KAWO丨Winter Cold Environment Guide

Winter Cold Environment Guide: Precautions for Using Diesel Generator Sets | KAWO Factory Blog

Entering the winter, low temperatures, freezing weather and cold snaps become the "invisible threats" to diesel generator sets used outdoors or in unheated environments. Problems such as difficult startup, poor fuel combustion, battery failure and component freezing not only cause sudden failures of the unit, affecting normal power supply, but also significantly reduce the service life of the equipment and increase maintenance costs. As a manufacturer specializing in the R&D and production of diesel generator sets, KAWO has compiled this comprehensive guide on precautions for using diesel generator sets in cold winter environments based on years of industry experience, helping you accurately avoid potential risks and ensure stable operation of the equipment in low-temperature conditions.

I. First, Understand: The Two Core Risks of Generator Sets in Cold Winter Environments

The reason why diesel generator sets are vulnerable in winter is mainly the dual impact of low-temperature environment on the "fuel system" and "electrical system" of the unit:

• Startup and Fuel System Risks: Low temperatures will cause diesel oil to become viscous or even freeze, affecting fuel injection and atomization effects, leading to difficult startup, incomplete combustion, increased fuel consumption and reduced power output of the unit. In severe cases, the fuel pipeline may be blocked, resulting in the unit being unable to start normally.

• Electrical System and Component Freezing Risks: The battery capacity of the unit will decrease significantly in low-temperature environments, making it difficult to provide sufficient starting power; electrical components such as wiring terminals and controllers may have reduced performance due to cold, and even short circuits may occur in severe cases. In addition, if there is residual water in the cooling system, it may freeze and expand, causing damage to components such as the water tank and cylinder block.

II. Core Precautions: 3 Key Measures to Ensure Smooth Startup in Winter

Smooth startup is the premise of the normal operation of the generator set in winter. The core is to do a good job in the protection of the fuel system and battery. Focus on starting from three dimensions: "fuel selection and insulation", "battery maintenance" and "pre-startup preparation":

1. Select Appropriate Fuel and Do a Good Job in Fuel System Insulation

This is the basic measure to avoid fuel viscosity and freezing, and the core is to ensure the fluidity and combustion efficiency of diesel oil:

• Choose Winter-Specific Diesel Oil: According to the minimum temperature in the region, select diesel oil with the appropriate label. For example, in areas where the temperature is between -10°C and 0°C, No. 0 diesel oil can be replaced with No. -10 diesel oil; in areas where the temperature is below -20°C, No. -20 or No. -35 diesel oil should be used. Winter diesel oil has better low-temperature fluidity and is not easy to freeze.

• Insulate Fuel Tanks and Pipelines: Wrap thermal insulation materials (such as thermal insulation cotton, aluminum foil thermal insulation tape) around the fuel tank and fuel pipeline of the unit to reduce heat loss and prevent diesel oil from freezing. For units used in extremely cold areas, a fuel tank heater can be installed (many outdoor models of KAWO can be equipped with this accessory) to ensure the temperature of the diesel oil.

• Regularly Check and Replace Fuel Filters: The water and impurities in the fuel are more likely to precipitate in low temperatures, which may block the fuel filter. It is necessary to regularly check the fuel filter, drain the water in the filter in time, and replace the filter element if it is clogged to ensure unobstructed fuel supply.

2. Strengthen Battery Maintenance to Ensure Starting Power

The battery is the key to starting the unit. Low temperature will seriously affect its performance. It is necessary to do a good job in maintenance and thermal insulation:

• Keep the Battery Fully Charged: In winter, the battery should be charged in time after use to avoid power loss. If the unit is not used for a long time, a trickle charger should be used for regular supplementary charging to ensure that the battery is in a fully charged state. A fully charged battery has better low-temperature performance.

• Check Electrolyte Level and Add Antifreeze (for Lead-Acid Batteries): For lead-acid batteries, regularly check the electrolyte level. If it is lower than the standard line, add distilled water in time. In extremely cold areas, battery antifreeze can be added appropriately (follow the battery manual) to prevent the electrolyte from freezing and damaging the battery.

• Do a Good Job in Battery Thermal Insulation: Place the battery in a warm environment as much as possible. If it is installed on the unit outdoors, a battery insulation cover can be installed to reduce the impact of low temperature on the battery. Avoid direct exposure of the battery to cold wind and snow.

3. Do a Good Job in Pre-Startup Preparation to Reduce Startup Difficulty

Scientific pre-startup preparation can effectively reduce the difficulty of starting the unit in low temperatures. The following steps should be followed:

• Pre-Heating Before Startup: Use the pre-heating device of the unit (most KAWO diesel generator sets are equipped with automatic pre-heating functions) to pre-heat the cylinder. The pre-heating time is generally 3-5 minutes. After the pre-heating indicator light goes out, start the unit. For units without a pre-heating device, an external pre-heater can be used.

• Check Before Startup: Before starting, check whether the cooling system is normal, whether there is leakage or freezing; check whether the oil level is sufficient, and use winter-grade engine oil (with lower viscosity, such as 5W-40) to ensure good lubrication at low temperatures; manually turn the crankshaft 2-3 times to check whether the unit is stuck, and at the same time make the engine oil enter the friction surface in advance.

• Correct Startup Operation: When starting the unit, the starting time should not exceed 5 seconds. If it fails to start, wait for 1-2 minutes before starting again to avoid burning the starter motor due to overheating. After starting, let the unit idle for 3-5 minutes to allow the temperature to rise gradually before putting it into load operation.

III. Long-Term Protection: 4 Practical Methods to Ensure Stable Operation in Winter

In addition to ensuring smooth startup, it is also necessary to do a good job in long-term protection during the operation and shutdown of the unit in winter to avoid failures caused by low temperatures. Focus on starting from four aspects: "cooling system protection", "unit thermal insulation", "operation monitoring" and "long-term shutdown protection":

1. Do a Good Job in Cooling System Protection to Avoid Freezing Damage

• Replace Antifreeze in Time: Before the arrival of winter, replace the cooling water in the unit's cooling system with special antifreeze. Choose antifreeze with the appropriate freezing point (the freezing point should be 5-10°C lower than the minimum temperature in the region). When replacing, thoroughly clean the cooling system to remove scale and impurities to ensure heat dissipation efficiency.

• Regularly Check Antifreeze Level and Quality: During winter use, regularly check the antifreeze level in the expansion tank. If it is insufficient, add the same type of antifreeze in time. At the same time, check the quality of the antifreeze. If it appears turbid, discolored or has precipitates, replace it in time to avoid reducing the antifreeze effect.

2. Strengthen Unit Thermal Insulation to Reduce Heat Loss

Proper thermal insulation of the unit can reduce heat loss during operation, improve fuel efficiency, and avoid component damage due to excessive temperature difference:

• Install Unit Insulation Cover: For outdoor units, install a professional unit insulation cover, which can not only keep warm but also prevent wind, snow and cold air from directly eroding the unit. Note that the insulation cover should not block the heat dissipation port of the unit to avoid overheating during operation.

• Insulate Key Components: Wrap thermal insulation materials around key components such as the engine cylinder block, exhaust pipe and water tank to reduce heat loss. For example, wrapping the exhaust pipe with thermal insulation cotton can not only reduce heat loss but also prevent personnel scalding.

3. Strengthen Operation Monitoring to Discover Abnormalities in Time

The working conditions of the unit in winter are more severe, so it is necessary to increase the frequency of operation monitoring to ensure timely discovery and handling of abnormalities:

• Monitor Operating Temperature: During unit operation, closely observe the temperature gauge on the instrument panel to ensure that the engine temperature is within the normal range (generally 80-90°C). If the temperature is too low, check whether the thermal insulation measures are in place; if the temperature is too high, check whether the cooling system is faulty.

• Check for Abnormal Phenomena: During operation, pay attention to whether there are abnormal noises, odors or oil leaks in the unit. If any abnormality is found, stop the machine immediately for inspection. At the same time, check the tightness of the wiring terminals regularly to avoid poor contact or short circuits caused by cold shrinkage and thermal expansion.

4. Special Protection for Long-Term Shutdown in Winter

If the unit is not used for a long time in winter, it is necessary to take comprehensive protective measures to avoid damage caused by low temperature and freezing:

• Drain all the antifreeze or cooling water in the cooling system to avoid freezing and expanding damage to components; drain the diesel oil in the fuel tank and fuel pipeline to prevent diesel oil from freezing and blocking the pipeline.

• Remove the battery and store it in a dry and warm indoor environment. Regularly supplement charging to avoid battery damage due to low temperature and power loss.

• Cover the unit with a waterproof and dustproof insulation cover to prevent wind, snow and cold air from eroding the unit. Before covering, clean the surface of the unit to remove dust and oil stains.

IV. KAWO Warm Reminder: Common Misunderstandings in Winter Use Should Be Avoided

• Misunderstanding 1: Using open fire to heat the fuel tank to melt frozen diesel → Correct approach: Using open fire to heat is extremely dangerous and may cause fuel combustion and fire. The correct method is to use a special fuel tank heater or replace it with winter-grade diesel oil.

• Misunderstanding 2: Immediately putting the unit into full load operation after startup → Correct approach: After startup in winter, the unit temperature is low. Immediately putting it into full load operation will increase the load on the engine and easily cause wear of parts. It should idle for 3-5 minutes first, and then put it into load operation after the temperature rises.

• Misunderstanding 3: Ignoring the replacement of engine oil in winter → Correct approach: Ordinary engine oil has poor fluidity at low temperatures, which will affect lubrication. It is necessary to replace it with winter-grade engine oil with appropriate viscosity to ensure good lubrication of the unit at low temperatures.

The key to using diesel generator sets in cold winter environments is "prevention first". By selecting appropriate fuels and lubricants, strengthening the maintenance of batteries and cooling systems, and doing a good job in thermal insulation and pre-startup preparation, potential risks can be effectively avoided, and the unit can operate stably and reliably. If you encounter problems in the winter use of the unit, or need to understand the relevant information of KAWO generator sets suitable for low-temperature environments, please feel free to contact our technical team, who will provide you with professional solutions.

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