PN E101-5927

INSTRUCTIONS

Wear safety goggles to protect your eyes.
Wear Nitrile®, Neoprene® or PVC gloves to protect your hands.
Wear a long-sleeved shirt to protect your arms.
IMPORTANT! The following instructions must be read and understood before attempting to use the BG CFX Cooling Fluid Exchanger. Read product Safety Data Sheet before handling any BG product.
  1. Caution: Heavy object. Consider mechanical aid or at least a two-person team lift when lifting machine.
  2. Make sure this service is performed in a well-ventilated area.
  3. Keep all hoses and tools away from moving engine parts.
  4. Check all lines, hoses, and points of connection for cracks and leaks before and after service.
  5. WARNING! Use EXTREME CAUTION when removing radiator cap to prevent being burned by hot fluid escaping the cooling system. Use EXTREME CAUTION when handling hoses and adaptors as they can reach the same temperature as coolant.
  6. WARNING! Fluid ejection hazard. Do not run machine unless properly connected to a cooling system.
  7. Ensure that the BG CFX Service Selector (V) is in the “Off” (O) position, and the Pressure Regulator (R) is turned all the way down (to the left) before connecting to shop air.
  8. Dispose of cooling system fluids and filters in accordance with federal, state, and local regulations.
  9. The BG CFX Cooling Fluid Exchanger is designed for use only with BG products described in these instructions. The use of any other chemicals or fluids with this system will void all warranties and could create hazardous conditions. DO NOT use the BG CFX to pump or transfer any flammable or combustible liquids.
  10. Caution: Operator can lose control of the machine while moving on uneven or inclined surfaces, risking the machine tipping over and causing injury to personnel or damage to property.
  1. Service Selector (V)
  2. Pressure Regulator (R)
  3. Gauge (G)
  4. New Fluid Fill Cap
  5. New Fluid Service Hose (H2)
  6. Used Fluid Service Hose (H1)
  7. New Fluid Tank (T2)
  8. Used Fluid Tank (T1)
  9. Suction Wand
  10. FB40 Bypass Adaptor
  11. Purge Connector (P)

The BG CFX Cooling Fluid Exchanger comes with Suction Wand, PN E101-5358.

Preparing for Service

Manual filling

  1. Remove the shop air connection from the BG CFX.
  2. Verify all pressure has been bled from the machine and the Gauge (G) reads “0”.
  3. Remove the New Fluid Fill Cap from the New Fluid Tank (T2).
  4. Pour the desired amount of coolant into the New Fluid Tank (T2). The New Fluid Tank (T2) should never be filled above the markings on the tank.
  5. Tightly reattach the New Fluid Fill Cap to the New Fluid Tank (T2).

Mixing the fluid in New Fluid Tank

  1. Verify the New Fluid Fill Cap is installed tightly on the New Fluid Tank (T2).
  2. Attach the Suction Wand to the end of the New Fluid Service Hose (H2).
  3. Connect shop air to the BG CFX.
  4. Turn Service Selector (V) to “Draw” (D).
  5. Open the ball valve on the Suction Wand.
  6. When the New Fluid Tank (T2) contents is fully mixed, close the ball valve on the Suction Wand.
  7. Turn Service Selector (V) to “Off” (O).

Bulk filling

  1. Verify the New Fluid Fill Cap is installed tightly on the New Fluid Tank (T2).
  2. Attach the Suction Wand to the end of the New Fluid Service Hose (H2).
  3. Roll the BG CFX to a new or recycled 50/50 bulk coolant supply. Be sure Service Selector (V) is set to “Off” (O).
  4. Connect shop air to the BG CFX.
  5. Insert the Suction Wand into the bulk coolant supply.
  6. Turn Service Selector (V) to “Draw” (D).
  7. Open the ball valve on the Suction Wand.
  8. Draw the desired amount of coolant into the New Fluid Tank (T2). The New Fluid Tank (T2) should never be filled above the markings on the tank.
  9. When the New Fluid Tank (T2) is full or desired level has been reached, close the ball valve on the Suction Wand.
  10. Turn Service Selector (V) to “Off” (O).

To empty the BG CFX Used Fluid Tank (T1):

  1. Remove the shop air connection from the BG CFX.
  2. Verify all pressure has been bled from the machine and the Gauge (G) reads “0”.
  3. Be sure Service Selector (V) is set to “Off” (O).
  4. Close the ball valve on the Suction Wand and connect to the Used Fluid Service Hose (H1).
  5. Connect shop air to the BG CFX.
  6. Turn Service Selector (V) to “Empty” (E).
  7. Place the Suction Wand into a suitable waste container and open the ball valve.
  8. Once the Used Fluid Tank (T1) is empty, close the ball valve on the Suction Wand.
  9. Turn the Service Selector (V) to “Off” (O).
  10. Disconnect shop air from the BG CFX.

To empty the BG CFX New Fluid Tank (T2):

  1. Remove the shop air connection from the BG CFX.
  2. Verify all pressure has been bled from the machine and the Gauge (G) reads “0”.
  3. Be sure Service Selector (V) is set to “Off” (O).
  4. Close the ball valve on the Suction Wand and connect to the New Fluid Service Hose (H2).
  5. Connect shop air to the BG CFX.
  6. Turn Service Selector (V) to “Empty” (E).
  7. Place the Suction Wand into a suitable waste container and open the ball valve.
  8. Once the New Fluid Tank (T2) is empty and the tank ball float stops, close the ball valve on the Suction Wand.
  9. Turn the Service Selector (V) to “Off” (O).
  10. Disconnect shop air from the BG CFX.

To completely empty the New Fluid Tank (T2) for a fluid color change:

  1. Remove the shop air connection from the BG CFX.
  2. Verify all pressure has been bled from the machine and the Gauge (G) reads “0”.
  3. Set Service Selector (V) to “Off” (O).
  4. Connect Used Fluid Service Hose (H1) to the Purge Connector (P) on the left side of the base plate.
  5. Close the ball valve on the Suction Wand and connect to the New Fluid Service Hose (H2).
  6. Turn Service Selector (V) to “Draw” (D).
  7. Wait 10 seconds to allow vacuum to build, then open the ball valve on the Suction Wand.
  8. Once the New Fluid Service Hose (H2)and New Fluid Tank (T2) are empty, close the ball valve on the Suction Wand.
  9. Turn Service Selector (V) to “Off” (O).
  10. Disconnect the Used Fluid Service Hose (H1) from Purge Connector (P).

BG Upper Radiator Hose Adaptor Set

PN E100-4455
Installation

  1. Radiator
  2. Upper radiator hose
  3. Radiator adaptor with hose
  4. FB40 Bypass Adaptor
  5. Ball valve on FB40
  6. BG CFX Used Fluid Service Hose (H1)
  7. BG CFX New Fluid Service Hose (H2)
  8. Loose clamp
  9. Quick connect
  10. Adaptor for radiator hose
CAUTION! To prevent being burned by hot fluid escaping from the cooling system, allow engine to cool before removing radiator cap!
  1. Close the ball valve on the Suction Wand and connect it to the Used Fluid Service Hose (H1).
  2. Remove radiator cap and insert the Suction Wand as deep into the radiator or pressurized tank as possible.
  3. Turn Service Selector (V) to “Draw” (D). Open the ball valve on the Suction Wand.
  4. Move the Suction Wand to the radiator overflow tank (if equipped).
  5. Close the ball valve on the Suction Wand and turn Service Selector (V) to “Off” (O).
  6. Clamp off the upper radiator hose with Pinch Pliers about 4–6 inches (10–15 cm) from the end that connects to the radiator. Remove the upper radiator hose from the radiator.
  7. Determine the correct size adaptor and matching short hose/adaptor assembly needed for the upper radiator hose. Screw the adaptors into the FB40 Bypass Adaptor—it makes no difference which adaptor goes into which end. Put the loose clamps into place on the hose—do not tighten.
  8. Install the Upper Radiator Hose Adaptor between the radiator and upper radiator hose and tighten all clamps. Be sure the ball valve on the connector hose is in the open position (handle parallel to the hose)

Note: The Upper Radiator Hose Adaptor is non-directional.

BG Cooling System Service
Procedure

  1. Install 12 oz. (354 mL) of BG Universal Cooling System Cleaner, PN 540, into the mouth of the radiator or pressurized tank.
  2. Close the ball valve on the Suction Wand and attach it to the New Fluid Service Hose (H2).
  3. Insert the Suction Wand into the radiator or tank.
  4. Turn Service Selector (V) to “Empty” (E).
  5. Slowly open the ball valve on the Suction Wand to avoid splashing the coolant. Fill the coolant system.
  6. Close the ball valve on the Suction Wand and turn Service Selector (V) to “Off” (O).
  7. Remove the Suction Wand from the radiator or tank.
  8. Replace the radiator cap securely.
  9. Start the engine and run at idle for 10–15 minutes with the thermostat open, to circulate the BG Universal Cooling System Cleaner.
  10. Stop engine and remove the Suction Wand from the end of the New Fluid Service Hose (H2).

Coolant Transfusion: Engine Off

Systems with thermostat connected to upper radiator hose:

  1. Attach the New Fluid Service Hose (H2) to the engine side of the Upper Radiator Hose Adaptor.
  2. Attach the Used Fluid Service Hose (H1) to the radiator side of the Upper Radiator Hose Adaptor.
  3. Close the ball valve on the Upper Radiator Hose Adaptor.
  4. Verify Pressure Regulator (R) is turned all the way down.
  5. Turn Service Selector (V) to “Service” (S) position.
  6. Slowly turn up Pressure Regulator (R) until used fluid is visible flowing through the Used Fluid Service Hose (H1).

Systems with thermostat connected to lower radiator hose:

  1. Attach the New Fluid Service Hose (H2) to the radiator side of the Upper Radiator Hose Adaptor.
  2. Attach the Used Fluid Service Hose (H1) to the engine side of the Upper Radiator Hose Adaptor.
  3. Close the ball valve on the Upper Radiator Hose Adaptor.
  4. Verify Pressure Regulator (R) is turned all the way down.
  5. Turn Service Selector (V) to “Service” (S).
  6. Slowly turn up Pressure Regulator (R) until used fluid is visible flowing through the Used Fluid Service Hose (H1).

NOTE: If attempting to do service and flow cannot be established, stop the service and switch the New Fluid Service Hose (H2) and Used Fluid Service Hose (H1). Resume service.

Removing the Upper Radiator Hose Adaptor

  1. When transfusion is complete, turn Service Selector (V) to “Off” (O).
  2. Turn Pressure Regulator (R) all the way down.
  3. Open the ball valve on the FB40 Bypass Adaptor to release any trapped pressure from the engine.
  4. Disconnect both service hoses (H1 and H2) from the FB40 Bypass Adaptor.
  5. Close the ball valve on the Suction Wand and attach it to the New Fluid Service Hose (H2).
  6. Turn Service Selector (V) to “Draw” (D).
  7. Important! Allow the engine to cool before removing the radiator cap! Remove radiator cap, and insert the Suction Wand as deep into the radiator or pressurized tank as possible.
  8. Open the ball valve on the Suction Wand and remove as much coolant as possible.
  9. Close the ball valve on the Suction Wand and turn Service Selector (V) to “Off” (O).
  10. Remove the Upper Radiator Hose Adaptor and reconnect the upper radiator hose securely.
  11. Add BG Universal Super Cool®, PN 546, to radiator or pressurized tank.
  12. Attach the Suction Wand to the New Fluid Service Hose (H2).
  13. Turn Service Selector (V) to “Empty” (E).
  14. Insert the Suction Wand into the Radiator or tank, slowly open the ball valve and fill the cooling system.
  15. When the system is full, close the ball valve on the Suction Wand.
  16. Remove the Suction Wand from the radiator or tank.
  17. Replace radiator cap securely.
  18. Move the Suction Wand to the overflow tank (if equipped) and fill to the normal level with new coolant.
  19. Turn Service Selector (V) to “Off” (O).

BG Cooling System Service
Using BG Expansion Tank Cooling System Hose Set

PN E101-1244

  1. Carefully remove the expansion tank cap and add BG Universal Cooling System Cleaner, PN 540.
  2. Replace the expansion tank cap, start the engine, and allow the vehicle to run for 15 minutes.
  3. Close the ball valve on the Suction Wand and attach it to the Used Fluid Service Hose (H1).
  4. Turn Service Selector (V) to “Draw” (D).
  5. Turn off the engine. Important! Allow the engine to cool before removing the expansion tank cap!
  6. Remove the expansion tank cap and insert the Suction Wand as deep into the expansion tank as possible.
  7. Open the ball valve on the Suction Wand, lower the coolant level in the expansion tank below the level of the hose coming off the side of the tank.
  8. Replace the expansion tank cap and remove the hose coming off the side of the expansion tank.
  9. Connect the appropriate size BG barbed adaptor to the vehicle hose. Secure with supplied worm gear hose clamp.
  10. Connect the appropriate size BG hose to the tank. Secure with supplied worm gear hose clamp.
  11. Connect New Fluid Service Hose (H2) and Used Fluid Service Hose (H1) to the BG adaptors.
  12. Verify Pressure Regulator (R) is turned all the way down.
  13. Turn Service Selector (V) to “Service” (S).
  14. Slowly turn up Pressure Regulator (R) until used fluid is visible flowing through the Used Fluid Service Hose (H1).

    Notes:     If flow is not established, turn Pressure Regulator (R) down, turn Service Selector (V) to “Off” (O), and switch the New Fluid Service Hose (H2) and Used Fluid Service Hose (H1). Resume at step 13.

    If the vehicle has more than one hose off the side of the tank, use Pinch Pliers to pinch off the other hose during service.

  15. When the service is complete, turn Service Selector (V) to “Off” (O) and turn Pressure Regulator (R) all the way down.
  16. Carefully remove the expansion tank cap to relieve cooling system pressure.
  17. Disconnect the New and Used Fluid Service Hoses from the tank.
  18. Close the ball valve on the Suction Wand and attach it to the New Fluid Service Hose (H2).
  19. Turn Service Selector (V) to “Draw” (D).
  20. Lower the coolant level in the expansion tank below the level of the hose coming off the side of the tank.
  21. Remove BG adaptors, reinstall the hose onto the side of the expansion tank and clamp it securely.
  22. Add BG Universal Super Cool®, PN 546, to the tank and top off the system with new coolant.
  23. Replace the expansion tank cap, start the vehicle, and check for system leaks.

Specifications

Height:
55 in/140 cm
Width:
20.25 in/51 cm
Depth:
16 in/41 cm
Weight:
88 lbs/40 kg
Maximum rated pressure:
200 psi/13.8 bar
Construction:
Aluminum frame with heavy duty casters, fiberglass tanks, and steel consoles
Process rate:
Average transfusion time is 5–10 minutes, depending on condition and model of vehicle.
Process method:
In loop with vehicle cooling system using pump to assist with delivery of new coolant while transferring used coolant to machine.