Charge Air Cooler Assembly Part No. 12420481

1. Basic Information

• Part Number: 12420481
• Alternative Interchangeable Part Number: 12420426
• Product Name: Water-cooled Charge Air Cooler Complete Assembly
• Original Manufacturer: MWM (Deutz Group)
• Application: Gas engine generator set (natural gas, biogas, coal-bed methane)

2. Compatible Engine Models

• TBG 604, TBG 620
• TCG 2020, CG170 gas internal combustion engines

3. Structural & Cooling Specifications

• Cooling Type: Water-to-air shell & tube heat exchanger
• Tube Material: Red copper / Brass
• Shell & Flange Material: Cast aluminum + carbon steel connecting flange
• Assembly Scope: Complete unit with air inlet/outlet flanges, mounting brackets and sealing flanges, no extra component assembly required
• Mounting Position: Side integrated installation on engine block

4. Core Functions

1. Cool high-temperature compressed boosted air from turbocharger, increase air density and optimize full combustion of gas fuel.
2. Prevent engine knocking, control exhaust gas temperature and ensure continuous full-load power generation of the genset.
3. Key heat exchange vulnerable component for gas generator units.

5. Typical Failure & Replacement Criteria

1. Internal water channel leakage or air-water mixing: Coolant enters intake manifold, causing unstable idling or engine stall.
2. Blockage & scaling on heat exchange fins: Insufficient intake cooling capacity, power derating, high exhaust temperature and system alarm activation.
3. Shell corrosion or flange air leakage: Low boost pressure, excessive fuel consumption and reduced generating capacity.

6. Sourcing & Selection Instructions

1. Original OEM unit: Comes with factory serial number, matched warranty aligned with engine overhaul cycle.
2. Domestic replacement unit: Customized duplication available according to overall dimensions, flange bore diameter and mounting hole spacing; hydraulic pressure & air tightness test mandatory (0.8 MPa holding pressure for 30 minutes without leakage).
3. Interchange Limit: Only applicable to TCG/TBG2020/620 series; incompatible with MWM 12452658, 12454124 and other series charge air coolers.

7. Installation Torque Values

1. Air inlet & outlet flange bolts: 38–42 N·m, tighten diagonally and evenly to avoid deformation and air leakage
2. Cooling water pipe connectors: 25–30 N·m, seal with PTFE tape to prevent water leakage
3. Main mounting bracket bolts: 45–50 N·m, lock with spring washers for anti-loosening under long-term engine vibration