High Efficiency Aluminum Tube Charge Air Cooler
Contents
1. IMPORTANT Before inserting new or original tubes into the header plates new seals must be installed and lubricated properly A 3 uo x de Pz 7 ae a ge t Pa P Sie Pes aS a ar ae i a F N EY AA y N Dg N lt it En 5 gt a fut A gt RD TE HA p EE A en e 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 Fig 14 At a convenient starting point push the top end of the tube end with the longest unfinned section into the tank marked earlier when the retainer bar was removed See Figure 1 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 15 Place the bottom end of the tube into respective seal in the bottom header plate CAUTION Minimize the insertion angle and do not force the tube Care must be taken not to damage seal or tube er PL A A PA ALO Fig 17 Using a light and inspection mirror inspect each seal after tube insertion Look for seal protrudi2. pick end of the removed properly and that the seal seal tool under the seal and groove is not scratched or marred pull out slightly AA 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 Seals that are inadvertently may be in the groove Use clean brush and inserting it into the seal dropped into tank must be compressed air to blow tanks clean groove and use a twisting motion to removed spread an even coat in groove Use a pea sized amount of lubricant per hole New Seal Installation Fig 8 Use the flat hooked end of the Fig 9 With your finger push the other Fig 10 Use the back of the seal seal tool pull the seal into an oval end of the seal into the groove while tool to press the seal firmly into the shape and insert one end of seal into controlling the opposing end with the groove the seal groove 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 gt excess lubricant NOTE The seal needs to be completely seated into the groove in order for tube to be installed properly
3. satisfaction WORLD HEADQUARTERS L amp M Radiator Inc 1414 East 37th Street Hibbing Minnesota 55746 U S A Telephone 218 263 8993 ISO 9001 2008 Fax 218 263 8234 _cerr r eo_ j L y M de Mexico S A de C V L amp M Radiator Pty Ltd Calle De La Plata y Los Nogales Cnr Kew amp Kathleen Streets Parque Industrial Welshpool Western Australia 6016 Hermosillo Sonora Mexico Telephone 61 8 93616855 Telephone 011 52 662 251 0480 Fax 61 8 94703075 Fax 011 52 662 251 0638 Email cooI MESABI com au Email ventas lym com mx MESABI is a registered trademark of L amp M Radiator Inc Copyright 2011 L amp M Radiator Inc
4. M S LIABILITY INCLUDE ANY SPECIAL INCIDENTAL CONSEQUENTIAL OR PUNITIVE DAMAGES EVEN IF L amp M KNEW OF THE LIKELIHOOD OF SUCH DAMAGES Any action or lawsuit for breach of the limited warranty in these L amp M terms and conditions must be commenced in Minnesota This warranty supersedes all previously published warranties MESABI PRODUCT SPECIFIC WARRANTY ALUMINUM TUBE CHARGE AIR COOLER MESABI aluminum tube charge air coolers are covered by the L amp M General Warranty along with the following Product Specific Warranty L amp M Radiator warrants MESABI aluminum tube charge air coolers against seal leakage during normal operation for 18 months from date of invoice Standard Parts MESABI Charge Air Cooler Exploded View High Efficiency Aluminum Tube Charge Air Cooler DESCRIPTION PART NO 1 SON APO 103997 2 Retainer Bar refer to parts list 3 Retainer Bolt 1s x 2 2 18 855 64801 09 4 Washer Seesen ee 106900 01 Br Allen een 106902 01 6 Allen Wrench s for retainer bolt standard 7 Retainer Bar tapped refer to parts list 8 Inspection MirroOF cccooccnccccnicoccnnnonnnoss 104574 9 BUSI sertido RORE TEREA 63451 10 Seal TOO ccostosicenisenco losetas ttcmicctan 97892 11 Tube Assembly Tool 105760 12 Support Bar refer to parts list Assembly Lubricant not shown 100276 External Cleaning and Tube Rem
5. SERVICE MANUAL MESABI JMESABI hion Efficiency Aluminum Tube Charge Air Cooler CONTENTS JANUARY 2011 Standard Pano aisiara a eaaa Page 3 External Cleaning and Tube Removal Page 4 Seal Removal and Header Plate Preparation Page 5 New Seal Installation ooocconncccccnnncccnccnonanononanonononos Page 5 O ceutncetuntwescicavenumeiuceersstuen Page 6 Retainer Bar Installation and Final Assembly Page 7 Pressure Testing nerd contiendas nica Page 7 Manufacturing and Parts Facilities Page 8 Captured seal provides dependable service The MESABI Charge Air Cooler CAC features a tube to header rubber seal that is held captive in the header plate by a special sealing process The flexible seals absorb stresses and thermal expansion that can cause conventional coolers to fail The CAC has all the features of MESABI flexible core heat exchangers e Lightweight aluminum cooling tubes and frame e Field repairable using simple hand tools e For air to air heat exchange L amp M RADIATOR INC GENERAL WARRANTY Consult L amp M before proceeding with warranty claims or repairs Failure to do so may void this limited warranty This limited warranty allocates the risk of failure of the product s between the buyer and L amp M and is reflected in the purchase price L amp M warrants that MESABI products will conform to L am
6. ng into the tank 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 Pressure testing procedure that follows recommends testing to 50 psi 345 kPa You should test to pressure rating specified on tag attached to your cooler If there is no pressure rating specified please contact L amp M Customer Service with the part number of your cooler Always bring pressure up slowly and use personal protection gear Tube retainer and support bars if applicable must be installed prior to testing 1 Install fittings or cover plates in or over all ports One port to have an air supply connector 2 Pressurize with shop line pressure not exceeding 50 psi 345 kPa and submerge in water Repair or tighten fittings rae gt y es Fig 19 Insert the tapped threaded retainer bar into the back side of the cooler Fig 21 With a 3 16 Allen wrench tighten bolts to 45 inch pounds of torque to eliminate leaking Note that air bubbles from trapped air in exterior pockets could appear for 10 to 15 minutes This is normal Repeat as needed until no leaks are detected 3 After successful pre testing to find and repair major leaks then cycle test Pressurize to 50 psi 845 kPa and hold submerged for 15 minutes Repair any leaks that occur and repeat until you have reached a 15 mi
7. nute time period successfully Then cycle to zero and pressure back to 50 psi 845 kPa and hold for one minute Repeat this process three more times and hold the last cycle for five minutes After any repairs in this stage start the cycling testing over from the beginning until you have a successful test MESARIS haat ayvrhar e f Ae ur 4 gt gt a Srl l r a Ar NAAT A L amp M RADIATOR FACTORY DIRECT SALES AND SERVICE Because so many of our radiators and heat exchangers are a custom design all sales are on a factory direct basis This assures that our customers receive a product that meets their cooling heating requirements offered to them at the least possible price We ship most parts within 24 hours On site technical and engineering assistance is available almost anywhere in the world within a few days notice Manufactured and distributed by Radiator Toll Free 800 346 3500 U S A and Canada Web Site MESABI com Email cool MESABI com L amp M Radiator Inc Independence lowa U S A L amp M Radiator Inc L amp M Radiator Inc El Paso Texas U S A Yankton South Dakota U S A EPIT A E gal ir a HAR A MYGI 9 GIG UIC WUIU E An A EE aA ae a a A F y a J g F JEI e o J o L amp M QUALITY POLICY The Quality Policy of L amp M Radiator is to produce a quality engineered guality manufactured product through continuous improvement that we deliver to the customer s
8. oval 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 8274 kPa 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 If 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 tank
9. p M s written quotation specifications and drawings MESABI framework components are warranted for 18 months from the date of invoice against defects in materials and workmanship during normal usage L amp M warranty against seal leakage during normal operation is stated in individual product literature L amp M s liability is limited to the rework or replacement at L amp M s sole option of products or parts manufactured by L amp M that are determined by L amp M to be defective in workmanship or material or do not meet L amp M s quoted specifications L amp M product warranty does not apply if the product has been subjected to abnormal use or conditions unauthorized modifications or repair corrosion misuse neglect abuse accident improper installation or other acts which are not the fault of L amp M including damage caused by shipping L amp M does not warranty products incorporated into L amp M products that are not manufactured by L amp M Buyer s sole recourse with respect to such products will be subject to the warranty of the individual manufacturer OTHER THAN AS STATED HEREIN L amp M MAKES NO REPRESENTATION OR WARRANTY OF ANY KIND EXPRESSED OR IMPLIED AS TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER MATTERS WITH RESPECT TO THE SALE OF L amp M PRODUCT S AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED IN NO EVENT WILL L amp
10. s 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 pH gt 9 0 or too acidic pH lt 5 0 are not recommended SEES ELE Removing MESABI Tubes After a thorough cleaning as described previously blow the cooler dry then remove the retainer bar from tubes as shown When reinstalling tubes the long unfinned tube end and retainer bar will need to be installed at this tank see figure 14 page 6 Use a standard 3 16 Allen wrench to remove bolts from retainer bar NOTE Mark the tank from which the retainer bar is removed Fig 2 o Fig 3 i 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 angle and do not force the tube out Care must be taken to not damage the tube 5 Seal Removal and 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 carefully will help ensure the seals are Fig 4 Insert the
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