TURN OFF AND LOCK OUT DRIVER BEFORE ENTERING

COOLER

PRIOR TO RUN-IN

NOTE: Check all nuts and bolts for tightness, bolting will loosen during shipment.

Fans
Check fan blade bolts and hub set screws for tightness. Rotate fan by
hand to insure that shaft, speed reducer, and driver turn freely. The fan should
be checked for adequate tip clearance and blade pitch angle. Slight adjustment
of the tip clearance can be made by loosening the fan shaft bearing bolts and
moving the complete fan and fan shaft assembly until it is centered in the ring.
To check the fan blade angle, use a level bubble protractor (this can be obtained
from the factory). Loosen the nuts on the bolts and place the protractor on the
angle setting mark or the clevis (refer to fan manufactures information for proper
location). Using a mallet tap on the shank end of the blade to adjust the angle.
Tighten fan blade bolts to the proper torque (refer to manufactures maintenance
instructions) making sure to tighten evenly. Recheck blade angle. Some coolers
are equipped with an automatic fan. These fans have blade angles controlled by
varying the air supply pressure. Air pressure should be applied by to the fan
before starting to check for proper operation. Before starting, the motor should
be bumped to check for proper direction of fan rotation.

Bearings
Bearing mounting bolts and set screws should be checked for
tightness. The manufacturer lubricates the bearings and no additional grease is
necessary to start. When remote lube lines are provided check to insure they are
full by loosening at the bearing end, then fill with grease from fitting end. This will
insure that the grease lines are full of grease. During high-speed operation too
much grease will cause over heating. To protect bearings against entrance of
foreign material when dust and water are present the bearings should contain as
much grease as speed will allow. Daily lubrication may be required to maintain a
slight leakage at the seals. Under normal conditions use the following table as a
guide. However, certain conditions may require a change of lubrication periods
such as the ones described above.
Read preceding page before establishing lubrication
schedule

LUBRICATION
GUIDE
Suggested Lubrication Period in
Weeks
HOURS 1 TO 251 TO 501 TO 751 TO 1001 TO 1501 TO 2001 TO 2501 TO
PER 250 500 750 1000 1500 2000 2500 3000
DAY RPM RPM RPM RPM RPM RPM RPM RPM

8 12 12 10 7 5 4 3 2
16 12 7 5 4 2 2 1 1
24 10 5 3 2 1 1 1 1
 Louvers
Check all mounting brackets and bolts for tightness. On manually
operated louvers, to insure that the linkage is adjusted properly, operate blades
from a fully open position to a fully closed position. On automatic air motor
(optional) operated louvers, air should be applied to actuator to check for proper
linkage adjustment, free operation, and sufficient air supply. See manufacturer
maintenance instructions for further information on air motors.

DO NOT WALK ON LOUVERS

OR USE AS A LADDER!!

U-Joints
Relubrication cycles vary depending on the service requirements and
operating conditions of the drive. Under normal conditions, a maximum
relubrication cycle of 30 to 60 days is recommended. Consult the manufacturer
service manual for specific grease and lubrication requirements.
 RUN-IN

Vibration Switch (optional) (Murphy & Nelson)

After the switch has been installed, adjust by turning the adjustment screw
in a clockwise direction until the starting torque does not trip the vibration switch.
For other brands see manufactures information.

Process Start-up
The process start-up should be conducted in a manner that will minimize
thermal shock of the tube bundles. Over cooling of fluids during periods of low
ambient temperature and low heat loads should also be avoided during start up.

Plugs
Header plugs are installed at room temperature in our plant. To correct any
minor leaking, it may be necessary to tighten the plugs when the bundle is at
operating temperature. WARNING: Do not tighten plugs while the bundle is
under pressure. If any plugs are removed, the gasket (for shoulder plugs only)
should always be replaced. Replacement gaskets should be ordered from the
factory. When installing the plugs, a thread lubricant and antigalling compound
should be used.
 LONG TERM

Fin Cleaning
Fins should be kept free of dirt and lint, which can be removed by directing
compressed air perpendicular to the tubes in a direction opposite to the normal
airflow. Do not use steam or chemicals to clean fins.

Tube Cleaning
The internal cleaning of tubes can be done three different ways:

1. Mechanical Cleaning
This consists of using drills, (or wire brushes), on long rods. And rotating
them with air or electric motors. This is normally followed by a water wash or air
purge.

2. Chemical Cleaning
This consists of circulating hot chemical solution through the tubes. The
solution contains inhibitors to avoid corrosion of the tube walls.

3. High Pressure Water Sprays

This consists of placing a high-pressure water jet head at the end of the
hollow rods and pushing through the individual tubes.

NOTE: The last two processes will not work on tubes that are plugged, they
must be drilled out mechanically.

Leaking Tubes
Tube leaks can be two types: (1) leaks through the tube wall and (2) leaks
in the tube attachment. In the first case it is most practical to plug both ends of
the tube. Only a limited number of tubes can be sealed off in this manner before
performance is affected. When performance drops below acceptable limits, tube
bundle must be retubed. If leaks develop in the tube end attachment, rerolling of
the tube will be necessary. Care must be taken in selecting the proper tube
expander for the size and gauge of tube to be rolled. When rolling a tube, over-
rolling must be avoided. Consult the factory for information on taper pins to plug
the tubes and roller tube sizes.
 INSTRUCTIONS FOR USING TAPER PINS FOR SEALING
LEAKING TUBES

1. Remove plug from one end of leaking tube (do not switch plugs in holes).
2. Insert taper pin through plug hole into tube and tap lightly with hammer until
seated firmly, but not too tight to be removed.
3. Measure plug for depth it was originally screwed into the plug sheet.
4. Measure the distance that the tape pin protrudes from the plug sheet in
seated position.
5. Add the distance measured in Steps 3 and 4 then subtract 1/8”. This will be
the length which should be cut off the large end of the taper pin

6. Remove the taper pin from the end of the tube.

7. Saw a piece off the large end of the taper pin, the length figured in Step 5. Be
careful not to cut the pin too short.
8. Re-insert the taper pin in the tube and drive well into place.
9. Lubricate plug (see PLUGS page 12) and replace in plug sheet. Run up
tightly. The plug should now seat and help hold the taper pin in place.
10. Repeat operation on opposite end of tube.

NOTE: If the plug removed does not seal replace it and the gasket if so
equipped.
 Recommended Spare Parts
We suggest that one each of the parts, which are designated by an
asterisk (*) on the parts list be carried in your stock of spare parts. The down
time caused by waiting for delivery of a spare part usually cost more in lost
production or service than the cost of the part itself.

Spare parts orders should be specified in accordance with the parts list
description and the Job number of the unit.

P.O. QTY. DESCRIPTION OF COMPONENTS

__ SECTIONS IN ACCORDANCE WITH SPECIFICATION SHEET DATED: ________
__ ____ STRUCTURE(S): ______________________________________________
__ SET(S) SHUTTERS: _________________________________________________
__ SET(S) TURNING VANES: ____________________________________________
*__ FAN (S) __” DIA. __ BLADES _____ HAND _______ MAKE ___ ANGLE AT ___
_____ “ BORE WITH ___”X___” KEYWAY. __________________________
*__ FAN SHAFT(S): ____” DIA. X __” LONG WITH ___” SQ. KEYS ____ END,
KEYWAY LENGTH __”
*__ ____” FAN BEARING(S): ____________________________________________
*__ ____” IDLER BEARING(S): ___________________________________________
*__ IDLER SHAFT(S) ___” DIA. X ___” LONG WITH ___” SQ. KEY _____” LONG ONE END.
*__ IDLER PIVOT SHAFT(S) ___” DIA. X ___” LONG, CRS, WITH ONE HOLE DRILLED FOR ¼”
COTTER PIN ¼” FROM THE END.
__ SET(S) ______ TYPE IDLER FRAME PARTS; PULLROD LENGTH ____”, MINIMUM
THREAD LENGTH__________
__ VIBRATION SWICHES ____ MAKE ______ MODEL
*__ V-BELTS: ______ TYPE, ___” CENTER DISTANCE, ___ HP EACH, MATCHED SETS OF __
__ SHEAVE SET(S):________________________
__ GROOVES, FAN SHEAVE: ___” OD, _____” BORE WITH ___” X ___” KEYWAY
__ PITCH, MOTOR SHEAVE: ____” OD, ____” BORE WITH ___” X ___” KEYWAY
*__ MOTOR (S): _______ HP, ___ RPM, __ PHASE, __ HZ, __ VOLTS, ___ ENCL., VARIABLE
TORQUE, SINGLE WINDING, _____ SHAFT, ___ MOUNTING, ____ FRAME, ____ SLIDEBASE,
CUST. SPECIFICATIONS __ , MOTOR DATA REQUIRED __ , WIRING DIAGRAMS ___

* RECOMMENDED SPARE PARTS

 INSPECTION

Tubes
Tubes are to be inspected for internal and external corrosion and/or
erosion periodically. This depends on the severity of service and atmosphere
that the tubes are in. Inspection of the tubes should be performed every six
months. Tube wall thickness can be checked externally using the ultrasonic
technique.

Fans
Fans should be inspected for wear (pitting, cracks and corrosion) on all
surfaces. These inspections should be preformed every six months. In addition
to surface inspections, all bolts and nuts must be checked for proper torque.

Bearings
In addition to bearing checks as recommended by the manufacture; the
mounting bolts should be checked for proper torque and alignment. These
checks should be done at least every six (6) months.

Structure
A general inspection of the structure should be performed every six (6)
months. This inspection should include checks for corrosion, damaged members
and sheeting, and for loose bolting.

Headers
Headers should be inspected for corrosion. This corrosion should not be
allowed to proceed past the stated corrosion allowance as stated on the
specification sheet.