Problems and Solutions of Diesel Generator Oil Cooler

The oil cooler serves to cool the lubricating oil and maintain the oil temperature within the normal operating range. For high-power enhanced engines, due to the high thermal load, it is necessary to install an oil cooler. When the engine is running, the oil viscosity becomes thinner as the temperature rises, reducing the lubricating capacity. Therefore, some engines are equipped with oil coolers to lower the oil temperature and maintain a certain viscosity of the lubricating oil. The oil cooler is arranged in the circulating oil path of the lubrication system.

If the oil cooler is damaged and not replaced in time, it will lead to serious consequences. At this time, the engine oil will continue to be at a high temperature, and the system will issue an alarm of excessive oil temperature. If the diesel generator set continues to be used in this situation, the oil will not be able to effectively lubricate the internal parts of the engine, which will cause increased wear of the internal engine parts, greatly reduce the performance of the engine, shorten the service life of the engine, and in severe cases, cause damage to the engine, according to Dingbo Power, a generator manufacturer.

The oil cooler of Yuchai diesel generators is prone to failures such as steel pipe rupture, cracks in the front and rear covers, and blockage inside the sealed steel pipes during operation. No matter which part of the diesel generator set fails, it is important to find out the cause of the failure so that the failure can be eliminated according to the cause!

1. Steel Pipe Rupture and Cracks in Front and Rear Covers

Most of the failures such as steel pipe rupture and cracks in the front and rear covers are caused by the operator not draining all the cooling water inside the diesel generator set body in winter. When the above parts are damaged, oil will enter the water cooler during the operation of the diesel generator set, and cooling water will enter the oil in the oil pan. When the diesel generator set is running, if the oil pressure is greater than the cooling water pressure, the oil will flow into the cooling water through the holes in the core, and the oil will enter the water cooler with the circulation of the cooling water.

When the diesel generator set stops running, the water level of the cooling water is high, and its pressure is greater than the oil pressure, causing the cooling water to flow into the oil through the holes in the core, and finally enter the oil pan. If the operator fails to detect this fault in time, the lubricating effect of the oil will be lost as the diesel generator set continues to run, and finally lead to accidents such as bearing bush burning of the diesel generator set.

2. Blockage of Individual Copper Tubes Inside the Cooler

After individual copper tubes inside the cooler are blocked by scale and impurities, it will affect the cooling effect of the oil and the circulation of the oil, so regular cleaning is required.

3. Troubleshooting of Oil Cooler Blockage in Diesel Generator Sets

Methods such as soaking in acetic acid solution are used to remove the scale on the surface of the heat-conducting core of the cooler. Then, diesel oil is injected into the heat-conducting core of the cooler, and the oil cooler is repeatedly soaked and cleaned, and the oil passage is cleaned to eliminate the fault.

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