100 Hour Initial Operation Guide for Diesel Generators

The service life of a diesel generator set is related not only to regular maintenance but also to proper operation. In particular, the operation of the diesel generator set during the first 100 hours has a decisive impact on the lifespan of the Cummins diesel generator set. Today, Dingbo Power Generator Manufacturer will discuss how to operate your diesel generator set during these initial 100 hours.

The correct operation procedures for the first 100 hours of a diesel generator set are as follows:

1. Operate the generator set at 70% load for as long as possible.

2. Avoid prolonged idling of the diesel generator set or operating at maximum power for more than 5 minutes.

3. Develop the habit of closely monitoring the diesel generator set's instruments during operation. If the oil temperature reaches 121°C or the coolant temperature exceeds 88°C, reduce the load immediately.

4. During the running-in period, check the oil level every 10 hours.

5. The fuel for the diesel generator set must be domestic "0" or "-10" light diesel oil that meets the national standard (GB252).

6. The engine oil for the diesel generator set should be the recommended oil (15W/40 CD, CE, CF, CH, etc.).

7. After starting, warm up the engine at idle speed or no more than 1000r/min until the oil pressure in the main oil passage stabilizes.

8. If the engine fails to start within 30 seconds, wait two minutes before attempting to start again.

9. After starting, idle for 3–5 minutes: After the diesel engine is started, it takes time to re-establish the oil film between the crankshaft and bearings, and between the piston and cylinder liner. The optimal clearance between moving parts can only work properly when the engine temperature reaches a certain level, so do not rush to apply high power, high torque or high speed at the beginning of starting to avoid the piston seizing in the cylinder or the bearing producing dry friction.

10. Before stopping, unload the generator set first, run it at no load for 1–2 minutes and then idle for 3–5 minutes, mainly to allow the lubricating oil to take away the heat from the combustion chamber, bearings and oil seals; especially for the turbocharger, if it is stopped suddenly, the possibility of bearing and oil seal seizure is high.

11. If any abnormal phenomenon is found during the operation of the diesel generator set, stop the generator set immediately for maintenance. Such as: sudden drop in oil pressure, abnormal sound, etc.

12. For standby diesel generator sets, start the engine at least once a month (for about half an hour).

13. Before each start of the diesel generator set, check the engine oil level, cooling water level, etc.

14. The battery of the standby unit should be charged regularly, and the battery liquid level should be checked at the same time.

15. It is strictly forbidden to remove the battery while the diesel generator set is running.

Dingbo Power was founded in 1974 and is one of the earliest manufacturers of generators and diesel generator sets in China. If you want get more information, please feel free to send email to [email protected] we will pay highly attention on your question.