How to Start Your Diesel Generator Set?

In many industrial and commercial scenarios, diesel generator sets are indispensable backup power sources. Whether responding to unexpected power outages or providing stable power in remote areas, correctly starting and maintaining a diesel generator set is crucial. This article will provide a detailed guide on the starting steps, operational management, and maintenance points for diesel generator sets, helping you ensure efficient operation and extend the service life of your equipment.

Before starting a diesel generator set, thorough preparations are key to ensuring normal operation. The following are several important items to check and confirm before startup.

Clean the Surrounding Area: Before starting, remove any debris around the generator set and ensure there is sufficient space for operation and ventilation. Good ventilation is vital for the heat dissipation of the diesel generator set, preventing overheating caused by poor heat dissipation.

Check the Cooling System: Ensure that the engine radiator has enough coolant or antifreeze. Insufficient coolant may cause engine overheating and damage engine components. In cold weather, antifreeze can prevent the coolant from freezing and protect the engine. Additionally, check the cooling system for leaks to ensure proper coolant circulation.

Lubricating oil is essential for the normal operation of the engine. Before starting, pull out the oil dipstick and check whether the lubricating oil is sufficient. The oil level should be between the upper and lower marks on the dipstick. If the oil is insufficient, replenish it to the specified full mark. Also, check the color and texture of the oil to ensure it has not deteriorated.

Check the Fuel System: Check that there is enough diesel in the fuel tank and that the fuel valve is open. Insufficient fuel may cause the engine to stop mid-operation, affecting normal power supply. Also, check the fuel system for leaks to ensure smooth fuel supply.

Check the Battery: The battery is a key component for starting the engine. Ensure that the battery voltage is normal and the terminals are tightly connected without looseness. If the battery charge is insufficient, recharge it promptly to ensure the engine can start smoothly.

Check the Air Filter: The air filter prevents dust and debris from entering the engine. Before starting, check whether the air filter is clean. If there is dust or debris, clean it promptly to ensure the engine receives clean air.

Check the Distribution System: Ensure all switches in the distribution cabinet are in the OFF position, and all meter indicators are at zero. Check whether all indicator lights function normally to ensure the distribution system is in good working condition.

Preheat the Equipment: If the ambient temperature is below 10°C, turn on the electric heater to preheat the machine. Preheating makes the engine easier to start and reduces wear during startup.

Correct starting procedures not only ensure the smooth operation of a diesel generator set but also effectively extend its service life and reduce the likelihood of malfunctions. The following are detailed steps for both manual and automatic starting for your reference.

Manually starting a diesel generator set is relatively simple but requires strict adherence to operational steps to ensure normal startup.

Turn on the power switch: Set the power switch on the generator control panel to the "ON" position.

Start the engine: Turn the key clockwise and press the engine start button. If the engine fails to start initially, press the corresponding reset button on the distribution panel. Wait until the alarm is cleared and the generator returns to normal status before attempting a second start.

Idle operation: After startup, if the engine sounds normal, the coolant pump indicator light is on, and all meters show normal readings, the startup is successful. Adjust the engine speed to 700 RPM and run for 3–5 minutes (8–10 minutes in winter). Observe oil pressure (normally above 0.2 MPa), water temperature, oil temperature, voltage, frequency, and check for abnormal phenomena such as water or oil leaks. If any abnormalities are found, stop the generator immediately for inspection.

Increase speed: Raise the diesel engine speed to the rated 1500 RPM. When the generator shows a frequency of 50 Hz and voltage of 400 V, close the output air switch to put it into operation.

Automatic start is suitable for diesel generator sets equipped with an auto-start function. This method is more convenient, especially for scenarios requiring automatic switching to generator power when mains power fails.

Set start conditions: Set the automatic start conditions according to needs, such as power outage or low voltage.

Start signal: When the set conditions are met, the control system will send a start signal. The generator will automatically start and run.

Check operating status: After automatic startup, check the generator's operating status via the monitoring system to ensure normal operation. Let the generator preheat for 3–5 minutes. During this period, closely monitor the fault indicator lights on the generator controller and observe water temperature and oil pressure indicators.

Power delivery operation: After the generator completes preheating and all checks are normal, turn on the power switch to deliver electricity. When entering the distribution room, switch between mains power and generator power to enable the self-generating system.

After starting, effective operational management is necessary to ensure stable operation and extend service life. The following aspects should be noted:

Regularly Check Meters: Check all meters every 10 minutes, paying attention to lubricating oil pressure and water temperature changes. Lubricating oil pressure should not be below 150 kPa, cooling water temperature should not exceed 95°C, and generator current (A) should not exceed the rated power of the generator.

Check Oil and Water Levels: Check the crankcase oil level, fuel tank oil level, and radiator water level. If any are below normal, replenish as needed. Ensure oil and water levels are within safe ranges to prevent equipment failure.

Observe Meters and Indicator Lights: Frequently monitor the distribution panel meters and indicator lights to ensure proper operation. Immediately investigate and address any abnormal indications.

Check the Charger: Check the charging status of the charger to ensure the battery can charge normally. Repair or replace the charger promptly if it malfunctions.

Listen to Equipment Operation: Listen to the sounds of various parts of the generator. Abnormal noises may indicate internal faults and should be addressed immediately by stopping the generator for inspection.

Check Equipment Temperature: Feel the temperatures of the generator housing, bearing housing, oil pipes, and water pipes. If the temperature is unusually high, it may indicate poor heat dissipation or other faults and should be addressed promptly.

Pay Attention to Odors: Monitor the generator and electrical equipment for any burning or unusual smells. Such odors may indicate overheating or electrical faults. Stop the generator immediately if detected.

Fault Handling: Address any detected issues promptly. For serious problems, stop the generator for maintenance. After resolving the fault, restart the generator.

Regular maintenance is key to ensuring long-term stable operation of diesel generator sets. Important maintenance points include:

Regularly Replace Lubricating Oil: Replace the lubricating oil according to the manufacturer's instructions. The replacement interval typically depends on usage frequency and operating conditions. Regular oil changes reduce engine wear and extend engine life.

Clean the Air Filter: Regularly clean the air filter to ensure it effectively filters air entering the engine. A clogged air filter can affect engine performance and fuel efficiency.

Check the Cooling System: Regularly inspect the cooling system to ensure sufficient coolant and no leaks. Check the radiator for blockages and clean dust and debris to maintain proper heat dissipation.

Inspect the Fuel System: Regularly check the fuel system to ensure smooth fuel supply. Check for clogged fuel filters and replace them periodically to prevent impurities from entering the engine.

Check the Battery: Regularly check battery voltage and electrolyte levels to ensure proper operation. Recharge if necessary and ensure battery terminals are secure to avoid poor connections.

Inspect Fasteners: Regularly check all fasteners to ensure components are firmly connected. Loose fasteners may cause unstable operation or damage the equipment.

Inspect the Electrical System: Regularly inspect the electrical system to ensure all connections are secure and undamaged. Check generator windings and verify that switches and meters in the distribution cabinet are functioning correctly.

Diesel generator sets play a critical role in many applications. Correct starting, operational management, and maintenance are essential for efficient operation and long service life. By following the detailed guidance in this article, you should have a clear understanding of the starting procedures, operational management, and maintenance points of diesel generator sets. Strict adherence to operational procedures and regular maintenance can effectively reduce equipment failures and ensure that your diesel generator provides reliable power support when needed.