Generator Overheating Causes & Prevention

Generator Overheating Causes & Prevention

Generator Overheating is one of the biggest issues for your vehicle that reduce the long-life duration of the Diesel engine. And if you want to take a smooth ride on-road and don’t want to face any issue then you need to provide services and maintain your generator from time to time.

Don’t push an engine too hard under load for an extended period of time because everything has an age limit if its extended period has been finished it will not work properly. However, some job site conditions sometimes mention the limit of their products after that they need to be changed.

If you find your diesel engine is overheating the article below will help you to find the reasons for overheating and how can you prevent them.

Why your Diesel Engine Generators Overheated?

The main issue behind Generator overheating is a low level of coolant, improper use and may be an issue in the generator. Temperature and pressure are the key points that help your engine and diesel fuel injection system work properly. And as you know that the pressure of the injection system is 30,000psi and it is enough to create a fine mist of fuel and create heat. And if it gets overheat then control it using air pockets as if you to know that it is due to the low cooling system then you need to increase the airflow because the air bubbles reduce the heat. Overheating generator effects alternator and damage insulating properties.

Reasons for Generator Overheating:

Broken Cooling Fans

Broken cooling fans is one of the reasons behind overheating. Fans break because of high tension. If the cooling fans have broken then it increases heat. This issue may occur due to broken fans so we need to change the entire fan system or there may be an electrical issue, so sometimes it solved by changing fixing some wires.

Diesel generator engine overheats due to Heat dissipation, cooling, and clogging of the lubrication system

Pipeline And Radiator Blockage

If the radiator and pipeline blocked then cooling water cannot circulate properly and the generator gets overheated.

Exhaust pipe Block

If exhaust pipe blocked while the diesel engine is running then exhaust gas will not work properly. Because of the blockage, some gas remains in the cylinder and next time when the cylinder is filled. It will become a mixture of fresh oil, remaining (exhaust gas) gas and gas mixture can’t come out properly. And Flame propagates and burns slowly, create overheat.

Plugging of The Oil Filter

Normally the diesel engine receives the oil through the oil filter. But if the oil filter has been blocked then, oil lubricant points of the diesel engine only through the bypass passage. Poor lubrication is the main reason for unfiltered oil and oil pipeline blockage. And generate high heat by the friction of coupler, and causing overheating.

Cooling System And Lubricant System Leaks, Cause Overheating

Leakage of the radiator and pipeline: Radiator or pipeline leaks because of the water storage capacity is over limit. By this leakage engine doesn’t get cooling water and causing overheat.

Low Coolant Issue(Coolant Leaks)

If you are facing coolant leaks issue then definitely there is an issue in your gasket. The gasket is damaged internally or externally. By this, you may face a serious issue so before facing any big issue go-to mechanic.

Over Fueling The Generator

Thermostat faults: Sometimes there will be an issue in the sensors. And they can’t able to detect if the Diesel engine is overheating. And not able to trigger the cooling system.

Generator Overload

Check Temperature Gauge: Sometimes there is no issue with internal parts of the engine. And you face this issue due to temperature gauge, sensors, and thermostats. Unfortunately, if the gauge doesn’t work properly don’t need to replace it immediately. It may be fixed doing some changes.

Some External Factors Affect The Generator

Sometimes external factors also affect the generator. In hilly or high altitude areas, air density is low and the engine doesn’t get air properly with low air density to work and generate overheating.

Same as in the hand in high-temperature areas, the low-density issue. When there is not good enough air is supplied, then less oxygen for combustion and engine tries to work with the same power and produces the issue of overheating. Another issue is high humidity also puts stress on the generator’s cooling system.

When the outside temperature is not high or worm or there is high humidity, it puts stress on the generator and causes the issue of overheating or generator damage issues.

 Some Internal Factors Also Affect The Generator

Diesel engines or Generators need proper flow of the air. So need to check the coolant level of the generator time-to-time. Make sure there is no other equipment or system that is placed nearby a generator that generates hot air. Or if the generator is on the ground floor or in the basement the room is enough to cool for the generator. And keep the proper supply of air.

Problems You May Face:

There are many issues your engine can face due to overheating. The overheated cylinder head can crush the gasket and blockage cooling system. It increases the camshaft and then it is a breakdown. And the piston can be expended in size and damage to the cylinder walls.

Warping of the rotor: Rotors are the large metals that state with the wheels. They rotate along with wheels and generate much amount of heat this heat to be need flown in the air as soon as possible as wheels need to stay down again. But if the disc surface is not even then the braking will be jittery and less effective. And this situation is referred to as warping.

Bearing starts to melt: Sometimes, breaks are also overheated due to the use of breaks for an extended time of period. And its losses all breaking power and creates dangerous situations for you.

Head gasket crashes due to overheating of the cylinder head: While driving if there is a white cloud following behind you at all times, you may have a bad head gasket. This is very bad news for your engine and needs immediate attention.

Radiator core can also be damaged: When the extreme amount of heat is generated combustion system then needs to be released outside as soon as possible. And then it is transferred by water jackets and cylinder head to the radiator and through the tubes, it goes to the cool atmosphere. But sometimes it doesn’t work properly and needs to replace.

Exhaust valves also damaged due to damage to the valve’s guide: Exhaust valves always damaged due to blockage of the cooling system and by using non-branding oil. To prevent yourself from these issues always clean your cooling system, use good quality of the oil.

How Can You Identify These Issues:

There are many reasons for engine overheating. First, check that there is no blockage in air intakes/outputs.

Make sure that nothing is put in the area of 2 meters of air intakes and outputs because it blocks or restricts the airflow.

Avoid to overload the generator beyond its limit. Weeping hoses and loose supporting clips need to check regularly. Checkout exhaust may be damage. Are you using cheap, non-brand oil or non-compliant oil? it may overheat the engine. Maybe your oil filter and air filter needs to be changed. If you are using the same oil filter and air filter for a long time it may be the reason for overheating.  Check the correct coolant level of water.

How Can You Prevent Your Engine From The Overheating:

As you see that there are many reasons for generator overheating. Now there are some points you can do to prevent engine overheating. The generator needs time to time servicing and maintenance. By this, there will rare chance of overheating and it also expends its life limit.

Check Your Engine Belt

Engine belt is used to transfer energy from the engine to its components like fans and water pumps. But if the fan belt has been broken then it will not able to supply energy to the components and the cooling system will stop. And the engine gets overheated.

The Condenser Should Be Clean

The engine will work properly if it gets the air-flown through the radiator. For proper flow of the air, a radiator should be dirt, dust-free. If there is an issue in the radiator then you should have contained air conditioning, your air conditioning condenser built to keep radiator clean. It increases the efficiency of the cooling level. And helps the engine to work properly.

Inspect Your Radiator Cap

The radiator cap is used to maintain pressure on the cooling system to prevent overheating. This helps to decrease pressure on the system. Be careful don’t touch the radiator cap while the engine is overheating.

Your Coolant Is Topped-Up and should Be In Good Condition

Your cooling system should be in the proper order to keep the temperature under control. Make sure the coolant is topped-up before driving. Like other fluid, coolant is also degraded over time. And it decreases the working flow of the radiator. Coolant systems also need time to time maintenance like other functions of the engine.

Always keep Extra Coolant

Low coolant is the main factor of overheating. So, always keep extra coolant for when running slow, or the engine is going to overheat. And it should the mixer of 50/50 antifreeze/water.

While driving keep the engine as steady position

As much as possible trying to be in steady position while driving. It reduces the chance of engine-generator overheating.

What To Do If The Engine Is Overheated

If you feel that your vehicle’s engine is heating up then don’t drive more then a quarter-mile. To avoid further damages. First, visit a mechanic but if the mechanic is not nearby your location then first pull out safely and turn off the engine. Open the hood and check the car after when the car is completely cool-down. Then check the coolant level in the radiator don’t touch it until it cooled down.

Make sure that there is no blockage in the radiator, gasket or cylinder. After that restart the engine again. Then check the temperature gauge that it should not be crossing its optical mark. If it is crossing then pull over to a safe location and turn the engine off.


Diesel engine overheating is something to never be ignored and may cause damage to many parts of the generator. Always keep your eyes on the temperature gauges and never push the engine beyond its extended limit. Anytime if you see that your vehicle engine is overheated then do one thing shut-down your engine without taking any time.

Some electronic diesel engines automatically turned on to air-cooled at the lowest power to prevent the overheating but this just temporarily for a permanent solution needs to visit a mechanic. And to replace or repair, you may need to pay some costs for it and sometimes need to buy another generator. It may also reduce the life of your generator. This means it stops working before its age limit. So, service and maintain your engine always. As to make it long-lasting.

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