During the use of water-cooled diesel generators, radiator overflow faults often occur. The main reasons are as follows:

(1) Aging and damage of cylinder gasket

When there is a slight wound on the cylinder gasket near the engine combustion chamber, the outflow situation is not as obvious as when the cylinder gasket is pushed. At the same time, after the cylinder gasket is pushed, the radiator not only flows out, but also the oil deteriorates due to water seepage, which is conducive to judgment. After slight damage to the cylinder gasket, only when the cylinder is in operation will it generate strong explosive force, causing high-pressure gas to seep into the water channel. The negative pressure generated during the intake process is not enough to suck water into the cylinder from the waterway, and only the radiator overflows without obvious deterioration.

(2) The sealing sleeve of the fuel injector is not tightly sealed or cracked

There is a waterproof sleeve between the fuel injector and the cylinder head. The waterproof sleeve is connected to the waterway, and the sealing is operated with a rubber sealing ring. After a period of operation, it is mainly due to the oxidation of the cylinder head, small gaps at the connection between the water jacket and the cylinder head, or abnormal sealing caused by rubber oxidation. The mixed gas in the combustion chamber infiltrates the channel through tiny gaps, which can easily cause water to flow out of the radiator.

(3) Malfunction of temperature regulator

The coolant can be divided into large circulation and small circulation. In the early stage of diesel engine start-up, when the coolant temperature is below 90 ℃, the thermostat closes. When the set temperature is exceeded, the thermostat opens and the water circuit circulates twice. That is to say, the flow rate of the temperature regulator varies depending on the temperature. Due to long-term use, after two thermostats rusted, the large circulation water circuit was completely opened; In addition, due to the small cross-sectional area of the small circular water circuit and the high resistance of water flow, the vast majority of water relies on the large circular water circuit (this situation becomes more apparent after the refueling door), causing water to flow out of the radiator. This phenomenon is rare in domestic machines, and in summer, domestic machines sometimes manually remove the thermostat to prevent overheating, so that the radiator does not overflow.

(4) The pump cylinder head has cracks

When the pump is working, if there are hidden injuries or small cracks, compressed air enters the water channel through the cracks and then overflows from the radiator; When the accelerator suddenly increases, this phenomenon becomes more pronounced, with the illusion of a radiator boiling.

(5) Oil cooler malfunction

The oil pressure inside the oil cooler exceeds the pressure of the water outlet. There may be two types of malfunctions in the oil cooler: 1. Cracks or sand holes in the radiator core; 2. The rubber sealing ring at the interface between the radiator core and the cylinder oil circuit is not tightly sealed. So, when the engine oil enters the water, too much engine oil will overflow from the radiator (this situation is easier to determine because organic oil containing water will overflow from the radiator, and the engine oil will only decrease and not deteriorate).

(6) Excessive dirt on the radiator

The upper and lower chambers of the radiator are connected by several water distribution pipes. If not used carefully, there will be a lot of accumulated dirt in the radiator, which can easily cause the water distribution pipe to be blocked. When the engine is at high speed, some of the water will flow into the small circulation after being pumped, and a part of it will flow into the radiator for water supply. But due to the blockage of the water distribution pipe, water overflowed from the upper water chamber. At this point, when used to individually touch the radiator, a noticeable temperature difference will be observed. When discharging, simply disassemble the radiator and unclog the drainage pipe; Or add vinegar to the radiator and let the engine run for 5 minutes before changing the water. After several cycles, the radiator can be cleaned thoroughly. This method is convenient and cost-effective.

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