Pre-Start Inspection and Precautions for Diesel Generator Sets | Professional Guide by Shanli

Diesel generator sets are essential as backup or primary power sources, and their stability and reliability are critical to uninterrupted operation. As a professional manufacturer of diesel generator sets, Shanli leverages years of industry experience to provide a comprehensive and standardized pre-start inspection guide to help you operate your genset safely and efficiently.

I. Comprehensive Pre-Start Inspection

1. Appearance and Environment Check
  • Unit Position: Ensure the generator set is placed on a level surface without tilt or displacement to avoid abnormal vibration during operation.
  • Surrounding Environment: Remove flammable or explosive materials nearby. Keep the area well-ventilated to prevent exhaust accumulation.
  • Cleanliness: Wipe off dust, oil, and debris from the surface to ensure proper heat dissipation.
2. Fuel System Inspection
  • Fuel Level and Type: Confirm that the tank has enough fuel and that the diesel grade (e.g., 0# or -10#/-20#) matches the environmental temperature.
  • Leakage Check: Inspect fuel lines, filters, and the tank for leaks or blockages.
  • Long-Term Shutdown Handling: If the unit has been idle for a long time, drain old fuel and remove water or impurities from the system.
diesel generator pre-start inspection
3. Lubrication System Inspection
  • Oil Level: Use the dipstick to check that the oil level is between the “L” (Low) and “H” (High) marks.
  • Oil Quality: Check for emulsification or impurities in the oil. Replace immediately if contamination is found.
4. Cooling System Inspection
  • Coolant Level: Inspect the radiator or water tank level. Refill with antifreeze or soft water if necessary.
  • System Integrity: Ensure hoses are sealed properly and the radiator is not clogged to avoid overheating.
5. Electrical System Inspection
  • Battery Status: Check electrolyte levels for non-maintenance-free batteries. Measure voltage (≥12.6V for 12V systems, ≥25V for 24V systems). Clean terminals to prevent corrosion and ensure good contact.
  • Wiring Tightness: Ensure all connections in the control panel, starter, and other electrical components are tight and free of exposure.
  • Output Breaker: Ensure the circuit breaker is in the OFF position before starting (no-load startup).
6. Air Intake and Exhaust System Inspection
  • Air Filter: Clean or replace the filter element to ensure sufficient air intake.
  • Exhaust System: Ensure exhaust pipes are clear and the muffler is securely installed.
7. Other Key Components
  • Belt Tension: Fan and alternator belts should have a deflection of about 10–15mm when pressed.
  • Dashboard Gauges: Confirm that all meters (oil pressure, water temperature, etc.) are functional and reset to zero before starting.

II. Pre-Start Precautions

  • No Load Start: Always start the genset with the circuit breaker turned off to avoid current surge damage.
  • Cold Weather Operation: In temperatures below 5°C, use a coolant preheater or manually pre-lubricate the cylinders.
  • Safety Measures: Operators should wear insulated gloves and safety goggles, and keep a safe distance from rotating parts.
  • Initial or Idle Restart: For first-time or long-idle startups, allow the unit to run at no load for 5–10 minutes while monitoring oil pressure and water temperature.
  • Emergency Preparedness: Keep a fire extinguisher nearby and familiarize yourself with the emergency stop button location.
  • No Improper Operation: Never use an open flame to heat the oil pan or add fuel/coolant while the engine is running.

III. Operational Reminders

1. Special Application Scenarios
  • Long-Idle Units: Check fuel quality and lubrication system for dryness. Replace oil and manually rotate the crankshaft if necessary.
  • Paralleled Units: Inspect synchronization controllers, phase alignment, and other electrical parameters.
  • Automatic Units: Test the ATS (Automatic Transfer Switch) to ensure proper functionality.
2. Operation and Maintenance
  • Follow the Manual: Different brands and models have variations. Always refer to the official operation manual.
  • Maintain a Logbook: Record key parameters (fuel level, voltage, oil pressure, temperature) before and after startup to support troubleshooting and preventive maintenance.

Reliable Power Starts with Quality | Shanli Diesel Generator Sets

  • Routine inspection and maintenance are the foundation of reliable generator operation. But selecting a high-quality, well-designed diesel genset is key to preventing failures at the source. As a professional manufacturer of diesel generator sets, Shanli offers:
  • ✅ Smart Customization: Flexible solutions for fixed, mobile, and automated applications.
  • ✅ Powerful Performance: Equipped with premium original engine components for strong, consistent power output.
  • ✅ High Safety & Durability: Enhanced designs for cooling, electrical, and structural systems. Strict quality control at every stage.

📞 Contact Us Today for Your Tailored Diesel Generator Power Solution!

Shanli Diesel Generator Sets | Your Trusted Power Partner
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