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29 

 CAUTION! Do not use over 65% ethylene glycol or over 60% propylene glycol 

antifreeze by volume. 

 

 CAUTION! Using a different type of glycol or a different % of glycol mixture than 

the system was designed for may affect the performance of the system. For example, 

propylene glycol is more viscous than ethylene glycol and results in more pressure drop 

and less heat transfer capability. 

 

 CAUTION! Do not use automotive coolants. 

 

 CAUTION! Do not mix brands or types of coolant and do not mix brands or types of 

additives and/or extenders. 

 

 

Water can be used in the coolant mixture because it is the most efficient, best known, 

and universally available heat transfer agent. However, each water source contains 
contaminant levels to various degrees. At operating temperatures, these contaminants 

form acids or scale deposits that can reduce cooling system service life.   

 

Rocore and engine manufacturers recommend using distilled or deionized water in 

coolant mixtures. When 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 water quality (See below). 

-

 

Never use water alone as a coolant. Coolant additives are required because 

water is corrosive at normal system operating temperatures. However, 

adding coolant additives to poor quality water does not ensure the water will 

be acceptable. 

 

Water can be used in a coolant mixture if contaminant levels are not excessive and 

proper cooling system maintenance is performed. Water used in coolant mixtures must 

conform to the following established limits: 

 

Acceptable Water Quality for Use in Cooling Systems per ASTM D-4985 

 

Properties 

 

grains/gal 

ppm   

Chlorides 

 

2.4 max 

40 max 

 

Sulfates 

 

5.9 max 

100 max 

 

Total Hardness 

10  max 

170 max 

 

Total Solids   

20  max 

340 max 

 

pH (5.5 to 9.0) 

N/A 

 

N/A 

 

 

 

To determine water quality in your area, contact the city water department or an 

independent laboratory that can test the water quality. 

 

 

Some coolants may have more stringent water qualities than the above, so check your 

coolant manufacturer’s water 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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