Problems for Using Diesel Generator Coolant Liquid

The use of coolant in diesel generator solves the problems of poor cooling and high temperature of the diesel generating set. Usually, we should replace the cooling liquid every one and a half years to two years. The standard replacement cycle of the cooling liquid will be very helpful for the genset protection. It can form a protective film on the surface of cylinder sleeve of the generator set so as to prevent the occurrence of cavitation and reducing wear and corrosion, which can prolong the maintenance intervals of the genset and reduce the maintenance cost. On the contrary, non-replacement for a long time, it will definitely reduce the using effects. So what problems should be paid attention to in the process of using diesel generator coolant?

Diesel Generators can have issues with the cooling systems.

Here we offer advice for on site checking of what to check before calling an engineer.

Operator’s Maintenance

The most important link in the maintenance chain is the engine operator.  His daily and weekly checks of the cooling system and reports on any questionable conditions he observes will help prevent engine breakdown on the job and provide valuable information to engine repair people.

Each must be recorded and reported as and when they are found.

Diesel Generator Checks Before Start-up

1.  Water level.

2.  Cleanliness of coolant.

3.  Radiator cap gasket.

4.  Hose and connections for leaks or hose collapse.

5.  Engine lubricating oil level.

Note

Oil level too low or too high will cause overheating and possible loss of the coolant.

6.  Check for water in the oil and vice versa.

7.  Inspect the fan for bent or damaged blades.

8.  Check the belt for tension and condition.

9.  Inspect the radiator for bent core fins or accumulation of debris.  Check shutters for

damage or linkage wear.

10.  Check for leaks at the cooler, water pump, or other accessories.

Diesel Generator Complaints and Causes

Loss of coolant due to external leakage.

1.  Leaking pipe plugs, such as core plugs, which seal off coolant passages.

2.  Loose clamps, faulty hose and piping.

3.  Leaking radiator:  Core hole plugs are sometimes loosened by corrosion or vibration.

These same conditions, or frozen coolant, can cause core seals to open up.

4.    Leaking radiator, de-aeration top tank or surge tank.

5.    Leaking gaskets due to improper tightening of cap screws, uneven gasket surfaces or

faulty gasket installation.

6.    Leaking drain cocks.

7.    Leaking water pump:  Badly worn or deteriorated seals are the cause of leaks at the

pump. Premature failure of the pump seals often results from suspended abrasive

materials in the cooling system, or excessive heat from lack of coolant or cavitation.

8.    Leaks at engine cylinder head gasket.

9.    Leaks at upper cylinder liner counter bore.

10.  Leaking engine or auxiliary oil cooler.

11.  Leaking air intake after cooler (intake air heater in some cases).

12.  Leaking water manifold and/or connections.

Loss of Coolant Due to Internal Leakage

1.  Leaking engine cylinder head gasket:  Coolant passes into the cylinders or the crankcase.

2.  Cracked engine cylinder head:  Coolant passes into cylinders and is blown out of the

exhaust.

3.  Deteriorated, severed or chafed liner packing; defective liner packing bore:  Coolant

passes into the engine crankcase.

4.  Improperly seated or defective sleeves:  Coolant can pass into the cylinder, crankcase,

and, if the heads have cylindrical injectors, coolant can enter the fuel system if it gets

past the injector body O-ring.

5.  Porous cylinder block or head casting:  Coolant can pass into the crank case via holes in

the system jacket.  If the cylinder heads have internal fuel passages, coolant can

enter the fuel system via holes in the wall of the fuel rifle which adjoins coolant passages.

6.  Cracked or porous water cooled exhaust manifold and faulty manifold to head mounting

gaskets.  Coolant passes into the cylinder or out through the exhaust system.

7.  Leaking engine or accessory oil cooler:  Coolant passes into the oil side of the cooler

when the engine is shut down.  The reverse almost always occurs when the engine is

operating.

8.  Leaking engine air intake after cooler or intake air heater:  Coolant passes into the

cylinders on naturally aspirated engines, also on turbo charged engines when the intake

manifold pressure is less than the coolant pressure.

Loss of Coolant Due to Overflow

1.  Over filled radiator:  As the engine reaches normal operating temperatures, the coolant

expands, and due to a lack of expansion space, unseats the pressure cap or relief valve,

allowing the coolant to pass out through the overflow pipe.  This does not occur with a

properly designed top tank – expansion space compensates for this.

2.  Slush freeze or frozen coolant resulting from insufficient antifreeze in the system or

poor mixing of antifreeze and water.

3.  Dirt, scale or sludge in the cooling system.

4.  Plugged radiator core.

5.  Restriction or plugging of fill line due to routing and/or deterioration.

6.  Combustion gas entering the cooling system and displacing the coolant causing it to