Cooling

Cooling System................................... 14-1

Overview.......................................... 14-1
Cautions........................................... 14-3
Component drawing......................... 14-4
Inspection and adjustment............... 14-5
Auxiliary Water Tank........................... 14-8
Overhaul........................................... 14-8
Water level sensor.......................... 14-10
Coolant ...............................................14-11
Replacement.................................. 14-11
Radiator.............................................. 14-13
Overhaul......................................... 14-13
 Cooling - Cooling System 14-1

Cooling System
Overview
The function of diesel engine cooling system is to diffuse the residual heat absorbed by
components during diesel engine combustion using cooling medium - coolant to ensure
normal operation of heated parts under allowable temperature conditions. For diesel en-
gine cooling, it requires proper cooling and not “The cooler, the better”. Over-cooling will
exert adverse impact on diesel engine operation: 1. It causes too low temperature inside 14
the cylinder and that will extend fuel ignition delay, reduce combustion speed and increase
heat loss; 2. It may cause rough work of diesel engine, increase fuel consumption; 3 It may
increase viscosity of lubricating oil, cause friction power loss of moving parts resulting in
the decrease of diesel engine power. Therefore, only proper cooling can guarantee normal
operation of diesel engine and excellent economy.
Using plain water to substitute coolant is prohibited, as the heat conductivity of water scale
building up after heating is 40 times different from iron casting, and the water scale depos-
ited on water jacket will decrease the performance of engine cooling system. Especially
when the water scale blocks the throttling orifice, the rational water flow will be destructed
and causes failures and damages.
Engine cooling system is composed of water pump, radiator, fan, thermostat, auxiliary wa-
ter tank, cooling pipe and water channels for cylinders and cooling water cavity for crank-
case.
Cylinder head

Expansion
water tank

Thermostat Radiator
Machine body

Bypass
Cylinder main water return passage

Cylinder sub water passage

Air compressor Oil cooler Water pump

fhwx140009
 14-2 Cooling - Cooling System

Radiator
The function of the radiator is to pass the heat absorbed by coolant from heated parts to
air and dissipate it into the atmosphere in order to decrease coolant temperature.
Auxiliary water tank
The function of the auxiliary water tank is to eliminate part of the vapor from the low pres-
sure section of cooling system in order not to cause air stuck and to replenish coolant. The
internal pressure of the auxiliary water tank should be kept at 50kPa and placed higher
14 than diesel engine and radiator.
All water tank covers of cooling system should be kept intact, do not open. Maintaining
50kPa of internal pressure in cooling system may increase the cooling effectiveness of
cooling system and keep it from boiling.
 Cooling - Cooling System 14-3

Cautions
1. Do not open pressure cap when the engine is still hot. Wait until coolant temper-
ature drops to below 50℃ , then open the pressure cap, or the high temperature
coolant or vapor will eject out and cause personal injury.
2. Use a special container to collect residual coolant when disconnecting cool-
ant system pipelines. If the residual coolant is not used any longer, dispose as
waste.
14
3. Do not allow any chip get into cooling system pipeline when disconnecting cool-
ing system pipelines, or it may damage cooling system and engine.
4. At disconnection of cooling system pipeline joints. To prevent dirts or foreign
objects from entering, special plugs must be used to seal ports of pipes.
5. Coolant contains harmful substance to human body. Keep it away from children
and pets if it is not used any more, and disposed as waste.
6. Different anti-freeze solution brands have different formula, if mix together,
chemical reactions may occur between additives and additives may become de-
fective.
7. The effective period for an anti-freeze solution is two years, confirm the effec-
tiveness before use.
8. It must be replaced periodically, usually 2 years.
9. Completely drain out the existing solution and clean cooling system thoroughly,
then replace with new solution.
10. Avoid add water in the solution. Conventional non-organic anti-freeze solution
is not mixable with water as it may produce sedimentation and influence the
normal function of anti-freeze solution adversely. Organic anti-freeze solution is
mixable with water, but not excessively.
11. When the temperature is below 0℃ , check the density of the anti-freeze solution
periodically.
12. Be careful when using silicon oil clutch fan. Do not lay it horizontally when the
fan is removed, otherwise the silicon oil may leak out from the fit clearance of
the sensor shaft resulting in failure of fan.
13. Coolant exhaust: at first filling of the anti-freeze solution (or replace), fill in
slowly and evenly (10lit./min is suggested). Start engine to exhaust (about 30
min, max. engine speed, water temp. 93±2℃ ), the water level in auxiliary water
tank will drop and needs to shutdown engine and refill to Max mark and vent
air again. When the water level is stabled and not dropping any longer, refill the
water level to MAX mark again then the vehicle may be used; or it may cause en-
gine and radiator damage.
 14-4 Cooling - Cooling System

Component drawing

14 2

9
7
8 8
4
10
12
11
13
14

10
6
10
15
16

1 Radiator and shroud assembly 10 Worm transmission hose clamp, type A

Hexagon head bolt, spring washer and 11 Engine water supply hose
2
flat washer combination Hexagon head bolt, spring washer and
12
3 Auxiliary water tank assembly flat washer combination
4 Heat insulating pad clamp 13 Clamp
5 Radiator wind screen assembly 14 Water pipe fixing bracket 3
6 Engine water supply hose 1 Auxiliary water tank moisturizing steel
15
7 Radiator degassing hose pipe
8 Worm transmission hose clamp, type A 16 Hexagon flange nut
9 Engine degassing hose
 Cooling - Cooling System 14-5

Inspection and adjustment

Fan
Manual test method: start engine, rotate for several minutes, then stall and turn the fan
with hand. If it is disengaged, and the fan turns, it indicates the silicon fan is good. Excep-
tion dose exists: the fan will not turn at low temperature and silicon oil is unable to return
immediately, it dose not always indicate that the fan is damaged. Starting engine and try
another time, run 1-2min at medium speed at low temperature, turn the fan with hand. If
14
it turns freely, it indicates that the silicon oil fan is good. When the temperature reaches
88℃ , shutdown the engine and turn the fan with hand, if ti does not turn, it indicates that
the silicon oil fan works normal; otherwise it indicates that the silicon oil fan is defective.

1 Fan 3 Thermometer
2 Radiator 4 Baffle plate

Dynamic test: Place a thermometer (with temperature range from - 18 ~ 105 ℃ ) in front of
the radiator. Place a plastic plate in front of the radiator to stop air flowing pass radiator. Make
sure the plate will stop the air. If an air conditioner is installed, its switch must be turned off.
Align timing lamp with fan blade, start engine and run at 2400r/min rotation speed. The air
temperature indication on dial thermometer should reach to 88℃ within 10 minutes. The ideal
engaging of fan clutch should be before 88℃ . Observe increase of fan speed.
After the air temperature reaches to 88℃ , take away the plastic plate, air temperature will
start falling. The ideal silicon oil fan clutch will make the air temperature to decrease by 11
more degrees, meanwhile the sound of air flow may be heard reduced. If the fan clutch
dose not meet the above requirement, replace silicon oil fan clutch assembly.
 14-6 Cooling - Cooling System

Water pump
Hot anti-freeze solution may be smelt in case cooling system leakage, an inspection must
be carried out to find out if the cooling water is leaking out from the water pump shaft seal-
ing. A small mirror and light may be used to check if the water pump air venting hole is
leaking water. Service periodically, pay attention to the loss of the anti-freeze solution in
water tank.
The severity of cooling system leakage should not be underestimated, it will not only de-
14 stroy the preset coolant flow pattern by intruding air resulting in hot spot but also will great-
ly corrode the water pump.
If the coolant is constantly insufficient, it may cause overheating of the engine accompa-
nied with vapor corrosion. And it will not only damage the radiator but also cause other wa-
ter pump problems.
When red color is notice in coolant, like iron rust, it is estimated that the blade wheel corro-
sion may have happened. Inspection of coolant circulation in water pump is required at this
situation. Drain a part of coolant in radiator and keep water level just above the water pipe,
then pre-heat engine and place the thermostat in fully open position. Good water circula-
tion should be observed at 3000r/min of engine rotation speed.
Thermostat
The safety service life of pellet type thermostat is usually 50000km drive mileage, therefore
it is required to replace the thermostat according to its safety service life.
1. Inspection of thermostat
(a) Both thermostat and thermometer may be put
into hot water.
(b) Check the opening temperature of the main
valve of thermostat .
(c) In case any one item is beyond the specified
fhwx140018 value, replace the thermostat.

Opening temperature Full opening temperature

80±2 ℃ 95 ℃

Water pipe
Check water pipe for foreign objects clogging, bulges and season cracking, check water
pipe joints for security of connections.
Auxiliary water tank
Check auxiliary water tank for cracks,; check water pipe of auxiliary water tank for bulges
and season cracking; check auxiliary water tank cover for completeness and free of dam-
ages.
Coolant
When engine runs at idle speed and pre- heats to normal working temperature, the coolant
level in the bottle is just between minimum mark and the maximum mark, as it is shown on
the tank. Use freezing point meter to test the density of coolant.
 Cooling - Cooling System 14-7

Radiator
Fill in hot water into the radiator, observe water flow for smoothness. If it is not smooth, it
indicates that the interior of the radiator is clogged. Flush the exterior of the radiator, and
wash the interior of the radiator with hot water. If the water scale still exists after washing,
a soft metal cleaning rod may be used to clean up the deposited dirt and wash clean us-
ing above steps. Remove broken fan blades in cooling pipe with long nose pliers, cut down
broken cooling pipe, insert cleaning rod from the end of the core, pass through the upper
and lower ports of cut section and flatten the edges. Cut a piece of usable cooling pipe the 14
same size as the cut piece from an old cooling pipe and solder weld the upper and lower
ports. Insert resistance heater into the cooling pipe to be replaced and apply 24V of power.
When the resistance fuse turns to red, the solder on cooling pipe will melt and disengage.
Cutoff the power, take out the cooling pipe together with the resistance heater replace with
new cooling pipe and weld securely. Place a radiator detector at radiator port cover, check
the leakage of the cooling system. Apply 150kPa pressure to the radiator, check the leak-
age of coolant under normal working temperature. In case of a leakage, repair.
 14-8 Cooling - Auxiliary Water Tank

Auxiliary Water Tank

Overhaul
△ Hint:
Component drawing, refer to Chapter 14 Cooling - Cooling System, component
drawing
1. Drain coolant, refer to Chapter 14 Cooling - Coolant, replacement
14
2. Lift up the cab
3. Remove auxiliary water tank
(a) Disconnect auxiliary water tank harness.

fhwx140001

(b) Open auxiliary water tank

Note:
Do not open pressure cap when the engine is
still hot. Wait until coolant temperature drops
to below 50℃ , then open the pressure cap, or
the high temperature coolant or vapor will eject
out and cause personal injury.
fhwx140002

(c) Disconnect the water pipe of the auxiliary wa-

ter tank.
Note:
To prevent dirts or foreign objects from enter-
ing, special plugs must be used to seal ports
of pipes at disconnection of cooling system
pipeline joints.
fhwx140003

(d) Remove auxiliary water tank fixing bolts.

fhwx140004
 Cooling - Auxiliary Water Tank 14-9

4. Check auxiliary water tank, refer to Chapter 14 Cooling - Cooling System, in-
spection and adjust
5. Install water tank
(a) Fit in auxiliary water tank fixing bolts.
Torque: 20N•m

14

fhwx140004

(b) Connect water pipe of auxiliary water tank.

fhwx140003

(c) Fill in coolant, refer to Chapter 14 Cooling-

Coolant, replacement
Note:
The coolant in auxiliary water tank should be
filled to the level between MIN mark and MAX
mark, try to be close to the MAX mark.
(d) Tighten auxiliary water tank cover.

fhwx140006

(e) Connect auxiliary water tank harness.

Note:
After installing auxiliary water tank, run the en-
gine to check for coolant leakage.

fhwx140006

6. Lower the cab cover

 14-10 Cooling - Auxiliary Water Tank

Water level sensor

Replacement
1. Remove water level sensor
(a) Disconnect auxiliary water tank harness.

14

fhwx140001

(b) Remove water level sensor.

fhwx140005

2. Install water level sensor

(a) Fit the water level sensor to its proper posi-
tion.

fhwx140005

(b) Install auxiliary water tank harness.

fhwx140001
 Cooling - Coolant 14-11

Coolant
Replacement
1. Drain coolant
(a) Disconnect the inlet water hose and air outlet
hose of the radiator.
Warning: 14
Do not disconnect the inlet water hose of radi-
ator when the engine is hot. Wait until coolant
temperature drops to below 50℃ , then discon-
fhwx140007
nect the inlet water hose of the radiator, or the
high temperature coolant or vapor will eject
out and cause personal injury.
Note:
At the disconnection of pipe joints of cooling
system. To prevent dirts or foreign objects
from entering, special plugs must be used to
seal ports of pipes.
(b) Remove the radiator drain bolt, drain the cool-
ant.
Note:
Coolant is toxic. If it is not used any longer,
keep it away from children and pets and dis-
pose as waste.

fhwx140008

(c) Loosen auxiliary water tank cover.

(d) Disconnect the water pipe of the auxiliary wa-
ter tank.
Note:
At the disconnection of pipe joints of cooling
system. To prevent dirts or foreign objects
from entering, special plugs must be used to
fhwx140002
seal ports of pipes.
Note:
Coolant is toxic. If it is not used any longer,
keep it away from children and pets and dis-
pose as waste.
 14-12 Cooling - Coolant

2. Fill in the coolant

(a) Connect the inlet water hose of the radiator.

14 fhwx140007

(b) Fit in drain bolt of the radiator.

fhwx140008

(c) Connect the water pipe of the auxiliary water

tank.
(d) Fill in coolant.
Note:
The coolant in auxiliary water tank should be
filled to the level between MIN mark and MAX
mark, try to be close to the MAX mark.
fhwx140006
(e) Tighten auxiliary water tank cover.

Note:
Different anti-freeze solution brands have different formula, if mix together, chemical
reactions may occur between additives and additives may become defective, so dif-
ferent brand of anti-freeze solution should not be mixed together and used.
Note:
The effective period for an anti-freeze solution is two years, confirm the effective-
ness before use.
3. Check coolant level
(a) Run the engine, check engine coolant level.
(b) In case the level is too low, refill coolant.
Note:
After installing auxiliary water tank, run the engine to check for coolant leakage.
 Cooling - Radiator 14-13

Radiator
Overhaul
△ Hint:
Component drawing, refer to Chapter 14 Cooling - Cooling System, Component
drawing
1. Drain coolant, refer to Chapter 14 Cooling- Coolant, replacement 14
2. Recollect refrigerant
3. Remove fan shroud
(a) Remove upper left fixing bolt on the fan
shroud.

fhwx140010

(b) Remove the lower left fixing bolt on the fan

shroud.
△ Hint:
The steps for right side fixing bolts removal at
the same as for the left side.

fhwx140016

4. Remove intercooler.
(a) Remove the upper left fixing bolt on the inter-
cooler.

fhwx140012
 14-14 Cooling - Radiator

(b) Remove the lower left fixing bolt on the inter-

cooler.

fhwx140011
14

(c) Remove the right side fixing bolt on the inter-

cooler.

fhwx140020
fhwx140014

(d) Remove the fixing bolts of the high pressure

pipe and low pressure pipe of the air condi-
tioner.

fhwx140013

(e) Remove the fixing bolts of warm air water

pipe.

fhwx140014
 Cooling - Radiator 14-15

(f) Remove the lower fixing bolts of the water

tank.
△ Hint:
There are three fixing bolts at the lower side.

fhwx140012 14

5. Check radiator, refer to Chapter 14 Cooling - Cooling System, overhaul

6. Install radiator
(a) Install radiator
• Put in the radiator downwardly.
• Install the fixing bolts to the lower side of the
water tank.
Torque: 23±2N•m
fhwx140012

(b) Fit in the fixing bolts of the warm air water tank
bracket.
Torque: 23±2N•m

fhwx140014

(c) Fit in the fixing bolts of both low and high pres-
sure pipes of the air conditioner.
Torque: 23±2N•m

fhwx140013
 14-16 Cooling - Radiator

(d) Install upper left fixing bolt of intercooler.

Torque: 23±2N•m

14

fhwx140019

(e) Install lower left fixing bolt of intercooler.

Torque: 23±2N•m

fhwx140011

(f) Install the right side fixing bolts of intercooler.

Torque: 23±2N•m

fhwx140019

7. Install fan shroud

(a) Fit in the upper left fixing bolt of the fan
shroud.
Torque: 20N•m

fhwx140010
 Cooling - Radiator 14-17

(b) Fit in the lower left fixing bolt of the fan shroud.
Torque: 20N•m
△ Hint:
Repeat the same installation steps for right
side fixing bolt of the fan shroud.

fhwx140016 14

8. Fill in coolant, refer to Chapter 14 Cooling- Coolant, replacement

9. Fill in refrigerant
- Memo -