PRODUCT SUPPORT PROGRAM FOR FLUSHING THE COOLING LINE OF ENGINE ON CERTAIN 311D-323D EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR FLUSHING THE COOLING LINE OF ENGINE ON CERTAIN 311D-323D EXCAVATORS

Usage:

TEBE0655-01

Show/hide table

03Dec2013

(Revised 25Feb2014)

U-594

A-407

D-485

O-495

Show/hide table

*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR FLUSHING THE COOLING LINE OF ENGINE ON CERTAIN 311D-323D EXCAVATORS
1393 1355 1808		PS52565

Show/hide table

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 "PS52565" 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.

Show/hide table

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.

Show/hide table


NOTE:	This Revised Service Letter replaces the 03Dec2013 Service Letter. Changes have been made to the Title, Problem, Affected Product, Parts Needed, Service Claim Allowances, and Rework Procedure to expand the affected products and reduce flushing cycle from 3 times to 2 times.

Show/hide table

TERMINATION DATE

31Dec2015

PROBLEM

Show/hide table

The existing engine can contaminate the coolant with the rust coming from the cooling line on certain 311D-323D Excavators.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
*****Group 1*****
320D	BWZ07904, 7916-9485, 9487, 9490-9492, 9494-9565, 9567-9568, 9580-9588 DFB00782-00846 FAL10243-11160 KGF09453-09859 KLM00208-00215 SNS00539-00616 WJN00264, 271-288
320D L	GDP01052-01067 SPN01712-01715, 1721-1724 TDH00322-00393
320D LRR	HJC00146 SCW00245-00257
320D RR	RBL01455-01653
323D L	YSD01356-01357

Show/hide table

*****Group 2*****
311D LRR	DWR00269-00272
312D	FBJ03545-03552, 3554-3566 RHL00317
312D LC	KES00198-00202 SKA00283-00284
315D LC	BZN00165, 168-169
319D LN	FMH00282-00283, 291, 293-297

Show/hide table

*****Group 3*****
314D LCR	TXN00612-00703

Show/hide table

*****Group 4*****
313D CR	LCE01084-01085
314D LCR	XHR00188-00189

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
*****Group 1*****
1	COOLANT	30L of Premix ELC
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 12% 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	COOLANT	25L of Premix ELC
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 6% 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 3*****
1	COOLANT	25L of Premix ELC
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 6% 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 4*****
1	COOLANT	25L of Premix ELC
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 6% 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

Show/hide table

If the color of the coolant gets darker or if some black deposits are found on the bottom of the reservoir tank, the engine should be flushed and the coolant should be replaced. Refer to the attached Rework Procedure.

Show/hide table

SERVICE CLAIM ALLOWANCES

Show/hide table

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, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 3.0-hour job for Group 1

Show/hide table

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, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 3.0-hour job for Group 2

Show/hide table

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 3*****
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 3.0-hour job for Group 3

Show/hide table

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 4*****
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 3.0-hour job for Group 4

PARTS DISPOSITION

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

Rework Procedure

Group Number 1 Group Number 2

This Rework Procedure Group Number 1 and Group Number 2 is for 311D/312D/315D/319D/320D/323D machines only.

Preparation:

Water
10cm of 17mm ID hose
10cm of 16mm ID hose
Plug for 17mm hose (Qty 2)
Plug for 16mm hose (Qty 2)
Coolant density measurement tool

1. Park the machine so the upper frame has 90 degree angle against the base frame. Refer to Image1.2.1. Remove the bottom cover located under the radiator and heater core. Refer Image1.2.2 for the location of heater core.

Image1.2.1

Image1.2.2

2. Start the engine and set the fan motor speed to 0 by over ride function of monitor. If machine's configuration is fix fan, then cover the front of radiator for warm up. Set the engine speed to dial 10 and repeat 2 pump relief for 5 minutes for warm up. Check the water temperature, if it is lower than 80 degrees Celsius, continue an additional three minute warm up with 0 fan motor speed until the water temperature is over 80 degrees Celsius. The water temperature regulator will start opening at 70 degrees Celsius and be fully opened at 80 degrees Celsius.

3. Once the water temperature is over 80 degrees Celsius, change the dial speed to dial 1. Set the fan revolution to 1,000 rpm by the override function. If machine's configuration is fix fan, then remove cover. Turn ON the air conditioner. Set the "Fresh air/Maximum blower fan/32dC temp/Compressor ON"?position for heater line cooling. Open the side door and keep at low idle for ten minutes for the cool down.

4. Stop the engine and drain the water from the drain hole of radiator.

5. Disconnect the bypass hose at the water temperature regulator housing and plug the hose. The inner diameter of the bypass hose is 17mm. Install an extra 17mm hose on the housing port and plug this extra hose. Refer to Image1.4.1 and 1.4.2.

Image1.4.1

Image1.4.2

6. Gain access to the heater hose under the cab and disconnect the HS hose (supply side with red tag). During this time the coolant inside heater circuit will need to be drained. Confirm that the temperature is not high enough to touch the heater hose and leave the pan underneath the hose. Refer to Image1.5.1.

Image1.5.1

7. Install an extra hose to HS port of heater core. The inner diameter of the hose is 16mm. Plug this extra hose. Plug the heater hose temporarily. Refer to Image1.6.1.

Image1.6.1

8. Close the drain port of the radiator and fill water inside radiator. Remove the plug from the heater hose. Hot water from inside engine will spout out. Take care when handling this hose. Refer to Image1.7.1.

Image1.7.1

9. Repeat filling water inside radiator until cleaned water comes out from heater hose.

10. Plug the heater hose. Fill water inside radiator and remove the extra hose of the HS port. Fill water inside the radiator until clean water comes out from heater core.

11. Drain the water inside the overflow subtank. After washing, fill 2 liters of water inside the subtank.

12. Return the bypass hose and heater hose to original condition and fill water inside radiator.

13. Repeat this procedure from Step 2 to 7 again only one time (total two times). Then do same procedure from Step 8 to 10 by using premix ELC until ELC comes out from heater hose.

14. Drain the water inside the overflow subtank. After washing the tank, fill up the tank with premix ELC.

15. Return the bypass hose and heater hose to original condition. Fill up the radiator with premix ELC.

16. Perform warmup. Refer to previous Step 2 and 3.

17. Complete the air purge. The air purge should be performed by the following steps:

- Start the engine.

- Operate the engine without the radiator cap until the water temperature regulator opens and the coolant level stabilizes.

- Fill up the radiator to brim full whenever the coolant level is low.

Group Number 3 Group Number 4

This Rework Procedure Group Number 3 and Group Number 4 is for 313D/314D machines only.

Preparation:

3m of drain hose whose ID is 16mm. You can use 5P-0767 heater hose if you can't find proper hose.
10cm of 17mm ID hose
Plug for 17mm hose (Qty 2)
Plug for 16mm hose (Qty 2)
Cover for radiator
Coolant density measurement tool

1. Park the machine to access water drain port located under radiator. Remove the bottom cover located under the radiator.

2. Start the engine and set the fan motor speed to 0 by over ride function of monitor.If machine's configuration is fix fan, then cover the front of radiator for warm up. Set the engine speed to dial 10 and repeat 2 pump relief for 5 minutes for warm up. Check the water temperature, if it is lower than 80 degrees Celsius, continue an additional three minute warm up with 0 fan motor speed until the water temperature is over 80 degrees Celsius. The water temperature regulator will start opening at 70 degrees Celsius and be fully opened at 80 degrees Celsius.

3. Once the water temperature is over 80 degrees Celsius, change the dial speed to dial 1. Set the fan revolution to 1,000 rpm by the override function. If machine configuration is fix fan, then remove cover. Turn ON the air conditioner. Set the "Fresh air/Maximum blower fan/32dC temp/Compressor ON"?position for heater line cooling. Open the side door and keep at low idle for ten minutes for the cool down.

4. Drain coolant from bottom of radiator.

Image2.4.1

Image2.4.2

6. Remove heater hose (HS) connected to the regulator housing. During this time the coolant inside heater circuit will need to be drained. Confirm that the temperature is not high enough to touch the heater hose and leave the pan underneath the hose. Refer to Image2.5.1.

Image2.5.1

7. Apply air to heater hose to drain coolant remained inside heater circuit from bottom of radiator.

8. Plug heater hose which is removed from regulator housing. Connect 3m of extra drain hose to regulator housing and route it to ground through inside engine room. Do NOT route this drain hose higher than top of radiator. Refer to Image 2.6.1. The inner diameter of the hose is 16mm. Leave the pan underneath the hose.

Image2.6.1

9. Close the drain port of the radiator and fill water inside radiator. Hot water from inside engine will spout out from extra drain hose.

10. Repeat filling water inside radiator until cleaned water comes out from drain hose.

11. Drain the water inside the overflow subtank. After washing, fill 2 liters of water inside the subtank.

12. Return the bypass hose and heater hose to original condition and fill water inside radiator.

13. Repeat this procedure from Step 2 to 8 again only one time (total two times). Then do same procedure from Step 9 to 10 by using premix ELC until ELC comes out from drain hose.

14. Drain the water inside the overflow subtank. After washing the tank, fill the tank with Premix ELC.

15. Return the bypass hose and heater hose to original condition.

16. Perform warmup. Refer to previous Step 2 and 3.