Installing the Package Mounted Radiator for the C175 Generator Set Engine {1353, 1356}
- Electric Power Generation
- C175-16 GEN SET (S/N: WYB1-UP)
Introduction
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.
This Special Instruction describes the procedures that are required to install the radiator for C175 Generator Set Engines.
Parts List
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Callout | Qty | Part Number | Description |
247-4903 Engine Oil Drain Lines Gp (1800 Frame Generator Sets) | |||
1 | 1 | Grommet | |
2 | 2 | O-Ring Seal | |
3 | 1 | Nut | |
4 | 1 | Cap As | |
5 | 1 | Union | |
6 | 2 | Washer | |
7 | 1 | O-Ring Seal | |
8 | 1 | Connector | |
9 | 1 | O-Ring Seal | |
10 | 1 | Hose As | |
247-4907 Engine Oil Drain Lines Gp (3000 Frame Generator Sets) | |||
1 | 1 | Grommet | |
2 | 2 | O-Ring Seal | |
3 | 1 | Nut | |
4 | 1 | Cap As | |
5 | 1 | Union | |
6 | 2 | Washer | |
7 | 1 | O-Ring Seal | |
8 | 1 | Connector | |
9 | 1 | O-Ring Seal | |
10 | 1 | Hose As | |
259-9104 Fumes Disposal Gp (If Equipped) | |||
11 | 4 | Hose Clamp | |
12 | 4 | Hard Washer | |
13 | 2 | Nut | |
14 | 2 | Bolt | |
15 | 2 | Clip | |
16 | 2 | Tube | |
17 | 2 | Hose As | |
259-9156 Radiator Mounting Gp(1) | |||
18 | 6 | Bolt | |
19 | 6 | Bolt | |
20 | 12 | Nut | |
21 | 12 | Washer | |
22 | 6 | Nut | |
23 | 24 | Hard Washer | |
24 | 6 | Bolt | |
25 | 2 | Mounting Plate | |
259-9224 Coolant Lines Gp (2) | |||
26 | 4 | O-Ring Seal | |
27 | 2 | Gasket | |
28 | 1 | Clip | |
29 | 1 | Clip | |
30 | 4 | O-Ring Seal | |
31 | 2 | Swivel Adapter | |
32 | 3 | Clip | |
33 | 6 | Hard Washer | |
34 | 3 | Nut | |
35 | 1 | Bolt | |
36 | 8 | Bolt | |
37 | 3 | Bolt | |
38 | 18 | Hard Washer | |
39 | 9 | Nut | |
40 | 1 | O-Ring Seal | |
41 | 1 | Connector | |
42 | 2 | O-Ring Plug | |
43 | 2 | Ball Valve | |
44 | 1 | O-Ring Seal | |
45 | 4 | Tube Joint | |
46 | 3 | Tube Joint | |
47 | 1 | Tube As | |
48 | 1 | Tube As | |
49 | 2 | Tube | |
50 | 1 | Tube As | |
51 | 1 | Tube | |
52 | 1 | Tube | |
53 | 1 | Gasket | |
54 | 2 | Tube Joint | |
55 | 1 | Bracket | |
56 | 1 | Hose As | |
57 | 1 | Tube | |
58 | 1 | Tube As | |
352-5048 Guard Gp(3) | |||
59 | 2 | Bolt | |
60 | 8 | Hard Washer | |
61 | 3 | Bolt | |
62 | 15 | Bolt | |
63 | 17 | Hard Washer | |
64 | 2 | Hard Washer | |
65 | 7 | Nut | |
66 | 2 | Top Guard | |
67 | 1 | Bracket As | |
68 | 1 | Base As | |
69 | 1 | Pull Handle | |
323-1263 Sensor Wiring Gp | |||
70 | 13 | Cable Strap | |
71 | 1 | Liquid Level Sensor Gp | |
72 | 1 | Sensor Harness As | |
332-4015 Sensor Wiring Gp | |||
73 | 18 | Cable Strap | |
74 | 1 | Liquid Level Sensor Gp | |
75 | 1 | Sensor Harness As | |
323-3909 Fan Drive Gp | |||
76 | 16 | Bolt | |
77 | 8 | Spring Pin | |
78 | 16 | Pin | |
79 | 2 | Socket Setscrew | |
80 | 1 | Shaft | |
81 | 2 | Coupling | |
82 | 2 | Hub | |
328-2199 Fan Drive Gp | |||
83 | 4 | Bolt | |
84 | 4 | Nut | |
85 | 8 | Hard Washer | |
86 | 1 | Fan Drive Gp | |
87 | 2 | Shaft Key | |
88 | 2 | Shim Pack |
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(1) | The |
(2) | Eight similar coolant lines groups are used. Refer to Table 2 |
(3) | The |
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Use of the Coolant Lines Groups | ||
Coolant Lines Group | Radiator and Fan Group | Frame Size |
259-9222 Coolant Lines Gp | 259-9166 Radiator and Fan Gp | 1800 |
259-9223 Coolant Lines Gp | 259-9166 Radiator and Fan Gp | 3000 |
259-9224 Coolant Lines Gp | 259-9167 Radiator and Fan Gp | 1800 |
259-9225 Coolant Lines Gp | 259-9167 Radiator and Fan Gp | 3000 |
296-0413 Coolant Lines Gp | 296-0410 Radiator Gp | 1800 |
296-0415 Coolant Lines Gp | 296-0410 Radiator Gp | 3000 |
363-2753 Coolant Lines Gp | 358-7625 Radiator and Fan Gp | 1800 |
368-8694 Coolant Lines Gp | 358-7625 Radiator and Fan Gp | 3000 |
Adjust the Drive Shaft on the Radiator
- Loosen six bolts (98).
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Illustration 2 g02124216 - Loosen four bolts (98). Remove fan guard gp (99).
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Illustration 3 g02124276 - Loosen 11 bolts (98).
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Illustration 4 g02124393 - Loosen two bolts (98). Remove guard group (105).
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Illustration 5 g02124454 - Loosen five bolts (98).
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Illustration 6 g02124520 - Loosen six bolts (98).
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Illustration 7 g02124536 - Loosen two bolts (98).
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Illustration 8 g02124654 - Remove two bolts (107), two washers (108), and two nuts (109). Remove guard group (106). Retain two bolts (107), two washers (108), and two nuts (109).
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Illustration 9 g02124834 - Loosen two bolts (98).
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Illustration 10 g02124913 - Loosen two bolts (98). Remove guard group (110).
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Illustration 11 g02124958 - Remove four bolts (111), four nuts (89), and eight washers (90). Remove two bearings (91). Discard four bolts (111), four nuts (89), and eight washers (90). Retain two bearings (91).
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Illustration 12 g02125156 - Remove bolt (92), two washers (93), and nut (94) from plate (95). Retain bolt (92), two washers (93), and nut (94).
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Illustration 13 g02125247 - Remove bolt (92), two washers (93), and nut (94) from plate (95). Retain bolt (92), two washers (93), and nut (94).
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Illustration 14 g02125253 - Remove five bolts (92), ten washers (93), and five nuts (94) from plate (95). Retain five bolts (92), ten washers (93), and five nuts (94).
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Illustration 15 g02125313 - Remove bolt (92), washer (93), and nut (94) from plate (95). Retain bolt (92), washer (93), and nut (94).
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Illustration 16 g02126116 - Adjust nut (96) in order to loosen the fan drive belts.
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Illustration 17 g02126124 - Move plate (95) into the correct location. The location of plate (95) is dependent on the engine. Secure plate (95) to the radiator with four bolts (92), four washers (93), and four nuts (94).
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Illustration 18 g02126373 (83) 7X-0354 Bolt
(84)7X-0448 Nut
(85)7X-0515 Hard Washer
(88)329-0291 Shim Pack - Place shim pack (88) under the two bearings (91). Shim pack (88) may not be needed on the machine. Secure shim pack (88) to the plate (95) with four bolts (83), four nuts (84), and four washers (85). Leave four bolts (83) loose.
Refer to Special Instruction, REHS4730 for more information on aligning the driveshaft.
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Illustration 1 | g02123137 |
Prepare the Engine and the Radiator to be Connected
- Assemble O-ring seal (7) and O-ring seal (9) to Connector (8).
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Illustration 20 g02126534 (8) 227-0065 Connector
(10)284-0030 Hose As - Place connector (8) onto the drain for the engine. Connect hose as (10) onto connector (8).
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Illustration 21 g02126610 (1) 5I-3876 Grommet (not shown)
(10)284-0030 Hose As or118-0907 Hose As - Place hose as (10) through base as (97) with grommet (1).
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Illustration 22 g02126618 (62) 8T-4183 Bolt
(63)8T-4223 Hard Washer
(65)8T-4244 Nut
(67)322-5011 Bracket As - Secure bracket as (67) to base as (97) with four bolts (62), eight washers (63), and four nuts (65).
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Illustration 23 g02126631 (61) 8T-4139 Bolt
(62)8T-4183 Bolt
(63)8T-4223 Hard Washer
(65)8T-4244 Nut
(67)322-5011 Bracket As
(68)322-5012 Base As - Secure base as (68) to bracket as (67) with three bolts (61) and three washers (63). Secure base as (68) to base as (97) with three bolts (62), three washers (63), and three nuts (65).
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Illustration 24 g02126686 (66) 322-5007 Top Guard - Place top guard (66) onto the engine. Refer to Illustration 24.
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Illustration 25 g02129237 (59) 5K-0906 Bolt
(64)8T-4224 Hard Washer
(66)322-5007 Top Guard
(69)338-8881 Pull Handle - Secure pull handle (69) to top guard (66) with two bolts (59) and two washers (64).
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Illustration 19 | g02126577 |
(7) (8) (9) |
Assemble the
- Install four spring pins (77) onto hub (82). Perform this operation for both hubs (82).
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Illustration 27 g02128625 (78) 095-0880 Pin
(80)328-2969 Shaft - Install eight pins (78) onto shaft (80). Perform this operation on both ends of shaft (80).
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Illustration 28 g02128655 (76) 7Y-1904 Bolt
(81)328-2970 Coupling
(82)328-2971 Hub - Secure coupling (81) to hub (82) with four bolts (76). Perform this operation for both hubs (82).
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Illustration 29 g02128694 (76) 7Y-1904 Bolt
(80)328-2969 Shaft
(81)328-2970 Coupling - Secure two couplings (81) to shaft (80) with eight bolts (76).
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Illustration 30 g02128733 (79) 160-8759 Socket Setscrew
(82)328-2971 Hub - Install setscrew (79) onto hub (82). Perform this operation on both hubs (82).
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Illustration 31 g02128877 (86) 323-3909 Fan Drive Gp
(87)326-6421 Shaft Key - Install shaft key (87) onto fan drive gp (86).
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Illustration 26 | g02128321 |
(77) (82) |
Install the Radiator onto the Engine
- Move the radiator close to the front of the engine.
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Illustration 32 g02128940 (86) 323-3909 Fan Drive Gp - Place fan drive gp (86) onto the radiator.
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Illustration 33 g02128973 (86) 323-3909 Fan Drive Gp - Move the radiator into the final mounting position at the front of the engine. Make sure that fan drive gp (86) is installed onto the engine and the radiator.
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Illustration 34 g02129113 (83) 7X-0354 Bolt - Tighten four bolts (83).
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Illustration 35 g02129182 (18) 7X-2563 Bolt
(21)8T-4123 Washer
(22)8T-4131 Nut - Secure the radiator to the engine with six bolts (18), 12 washers (21), and six nuts (22).
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Illustration 36 g02129191 (19) 7X-2575 Bolt
(20)8T-4001 Nut
(23)8T-4167 Hard Washer
(24)8T-5878 Bolt
(25)259-1778 Mounting Plate - Secure the engine to the radiator with three bolts (19),six nuts (20), 12 washers (23), three bolts (24), and mounting plate (25).
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Illustration 37 g02129226 (19) 7X-2575 Bolt
(20)8T-4001 Nut
(23)8T-4167 Hard Washer
(24)8T-5878 Bolt
(25)259-1778 Mounting Plate - Secure the engine to the radiator with three bolts (19),six nuts (20), 12 washers (23), three bolts (24), and mounting plate (25).
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Illustration 38 g02129635 (60) 5P-1076 Hard Washer
(62)8T-4183 Bolt
(66)322-5007 Top Guard - Secure top guard (66) to the machine with eight washers (60) and eight bolts (62) in the location that is shown in Illustration 38.
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Illustration 39 g02130007 (2) 5K-9090 O-Ring Seal
(5)7X-2464 Union - Assemble two O-ring seals (2) to union (5).
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Illustration 40 g02130470 (5) 7X-2464 Union
(6)9X-8259 Washer - Secure union (5) and washer (6) to base as (97).
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Illustration 41 g02131995 (3) 6V-9172 Nut
(4)6V-9833 Cap As
(5)7X-2464 Union
(6)9X-8259 Washer - Secure union (5) to base as (97) with washer (6) and nut (3). Place cap as (4) onto union (5).
Install the Coolant Lines
- Remove cover (100) and all hardware. Discard cover (100) and all hardware.
- Remove bolts (101), washers (102), and nuts (103) from three covers (104). Discard three covers (104). Retain bolts (101), washers (102), and nuts (103).
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Illustration 43 g02132795 (27) 5B-7368 Gasket
(48)274-6923 Tube As - Install gasket (27) onto the engine. Secure tube as (48) onto the machine with eight bolts (101), eight washers (102), and eight nuts (103).
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Illustration 44 g02132958 Parts of the 216-2783 Tube Joint
(A) Seal
(B) Clamp
(C) Bolt
(D) Nut
(E) Body
(F) CollarShow/hide tableIllustration 45 g02132957 (48) 274-6923 Tube As - Apply 207-1600 Rubber Lubricant to the outside face of seal (A).
- Install seal (A) and collar (F) onto tube as (48).
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Illustration 46 g02132890 - Apply 207-1600 Rubber Lubricant to the outside face of seal (A).
- Install seal (A) and collar (F) onto the radiator.
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Illustration 47 g02134213 (49) 274-6926 Tube - Apply 207-1600 Rubber Lubricant to the outside face of seal (A).
- Install seal (A) and collar (F) onto tube (49).
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Illustration 48 g02134473 (48) 274-6923 Tube As - Install body (E) onto the radiator. Install body (E) onto tube as (48).
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Illustration 49 g02134554 (49) 274-6926 Tube - Install tube as (49) into two bodies (E).
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Illustration 50 g02134655 - Secure four clamps (B) with four bolts (C) and four nuts (D). Tighten four bolts (C) to a torque of
34 ± 0.5 N·m (25 ± 0.5 lb ft) .Show/hide tableIllustration 51 g02134714 (27) 5B-7368 Gasket
(47)274-6922 Tube As - Place gasket (27) onto the engine. Secure tube as (47) onto the engine with eight bolts (101), eight washers (102), and eight nuts (103).
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Illustration 52 g02134993 Parts of the 216-2783 Tube Joint
(A) Seal
(B) Clamp
(C) Bolt
(D) Nut
(E) Body
(F) CollarShow/hide tableIllustration 53 g02134913 - Apply 207-1600 Rubber Lubricant to the outside face of seal (A).
- Install seal (A) and collar (F) onto tube as (48).
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Illustration 54 g02135016 - Apply 207-1600 Rubber Lubricant to the outside face of seal (A).
- Install seal (A) and collar (F) onto the radiator.
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Illustration 55 g02134213 (49) 274-6926 Tube - Apply 207-1600 Rubber Lubricant to the outside face of seal (A).
- Install seal (A) and collar (F) onto tube (49).
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Illustration 56 g02136753 (47) 274-6922 Tube As - Install body (E) onto the radiator. Install body (E) onto tube as (47).
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Illustration 57 g02136814 (49) 274-6926 Tube - Install tube as (49) into two bodies (E).
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Illustration 58 g02136876 - Secure four clamps (B) with four bolts (C) and four nuts (D). Tighten four bolts (C) to a torque of
34 ± 0.5 N·m (25 ± 0.5 lb ft) .Show/hide tableIllustration 59 g02136893 (50) 274-6928 Tube As
(53)287-7042 Gasket - Install gasket (53) onto the engine. Secure tube as (50) onto the engine with eight bolts (101), eight washers (102), and eight nuts (103).
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Illustration 60 g02137452 Parts of the 216-2784 Tube Joint
(G) Clamp
(H) Bolt
(J) Nut
(K) Seal
(M) Body
(N) CollarShow/hide tableIllustration 61 g02136934 (50) 274-6928 Tube As - Apply 207-1600 Rubber Lubricant to the outside face of seal (K).
- Install seal (K) and collar (N) onto tube as (50).
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Illustration 62 g02137482 (33) 8T-4121 Hard Washer
(34)8T-4133 Nut
(35)8T-4183 Bolt
(55)320-8736 Bracket - Install bracket (55) onto the radiator with four washers (33), two nuts (34), and two bolts (35).
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Illustration 63 g02137634 - Apply 207-1600 Rubber Lubricant to the outside face of seal (K).
- Install seal (K) and collar (N) onto the radiator.
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Illustration 64 g02137933 (51) 274-6929 Tube - Apply 207-1600 Rubber Lubricant to the outside face of seal (K).
- Install seal (K) and collar (N) onto 274-6929 Tube (51).
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Illustration 65 g02137950 (52) 275-0862 Tube - Apply 207-1600 Rubber Lubricant to the outside face of seal (K).
- Install two seals (K) and two collars (N) onto 275-0862 Tube (52).
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Illustration 66 g02138068 (50) 274-6928 Tube As - Secure body (M) to tube as (50).
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Illustration 67 g02137962 (51) 274-6929 Tube - Place tube (51) into body (M).
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Illustration 68 g02137972 - Secure two clamps (G) with two bolts (H) and two nuts (J). Tighten two bolts (G) to a torque of
28 ± 0.5 N·m (21 ± 0.5 lb ft) .Show/hide tableIllustration 69 g02138137 (51) 274-6929 Tube - Place body (M) onto tube (51) and onto the radiator.
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Illustration 70 g02138139 (52) 275-0862 Tube - Place tube (52) into two bodies (M).
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Illustration 71 g02138186 - Secure four clamps (G) with four bolts (H) and four nuts (J). Tighten four bolts (G) to a torque of
28 ± 0.5 N·m (21 ± 0.5 lb ft) .Show/hide tableIllustration 72 g02138227 (28) 6V-4356 Clip
(29)6V-4357 Clip
(35)8T-4183 Bolt
(38)8T-4223 Hard Washer
(39)8T-4244 Nut
(55)320-8736 Bracket - Secure clip (28) and clip (29) to bracket (55) with bolt (35), two hard washers (38), and nut (39).
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Illustration 73 g02138290 (44) 129-1610 O-Ring Seal - Place O-ring seal (44) onto the engine.
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Illustration 74 g02138253 (36) 8T-4194 Bolt
(38)8T-4223 Hard Washer
(39)8T-4244 Nut
(58)342-2106 Tube As - Secure tube as (58) to the engine with eight bolts (36), 16 washers (38), and eight nuts (39).
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Illustration 75 g02139156 Parts of the 319-5890 Tube Joint
(P) Clamp
(R) Bolt
(S) Nut
(T) Seal
(U) Body
(V) CollarShow/hide tableIllustration 76 g02138577 (58) 342-2106 Tube As - Apply 207-1600 Rubber Lubricant to the outside face of seal (T).
- Install seal (T) and collar (V) onto tube as (58).
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Illustration 77 g02139168 - Apply 207-1600 Rubber Lubricant to the outside face of seal (T).
- Install seal (T) and collar (V) onto the radiator.
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Illustration 78 g02139172 (57) 341-6858 Tube - Apply 207-1600 Rubber Lubricant to the outside face of seal (T).
- Install two seals (T) and two collars (V) onto tube (57).
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Illustration 79 g02139221 (58) 342-2106 Tube As - Place body (U) onto tube as (58) and place body (U) onto the radiator.
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Illustration 80 g02139230 (57) 341-6858 Tube - Place tube (57) into two bodies (U).
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Illustration 81 g02139272 - Secure four clamps (P) with four bolts (R) and four nuts (S). Tighten four bolts (R) to a torque of
34 ± 0.5 N·m (25 ± 0.5 lb ft) .Show/hide tableIllustration 82 g02139291 (40) 8T-6850 O-Ring Seal
(41)8T-7488 Connector - Place O-ring seal (40) and connector (41) onto the engine.
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Illustration 83 g02139388 (30) 6V-8398 O-Ring Seal
(56)323-3929 Hose As - Install hose as (56) onto the radiator and the engine with two O-ring seals (30).
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Illustration 84 g02139402 (32) 8S-0948 Clip
(33)8T-4121 Hard Washer
(34)8T-4133 Nut
(37)8T-4195 Bolt
(56)323-3929 Hose As - Secure hose as (56) to the radiator with three clips (32). Secure two clips (32) to the radiator with the existing hardware. Secure one clip (32) to the radiator with washer (33), nut (34), and bolt (37).
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Illustration 85 g02139407 Show/hide tableIllustration 86 g02139412 View A
(26)3K-0360 O-Ring Seal
(30)6V-8398 O-Ring Seal
(31)7X-3164 Swivel Adapter
(42)9S-4185 O-Ring Plug
(43)109-0897 Ball Valve - Install four O-ring seals (26), two O-ring seals (30), two swivel adapters (31), two O-ring seals (42), and two ball valves (43) onto the radiator.
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Illustration 42 | g02132693 |
Install the
- Install liquid level sensor gp (71) onto the radiator. Install sensor harness as (72) onto liquid level sensor gp (71).
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Illustration 89 g02139443 (72) 323-1262 Sensor Harness As - Install sensor harness (72) onto the engine.
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Illustration 90 g02139445 (70) 7K-1181 Tie Strap
(72)323-1262 Sensor Harness As - Secure sensor harness as (72) to the engine and the radiator with 13 tie straps (70).
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Illustration 87 | g02139804 |
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Illustration 88 | g02139428 |
View B (71) (72) |
Install the
- Install liquid level sensor gp (74) onto the radiator. Install sensor harness as (75) onto liquid level sensor gp (74).
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Illustration 93 g02227553 (75) 323-1261 Sensor Harness As - Install sensor harness (75) onto the engine.
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Illustration 94 g02227573 Show/hide tableIllustration 95 g02227593 (73) 7K-1181 Tie Strap
(75)323-1261 Sensor Harness As - Secure sensor harness as (75) to the engine and the radiator with 18 tie straps (73).
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Illustration 91 | g02205655 |
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Illustration 92 | g02227533 |
View C (74) (75) |
Install the
- Secure tube (16) to hose as (112) and hose as (17) with two hose clamps (11)
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Illustration 97 g02139866 ( 12) 8T-4121 Hard Washer
(13)8T-4133 Nut
(14)8T-4196 Bolt
(15)120-5867 Clip
(17)283-1131 Hose As - Secure hose as (17) to base as (97) with two washers (12), nut (13), bolt (14), and clip (15).
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Illustration 98 g02139891 (17) 283-1131 Hose As - Make sure that the hose as (17) is in the location that is shown in Illustration 98.
- Perform Step 1 through Step 3 for the other side of the hose as (17) on the other side of the engine.
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Illustration 96 | g02139844 |
(11) (16) (17) |
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