Diesel Generator Use & Maintenance in Cold Environments

In modern society, the stability of power supply is crucial to our daily lives and work. However, natural disasters and resource shortages often lead to power outages or blackouts. In such situations, diesel generators have become an indispensable emergency power source. Whether in homes, ships, hospitals, tourist attractions, construction sites, or businesses, diesel generators play a vital role. However, if not used and maintained properly in low-temperature environments, diesel generators may suffer damage or even fail to operate. This article will provide a detailed guide on the precautions to take when using diesel generators in low-temperature environments, helping users to better operate and maintain their equipment to ensure it functions properly when needed.

Starting diesel generators in low-temperature environments requires extra caution, as low temperatures can have many adverse effects on the equipment. Here are several key points to consider during the starting process.

In low-temperature environments, preheating is essential for starting diesel generators. The correct preheating method is as follows: First, cover the radiator with an insulating cover and open the drain valve. Continuously pour clean soft water at 60-70°C into the radiator. When the water flowing out of the drain valve feels hot to the touch, close the valve and fill the radiator with clean soft water at 90-100°C. At the same time, rotate the crankshaft to ensure that all moving parts are adequately lubricated before starting the generator. This preheating method can effectively prevent starting difficulties and machine damage caused by low temperatures.

Some operators may attempt to start diesel generators without water (starting first and then adding coolant), which is an improper method. This practice is extremely dangerous and can cause severe damage to the machine. In low-temperature environments, starting without coolant can lead to engine overheating and even engine damage. Therefore, this method is strictly prohibited.

After the diesel generator has started, it should not be immediately loaded. At this point, the engine temperature is low, and the viscosity of the engine oil is high, making it difficult for the oil to reach the friction surfaces of the moving parts, which can cause severe wear on the machine. Additionally, the plunger spring, valve spring, and fuel injector spring may be prone to breakage due to "cold brittleness." Therefore, after starting in low temperatures, the diesel generator should run at low to medium speed without load for a few minutes until the coolant temperature reaches 60°C before loading.

The performance of diesel fuel is significantly affected in low-temperature environments, making the choice of fuel crucial. Here are the key points for fuel selection in low temperatures.

Low temperatures in winter can reduce the fluidity of diesel fuel, increase its viscosity, and make it difficult to atomize properly, leading to poor combustion and reduced power and economic performance of the diesel generator. Therefore, when using diesel generators in low-temperature environments, it is advisable to choose light diesel with lower viscosity, lower pour point, and better ignition properties. Generally, the pour point of the diesel should be 7-10°C lower than the current seasonal temperature in the local area. This ensures that the fuel remains fluid and combustible in low temperatures, preventing engine start-up or operational issues due to fuel solidification.

In addition to selecting the right fuel, it is essential to ensure that the fuel lines and fuel tank are free of ice. In low-temperature environments, diesel fuel can easily solidify and block the fuel lines, preventing the engine from receiving fuel. Before using the diesel generator, check the fuel lines and tank to ensure that fuel flows smoothly. If ice is found in the fuel lines or tank, take immediate measures to clear and heat the affected areas to ensure a continuous fuel supply.

The performance of the lubrication system is critical for the normal operation of diesel generators in low-temperature environments. Low temperatures can increase the viscosity and reduce the fluidity of engine oil, affecting the lubrication of the engine.

In winter, the fluidity of engine oil decreases due to lower temperatures. Therefore, when using diesel generators in low-temperature environments, it is necessary to use low-viscosity engine oil to ensure the normal operation of the engine. When selecting engine oil, choose the appropriate grade based on local temperature conditions and engine requirements. Generally, in winter, it is advisable to select engine oil with lower viscosity and pour point to ensure that the oil remains fluid in low temperatures and provides good lubrication for the engine.

Engine oil gradually deteriorates and loses its lubricating properties with use. Therefore, regular oil changes are essential. In low-temperature environments, the reduced fluidity of engine oil may necessitate more frequent oil changes. It is generally recommended to change the engine oil every 50-100 hours of operation to ensure that the engine remains well-lubricated. Additionally, when changing the engine oil, inspect the oil filter and replace it if necessary to maintain the quality of the engine oil.

Cooling system maintenance is equally important in low-temperature environments. Proper maintenance not only prevents coolant freezing and equipment damage but also ensures that the engine maintains an appropriate operating temperature in the cold. Here are the key maintenance points.

In low-temperature environments, the coolant in diesel generators should be drained promptly after shutdown. When the temperature drops below -4°C, it is essential to drain the coolant from the diesel engine's radiator. At -4°C, water freezes and expands in volume, which can cause the radiator to crack and damage the cooling system. When draining the coolant, ensure that all water is completely removed to prevent residual water from freezing and damaging the equipment. Before draining, allow the engine to idle until the coolant temperature drops below 60°C and the water is no longer hot to the touch. This prevents the engine from sudden cooling and contracting, which could cause cracks.

In winter, the temperature of the engine coolant can drop, making it prone to freezing. Therefore, it is necessary to check whether the freezing point of the coolant meets the requirements and ensure that there are no leaks or blockages in the cooling system. Generally, the freezing point of the coolant should be about 10°C lower than the lowest local temperature. If the freezing point of the coolant does not meet the requirements, replace or add antifreeze promptly to ensure that the coolant does not freeze in low temperatures and maintains proper engine cooling.

In winter, the air contains more dust and impurities, so it is essential to regularly inspect and clean the air filter to prevent the engine from ingesting dust and debris that could cause damage. In low-temperature environments, air filter maintenance is particularly important. A clogged air filter can lead to insufficient engine intake, affecting engine performance and fuel economy. Therefore, regularly check the condition of the air filter and replace or clean it as necessary to ensure proper engine air intake.

In addition to the aforementioned precautions regarding starting, fuel selection, lubrication system, and cooling system maintenance, there are other important matters to consider when using diesel generators in low-temperature environments. These details can also affect the performance and lifespan of the equipment. Here are the specific precautions.

In winter, the low temperatures can cause water in the exhaust pipe to freeze, leading to blockages. Therefore, it is necessary to drain any water from the exhaust pipe and ensure that it is not blocked. When using diesel generators, pay attention to the condition of the exhaust pipe and take measures to heat or insulate it if necessary to prevent water from freezing inside.

Insulation is key to using diesel generators in low-temperature environments. Therefore, diesel generators should be equipped with insulation covers and curtains to protect against the cold. These insulation devices can effectively reduce heat loss from the engine, maintain the normal operating temperature of the engine in low-temperature environments, and improve engine start-up performance and operational efficiency.

The oil pan of the diesel generator should not be heated with an open flame. This can cause the engine oil inside the pan to deteriorate or even burn, reducing or completely losing its lubricating properties, which can lead to increased machine wear. In winter, it is advisable to use low-pour-point engine oil to ensure that the oil remains fluid in low temperatures and provides good lubrication for the engine.

The use and maintenance of diesel generators in low-temperature environments require special attention. By properly preheating the generator, selecting the right fuel and engine oil, regularly maintaining the cooling system and air filter, taking insulation measures, and avoiding improper operations, the lifespan and operational efficiency of diesel generators in low-temperature environments can be significantly improved. When using diesel generators, it is essential to strictly follow the operating procedures and regularly inspect and maintain the equipment to ensure that it remains in good working condition. Only in this way can diesel generators function as intended in critical situations, providing a reliable power supply for our daily lives and work.