Usage:
Introduction
This instruction gives the recommended procedure for replacing the folded core module type radiator with a new improved multirow radiator.
While parts exist to convert to a conventional radiator as well, the modular type IMRM radiator should be a more cost effective method with the benefit of modular construction. In addition, there are now nine fin per inch and six fin per inch cores available.
Reference: Parts Manual, Operation and Maintenance Manual and Service Magazine Article 23 Mar 92.
Necessary Parts
Parts required to convert a Folded Core Radiator System to an Improved Multirow Module (IMRM) System in 814B and 815B Compactors.
Parts required to convert a Folded Core Radiator System to an Improved Multirow Module (IMRM) System in 816B Compactor.
The improved multi-row radiator has more space between the fins than the folded core modules. This will allow debris to flow through making it more resistant to plugging. In many applications, this can result in decreased maintenance and improved engine performance.
Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.
Order the individual parts for the conversion group for your machine only.
(Not Serviced as a Group)
Drawing C. 7V9352 Plate.
Dimensions required to fabricate two plates from mild structural steel. (A) 20 mm (.8 in). (B) 30 mm (1.2 in). (C) 28 mm diameter (1.1 in diameter). (D) 3 mm (.1 in). The radius on all corners equals 6 mm (.2 in) maximum.
Radiator Assembly
1. Remove and disassemble the folded core radiator from the machine being converted.
Drawing A.
2. Locate the two 4P6923 cooler brackets on the side channels as indicated by drawing above. Weld in place using a 20-40 skip weld.
Drawing B.
3. Notch the radiator bottom tank as shown to provide wrench clearance for the cooler line fittings.
4. Block the bottom tank up off the floor. Bolt the side channels back onto the bottom tank after the cooler brackets have been welded in place. Install new 4P9942 and 4P9943 coolant seals in the bottom tank and properly lubricate them with 5P3975 Rubber Lubricant or liquid dish soap.
5. Install eight 4P0894 (or 4Q5320, 6 fin/inch) IMRM water cores; install all the "outboard" cores first. See earlier photo. The hydraulic cooler will be relocated at the rear of the radiator.
6. Install the 2W5555 strap assemblies as the cores are positioned, but do not tighten the bolts. Note that the 4P6923 cooler brackets are welded in place.
7. Install new 4P9942 and 4P9943 coolant seals in the top tank and properly lubricate them with 5P3975 Rubber Lubricant or liquid dish soap.
8. Install the top tank and bolt in place. Tighten all remaining bolts of the radiator assembly.
Before Radiator Installation
NOTE: It may be necessary to relocate the stud at the bottom of the radiator guard to a higher position to allow clearance for the 8V8825 long cooler tube.
1. Remove old cooler lines and fittings and loosen the back-up alarm for the new cooler line clearance.
2. Install new 5P3621 Elbows (shown at right) at the old cooler line bulkhead. Fabricate two 7V9352 Plates.
3. Install the 8V8826 Oil Tube (short) and 8V8825 Oil Tube (long) at the 5P3621 Elbows and then install the 2P1283 Bulkhead fittings from the old folded core cooler lines to locate the fabricated plates.
4. Install the 7V9352 Plates to the fittings and tack weld in place. Remove the cooler lines and weld the plates in place.
Radiator Installation
1. Lower the assembled radiator in place.
2. Secure the radiator by starting the bolts into the radiator guard (side) mounting strips. Position the top and bottom baffles (engine side) and start bolts. Tighten the bolts holding the radiator and baffles in place.
3. Modify the lower rear baffle by cutting a slot approximately 110 mm (4.33 in) deep to clear one of the 7V9352 Plates. Install the lower baffle.
4. Bolt the 1W3841 Cooler Mounting Bracket to the right side 4P6943 Bracket using 8T2502 Bolts. Do NOT tighten bolts.
5. Install 307950 Fittings and 3D2824 O-Ring Seals on the cooler.
6. Install the cooler using four 4L6454 Bolts. Tighten the bracket and cooler bolts.
7. Reinstall the cooler tube fitted above.
8. Install the 7V9803 lower cooler hose (note notch cut in bottom tank for wrench clearance) and secure with 8T7529 Clips and 7K3215 Bosses using 9B7237 Bolts.
9. Grind the stud on the inside of radiator guard to gain necessary clearance for the upper cooler hose. Install the 7V9802 Upper Cooler Hose and secure with 8T7529 Clips and two 7K3215 Bosses, using 9B7237 Bolts.
10. Install all fan guards and radiator hoses removed earlier.
11. Fill the radiator with coolant and check for leaks. Refer to Operation and Maintenance Manual for quantity.