safety tips
Wear gloves, safety glasses, and a mask to protect yourself from toxic oils, liquids, and gases.
Do not turn the diesel generator on in closed places.
Avoid getting close to the diesel generator when it is working.
If there is any problem with the diesel generator, do not turn it on and contact an expert.
Pre-launch preparation:
1. Full inspection
a. Before starting the diesel generator, the control panel key must be turned off before the inspection. Be careful not to short-circuit the battery output electrode.
b. Clean and inspect the machine room again to ensure that there are no flammable or explosive materials around the machine. Make sure there is clear and unobstructed air inside and outside the car room.
c. Thoroughly inspect and ensure that electrical and control components are properly connected, in good contact, reliable and free from aging.
d. Check the reliability of the fastener and the throttle adjustment system, ensure that the operating mechanisms are flexible, light and reliable, and pre-check the tightening of the water pump belt, charger belt and fan belt.
e. Clean the surface of the generator assembly, especially the rotating part of the machine to make sure there are no foreign objects. Check to make sure there are no leaks of coolant liquid, fuel and oil.
After buying a diesel generator, be sure to check the oil level. Check to make sure the oil level is between the highest and lowest marks and close to the upper limit as much as possible.
2. Check the fuel level
a. Note that unfiltered fuel should never be injected into a diesel engine.
b. Check the amount of fuel in the fuel tank and add appropriate fuel if necessary.
c. When starting a diesel generator, check to make sure there is no air in the fuel when the unit is first started or stopped for a long time and then restarted.
3. Cooling surface
Check the coolant level within 5 cm of the filler cap to ensure there is no obstruction outside the radiator.
4. Check the air filter
a. Do not use diesel engine without an air filter.
b. Check the air filter clogging indicator. If the indicator is red, replace the air filter.
5. Checking the battery level
Close the power switch and check the battery voltage from the control panel. If it is less than 22 V and cannot meet the starting requirements, the battery needs to be charged.
6. Governor fuel quantity control
For a mechanical speed control unit, the mechanical governor fuel quantity control lever should be set to the throttle position of about 800 r/min. The electronic speed control device does not need to be adjusted.
How to start a diesel generator
a. Do not start the genset with load when starting the diesel generator.
b. Press the start button to start the diesel generator. If the startup fails, wait about 20 seconds before trying again. If the diesel generator fails to start 3 times in a row, stop the starter and remove the fault factors such as battery voltage or oil circuit before starting.
Note that continuous start-up in a malfunctioning system will cause unburned gas to accumulate in the exhaust system, posing a potential explosion hazard.
c. For the mechanical speed control unit, after idling for about 1 minute, the throttle is gradually increased to 1500 r/min. The electronic speed control unit does not need to be adjusted.
d. Preparations must be made to start the diesel generator in a cold environment. Use winter fuel suitable for local temperatures (qualified brand). This can reduce the risk of wax deposits in the fuel injection system.
In case of very low ambient temperature, it is recommended to install a preheating system (water jacket preheating, oil heating, fuel heating) and ensure that the cooling system is filled with antifreeze.
Diesel generator set is now working:
a. Check the oil pressure, water temperature, voltage, frequency, etc. of the control module. If there is any abnormality, immediately stop the machine for inspection. After fixing the problem, the device can be restarted.
b. Check the oil circuit, water line, gas circuit and smoke exhaust system of the device for leakage. Check the connection of the device for looseness and excessive vibration. Check whether the various protective and monitoring devices of the device are normal or not.
c. When the rotation speed reaches 1500 r/min and the no-load operation is stable, the switch can only be closed to supply the load power. The device is not allowed to be continuously idle for more than half an hour or less than 30% of the load. The genset must be protected when running. Overloading is strictly prohibited.
d. Do not short circuit when the device is working, otherwise it will cause serious damage to the equipment. It is strictly forbidden to remove parts from the generator set during operation.
e. Do not touch under the fan shield and any other part that has relative movement!
f. Do not try to touch the exhaust pipe, turbo-charger, high-temperature coolant, heater and other high-temperature surfaces with your hands, there is a risk of burns.
g. Check the output voltage and frequency from the control panel. The output voltage of the device is set at the factory, so it should be shown within the normal range. For units with mechanical speed regulation, the frequency should be close to 52 hr under no-load conditions.
For units with electronic speed control or EFI speed control, the frequency is closer to 50 hr under no-load conditions.
Do not exceed the nominal load on the diesel generator set. Some models can run at 110% rated power continuously for 1 hour if necessary, but only after 1 hour of rated power operation.
Turn off the diesel generator setting
In the following, we have explained the various methods of turning off the diesel generator step by step These items include:
1. Normal shutdown of the genset
a. Stop: The unit controlled by the automatic module can be stopped normally by pressing the stop button manually. A manually controlled unit can only turn the key to the “STOP” position and can also achieve a normal shutdown.
b. Check the output voltage and frequency from the control panel. The output voltage of the device is set at the factory, so it should be shown within the normal range. For units with mechanical speed regulation, the frequency should be close to 52 hr under no-load conditions.
c. When the load cable is connected or disconnected, the negative battery wiring must be disconnected and removed.
2. Genset emergency shutdown
a. If any unusual noise or smell is emitted during start-up or operation, the device should be switched off immediately.
b. When the oil pressure of the unit suddenly drops to the limit or there is no oil pressure, the error light is red and it should be stopped immediately.
3. The machine must stop immediately
a. When the water temperature of the unit suddenly rises above the specified value and the error light turns red.
b. When the output voltage of the unit, exceeds the maximum reading on the meter.
c. When there is a fire, power outage, or other natural disaster that may endanger the safety of crew and operators.
At this point, press the emergency stop button or quickly push the fuel pump stop control handle to the stop position. The device quickly shuts off the load then the throttle while the red “Emergency Stop” indicator light is on.
The button must be turned again to release the emergency stop signal. When the generator set is working normally or is supplying power to the equipment, in the absence of special emergency conditions, it is recommended that the user does not voluntarily perform the emergency shutdown operation.
After turning off
a. Check for leaks in engine or engine compartment.
b. Close the fuel valve.
c. If the device is to be stopped for a while, turn off the main switch.
d. During extended shutdowns, you should drain the fuel and coolant. Also charge the battery periodically according to maintenance specifications.
e. When the ambient temperature is below 5 degrees Celsius, the device must take anti-freeze measures after turning off to prevent cracking and freezing of the body and water tank.
