PRODUCT SUPPORT PROGRAM FOR REPLACING THE RADIATOR CORE ASSEMBLY ON CERTAIN 324D, 325D, AND M325D EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE RADIATOR CORE ASSEMBLY ON CERTAIN 324D, 325D, AND M325D EXCAVATORS

Usage:

REBE5110-00

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16Jun2009

U-221

A-190

D-190

O-195

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After Failure Only Parts stock action needed	PRODUCT SUPPORT PROGRAM FOR REPLACING THE RADIATOR CORE ASSEMBLY ON CERTAIN 324D, 325D, AND M325D EXCAVATORS
1353 7750		PS51680

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51680" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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

30Jun2011

PROBLEM

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The radiator core may crack between the radiator top tank and the coolant tube assembly on certain 324D, 325D, and M325D Excavators. The radiator core needs to be replaced.

AFFECTED PRODUCT

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Model	Identification Number
324D	CJX00175-00509 JZR00146-00149, 151-169
324D FM	JKR00163-00195, 1200-1206
324D FM HEEL	JLS00152-00186, 1300-1303
324D FM LGP	JGK00127-00132
324D L	DFP00130-00520 JJG00120-01200 SYM00155-00797 T2D00221-00680 TSN00172-00174
324D LN	EJC00222-00899 LAB00261-00417
324D OEM	KJR00101-00159
325D	AZP00140 CYW00192 DBH00105-00676 GBR00131-00191 GPB00167-01120 KBE00125-00312 KDG00148-00169, 171-280 PKE00193-01203 SCR00249-01069
325D FM	C7K00192-00211
325D FM BUTT N	C9M00133-00147
325D FM HEEL	C8L00153-00184, 1400-1404
325D L	A3R00114-01436 ERK00201-00232 LAL00251-00526 MCL00151-00232 NAC00251-00276 PAL00251-00465 T2S00251-00401
325D L OEM	H3N00101-00104 X3N00103-00240
325D MH FCR	RJK00126-00163
325D MH HCR	C4H00208-00222
325D OEM	C3N00100-00153, 155-566 SRC00101-00106
M325D L MH	KAY00231-00234, 236-237, 239, 242-261, 264, 267-278 KGG00211-00307
M325D MH	EDF00221-00304

PARTS NEEDED

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Qty	Part Number	Description
2	2653632	SEAL
1	3263870	CORE AS-RADIATOR
33	COOLANT	USE ONLY CAT ELC - 50/50 PREMIX (33 Liters)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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 ****

Remove all 245-9207 Radiator Cores from dealer parts stock.

****Affected Product****

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Refer to the attached Rework Procedure.

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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%
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
3001-6000 hrs, 25-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 6.0-hour job

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PARTS DISPOSITION

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****Parts Stock****

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

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****Affected Product****

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

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Rework Procedure

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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 "CAT ELC(50/50 Premix)". Refer to your machines Operation and Maintenance Manual.

25. 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".

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

27. 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.

28. 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.