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8 Rules for Safe and Efficient Operation of Diesel Generator Sets
I. Prolonged Continuous Starting.
Extended starting cycles of diesel generator sets can damage the battery. Avoid excessive starting duration; if the engine fails to start on the first attempt, wait several seconds before retrying.
II. Starting the diesel engine by pulling the vehicle.
Starting the diesel generator set by pulling the vehicle when the engine is cold and the oil is viscous will accelerate wear between moving parts, thereby reducing the unit's service life.
III.. Using open flames to heat the oil pan or igniting the intake manifold for starting.
To prevent fire hazards, use a low flame or coal fire to warm the oil pan from a safe distance while slowly rotating the crankshaft. This ensures even heating of the engine oil for comprehensive lubrication. Igniting fuel at the intake manifold draws combustion residue and debris into the cylinders, compromising valve sealing and accelerating cylinder wear.
IV. Immediately Running at High Speed After Start-up
When the diesel generator set is first started, the lubricating oil is cold and has poor fluidity. Running it at high speed immediately can cause rapid wear on moving parts due to insufficient lubrication. In severe cases, this may lead to bearing seizure or shaft locking.
V. Starting the diesel generator set without coolant or by adding boiling water, then adding coolant after startup.
This causes critical components like the hot cylinder liner and cylinder head to crack or deform due to sudden cooling. Similarly, abruptly adding 100°C boiling water to a cold engine block can cause the cylinder head and block to crack. Wait until the water temperature drops to 60–70°C before adding coolant.
VI. Directly adding engine oil to the cylinder.
While adding oil to the cylinder may temporarily improve sealing, boost pressure, and increase temperature to facilitate cold starts, the oil fails to burn completely. This leads to carbon buildup, weakening piston ring elasticity and degrading cylinder sealing performance. Additionally, it accelerates cylinder liner wear, reducing generator power output and making future starts more difficult. Therefore, never add engine oil directly to the cylinder.
VII. Prolonged Use of Glow Plugs and Flame Preheaters
Both glow plugs and flame preheaters utilize electric heating elements that consume significant power and generate high heat. Extended operation causes rapid battery discharge, potentially damaging the battery and burning out the heating elements. Therefore, the continuous operation time for glow plugs should not exceed 1 minute per use, while flame preheaters should be limited to under 20 seconds per use.
VIII. Failure to change lubricating oil and fuel according to schedule.
During cold weather seasons, if low-viscosity lubricating oil and fuel are not promptly switched, the diesel engine will be difficult to start.
Following these eight rules is not only essential maintenance for your equipment but also a high-return investment. It ensures your diesel generator set delivers stable power when it matters most, keeping your business running smoothly.
