ENGINE 128 SERVICE INSTRUCTION FOR ALUMINUM Radiator : Heat Rejection - 87.5 Kw. With 2 electric fans 300 mm dia. Mounted on fan shroud. Max fan speed 2900 rpm. 1. Introduction This manual explains the procedure for servicing of Aluminum Radiators with plastic tanks. The following aspects are covered. Leakage spot detection Sealing Techniques Confirmation of proper sealing. 2. Procedure for Servicing 2.1 Removal of Radiator from Vehicle Allow the coolant in the radiator to reach to the room temperature.Drain the coolant from radiator completely. Take out the radiator from vehicle carefully to avoid damage to any of it’s parts CAUTION: Radiator core and plastic tanks are susceptible to cracking due to impact and deformation 2.2 Detection of Leakage Spot Connect the inlet of the radiator to air supply at the gauge pressure of 1.5 bar Seal all other outlet points. Dip the radiator completely in a clean water tank Tilt the radiator and shake it vigorously to let the air bubbles trapped at the clinching area to escape. Observe carefully for one minute and locate the source of air leakage on the radiator from the direction of air bubbles that are coming out of radiator. If the Leakage spot is at radiator core then follow the procedure given at Sr.No. 2.3 to seal the leakage, else if the Leakage spot is found at Tank or its accessories then follow the procedure given at Sr.No.2.4 to seal the leakage CAUTION : Do not use the water tank that is used for copper radiator 2.3 Sealing the Leakage at Radiator Core Different procedure of sealing shall be followed for MINOR and MAJOR leaks in the radiator core. MINOR LEAKS: Leak spots which are very minute are to be sealed in following manner. Install the radiator on vehicle as explained Sr.No.3 (Radiator Installation) Pour the contents of ALUMASEAL in the radiator. Fill proper quantity of coolant liquid. Run the engine in idling speed for 20 minutes. MAJOR LEAKS Procedure of sealing major leaks in the radiator is as follows: Wash the core with clean water and brush to remove dirt, dust etc. To remove the greasy spot on the core, apply thinner with cotton swab and take off the grease. Dry the core using a dryer (Do not use heating source). Mix adequate quantity of ARALDITE RESIN (Araldite rapid may be used in place of Araldite standard for faster drying & curing of seal) and HARDENER in the ratio of 1:1 and stir it thoroughly. Apply the mixture immediately at the leakage spot with the applicator. Allow the mixture to dry and harden under the shade at room temperature for 10-12 hour. Silver color paint may be used for touching up the araldite spots and impart the aluminum type appearance. CAUTION Do not damage the fins during process. As the Araldite is inflammable do not dry it by using any heating source. Proper cleaning of leakage area is must for proper setting of Araldite or else it will come off. 2.4 Servicing of Tank and its accessories If the source of leakage is tank, then replace the tank. Take out the member support using correct size spanner Remove the tabs of the header plate using screw driver and monkey plier. After making all clinching projections up, take out the tank from its seat in header plate. In case it takes more effort, pat the tank with rubber or plastic hammer lightly. Take of the tank packing. INSPECTION AND CLEANING RADIATOR AND CAP Cleaning Fit radiator cap. Close radiator drain cock firmly. Refer Figure 60. Place radiator upside down on ground. Connect water supply line to radiator bottom tank at its outlet. Slowly increase water supply to radiator. Maximum pressure in system should not exceed 1.0 bar. Continue water flow till outlet water is visually clean and clear. Remove connection made for cleaning. Remove radiator cap and suitably plug inlet and outlet of radiator. Completely fill radiator with measured quantity of water. If radiator capacity is less than specified it reflects choked tube. e clean/ de-scale radiator using suitable cleaning compound as per manufacturer’s instruction. Fit back radiator
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