admin

The first startup of a diesel generator set is a critical step. Improper operation can lead to equipment damage, poor performance, or even safety accidents. The following are important precautions, please follow them carefully:

🛡 I. Pre-Start Comprehensive Inspection and Preparation

Safety First:

  • Read the Manual: This is the most important step! Be sure to thoroughly read and understand the manufacturer’s operating and maintenance manual to know the specific model’s requirements and precautions.
  • Personal Protective Equipment: Wear appropriate personal protective equipment such as safety goggles, work gloves, and safety shoes (preferably oil-resistant and non-slip). Avoid loose clothing.
  • Ventilation: Ensure the generator operates in a well-ventilated area, away from doors, windows, and vents, to prevent exhaust gases (carbon monoxide) from accumulating indoors, which is a deadly risk! Even when used outdoors, take wind direction into account.
  • Clean Environment: Clear away debris and flammable materials (such as oil cloth, paper, fuel drums, etc.) around the generator, ensuring enough operating and cooling space.
  • Fire Prevention: Prepare a suitable fire extinguisher (e.g., ABC dry powder extinguisher) and place it in an easily accessible location.
  • Keep Away from Children and Pets: Ensure that no unauthorized personnel (especially children and pets) are near the equipment during startup and operation.

Fuel System:

  • Fuel Type: Confirm that the fuel is the clean diesel type and grade recommended by the manufacturer (e.g., 0#, -10#, depending on the environment temperature). Gasoline is strictly prohibited!
  • Fuel Level: Check the fuel tank level to ensure it is adequate. For new units or units that have been unused for a long time, the fuel tank may be empty.
  • Fuel Lines: Check if all fuel line connections are tight and leak-free. New machines may have no fuel inside the lines.
  • Bleeding the Fuel System: A critical step! Bleed the fuel system by finding the manual fuel pump (usually on the fuel filter or transfer pump). Press the manual fuel pump until resistance increases (indicating the pump is full of fuel). Then loosen the bleed screws on the high-pressure pump or injectors (might need a wrench). Once continuous, bubble-free diesel flows out, tighten the screws. This removes air from the lines, which could cause failure to start or unstable operation.

Lubrication System:

  • Oil Type and Level: Check the engine oil level. Use the manufacturer-recommended oil type and grade (e.g., CF-4, CH-4, CI-4, etc.). The oil level should be between the upper and lower marks on the dipstick (usually slightly above the middle). This must be checked before the first startup! New machines may already have oil or may require the user to add it.
  • Pre-lubrication (for large units): For larger power or units with pre-oil pumps, pre-oil pumps (if available) or other specific methods (as per the manual) can be operated to build oil pressure before starting, reducing dry friction during the initial startup.

Cooling System:

  • Coolant Type and Level: Check the coolant level in the radiator or expansion tank. Use the manufacturer-recommended antifreeze and rust inhibitor fluid (usually ethylene glycol-based) mixed with pure water at the correct ratio. The coolant level should meet the required position (checked in cold state). Ensure there are no leaks.
  • Radiator: Ensure the radiator fins are clean and unobstructed (such as any packaging materials, e.g., cardboard or plastic film).
  • Fan Belt: Check the tension of the fan belt to ensure it is correct (usually with a specific deflection requirement), and check for cracks or wear.

Electrical System:

  • Battery:
    • Check that the terminal connections are tight, clean, and corrosion-free. Ensure the correct polarity is connected.
    • Check the electrolyte level (for non-maintenance-free batteries) and add distilled water if necessary.
    • Use a multimeter to measure the voltage (should be close to 12.6V or 24.6V). Insufficient voltage is a common cause of failure to start. Recharge or replace the battery if necessary.
  • Starting Circuit: Check that the connections of the starter motor, relay, and other circuits are reliable.
  • Control Panel: Check that all switches are in the correct position (usually “Off” or “Automatic” position; before starting, move to “Manual” or “Run” position as per the panel design). Ensure that the emergency stop button is in the released (not pressed) state.
  • Output Breaker: Ensure the main output breaker is in the “OFF” position. The first startup must be done with no load!

Intake and Exhaust Systems:

  • Air Filter: Check that the air filter is properly installed and clean (new filters usually come wrapped in plastic, which must be removed before startup).
  • Exhaust System: Ensure the exhaust pipe connections are tight and leak-free, and make sure the exhaust system is unblocked.

🚀 II. Startup Operation

Double-Check:

  • Quickly review all inspection points, especially fuel, engine oil, coolant, battery, and the output switch being off.
  • Ensure no one is near rotating parts (fans, belts, etc.).

Startup Procedure:

  • Set the control panel mode switch to “Manual” or “Start” (depending on panel design).
  • Press the start button or turn the key to start. The starter motor will rotate the engine.
  • Startup Time: Usually, do not press the start button for more than 10-15 seconds. If it doesn’t start, release the button/turn the key and wait at least 30 seconds to 1 minute for the starter motor to cool down.
  • Attempts: If the engine still doesn’t start after 3-4 tries (with 30-60 second intervals), stop attempting! Check the cause:
    • Is there air in the fuel system? (Try bleeding again.)
    • Is the battery voltage sufficient? (Measure the voltage; it should not be lower than 9.6V/19.2V when starting.)
    • Is the fuel supply adequate? (Check if the fuel tank valve is open, and if the filter is clogged.)
    • Other potential faults (need professional inspection).
  • Successful Startup: After the engine starts, immediately release the start button/key.

👀 III. Post-Startup Inspection and Warm-up

Initial Observation:

  • Panel Monitoring: Keep an eye on the control panel gauges:
    • Oil Pressure: Should rise rapidly to the normal range within a few seconds (typically in the green zone). If it remains low or shows no pressure, immediately shut down and check. This is a serious issue.
    • Speed/Frequency: Should stabilize around the rated speed (e.g., 1500 rpm for 50 Hz or 1800 rpm for 60 Hz).
    • Voltage: Should stabilize at the rated voltage (e.g., 230V/400V).
    • Coolant Temperature: Should gradually increase from a low temperature.
    • Battery Voltage/Charging Current: Should indicate normal charging status.

Sensory Check:

  • Listen: Is the engine sound smooth and continuous? Any unusual knocking or friction noises?
  • Look: Check the exhaust smoke color. It should normally be light gray or invisible. Persistent black smoke (indicating poor combustion), blue smoke (indicating burning oil), or white smoke (indicating water or unburnt fuel) are abnormal. Look for any oil, water, or gas leaks.
  • Smell: Any unusual burnt smells?

Warm-up Operation:

  • Allow the engine to run idle for at least 5-10 minutes (longer in cold weather). Refer to the manual for the exact time. Purpose: Raise oil temperature to improve fluidity and provide full lubrication to all parts; gradually bring the coolant to working temperature; allow engine components to expand uniformly to reach optimal working clearances; stabilize operational parameters.

Loading (only after warm-up and when everything is normal):

  • Gradual Loading: After warm-up, confirm that voltage and frequency are stable at the rated values.
    • First, connect a small load (if multiple outputs) or gradually increase the load.
    • Avoid sudden full load: Applying a full load suddenly, especially on a cold engine, can have a severe impact on the engine.
    • Monitor the gauges after loading (voltage, frequency, oil pressure, and coolant temperature) to ensure they remain stable within normal ranges.

⏹ IV. Shutdown

Unload: Before shutting down, gradually disconnect the load and let the generator run idle for 3-5 minutes.

Cooling: Idle operation helps reduce the speed of the turbocharger (if equipped) and cool it down (stopping immediately at high temperatures can damage the turbocharger bearings). It also helps the engine temperature to decrease slightly.

Normal Shutdown: Use the shutdown switch or button on the control panel to shut down the generator. The engine will shut off following the program.

Emergency Shutdown: Only use the emergency shutdown button in case of emergencies (e.g., severe leaks, overspeed, unusual loud noises). Do not use it for non-emergency situations!

After Shutdown: Close the fuel valve (if the unit is to be left unused for a long time). Record the operating time and any abnormal observations.

Yangzhou Vosto machinery established in 2010, is an manufacturer of diesel generator in China, integrates design, supply, commissioning and maintenance of diesel generator set.
Vosto machinery attach great importance to CUMMINS, PERKINS, WEICHAI POWER, DEUTZ, DOOSAN, VOLVO, STAMFORD, MECCALTE and other world-class manufacturer partners, and established a long-term and stable OEM partnership, relying on its global supply and service system, to provide our products and customers with strong supply support and service guarantee.