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Diesel Generator – Essential Dos & Don'ts for Safe and Efficient Operation

Introduction
Proper maintenance and operation of a diesel generator (DG) are essential for ensuring reliability, efficiency, and longevity. Incorrect handling can lead to engine damage, increased fuel consumption, and higher emissions. Following best practices helps in reducing breakdowns, optimizing performance, and ensuring safety.
In this guide, we outline the most important Dos and Don'ts for operating a diesel generator efficiently.

Dos: Best Practices for Diesel Generator Operation

  • Idle the Engine Before Shutdown
    • Always allow the engine to idle for 3 to 5 minutes before shutting down.
    • This helps lubricating oil and coolant carry heat away from critical components like the combustion chamber, bearings, and shafts, preventing overheating and thermal shock.
  • Monitor Oil Pressure
    • The oil pressure gauge should display pressure within 15 seconds of starting.
    • If oil pressure is not indicated within this time, shut off the engine immediately to prevent severe damage.
  • Maintain Proper Oil Temperature
    • The ideal oil temperature range is between 75°C to 105°C.
    • A sudden increase in oil temperature is a sign of potential engine problems stop the generator immediately if this occurs.
  • Ensure Correct Coolant Temperature
    • Maintain coolant temperature between 75°C and 95°C to prevent overheating.
    • Overheating can cause engine damage and reduce efficiency.
  • Monitor Engine Pressure at High Temperatures
    • At 105°C, engine pressure should be within these limits:
      • 3 to 7 kg/cm² at rated speed.
      • 1 to 2 kg/cm² at idle.
    • Regularly check the pressure to ensure smooth engine operation.
Don'ts: Common Mistakes to Avoid in Diesel Generator Operation
  • Avoid Long Periods of Idling
    • Extended idling reduces combustion chamber temperature, leading to incomplete fuel burn.
    • This can cause carbon buildup, clogging injector spray holes, piston rings, and valves, affecting engine performance.
  • Do Not Over Crank the Engine
    • Do not crank the engine for more than 10 seconds continuously to avoid damage to the cranking motor.
    • If the engine fails to start after three attempts, stop cranking and inspect the fuel system for possible issues such as:
      • Fuel blockages
      • Air in the fuel lines
      • Battery or starter motor issues
Final Words
Following these dos and don'ts ensures that your diesel generator operates safely, efficiently, and with minimal wear and tear. Proper monitoring of oil pressure, coolant levels, and engine temperature helps prevent breakdowns and extends the generator’s lifespan. Avoiding bad practices like over-cranking and prolonged idling keeps the engine in optimal working condition.
By adhering to these best practices, you can maximize your diesel generator’s performance and reliability, ensuring uninterrupted power supply when you need it the most.

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