PRODUCT SUPPORT PROGRAM FOR ADDING SEALS AROUND THE RADIATOR IF THE ENGINE OVERHEATS ON CERTAIN 303.5 AND 304.5 MINI-EXCAVATORS

Usage:

SEBE7919

February 21, 2002
U-41
A-31
AU-26
S-26
H-26
O-31

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*After failure only*	PRODUCT SUPPORT PROGRAM FOR ADDING SEALS AROUND THE RADIATOR IF THE ENGINE OVERHEATS ON CERTAIN 303.5 AND 304.5 MINI-EXCAVATORS
7555		PS50390

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 "PS50390" 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.

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.

TERMINATION DATE

February 29, 2004

PROBLEM

Seals around the radiator need to be added if the engine overheats on certain 303.5 and 304.5 Mini-Excavators. Missing seals allow air to re-circulate around the radiator. On machines equipped with a Canopy, there is also a hose fitted to connect the engine coolant heater outlet and inlet points. This allows water to bypass the radiator.

AFFECTED PRODUCT

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Model	Identification Number
*** Group 1 ***
303.5	AFW1-1822

*** Group 2 ***
304.5	ANR1-904 WAK1-214, 216, 221-222, 227-242, 247-250, 258-261, 375, 377-380, 382-385, 387-392, 394-403, 405-407, 409, 415

PARTS NEEDED

***** Group 1 *****

2 - 5D1026 Clamp - Hose (for canopy machines only)
6 - 3E3892 Seal (Bulk)
3 - 8T1133 Seal (Bulk)
60 - 1243243 Seal (Bulk)
2 - 2152265 Plug (for canopy machines only)

***** Group 2 *****

2 - 5D1026 Clamp - Hose (for canopy machines only)
1 - 1862650 Seal (Bulk)
1 - 1903376 Seal (Bulk)
72 - 1243243 Seal (Bulk)
2 - 2152265 Plug (for canopy machines only)

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

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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 / 0-36 Months	100%	1	0	0	0	0
NOTE: 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

With any complaint of engine overheating, check if the radiator seals and heater hose plugs (Canopy only) are fitted. If not, carry out this rework procedure and retest. Engine overheating may also be caused by blocked radiator, faulty thermostat, low coolant, etc.

303.5 Cab and Canopy machines:

Raise the hood and check if there is a seal on the edge of the panel which holds the radiator.

Illustration 1

If there is no seal, add 60cm of 1243243 Seal:

Add 58 mm of 3E3892 Seal between upper frame and bottom guard. Add 30 mm of 8T1133 Seal between suction pipe and bottom guard.

Illustration 2

view underneath right hand side of machine

On Canopy machines only, remove front floorplate 1722104. Pull some of the heater hose up through the floorplate. Apply 2 hand clamps approximately 150 mm apart to stop the flow. Cut the hose and install (2) 2152265 Plugs and (2) 5D1026 Clamps to seal the open ends.

Illustration 3

Illustration 4

304.5 Cab and Canopy machines:

Raise the hood and check if there is a seal on the edge of the panel, which holds the radiator. If there is no seal, add 72 cm of 1243243 Seal. Add a 1903376 Seal to the hood, above the radiator.

Illustration 5

Remove 1862649 Plate Assembly from below the right hand rear of the machine. Remove the existing seals. Refit the 3E8299 Seal, and fit a new 1862650 Seal, as shown.

Illustration 6
On Canopy machines only, remove front floorplate 1722104. Pull some of the heater hose up through the floorplate. Apply 2 hand clamps approximately 150 mm apart to stop the flow. Cut the hose and install (2) 2152265 Plugs and (2) 5D1026 Clamps to seal the open ends.