G Drive Cummins

Assembly Instructions
QSG12-G1 G2 G-Drive Coolpac
Air Cleaner Assembly A054F708 Normal Duty

G1
Air Cleaner Assembly A057E961 Heavy Duty
G1
Air Cleaner Assembly A054L178 Normal Duty
G2
Air Cleaner Assembly A057E963 Heavy Duty
G2
Radiator Assembly A054J079
English
Original Instructions 12-2017 A054M513 (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 Water Quality Check ....................................................................................................... 4
1.13 How to Obtain Service .................................................................................................... 4
2. PARTS INFORMATION ........................................................................................................... 5

2.1 Introduction ....................................................................................................................... 5
2.2 Accessories ....................................................................................................................... 5
2.3 Normal Duty Air Cleaner Assemblies .............................................................................. 11
2.4 Heavy Duty Air Cleaner Assemblies ............................................................................... 13
2.5 Radiator Assembly ......................................................................................................... 15
3. ENGINE MOUNTINGS ........................................................................................................... 17

3.1 Engine Mountings........................................................................................................... 17
4. AIR CLEANER ASSEMBLY .................................................................................................. 19

4.1 Introduction ..................................................................................................................... 19
4.2 Required Tools ................................................................................................................ 19
4.3 Items Required by Customer to Complete Installation.................................................... 19
4.4 Air Cleaner Assembly Instructions - Normal Duty ........................................................... 19
4.5 Air Cleaner Assembly Instructions - Heavy Duty ............................................................ 21
5. RADIATOR ASSEMBLY ........................................................................................................ 25

5.1 Introduction ..................................................................................................................... 25
5.2 Cooling Fan Assembly .................................................................................................... 25
5.2.1 Required Tools ..................................................................................................... 25
5.2.2 Items Required by Customer to Complete Installation ......................................... 25
5.2.3 Cooling Fan Assembly Installation ....................................................................... 25
5.3 Radiator Assembly Instructions....................................................................................... 27
5.3.1 Required Tools ..................................................................................................... 27
5.3.2 Items Required by Customer to Complete Installation ......................................... 27
5.3.3 Mounting the Radiator ......................................................................................... 28
5.3.4 Radiator Fan Guards ........................................................................................... 30
5.3.5 Connecting the Radiator ...................................................................................... 31
5.4 Filling the Cooling System............................................................................................... 36
5.4.1 Cooling System Filling Procedure ........................................................................ 36
A054M513 (Issue 1) i Copyright © 2017 Cummins Inc.

Table of Contents 12-2017
6. TESTING THE INSTALLATION ............................................................................................. 39

6.1 Testing the Installation .................................................................................................... 39
APPENDIX A. OUTLINE DRAWING .......................................................................................... 41

A.0 A059G614 Outline Drawing ............................................................................................ 43
Copyright © 2017 Cummins Inc. ii A054M513 (Issue 1)

1 Introduction
WARNING
Hazardous Voltage
Contact with high voltages can cause severe electrical shock, burns, or death.
Make sure that only a trained and experienced electrician makes generator set electrical
output connections, in accordance with the installation instructions and all applicable codes.
WARNING
Electrical Generating Equipment
Faulty electrical generating equipment can cause severe personal injury or death.
Generator sets must be installed, certified, and operated by 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
Inc. Application Engineering Bulletins (AEBs) which highlight interfaces, installation requirements and
operating limits, together with all applicable codes and product standards. In line with Cummins Inc.
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 installer's 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 Inc. 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://quickserve.cummins.com).
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 equipment.
DANGER
Indicates a hazardous situation that, if not avoided, will result in death or serious injury.
A054M513 (Issue 1) 1 Copyright © 2017 Cummins Inc.

1. Introduction 12-2017
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.
NOTICE
Indicates information considered important, but not hazard-related (e.g., messages relating to
property damage).
1.3 Safety Precautions

WARNING
Incorrect installation.
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.
NOTICE
Sharp edges/burrs on housing panels/parts can cause severe cuts/abrasions. When handling
parts, always wear gloves.
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.
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 your 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 be 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.
Copyright © 2017 Cummins Inc. 2 A054M513 (Issue 1)

12-2017 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.

1. Introduction 12-2017
1.11 Specifications
TABLE 1. SPECIFICATIONS
Item Data
Engine Weight
Dry 785 kg (1731lbs)
Approximate (Dry) Engine Weight
Radiator Assembly Weight Dry 169 kg (373 lbs)
Air Cleaner Housing Weight
Normal Duty 18.5 kg (41 lbs)
Heavy Duty 46.4 kg (102 lbs)
Air Cleaner support plate 8.4 kg (10 lbs)
Cooling System
48 L (12.7 US gal)
Capacity with Standard Radiator
Lubricating System
Oil Capacity with Filters 34.1 L (9 US gal)
1.12 Water Quality Check

Excessive levels of calcium and magnesium contribute to scaling problems, and excessive levels of
chloride and sulfate cause cooling system corrosion. If water quality is unknown, it can be tested with
the Fleetguard® Monitor C™ program or Water-Chek™ test strip. Water test results can also be
obtained from local water utility departments. Test data must show the following elements, and the
levels must not exceed the published limits for use in cooling systems.
Calcium, Magnesium (Hardness) Maximum level 170 ppm (as CaC03)
Chloride 40 ppm (as Cl)
Sulfate 100 ppm (as SO4)
Fleetguard® Water-Chek™ Test Strip, Part Number CC2609, can be used to determine the quality of
make-up and shop tap water. The Water-Chek™ test strip measures hardness, pH, and chloride
levels in make-up water.
For additional information or advice refer to your local distributor.
1.13 How to Obtain Service

When a product requires servicing, contact the nearest Cummins service provider. To locate the
distributor, go to www.cummins.com/support and select Sales and Locator. When contacting the
service provider, always supply the complete model, specification, and serial number as shown on the
nameplate.

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. Contact your authorized distributor with any discrepancies.
2.2 Accessories
No Part Number Description Qty

1 A057A345 Retaining Bolts 6
2 A057A335 Spacer 1
3 A057A333 Spacer 2
4 A057A337 Fan 1
5 A057A331 Spacer 1
FIGURE 1. FAN ASSEMBLY

2. Parts Information 12-2017
No. Part No Description Qty No. Part No Description Qty

1 5371607 Rear Engine Support Legs 2 2 4006384 M14x2 Flange Bolt 8
FIGURE 2. REAR ENGINE SUPPORT LEGS

12-2017 2. Parts Information

1 5371609 Front Right Engine 1 3 4006384 M14x2 Flange Bolt 8
Support Leg
2 5371605 Front Left Engine Support 1
Leg
FIGURE 3. FRONT ENGINE SUPPORT LEGS


1 A054F973 Bracket, Fuel filter 1 4 A024Z615 Screw 4
2 A024Z661 Washer, Flat 6 5 A024Z651 Nut 2
3 A024Z674 Washer, Spring 4
FIGURE 4. FUEL/WATER SEPARATOR


1 12065298 Low Coolant Sender 1 3 12048074 Low Coolant Engine 1
Connection Harness Connection
2 A0456F32 Harness, Low Coolant 1 4 A049Z918 Low Coolant Sender 1
Level
FIGURE 5. LOW COOLANT LEVEL HARNESS

TABLE 2. POWER GENERATION INTERFACE (PGI) CONNECTOR KIT
No Part Number Description QTY No Part Number Description QTY

1 A040B973 Terminal, Electrical 3 4 A040C012 Seal, Connector 7
2 A040C195 Connector, Electrical 1 5 A040C169 Contact, Socket 9
3 A040B993 Connector, Electrical 1 6 A040C006 Connector, Socket 1
The Power Generation Interface (PGI) socket (6) is supplied to allow connection to the Engine Control
Management (ECM). Socket (3) is for connection to the CAN data link.

2.3 Normal Duty Air Cleaner Assemblies

TABLE 3. NORMAL DUTY AIR CLEANER ASSEMBLIES
No Part Number Description Qty No Part Number Description Qty

1 A054F958 Bracket, Air ,Filter 1 7 A024Z676 Washer, Spring 4
2 A054F960 Filter, Air 1 8 A005Y942 Screw, Hex, Head 4
3 A054J596 Spacer 4 9 A035N049 Washer, Flat 6
4 A054F952 Kit, Air filter, G1 1 10 A042W385 Washer, Lock 6
5 A054L186 Kit, Air filter, G2 1 11 A035M691 Screw, Hex Head 6
6 A024Z662 Washer, Flat 4

TABLE 4. NORMAL DUTY AIR CLEANER KIT

1 A055A120 Elbow, Air Filter 1 7 A055B397 Clamp, Hose G1 2
2 A055B393 Hose, Hump G1 1 8 A055B399 Clamp, Hose G1 1
3 A055A124 Hose, Hump G2 1 9 A055A126 Clamp, Hose G2 2
4 A055B395 Pipe, Air Inlet G1 1 10 A054Z980 Clamp, Hose G2 1
5 A055B395 Pipe, Air Inlet G2 1 11 A054Z982 Clamp, Hose G2 1
6 A054Z980 Clamp, Hose G1 1

2.4 Heavy Duty Air Cleaner Assemblies

TABLE 5. HEAVY DUTY AIR CLEANER ASSEMBLIES

1 A054F958 Bracket, Air ,Filter 1 7 A024Z651 Nut 4
2 A057G320 Kit, Air filter, G1 1 8 A005Y414 Screw, Hex, Head 4
3 A057G321 Kit, Air filter, G2 1 9 A035N049 Washer, Flat 6
4 A057E955 Pipe, Air, Inlet 1 10 A042W385 Washer, Lock 6
5 A024Z661 Washer, Flat 4 11 A035M691 Screw, Hex Head 6
6 A024Z674 Washer, Spring 4


1 A000C774 Filter, Air 1 7 A057E937 Clamp, Hose 2
2 A057E936 Mounting, Bracket 2 8 A057E947 Hose, Hump G1 1
3 A001A676 Cap, Rain 1 9 A057E954 Hose, Hump G2 1
4 A003R787 Indicator, Service 1 10 A057E945 Clamp, Hose G1 1
5 A057E958 Cap, Dust 1 11 A057E943 Clamp, Hose G2 2
6 A057E942 Elbow, Air Filter 1
FIGURE 6. HEAVY DUTY AIR CLEANER KIT

2.5 Radiator Assembly
FIGURE 7. RADIATOR ASSEMBLY A054J079

TABLE 6. RADIATOR ASSEMBLY A054J079

1 A057A172 RADIATOR 1 22 A057A371 ROD,TIE 1
2 A057A208 TUBE,RADIATOR 1 23 A058H240 CONNECTION,WATER 2
INLET
3 A057A210 TUBE,RADIATOR 1 24 A057A369 SHIELD,HEAT 1
4 A057A212 TUBE,RADIATOR 1 25 A057A365 ROD,TIE 2
5 A057A309 HOSE,VENT 1 26 A057A200 GUARD,FAN 1
6 A057A311 HOSE,VENT 1 27 A057A202 GUARD,FAN 1
7 A057A313 HOSE,RADIATOR 2 28 A057A204 GUARD,FAN 1
8 A057A319 HOSE,RADIATOR 2 29 A057A206 GUARD,FAN 1
9 A057A321 CLAMP,HOSE 4 30 A049Z918 SENSOR,COOLANT 1
LEVEL
10 A057A323 CLAMP,HOSE 2 31 A057A303 CLAMP,HOSE 4
11 A057A325 CLAMP,HOSE 4 32 A057A301 HOSE,RADIATOR 2
12 A057A327 CLAMP,HOSE 4 33 A057A307 CLAMP,HOSE 4
13 A057A347 VALVE,COOLANT 1 34 A057A305 HOSE,RADIATOR 2
14 A055Y140 VALVE,BALL 2 35 A057A214 TUBE,RADIATOR 1
15 A057A350 SUPPORT,HOSE 1 36 A057A329 KIT,FAN 1
16 A057A362 BRACE,RADIATOR 4 37 A005Y908 SCREW,HEX HEAD 8
17 A057A354 SUPPORT,HOSE 1
18 A057A358 GUARD,FAN 1
19 A057A356 GUARD,FAN 1
20 A057A360 CLAMP 2
21 A057A315 HOSE,VENT 1

3 Engine Mountings
3.1 Engine Mountings
NOTICE
Mark the bolt heads with white pen to indicate that the required torque has been set.
NOTICE
Numbers in Parenthesis relate to the parts list
FIGURE 8. FRONT ENGINE MOUNTINGS

1. Using the 8 M14X2 flange bolts (3), fit the front engine support legs (1) (2) to both sides of the
engine.
a. Using a 22 mm (7/8 in A/F) socket wrench, torque the bolts to 180 Nm (133 ft-lb).

3. Engine Mountings 12-2017
FIGURE 9. REAR ENGINE MOUNTINGS

2. Using the 8 M14X2 flange bolts (3), fit the front engine support legs (1) (2) to both sides of the
engine.
a. Using a 22 mm (7/8 in A/F) socket wrench, torque the bolts to 180 Nm (133 ft-lb).

4 Air Cleaner Assembly
4.1 Introduction
4.2 Required Tools

• Lifting straps with shackles capable of lifting 46 Kg (102 lbs)
• Lifting equipment capable of lifting 46 Kg (102 lbs)
• Torque wrench minimum value 0-200 Nm (0-147 ft-lbs)
• 13 mm (1/2 in A/F) 18 mm (11/16 in A/F) 20 mm (3/4 in A/F) Wrenches
• 13 mm (1/2 in A/F) 18 mm (11/16 in A/F) 20 mm (3/4 in A/F) Impact sockets
• Air ratchet wrench or 12V/18V cordless drill
4.3 Items Required by Customer to Complete

Installation
Add or remove items from table as required for your installation
The following items are required to complete this installation.
Part Description Quatity Where Used

Hose Lubricant A/R Hose Installation
White Paint Pen Mounting Bolts
4.4 Air Cleaner Assembly Instructions - Normal Duty

NOTICE
NOTICE
Numbers in Parenthesis relate to the parts list Section 2.3 on page 11

4. Air Cleaner Assembly 12-2017
FIGURE 10. NORMAL DUTY AIR CLEANER

1. To aid installation attach a suitable hoist and sling to the air cleaner support bracket (1).
2. Using a 20 mm (3/4 in AF) socket wrench, fit the air cleaner support plate (1) and the fuel/water
separator bracket (Figure 11 on page 21 to the engine using 6 off M14 mm hex head bolts (11)
with 6 M14 spring washers (10) and 6 M14 flat washers (9). Torque all bolts to 159 Nm (117 ft-
lbs).
3. To aid installation attach a suitable hoist and sling to the air cleaner assembly (2).
4. Using a 18 mm (11/16 in A/F) socket wrench, fit the air cleaner assembly (2) with the 4 spacers
(3) to the support plate using 4 off M12 mm hex head bolts (8) with 4 M12 spring, 4 M12 flat
washers. Torque the bolts to 100 Nm (74 ft-lbs).
5. Lubricate the hose hump and elbow with a suitable hose lubricant as required.
6. Connect the assemble between the air cleaner and turbocharger.
7. Using a 13 mm (1/2 in A/F) fully tighten the hose clamps. Torque the clamp bolts to 12 Nm (9 ft-
lbs).

12-2017 4. Air Cleaner Assembly
FIGURE 11. FUEL FILTER/WATER SEPARATOR

8. Using a 17 mm (11/16 in A/F) spanner wrench, install the fuel/water separator filter to the
support bracket (1) with the 4 M10 screws (4), 4 M10 spring washers and 6 M10 flat washers.
4.5 Air Cleaner Assembly Instructions - Heavy Duty

NOTICE
NOTICE
Numbers in Parenthesis relate to the parts list Section 2.4 on page 13

FIGURE 12. AIR CLEANER ASSEMBLY

1. To aid installation attach a suitable hoist and sling to the air cleaner support bracket (1).
2. Using a 20 mm (3/4 in AF)socket wrench, fit the air cleaner support plate (1) and the fuel
filter/water separator bracket (1)Figure 13 on page 23 to the engine using 6 off M14 mm hex
head bolts (11) with 6 M14 spring washers (10) and 6 M14 flat washers (9). Torque all bolts to
159 Nm (117 ft-lbs).
3. To aid installation attach a suitable hoist and sling to the air cleaner assembly (2) or (3).
4. Using a 18 mm (11/16 in A/F) socket wrench, using 4 off M10 hex head bolts (8) with 4 M10 flat
washers (5), 4 M10 spring washers (6) and 4 M10 nuts (7), fit the air cleaner assembly mounting
brackets to the air cleaner support bracket (1). Torque all bolts to 100 Nm (74 ft-lbs)).
5. Fit the air cleaner housing (2) or (3) between the band mountings Figure 6 on page 14, and
tighten the band mounting clamp bolts.
6. Assemble the air cleaner inlet hose (4) or (5) see Figure 6 on page 14.
7. Lubricate the hose hump and elbow with a suitable hose lubricant as required.
8. Connect the assemble between the air cleaner and turbocharger.
9. Using a 13 mm (1/2 in A/F) wrench, fully tighten the hose clamps. Torque the clamps to 12 Nm
(9 ft-lbs)
10. Install the rain cap and service indicator see Figure 6 on page 14.

12-2017 4. Air Cleaner Assembly
FIGURE 13. FUEL FILTER/WATER SEPARATOR

11. Using a 17 mm (11/16 in A/F) spanner wrench, install the fuel/water separator filter to the
support bracket (1) with the 4 M10 screws (4), 4 M10 spring washers and 6 M10 flat washers.

This page is intentionally blank.

5 Radiator Assembly
5.1 Introduction
5.2 Cooling Fan Assembly

5.2.1 Required Tools
• Lifting straps with shackles capable of lifting 100 Kg (220 lb)
• Lifting equipment capable of lifting 100 Kg (220 lb)
• Torque wrench minimum value 0-100 Nm (0-74 ft-lb)
• 17 mm (11/16 in A/F) Wrench
• 17 mm (11/16 in A/F) Impact sockets
5.2.2 Items Required by Customer to Complete Installation


White Paint Pen Mounting Bolts
5.2.3 Cooling Fan Assembly Installation
FIGURE 14. DOWEL BOLT

1. To aid in the installation of the fan locally produced dowel bolts, will assist in the alignment and
support of the spacers.

5. Radiator Assembly 12-2017
FIGURE 15. DOWEL BOLT INSERTION

2. Insert two dowel bolts (A) into the fan drive pulley (B). Slide the spacers (3) (5) over the dowel
bolts.

12-2017 5. Radiator Assembly
FIGURE 16. FAN INSTALLATION

3. With the aid of another person, slide the fan (4), spacers (2) (3) over the dowel bolts.
4. Apply Loctite 242 to the retaining bolts (1).
5. Insert four of the retaining bolts (1), do not fully tighten at this stage.
6. Remove the two dowel bolts and insert the two remaining retaining bolts (1).
7. Using a 17 mm (11/16 in A/F) socket wrench, tighten the retaining bolts in an opposite sequence
to 92 Nm (68 ft-lb) +/- 2 Nm.
5.3 Radiator Assembly Instructions

5.3.1 Required Tools
• Lifting straps with shackles capable of lifting 169 Kg (373 lbs)
• Lifting equipment capable of lifting 169 Kg (373 lbs)
• Torque wrench minimum value 0-100 Nm (0-74 ft-lbs)
• 10 mm (3/8 in A/F) 13 mm (1/2 in A/F) 16 mm (5/8 in A/F) 18 mm (11/16 in A/F) Wrenches
• 10 mm (3/8 in A/F) 13 mm (1/2 in A/F) 16 mm (5/8 in A/F) 18 mm (11/16 in A/F) Impact sockets
5.3.2 Items Required by Customer to Complete Installation



White Paint Marker A/R Mounting Bolts
5.3.3 Mounting the Radiator

WARNING
Heavy Load
Incorrect lifting or repositioning can cause severe personal injury or death.
Use a hoist of sufficient capacity for lifting and moving the radiator assembly.
FIGURE 17. LIFTING

1. Attach shackles and lifting straps to the lifting points on the radiator.

2. With the aid of another person, carefully lower the radiator onto its mounting point using slow
progressive movements.
3. Secure the radiator with the four mounting bolts with flat washers. Using a 18 mm (11/16 in A/F)
socket wrench, tighten to 91 Nm (67 ft-lbs).
4. Install the radiator Guards see Section 5.3.4 on page 30
FIGURE 18. FAN ALIGNMENT

5. When Installing the radiator assembly, check the fan alignment to the radiator cowl, making sure
there is a 5 to 15 mm (.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.

5.3.4 Radiator Fan Guards
FIGURE 19. CHARGE ALTERNATOR GUARD
FIGURE 20. LEFT HAND RADIATOR GUARD

FIGURE 21. RIGHT HAND LOWER RADIATOR GUARD
FIGURE 22. RIGHT HAND RADIATOR GUARD
5.3.5 Connecting the Radiator

1. Connect the radiator.

FIGURE 23. RADIATOR VENT HOSES

2. Connect the coolant level sensor (30).
3. Connect the vent pipes (6) (21).

FIGURE 24. CAC INLET PIPE

4. Using a suitable hose lubricant, lubricate the hoses (32) and connect the CAC Inlet pipe (3).
a. Using a 10 mm (3/8 in AF) wrench, tighten the top hose clamps (31) to 12 Nm (9 ft-lbs).
b. Using a 13 mm (1/2in AF) wrench, install the two support braces (16).
c. Using a 10 mm (3/8 in AF) wrench, tighten the bottom hose clamps (31) to 12 Nm (9 ft-lbs).
d. Install the heat shield (24).
e. Using a 13 mm (1/2in AF) wrench, using the screw hex head bolts (37) install the two rod
ties (25).

FIGURE 25. RADIATOR BOTTOM HOSE

5. Using a suitable hose lubricant, lubricate the hoses (8) and connect the lower coolant hose (35).
a. Using a 10 mm (3/8 in AF) wrench, tighten the hose clamps (9) to 12 Nm (9 ft-lbs).
b. Install the connection, water inlet (23).

FIGURE 26. CAC OUTLET PIPE

6. Using a suitable hose lubricant, lubricate the hoses (34) and connect the CAC outlet pipe (2)
from the CAC to the air intake manifold.
a. Using a 10 mm (3/8 in AF) wrench, tighten the bottom hose clamps (33) to 12 Nm (9 ft-lbs).
b. Using a 13 mm (1/2 in A/F) wrench, install the two rod ties (22) between the CAC pipe and
radiator.
c. Using a 10 mm (3/8 in AF) wrench, tighten the top hose clamps (33) to 12 Nm (9 ft-lbs).
d. Using a 16 mm (9/16 in AF) wrench, install the two clamps (20) and support brackets (16).

FIGURE 27. TOP COOLANT HOSE

7. Using a suitable hose lubricant, lubricate the hoses (7) and connect the top coolant pipe (4)
between the radiator and engine.
a. Using a 10 mm (3/8 in AF) wrench, tighten the hose clamps (12) to 12 Nm (9 ft-lbs).
b. Install the top clamp to support the coolant pipe.
8. Fill the coolant system see Section 5.4.1 on page 36.
5.4 Filling the Cooling System

After the components have been properly assembled and mounted, fill the cooling system.
5.4.1 Cooling System Filling Procedure

WARNING
Hot Pressurized Liquid
Contact with hot liquid can cause severe burns.
Make sure the radiator cap is properly secured before operating the generator set.

NOTICE
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.
Fill the cooling system with premixed fully formulated coolant or with a 50/50 mixture of high-quality
water distilled or deionized and fully formulated concentrated antifreeze. The fully formulated
coolant/antifreeze, either ethylene glycol or propylene glycol, must meet Cummins Engineering
Standard 14603. Cummins Inc. recommends using Fleetguard® coolants containing DCA4. If the
radiators are not filled using Fleetguard "Compleat" brand antifreeze or equivalent antifreeze, the
DCA4 needs to be added to the cooling systems.
Refer to the engine manufacturer's Owner's manual for recommended coolant type.
If water quality is unknown, it can be tested with the Fleetguard® Monitor C™ program or Water-
Chek™ test strip.
1. Begin slowly filling the radiator with a 50/50 mixture of fully formulated coolant and DCA4 (or
equivalent).
2. Observe the coolant level through the sight glass on the expansion tank. Coolant level should be
approximately at the fill level in the sight glass with a cool engine.
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.
4. Start the engine an allow to warm up and check for leaks. Repair as necessary.


6 Testing the Installation
6.1 Testing the Installation
WARNING
Moving Parts
Moving parts can cause severe personal injury.
When the belt guards are not installed, wear safety glasses and stand back from the running
fan drive.
WARNING
Hot Pressurized Liquid
Contact with hot liquid can cause severe burns.
Do not open the pressure cap while the engine is running. Let the engine cool down before
removing the cap. Turn the cap slowly and do not open it fully until the pressure has been
relieved.
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.

6. Testing the Installation 12-2017

Appendix A. Outline Drawing
Table of Contents
Figure 28. Sheet 1 of 3 ........................................................................................................................... 43
Figure 29. Sheet 2 of 3 ........................................................................................................................... 44
Figure 30. Sheet 3 of 3 ........................................................................................................................... 45

Appendix A. Outline Drawing 12-2017

12-2017 Appendix A. Outline Drawing
A.0 A059G614 Outline Drawing
FIGURE 28. SHEET 1 OF 3


12-2017 Appendix A. Outline Drawing


power.cummins.com
Copyright © 2017 Cummins Inc. All rights reserved.
Cummins, the "C" logo, PowerCommand, AmpSentry, and InPower are trademarks of Cummins Inc.
Other company, product, or service names may be trademarks or service marks of others.
Specifications are subject to change without notice.

G Drive Cummins

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

G Drive Cummins

Uploaded by

Copyright:

Available Formats

Assembly Instructions

QSG12-G1 G2 G-Drive Coolpac

Air Cleaner Assembly A054F708 Normal Duty

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

3. ENGINE MOUNTINGS ........................................................................................................... 17

4. AIR CLEANER ASSEMBLY .................................................................................................. 19

5. RADIATOR ASSEMBLY ........................................................................................................ 25

A054M513 (Issue 1) i Copyright © 2017 Cummins Inc.

6. TESTING THE INSTALLATION ............................................................................................. 39

APPENDIX A. OUTLINE DRAWING .......................................................................................... 41

Copyright © 2017 Cummins Inc. ii A054M513 (Issue 1)

1.1 About These Assembly Instructions

1.2 Warning, Caution, and Note Styles Used in This

A054M513 (Issue 1) 1 Copyright © 2017 Cummins Inc.

1.3 Safety Precautions

1.5 Guarding Against Hot Surfaces

Copyright © 2017 Cummins Inc. 2 A054M513 (Issue 1)

1.6 Guarding Against Moving Parts

1.7 Control System

A054M513 (Issue 1) 3 Copyright © 2017 Cummins Inc.

1.12 Water Quality Check

1.13 How to Obtain Service

Copyright © 2017 Cummins Inc. 4 A054M513 (Issue 1)

No Part Number Description Qty

FIGURE 1. FAN ASSEMBLY

A054M513 (Issue 1) 5 Copyright © 2017 Cummins Inc.

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

FIGURE 2. REAR ENGINE SUPPORT LEGS

Copyright © 2017 Cummins Inc. 6 A054M513 (Issue 1)

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

FIGURE 3. FRONT ENGINE SUPPORT LEGS

A054M513 (Issue 1) 7 Copyright © 2017 Cummins Inc.

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

FIGURE 4. FUEL/WATER SEPARATOR

Copyright © 2017 Cummins Inc. 8 A054M513 (Issue 1)

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

FIGURE 5. LOW COOLANT LEVEL HARNESS

A054M513 (Issue 1) 9 Copyright © 2017 Cummins Inc.

TABLE 2. POWER GENERATION INTERFACE (PGI) CONNECTOR KIT

No Part Number Description QTY No Part Number Description QTY

Copyright © 2017 Cummins Inc. 10 A054M513 (Issue 1)

2.3 Normal Duty Air Cleaner Assemblies

No Part Number Description Qty No Part Number Description Qty

A054M513 (Issue 1) 11 Copyright © 2017 Cummins Inc.

TABLE 4. NORMAL DUTY AIR CLEANER KIT

No Part Number Description Qty No Part Number Description Qty

Copyright © 2017 Cummins Inc. 12 A054M513 (Issue 1)

2.4 Heavy Duty Air Cleaner Assemblies

No Part Number Description Qty No Part Number Description Qty

A054M513 (Issue 1) 13 Copyright © 2017 Cummins Inc.

No Part Number Description Qty No Part Number Description Qty

FIGURE 6. HEAVY DUTY AIR CLEANER KIT

Copyright © 2017 Cummins Inc. 14 A054M513 (Issue 1)

2.5 Radiator Assembly

FIGURE 7. RADIATOR ASSEMBLY A054J079

A054M513 (Issue 1) 15 Copyright © 2017 Cummins Inc.

TABLE 6. RADIATOR ASSEMBLY A054J079

No Part Number Description Qty No Part Number Description Qty

Copyright © 2017 Cummins Inc. 16 A054M513 (Issue 1)

FIGURE 8. FRONT ENGINE MOUNTINGS

A054M513 (Issue 1) 17 Copyright © 2017 Cummins Inc.

FIGURE 9. REAR ENGINE MOUNTINGS