Troubleshooting Diesel Engine Cooling System

by Generator D. Diesel Generator

Cooling System for an engine is one of the most important parts. Each engine has its own cooling system. We use different cooling system for different engine. Water cooling, Oil cooling, Air cooling is most common cooling system. In this post I will discuss about the Diesel Engine Generator Water cooling system. If we burn diesel inside the engine then it will become hot. For this reason we use water inside the engine and it reduces engine inner temperature. This method name is Jacket Water Cooling System. Let’s learn more about this cooling system.

Jacket Water Cooling System is normally two types: – a) Open Circuit Cooling System b) Close Circuit Cooling System.

Open Circuit Cooling System: Usually in this method the engine is cooled by water from the external source like ponds or water tanks.

Close Circuit Cooling System: In this method the water reserved inside the engine and the radiator or a heat exchanger is used to cool the water during engine running time.

Now I am going to discuss about the Engine Cooling System and I am going take an example of Caterpillar Diesel Engine Generators. Normally Caterpillar Diesel Engine Generators use Close Circuit Cooling Systems. Main parts of this cooling system includes jacket water transfer pump, radiator, coolie fan, thermostat, fan belt, radiator expansion tank, jacket water temperature sensor etc.

How Jacket Water Cooling System Works?:

Normally when the generator engine starts then the engine jacket water pump is turned on. This water pump use to drag the water from inside the engine and send it to the radiator and after cooling it send back cold water to the engine. When engine start, thermostat valve of cooling system stay closed, so that the engine water can just only flow inside the engine. After running for a while, the temperature of the water increased almost 80-850C then thermostat valve open automatically. Now the hot water from the engine goes to radiator. Air flows through the fan on the radiator and for this reason the radiator’s water become cold. After cooling, water goes back to the engine and cools the engine. However by using this cooling system some others hot areas use to cool like Lube Oil Cooler, Turbo Charger, Cylinder Head, Engine Liner and After Cooler.

Jacket Water Cooling System Problems and How to Solve?:

Fresh air movement is very important for this kind of engine. If the engine placed in a surround small place then cooling system will not work properly. The jacket water level at the engine’s radiator will be checked so that there is never water emptiness in radiator. Radiator water cannot be cold properly due to dust inside the radiator. For this problem sometimes the radiator should be cleaned. Check the radiator fan. If needed radiator fan belts need to be adjusting again. Should check jacket water pump is works properly or not. If the jacket water thermostat does not work properly then the water cannot go to radiator. Then the jacket water temperature will increase in the engine. So valve need to check and if needed change the thermostat valve. In the engine jacket water chemical must to be given. It protects the engine’s cooling system and prevents rust from other parts. In winter season the engine is usually stay cold so the engine’s jacket water temperature stay low. In this situation sometime the alarm came when the engine started. If the engine running little more time then the alarm goes away.

Five Tips for Winterizing Heavy-Duty Diesel Engines

Tip 1: Treat the fuel.

When preparing your fleet for winter, one of the most commonly overlooked items is the fuel itself. Fuel needs to be winterized, especially for trucks that are used throughout the winter.

Paraffin wax is present in all diesel fuels as a natural lubricity agent. Like any wax, as the ambient temperature of the fuel drops, the wax begins to form large square-shaped structures. These can come out of suspension and cause fuel to gel, which clogs the fuel filter.

To prevent gelling, use a cold-flow improver (CFI) that includes de-icers and wax anti-settling agents, which extend the operability of the fuel. But don’t overtreat. Additional treatments of CFI are more likely to inhibit the fuel’s performance than help.

A second option is to use a diesel fuel specially formulated for low temperatures, such as Cenex® winterized premium diesel fuels. Cold-flow improvers, de-icers and wax anti-settling agents are included in the additive packages for these fuels.

Tip 2: Drain the water separator and replace filters.

Water in the fuel system can reduce engine performance and damage components like fuel pumps and injectors. Avoid these issues by replacing water-absorbing filters and draining the water separator regularly. Fuel gelling can be an issue, but it’s water turning to ice in fuel storage tanks and filtration that typically plugs filters during the first couple of cold snaps.

Fill fuel and hydraulic oil tanks full to prevent condensation from forming during temperature and humidity changes.

Tip 3: Check the coolant system.

Regular preventive maintenance will reveal any issues before they become major problems. Check for radiator leaks, plugged or hardened hoses and cracked belts. Tighten any loose hose clamps. Check coolant levels and antifreeze strength.

Tip 4: Prepare the battery.

Old Man Winter can drain batteries quickly. If a battery is close to the end of a typical 48- to 72-month cycle, replace it. Clean battery terminals, and be sure connections are tight. If equipment will be stored over the winter, disconnect battery ground cables to prevent battery drain.

Tip 5: Clean and inspect the exterior.

Use a high-pressure washer to remove dirt, dust and residue, and grease unpainted metal parts to protect them from the elements. Then apply a wax to the surface, which will help repel snow, salt and road chemicals. Use a lanolin-based spray-on protectant to prevent rust and corrosion.