PRODUCT SUPPORT PROGRAM FOR REPLACING THE RADIATOR CORE ASSEMBLY AND ENGINE COOLANT TEMPERATURE REGULATOR ON CERTAIN 320D(L) EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE RADIATOR CORE ASSEMBLY AND ENGINE COOLANT TEMPERATURE REGULATOR ON CERTAIN 320D(L) EXCAVATORS

Usage:

REBE4989-00

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31Jul2009

D-248

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Before/After Parts stock action needed	PRODUCT SUPPORT PROGRAM FOR REPLACING THE RADIATOR CORE ASSEMBLY AND ENGINE COOLANT TEMPERATURE REGULATOR ON CERTAIN 320D(L) EXCAVATORS
1353 1351 1380 1355 7750		PS42952

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS42952" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7755" as the Group Number, "56" as the Description Code.

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NOTE:

Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible.

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NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

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TERMINATION DATE

31Jul2011

PROBLEM

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The radiator core may crack between the radiator top tank and the coolant tube assembly on certain 320D(L) Excavators. The radiator core and the engine coolant temperature regulator need to be replaced.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
320D	JGZ00162, 172-175, 188-189, 192, 194, 210, 223, 321, 327, 331, 333, 336-337, 340, 342, 345, 348, 350, 353, 357, 359-363, 365, 367, 369, 374, 376-379, 381-385, 388, 392, 394-395, 397, 401, 403-404, 408, 417, 490, 494-496, 513-517, 519-520, 524, 527, 529, 534-535, 537-539, 541-542, 545, 559-560, 562-563, 565-566, 568-575, 580, 582-583, 585, 587-588, 601-602, 606-609, 612, 616, 618, 620-623, 625-629, 644-645, 648-649, 651-653, 655, 657, 660-661, 667, 669, 671-672, 674-677, 679-680, 682-685, 688-689, 692, 695, 698-701, 726-727, 731, 735-738, 769, 774, 780-781, 784, 786, 811, 813-815, 818-819, 892, 904-906, 909, 912, 918, 920-922, 937-938, 942-946, 950-952, 955-957, 962, 972-976, 981, 992-993, 995, 1001, 1005, 1007-1009, 1013-1014, 1020-1023, 1026-1029, 1032, 1034-1037, 1039-1046, 1049-1050, 1052-1054, 1058, 1060, 1062, 1064, 1068, 1070, 1076, 1078-1081, 1084, 1086, 1090-1092, 1096-1097, 1099-1100, 1104-1105, 1109-1110, 1114, 1117, 1126-1128, 1137, 1139-1140, 1156, 1215-1218, 1220-1222, 1224-1227, 1229, 1233-1234, 1237, 1245, 1253-1258, 1261, 1270, 1278, 1280-1283, 1285, 1288-1290, 1298, 1301-1303, 1308, 1312-1313, 1316-1320, 1328-1329, 1331-1334, 1337-1338, 1341-1342, 1345-1346, 1373, 1393, 1404-1406, 1416, 1418, 1420, 1423-1425, 1440, 1452, 1466, 1468, 1473, 1476, 1478, 1484, 1486, 1489, 1497, 1499-1500, 1508-1509, 1512, 1514-1516, 1537-1538, 1540-1542, 1544, 1550, 1553-1557, 1559, 1562, 1564, 1574-1575, 1579-1583, 1601-1602, 1612, 1616-1617, 1622, 1628-1629, 1636-1637, 1639-1640, 1642-1643, 1656-1657, 1662, 1668, 1670, 1673-1674, 1676, 1679-1680, 1682, 1688-1690, 1692-1700, 1702, 1704-1705, 1707, 1709-1713, 1716, 1804, 1810, 1812, 1833-1835, 1837, 1850-1856, 1874-1875, 1879-1880, 1890-1892, 1895-1897, 1908-1916, 1931, 1935-1937, 1939, 1942-1945, 1949-1950, 1953-1955, 1958, 1961, 1964, 1968, 1970-1973, 1975-1980, 1982, 1984-1987, 1999, 2004, 2121-2123, 2127, 2144-2146, 2171-2172, 2174-2176, 2178-2179, 2183-2186, 2189, 2195-2198, 2210, 2221, 2236-2238, 2247, 2259, 2264, 2268, 2271-2272, 2275-2276, 2278-2279, 2283-2287, 2295, 2298, 2300, 2302, 2304, 2308-2311, 2314-2317, 2319-2320, 2322, 2325-2328, 2330-2334, 2337-2339, 2344-2346, 2348-2351, 2353, 2355, 2357, 2359-2363, 2365-2366, 2368-2369, 2371-2373, 2378, 2388-2390, 2395-2397, 2408, 2410, 2417-2420, 2437, 2439, 2550, 2558, 2563, 2566-2571, 2573, 2577, 2580-2581, 2594-2595, 2606-2608, 2612-2613, 2632-2634, 2644-2645, 2657, 2659, 2661, 2679-2681, 2691, 2707, 2711, 2725, 2777-2779, 2783-2787, 2790, 2792-2798, 2804, 2813-2815, 2823, 2826, 2828, 2830-2832, 2839-2840, 2844, 2876, 2886, 2894, 2897, 2899, 2901-2904, 2911-2916, 2922-2924, 2926-2929
320D L	MDE00255, 258-259, 266, 276, 278, 332-333, 335-336, 342, 481, 566, 569, 574, 592, 610, 613, 815-816, 821, 850-851, 853, 863, 874, 925, 934, 936, 968, 1009, 1036, 1039, 1052-1053, 1061-1062, 1069, 1081, 1123, 1133-1135, 1139-1142, 1144, 1147, 1151-1152, 1156, 1168-1169, 1175

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*****Group 2*****
320D	JGZ00151-00161, 163-171, 176-187, 190-191, 193, 195-209, 211-222, 224-320, 322-326, 328-330, 332, 334-335, 338-339, 341, 343-344, 346-347, 349, 351-352, 354-356, 358, 364, 366, 368, 370-373, 375, 380, 386-387, 389-391, 393, 396, 398-400, 402, 405-407, 409-416, 489, 491-493, 497-512, 518, 521-523, 525-526, 528, 530-533, 536, 540, 543-544, 546-558, 564, 567, 576-579, 581, 584, 586, 589-600, 603-605, 610-611, 613-615, 617, 619, 624, 630-643, 646-647, 650, 654, 656, 658-659, 662-666, 668, 670, 673, 678, 681, 686-687, 690-691, 693-694, 696-697, 702-725, 728-730, 732-734, 739, 741-768, 770-773, 775-779, 782-783, 785, 787-810, 812, 816-817, 820-830, 880-891, 893-903, 907-908, 910-911, 913-917, 919, 923-936, 939-941, 947-949, 953-954, 958-961, 963-971, 977-980, 982-991, 994, 996-1000, 1002-1004, 1006, 1010-1012, 1015-1019, 1024-1025, 1030-1031, 1033, 1038, 1047-1048, 1051, 1055-1057, 1059, 1061, 1063, 1065-1067, 1069, 1071-1075, 1077, 1082-1083, 1085, 1087-1089, 1093-1095, 1098, 1101-1103, 1106-1108, 1111-1113, 1115-1116, 1118-1122, 1125, 1129-1136, 1138, 1141-1155, 1157-1162, 1219, 1223, 1228, 1230-1232, 1235-1236, 1238-1244, 1246-1252, 1259-1260, 1262-1269, 1271-1277, 1279, 1284, 1286-1287, 1299-1300, 1304-1307, 1309-1311, 1314-1315, 1321-1327, 1330, 1335-1336, 1339-1340, 1343-1344, 1347-1372, 1374-1392, 1394-1403, 1407-1415, 1417, 1419, 1421-1422, 1426-1439, 1441-1451, 1453-1462, 1467, 1469-1472, 1474-1475, 1477, 1479-1483, 1485, 1487-1488, 1490-1496, 1498, 1501-1507, 1510-1511, 1513, 1517-1536, 1539, 1543, 1545-1549, 1551-1552, 1558, 1560-1561, 1563, 1565-1573, 1576-1578, 1584-1600, 1603-1611, 1613-1615, 1618-1621, 1623-1627, 1630-1635, 1638, 1641, 1644-1655, 1658-1661, 1663-1667, 1669, 1671-1672, 1675, 1677-1678, 1681, 1683-1687, 1691, 1701, 1703, 1706, 1708, 1714-1715, 1717, 1788-1803, 1805-1809, 1811, 1813-1832, 1836, 1838-1849, 1857-1873, 1876-1878, 1881-1889, 1893-1894, 1898-1907, 1917-1930, 1932-1934, 1938, 1940-1941, 1946-1948, 1951-1952, 1956-1957, 1959-1960, 1962-1963, 1965-1967, 1969, 1974, 1981, 1983, 1988-1998, 2000-2003, 2005, 2108-2120, 2124-2126, 2128-2143, 2147-2170, 2173, 2177, 2180-2181, 2187-2188, 2190-2194, 2201-2209, 2211-2220, 2222-2228, 2239, 2241-2246, 2248-2258, 2260-2263, 2265-2267, 2269-2270, 2273-2274, 2277, 2280-2282, 2288-2294, 2296-2297, 2299, 2301, 2303, 2305-2307, 2312-2313, 2318, 2321, 2323-2324, 2329, 2335-2336, 2342-2343, 2347, 2352, 2354, 2356, 2358, 2364, 2367, 2370, 2374-2377, 2379-2387, 2391-2394, 2398-2407, 2409, 2411-2416, 2421-2436, 2438, 2440-2450, 2532-2549, 2551-2557, 2559-2562, 2564-2565, 2572, 2574-2576, 2578-2579, 2582-2593, 2596-2605, 2609-2611, 2614-2631, 2635-2643, 2646-2656, 2658, 2660, 2662-2678, 2682-2690, 2692-2706, 2708-2710, 2712-2724, 2726-2776, 2782, 2788, 2791, 2799-2803, 2805-2812, 2816-2822, 2824-2825, 2827, 2829, 2833-2838, 2841-2843, 2845-2875, 2877-2885, 2887-2893, 2895-2896, 2898, 2900, 2905-2910, 2917-2921, 2925, 2930-2934
320D L	MDE00114-00123, 189-193, 248-249, 256-257, 267-270, 277, 334, 343-346, 352-353, 374-378, 395-398, 403-407, 414-417, 422-426, 433-436, 441-445, 452-455, 460-464, 471-474, 479-480, 482-483, 567-568, 575-591, 593-609, 611-612, 614-618, 679-682, 687-690, 695-700, 704-711, 804-808, 813-814, 822-825, 830-835, 840-845, 852, 858, 864, 873, 883-884, 893-894, 903-904, 913-914, 923-924, 935, 945-947, 956-958, 967, 987, 992, 997-998, 1003-1004, 1014, 1020, 1025-1026, 1031, 1034-1035, 1040-1042, 1045-1048, 1051, 1054-1060, 1063, 1068, 1074-1075, 1080, 1086-1087, 1092-1093, 1098-1099, 1104-1105, 1110-1111, 1116-1117, 1122, 1130-1132, 1136-1138, 1143, 1145-1146, 1148-1150, 1153-1155, 1157-1159, 1163-1164, 1170, 1176, 1181, 1186-1187, 1192-1193

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
7	1195150	COOLANT
2	2653632	SEAL
1	3263870	CORE AS-RADIATOR
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 2*****
1	5I7572	GASKET
1	5I7735	GASKET
7	1195150	COOLANT
2	2653632	SEAL
1	3244128	REGULATOR
1	3263870	CORE AS-RADIATOR
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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****Parts Stock ****

Scrap the 265-3624 Radiator-Core from dealer parts stock.

****Affected Product****

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Refer to the attached Rework Procedure. The affected product in Group 1 should be replaced with the new 326-3870 Radiator-Core. The affected product in Group 2 should be replaced with the new 326-3870 Radiator-Core and the new 324-4128 Engine Coolant Temperature Regulator.

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SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all parts removed from dealer parts stock.

****Affected Product****

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-3000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
3001-6000 hrs, 13-24 mo	33.3%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 6.0-hour job for Group 1

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
3001-6000 hrs, 25-48 mo	33.3%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 6.0-hour job for Group 2

PARTS DISPOSITION

****Parts Stock****

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

****Affected Product****

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

1. Move the machine to the rework area and rest the front linkage on the ground. Turn the engine key off and leave the hydraulic lock lever in the operational position. Release the residual hydraulic pressure of pilot lines by moving the implement control lever. Place the hydraulic lock lever in the locked position.

2. Allow the cooling system to cool down. Slowly loosen the pressure cap in order to release pressure from the cooling system. Remove the pressure cap.

Image1.2.1

3. Remove the access cover that is underneath the radiator. Open the drain valve and allow the coolant to drain into a suitable container. The drain valve is located on the bottom of the radiator. Remove the water hose and the drain valve from the existing radiator core.

Image1.3.1

4. Loosen the band clamp and remove the lower hose from the existing radiator core. Cover the hose end with a vinyl sheet in order to prevent dust from entering the hose.

Image1.4.1

5. Remove the bolt and the washer. Remove the clip.

Image1.5.1

6. Loosen the band clamp and remove the upper hose from the radiator. Cover the hose end with a vinyl sheet in order to prevent dust from entering the hose.

Image1.6.1

7. Remove the water hose from the radiator. Cover the hose end with a vinyl sheet in order to prevent dust from entering the hose.

Image1.7.1

8. Remove the bolt for the hood support. Fully open the engine hood.

Image1.8.1

9. Remove the nine bolts and washers from the fan guard. Remove both the upper and lower guard from the radiator group.

Image1.9.1

Image1.9.2

Image1.9.3

10. Remove eight bolts and washers from the radiator group.

Image1.10.1

11. Remove two bolts, two washers, two rubber cushions, and two bosses from the radiator group.

Image1.11.1

12. Move the shroud 50mm forward to the engine.

Image1.12.1

13. Remove the existing radiator core from the radiator group. Make sure the two rubber cushions keep in place on the bosses. Refer to Image 1.13.2.

Image1.13.1

Image1.13.2

14. Attach the 265-3632 Seal to the new 326-3870 Radiator Core Assembly.

Image1.14.1

15. Install the new 326-3870 Radiator Core Assembly to the radiator group.

Image1.15.1

16. Use the eight bolts and washers that were removed in Step 10 in order to assemble the shroud to the radiator group. Tighten the bolts to a torque of 28+/-7 Nm.

17. Use the two bolts, two washers, two rubber cushions, and two bosses that were removed in Step 11 in order to connect the new 326-3870 Radiator Core Assembly to the radiator group. Tighten the bolts to a torque of 55 +/-10 Nm.

18. Use the nine bolts and washers that were removed in Step 9 in order to assemble the upper and lower guard to the radiator group. Tighten the bolts to a torque of 55+/-10 Nm.

19. Assemble the water hose that was removed in Step 6.

20. Assemble the upper hose that was removed in Step 5 to the new 326-3870 Radiator Core Assembly. Use the band clamp that was removed in Step 5 in order to attach the upper hose. Tighten the screw of the band clamp to a torque of 4.5+/-0.5 Nm.

21. Use the bolt and washer that was removed in Step 4 in order to attach the hose. Tighten the bolt to a torque of 55+/-10 Nm.

22. Use the band clamp that was removed in Step 3 in order to assemble the lower hose to the new 326-3870 Radiator Core Assembly. Tighten the screw of the band clamp to a torque of 4.5+/-0.5 Nm.

23. Assemble the water hose and the drain valve that were removed in Step 2 to the new 326-3870 Radiator Core Assembly. Tighten the drain valve by hand. Close the drain valve.

24. Fill the radiator/cooling system using the 119-5150 Coolant and clean water. Refer to your machines Operation and Maintenance Manual, "Capacities (Refill)" and to SEBU6250 "Caterpillar Machine Fluids Recommendations" for further details.

25. Perform this step only for machines in Group 2. Replace the current 5I-8010 Engine Coolant Temperature Regulator with the new 324-4128 Engine Coolant Temperature Regulator. Use the new 5I-7735 and 5I-7572 gasket for the replacement. Refer to the "Disassembly and Assembly" engine supplement for the machine for further details.

26. Start the engine. Operate the engine without the pressure cap assembly until the water temperature regulator opens and the coolant level stabilizes. Maintain the coolant level and confirm water leakage from cooling system. Refer to your machines "Operation and Maintenance Manual".

27. Install the pressure cap assembly that was removed in Step 2.

28. Use the bolts of the hood support that were removed in Step 8 in order to close the engine hood group. Tighten the bolts to a torque of 100+/-20 Nm.

29. Use the bolts that were removed in Step 3 in order to assemble the access cover. Tighten the bolts to a torque of 100+/-20 Nm.