Installation, Start-up, Operating,

Maintenance and Storage Procedures

Thermal Systems, Inc.
Form Number: IM-1 Reference:
Phone: 919-563-4871 Catalog Section: Applications Page Number: 1 OF 2
Fax: 919-563-4917 Effective Date: 1/1/2006 Supersedes:

GENERAL SAFETY INFORMATION

Never exceed the maximum allowable temperature or pressure ratings.
Maximum Operating Pressure: 250 PSI
Maximum Operating Temperature: 250*F
Never exceed the published maximum allowable flow rate.
Be sure the system pressure is relieved prior to opening the cooler.
Disconnect the electrical power before servicing.
The fluid being cooled should be compatible with Aluminum.

UNPACKING
Prior to installation, unpack the unit and check for loose or missing
pieces. Minor damage to the cooling fins can be corrected by gently
bending them straight. Caps should be removed from the fluid
connections and a visual inspection performed to check for any debris
or corrosion that may have occurred during storage or shipment.

STORAGE
Product should be stored in a dry area that has a constant temperature.
Temperature changes in the storage area cause condensation to form
inside the heat exchanger. This condensation then causes corrosion which
causes product failure. This failure is not covered by the guarantee.
If this criteria cannot be met, the cooler should be stored in a sealed
plastic bag with desiccant added to absorb the moisture.
Storage term:
6 Months: No specific internal corrosion protection procedures are
required. All openings should be sealed with plastic plugs
7-24 Months: Coolers should be flushed with oil and all openings
re-sealed with plastic plugs.
25+ Months: Coolers should be completely filled with oil and sealed.
These coolers should be flushed, inspected and re-sealed every
24 Months.

INSTALLATION
MOUNTING: The cooler should be mounted in such a fashion that there is
no restriction to the cooling air supply. Recirculation of warmed up air
must be avoided. If mounted in a closed area, sufficient ventilation must
be provided. Corrosive atmospheres can cause premature failure.
If mounted in a location where ambient temperature may be quite cold,
allowance has to be made for high oil viscosity, and potential freeze up.
A temperature controlled by-pass valve or an additional oil heating
system may be installed.
Care should be taken to select a location that has reasonably clean
cooling air. Dirty air fouls the unit and causes overheating.
The cooler should be securely mounted to avoid injury.
 Installation, Start-up, Operating,
Maintenance and Storage Procedures
Thermal Systems, Inc.
Form Number: IM-1 Reference:
Phone: 919-563-4871 Catalog Section: Applications Page Number: 2 OF 2
Fax: 919-563-4917 Effective Date: 10/13/2000 Supersedes:

INSTALLATION
PIPING: All piping must be properly supported to prevent strain to the
cooler. Pipe sizes should be based on the oil flow and pressure drop
requirements, not the oil coolers connection size. Where excessive
vibration may be a concern, flexible connectors should be used to
eliminate stress.

ELECTRICAL
Certified electrician should comply with all local codes. The fan motors
should be connected to a power supply that matches that of the motor
nameplate. The fan blade should be spun by hand prior to hookup to
make sure it has proper clearance. Voltage may vary 10% or nameplate
or voltage. Be sure to provide proper fusing to prevent possible motor
burnout.

START-UP
Check fan air flow to be sure it matches the directional arrow on the unit.
Make sure oil connections are properly sealed.
Check for blockage to the air supply.

OPERATION
Once the unit is installed, the system may be operated normally. If the
source of air is other than the main engine fan, be sure that the fan is
functioning properly.

MAINTENANCE
Be sure to disconnect the power supply prior to servicing.
Inspect the product regularly for corrosion, and dirty or clogged heat
transfer surfaces.
EXTERNAL CLEANING: this can be done by either washing the cooler with
a mild cleaner (compatible with aluminum), or with compressed air. A
power spray washer works well. Care should be taken not to damage
the fins
INTERNAL CLEANING: The cooler should be disconnected, and a cleaner
suitable for removing the type of deposit, yet safe on aluminum should
be recalculated through the cooler until clean. Make sure the internals
are rinsed thoroughly after cleaning. It may help to blow the unit out with
compressed air.
 REVISION
REV. ECN DESCRIPTION DATE DESIGNER
- - - - -

615
281
126
0
57
113
945
919
905 RO
TA 25 (2X)
800 TIO
749 N
698

480

280 AIR FLOW

230
1/4" NPT 179
A
74
54
0 0 0

0
5

18
56
6

102
552
1002
1048
1086
1104
43
TAP FOR M12 X20
HELICOIL (8X)

0
23
38
107
997
1065
1081
1104
5 6
3 4 78
281
225

2 2" SAE 4-BOLT

17/32" (4X) FLANGE (2X)
25 DETAIL A
SCALE 1 : 2
0

NOTE:
113 ITEMS #1 THRU 6 ARE HERESITE COATED
Work Pressure THE INFORMATION HEREON IS THE PROPERTY TITLE
1 (psi) (Max) 250 OF AKGTS. ANY COPYING OR
TRANSMITTAL WITHOUT PERMISSION FROM
Test Pressure UNLESS OTHERWISE SPECIFIED AKG OF AMERICA IS PROHIBITED
(psi) (Max) 190 1. Dimensions are mm. AC100-31972
AKG Thermal Systems
Max Temperature (°F) 2. All dimensions are DRWN BY: Burress
250 PO BOX 189
reference unless DWG. NO. REV.
Paint BLACK Mebane, NC 27302 DATE: 07/17/06
tolerance is specified. Phone(919)563-4871 3703.175.0000 -
Cust. Part No: AC100-31972 Fax (919)563-4917 ENGR: Burress PAGE: 1 of 2
PRINT DATE: 7/17/2006
ITEM NO. QTY. PART NUMBER DESCRIPTION
1 1 3703.021.1000 AC100-C
2 1 3703.021.4010 26" Fan Shroud
3 1 1872.017.4030 27" Fan Guard NOTE:
4 1 3703.021.0060 Motor Mount Bracket ITEMS #1 THRU 6 ARE HERESITE COATED
5 1 3703.021.0002 Left Mounting Bracket
6 1 3703.021.0001 Right Mounting Bracket
7 1 8407.112.4307 Electric Motor Baldor VM7044T
8 1 8400.131.0026 FAN 26-9-4ZL-PPG-35°BRSH 1-1/8"X1/4"

8 3

1
5

Work Pressure THE INFORMATION HEREON IS THE PROPERTY TITLE

(psi) (Max) 250 OF AKGTS. ANY COPYING OR
TRANSMITTAL WITHOUT PERMISSION FROM
Test Pressure UNLESS OTHERWISE SPECIFIED AKG OF AMERICA IS PROHIBITED
(psi) (Max) 190 1. Dimensions are mm. AC100-31972
AKG Thermal Systems
Max Temperature (°F) 2. All dimensions are DRWN BY: Burress
250 PO BOX 189
reference unless DWG. NO. REV.
Paint BLACK Mebane, NC 27302 DATE: 07/17/06
tolerance is specified. Phone(919)563-4871 3703.175.0000 -
Cust. Part No: AC100-31972 Fax (919)563-4917 ENGR: Burress PAGE: 2 of 2
PRINT DATE: 7/17/2006