process, which causes mechanical stress. Only use emergency stops when necessary.

Conclusion

The startup and shutdown process protects your generator from hastened wear and tear. Your investment performs better when you follow this strict protocol. Even the efficiency is higher after you put strict protocol in place.

Huaquan Power offers the best power solution. There is an extensive range of diesel generators on our website. Our brand is known for durability and efficiency. Contact us to pair up with the right generator for your needs.

Frequently Asked Questions

1. Why Must I Idle the Generator before Shutdown?

The idling process allows the oil and coolant to lower the engine’s temperature. It prevents thermal shock and damage to the turbocharger.

2. How Often Should I Check the Generator Oil Level?

The ideal frequency is everything before each startup. Running on low oil can damage your engine.

3. Can I Start My Diesel Generator with the Breaker On?

No. Staring under load is not recommended. It strains the engine and can burn the voltage regulator. Start with the breaker off always.

4. What if the Oil Pressure Doesn’t Rise After Starting?

Turn off the engine immediately. Running without the right oil pressure is dangerous. Check if the reader is miscalibrated or top up the oil. Then, you can redo the process and watch.