Diesel Generator Overheating? 7 Causes

High operating temperature in a diesel generator set is a common issue that affects equipment stability and lifespan. Quickly identifying and resolving the cause is essential.

1.Coolant Issues

Cause: Using an improper type of coolant or having an insufficient coolant/water level directly reduces cooling efficiency, causing the temperature to rise.

2.Radiator Blockage

Cause: Large areas of bent fins or clogging by sludge, dust, and debris between fins severely restrict airflow. Oil contamination on the surface is particularly problematic, as the resulting oil-dust sludge mixture has very poor thermal conductivity, drastically hindering heat dissipation.

3.Faulty Indication

Cause: A damaged water temperature sensor, shorted wiring, or a faulty gauge can cause false alarms (indicating high temperature when the actual temperature is normal).

Check Method: Use a surface thermometer to measure the actual temperature at the sensor and compare it with the gauge reading.

4. Low Fan Efficiency

Cause: A loose fan belt causes low rotational speed and reduced airflow. Belts that are aging, have damaged rubber, or broken cords must be replaced.

5.Water Pump Failure

Cause: Pump damage, low speed, or excessive scale buildup inside the pump narrowing the passages. All these reduce coolant flow rate and degrade cooling performance.

6.Thermostat Failure

Cause: A stuck thermostat fails to open properly, preventing the coolant from circulating through the main radiator circuit for effective cooling.

Check Method: Remove the thermostat, suspend it in heated water, and use a thermometer to observe if its opening and fully-open temperatures meet specifications. Replace if they do not.

7.Overload Operation

Cause: Overloading the diesel engine increases fuel supply, generating more heat than the cooling system is designed to handle, raising the coolant temperature. This is often accompanied by black smoke, increased fuel consumption, and abnormal noises.

Regular inspection and proper maintenance are key to preventing overheating failures.

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