Assembly Instructions

Engine G-Drive Coolpac

Air Cleaner Assembly A042Y496

Radiator Assembly A044K867 (35 Kva)
Radiator Assembly A044L330 (40 Kva)

English
Original Instructions MARCH-2012 A043E008 (Issue 1)
Table of Contents
1. INTRODUCTION............................................................................................................................ 1
1.1 About These Assembly Instructions ....................................................................................... 1
1.2 Warning, Caution, and Note Styles Used In This Manual ...................................................... 1
1.3 Safety Precautions.................................................................................................................. 2
1.4 Lifting ...................................................................................................................................... 2
1.5 Guarding Against Hot Surfaces .............................................................................................. 2
1.6 Guarding Against Moving Parts .............................................................................................. 3
1.7 Control System ....................................................................................................................... 3
1.8 Stability ................................................................................................................................... 3
1.9 Noise....................................................................................................................................... 3
1.10 Vibration ................................................................................................................................ 3
1.11 Specifications........................................................................................................................ 4
1.12 How to Obtain Service .......................................................................................................... 4

2. PARTS INFORMATION ................................................................................................................. 5

2.1 Introduction ............................................................................................................................. 5
2.2 Air Cleaner Assembly ............................................................................................................. 5
2.3 Radiator Assembly ................................................................................................................. 6
2.4 Radiator Assembly ................................................................................................................. 8

3. AIR CLEANER ASSEMBLY .......................................................................................................... 9

3.1 Introduction ............................................................................................................................. 9
3.2 Required Tools........................................................................................................................ 9
3.3 Items Required by Customer to Complete Installation ........................................................... 9
3.4 Air Cleaner Assembly Instructions........................................................................................ 10

4. RADIATOR ASSEMBLY ............................................................................................................. 11

4.1 Introduction ........................................................................................................................... 11
4.2 Cooling Fan Assembly .......................................................................................................... 11
4.2.1 Required Tools........................................................................................................... 11
4.2.2 Items Required by Customer to Complete Installation .............................................. 11
4.2.3 Cooling Fan Assembly ............................................................................................... 12
4.3 Radiator Assembly Instructions ............................................................................................ 13
4.3.1 Required Tools........................................................................................................... 13
4.3.2 Items Required by Customer to Complete Installation .............................................. 13
4.3.3 Mounting the Radiator................................................................................................ 13
4.3.4 Connecting the Radiator to the Engine...................................................................... 14
4.3.5 Radiator Installation ................................................................................................... 16
4.4 Filling the Cooling System .................................................................................................... 17
4.4.1 Cooling System Filling Procedure............................................................................. 17

5. TESTING THE INSTALLATION ................................................................................................... 19

5.1 Testing the Installation .......................................................................................................... 19

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ii A043E008 (Issue 1)
1 Introduction
WARNING: Improperly connected generator electrical output connections can cause
equipment damage, severe personal injury, or death and therefore must be
made by a trained and experienced electrician in accordance with the
installation instructions and all applicable codes.
WARNING: Improper installations can cause equipment damage, severe personal injury,
or death and therefore all installations must be conducted by a trained and
experienced person in accordance with the installation instructions and all
applicable codes.

1.1 About These Assembly Instructions

The purpose of these instructions is to provide the assembly instructions and corresponding
parts list for the component or components listed on the front cover.These instructions should
be followed during the assembly and installation of equipment supplied without a control system
or wiring. They also contain a description of the conditions that must be satisfied, so as to not
compromise health and safety.
In addition to the requirements stated below,installers must comply with the requirements of
Cummins Application Engineering Bulletins (AEBs) which highlight interfaces, installation
requirements, and operating limits, together with all applicable codes and product standards. In
line with Cummins policy of continuous development and improvement, the AEBs may be
updated from time to time. Installers should make sure that before commencing any work, they
have reviewed the latest information available.
Safe and efficient operation can be achieved only if the equipment is properly operated and
maintained. Many accidents are caused by failure to follow fundamental rules and precautions.
It is the installers responsibility to employ competent persons to carry out any installation work.
Refer to the parts information prior to installing the assemblies. The numbers in parenthesis ()
included in the instructions correspond to the part call-out numbers.
The information contained within the manual is based on information available at the time of
going to print. In line with Cummins Power Generation policy of continuous development and
improvement, information may change at any time without notice. The users should therefore
make sure that before commencing any work, they have the latest information available. The
latest version of this manual is available on QuickServe Online
(https://qsol.cummins.com/info/index.html).
For further assistance, contact your authorized distributor.

1.2 Warning, Caution, and Note Styles Used In This

Manual
The following safety styles and symbols found throughout this manual indicate potentially
hazardous conditions to the operator, service personnel, or the equipment .

DANGER: Indicates a hazardous situation that, if not avoided, will result in death
or serious injury.

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1. Introduction MARCH-2012

WARNING: Indicates a hazardous situation that, if not avoided, could result in death or
serious injury.
CAUTION: Indicates a hazardous situation that, if not avoided, could result in minor or
moderate injury.

NOTE: Indicates information considered important, but not hazard-related (e.g.,

messages relating to property damage).

1.3 Safety Precautions

Read these instructions completely and become familiar with safety warnings, cautions, and
procedures before starting the installation.
The installer must be familiar with the techniques of working on heavy machinery. A hoist must
be available which can support the weight of the assemblies, with an appropriate lifting strength
margin.

WARNING: Incorrect installation, service, or parts replacement can result in severe

personal injury, death, and/or equipment damage. Service personnel must be
trained and experienced to perform electrical and mechanical component
installations.

CAUTION: Sharp edges/burrs on housing panels/parts can cause severe cuts/abrasions.

When handling parts, always wear gloves.

1.4 Lifting
· Take the necessary precautions when lifting the assembly.
· Never lift the assembly over a person. Clear the area before lifting.
· Never divert you attention from the lift.
· Never use a broken hoist.
· Never attempt to lift more weight than the hoist is rated for.
· The mass of the assembly is stated in the specification table.
· The mass quoted does not include packing materials.
· The correct lifting device must used and attached to the designated lifting brackets.
· All lifting operations must be carried out by qualified personnel and using suitably rated
and tested equipment in accordance with all applicable safety procedures.

1.5 Guarding Against Hot Surfaces

The assembly will be provided with standard CPG hot surface guarding. The builder must make
sure that the remainder of the exhaust installation is properly guarded in accordance with the
requirements of EN 12601, latest edition, or relevant building code.

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MARCH-2012 1. Introduction

1.6 Guarding Against Moving Parts

If any guards for moving parts are disturbed or modified, the builder must comply with the
relevant product standards, such as EN 12601, latest edition.

1.7 Control System

The equipment is supplied without a control system. The installer must make sure that a
suitable control and wiring system is fitted to control and protect the equipment in accordance
with:
· AEBs
· Engine and sub-system operating instructions
· Machinery Directive 2006/42/EC requirements
· EN60204-1 requirements
The installer is responsible for making sure that the equipment complies with the
Electromagnetic Compatibility Directive and Low Voltage Directive.

1.8 Stability
The installer is responsible for making sure that the equipment is stable under all foreseeable
conditions, such as:
· load
· overload
· fault conditions
· conditions during transit
· positioning

1.9 Noise
The equipment emits noise during operation. The installer is responsible for assessing any
hazard that may result from noise emissions and for providing warnings and hearing protection
advice.
Noise information is given in the appropriate generator set Installation Manual.
The installer is responsible for making sure conditions comply with the Noise Directive
2000/14/EC together with any local code requirements.

1.10 Vibration
The equipment produces vibration during operation. The installer is responsible for assessing
the effects of vibration on the installation design and for including appropriate vibration
considerations within the machinery design or installation.
Do not fit additional spring mounts underneath the chassis of equipment with built-in rubber or
spring isolation systems.

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1. Introduction MARCH-2012

1.11 Specifications
TABLE 1. (EXAMPLE QSK19-G2 G3) SPECIFICATIONS

Item Data
Engine Weight 1900 kg (4188 lb)

Radiator Assembly Weight 550 kg (1212 lb)

Air Cleaner Assembly Weight 25 kg (55 lb)

Cooling System For 50 °C radiator; 55 L (14.5 US gal)

Capacity with Standard Radiator For 40 °C radiator; 41.6 L (10.8 US gal)
Lubricating System
Oil Capacity with Filters 84 L (23 US gal)

1.12 How to Obtain Service

When a product requires servicing, contact your nearest Cummins Power Generation
distributor . To locate your local Cummins Power Generation distributor, refer to
www.cumminspower.com and select Distributor Locator. When contacting your distributor,
always supply the complete model, specification, and serial number as shown on the
nameplate .

4 A043E008 (Issue 1)
2 Parts Information
2.1 Introduction
Refer to the parts information prior to installing the assembly to ensure that all components
listed are in the kit provided. Any discrepancies contact your authorized distributor.

2.2 Air Cleaner Assembly

FIGURE 1. AIR CLEANER ASSEMBLY A042Y496

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2. Parts Information MARCH-2012

2.3 Radiator Assembly

FIGURE 2. RADIATOR ASSEMBLY A044K867 (35 KVA)

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MARCH-2012 2. Parts Information

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2. Parts Information MARCH-2012

2.4 Radiator Assembly

FIGURE 3. RADIATOR ASSEMBLY A044L330 (40 KVA)

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3 Air Cleaner Assembly
3.1 Introduction
Refer to the parts information prior to installing the assembly to ensure that all components
listed are in the kit provided. Any discrepancies contact your authorized distributor.

3.2 Required Tools

The following tools are required to complete this installation.
· Lifting straps with shackles capable of lifting 227 Kg (500.45 lb)
· Spirit Level
· Pulley alignment tools
· Pry bar
· Torque wrench value for air cleaner 52 Nm (70.5 ft-lb)
· TOrque wrench value for air cleaner bracket 90 Nm (122 ft-lb)
· White paint pen
· (16 mm) Wrenches
· (14 & 15 mm) Impact sockets
· Air ratchet wrench or 12V/18V cordless drill
· Hot air gun

3.3 Items Required by Customer to Complete

Installation
The following items are required to complete this installation.

Part Description QTY Where Used

Low Coolant Sender 1 On Radiator
Loctite 577 Thread Sealant A/R Low Coolant Level Sender and
Breather Pipe
Loctite 242 Thread Sealant A/R Fan Installation
Hellerine Lubricant A/R Hose Installation
Cable Ties A/R Vent Hose
Check Valves A/R Outside Vent Lines (customer option)
Coolant Mixture A/R Refer to Specification Table
40oC Radiator
50oC Radiator

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3. Air Cleaner Assembly MARCH-2012

3.4 Air Cleaner Assembly Instructions

FIGURE 4. AIR CLEANER ASSEMBLY A044G826

NOTE: Mark the bolt heads with white pen to indicate that the required torque has
been set.
1. Fit the air cleaner support brackets to both sides of the flywheel housing, using hex bolts
with flat washer, ensure the brackets are level, and torque the bolts to 90 Nm.
2. Fit the air cleaner support plate to the side brackets using hex head bolts with flat
washers.Torque the bolts
3. Secure the air cleaner tube band to the air cleaner bracket with hex head screws,washers.
4. Fit air cleaner band clamps to the support plate using head bolts with spring, flat washers,
and nuts. Fit the air cleaner housing. Tighten the clamps to secure the air cleaner housing.
Torque the bolts.
5. Assemble the rubber reducer to the air cleaner, lubricate with Hellerine as required, insert
the air cleaner tube, fit the hose clamps and fully tighten.
6. Assemble the elbow hose to the turbocharger, lubricate with Hellerine as required. Fit the
hose clamps and fully tighten.
7. Fit the restriction indicator.

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4 Radiator Assembly
4.1 Introduction
Refer to the parts information prior to installing the assembly to ensure that all components
listed are in the kit provided. Any discrepancies contact your authorized distributor.

4.2 Cooling Fan Assembly

4.2.1 Required Tools
The following tools are required to complete this installation
· Spirit Level
· Pulley alignment tools
· Pry bar
· Torque wrench value 52 Nm (70.5 ft-lb)
· White paint pen
· (14 mm) Impact sockets
· Air ratchet wrench or 12V/18V cordless drill
· Hot air gun

4.2.2 Items Required by Customer to Complete Installation

The following items are required to complete this installation.

Part Description QTY Where Used

Low Coolant Sender 1 On Radiator
Loctite 577 Thread Sealant A/R Low Coolant Level Sender and
Breather Pipe
Loctite 242 Thread Sealant A/R Fan Installation
Hellerine Lubricant A/R Hose Installation
Cable Ties A/R Vent Hose
Check Valves A/R Outside Vent Lines (customer option)
Coolant Mixture A/R Refer to Specification Table
40oC Radiator
50oC Radiator

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4. Radiator Assembly MARCH-2012

4.2.3 Cooling Fan Assembly

No. Part No Description Qty No. Part No Description Qty

1 A024L159 FAN 1
2 A024M614 SCREW,HEX FLANGE 4
HEAD

FIGURE 5. COOLING FAN A024L159

1. Remove the set screws from the engine pulley in order to install the fan (if fitted).
2. Secure a suitable lifting strap on to the fan.
3. Using a crane or similar lifting device, lift the fan.
4. With the aid of another person align the fan to the drive pulley on the engine. Insert the
spacer between the fan and the drive pulley on the engine using the set screws and lock
washers to secure the fan to the engine.
5. Apply Loctite 242 to the screws and torque to to 52 Nm (70.5 ft-lb).
6. Use a white paint pen to line mark the screws.

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MARCH-2012 4. Radiator Assembly

4.3 Radiator Assembly Instructions

4.3.1 Required Tools
The following tools are required to complete this installation.
· Lifting straps with shackles capable of lifting 227 Kg (500.45 lb)
· Spirit Level
· Pulley alignment tools
· Pry bar
· Torque wrench value 57Nm (77.3ft-lb)
· White paint pen
· (14-15 mm) Wrenches
· (15 mm) Impact sockets
· Air ratchet wrench or 12V/18V cordless drill
· Hot air gun

4.3.2 Items Required by Customer to Complete Installation

The following items are required to complete this installation.

Part Description QTY Where Used

Low Coolant Sender 1 On Radiator
Loctite 577 Thread Sealant A/R Low Coolant Level Sender and
Breather Pipe
Loctite 242 Thread Sealant A/R Fan Installation
Hellerine Lubricant A/R Hose Installation
Cable Ties A/R Vent Hose
Check Valves A/R Outside Vent Lines (customer option)
Coolant Mixture A/R Refer to Specification Table
40oC Radiator
50oC Radiator

4.3.3 Mounting the Radiator

WARNING: Dropping the radiator assembly can cause severe personal injury or death.
The radiator assembly is heavy. Use a hoist of sufficient capacity for lifting
and moving the radiator assembly to the desired position.

NOTE: It is recommended that the radiator be installed on a skid, along with the
engine. The customer must make sure that the engine is properly installed.
The customer must also provide mounting hardware.

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4. Radiator Assembly MARCH-2012

FIGURE 6. RADIATOR INSTALLATION

1. Remove the hardware and mounting straps (if present) securing the radiator assembly to
the transportation skid. Remove the loose items.
2. Attach shackles and lifting straps to the lifting points on the radiator and raise it clear of the
pallet.
3. With the radiator in the air, remove the bottom radiator guard and the charge alternator
guard, put them to one side.
4. Carefully lower the radiator over the fan using slow progressive movements.
5. When Installing the radiator assembly, check the fan alignment to the radiator cowl, making
sure there is a 15mm (.59 inches) equal gap between the edge of the fan blades and the
cowl. If out of alignment, loosen the hold-down bolts and re-adjust the radiator’s position;
then retighten the bolts.
6. Ensure the fan is positioned 1/3 in and 2/3 out of the fan cowl.
7. Secure the radiator bolts with flat washers.

4.3.4 Connecting the Radiator to the Engine

The numbers in parenthesis ( ) correspond to the parts called out numbers

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MARCH-2012 4. Radiator Assembly

FIGURE 7. RADIATOR HOSES

1. Assemble the lower coolant return and fill tube assembly.
a. Remove all radiator hole plugs.
b. Use two hose clamps to install a hose coupling on the radiator end of the coolant
return tube and hose coupling on the engine end.
c. Use two hose clamps to secure the coolant return tube to the engine and the radiator.
d. Remove the hole plug from the fill pipe port and install the fill pipe between the
radiator and the coolant tube using two clamps , and make sure all connections are
watertight.
e. Use an 8mm socket wrench to tighten the hose clamps, and make sure all
connections are watertight.

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4. Radiator Assembly MARCH-2012

2. Install the upper coolant tube assembly (see figure above).

a. Remove the plugs from the ports on the radiator and the engine where the upper
coolant assembly is to be installed.
b. Use two hose clamps to install a hose coupling on the radiator end of the upper
coolant tube and a hose coupling on the engine end.
c. Use two hose clamps to secure the upper coolant assembly to the engine and the
radiator. Make sure the “elbow” portion of the upper coolant tube is not higher than
the radiator fitting see.
d. Use an 8mm socket wrench to tighten the hose clamps and make sure all connections
are watertight.
3. Remove the hole plug from the low coolant level sender port. Apply Loctite 577 to the low
coolant level sender and install it on the radiator. Connect the engine harness to the low
coolant level sender.
4. Install the vent hose shown in on the radiator using two clamps. Route the hose from the
radiator to the engine connector, making sure the vent hose runs continuously upwards.
5. Use cable ties to secure the vent hose to the upper coolant tube.

4.3.5 Radiator Installation

FIGURE 8. RADIATOR

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MARCH-2012 4. Radiator Assembly

The cooling fan, along with the belt tensioner assembly, is pre-assembled with the radiator. The
belt tensioner system allows for manual adjustment of the horizontal positioning of the idler
pulley. The idler pulley is adjusted manually in order to install the V-belts over the pulleys and
set the recommended belt tension. Once the correct tension is set by adjusting the bolts and
adjusting the position of the manual tensioner, completion of the belt installation requires locking
the manual tensioner in place by tightening the bolts, as illustrated in.
The engine pulley must be assembled and aligned with the fan pulley before the radiator is
completely installed. Belt guards must be installed last, after completion of the belt installation
and alignment procedures and test running the generator set.

4.4 Filling the Cooling System

After the components have been properly assembled and mounted, fill the cooling system.

NOTE: The cooling system must be filled before aligning the fan drive. The weight of
the coolant can change alignment.

4.4.1 Cooling System Filling Procedure

WARNING: The failure to properly replace coolant caps can result in hot pressurized
coolant escaping from the radiator fill necks, causing severe personal injury
and engine damage. Always make sure the radiator cap is properly secured
before operating the generator set.

CAUTION: Failure to use the correct type of coolant, maintain the correct level, and bleed the
systems of air can result in severe engine damage. Make sure the correct coolant
and additive is used.
The system requires a 50/50 mixture of fully formulated coolant (ethylene glycol or propylene
glycol) and corrosion inhibitor.
Fill the radiator with a combination of the fully formulated coolant and Fleetguard
recommeneded doses of corrosion inhibitor (DCA4). Refer to the engine manufacturer's owner's
manual for recommended coolant type.
1. Begin slowly filling the radiator with a 50/50 mixture of fully formulated coolant and DCA4
(or equivelant).
2. Observe the coolant level through the sight glass (if fitted) at the top of the expansion tank.
Coolant level should be approximately at the fill level in the sight glass with a cool engine
or level with the bottom of the filler neck for radiators without a sight level glass.
3. When the radiator is full, replace the radiator cap securely. Push down and twist clockwise
until the cap lip hits the tank stop flange.

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18 A043E008 (Issue 1)
5 Testing the Installation
5.1 Testing the Installation
WARNING: A misaligned fan drive or improperly installed drive belt can cause the belt to
break, causing severe injury to near-by personnel. A properly aligned belt
can grab loose clothing or body parts, causing severe personal injury. When
the belt guards are not installed, wear safety glasses and stand back from
the running fan drive.
WARNING: Contact with belts or pulleys can result in severe personal injury. All guard
pieces must be properly fastened in place to prevent unintended contact.

WARNING: Contact with hot coolant can result in serious burns. Allow the engine to cool
before loosening the radiator cap or coolant drain.
To verify that the installation has been done properly, it is important to observe the drive belt or
belts and confirm that the belts are properly seated in all grooves while the engine is running.
1. Connect the negative (–) cable to the battery using an insulated wrench.
2. If equipped, connect the battery charger and turn it on.
3. In order to purge air from the coolant system, start the engine and allow it to warm up.
4. Verify that the V-belts are not squealing under peak load conditions, and observe the drive
belts to confirm that the belts are properly seated.
5. If any of the belts need to be corrected, or a coolant leak occurs, stop the engine and when
it has cooled down, and disconnect the negative (–) lead of the starting batteries using an
insulated wrench. Correct as necessary.

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