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11 

E. 

SAFETY AND ADVISORY MESSAGES

 

 

1. 

 WARNING! Vertical radiators are 

subject to wind effects and installation 

should consider the potentially 

dramatic effect of prevailing winds on 

cooling system performance. 

 

2. 

 CAUTION! Caution must be used 

when city water make up lines are 

connected to the cooling system. City 

water supply pressure may exceed the 

20 PSI maximum limit of the radiator. 

 

3. 

 CAUTION! Piping to radiators 

should be externally supported and 

not hung on the radiator. Flexible 

connections should be used when 

piping to the radiator. 

 

4. 

 DANGER! For radiators that 

include fan, motors, etc.: before initial 

startup, inspect the fan to make sure 

the blade tips do not hit the shroud, fan 

ring or fan guard. Also, inspect all 

moving parts (such as fans, motors, 

shafts, sheaves and belts) for damage 

and/or loose bolts. 

 

5. 

 DANGER! Failure to observe safety 

precautions could cause personal injury 

or equipment damage. 

 

6. 

 DANGER! Do not operate without 

guards.  Turn off power to install or 

service. Use approved lockout/tagout 

procedures. 

 

7. 

 DANGER! High voltage and 

rotating parts may cause serious or fatal 

injury. 

 

 

8. 

 WARNING! Over-tensioning belts 

shortens belt and bearing life. (See 

Section IV. B. for correct belt tensioning) 

 

9. 

 WARNING! Under-tensioning belts 

can cause the following (See Section   

IVB. for correct belt tensioning): 

− Premature belt wear 

− Reduced radiator cooling          

performance as a result of slower fan 

speed 

− Fan failure. Some types of fans may  

have critical or resonant frequencies  

that must be avoided. 

 

10. 

 DANGER! Do not make any 

changes to any fan drive components 

that may change or vary the original 

design fan speed. All fans have a 

maximum safe operating speed and 

some fans may have minimum and/or 

resonance speeds that must be 

considered. Consult with Rocore 

engineering before considering, changing 

or varying a fan’s speed. 

 

11. 

 DANGER! Avoid extended exposure to 

equipment with high noise levels. 

 

12. 

 CAUTION! Do not overfill the 

radiator or surge tank. As the system 

heats up, the coolant will expand and hot 

coolant or steam will be forced out of the 

overflow hose. (See Section III. F. for 

correct filling instructions) 

 
13. 

 CAUTION! Check with engine 

manufacturer to ensure that the coolant 
used is compatible with their 

requirements. 

 

 

Summary of Contents for ROCORE VB Series

Page 1: ...To access digital copies of this manual other manuals or additional information scan the code on the left or visit www rocore com STANDARD RADIATOR IOM MANUAL INSTALLATION OPERATION AND MAINTENANCE M...

Page 2: ...The complete terms and conditions of the Limited Warranty accompany the product packaging and shipping material If you cannot find or misplace this limited warranty information please call 1 317 227...

Page 3: ...and Lifting 9 E Safety and Advisory Messages 11 III INSTALLATION A Placement and Mounting 12 B Mounting Surge Tanks on Remote Radiators 13 C Piping 16 D Electrical Wiring 26 E Coolant Level Switches...

Page 4: ...NERAL MAINTENANCE A Lubrication 36 B Belt Tension 38 C Bolts and Torque Requirements 39 D Core Cleaning 40 E Fans 40 F Coolants 41 G Replacement Parts 42 H Miscellaneous Maintenance 43 V TROUBLESHOOTI...

Page 5: ...oduct manufactured by it which has defects in material or workmanship provided a Customer notified Rocore in writing of any claim of defect in material or workmanship within sixty 60 days from the dat...

Page 6: ...nt freight collect on approval by Rocore and the following information with each returned unit a In Service date b Number of miles in service1 c Number of hours in service2 d Mode and details of failu...

Page 7: ...arbitration before beginning formal proceedings for the judicial resolution of such dispute This Standard Limited Warranty and all matters relating thereto will be deemed to have been entered into in...

Page 8: ...been received Accessories and ship loose items may be banded to the skid or a separate skid s and should be included on the packing slip and bill of lading Check the radiator and or accessories for d...

Page 9: ...he shafts several turns once per month to redistribute the grease in the bearings D MOVING AND LIFTING When the radiator is moved from the receiving area use the following recommended procedures It is...

Page 10: ...rotating To rotate move in this direction while lifting Figure 1B Lifting horizontal radiators Figure 1A Rotate from vertical to horizontal NOTE Refer to the radiator assembly drawing for more exact...

Page 11: ...procedures 7 DANGER High voltage and rotating parts may cause serious or fatal injury 8 WARNING Over tensioning belts shortens belt and bearing life See Section IV B for correct belt tensioning 9 WARN...

Page 12: ...rs usually are not sized to accommodate engine room or any other air rise or external static restrictions to airflow unless specified in the application design data Standard remote radiators should be...

Page 13: ...ed loose and must be installed by the customer See the radiator assembly drawing for the proper location and orientation of the surge tank on the radiator See Figure 3 for additional details on connec...

Page 14: ...14 CUSTOMER SUPPLIED BRACES 2 Figure 2A Model N engine mounted radiator installation CUSTOMER SUPPLIED BRACES 2 Figure 2B Model F engine mounted radiator installation...

Page 15: ...15 Outlet Figure 3 Mounting surge tanks on horizontal radiators...

Page 16: ...ator top tank is recommended A fast fill port may be provided on radiators with a deaeration baffle This port is used to initially fill the radiator If a fast fill port is not available fill through t...

Page 17: ...tor Engine Pump Flexible Connections Typical Drain Outlet Inlet Cap Keep Top Tank 1 4 to 1 3 Full when Cold 1 4 to 1 2 Vent Line from Thermostat Housing If Engine Requires It NOTE All lines are shown...

Page 18: ...Engine Pump Suction Engine Pump Flexible Connections Typical Drain Outlet Inlet Cap Keep Top Tank 1 4 to 1 3 Full when Cold 1 4 to 1 2 Vent Line from Thermostat Housing Fast Fill Port If Included NOT...

Page 19: ...r Optional Drain Engine Pump Flexible Connections Typical Drain Outlet Inlet Cap Keep Top Tank 1 4 to 1 3 Full when Cold 1 4 to 1 2 Vent Line from Thermostat Housing If Engine Requires It NOTE All lin...

Page 20: ...Pump Strainer Optional Drain Drain Outlet Inlet 1 4 to 1 2 Vent Line from Thermostat Housing If Engine Requires It 1 4 to 1 2 Vent Line 3 4 to 1 Fill Line to Engine Pump Suction Keep Surge Tank 1 4 to...

Page 21: ...d as a two circuit radiator it should be piped as shown in Figure 10 When low flow in the aftercooler circuit requires a two pass arrangement both the inlet and outlet will be in the bottom tank The r...

Page 22: ...Strainer Optional Drain Outlet Inlet 1 4 to 1 2 Vent Line from Thermostat Housing If Engine Requires It 1 4 to 1 2 Vent Line 3 4 to 1 Fill Line to Radiator Outlet Tank Keep Surge Tank 1 4 to 1 3 Full...

Page 23: ...to 1 Fill Line to Engine Pump Suction Cap 1 4 to 1 2 Vent Line from Thermostat Housing If Engine Requires It Flexible Connections Typical Auxiliary Pump Strainer Optional 3 4 to 1 Fill Line to Radiat...

Page 24: ...ain JW Outlet JW Inlet JW Cap Engine AC Pump Strainer Optional Drain AC Outlet AC Inlet AC Cap Drain 1 4 to 1 2 Vent Line from Thermostat Housing If Engine Requires It Keep Both Circuits of Top Tank 1...

Page 25: ...ainer Optional Drain Drain Strainer Optional Engine AC Pump Engine JW Pump JW Inlet AC Outlet Flexible Connections Typical JW Outlet AC Inlet 3 4 to 1 Fill Lines 1 4 to 1 2 Vent Lines AC Circuit 1 4 t...

Page 26: ...be changed allow the motor to stop completely disconnect power lockout tagout and then interchange any two leads of a 3 phase motor 3 Dual voltage and single voltage motors can be connected for the d...

Page 27: ...s shown in Figure 12 The top connection of the switch is piped to the lowest acceptable coolant level port in the top tank The lower connection is piped to a drain port in the radiator bottom tank The...

Page 28: ...e The datasheet which accompanies your radiator will show the type and concentration of coolant antifreeze that the radiator is designed to operate with Rocore and engine manufacturers strongly recomm...

Page 29: ...distilled or deionized water is not available use the following guidelines Never use salt water Never use softened water Select the best quality fresh water available Test the water to determine wate...

Page 30: ...TION Most Rocore radiators are made of steel copper brass and solder materials Some radiators may include aluminum materials If you have an aluminum radiator special attention must be made in selectin...

Page 31: ...below the centerline location of the level switch Level Switch Figure 13 Surge tank coolant level switch installation Radiator In this case the level switch will indicate a low coolant level when the...

Page 32: ...e mounted radiators that use the engine mounted fan for cooling the fan must be correctly positioned in the radiator s fan shroud opening to obtain optimum fan performance The projected blade width ne...

Page 33: ...33 Belts Level OR Straight Edge Engine Crank Sheave Idler Sheave Belts Fan Sheave Figure 14 Sheave alignment...

Page 34: ...Fan Shroud Radiator Sucker Fan Application Airflow Fan Shroud Radiator Blower Fan Application Projected Fan Width 2 3 of Projected Fan Width Projected Fan Width 1 3 of Projected Fan Width Figure 15 Fa...

Page 35: ...hot coolant The solder joint construction used to bond the radiator s core tubes to the radiator s headers will eventually fail from stresses created by the thermal expansion and contraction of the su...

Page 36: ...ended that the housing be filled until a bead of grease starts to come out around the seals Do not use excessive pressure as this can damage the bearing seals Do not mix grease types Grease compatibil...

Page 37: ...erate at speeds greater than 1800 RPM should be lubricated on a more frequent maintenance schedule depending on duty cycle Do not mix grease types Table 3 Bearing type descriptions and maintenance SER...

Page 38: ...16 0 12 7 15 5 18 9 23 4 13 7 17 1 22 1 25 5 The deflection force in the above table should be measured at the midpoint of the belt span distance between two sheave centerlines with a belt tension ch...

Page 39: ...ssure The gaskets may swell enough to stop the leaking If not the bolts will need to be re torqued Remove the fan or core guards and re torque bolts in the area of the leak All header bolts should als...

Page 40: ...ed by high pressure close to the core E FANS For all fans clean any accumulated scale or foreign matter from the fan assembly when you perform the regular maintenance Also for all fans check the fan f...

Page 41: ...1 Level 2 2 Conventional Heavy Duty Coolant Antifreeze Every 250 hours or 6 months Yearly 3 Extended Life Coolant Optional 3 Yearly 3 1 A Level 1 test includes Glycol concentration for freeze and boil...

Page 42: ...r 6 years 1 Use the interval that occurs first 2 These intervals are only achievable with annual Level 2 coolant sampling and analysis See subsection G Coolants under section III Installation for more...

Page 43: ...all times Regularly inspect the radiator hoses and piping for leaks Regularly inspect for excessive vibration or noise Regularly inspect for loose or missing fasteners especially on or near moving par...

Page 44: ...s Replace gaskets Defective radiator cap Replace cap Air in system settles out after initial filling running Add additional coolant Over pressurization of the radiator Repair or replace damaged compon...

Page 45: ...winds Relocate radiator Loose belts Correct belt tension Low coolant flow Check for pump cavitation Piping restrictions Check for correct venting makeup piping Vent all high points in the piping Low c...

Page 46: ...r incorrect wiring Wrong voltage applied to motor Check available operating voltage vs motor nameplate Operated by VFD Adjust VFD settings and or add noise filter and or proper wire type Operated by V...

Page 47: ...issing or broken fasteners Mounted on spring isolators If vibration isolation is required use rubber pad type Vibration induced from engine or other equipment Use flex connectors between radiator pipi...

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