Introduction DESCRIPTION: The CQC-HD (Coolant Quick Changer-Heavy Duty) is a time saving member of FTI’s family of coolant handling equipment. This portable unit safely drains and refills larger engine-cooling systems in a fraction of the time it takes for conventional methods. When properly operated, this unit induces no air and less than 5 psi pressure into the engine’s cooling system. No hose cutting or tee is required – the CQC-HD fill pump and the engine’s own water pump perform the service.
Safety Precautions ! CAUTION: FAILURE TO FOLLOW THE PROCEDURES AND PRECAUTIONS AS OUTLINED IN THE OPERATION MANUAL CAN RESULT IN DAMAGE TO THE ENGINE, VEHICLE OR EQUIPMENT AND IS NOT SUPPORTED OR WARRANTED IN ANY WAY. ! WARNING: FAILURE TO FOLLOW THESE PRECAUTIONS CAN RESULT IN SERIOUS INJURY OR DEATH. • Read and understand the operation manual completely before operating this unit. • Always wear proper eye and skin protection when operating and maintaining this equipment. • Hazardous voltages present.
Assembly INSTALLATION OF SWIVEL CASTERS: Locate the 4 swivel casters and bag of hardware that was shipped with the unit. Have a helper tilt the unit on its bottom edge to install each caster. Insert the bolt from the top, with the washer and nut on the bottom. Tighten with a 1/2” wrench or socket. 3.
Sequence of Operation This section is a brief overview of the operation of this equipment. The CQC-HD is a machine designed to perform quick and simple engine coolant changes on larger trucks, tractor-trailers and construction equipment, forklifts, pickup trucks and automobiles. When properly operated, this quick change can be accomplished in as little as ten minutes. The following is the normal sequence of operation for a CQC-HD.
CQC-HD Quick Change Process Color Code Chart HOSE TYPE PURPOSE RED Evacuation pump/hose Removes old coolant from radiator and reservoir. Can also be used to pump out waste coolant from 30 gallon holding tank to customer supplied 55 gallon drum or tank. GREEN Fill/Quick change hose In the fill position, fills new coolant into fill container from customer’s 55 gallon drum of new antifreeze. In the quick-change position, fills the vehicle’s coolant system with new antifreeze.
Performing A Quick Change Following these guidelines will perform a quick change on most vehicles. Due to the variety of diesel and heavy duty cooling system designs, slight variations of this procedure may be necessary. PREPARE FOR OPERATION: 1. A quick change works best on a warm vehicle. Allow vehicle to run at an idle for several minutes prior to initiating a quick change. ! WARNING: Wear proper eye and skin protection such as safety glasses and industrial work gloves.
USE OF THE DRAIN PUMP: ! CAUTION: The CQC-HD has a high center of gravity and could tip over. Use caution when moving the CQCHD with the fill container full. ! WARNING: Large vehicle cooling systems can be under pressure and extremely hot. Allow the vehicle’s cooling system to cool down and use extreme caution when removing caps and hoses. Consult the vehicle manufacturer for recommended procedure on removing the radiator cap. 1.
Connecting the CQC-HD to the Vehicle HINT: It may save time on the coolant exchange process if you attach the CQC-HD drain and fill hose connections to the vehicle’s radiator while the engine is cold. Keep both valves on the hoses closed at this point. ! CAUTION: Prior to connecting the CQC-HD to the vehicle, check for proper operation of the fill pump.
Coolant Exchange Operation ! WARNING: Keep clothing, hair, hands, etc. away from all moving parts of the vehicle. ! CAUTION: Continuous monitoring of the quick-change process is required. Leaving the vehicle unattended while operating this equipment can result in damage to the engine, vehicle, and/or equipment. 1. Verify that the 3-way valve located on the side of the unit is in the quickchange position (Figure 5). 2. Open the fill valve on the green fill hose and turn the fill pump on.
! CAUTION: Never allow the fill pump to operate without liquid. Running the pump dry will cause premature wear or damage to the pump and is not covered under warranty. 8. It is highly sugested that the operator wear industrial work gloves when disconnecting the CQC-HD from the vehicle. Close the drain valve on the black drain hose after the engine is turned off. 9. Disconnect the CQC-HD from the vehicle. Carefully reconnect the upper radiator hose to the radiator and securely clamp. 10.
Per for ming A Quick-Change thr ough the Heater Hose Perfor forming through Many heavy-duty diesel engines have heater hoses running to and from the engine block below the thermostat location through a fuel pre-heat exchanger and then on to a cab heater on the firewall. On many diesel engines these hoses are more accessible than the upper radiator hoses. On this type of engine configuration, it is possible to conduct the coolant exchange process with the CQ-HD through these heater hoses.
Coolant Exchange Operations for Heater Hose 11. Verify that the three way valve located on the side of the CQC-HD is in the quick-change position 12. Open the fill valve on the green hose and turn the fill pump on. The vehicle’s engine does not have to be turned on. 13. Open the drain valve on the black hose. The new coolant will fill the engine block and the old coolant will drain into the 30-gallon waste tank in the back of the CQC-HD. 14.
Maintenance Schedule EVERY USE: CLEANUP ANY SPILLS – Antifreeze/coolants can be corrosive to the unit’s painted finish. Immediately wipe, rinse and dry any spills thoroughly. AS REQUIRED: FLUSH THE DRAIN PUMP – Dirt and grit from waste coolant can cause premature wear on the drain pump’s impeller. Periodically flush the pump by pumping 5 gallons of cool, clean water through the red hose.
Helpful Hints • It is recommended that during initial operation the drain and fill pumps be primed. To do this, pour approximately one gallon of water into the upper fill container. FILL PUMP - place the valve in “container fill” position and turn on fill pump until flow is observed through the bypass loop. Turn off the fill pump. EVACUATION PUMP - place wand in fill container and turn on evacuation pump. Water flows into waste coolant drum. Turn off evacuation pump when fill container is empty.
Helpful Hints (continued) • It is possible to connect the drain and fill hoses on the CQC-HD to the engine while it is cold. It is important to keep both valves on the hoses closed at this time. (see steps 1 - 5 on page 8) • It is possible to fill an empty cooling system (after water pump replacement, engine overhaul, radiator replacement, etc.) by using the heater hose quick change procedures (see page 11). ! CAUTION: Do not allow the liquid temperature in the fill container to exceed 130ºF/55ºC.
Common Spare Parts Coolant Quick Changer: 11 2 14 3 4 5 1 7 6 8 Item Description Part Number 1 On/Off Switches J101704 2 Fill Container M102175 3 1st Step Adapter (up to hose sizes 2-3/4”) M102169 4 Ball Valve J101629 5 Plastic Wand for RED Hose M101271 6 RED Pump Hose M101270 7 GREEN Fill Hose M101269 8 BLACK Drain Hose M101268 9* Pump Impeller Kit J101775 10* Evacuation Pump & Motor Assembly A101591 11 Bypass Check Valve J103686 12* Fill/Quick Change Pump and M
Tech Service 1-800-888-3743 Literature ID No.
