Common Misoperations in Diesel Generator Operation

Mistake 2: Emergency Shutdown Under Load or Immediate Shutdown After Sudden Load Removal

After a diesel generator shuts down, water circulation in the cooling system stops, drastically reducing heat dissipation. Heated components lose cooling, risking overheating and cracks in parts like the cylinder head, liner, and block, or piston seizure due to excessive expansion. Additionally, shutting down without idling to cool down leaves insufficient oil on friction surfaces, leading to poor lubrication and accelerated wear during subsequent startups. Therefore, before shutting down, remove the load, gradually reduce speed, and run the generator at no-load for several minutes (required: 3 minutes of no-load operation).

Mistake 3: Applying Load Immediately After Cold Start Without Warm-Up

During cold starts, high oil viscosity and poor fluidity restrict oil pump supply, causing insufficient lubrication on friction surfaces. This leads to rapid wear, or even cylinder scuffing or bearing burnout. Thus, after a cold start, the diesel engine should idle to warm up: wait until oil temperature exceeds 40°C (or coolant reaches 60°C in winter) before applying load. When starting operation, use low gears and run briefly in each gear sequentially until oil temperature normalizes and lubrication is adequate, then switch to normal operation.

Mistake 4: Revving the Engine Violently After Cold Start

Violent revving causes a sudden increase in generator speed, leading to dry friction and severe wear on some friction surfaces. Moreover, abrupt throttle changes create sharp force fluctuations in pistons, connecting rods, and crankshafts, causing intense impacts that may damage components.

Mistake 5: Operating With Insufficient Cooling Water or Excessively High Coolant/Oil Temperatures

Inadequate cooling water reduces cooling efficiency, causing the diesel engine to overheat from poor heat dissipation. Excessively high coolant or oil temperatures also trigger overheating, weakening the mechanical properties (strength, toughness) of critical heat-loaded parts (cylinder head, liner, piston assembly, valves). This increases deformation, reduces component clearances, accelerates wear, and may even cause cracks or seizures. Overheating also degrades combustion, disrupts injector performance, impairs fuel atomization, and increases carbon deposits.

Guangxi Dingbo Power Equipment Manufacturing Co.,Ltd was founded in 1974 and is one of the earliest manufacturers of generators and diesel generator sets in China. The company has a registered capital of 218.88 million yuan. The company covers an area of 86,000 square meters and a building area of 55,000 square meters. There are more than 660 employees, including 456 professional technicians and 106 senior technicians. It has 46 sales and service outlets nationwide. The main products are diesel engines, generator sets, and diesel generators, providing users with a one-stop service of design, supply, debugging and maintenance at any time. Dingbo has always insisted on using first-class talents, building first-class enterprises, manufacturing first-class products, creating first-class services, and making every effort to build a first-class domestic enterprise. If any question please feel free to visit our website https://www.dieselgeneratortech.com/ or send email to [email protected].