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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