Usage:
Introduction
This instruction gives the recommended procedure for replacing the folded core modules of the folded core radiator with multiple row modules.
In some applications, dust, fibrous or fluffy debris can cause air side plugging of the folded core modules. This can result in increased maintenance intervals.
The multiple row modules have a lower fin density of approximately 3.5 fins/cm (9fins/in) versus approximately 13 fins/cm (33 fins/in) on the folded core module. The lower fin density of the multiple row modules are more open to air flow through the core, making it more resistant to plugging by fine, fibrous or fluffy debris. The use of multiple row modules will improve resistance to debris plugging on the air side of the radiator.
However, unlike the folded core module, the multiple row modules have no locating pins on the end tanks to correctly position the modules. Therefore the locating depressions (dimples) in the radiator bottom tank are used.
This procedure applies to all vehicular engine applications that currently have multiple row modules available for conversion, However, no modules or procedures are available at this time for Off-Highway Trucks and Tractors.
Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.
Reference: Service Manual, Parts Manual, Operation and Maintenance Manual.
Installation Procedure\Applicable Models: All vehicles except 627E, 637E, and 657 Scrapers
Correct location of the module is required because of the unequal spacing between adjacent module openings in the end tanks.
(A) Typical hole spacing in the top and bottom tanks. (B) Air flow. (C) Trash gap. (D) Folded core modules. (E) Smaller spacing. (F) Larger spacing.
The unequal spacing exists because of the folded core "trash gaps".
The diagonal cut (notch) on the stiffener tab and the two ribs in the end tanks represent the wide spacing for the trash gaps.
Location of the two ribs and typical dimple locations. (G) 2 small ribs. (H) Center stiffener notch. (J) Former trash gap.
Dimples (solid dots) are shown for illustration purposes only. Also notice that the location of the dimples are staggered.
Positioning the modules may be confusing because some modules have a trash gap formed by the first and second folded core modules while other models form the trash gap with the second and third modules.
Position of multiple row modules in D4H Tractors, 916, 926 Loaders and IT 18, IT28 Toolcarriers. (H) Center stiffener notch. (J) Former trash gap.
Trash gaps located between the second and third, fourth and fifth module. Typical dimple locations (solid dots). Dimples shown above for illustration purposes only. Also notice that the location of the dimples are staggered.
This means that regardless of the position of the first module, the multiple row modules should have the "narrow" sides toward each other and the wide sides toward each other.
End view of multiple row module. (G) Embossed ribs on end tanks. (H) Center Stiffener Notch. (L) End view of multiple row module. (M) Neck.
Dimensions for positioning the module with the "narrow" side toward each other, and the "wide" sides toward each other, given above.
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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 after the engine has been stopped and the fill 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 cooling system and remove the radiator from the machine, if necessary.
See the Service Manual for the correct procedure.
2. Remove the top tank from the radiator.
3. Remove the radiator cores.
NOTE: It is important that the multiple row modules are correctly oriented when installed.
The neck location is identified in two ways.
- * There is an embossed rib pattern on top of the module. The two small ribs at location (G) indicate the side of the module with the larger dimension. * The center stiffener has one corner notched at location (H). The larger dimension is on the half that is notched.
4. Identify the folded core locating depressions (dimples) in the bottom tank. Only the row of dimples CLOSEST to the radiator guard (away from the engine) are used.
5. Install new 9Y1654 and 9Y1655 Seals, and 7E2308 Supports. These must be installed on the top and bottom tanks first.
Although there is no particular starting point, it is recommended to position and install from one end and work toward the opposite end. This will reduce the chance of any possible damage to the cooling fins on adjacent modules.
6. Determine whether the locating dimple in the bottom tank (guard side) is to the right or left of the coolant hole.
Position the multiple row module so that the notch in the center tab is to the SAME side as the dimple. See the second illustration.
Continue with this procedure until all multiple row modules are installed.
It is no longer necessary to keep track of the former trash gap locations. The notch in the center tabs will alternate directions automatically. It should also be noted that air conditioning condenser cores and hydraulic coolers will not affect this procedure either.
Applicable Models: 627E, 637E, 657E, 3400 and 3500 Commercial Radiators
NOTE: Some of the smaller radiators for 3400 Engines have the correct hole spacing and lengths to accept multiple row modules.
627E, 637E, 657E and commercial radiators which use folded core modules in the 3400 and 3500 Families of Engines. (H) Notch. (N) Narrow gap.
If a conversion is to be performed, follow Steps 4 and 5 above. But, instead of placing the notch in the center tab on the same side of the center as the locating dimple, the notch must face to the OPPOSITE side of the dimple. See illustration 3.
7. Install radiator. Refer to the Service Manual for correct procedure.
8. Fill the cooling system with coolant. Refer to the Operation and Maintenance Manual for the correct type and quantity of coolant.
9. Start the engine and check for leaks. If leaks occur, stop the engine and make the necessary repairs.