Charge Air Cooler - L&M Radiator Pty Ltd
Contents
1. L amp M Radiator warrants the MESABI Charge Air Coolers manufactured by L amp M for a period of 18 months from date of invoice Under this warranty our obligation is limited to the repair or replacement at our option of products or parts manufactured by L amp M that are proven to be defective in workmanship or material L amp M further warrants the MESABI Charge Air Coolers against seal leakage during normal use for 18 months from date of invoice on new Charge Air Coolers with MESABI fluorocarbon seals installed Damage or leakage due to accidents misuse or corrosion is not warranted Warranty on components not manufactured by L amp M Radiator shall be that of the individual manufacturers Individual manufacturers operational and maintenance requirements must be met and their policies regarding shipment and inspection of claimed defective parts will apply L amp M is not liable for consequential or incidental damages nor their related costs Consult factory before proceeding with warranty claims This warranty supersedes all previously published warranties Standard Parts MESABI Charge Air Cooler SP eS Pe NS Exploded View High Efficiency Aluminum Tube Charge Air Cooler DESCRIPTION PART NO DCA e E E 103997 Retainer Bar seisecedncnccsaiecexdanenndess refer to parts list Retainer Bolt 16 x 21 2 18 855 64801 09 WAaShOT socehettadus taesetemeresaniuecusinseoreabecs 106900 01 O Ring2. 4 Email cool mesabi com L amp M Radiator Inc 6966 Market Street El Paso Texas 79915 U S A Telephone 915 779 3866 Fax 915 779 3195 Email cool mesabi com MEXICO L y M de Mexico S A de C V Calle De La Plata y Los Nogales Parque Industrial Hermosillo Sonora Mexico Telephone 011 52 662 251 0480 Fax 011 52 662 251 0638 Email ventas lym com mx 2005 L amp M Radiator Inc depots are located in the following countries AUSTRALIA L amp M Radiator Pty Ltd Cnr Kew amp Kathleen Streets Welshpool W A P O Box 1049 East Victoria Park 6981 Western Australia Telephone 011 61 89 36 16855 Fax 011 61 89 47 03075 Email Imrad q net net au Printed in U S A VV 2M 10 02
3. SAE 208 ccccceeeesseeeeeeees 106902 01 Allen Wrench e for retainer bolt standard Retainer Bar tapped refer to parts list Inspection MIN OP iiivinverssveicseietatenctansssneccsn 104574 B USI cecossezenseacstntacseieciegntinstoesesccceuteasaneciuins 63451 Cdl TOOL segetcccssdantcceeaensteecatanccacheaneestceccea 97892 Tube Assembly Tool cc csscccsesereeesees 105760 Support Bar saccczerescsccssecnegascenena refer to parts list Assembly Lubricant not shown 100276 REPAIR PROCEDURE External Cleaning and Tube Removal HELPFUL HINTS e Read this manual thoroughly e Work in a clean environment e Good lighting is a must e Use the proper tools and lubricant e Call L amp M Customer Service with questions External Cleaning To maintain efficiency and assure maximum life of a MESABI Charge Air Cooler reasonable care must be taken when cleaning In some cases it may be best to blow out any dry dirt with shop air prior to washing the core with a high pressure hot water wash If there is any doubt about the cleaning method to be used try the method on a portion of a single tube first or contact L amp M Customer Service For general external cleaning high pressure hot water with or without soap can be used at pressures up to 1200 psi CAUTION To prevent fin deformation stay at least 6 away from the core and you must spray straight into the core not at an angle I
4. SERVICE MANUAL MAESABI High Efficiency Aluminum Tube CHARGE AIR COOLER Please read and follow instructions carefully before installing the MESABI Charge Air Cooler Consult factory before proceeding with any possible warranty claims August 2005 NAESABI High Efficiency Aluminum Tube Charge Air Cooler CONTENTS Standard PAWS siecieonsaxsncsbeecssanceumsmneenteherwennetpetnd ccs Page 3 External Cleaning and Tube Removal 00ccceeees Page 4 Seal Removal amp Installation Header Plate Preparation Page 5 Tube Installation cccccccsseceseseeseesessseeseseeseeeesseeeenes Page 6 Retainer Bar Installation Final Assembly 06 Page 7 NSU EOE E E E ces Page 7 Manufacturing Facilities and Parts Depot Page 8 Special captured seal offers dependable service The MESABI Charge Air Cooler CAC features a tube to header seal that is held captive in the header plate by a special sealing process The flexible fluorocarbon rubber seals absorb stresses and thermal tube expansion that can cause conventional coolers to fail The CAC has the following features as well as all the replaceable tube features of MESABI heat exchangers e Field repairable using simple hand tools e Lightweight aluminum cooling tubes and frame MESABI Removable Tube Charge Air Cooler e For air to air heat exchange MESABI CHARGE AIR COOLER 18 MONTH WARRANTY
5. e and do not force the tube out Care must be taken not damage the tube Seal Removal amp Installation Header Plate Preparation After the tubes are removed clean the header plate area with a high pressure washer then blow the inside and outside surfaces of the tanks thoroughly dry with air CAUTION Following these steps Fig 4 Insert the pick end of P carefully will help ensure the seals the seal tool under the seal and are removed properly and that the pull out slightly seal groove is not damaged a fen 4 gt 4 fy e k ae EIF y A z ag 4 KT Se ie f aa y A fis sey 23S LA Bu SNT N AN A RaR e a i gt x K m wy x Eez Re LA Fig 5 Insert the seal tool between the Fig 6 Insert a clean brush into the Fig 7 With a clean brush apply seal and groove then remove the seal header plate tube hole Rotate the assembly lubricant to the seal groove from the groove brush to remove any debris that Do this by putting lubricant on the may be in the groove Use clean brush and inserting it into the seal compressed air to blow tanks clean groove and use a twisting motion to spread an even coat in groove Use a pea sized amount of lubricant per hole Seals that are inadvertently dropped into tank must be removed New Seal Installation Fig 8 Use the flat hooked end of the Fig 9 With your finger push the Fig 10 Use the back of the seal tool seal tool pull the seal into a
6. f the cooler is still in the machine you may have to use an offset angled nozzle so that you can spray straight into the core If there is any doubt try your cleaning method on a small portion of the core first It is important to start on the air exit side Work from the top to the bottom Concentrate on small areas and work slowly Wash until the water exiting the opposite side is free from dirt and debris Complete this side and then repeat the process from the other side Many radiator shops use a hot alkaline soap or caustic soda in their boil out tanks with chemical additives Soaking in high pH solutions may damage the aluminum alloy depending on the exact characteristics of the solution Solutions that are either too alkaline OH gt 9 0 or too acidic OH lt 5 0 are not recommended Fig 1 Removing MESABI Tubes After a thorough cleaning as described previously blow the cooler dry then remove the retainer bar from the top portion of the tube as shown Use standard 3 16 Allen wrench to remove bolts from retainer bar Fig 3 Slide the front end of the tube assembly tool between the header plate and the fin on a single tube Then squeeze the handle together The tube will become free from the lower seal With the tube tool still on the tube pull the tube out of the core as shown in Fig 2 Then remove tool and use hands to pull tube from upper seal as shown in Fig 3 CAUTION Minimize the removal angl
7. n oval other end of the seal into the groove to press the seal firmly into the groove shape and insert one end of seal into while controlling the opposing end with the seal groove the flat end of the seal tool Fig 11 To avoid pinching the seal between the tube and groove a small amount of lubricant may be needed to hold the seal tightly to the long sides of the groove Fig 12 Use the brush to smooth any P excess lubricant NOTE The seal needs to be completely seated into the groove in order for tube to be installed properly Tube Installation IMPORTANT Before inserting new or original tubes into the header plates new seals must be installed and lubricated properly a a f h d x TF z zs 2 Le ee R ee i f et ae i E T l w f Py T vee x g f k f A Ge Bopi d n j ag A PH ans res wis levee ETE IEN _ af y F Fig 13 Prior to installing tubes the tube ends must be clean and undamaged A cloth buffing wheel can be used Precaution should be taken when buffing so as not to mar the tube finish Use a brush and assembly lubricant to apply a thin film on the first 1 4 of tube ends 4 Fig 14 At a convenient Fig 15 Place the bottom starting point push the end of the tube into res top end of the tube end pective seal in the bottom with the longest unfinned header plate section into the upper header plate seal CAUTION Minimize the insertion angle and do n
8. ot force the tube Care must be taken not to damage seal or tube Fig 16 Push the tube down and into the seal until the fin is located on top of the header plate This can usually be done by grasping the tube with your hands and pulling downward until seated or by using the tube assembly tool CAUTION Be sure the tube is properly centered in the seal before pushing the tube into place Fig 17 Using a light and inspection mirror inspect each seal after tube insertion Look for seal protruding into the tank Retainer Bar Installation Final Assembly Fig 18 RETAINER BAR SYSTEM NOTE Use high temperature anti seize product on threads to aid in removal Fig 20 Insert the front retainer bar with retainer bolts washers and o rings through cooler Testing CAUTION Full face protection must be worn when working on pressurized units Use only appropriate pressure fittings Pressure must be applied slowly Fig 19 Insert the tapped threaded retainer bar into the back side of the cooler Fig 21 With a 3 4 Allen wrench tighten bolts to 45 inch pounds of torque Submerge the unit under water prior to applying pressure Test to 50 psi During testing note that bubbles from trapped air in exterior pockets could appear for 10 to 15 minutes this is normal Hold the pressure at 50 psi for 15 minutes Stop the test immediately if any leaks are noted Repair and test again We solve big heat tran
9. sfer problems around the world A Ta OP T a ar P Mn ee e L E bS P i Ro E s f AANA et m m m or i 3 J J l 8 i ish EEN N TEKTETIATT RY ey mas gt G Aai ney S z i c x d Baw 2 7 PN pr d or E es al wy a a s y W a E y HH si jj j MN J Pay i 7 Hs AA a at Fua Eii Parts shipped within 48 hours from four plants around the world MESABI Radiator Cores oil coolers and related cooling components are marketed on a factory direct basis from four L amp M Radiator plants around the world L amp M Radiator is able to give exceptional service to users and OEMs because all service is controlled at the manufacturer level In emergencies we can ship complete radiator cores or parts within 48 hours On site technical and engineering assistance is available nearly anywhere in the world within a few days notice L amp M Radiator is proud to provide both old and new customers around the world with products known for quality and dependability since 1957 L amp M Radiator manufacturing facilities and parts Manufactured and distributed by RAT L amp M RADIATOR Toll Free 800 346 3500 U S A and Canada mesabi com ISO 9001 2000 ML CERTIFIED Ji MESABI is a registered trademark of L amp M Radiator Inc UNITED STATES L amp M Radiator Inc 1414 East 37th Street Hibbing Minnesota 55746 U S A Telephone 218 263 8993 Fax 218 263 823
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