PRODUCT IMPROVEMENT PROGRAM FOR FLUSHING THE COOLANT SYSTEM ON CERTAIN 314D LCR, 321D CR, AND 321D LCR EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR FLUSHING THE COOLANT SYSTEM ON CERTAIN 314D LCR, 321D CR, AND 321D LCR EXCAVATORS

Usage:

TEBE0807-01

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10Feb2014

(Revised 09Sep2014)

U-65

A-46

D-62

O-58

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR FLUSHING THE COOLANT SYSTEM ON CERTAIN 314D LCR, 321D CR, AND 321D LCR EXCAVATORS
1812 7304 7320		PI32295

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32295" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI32295" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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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NOTE:	This Revised Service Letter replaces the 10Feb2014 Service Letter. Changes have been made to the Affected Product.

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COMPLETION DATE	TERMINATION DATE
31Aug2014	28Feb2015

PROBLEM

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Contamination in the engine and radiator cooling system can lead to issues with cab heater core on certain 314D LCR, 321D CR, and 321D LCR Excavators.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
314D LCR	TXN00704-00815

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*****Group 2*****
321D CR	JCX00184
321D LCR	KBH00260 KBZ00199 MPG00525-00905 TXA00347-00571

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	2299136	CORE AS-HEATER (After Failure Only)
1	A/C_GAS	800g of refrigerant (After Failure Only)
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 30% 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	2299136	CORE AS-HEATER (After Failure Only)
1	A/C_GAS	800g of refrigerant (After Failure Only)
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 34% 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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Flush engine and radiator cooling system, refill with new coolant. Refer to the attached Rework Procedure.

If heater core is leaking or not functioning correctly, replace the heater core.

Refer to KENR6404 (for 314DCR) and KENR6012 (for 321DCR), Disassembly and Assembly, "Heating and Air Conditioning Unit - Remove and Install".

Refer to KENR6799, "308D, 314D, 321D and 328D Excavators Air Conditioning and Heating".

Then, flush the cooling system. Refer to the attached Rework Procedure.

Note: Replacing the coolant only inside the radiator will not clean up the cooling circuit correctly. Complete the cooling system flush, refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 3.0-hour job for Group 1
3.0 hours will be allowed for flushing water circuit. An additional 15.0 hours will be allowed to replace heater core for an after failure repair only.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 3.0-hour job for Group 2
3.0 hours will be allowed for flushing water circuit. An additional 15.0 hours will be allowed to replace heater core for an after failure repair only.

PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR FLUSHING THE COOLANT SYSTEM

MODELS INVOLVED - CERTAIN 314D LCR, 321D CR, AND 321D LCR EXCAVATORS

Dear Cat Product Owner:

The coolant needs to be replaced and the system flushed on the products listed below. The existing heater core can be cracked. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this products, please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 10Feb2014 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 10Feb2014 Service Letter

Rework Procedure

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 on a smooth and level surface in order 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 the machine's configuration is a 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 the machine configuration is a fix fan, remove the 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. 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 Image1.5.1. and 1.5.2 for location.

Image1.5.1

Image1.5.2

7. Apply air to the heater hose in order to drain the remaining coolant inside heater circuit from bottom of radiator.

8. Plug the heater hose which is removed from regulator housing. Connect 3m of extra drain hose to the regulator housing and route it to ground through inside engine room. Do NOT route this drain hose higher than the top of the radiator. Refer to Image1.6.1. The inner diameter of the hose is 16mm. Leave the pan underneath the hose.

A - Original heater hose
B - Routing of the drain hose

Image1.6.1

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

10. Repeat filling water inside radiator until clean 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 2 times). Then complete the 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.

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.