PowerBook running warm/hot & fans almost always running

Does anyone else have their fan(s) constantly running? I can be doing something as simple as checking my e-mail on a flat table like surface and before I know it both fans are running. Back a couple years ago Apple replaced my fan under the screen under AppleCare, now it is buzzing again and being out of AppleCare coverage I'm not rushing to have it replaced. Any ideas why my book's fans are always running? Anyone else have this?

Hi, PBJohn. Assuming for the moment that your hardware is working properly and your fans are running to remedy an excessive heat buildup, plausible reasons for the heat might include:
1. accumulated dust and crud inside the Powerbook, obstructing the fans and/or the cooling airways;
2. multiple CPU-intensive processes running at once, including processes running in the background that you've forgotten or never known about;
3. insufficient heat-transfer paste between the processor and the heat sink;
4. lack of routine maintenance and periodic cache cleanup;
5. an overly full hard drive;
There are probably others I'm forgetting, but this list gives you some things to check.
For 1, flip back the keyboard and blow the interior out with compressed air, then remove the bottom panel and do the same to the underside of things. Make sure the air intake and outlet vents are unobstructed.
For 2, open Activity Monitor and see what's running. If you have Tiger installed, turn off Widgets — they're incredibly CPU-intensive. Drive indexing can also consume a lot of CPU cycles and produce constant hard drive activity.
3 is quite unlikely, unless you've dismantled the Powerbook and separated the processor and heat sink yourself, wiping off the transfer paste and then forgetting to apply any when reassembling.
For 4, run the background maintenance tasks manually and/or download Onyx and use it to run them and clean the various caches.
Mac OS X: How to force background maintenance tasks (logs and temporary items)
For 5, make sure your hard drive has at least 3GB and preferably at least 5GB of free space available at all times.
If you check on all these things and still can't reduce the constant operation of your fans, you may have a hardware problem.

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