Oil Cooler Mod Kit Installation (872.008.01).qxp

Oil Cooler Mod Kit Installation (872.008.01).qxp
INSTALLATION
MANUAL
R 5 Series
Oil Cooler Modification Kits
INSTALLATION INSTRUCTIONS
R5 OIL COOLER MODIFICATION KITS
General:
The R5 oil cooler modification kits are intended for use on all
versions of R5’s, from RA/RC0025 through RA/RC1600,
when operating in conditions where high ambient temperatures exist. They retain the use of the standard oil filter while
allowing remote mounting of a water-cooled heat exchanger. Conversion takes only a few minutes and may be done
by anyone with a set of wrenches. All required parts are
included in the kit.
Notes on Installation:
• Keep rubber hoses away from sharp edges and other
points of wear, and hot surfaces.
• Do not bend hoses too tightly; they will crimp, causing
the flow of oil to the cooler to stop. It is important to note that
in the event this should happen, the filter adapter thermostat
is designed to allow the flow of oil to bypass the heat
exchanger.
• Installation of the heat exchanger should be below the
oil level in the exhaust box of the pump.
• When tightening the hose clamps, only do so until the
rubber begins to extrude through the slots in the clamp and
is even with the surface of the clamp.
• Pipe fittings should be sealed with TeflonTM tape. DO
NOT OVERTIGHTEN FITTINGS. Fittings should be tightened to 15 ft. lbs. torque.
(Model)
Pump Type
Oil Cooler Modification
Kit Number
0025 thru 0205, 0255, 0305
OCM-1
0400, 0502, 0630
OCM-2
1000, 1600
OCM-3
0250*
OCM-4
0250**
OCM-1
*
**
Serial numbers starting with "C"
Serial numbers starting with "D"
We reserve the right to change the product at any time without any form of notification. The information in this publication is accurate to the best of our ability at the time of printing. Busch, Inc. will not be responsible for errors
encountered when attempting to perform tasks outlined in this publication which is copyright protected.
1
INSTALLATION PROCEDURE
MODEL OCM-1
(1)
(8)
Connect hoses to hose nipples. Hose should
be rough cut at least 1" longer than measured.
Drain oil.
(9)
Attach the oil filter to the filter adapter. Hand
tighten only.
(2)
Remove oil filter, replace if dirty. DO NOT DISCARD NIPPLE; this will be used to assemble the kit.
(10)
Assemble hose fittings to heat exchanger.
(11)
Connect hoses to heat exchanger. Note: It is
not critical to assemble hoses to the heat exchanger in
any particular port.
(3)
Assemble hose fittings to filter adapter with
TeflonTM tape. Do not overtighten.
CAUTION: Do not mar machined sealing surface; leaks may occur.
(12)
Connect the water in and out lines to the heat
exchanger in the correct ports on the heat exchanger.
(4)
Apply a light coating of oil to the O-ring seal in
the filter adapter.
(13)
Heat exchanger should be mounted below oil
level in exhaust box.
(5)
Insert adapter shaft into filter adapter with hex
against surface adjacent to the thermostat coil.
(14)
(6)
Screw nipple, which was removed from oil filter, into adapter shaft half way.
(15)
Turn water supply on and start pump to clear air
from lines; check for leaks.
(7)
Assemble to the pump exhaust box at filter
location; position filter adapter with ports down, or to the
side, and O-ring against exhaust box surface.
(16)
After 15 minutes, stop pump and check oil level
in pump oil box. Add additional oil if necessary.
Add oil to fill level on exhaust box.
(17)
Run pump for an additional hour; stop pump
and check oil level again.
ASSEMBLY OCM-1
1.
2.
3.
4.
5.
6.
7.
Oil cooler adapter
Heat exchanger
Oil cooler adapter shaft
1/2 NPT x 1/2 hose nipple
1/2 hose clamp
1/2 ID oil resistant hose
Reducing bushing
2
INSTALLATION PROCEDURE
MODEL OCM-2
MODEL OCM-3*
(9)
Attach the oil filter to the filter adapter. Hand
tighten only.
(10)
(1)
Drain oil.
(2)
Remove oil filter, replace if dirty.
Assemble hose fittings to heat exchanger.
(11)
Connect hoses to heat exchanger. Note: It is
not critical to assemble hoses to the heat exchanger in
any particular port.
(3)
Assemble hose fittings to filter adapter with
TeflonTM tape. Do not overtighten.
(12)
Connect the water in and out lines to the heat
exchanger in the correct ports on the heat exchanger.
CAUTION: Do not mar machined sealing surface; leaks may occur.
(13)
Heat exchanger should be mounted below oil
level in exhaust box.
(4)
Apply a light coating of oil to the O-ring seal in
the filter adapter.
(14)
(5)
Insert adapter shaft into filter adapter with hex
against surface adjacent to the thermostat coil.
(15)
Turn water supply on and start pump to clear air
from lines; check for leaks.
(6)
Screw nipple, which was removed from oil filter, into adapter shaft half way.
(16)
After 15 minutes, stop pump and check oil level
in pump oil box. Add additional oil if necessary.
(7)
Assemble to the pump exhaust box at filter
location; position filter adapter with ports down, or to the
side, and O-ring against exhaust box surface.
(17)
Run pump for an additional hour; stop pump
and check oil level again.
* Installation instructions for Model OCM-3 are the
same as for OCM-2, except that there are two complete
kits (one for each oil filter).
(8)
Connect hoses to hose nipples. Hose should
be rough cut at least 1" longer than measured.
ASSEMBLY OCM-2/OCM-3
1.
2.
3.
4.
5.
6.
7.
Add oil to fill level on exhaust box.
Oil cooler adapter
Heat exchanger
Oil cooler adapter shaft
1/2 NPT x 1/2 hose nipple
1/2 hose clamp
1/2 ID oil resistant hose
Reducing bushing
3
INSTALLATION PROCEDURE
MODEL OCM-4
OIL COOLER AND SINGLE FLOW OIL KIT
exhaust box at the filter location; position filter adapter
with ports down, or to the side, and O-ring against
exhaust box surface.
(1)
Shut off the power to the pump. Secure the
power supply so that it cannot be inadvertently started
while it is being worked on.
(15)
Connect hoses to hose nipples. Hoses should
be rough cut at least 1" longer than measured.
(16)
Attach the oil filter to the filter adapter. Hand
tighten only.
(2)
Drain the oil from the pump and remove the
canister (automotive-type) oil filter. Do not discard the
pipe nipple that the oil filter screws into.
(3)
Remove the pump fan guard.
(17)
Assemble hose fittings to heat exchanger.
(18)
Connect hoses to heat exchanger.
(4)
Insert a long Allen wrench through the access
hole in the fan blade to loosen the set screw that locks
the fan to the shaft. Slide the fan off the shaft.
(19)
Connect the water in and out lines to the heat
exchanger in the correct ports (at the side of the
exchanger) on the heat exchanger.
(5)
Remove the oil line assembly that runs from the
fan side endplate to the oil sump in the bottom of the
exhaust box. Use the plug provided in the kit to plug off
the open port in the exhaust box.
(20)
The heat exchanger should be mounted below
the oil level in the exhaust box. Briefly start, then stop
the pump to check the motor rotation. If the pump is
operating backwards, switch any two electric leads.
(6)
Install a new oil line from the fan side endplate,
connect hose, hose nipples and bell reducer. The steel
line may require forming to fit the application. Reuse
the endplate fitting with a new ferrule and a new fitting
on the opposite end. Run the hose to the end connection on the heat exchanger (See OCM-4 illustration).
(21)
(22)
Turn water supply on and start pump to clear air
from lines; check for leaks.
(23)
After 15 minutes, stop pump and check oil level
in pump oil box. Add additional oil if necessary.
(7)
Remove the exhaust box oil drain plug. Install a
pipe nipple in the drain hole and connect a pipe tee to
the nipple. Reinstall the oil drain plug in the tee end
connection. Install the hose nipple and hardware into
the tee side connection. Run the hose to the end connection on the heat exchanger, beside the connection
used in step 6. (See OCM-4 illustration).
(24)
Run pump for an additional hour; stop pump
and check oil level again.
(8)
Replace the pump fan, locking it into position
by tightening the set screw.
(9)
Replace the fan cover, securing it with the
mounting screws.
(10)
Assemble hose fittings to filter adapter with
TeflonTM tape. Do not over-tighten.
CAUTION: Do not mar machined sealing surface; leaks may occur.
(11)
Apply a light coating of oil to the O-ring seal in
the filter adapter.
(12)
Insert adapter shaft into filter adapter with hex
against surface adjacent to the thermostat coil.
(13)
Screw nipple, which was removed from oil filter,
into adapter shaft half way.
(14)
Add oil to fill level on exhaust box.
Screw the adapter assembly into the pump
4
ASSEMBLY OCM-4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11
12.
13.
14.
15.
16.
Oil cooler adapter
Heat exchanger
Oil cooler adapter shaft
3/8 NPT x 1/2 hose nipple
1/2 hose clamp
1/2 ID oil resistant hose
3/4 x 3/8 NPT reducing bushing
1/2 NPT to ISO pipe nipple and gasket
1/2 pipe tee
3/8" NPT to 1/4" bell reducer
Oil tubing assembly 10mm.
Plug R1/4"
1/2 x 3/8 NPT reducing bushing
3/4" pipe tee
3/4" NPT close nipple
3/4" pipe plug
5
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Cerritos, CA 90703
Phone (562) 926-8422
Fax (562) 926-7262
service.ca@buschinc.com
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Glendale Heights, IL 60139
Phone (630) 545-1310
Fax (630) 545-1384
service.il@buschinc.com
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Phone (908) 561-3233
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Phone (787) 798-5045
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Virginia
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Houston, TX 77032
Phone (281) 449-2381
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516 Viking Drive
Virginia Beach, VA 23452
Phone (757) 463-7800
Fax (757) 463-7407
service.va@buschinc.com
6
© 2005 Busch, Inc.
P/N 872.008.01
Revision 03/05
Busch, Inc.
516 Viking Drive
Virginia Beach, Virginia 23452
Phone: (757) 463-7800
FAX: (757) 463-7407
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