PRODUCT SUPPORT PROGRAM FOR REPLACING THE RADIATOR CORE ASSEMBLY AND ENGINE COOLANT TEMPERATURE REGULATOR ON CERTAIN 320D AND 323D EXCAVATORS
[REBE5105]
COOLING SYSTEM
RADIATOR GP
PRODUCT SUPPORT PROGRAM FOR REPLACING THE RADIATOR CORE ASSEMBLY AND ENGINE COOLANT TEMPERATURE REGULATOR ON CERTAIN 320D AND 323D EXCAVATORS
REBE5105-02
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| 31Jul2009 |
| (Revised 03Jun2010) |
U-283
A-240
D-247
O-255
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| After Failure Only Parts stock action needed | PRODUCT SUPPORT PROGRAM FOR REPLACING THE RADIATOR CORE ASSEMBLY AND ENGINE COOLANT TEMPERATURE REGULATOR ON CERTAIN 320D AND 323D EXCAVATORS |
|
| 1353 7750 | PS51705 |
|
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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 "PS51705" 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 AVSpare product analyst. |
| NOTE: | This Revised Service Letter replaces the 31Jul2009 (Revised 28May2010) Service Letter. Changes have been made to the Rework Procedure in order to correct the regulator part number listed in Step 27. |
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TERMINATION DATE |
| 31Jul2011 |
PROBLEM
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| The radiator core may crack between the radiator top tank and the coolant tube assembly on certain 320D and 323D Excavators. The radiator core and the engine coolant temperature regulator needs to be replaced. |
AFFECTED PRODUCT
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| Model | Identification Number |
| 320D | A6F00151-00803 BZP00182-01063 CXY00149-00415 DFT00164-00589 DHK00125-01061 FAL00177-02464 JFZ00199-00212, 214-221, 224-230, 232-233, 236-241, 247, 249-251, 254, 257, 266, 270-273, 275, 277, 280, 283, 287, 300, 303-307, 309-324, 327, 331-332, 335-340, 342-343, 345-350, 354, 357-363, 367, 370, 373-376, 378-381, 383-390, 392-401, 403-405, 409, 411-412, 419-421, 423-432, 439-441, 447, 449-450, 452-454, 457, 459, 461-463, 466-476, 480-485, 487-488, 492-494, 496, 498-499, 501, 503-504, 507-508, 510-517, 519, 522-532, 536-538, 545, 549-550, 555, 560-562, 567-572, 585-586, 593-596, 598-601, 610, 613, 616-619, 624, 626, 628, 631-632, 639, 643, 647, 649, 652, 657-658, 660-661, 664, 666, 674-676, 678, 682, 685-686, 692, 694-709, 713, 715, 722-723, 725-726, 729-742, 744-746, 748-801, 803-812, 814-825, 827-829, 833-847, 856, 860-862, 864, 869, 877-878, 882-884, 888, 890-891, 893-895, 898-900, 902-904, 906-907, 909, 913, 916, 920, 922, 924-926, 930-937, 939-941, 945-948, 950-951, 954-955, 958-960, 968, 970-979, 981-983, 989, 991-992, 995, 1002-1015, 1017-1018, 1020, 1022-1032, 1036-1051, 1054, 1057-1060, 1063, 1069-1110, 1114-1115, 1117-1120, 1122, 1124, 1126-1130, 1134-1141, 1143-1144, 1147-1152, 1155-1162, 1164-1165, 1168, 1170, 1184, 1186-1188, 1191-1193, 1195-1197, 1200-1201, 1204-1226, 1228-1235, 1237-1240, 1242, 1244-1258, 1260-1262, 1264-1266, 1269-1273, 1275-1277, 1279, 1281-1282, 1286, 1289-1292, 1294-1296, 1299-1303, 1306, 1309, 1313, 1318-1320, 1324, 1328-1329, 1332, 1334, 1343, 1345, 1347, 1349-1351, 1353-1354, 1356-1360, 1363-1365, 1368, 1374, 1376, 1378-1379, 1381-1382, 1384-1386, 1391, 1439-1447, 1449-1459, 1461-1470, 1472-1483, 1488-1509, 1511-1564, 1567, 1569-1571, 1573-1586, 1589, 1591, 1595-1597, 1599-1600, 1602-1604, 1606, 1609-1612, 1617, 1621-1622, 1625-1626, 1629, 1631-1634, 1637-1639, 1643-1644, 1649, 1651-1665, 1667, 1676-1677, 1679, 1683, 1686-1693, 1695, 1701, 1704, 1706, 1708, 1712-1714, 1716, 1719, 1721-1737, 1739-1777, 1779-1826, 1828-1856, 1860, 1862, 1867, 1876-1877, 1879-1880, 1884-1889, 1892, 1897, 1906, 1908-1910, 1912-1919, 1921-1923, 1926, 1929-1930, 1932, 1934, 1936-1937, 1941-1942, 1944-1945, 1947-1957, 1959-1963, 1965, 1967-1968, 1971, 1975-1976, 1981-1984, 1986-1990, 1992, 1995-1996, 2000-2001, 2003-2007, 2009-2010, 2012-2014, 2016, 2018, 2021-2025, 2029-2033, 2035, 2038-2123, 2125-2133, 2135-2139, 2142-2164, 2166, 2168-2171, 2174-2179, 2182-2199, 2201-2206, 2208, 2211-2213, 2217, 2219, 2225, 2228-2243, 2245-2248, 2250, 2256, 2258, 2264, 2267, 2271, 2277, 2280, 2289, 2291, 2296, 2298-2299, 2302-2303, 2305-2307, 2310, 2320-2326, 2328-2335, 2338-2415, 2417, 2419-2428, 2431-2433, 2437-2441, 2446-2450, 2452-2463, 2465-2469, 2471-2473, 2475-2476, 2479-2481, 2485-2486, 2488-2495, 2515-2516, 2518, 2520, 2553-2554, 2558-2603, 2616-2624, 2630, 2633-2641, 2650-2667, 2670-2673, 2677-2705, 2707, 2709, 2712-2713, 2745-2748, 2751-2752, 2789-2791, 2793-2799, 2801-4166, 4182-4191, 4194-4378, 4391-4421, 4431-4438, 4441-4442 JGZ00418-00488, 740, 831-879, 1123, 1163-1214, 1291-1297, 1463-1465, 1718-1787, 2006-2107, 2182, 2199-2200, 2229-2235, 2240, 2340-2341, 2451-2531, 2789 KGF00106-03289 MCH00198 PHX00119-00122, 124-2165 |
| 320D FM HD/LC | BZF00183-00212 |
| 320D FM HEEL | GKS00180-00210 |
| 320D FM HW | EAX00161-00174 |
| 320D FM LC | BWW00101-00106 CYZ00202-00203 |
| 320D L | A8F00152-01150 A9F00151-00157 MDE00124-00188, 194-247, 250-254, 260-265, 271-275, 279-331, 337-341, 347-351, 354-373, 379-394, 399-402, 408-413, 418-421, 427-432, 437-440, 446-451, 456-459, 465-470, 475-478, 484-565, 570-573, 619-678, 683-686, 691-694, 701-703, 712-803, 809-812, 817-820, 826-829, 836-839, 846-849, 854-857, 859-862, 865-872, 875-882, 885-892, 895-902, 905-912, 915-922, 926-933, 937-944, 948-955, 959-966, 969-986, 988-991, 993-996, 999-1002, 1005-1008, 1010-1013, 1015-1019, 1021-1024, 1027-1030, 1032-1033, 1037-1038, 1043-1044, 1049-1050, 1064-1067, 1070-1073, 1076-1079, 1082-1085, 1088-1091, 1094-1097, 1100-1103, 1106-1109, 1112-1115, 1118-1121, 1124-1129, 1160-1162, 1165-1167, 1171-1174, 1177-1180, 1182-1185, 1188-1191 MGG00108-00176, 178-217, 220-228, 230-284, 286-291, 293-337, 339-343, 345-349, 351-372, 374, 376-395, 398-405, 407-413, 416-422, 424, 428-433, 438-542, 546-549, 552-574, 577-578, 581-595, 597-604, 606-609, 611-612, 615-617, 619-621, 623-635, 637, 639, 641, 644, 646-647, 652, 655-668, 670-673, 676, 680-689, 691-756, 758-767, 769-777, 779-816, 818-825, 827-847, 853-855, 862-937, 943-947, 954-958, 965-969, 976-1521, 1533-1542, 1545-1601, 1605-1610, 1612, 1615 |
| 320D LN | WBN00148-00254 |
| 320D LRR | EBY00113-00118 FXK00190-00224 TAE00106-00117 XCK00167-00468 ZGB00121-00166 |
| 320D OEM | GPX00300-00376 |
| 320D RR | GKL00136-00139 YDS00157-00169 |
| 320D RR FM | SRT00151-00153 |
| 320D RR OEM | PRR00101-00102 |
| 323D L | BYM00107-00826 JLG00271-00446 LFL00101-00201 NDE00183-00247 PBE00242-00274, 283-289, 301-306 PBM00224-00520, 522-586 SDC00248-00933 WGC00151-00189 YSD00177-00255 |
| 323D LN | CYD00169-00614 RAC00252-00635 |
| 323D LN OEM | DCJ00103-00148, 11455 |
| 323D OEM | GRL00100-00108 GRN00100-00101 |
| 323D S | DKW00171-00334 |
| 323D SA | SED00195-00421 |
PARTS NEEDED
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Qty |
Part Number | Description |
| 1 | 5I7572 | GASKET |
| 1 | 5I7735 | GASKET |
| 2 | 2653632 | SEAL |
| 1 | 3244128 | REGULATOR |
| 1 | 3263870 | CORE AS-RADIATOR |
| 27 | COOLANT | USE ONLY AVS ELC - 50/50 PREMIX (27 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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Remove all 265-3624 Radiator Core Assemblies from dealer parts stock. |
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| Refer to the attached Rework Procedure. |
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SERVICE CLAIM ALLOWANCES
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|
Submit one claim for all parts removed from dealer parts stock. |
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0-24 mo |
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25-48 mo |
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| NOTE: This is a 6.0-hour job | ||||||
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PARTS DISPOSITION
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| Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
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| Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
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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. |
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| 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. |
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| 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. |
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| Image1.4.1 |
| 5. Remove the bolt and the washer. Remove the clip. |
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| 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. |
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| 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. |
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| Image1.7.1 |
| 8. Remove the bolt for the hood support. Fully open the engine hood. |
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| 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. |
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| Image1.9.1 |
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| Image1.9.2 |
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| Image1.9.3 |
| 10. Remove eight bolts and washers from the radiator group. |
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| Image1.10.1 |
| 11. Remove two bolts, two washers, two rubber cushions, and two bosses from the radiator group. |
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| Image1.11.1 |
| 12. Move the shroud 50mm forward to the engine. |
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| 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. |
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| Image1.13.1 |
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| Image1.13.2 |
| 14. Attach the 265-3632 Seal to the new 326-3870 Radiator Core Assembly. |
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| Image1.14.1 |
| 15. Install the new 326-3870 Radiator Core Assembly to the radiator group. |
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| 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. Replace the current 5I-8010 Engine Coolant Temperature Regulator with the new 324-4128 Engine Coolant Temperature Regulator. |
| 25. Loosen the clamp and disconnect the hose. |
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| Image1.25.1 |
| 26. Loosen the clamp and disconnect hose. Remove the three bolts. Remove the housing and two gaskets. Remove the engine coolant temperature regulator. |
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| Image1.26.1 |
| 27. Install the new 324-4128 Engine Coolant Temperature Regulator and the new 5I-7735 Gasket. Use the three bolts that were removed in Step 26 in order to assemble the housing with the new 5I-7572 Gasket. Tighten the bolts to a torque of 17+/-2 Nm. |
| 28. Connect the hose and tighten the clamp to a torque of 7+/-0.2 Nm. |
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| Image1.28.1 |
| 29. Connect the hose and tighten the clamp to the washer stacks are nearly collapsed flat. |
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| Image1.29.1 |
| 30. Fill the radiator/cooling system using the "AVS ELC(50/50 Premix)". Refer to your machines Operation and Maintenance Manual. |
| 31. 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". |
| 32. Install the pressure cap assembly that was removed in Step 2. |
| 33. 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. |
| 34. 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. |
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