In today’s fast-paced world, warehouses work 24/7 to meet increased customer and business demands. This increase in demand and round-the-clock work cycles take a toll on the workers and equipment, and industrial engines are one of the most common causes of failure.

With proper maintenance, you can optimize productivity and increase safety measures. However, industrial engines are susceptible to wear-and-tear issues that can disrupt operations and impact overall efficiency like any complex machinery.

5 Common Engine Problems And Ways To Troubleshoot Them

Engine diagnostics is one of the most crucial elements to keep your warehouse or industry running like a well-oiled machine. Often, these engines can develop common problems due to constant usage or wear and tear.

Here are the top 5 most commonly faced issues with industrial engines and how to troubleshoot them:

1. Issues With Ignition

The most common issue with industrial engines is difficulty starting, which can be due to intermittent engine stalling or the engine not working at all.

If you encounter this issue, here are some quick steps to follow:

  1. Check the battery to ensure that it is connected and working correctly.
  2. Inspect spark plugs, as old or worn-out ones can often cause ignition problems. If needed, replace them.
  3. Check the fuel supply. If adequate, check for fuel line clogs or blockages.
  4. Finally, check the ignition system, as a faulty ignition coil can often lead to ignition issues. If needed, this will need to be replaced.

2. Issues With Engine Heating

The second most common issue is engine overheating. This can be seen with the temperature Gaude showing overheating, steam or coolant leakage, or foul smell emitting from the engine.

If you encounter these issues, follow the steps below:

  1. Ensure the coolant reservoir is filled to the recommended level. Top up or replace coolant if needed.
  2. Look for leaks, damaged hoses, or a malfunctioning thermostat. Repair or replace components as necessary.
  3. Dust and debris can obstruct airflow, causing overheating. Clean the radiator and cooling fins for improved efficiency.
Engine Troubleshoot

3. Issues With Exhaust Smoke

If you are using a diesel generator engine, the emission of black smoke can be a common issue. Many times, engine accumulations in critical areas can lead to increased smoke, and this can be due to:

  1. Continuous running
  2. The diesel used is not from a refinery with special detergent packages already added

The easiest way to resolve this is to regularly add a detergent additive to the diesel fuel and clean out any deposits to extend the life of the diesel engine.

4. Issues With Engine Oil Levels

Another common issue is decreased oil levels or visible oil leaks. These should not be dismissed as minor, as it can eventually lead to significant issues.

If you notice this issue, follow the steps below:

  1. Look for oil stains and use UV dye if needed to identify the source of the leak.
  2. Worn-out gaskets or seals can cause oil leaks. Make sure to replace them to prevent further oil loss.
  3. Ensure the drain plug is properly tightened to prevent oil seepage.
Generator

5. Issues With Engine Noise

Have you noticed an increase in engine noise? Although most industrial engines tend to be loud, they need to be within the range of 75 – 85 DB (A) at one meter, as higher sound levels can impact the quality of human hearing.

As per OSHA (Occupational Safety and Health Administration), continuous exposure to loud noise levels can lead to permanent hearing loss, posing a serious health risk for your workers.

It is time to fix if you notice strange noises from your engine or an increase in overall sound levels. Make sure to follow the steps below:

  1. Use a sound level meter to measure the engine noise levels accurately and determine if they exceed the allowed limits.
  2. Inspect the engine components to identify any worn-out, loose, or damaged parts contributing to the excessive noise.
  3. Check for leaks or damages in the exhaust system, including the muffler and catalytic converter, and repair or replace them as needed.
  4. If required, install noise-dampening materials in the engine compartment and other areas prone to noise transmission to reduce overall noise levels.
Engine Troubleshoot

Remember that if the problem persists despite diagnostic checks, the ideal option is to work with a mechanic and fix it on time. 

Conclusion

It is crucial for your workers and staff to always be careful about how they use the generator engine. If the engine is older or has undergone continuous usage, it is bound to develop some issues.

Engine damage is, at times, unavoidable. But with timely assessment and safety inspections, most common issues can be resolved before they become a major hassle.

By working closely with specialists and experts, you can help increase your engine’s life and keep it running optimally. Get in touch with Mid-America Engine for any technical support. You can email or call us for a one-on-one conversation with our experts.

Mostly Asked Questions on Common Engine Problems & Troubleshooting

1. What are some common signs of engine problems?

Although there are several signs of engine problems, some common signs include sudden rattling or knocking noises, decreased performance, rough idling, excessive exhaust smoke, illuminated check engine light, and engine overheating.

2. What can I do if there are strange noises from the engine?

If you notice a sudden change in the engine noise, check for any over-the-top issues. This could be worn-out components, loose parts, or some issues with the combustion. You can stop the engine and try rerunning it, and if the noise persists, get it checked thoroughly.

3. Why is my engine emitting excessive smoke?

If your engine emits excessive smoke, it can indicate issues like burning oil (blue smoke), coolant leakage (white smoke), or a rich fuel mixture (black smoke) in the engine.

4. What are the potential reasons behind engine overheating?

Several reasons, including a faulty cooling system, low coolant levels, a malfunctioning thermostat, or a clogged radiator, can cause engine overheating.

5. What should I do if my engine experiences a sudden loss of power?

If your industrial engine is used for long periods or is old, sudden loss of power to the engine is a common problem. Check for issues like a clogged fuel filter, a failing fuel pump, or problems with the air intake system. Address the specific cause to restore engine power.