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Diesel Generator Startup Inspection & Operational Guide

Diesel Generator Startup Inspection & Operational Guide

March 20, 2021

Diesel Generator Startup Inspection & Operational Guide

I. Starting System Components & Principles

Diesel generators transition from standby to operational state via an electric starting system, comprising:

  • DC starter motor (4-pole series-wound)
  • Solenoid switch
  • Overrunning clutch
  • Throttle actuator 
  • Battery (12V/24V) 
  • Charger

Operating Principle: Battery powers the starter motor, which rotates the crankshaft until ignition.

II. Operational Procedures

1. Pre-Start Checks

(A) General Inspection

Disconnect battery before servicing (prevent short circuits)

Clear flammable materials; ensure ventilation (min. 3x generator airflow) 

Verify:

  • Electrical connections (torque to 25 Nm)
  • Belt tension (10-15mm deflection)
  • No coolant/fuel/oil leaks

(B) Fluid Levels

Oil: Between MIN/MAX marks (SAE 15W-40 for -20°C to 40°C)

Fuel:

  • Use ASTM D975 diesel
  • Bleed air from filters (pump until bubble-free)
  • Coolant: 5cm below filler neck (50% glycol mix)

(C) Critical Components

Air filter: Replace if restriction indicator turns red

Battery:

  • Voltage >23V (12V system) or >46V (24V system) 
  • Top up distilled water if applicable

2. Startup Protocol

Manual Mode:

  • Set control panel to "Manual"
  • Crank ≤10 seconds; wait 2 minutes between attempts
  • After 3 failed starts, diagnose (fuel/compression/spark)

Cold Weather (<5°C):

  • Preheat coolant to 30°C
  • Idle 1-3 minutes before loading

Warning: Never load-start; open breaker if no ATS.

3. Automatic Mode

Prerequisites:

  • Control switch → "Auto" 
  • Breaker → Closed 

Maintenance:

  • Daily Level-A checks (oil/coolant/fuel)
  • Weekly load testing (>30% for 30 mins)
  •  

Key Safety Notes

Prohibited Actions:

  • Adding unfiltered fuel
  • Operating without air filter  

Cummins Generator With Big Fuel Tank

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