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Inspect and Repair Volvo Diesel Generator Intercooler

Aug. 25, 2021

The Volvo diesel generator intercooler is installed together with the water tank radiator and installed in front of the engine. It is cooled by the suction fan and the wind from the car. Poor cooling of the intercooler will result in insufficient engine power and increased fuel consumption. The intercooler should be inspected and maintained regularly, the main contents are:

1. External cleaning (car cleaning method)

Since the Volvo diesel generator intercooler is installed at the front, the radiator fin passage of the intercooler is often blocked by leaves, sludge (hydraulic oil overflowing from the steering oil tank), etc., which hinders the heat dissipation of the intercooler, so the place should be fixed regularly. Clean. In the process of air being sucked into the turbocharger, the airflow encounters a large resistance, and the negative pressure of the compressor intake is too high. The lubricating oil is sucked into the compressor and enters the combustion chamber along with the compressed air for combustion. Causes include clogging of the air filter, fouling of the compressor or intercooler, long-term idling of the diesel engine or low-speed blocked load operation.

The method of cleaning is to use a water gun with a pressure that is not too high to flush slowly from top to bottom or bottom to top at an angle perpendicular to the plane of the intercooler, but it must not be flushed diagonally to prevent damage to the intercooler.

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2. Internal cleaning and inspection (disassembly, inspection and cleaning method)

The internal pipes of Volvo diesel generator intercooler are often accompanied by sludge, gum and other dirt, which not only narrows the air flow channel, but also reduces the cooling heat exchange capacity. For this reason, maintenance and cleaning are also necessary. Generally, the interior of the intercooler should be cleaned and inspected every year or when the engine is overhauled or the water tank is welded and repaired.

There is a phenomenon that has attracted the attention of maintenance personnel, that is, when the diesel engine of Volvo diesel generator accelerates to high speed, some black smoke is emitted from the exhaust pipe, and there is a slight air leakage sound when idling. Check the source of the air leakage. It turned out that the air inlet hose of the intercooler (supercharger-intercooler) was cracked, causing air leakage, especially during high-speed operation, a large amount of high-pressure gas from the turbocharger leaked from the gap in the hose. The amount of air entering the cylinder from the chamber decreases, which affects the power output of the diesel engine. Causes poor acceleration at medium and high speeds.

Cleaning method: add 2% soda ash aqueous solution (temperature should be 70-80℃) into the intercooler, fill it up, wait for 15 minutes to see if there is any leakage in the intercooler. If necessary, it should be disassembled and inspected and repaired by welding (the same as repairing the water tank); if there is no leakage, shake it back and forth, repeat several times, pour out the lotion, and then fill it with a clean aqueous solution containing 2% soda ash to rinse. Until it is relatively clean, add clean hot water (80-90℃) for cleaning until the released water is clean.

If the Volvo diesel generator intercooler is stained with oil, it can also be cleaned with alkaline water. The method is: soak the oil in lye and remove it with a brush until it is clean.

After cleaning, use compressed air to dry the water in the intercooler of Volvo diesel generator or let it dry naturally. When there is no moisture in the air port, connect the engine intake pipe. If you find that the intercooler core is seriously dirty, you should carefully check where there are leaks in the air filter and the air intake pipes, and eliminate the fault.

Starlight Power was founded in 1974 and is one of the earliest manufacturers of generators and diesel generator sets in China. If you want get more information, please feel free to send email to sales@dieselgeneratortech.com we will pay highly attention on your question.

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