Operating diesel generator sets in cold weather puts extra demands on the engine and supporting systems. Even reliable Perkins engines can face starting difficulties due to reduced fuel atomization, low combustion efficiency, over-cooled cylinders, and weaker battery output. At –17°C, starting a diesel engine can be up to five times harder than at 26°C. Proper winter maintenance is essential. While startup procedures are similar across different engine brands, we will use Perkins engines as an example to show how to do the operation and maintenance.
1. Fuel System: Ensuring Fuel Flowability in Cold Conditions
✅ Perkins Recommended Practices
· Use winter-grade or low-pour-point diesel fuel suitable for local ambient temperatures to prevent fuel waxing and blockage of fuel lines and filters.
· Store diesel fuel in clean, temperature-controlled environments whenever possible to minimize condensation caused by temperature fluctuations.
· Drain water from the fuel filter and water separator daily, preferably after engine shutdown, to prevent freezing within the fuel system.
· Fill the fuel tank at the end of each operating day to reduce air space and minimize condensation formation.
❌ Practices to Avoid
· Neglecting the fuel filter. Fuel filters are among the most vulnerable components to waxing and blockage in cold weather.
· Failing to drain water from the fuel/water separator, which can freeze and interrupt fuel supply.
2. Filtration System: Preparation Before Cold Weather Arrives
✅ Perkins Recommended Practices
· Replace fuel filters before the onset of winter to reduce the risk of filter freezing or blockage.
· Ensure genuine Perkins or specification-approved spare filters are available on site. In cold conditions, replacing a filter is far safer and more efficient than attempting to thaw frozen components.
3. Lubrication System: Selecting the Correct Low-Temperature Oil
✅ Perkins Recommended Practices
· Select low-viscosity, multi-grade engine oil strictly in accordance with Perkins technical manuals to ensure adequate lubrication during cold starts.
· During startup at low temperatures, internal engine friction is at its highest; proper oil flow is critical to minimizing wear and extending engine life.
❌ Practices to Avoid
· Do not use engine oil with a viscosity below Perkins’ recommended specifications, as overly thin oil may fail to provide adequate protection at normal operating temperatures and high loads.
4. Cooling System: Maintaining Adequate Freeze Protection
✅ Perkins Recommended Practices
· Use a coolant hydrometer to check antifreeze concentration and ensure the water-to-ethylene-glycol ratio matches the lowest expected ambient temperature.
· Perkins-approved coolant not only lowers the freezing point but also protects against internal corrosion and improves overall system reliability.
❌ Practices to Avoid
· Never top up the cooling system with plain water. Always use a properly mixed coolant solution to prevent freezing and damage to the engine or radiator.
5. Generator Set Storage and Starting: Protection and Preheating
✅ Perkins Recommended Practices
· Whenever possible, install or store the generator set in a sheltered or enclosed generator room, protected from extreme cold, wind, and snow.
· In cold or extremely cold regions, the following are strongly recommended:
Engine block heaters
Coolant heaters
Battery heaters or insulation systems
These measures ensure the generator set is ready for immediate and reliable startup.
❌ Practices to Avoid
· Unless the engine is equipped with a Perkins-approved starting aid system, avoid the use of starting fluid. Improper use can cause backfire, engine damage, and serious fire or explosion hazards.
· Do not neglect battery maintenance. After high-temperature summer operation, batteries may already suffer from corrosion or electrolyte loss, and cold weather further accelerates performance degradation, increasing the risk of starting failure.
Conclusion
Reliable winter operation of Perkins diesel generator sets depends on systematic preparation and strict adherence to OEM guidelines. The core principles are:
Prevent waxing and freezing, prepare in advance, and follow Perkins-approved maintenance practices.
By properly maintaining the fuel, lubrication, cooling, electrical, and starting systems, Perkins diesel generator sets can deliver stable, efficient, and dependable performance throughout the winter season—providing continuous power for critical applications.
