Changing Coolant And Cleaning Cooling System of Shangchai Engine

Shangchai W series diesel engine is the main part of Shangchai generator. The maintenance of it very important for machine maintenance. The coolant system is a crucial part for the machine, in order ensure the engine coolant to be good in cooling and anti corrosion,the replacement of coolant and clearing of cooling system are required every 2,000 hours or 2 years, whichever comes first.

Warning: At operating temperature, engine coolant is hot and under pressure, and coolant steam can cause personal injury. Do not remove the pressure cap on the radiator until the engine stops and coolant temperature goes below 50℃. Slowly unscrew the pressure cap to release the cooling system pressure.

Warning: The anti-rust additive in the coolant contains alkali. Avoid skin contact with it to prevent personal injury.

(1) Stop the engine and wait until the temperature of the coolant falls to below 50℃. slowly unscrew the pressure cap to release the cooling system pressure and remove it. Loosen the drain cock on the radiator to completely drain the coolant in the radiator.

(2) Loosen the water drain cock on the engine (on the fuel pump side and near the flywheel housing), as well as the water drain cock on the water pump, and completely drain the coolant in the cooling system.

(3) Clean the cooling system according to the following steps.

A. Install and screw up all the drain cocks and plug, and add the sodium carbonate solution (or the mixture of sodium carbonate and water that is available in market) into the cooling system from the coolant filter.

Caution: Each 23 L of water should be mixed with 0.5KG sodium carbonate. Do not use caustic cleaner, or it will do harm to aluminum parts.

Caution: Purge the air in the coolant system while adding the cleaning fluid. Pour the cleaning fluid slowly to avoid air block. The cleaning fluid should be added up to the bottom of the filter in the radiator and wait for about 3-5 minutes for a full purge of air.

B. Start the engine and keep it running for 5 minutes after the cleaning fluid temperature has gone up to above 80℃, then stop the engine and completely drain the cleaning fluid in the cooling system.

Caution: During the whole cleaning process the pressure cap should not be on and the engine runs without the cap on.

C. Add clean water into the cooling system.

Caution: Pour clean water slowly to avoid air block. Clean water should be added up to the bottom of the filter in the radiator and wait for about 3-5 minutes for a full purge of air.

D. Start the engine and keep it running for 5 minutes after the water temperature has gone up to above 80℃, then stop the engine and completely drain the clean water in the cooling system.

Caution: If the discharged water is still dirty, clean the cooling system again according to the aforesaid steps until discharged water becomes clean.

(4) After the cleaning, tighten the water drain cock on the radiator, and tighten the drain cocks on the engine and water pump.

(5) Add coolant. Fill the cooling system with proper coolant. The total engine coolant capacity is 56L.

Caution: The actual amount of coolant should refer to the equipment date.

Caution: Add coolant slowly to avoid air block. Coolant should be added up to the bottom of the filter in the radiator or meet the requirement of the equipment manufacturer. Wait for about 2-3 minutes for a full purge of air.

(6) Install the pressure cap on the radiator, start and run the engine until coolant temperature reaches 80℃, then stop the engine and check and wait until the coolant temperature falls to below 50℃. then open then pressure cap and recheck the coolant level. Supplement properly, if necessary.

Replacing air filter element

(1) Blow off dirt on the filter with compressed air.

(2) Remove the filter cover, remove and scrap the element.

(3) Cover the compressor inlet from inside the air filter body with clean stuff to prevent dirt from entering the intake system.

(4) Clean the inside of the filter body.

(5) Check the new filter element for any defects and remove the covering stuff from the compressor inlet. Install the new element and make sure a sound seal at both ends.

(6) Install the air filter cover and the service indicator.

Caution: Be sure that both end faces of the air filter are reliably sealed without leakage after the air filter element has been changed.