Usage:
571G (16W256-515);
572G (40U411-948)
Radiator Conversion Parts (Folded Core) can be installed as a replacement for the one piece radiator core. The new radiator core is made up of twelve modules (sections) for the Power Shift Models and eight modules (sections) for the Direct Drive Models; if one or more of the modules is damaged, or if there is a failure, replacement of only the damaged module is necessary.
Radiator Removal
(1) Drain the coolant; remove guards (1) and (2). Remove brackets (3) and (4) from the radiator guard. These brackets are not used again, but six bolts and washers will be used to install the new brackets.
(2) Remove radiator (5); see the Service Manual.
D7G - 92V4181-92V11466; 571G - 16W294-16W515; 572G - 40U526-40U948
The parts in the list below, plus those in the list above, are needed for D7G - 92V2127-92V4180, 571G - 16W256-16W293, and 572G - 40U411-40U525.
D7G - 91V954, 91V957-91V1126, 92V2127-92V4180; 571G - 16W256-16W293; 572G - 40U411-40U525;
For the above machines, do the following steps one and two.
(1) Remove blocks (1) from radiator guard (2).
(2) Weld 7B237 Lugs (3) to guard (2) at the dimensions shown with 4.8 (.19") fillet welds on each side.
D7G - 92V4181-92V11466; 571G - 16W294-16W515; 572G - 40U526-40U948;
Assembly Of Radiator Group (Folded Core)
(1) Put 1W8849 Tank (1) on blocks as shown.
(3) Fasten 8N3867 Channel (4) and 8N3865 Channel (5) to tank (1) with four L1351 Bolts and 5P1075 Washers, in each channel.
(4) Clean each hole in the tank. Put liquid soap on the sealing areas and install 8N5130 and 8N7139 Seals (6).
NOTE: Make application of the liquid soap to the seals, just before assembly.
(5) Put liquid soap inside the holes in seals (6). Fasten 8N7908 Bracket (7) to 1W2848 Core (8) with L1351 Bolt and 5P1075 Washer; install core (8). Fasten bracket (7) to channel (5) with L1351 Bolt and 5P1075 Washer. Install the second core (8) with bevels (A) together. Fasten 8N7906 Strap (9) between the cores with L1351 Bolts and 8M7145 Washers. Do not tighten the bolts.
(6) Install the remainder of cores (8), with the bevels together; connect the cores with straps (9), bolts and washers. Connect end core (8) to channel (4) with 8N7908 Bracket (7), L1351 Bolts and 5P1075 Washers. Do not tighten the bolts.
(7) Put 8N7139 and 8N5130 Seals (10) on the cores. Clean each hole in 1W8852 Tank (11) and put liquid soap on the sealing areas. Install tank (11), making sure each core is in alignment with the holes in tank (11); use some pressure and carefully push tank (11) fully on the cores. Install and tighten four S1588 Bolts and 5P1075 Washers where channels (4) and (5) fasten to tank (11). Install the plugs, removed from the former tank.
(8) Remove 7N752 supports (12) from the former radiator and install them as shown with S1595 Bolts and 5P8245 Washers. Do not tighten the bolts.
(9) Adjust cores (8) to get a 6.5 (.25") gap between the ends of the cores with the bevel corners (grille side). Tighten straps (9) as you go.
(10) Remove valve (13) from the former radiator and and install it with two 5S4629 Gaskets.
(11) Install 8N3877 Baffle (14) and former 4N7688 Strip with eight S1591 Bolts, 5P1075 Washers, 1S1150 Spacers, 1T689 Washers and 1D4717 Nuts. Install two 8N3617 Brackets (15) with the six 7B3235 Bolts and 5P8245 Washers, removed in step one.
(12) Install 8N3880 Baffle (16) with five L1351 Bolts and 5P1075 Washers. Install 8N3882 Baffle (17) with three L1351 Bolts and 5P1075 Washers.
(13) Install radiator assembly (18) to the guard with 1A1460 Bolts (19), and 5P8245 Washers removed from the former radiator. Tighten the bolts in supports (12).
(14) Install two 8N3616 Brackets (20) and four S1588 Bolts (21) and (22) and 5P1075 Washers as shown, in each bracket.
(15) Cut 5P1262 Hose in two pieces; make hose (23) 114.3 (4.5") long and hose (24) 101.6 (4.0") long. Install hoses (23) and (24) on 1W2533 Tube (25); use two clamps (26) from the former radiator and two new 5P4868 Clamps (27). Install the assembly between radiator (18) and the water pump. Tighten the clamps.
(16) Install 9P862 Cover (28), the lights and brackets (29) and horn (30).
(17) Install elbow (31) from the former radiator with a new 1P6434 Gasket. Close the drain valve and fill the radiator with the correct coolant mixture; see the Lubrication and Maintenance Guide. Install the hood, muffler and front radiator guards.
Parts Needed D7G-91V1127-91V1881
The parts in the list below, plus those in the list above, are needed for D7G-91V954 and 91V957-91V1126. See the instruction on page four for installation of 7B237 Lugs.
D7G - 91V954, 91V957-91V1126
Assembly of Radiator Group (Folded Core)
(1) Put 1W2856 Tank (1) on blocks as shown.
(3) Fasten 8N3867 Channel (4) and 8N3865 Channel (5) to tank (1) with four L1351 Bolts and 5P1075 Washers, in each channel.
(4) Clean each hole in the tank. Put liquid soap on the sealing areas and install 8N5130 and 8N7139 Seals (6).
NOTE: Make application of the liquid soap to the seals, just before assembly.
(5) Put liquid soap inside the holes in seals (6). Fasten 1W2859 Bracket (7) to 1W2848 Core (8) with L1351 Bolt and 8M7145 Washer; install core (8). Fasten bracket (7) to channel (5) with L1351 Bolt and 5P1075 Washer. Install the second core (8) with bevels (A) together. Fasten 1W2857 Strap (9) between the cores with L1351 Bolts and 8M7145 Washers. Do not tighten the bolts.
(6) Install the remainder of cores (8), with the bevels together; connect the cores with straps (9), bolts and washers. Connect end core (8) to channel (4) with 1W2859 Bracket (7), L1351 Bolts and 5P1075 Washers. Do not tighten the bolts.
(7) Put 8N7139 and 8N5130 Seals (10) on the cores. Clean each hole in 1W2851 Tank (11) and put liquid soap on the sealing areas. Install tank (11), making sure each core is in alignment with the holes in tank (11); use some pressure and carefully push tank (11) fully on the cores. Install and tighten four S1588 Bolts (12), L1351 Bolts (13) and 5P1075 Washers where channels (4) and (5) fasten to tank (11). Install plugs (14), removed from the former tank.
(8) Install 7N752 Supports (15) on each side of the radiator with four S1595 Bolts (16) and 5P8245 Washers. Do not tighten the bolts.
(9) Adjust cores (8) to get a 6.5 (.25") gap between the ends of the cores with the bevel corners (grille side). Tighten straps (9) as you go.
(10) Remove valve (17) from the former radiator and and install it with two 5S4629 Gaskets.
(11) Install 8N3877 Baffle (18) and former 4N7688 Strip with eight S1591 Bolts, 5P1075 Washers, 1S1150 Spacers, 1T689 Washers and 1D4717 Nuts. Install two 8N3617 Brackets (19) with the six 7B3235 Bolts and 5P8245 Washers, removed in step one.
(12) Install 8N3880 Baffle (20) with five L1351 Bolts and 5P1075 Washers. Install 8N3882 Baffle (21) with three L1351 Bolts and 5P1075 Washers.
(13) Install radiator assembly (22) to the guard with 1A1460 Bolts (23) and 5P8245 Washers. Tighten the bolts in supports (15).
(14) Install two 8N3616 Brackets (24), four S1588 Bolts (25) and (26) and 5P1075 Washers as shown, in each bracket.
(15) Cut 5P1262 Hose in two pieces; make hose (27) 114.3 (4.5") long and hose (28) 101.6 (4.0") long. Install hoses (27) and (28) on 1W2533 Tube (29); use two clamps (30) from the former radiator and two new 5P4868 Clamps (31). Install the assembly between radiator (22) and the water pump. Tighten the clamps.
(16) Install 9P0862 Cover (32), the lights and brackets (33) and horn (34).
(17) Install elbow (35) from the former radiator with a new 1P6434 Gasket. Close the drain valve and fill the radiator with the correct coolant mixture; see the Lubrication and Maintenance Guide. Install the hood, muffler and front radiator guards.