Common Causes of Diesel Powered Generators Overheating & How to Prevent It
Diesel powered generators are known for their fuel efficiency, reliability, long service life and wide application. However, they still have the problems or malfunctions that they should have as well as other machines. One such problem is overheating. Overheating can be caused by a low level of coolant, coolant pipeline blockage, improper use, insufficient lubrication, clogged exhaust or a problem with the generator.
Is an overheated generator a bad thing?
If the generator starts to overheat, the alternator will overheat and the windings will be burned, affecting its insulation performance. The winding insulation will start to soften, and then they may melt or catch fire. When the slip rings and brushes are exposed to such a high temperature, they will unsolder themselves. Other problems you may encounter include:
• Warping of the rotor.
• The bearing begins to melt.
• If the cylinder head is overheated, the cylinder head gasket may be damaged, which will restrict the flow of coolant to the cylinder.
• Overheating may damage the radiator core.
• The exhaust valve will also expand, thereby damaging the valve guide.
Overheating can cause damages to different parts of the diesel powered generator, which requires repair or replacement. In some occasions, maintenance costs can exceed the cost of purchasing a new generator. Overheating can also greatly shorten the service life of the generator, which means you must replace it earlier than originally planned.
Common causes of overheating in diesel powered generators
Since you know the damages that can be caused by the generator overheating, you may want to know the cause of the generator overheating. Some of them are as below:
1. Low coolant level. The coolant is probably leaking internally or externally. Coolant leakage may be caused by loose clamps or leaking gaskets.
2. Poor coolant circulation. This might be caused by a collapsed soft hose leading to a restriction.
3. Heavy accumulation of grease and dirt on the surface of the generator hinders normal heat dissipation.
4. Over fueling the generator.
5. Damaged cooling fan or improper fan belt tension.
6. Blocked diesel injector. If the injector is blocked the system will have to overwork to compensate for the clogging of the injector, which can cause overheating.
7. Clogged air filter, which will cause the generator to overheat and cut off.
8. Damaged exhaust, which restricts the exhaust.
9. Overloaded generator.
10. Low oil level.
It should be noted that that a meter failure can also cause overheating, because if the generator overheats but the meter fails, the cooling system will not be triggered when the generator needs it. A meter failure may also indicate that the generator is actually overheating when it is within its normal operating temperature range. When troubleshooting is required, make sure to check the pressure gauge carefully.
How to prevent the generator from overheating
Even if the generator is mechanical and will fail occasionally, you can still take some measures to prevent the diesel generator from overheating. To prevent the generator from overheating, the most important thing you need to do is to have a professional repair it regularly in accordance with the manufacturer's instructions. Correct maintenance can not only keep the generator running smoothly, but also extend its service life.
In addition to regular maintenance, other measures should be taken to prevent the generator from overheating.
• Keep both the coolant and oil levels at the correct level.
• Monitor the exhaust pipe to make sure it is not blocked.
• Place the generator in a protected but well-ventilated area.
• Do not place the generator near other heat-generating equipment.
• Run the generator regularly to ensure it is in good working condition.
• Do not overload the generator. If you need more power, please replace your current generator with a more powerful generator.
• Ensure the use of high-quality fuel and coolant.
Diesel generators have many problems, but the most common one is overheating. The generator protection points listed above must be implemented to extend the service life of the generator.
