PRODUCT SUPPORT PROGRAM FOR REPLACING THE RADIATOR THAT LEAKS ON CERTAIN 525B AND 535B SKIDDERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE RADIATOR THAT LEAKS ON CERTAIN 525B AND 535B SKIDDERS

Usage:

SEBE8202-02

November 8, 2002
(Revised August 2003)
U-292
A-202
AU-214
S-213
H-211
O-237

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*After failure only* *Parts stock action needed*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE RADIATOR THAT LEAKS ON CERTAIN 525B AND 535B SKIDDERS
1353 1375		PS50561

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 "PS50561" 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: 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.

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.

NOTE: This Revised Service Letter replaces the November 8, 2002 (Revised November 2002) Service Letter. Changes have been made to the Parts Disposition.

TERMINATION DATE

November 30, 2003

PROBLEM

The radiator leaks and needs to be replaced on certain 525B and 535B Skidders. The 1565881 Radiator may leak prematurely at the soldered joints.

AFFECTED PRODUCT

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Model	Identification Number
525B	3KZ225-325, 400-795, 797-825, 827-834
535B	AAE401-462, 500-568, 570

PARTS NEEDED

4 - 7T5947 Washer - Retaining
4 - 8T4910 Bolt
174 - 1222228 Seal - Bulk
1 - 2212659 Radiator Group
2 - 2245631 Plate

ACTION REQUIRED

***** Parts Stock *****

Remove all 1565881 Radiators from parts stock.

***** Affected Product *****

Include the date code of the failed radiator in the claim story. See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

***** Parts Stock *****

Submit one claim for all 1565881 Radiators that are removed from 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
0-4000 / 0-24 Months	100%	8	0	0	0	0
4001-6000 / 25-36 months	33 1/3%	4	0	0	50%	4
NOTE: This is a 8?hour job. NOTE: Include the date code of the failed radiator in the claim story.

PARTS DISPOSITION

Record the date code from the failed radiator on the service report. The date code from the failed radiator must be included in the claim story.
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Attach. (1-Rework Procedure)

Rework Procedure

Remove the 1565881 Radiator from the machine. Refer to RENR4345 Disassembly and Assembly, 525B Wheel Skidder and 535B Wheel Skidder Engine Supplement, "Radiator - Remove and Install" for safety information and instructions on removing the radiator.

Illustration 1 - 1565881 Radiator

The 1565881 Radiator can be identified by the following three ways.

X support from corner to corner
Soldered core to tank joints
Part number tag on front lower corner

Record the date code of the failed radiator for the claim story.
Remove the existing 1228339 Seal from the top and bottom horizontal edges of the radiator guard group.

Note: If the 1222228 Seal is not available, the existing 1228339 Seal can be trimmed to a thickness of 10 mm (0.4 in).

Note: Do not remove the seal from the vertical edges of the radiator guard group.

Illustration 2 - 2212659 Radiator Group installed

Apply the adhesive side of the 1222228 Seal to horizontal top and bottom edges of the new radiator.

Note: If the 1222228 Seal is not available you can trim the existing seal to a thickness of 10 mm (0.4 in).

Install the new radiator and shroud into the radiator guard.
Tighten the four 8T4910 Bolts to a torque of 100 +/- 20 N.m (74 +/- 15 lb.-ft).
Install the fan guard to the shroud with the existing M10 bolts.

Note: A few of the earlier shrouds were built with M8 weld nuts. If you have a shroud with M8 weld nuts you will need twelve 8T4908 Bolts.

Illustration 3 - Condenser Mounting Group

Install the condenser with the new 2245631 Brackets (if available).

Note: If the new brackets are not available, you can use four 1W5040 Spacers and four 8T4182 Bolts. Install the spacers between the rubber mount and the condenser core.