Usage:
Introduction
This instruction gives the recommended procedure for replacing the folded core radiator with a conventional radiator. This can result in decreased maintenance intervals.
Fine, fibrous or fluffy debris can cause plugging of the air side of the folded core modules used in the folded core radiator assemblies.
The conventional radiator has a lower cooling fin density than the folded core modules. Therefore, the conventional radiator is more open to air flow through the core which makes them more resistant to debris plugging.
The 2Z8616 Radiator Arrangement is a direct replacement for the standard radiator group, oil lines group and guard assembly. The 2Z8616 Radiator Arrangement is not serviced. All of the components of the individual groups are serviced.
The 2Z8616 Radiator Arrangement consists of:
- * Radiator Group
- * Oil Cooler Group
- * Oil Cooler Lines Group
- * Guard Assembly
- * Oil Cooler Group
The engine fan rotation speed must be increased by using the Auxiliary Drive Pump Group.
Reference: Service Manual, Operation and Maintenance Guide and Parts Book.
Necessary Parts
Refer to Chart A for the Radiator Group component information.
Refer to Chart B for the Oil Cooler Group component information.
Refer to Chart C for the Oil Cooler Lines Group component information.
Refer to Chart D for the Auxiliary Drive Pulley Group component information.
Refer to Chart E for components to convert 6W4781 Guard Assembly to a guard assembly that is necessary for use with the conventional radiator and oil cooler.
Radiator Guard Assembly Modification
The following modification converts 6W4781 Guard Assembly that is used with the folded core radiator to a guard assembly that is necessary for use with the conventional radiator and oil cooler.
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At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Remove the fill cap only when the engine is stopped, and the cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury. |
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1. Drain the coolant from the radiator.
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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil can cause burns. |
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2. Remove hydraulic oil cooler lines up to the two tubes located at the front of the engine.
3. Remove the radiator and guard assembly from the machine.
Radiator Guard Assembly Modification
View of Left Side of Guard Assembly
View of Right Side of Guard Assembly
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An accumulation of any flammable substance may ignite and cause personal injury. Wipe away any spilled oil or other flammable substance before cutting with an air carbon arc torch or similar tool. |
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4. Use low hydrogen AWS Specification E7018 Electrodes for the following fabricating and welding procedures.
5. Cut off bar (1) and (2) at location (A) and (B) to dimensions shown.
6. Cut two notches 20 mm (.79") deep in bar (1) and bar (2) at location (C) and (D) as shown.
7. Fabricate two lugs from low carbon steel to the dimensions shown.
8. Position one lug at each location (E).
9. Make a 5 mm (.20") fillet weld at each location (F).
10. Fabricate two lugs from low carbon steel to the dimensions shown.
11. Position one lug at each location (G).
12. Make a 5 mm (.20") fillet weld on each side of both lugs.
13. Position one 8K0273 Boss at each location (H).
14. Make a 5 mm (.20") fillet weld around each boss.
Assembly and Installation of Radiator Group
1. Assemble the radiator group.
NOTE: Refer to similar 7N4309 and 7N4786 Radiator Groups in the Parts Book for component location.
2. Install one 1S0286 Stud in top of the radiator cap opening of the radiator group.
NOTE: Use the same radiator cap and stud that was on the folded core radiator.
3. Install 5M6214 Pipe Plug (3) in top of the radiator, next to the relief valve.
4. Install 5M6213 Pipe Plug (4) in the fan side of top tank, next to the inlet.
5. Install the relief valve (5) that was used on the folded core radiator with a new 5S4629 Valve Gasket on either side of brass plate.
6. Install a 6N4533 Baffle Assembly (6) with 0S0509 Bolts and 5M2894 Hard Washers on the fan side of the radiator as shown.
7. Mount 6N0683 Radiator Outlet Elbow (7) that was used on the folded core on the bottom side of the radiator with a new 4N1419 Outlet Gasket.
NOTE: Two 1W8648 Blocks used in the lower mounting are eliminated on the conventional radiator installation.
8. Install the two remaining lower mounting blocks and bushings that were used with the folded core radiator on the front of the radiator.
9. Assemble radiator into guard assembly.
10. Install 9K5737 Cap on both upper side mounts to secure radiator to guard assembly.
NOTE: Use the same caps that were used on the folded core radiator.
11. Reuse the lower mounting bolts and nuts from the folded core radiator to secure the conventional radiator to guard assembly as shown.
12. Replace 6W0500 Angle Assembly with 6N4672 Lower Baffle Assembly on the bottom side of the radiator.
13. The 4W2479 Tube Assembly connecting the regulator cover to the radiator inlet can be modified for use by removing the orifice inside the flange.
NOTE: The alternative to modifying 4W2479 Tube Assembly is to replace it with 6N9747 Tube Assembly.
Installation of Oil Cooler and Lines Group
1. Position 1W0282 Oil Cooler Core Assembly through the notches in the radiator guard in place in front of the radiator.
2. Use two 6H1717 Bolts and two 2M0849 Hard Washers to secure the left side of oil cooler core assembly into the lugs on the radiator guard at location (J).
3. Mount the right side of oil cooler core assembly into the bosses on the radiator guard using two 3H8726 Mount Assemblies, 9S1366 Bolts and 5M2894 Hard Washers at location (K).
4. Use two 0S1590 Bolts and 5M2894 Hard Washers to tighten cap to secure mount assemblies at location (L).
5. Assemble 8F4731 Valve Body into the oil cooler core assembly at location (M).
7. Install one 5M6214 Pipe Plug in each lower corner of the oil cooler.
8. Mount 3V8097 Tube Assembly on the lower right corner of the oil cooler core assembly with one 4J0519 O-Ring Seal and four 2A4639 Bolts at location (N).
9. Mount 3V8095 Tube Assembly on the lower left corner of the oil cooler core assembly with one 4J0519 O-Ring Seal and four 2A4639 Bolts at location (P).
Installation of Auxiliary Drive Pulley Group
1. Remove belts from drive pulley.
4. Replace belts with 4N6302 Vee Belt Set and install belts on drive pulley.
Assembly of the Machine
1. Install the radiator and guard assembly in the machine.
4. Use 5P2094 Hose (9) as required to connect tubes as shown.
5. Fill the hydraulic system with fluid and the cooling system with coolant.
See the Operation and Maintenance Guide.
6. Start the engine and check for leaks. If leaks occur, stop the engine and make the necessary repairs.