3825716 Volvo.Penta Gear

Problem
The cooling system on certain 953B Loaders may not provide adequate engine cooling.
Affected Product
Model & Identification Number
Group 1 - Units Without Sound Suppression
953B (5MK1-982)
Group 2 - Units Without Sound Suppression
953B (5MK983-1019)
Group 3 - Units With Sound Suppression
953B (5MK1-962)
Group 4 - Units With Sound Suppression
953B (5MK963-1019)
Group 5
953B (5MK1020-1114)
Parts Needed
Group 1 - Units Without Sound Suppression
1 - 7B2002 Washer1 - 7E6192 V-Belt1 - 4P2843 Pulley1 - 4W0549 Gasket1 - 1026339 Radiator Assembly3 - 8C3684 AntifreezeGroup 2 - Units Without Sound Suppression
1 - 7B2002 Washer1 - 4W0549 Gasket1 - 1026339 Radiator Assembly3 - 8C3684 AntifreezeGroup 3 - Units With Sound Suppression
1 - 7B2002 Washer1 - 8G7776 Grill Assembly (for tractors without rear lights)1 - 8G7779 Grill Assembly (for tractors with rear lights)1 - 7P8129 Bracket2 - 7P8131 Bracket1 - 4W0549 Gasket1 - 1026339 Radiator Assembly3 - 8C3684 AntifreezeGroup 4 - Units With Sound Suppression
1 - 7B2002 Washer1 - 4W0549 Gasket1 - 1026339 Radiator Assembly3 - 8C3684 AntifreezeGroup 5
1 - 7B2002 Washer1 - 4W0549 GasketAction Required
See attached rework procedure.
Service Claim Allowances
Group 1 This is a 7-hour job.
Groups 2, 3, and 4 This is a 6-hour job.
Group 5 This is a 1-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
Group 1 - Units Without Sound Suppression
1. Drain and properly dispose of the coolant from the engine and radiator.2. Remove the existing 2W1881 Radiator Assembly.3. Remove the existing 7E6441 V-Belt set.4. Remove the existing 7C2427 Pulley from the end of the crankshaft.5. Install a new 4P2843 Pulley on the end of crankshaft.6. Install a new 7E6192 V-Belt set.7. Remove the 4W0548 Pipe (part of the 7C1567 Water Lines Group). Weld a 7B2002 Washer to the top of the 4W0548 Pipe as shown in the attached Illustration. Spot weld the washer to the pipe in only two places.
8. Enlarge the hole in the center of the washer by drilling it to a diameter of 19 mm. (.75 in.).9. Install the modified pipe with a new 4W0549 Gasket.10. Install a new 1026339 Radiator Assembly.11. Connect the coolant hoses and lines to the new radiator and fill the system with new coolant.Group 2 - Units Without Sound Suppression
1. Drain and properly dispose of the coolant from the engine and radiator.2. Remove the existing 2W1881 Radiator Assembly.3. Remove the 4W0548 Pipe (part of the 7C1567 Water Lines Group). Weld a 7B2002 Washer to the top of the 4W0548 Pipe as shown in the attached Illustration. Spot weld the washer to the pipe in only two places.
4. Enlarge the hole in the center of the washer by drilling it to a diameter of 19 mm. (.75 in.).5. Install the modified pipe with a new 4W0549 Gasket.6. Install a new 1026339 Radiator Assembly.7. Connect the coolant hoses and lines to the new radiator and fill the system with new coolant.Group 3 - Units With Sound Suppression
1. Drain and properly dispose of the coolant from the engine and radiator.2. Remove the existing 2W1881 Radiator Assembly.3. Remove the 4W0548 Pipe (part of the 7C1567 Water Lines Group). Weld a 7B2002 Washer to the top of the 4W0548 Pipe as shown in the attached Illustration. Spot weld the washer to the pipe in only two places.
4. Enlarge the hole in the center of the washer by drilling it to a diameter of 19 mm. (.75 in.).5. Install the modified pipe with a new 4W0549 Gasket.6. Install a new 1026339 Radiator Assembly.7. For tractors without rear lights, install a new 8G7776 Grill Assembly using 1 - 7P8129 Bracket, 2 - 7P8131 Brackets, 4 - 4L6459 Bolts and 4 - 8M7145 Washers.8. For tractors equipped with rear lights, install a new 8G7779 Grill Assembly using 1 - 7P8129 Bracket, 2 - 7P8131 Brackets, 4 - 4L6459 Bolts and 4 - 8M7145 Washers.9. Connect the coolant hoses and lines to the new radiator and fill the system with new coolant.Group 4 - Units With Sound Suppression
1. Drain and properly dispose of the coolant from the engine and radiator.2. Remove the existing 2W1881 Radiator Assembly.3. Remove the 4W0548 Pipe (part of the 7C1567 Water Lines Group). Weld a 7B2002 Washer to the top of the 4W0548 Pipe as shown in the attached Illustration. Spot weld the washer to the pipe in only two places.
4. Enlarge the hole in the center of the washer by drilling it to a diameter of 19 mm. (.75 in.).5. Install the modified pipe with a new 4W0549 Gasket.6. Install a new 1026339 Radiator Assembly.7. Connect the coolant hoses and lines to the new radiator and fill the system with new coolant.Group 5
1. Remove the 4W0548 Pipe (part of the 7C1567 Water Lines Group). Weld a 7B2002 Washer to the top of the 4W0548 Pipe as shown in the attached Illustration. Spot weld the washer to the pipe in only two places.
2. Enlarge the hole in the center of the washer by drilling it to a diameter of 19 mm. (.75 in.).3. Install the modified pipe with a new 4W0549 Gasket.4. Install the coolant hose to the radiator and fill the system with new coolant.
Illustration of Modification to 4W0548 Pipe