service, maintenance and repair manual radiator part … · 2019. 6. 28. · service, maintenance...

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Quality Process Owner Technical M RICHARDSON J SPRECKLEY M EGGLETON/D DOOLEY

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SERVICE, MAINTENANCE AND REPAIR MANUAL

RADIATOR PART NUMBERS COVERED BY THIS

INSTRUCTION:

MTU PART NUMBER BEARWARD PART NUMBER

X52220500060 5685000100

X52220500063 5685200000

X52220500064 5685200100

X52220500067 5685400000

X52220500068 5685200000

X52220500069 5685300000

X52220500071 SK6132

X52220500072 5685500000

X52220500075 SK5572

X52220500077 SK5886

X52220500078 SK5570

X52220500079 SK5571

X52220500080 SK5711

X52220500081 SK5724

X52220500105 SK5885

X52220500107 SK6217

X52220500108 SK6218

X52220500201 5685200500

X54420500006

X54420500007

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1. INTRODUCTION. 3 1.1. ABOUT THIS DOCUMENT. 3 1.2. SAFETY. 3 1.3. CONTACT DETAILS. 4

2. INSTALLATION 6 3. FILLING 6 4. SERVICE REQUIREMENTS. 7

4.1. CHECKING COOLANT CONDITION AND LEVEL. 7 5. GENERAL MAINTENANCE. 8

5.1. CLEANING CORES. 8 5.2. CLEANING INTERVAL. 9 5.3. CLEANING THE FAN/IMPELLER. 9 5.4. CLEANING THE CORE MATRIX “AIR ON” OR OUTER FACE OF THE LTA SECTION. 9 5.5. PRE WASHING. 11 5.6. WASHING. 11 5.7. RINSING 12 5.8. POST CLEANING. 12 5.9. REPLACING HOSES, CLIPS AND GROMMET SEALS. 12

6. REPAIR. 12 6.1. CORE REMOVAL AND REPLACEMENT. 12 6.2. PREPARING JW SECTION. 13 6.3. LIFTING COOLANT EXPANSION TANKS. 13 6.4. PREPARING SECTIONS FOR CORE REMOVAL. 13 6.5. JACKET WATER (JW) SECTION. 14 6.6. REMOVING CORES FROM JW SECTION. 18 6.7. REMOVING CORES FROM LTA SECTION. 21 6.8. REPLACING CORES. 27 6.9. RADIATOR REASSEMBLY. 30 6.10. FANS. 31

7. SPECIFICATIONS. 33 7.1. CAPACITIES: 33 CAPACITIES (INCLUDING PIPEWORK, NOT INCLUDING ENGINE). 33 7.2. FASTENER MAXIMUM RECOMMENDED TIGHTENING TORQUES. 33

8. MAINTENANCE TOOLS. 34 TOOLS REQUIRED FOR SERVICE AND MAINTENANCE. 34

9. FAULT FINDING. 35 9.1. ENGINE OVERHEATING. 35 9.2. RADIATOR VIBRATING. 35

DECLARATION OF INCORPORATION OF PARTLY COMPLETED MACHINERY 36

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1. INTRODUCTION. 1.1. About this document. Safe and efficient operation of the radiator can only be achieved if the equipment is properly operated and maintained. Perceived poor performance or failure of the radiator can often be caused by a failure to follow fundamental rules and precautions. The purpose of these instructions is to provide the user with information specific to the installation, use and operation of the radiator. It is important to read all instructions fully before proceeding with any Service, Maintenance or Repair tasks. If in doubt please contact the manufacturer, see Section 1.3. Note that original radiator installation to the Genset is covered in the Genset manufacturer’s assembly literature. The information contained within this document is based upon information available at the time of issue; however, the manufacturers policy of continuous product improvement may mean that the product could change at any time. The user should make sure before commencing any work that they have the latest information available, please contact the manufacturer if in doubt, see Section 1.3

1.2. Safety. It is the operator’s responsibility to ensure that only competent persons are employed to carry out any tasks on the radiator. Important safety points are:

• Isolate Genset electrically before attempting any tasks. Ensure battery pack is disconnected.

• Before lifting components assess the weight and route. Use 2 persons on heavy or large components.

• Working at heights. Use harnesses when working on top of radiator.

• Be aware of potentially sharp edges on some steel components.

• Ensure radiator is cooled before starting work.

• Beware coolant and/or fuel oil contact. Risk of skin irritation if hands and/or clothing become contaminated.

• Genset environments will be noisy when running. Wear suitable hearing protection.

• Beware of trapping fingers, long hair and clothing in rotatable parts of the Genset even when it is not running i.e fan drive belts and pulleys when turning the fan by hand.

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Fig.1. Safe operating practice risk notifications

1.3. Contact details. Bearward Engineering Main Rd Far Cotton Northampton England NN4 8HJ Tel: +44 (0)1604 762851 General Web Enquiries: www.bearward.com For Sales Enquiries: [email protected] For Service Enquiries: [email protected] For Spare parts Enquiries: [email protected]

http://www.bearward.com/

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Fig.2. Radiator showing general shipping arrangement.

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2. INSTALLATION This section should be read in conjunction with the installation drawings provided as part of the documentation pack and the Genset manufacturers installation literature. Please also see accompanying instruction BI-05-05-00-18 for installation and site recommendations. 2.1. These radiators are delivered in the vertical orientation and secured to a pallet. 2.2. Remove any ancillary components from the radiator and place to one side before

attempting to move it to final position. Follow genset builder guidelines for fitting the radiator to the generator. However the below steps can be used as an accompaniment to that guide. 2.3. Remove the securing bolts from the pallet and attach appropriate lifting hooks to

the lifting brackets circled in Fig.2. The mass and overall dimensions can be found on the accompanying drawings.

2.4. Remove the guarding to allow access for the fan. 2.5. Hoist radiator on to engine bed frame and slide over the fan. Keep the chains /

sling tight while the radiator is not secured to the bed frame. 2.6. Insert bolts through the radiator feet and into the frame, loosely fit nuts onto the

bolts to help secure the radiator but also allow for fine adjustment. 2.7. Once in position all connections can be made as per the installation drawings: 2.8. Hose clips are to be fitted according to: PI-15-00-00-02 2.9. Torque applied as per: BPS-20-35-10-04 2.10. Tighten radiator to bed frame bolts to the specified torque. 2.11. Refit fan guarding.

3. FILLING Fill radiator using the coolant recommended by the engine manufacturer. DO NOT OVERFILL this radiator. Only fill to the “max coolant level” label (If fitted) or to the bottom of the filler neck pipe. Run engine to clear any potential airlocks. The engine should be run long enough to open the thermostats and allow the full system to circulate. Shut down and allow to cool before checking the level gauges and topping up if required.

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4. SERVICE REQUIREMENTS.

Application No. of runs/ year

Run hours/ year

Recommended coolant check

interval

Recommended core clean

interval

Expected radiator life (years)

Commercial standby

52 200 each use As required * 20

Commercial prime

(limited) 200 750 each use As required * 20

Commercial prime

(unlimited) 360 3000 each use As required * 5

Commercial continuous

360 8280 each use As required * 4

*Core clean interval is dependent upon visible degree of fouling of the core. This will very much depend upon local environment and Genset usage but as a general rule it is best to ensure a visible core fin edge profile and also unobstructed view through the core matrix. However, the maximum effective period between core cleaning cycles will be determined by radiator cooling performance and its effect upon Genset engine overheating.

Fig.3. Table listing service intervals.

4.1. Checking coolant condition and level.

Important note. Ensure coolant temperature is at ambient room temperature before checking level; this check will usually be done prior to starting the Genset. This will avoid problems associated with apparent high coolant levels due to coolant expansion and will also avoid the risks of hot coolant scalds. Never check coolant level when engine is running.

Fig.4. Coolant level inspection sight glasses (if fitted).

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4.1.1. Ethylene glycol coolant (anti-freeze) use Genset manufacturer recommended coolant mixed to the concentration specified for the site conditions. If possible use pre-mixed bulk supply. Maintain coolant as per supplier’s recommendation. A visual check on coolant level can be made using the sight glass mounted in the expansion tanks at the top of the radiator (If fitted). Visible coolant should fill the glass. Or check by removing the filler cap and checking the coolant level is up to the bottom of the filler neck pipe. A low coolant level sensor is also incorporated into the radiator and connected to the engine control panel.

4.1.2. When using water plus supplemental coolant additives (SCA), use Genset

manufacturers preferred product. Maintain coolant as per supplier’s recommendation. Coolant test kits for water pH and Molybdate and Phosphate levels are available from MTU. Please follow manufacturer’s instructions included with kit. A visual check on coolant level can be made using the sight glass mounted in the expansion tanks at the top of the radiator. Visible coolant should fill the glass. A low coolant level sensor is also incorporated into the radiator and connected to the engine control panel.

5. GENERAL MAINTENANCE.

5.1. Cleaning cores.

During Genset operation significant quantities of atmospheric fume, dust and debris can be drawn into the radiator. This will contaminate the surface of the core matrix and lead to restriction of the air flow through the radiator and consequent deterioration in cooling performance. Routine cleaning of the core matrix will help to maintain cooling efficiency; however it should be noted that the method of cleaning employed needs to be appropriate for the type of contamination seen. Core matrix contaminants basically break down into 3 main types. 5.1.1. Oil fumes. These will coalesce on the core surface and cause any dust or debris to adhere to the core. Oil fumes can penetrate deeply into the core matrix and will be difficult to remove without the assistance of specialist cleaning chemicals and pressure washing equipment. Cleaning must be performed in the opposite direction to the normal operating air flow to ensure thorough cleaning of the internal features of the core. 5.1.2. Dust. Dry dust will penetrate the core matrix but can also pass directly through it leaving only the larger particles trapped within the matrix. Dry dust however may also absorb moisture and if allowed to dry out can create a hard cement like deposit. It can also absorb atmospheric contaminants such as those present in chemical processing plants or marine environments which will lead to premature core failure linked to the formation of corrosion products.

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Dry dust can be removed by the use of vacuum cleaning from the outer surface however any hard deposits may be difficult to remove without the assistance of clean water (maybe with added surfactants) and pressure washing equipment. Cleaning must be performed in the opposite direction to the normal operating air flow. 5.1.3. Vegetation and insect debris. This type of debris does not ordinarily penetrate into the core matrix and can usually be removed adequately by the use of vacuum cleaning from the outer surface. If combined with oil fume contamination however, it may form a hard, matted surface layer which will not vacuum clean off. This will need to be treated as for oil fume contamination in the first paragraph above.

5.2. Cleaning interval. Under normal operating conditions it would be advisable to check and if necessary clean the radiator cores on a regular basis before the Genset engine is affected. This schedule must be reviewed for the particular environment under which the Genset is operating, certain types of local environmental conditions can significantly shorten the cleaning schedule interval, see Section 2.0 Service requirements table, Fig.3. A good guideline would be to monitor the engine operating conditions, especially with respect to coolant temperature, to ensure that the radiator is still operating effectively.

5.3. Cleaning the fan/impeller. 5.3.1. Remove any fan guarding to gain access to the fan. 5.3.2. Visually inspect the blades for evidence of damage and then clean them using a

brush and cloth. The cloth may be dipped in water or a suitable solvent if the contaminant is hard to remove. Check with Bearward Engineering before using a solvent as some may damage the fan. Do not use any harsh abrasives as this could damage the fan or create fatigue crack initiation points.

5.3.3. Dry the fan blades after cleaning.

5.4. Cleaning the core matrix “air on” or outer face of the LTA section. 5.4.1. It is usually only advisable for vacuum cleaning of dry dust or vegetation/insect

debris from the outer surface of the LTA core. 5.4.2. Using the vacuum cleaner hose, remove all the loose dust and debris from the

core surface taking care not to damage the cooling fins and tubes in the matrix. If considered necessary, use a soft bristled hand brush to loosen any adherent debris prior to using the vacuum cleaner.

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Fig.5. Vacuum cleaning the core

surface.

5.4.3. Due to the construction of the radiator it is not practical to attempt to wet clean the cores in situ. Cores should be removed following the procedures in Section 6.1 Core removal and replacement.

Before starting the cleaning process, it is essential that the fan, engine and drive system are protected from any cleaning spray and chemicals. It is advised to cover them with waterproof sheeting secured tightly in place. It should be noted that allowance needs to be made for drainage and collection of the used cleaning fluids from the local work area. 5.4.3.1. Any commercially available pressure

washer rated for a pressure range of 1,500 psi to 2,000 psi is recommended.

5.4.3.2. Any commercially available non-caustic

engine cleaner suitable for use in pressure washers should be adequate. Bearward Engineering recommends the use of Autosmart G101Multi Purpose Non-Caustic cleaner.

Fig.6. Bearward recommended cleaning fluid.

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5.5. Pre washing. 5.5.1. Carefully remove all the cores from the J/W section and place “air on” face down

on a smooth, flat surface free from loose stone chippings or gravel. A slight fall or slope on the surface may be helpful in allowing used cleaning fluids to drain away from the work area.

5.5.2. Carefully remove all the cores from the LTA section and place “air on” face down on a smooth, flat surface free from loose stone chippings or gravel. A slight fall or slope on the surface may be helpful in allowing used cleaning fluids to drain away from the work area.

5.5.3. Apply cleaning agent preferably using a low-pressure spray or mist dispenser as per manufacturers recommendations and allow to soak into the surface dirt.

Fig.7. Cores laid out in preparation for washing.

5.6. Washing. 5.6.1. Using pressure washer apply cleaning spray fan jet at right angles to the core

surface from a minimum distance of 100mm. Avoid applying the high-pressure jet too close to or at an acute angle to the core surfaces as it will damage the cooling fins in the core matrix.

5.6.2. Note that the cleaning jet should be applied from the reverse side of the core to the “air on” face. This will ensure that dirt and contaminants are pushed back through the core matrix rather than compacted into it.

Fig.8. Core being washed. Note distance and angle of spray nozzle from core top surface.

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5.7. Rinsing 5.7.1. Final rinsing of the cores may be required to remove any residual cleaning

fluids.

5.8. Post cleaning. 5.8.1. Replace all the cores into the radiator ensuring that the correct cores are

installed into the correct sections i.e. LTA cores into LTA section and JW cores into JW section.

5.8.2. Re-assemble the radiator and re-fit all panels back into the radiator structure. Check that there are no foreign bodies or debris in the plenum that could be picked up by the fan and projected into the core face. 5.8.3. Remove any protective waterproof sheeting from the fan / engine. 5.8.4. Return the radiator to on-line function. 5.8.5. Care must be taken on first Genset start up to ensure that residual rinsing fluid

in the core matrix does not cause any contamination problems when the fan is started.

5.9. Replacing hoses, clips and grommet seals.

5.9.1. Check hoses for signs of deterioration such as surface cuts, splits, cracks and/or bulges, at regular intervals.

Fig.9. Typical visible hose deterioration.

5.9.2. Replace hoses and clips at major engine service intervals or at 10,000 hours / 2 years run time, whichever comes first.

5.9.3. Replace grommet seals whenever cores have been removed (either for cleaning or replacement) or at 10,000 hours / 2 years run time, whichever comes first.

6. REPAIR. 6.1. Core removal and replacement. 6.1.1. Isolate Genset. 6.1.2. Drain radiator slab. Radiator coolants can be hazardous to the environment and

care should be taken to ensure that the coolant volume does not exceed the capacity of the container being used. See section 7.1 for radiator volumes.

6.1.3. The drain socket is generally located on the bottom pipe of the jacket water slab. There may also be drain points on the bottom tank on some radiators.

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6.2. Preparing JW section. 6.2.1. Disconnect and remove flexible downstream air outlet ducting.

6.3. Lifting coolant expansion tanks. 6.3.1. Remove lifting eyes from top of sidemembers. Disconnect rubber connector

hoses and relocate top expansion tanks. Secure tanks onto top of sidemembers using long bolts and packing pieces to prevent tanks from falling from radiator.

Fig.10. View showing packers and securing bolts in place under

expansion tank.

6.4. Preparing sections for core removal. 6.4.1. Remove fasteners holding horizontal duct closers in position and lift away from

radiator.

Fig’s.11a and

11b. Duct closers before removal from

radiator.

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6.4.2. (If fitted) Remove fasteners holding vertical braces to top collector tanks on both “air on” and “air off” sides of the collector tank. Undo and remove the small duct closer plates adjacent to the vertical braces. Note location and orientation of closer plates for subsequent reassembly.

Fig.12. Vertical brace top JW “air

on” and CA “air off” collector tank

brackets.

6.5. Jacket Water (JW) section. 6.5.1. (If fitted) Remove fasteners securing vertical brace to “air off” side of top and

bottom collector tank brackets.

Fig. 13a & 13b

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6.5.2. Remove fasteners securing vertical brace to “air off” horizontal core cross brace and lift vertical brace out through downstream ducting. Note location and orientation of all vertical braces for subsequent reassembly.

Fig.14. Vertical brace to horizontal core brace bracket JW “air off” face.

Fig.15. Vertical brace being removed from “air off” face of JW section.

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6.5.3. Undo and remove the top and middle position fasteners from the top collector tank and loosen the lower fasteners to allow them to slide in the elongated slotted holes.

Fig.16. View showing fasteners removed from top collector tank end

plate.

6.5.4. Raise tank in slots in sidemember to Service position. Use Service tool between the top of the core and the bottom of the collector tank if necessary to overcome any stiction between the core nozzles and the tank seals. Replace middle fasteners to secure collector tank in Service position.

Fig.17. View showing fasteners with top

collector tank in Service position.

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6.5.5. Loosen horizontal core brace fasteners “air off” face of the section being worked on but do not remove yet because the brace prevents the cores from falling out of the slab during subsequent operations.

Fig’s.18a and 18b.

Horizontal core brace securing screws in JW

section “air off” face.

Fig.19. Horizontal core brace securing screws in JW section “air

on” face.

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6.6. Removing cores from JW section. 6.6.1. Raise individual cores from bottom collector tank using Bearward Service tool or

large pry bar. Place tool under the bottom bonnet to avoid damaging the bonnet profile. The top nozzle of the core should still be engaged in the top collector tank seal so the core should slide upwards without too much effort.

Fig.20. Service tool in position lifting bottom of core.

6.6.2. Place 14mm thick nylon strip Service packers under bottom of bottom bonnet on core. Position the packers at the outer edges of the bonnet to avoid damaging the bonnet profile. Repeat for all cores in the JW slab

Fig.21. 14mm nylon packers in

position under bottom bonnet.

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Fig.22. View of JW slab with packers in position under cores.

6.6.3. Remove the nylon packers from under the bottom bonnet of the core that is being removed.

6.6.4. Carefully lower core down until the top bonnet nozzle is disengaged from the grommet seal. Use Service pry bar if necessary. Lift core out of section taking care not to damage adjacent cores.

Fig.23. View of Service pry bar being used to lower the core into the bottom grommet

seal.

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Fig.24. Core being lifted out of JW section.

Take care when handling cores to avoid damaging the cooling fins in the core matrix. Take special care when lowering the cores to the floor to avoid heavy impacts on the end of the core which can cause significant damage to the core tubes which may be hard to detect without close inspection.

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6.7. Removing cores from LTA section. 6.7.1. Before starting work ensure that all the exposed grommet seal holes in the JW

bottom tank are covered to prevent stray fasteners falling into the tank. Remove internal duct closers and fill pipe closer plates. Note location and orientation of all closer plates and hose clips for later reassembly.

Fig.25. View showing internal duct closers and fill

pipe closer plates.

6.7.2. Remove fasteners holding bottom internal duct closer plate in place. Rotate

closer plate to expose bottom fasteners on JW “air on” vertical brace but do not remove closer plate at this time.

Fig.26. View showing internal bottom duct closer being

rotated to expose vertical brace lower fasteners.

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6.7.3. (If fitted) Remove JW “air on” vertical brace fasteners and lift brace out of radiator. Note that when the fasteners are removed the bottom collector tank central support foot can also be removed.

Fig.27. JW “air on” vertical brace being removed.

6.7.4. Remove JW “air on” horizontal

brace.

Fig.28. View showing JW section “air on” horizontal core brace

being removed.

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6.7.5. Remove bottom internal closer plate.

Fig.29. View showing bottom internal closer plate being

removed.

6.7.6. Undo the fasteners connecting the CA “air off” horizontal brace to the vertical brace. Undo the CA “air off” vertical brace lower fasteners and remove the vertical brace.

Fig.30. View showing LTA “air off” face vertical brace being removed.

6.7.7. Loosen CA “air off” and “air on” horizontal braces. Remove cover plate for access to “air on” fasteners.

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6.7.8. Remove CA top collector tank fasteners and raise tank as per method described

for JW section collector tank.

Fig.31. View showing CA top tank in Service

position.

6.7.9. Raise CA cores.

Fig.32. View showing CA cores being raised from tank.

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6.7.10. Insert 14mm thick spacers under bonnets.

Fig.33. View showing 14mm Service spacers

supporting bottom of CA cores.

6.7.11. Remove LTA “air off” horizontal brace.

Fig.34. View of LTA horizontal core brace being removed from

radiator.

6.7.11.1. Remove spacers and drop cores.

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Fig.35. View showing LTA core being lowered down to

bottom grommet seal.

6.7.12. Remove cores.

Fig.36. View showing LTA core being removed from radiator.

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Take care when handling cores to avoid damaging the cooling fins in the core matrix. Take special care when lowering the cores to the floor to avoid heavy impacts on the end of the core which can cause significant damage to the core tubes which may be hard to detect without close inspection.

6.8. Replacing cores. 6.8.1. Remove grommet seals from both top and bottom collector tanks. Note that

when removing top grommet seals a quantity of residual coolant will spill out from the tank.

Fig.37. Top collector tank grommet seal being removed

6.8.2. Inspect seal location holes for damage or corrosion. Clean and, if necessary,

dress or clean up the holes in preparation for new seals. 6.8.3. Always replace grommet seals with new items. Ensure seals are engaged

correctly in the collector tank holes and lubricate evenly with Molykote 111 assembly lubricant.

Fig.38. Grommet seal being replaced and greased.

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6.8.4. Core replacement is the reverse of core removal starting with insertion of the bottom bonnet nozzle into the bottom collector tank seal.

6.8.5. Carefully fit the bottom section of the core into the available space and guide the bottom bonnet nozzle into the grommet seal. Take care when handling cores to avoid damaging the cooling fins in the core matrix. Take special care when handling cores in the vertical orientation to avoid heavy impacts on the end of the core which can cause significant damage to the core tubes which may be hard to detect without close inspection.

Fig.39. Core nozzle inserted into grommet seal in bottom

collector tank.

6.8.6. Cores are designed to have a close clearance fit however manufacturing tolerances can allow core side shields to contact with adjacent cores, therefore care should be taken when fitting new cores to ensure that the side shields do not become engaged with the side shields of adjacent cores. This can be difficult to see and will make core installation impossible without causing significant damage to both cores.

6.8.7. It has been found that brushing a slight chamfer along the leading edges of the side shields with a flat bar can ease core installation if they are a tight fit.

Fig.40. Chamfering core side shield to aid core replacement.

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6.8.8. The use of Molykote 111 assembly lubricant lightly smeared on the side shields can also be of help.

6.8.9. With the bottom bonnet nozzle engaged in the seal firmly press the face of the core with the palm of the hand into the core slab working your way up the core length until the top bonnet nozzle is positioned directly below the top grommet seal. Take care not to damage the core face or snag the top seal.

Fig.41. Core being pushed back into position.

6.8.10. Using the service tool between the underside of the bottom bonnet and the top of the bottom collector tank gently ease the core up until the top bonnet nozzle engages in the top seal.

6.8.11. Place a 6mm thick spacer under the bottom bonnet and use the Service tool to bring the core down until the bottom bonnet is firmly seated on the spacer. The top bonnet should still be engaged in the top seal.

6.8.12. Inspect grommet seals for signs of deformation or being drawn into the collector tank. If the seals are damaged or deformed the core will have to be removed and the seals replaced.

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Fig.42. View on top grommet seal showing incorrect seating. This

grommet should be removed and replaced correctly.

6.9. Radiator reassembly. 6.9.1. Bring down the top tank to the assembly position. Use a pry bar inserted into the

punched slots in the top tank end plates.

Fig.43. View showing pry bar in position for pulling top collector

tank down.

6.9.2. Remove the nylon packers, bring the top tank down fully to the final assembly position.

6.9.3. Replace and tighten all the tank end plates, horizontal and vertical braces. 6.9.4. Close and fasten all ducting, replace inspection panels and perform a final

inspection to ensure nothing has been left in the radiator that should not be there.

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6.10. Fans. 6.10.1. Fan penetration. This should be set with the fan secured to the end of the shaft. Fan penetration should be 14mm, e.g. the fan blade tip should extend 14mm out of the cowl ring into the plenum section (in the Z axis). Check fan penetration is equal for all fan blades. The 14mm dimension is set as a compensation factor to allow for fan deformation whilst running. A tape measure with 1mm increments is considered adequate for measuring penetration.

Fig.44. View showing fan penetration being measured

with tape measure.

6.10.2. Fan clearance. Fan clearance should be set such that there is an equal gap between the fan tip and the cowl ring around the circumference of the cowl ring. This is designed to be6mm +/- 2mm. A simple 6mm spacer or tapered gap gauge can be used to set the gap. Fan clearance is designed to give optimal fan efficiency and ensure that the fan does not contact the cowl ring when running. Clearance is adjusted by repositioning of radiator or the orifice plate can be adjusted by loosening the securing bolts and moving the plate in its slots.

Difficulties in obtaining the correct fan clearance may indicate a problem somewhere else in the fan drive system which should be resolved first.

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Fig.45. View showing fan clearance being measured with

tapered gap gauge.

6.10.3. Fan alignment. Fan alignment should be set such that the fan blade penetration is equal around the fan cowl ring in both X (side to side) and Y (top to bottom) axes. A tape measure with 1mm increments is considered adequate for measuring penetration and setting alignment.

Difficulties in obtaining the correct fan alignment may indicate a problem somewhere else in the fan drive system which should be resolved first.

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7. SPECIFICATIONS. All weights and dimensions can be found on the customer drawings each radiator.

7.1. Capacities: Capacities (including pipework, not including engine).

7.2. Fastener maximum recommended tightening torques.

M6 8.8 Grade SEM Screw 7 Nm

Norma T Clip 20 Nm 8.8 Grade Set Screw 12 Nm

M8 8.8 Grade SEM Screw 29 Nm Norma Work Drive Hose

Clamp BE36001 3 Nm

8.8 Grade Set Screw 29 Nm

M12 8.8 Grade Bolt 55 Nm Norma Work Drive Hose Clamp BE36005

7 Nm M16 8.8 Grade Bolt 210 Nm

M20 8.8 Grade Bolt 350 Nm Breeze CT hose clamp 14 Nm

Radiator number Coolant Capacity (l)

BE5685000100 47.8

BE5685200000 68.9

BE5685200100 68.9

BE5685400000 68.9

BE5685300000 86.6

SK6132 68.5

BE5685500000 76.9

SK5572 86.6

SK5886 105.5

SK5570 47.8

SK5571 47.8

SK5711 68.7

SK5724 68.7

SK5885 92.9

SK6217 76.9

SK6218 86.6

BE5685200500 76.9

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8. MAINTENANCE TOOLS. Tools required for Service and Maintenance.

7mm AF socket and flexible drive 3/8” AF spanner and socket

10mm AF spanners and sockets 13mm AF spanners and sockets

19mm AF spanners and sockets 24mm AF spanner and sockets

30mm AF spanners and sockets

8mm AF hexagon wrench Service pry bar, Bearward part No. 6200998300

500mm long pry bar Torque wrench 0 to 50Nm

Torque wrench 80 to 400Nm Molykote 111 assembly lubricant

6mm thick site build spacer, Bearward part No. 2900286100

14mm thick site build spacer, Bearward part no. 2900286200

Large hide faced mallet Pressure washer and attachments

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9. FAULT FINDING. 9.1. Engine overheating. 9.1.1. Check that fan rotates and runs at correct speed 9.1.2. Check for presence of key in joint 9.1.3. Check direction of fan rotation is correct (anti-clockwise when viewed from the

“air on” face. 9.1.4. Radiator core matrix obscured 9.1.5. Remove obstructions. 9.1.6. Clean radiator cores. 9.1.7. Low coolant level 9.1.8. Check coolant level sensor operates correctly. 9.1.9. Check pressure cap is correct and seated properly. 9.1.10. Check hoses for damage 9.1.11. Check hose clips for tightness 9.1.12. Check cores for leaks from damage 9.1.13. Check cores for leaks from potentially corroded areas 9.1.14. Check coolant condition 9.1.15. Review local operating environment within Genset facility 9.1.16. Review general environment outside Genset facility 9.1.17. Check cores for leaks from potentially vibration induced damage 9.1.18. Tube to header joint failures 9.1.19. Tube fractures

9.2. Radiator vibrating. 9.2.1. Fan failure 9.2.2. Check fan mounting on shaft. 9.2.3. Check fan direction of rotation. 9.2.4. Review airflow conditions, especially for obstructions internal and external to

Genset facility

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Declaration of Incorporation of Partly Completed

Machinery

(This declaration is issued under the sole responsibility of the manufacturer)

Name of manufacturer or supplier

Bearward Engineering (Wabtec)

Full postal address including country of origin

Main Road, Far Cotton Northampton NN4 8HJ, England

Description of Product.

Radiators as denoted by the part numbers listed below all of which are consisting of Jacket water and Charge air circuit. Pressure assembly comprising of a series of cooling radiator sections connected to upper and lower collector tanks secured with supporting steelwork.

Name: Radiator Models

BE5685000100, BE5685200000, BE5685200100, BE5685400000, BE5685300000, SK6132, BE5685500000, SK5572, SK5886, SK5570, SK5571, SK5711, SK5724, SK5885, SK6217, SK6218, BE5685200500

Conformity assessment procedure: Module A (Internal production control)

Name of Authorised Representative J Spreckley

Position of Authorised Representative Technical Manager

Full Postal Address (If different from above.) As Above

The Technical Construction File required by this Directive is maintained by: Name: J Spreckley I declare that I will maintain the Technical Construction file and ensure its full and compliant content. The technical documents have been compiled according to Annex III Paragraph 2 and we commit to deliver these documents to a Market Surveillance Authority on demand. Signature of Representative Date 14/12/18

Declaration We hereby declare that the products mentioned above comply with the following basic requirements of the Pressure Equipment Directive (2006/42/EC). Annex I, Clauses 2.1, 2.2.4, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 2.10,

Signature of Authorised Representative

Date 14/12/18

Place of Issue Bearward Engineering UK

service, maintenance and repair manual radiator part … · 2019. 6. 28. · service, maintenance...

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