Coolpac Installation Instructions

English – Original Instructions 10-2009 0908-0169 (Issue 2)

Installation Instructions

Radiator Assembly A029V596

Used on Generator Sets with VTA28G5 and G6 Engines

Document No 0908-0169 (Issue 2) of 14

Installation Instructions for Radiator Kit A029V596 (Used on Generator sets with VTA28G5 Engines)

This instruction sheet describes the installation of the radiator assembly shown in Figure 15 on VTA28G5 engines. Figure 17 is an outline drawing showing the installed radiator assembly.

The engine comes with the fan (FN4804) and air cleaner assembly (AC5103) already installed. Figure 16 is included in this Instruction Sheet to provide air cleaner replacement parts information.

The following items must be supplied by the customer to complete the installation.

Part Description Qty Where Used Mounting hardware to secure the radiator to a skid Low Coolant Level Sensor

1 On the radiator

Loctite 577 Thread Sealant

1 Connectors

Nipple 1 Hose Clamp 1

To install the overflow hose

GENERAL PRECAUTIONS

Read these installation instructions completely and become familiar with safety warnings, cautions, and the installation procedure before starting.

Incorrect service or replacement of parts can

result in severe personal injury or death, and/or equipment damage. Service personnel must be trained and experienced to perform electrical and mechanical service.

Ignition of explosive battery gases can cause

severe personal injury or death. Arcing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ignite battery gas. Do not smoke, or switch trouble light ON or OFF near battery. Discharge static electricity from body before touching batteries by first touching a grounded metal surface. Ventilate the battery area before working on or near the battery—

Wear goggles—Stop the generator set and disconnect the battery

charger before disconnecting battery cables—Disconnect the negative (-) cable first and reconnect it last.

Disconnect the battery charger from its AC source before disconnecting battery cables. Otherwise, disconnecting the cables can result in voltage spikes damaging to DC control circuits of the generator set.

Accidental starting of the generator set can cause

severe personal injury or death. Prevent accidental starting by disconnecting the negative (-) cable from the battery terminal.

REQUIRED TOOLS This installation requires the following tools: • 17mm Spanner Wrench • 17mm Socket • 13mm Spanner Wrench • 13mm Socket • Air Ratchet Wrench • Shackles and Lifting Straps

! CAUTION!

! WARNING!

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of 14 Document No 0908-0169 (Issue 2)

INSTALLATION The numbers in parenthesis ( ) correspond to the part callout numbers in Figure 13.

1. Make sure the generator set is disabled.

a. The generator set Run/Off/Auto switch is in the Off position.

b. The battery charger (if equipped) is turned off and disconnected.

c. The negative (-) cable from the battery is disconnected to prevent accidental starting.

FIGURE 1. RADIATOR LIFTING POINTS

2. Prepare the radiator for installation.

a. Remove the shipping container from the radiator assembly.

b. Remove the loose parts secured to the radiator and shipping pallet .

c. Remove the hardware securing the radiator to the shipping pallet.

d. Remove half of the guarding.

e. Attach shackles to the top two lifting points on the radiator (see Figure 1).

FIGURE 2. POSITIONING THE RADIATOR

The radiator cooling system is heavy; it has

an approximate dry weight of 280 kg (617 pounds). Dropping the radiator assembly can cause severe personal injury or death. Use a hoist of sufficient capacity, do not stand under a raised radiator, and keep hands and feet clear of the perimeter of the radiator while maneuvering it.

3. Install the radiator assembly.

a. Using a crane or similar lifting device and the two–strap assembly lifting tackle, raise the radiator and position the radiator next to the engine as shown in .

b. Remove Half the Radiator guarding on one side to allow the radiator to slide over the fan.

c. Slide the radiator over so half the fan sits inside the radiator guarding (see Figure 2).

d. Lower the radiator to the bearer and loosely fit the radiator hold–down bolts (three on each side).

NOTE: It is recommended that the radiator be installed on a skid (as shown in Figure 4), along with the engine. The customer must

! WARNING!


make sure that the engine is properly installed and the radiator is correctly aligned to the engine (packing may be required). The customer must also provide mounting hardware (such as six M10 bolts, twelve M10 flat washers, and six M10 nuts).

Contact between the fan blades and the

radiator can result is serious equipment damage. Make sure there is adequate space between the fan blades and the radiator grill.

4. While using a spirit level, shuffle the radiator assembly until it is vertical and check the fan alignment to the radiator cowl, making sure there is a 12mm +/-3mm (0.47 inches +/-0.12 inches) equal gap between the edge of the fan blades and the cowl horizontally and 25mm +/-3mm (0.86 inch +/-0.12 inches) vertically (see Figure 3). If out of alignment, loosen the hold–down bolts and re–adjust the radiator’s position; then nip up the bolts.

5. Ensure the fan is positioned 1/3 in and 2/3 out of the fan cowl.

6. Tighten the radiator assembly hold–down bolts.

7. Reinstall the guarding removed in step 2b (see Figure 5).

8. Use 20 M8 screws and flat washers included in this kit to install the pulley guarding (see Figure 6)

9. Install the charge alternator guard by removing the fixing from behind the alternator (See Figure 7). Attach the charge alternator guarding (See Figure 8) using the supplied fixings (42,43,44) and replace the charge alternator fixing (See Figure 7)

FIGURE 3. RADIATOR PLACEMENT.

FIGURE 4. SECURE THE RADIATOR

FIGURE 5. REINSTALLED RADIATOR GUARDING

! CAUTION !

12MM +/-3mm

12MM+/-3mm

25MM +/-3mm


FIGURE 6. PULLEY GUARDING

FIGURE 7. CHARGE ALTERNATOR FIXING

FIGURE 8. CHARGE ALTERNATOR GUARDING

10. Install the pipe adaptor (41) using Loctite sealant and the coolant drain tap (40) onto the coolant return hose (35). (See Figure 9)

FIGURE 9. DRAIN TAP

11. Use two hose couplings, and four hose clamps supplied, to install the coolant return tube (35) (see Figure 10). Tighten the hose clamps to make sure that the fittings are watertight. Ensure the return tube is positioned vertically and the drain tap lever is parallel with the bed frame.

FIGURE 10. COOLANT RETURN TUBE


FIGURE 11. LEVEL DRAIN TAP

12. Use the four hose couplings, and eight hose clamps supplied to install the two upper coolant tubes (34) to the radiator and engine (see Figure 12). Tighten the hose clamps to make sure that the fittings are watertight.

13. Connect the radiator vent hoses from the radiator to the engine (37, 38).

14. Ensure all vent pipes run continuously upward to prevent air locks.

15. Apply Loctite 577 and install a customer–supplied low coolant level sensor on the radiator and connect the engine harness to the sensor.

16. Use two hose clamps to install an overflow hose from the radiator to the engine (see Figures 12 and 13). Tighten the hose clamps to make sure that the fittings are watertight.

17. Use cable ties included in this kit to secure the vent hoses, overflow hose, and engine harness to the upper radiator coolant tubes (see Figure 13).

18. Install the plastic vent tube on the radiator fill port. Feed the hose down the side of the radiator and secure the tube to the side of the radiator. (see Figure 14)

FIGURE 12. UPPER COOLANT TUBES, OVERFLOW HOSE, AND VENT HOSES

FIGURE 13. RADIATOR OVERFLOW HOSE


19. Make sure all hose clamps are tight.

20. Fill the radiator with coolant. The system coolant capacity is 110 litres (24.2 gallons). Refer to the engine manufacturer’s Owner’s Manual for recommended coolant type.

21. Connect the negative (-) cable to the battery.

22. Connect the battery charger (if applicable) and turn it on.

23. In order to purge air from the system, it is necessary to start the engine and allow it to warm up.

24. After the generator set has been stopped, isolated and the engine has cooled down, check for coolant leaks and repair as necessary.

25. Recheck the coolant level and, if needed, add coolant.

FIGURE 14. RADIATOR VENT TUBE


FIGURE 15. RADIATOR A029V596

Table 1 Radiator A029V596 parts

Ref Part Number Description Qty Ref Part Number Description Qty 1 A029X254 CORE,RADIATOR 6 25 A029X605 GUARD,FAN 1 2 A029X255 TANK,RADIATOR 1 26 A029X606 GUARD,FAN 1 3 A006A670 SEAL,RADIATOR 12 27 A000J931 BOLT 12 4 A029X256 TANK,RADIATOR 1 28 A029M981 NUT 24 5 A029X257 MEMBER,SIDE 1 29 A005Y279 SCREW,HEX HEAD 2 6 A029X258 MEMBER,SIDE 1 30 A029X272 NUT 14 7 A001A620 CAP,PRESSURE 1 31 A029X277 PANEL,MESH 2 8 A029X259 PLATE,CLOSING 1 32 A029X279 GUARD,FAN 1 9 A029X260 PLATE,CLOSING 1 33 A029X280 GUARD,FAN 1 10 A029X262 WASHER 40 34 A029X281 TUBE,RADIATOR 2 11 A005Y924 SCREW,HEX HEAD 31 REF 0130-5353* Hose 4 12 A029M927 NUT 30 REF 0503-2659* Clip 8 13 A000J934 BOLT 58 35 A029X284 TUBE,RADIATOR 1 14 A004W487 NUT,HEX 9 REF 0130-6567** Hose 2 15 A029X263 SHROUD,TOP FAN 1 REF A029X285** Clip 4

16 A029X264 SHROUD,BOTTOM FAN 1 36 A029X286 TUBE,FILL 1

17 A029X265 NUT 35 37 A029X287 HOSE,VENT 1 18 A029X266 BRACKET 4 38 A029X288 HOSE,VENT 1 19 A029X267 GUARD,FAN 1 39 A029X289 WASHER 14 20 A029X268 GUARD,FAN 1 40 A007J904 VALVE,BALL 1 21 A029X601 GUARD,FAN 1 41 A004V993 FITTING,NIPPLE 1 22 A029X602 GUARD,FAN 1 42 A008P613 SCREW,HEX HEAD 2 23 A029X603 GUARD,FAN 1 43 A007L392 WASHER,LOCK 2 24 A029X604 GUARD,FAN 1 44 A007L038 WASHER,FLAT 2

* Items are included in item 34 ** Items are included in item 35


Air Cleaner Assembly AC5103

FIGURE 16. AIR CLEANER ASSEMBLY FOR VTA28G5 AND G6 ENGINES

1 2

3

4

5

6

6

78

9

10

11

12

13

14

15

16

1718

19

20

21

Table 2 Air Cleaner AC5103 parts

Ref Part Number Description Qty 1 S 217 Nut, Hex - Heavy (7/16-14) 2

2 S 608 Washer, Lock (1/2 Inch) 3

3 S 610 Washer, Lock (7/16 Inch) 2

4 103009 Screw, Cap - Hex Head (7/16-14 x 1–1/4 Inch) 2


6 203760 Washer, Flat (7/16 Inch) 4

7 3000953 Brace, Air Cleaner 1


9 3000952 Brace, Air Cleaner 1

10 S 145 Screw, Cap - Hex Head (1/2-13 x 1–1/4 Inch) 2

11 203310 Washer, Flat (9/16 Inch) 2

12 3065699 Bracket, Air Cleaner 1

13 S 104 Screw, Cap - Hex Head (3/8–16 x 2–1/4 Inch) 8

14 S 602 Washer, Flat (3/8 Inch) 8

15 3175239 Nut, Lock 8

16 3315741 Cleaner, Air 2 #

17 125740 Clamp, T Bolt (4–1/2 Inch) 2

18 125741 Clamp, T Bolt (6 Inch) 6 #

19 3030763 Hose, Hump 2 #

20 4072920 Pipe, Air Inlet 1

21 4072921 Pipe, Air Inlet 1

# Indicates the recommended spares (one of each).


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