60185-ZY6-003 Honda CABLE B, COVER LOCK (Honda Code 7635691).

February 21, 2002
U-41
A-31
AU-26
S-26
H-26
O-31
Afterfailure only PRODUCT SUPPORT PROGRAMFOR ADDING SEALS AROUND THE RADIATOR IF THE ENGINE OVERHEATS ON CERTAIN303.5 AND 304.5 MINI-EXCAVATORS
7555 PS50390
This Program can only be administeredafter a failure occurs. The decision whether to apply the Program is madeby the dealer. When reporting the repair, use "PS50390" as the Part numberand "7755" as the Group Number. Use "96" as the Warranty Claim DescriptionCode and use "Z" as the SIMS Description Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
February 29, 2004PROBLEM
Seals around the radiator need to be added ifthe engine overheats on certain 303.5 and 304.5 Mini-Excavators. Missingseals allow air to re-circulate around the radiator. On machines equippedwith a Canopy, there is also a hose fitted to connect the engine coolantheater outlet and inlet points. This allows water to bypass the radiator.AFFECTED PRODUCT
Model Identification Number
***** Group 1 *****
303.5 AFW1-1822
***** Group 2 *****
304.5 ANR1-904WAK1-214, 216, 221-222, 227-242, 247-250, 258-261,375, 377-380, 382-385, 387-392, 394-403, 405-407, 409, 415PARTS NEEDED
***** Group 1 *****2 - 5D1026 Clamp - Hose (for canopy machinesonly)
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 machinesonly)
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
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-3000/
0-36 Months 100% 1 0 0 0 0
This is a 1?hour job.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
With any complaint of engine overheating, checkif the radiator seals and heater hose plugs (Canopy only) are fitted. Ifnot, carry out this rework procedure and retest. Engine overheating mayalso 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 sealon the edge of the panel which holds the radiator. Illustration 1If there is no seal, add 60cm of 1243243 Seal:Add 58 mm of 3E3892 Seal between upper frameand bottom guard. Add 30 mm of 8T1133 Seal between suction pipe and bottomguard. Illustration 2
view underneath right hand side of machine
On Canopy machines only, remove front floorplate1722104. Pull some of the heater hose up through the floorplate. Apply2 hand clamps approximately 150 mm apart to stop the flow. Cut the hoseand 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 sealon 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 5Remove 1862649 Plate Assembly from below theright hand rear of the machine. Remove the existing seals. Refit the 3E8299Seal, and fit a new 1862650 Seal, as shown. Illustration 6
On Canopy machines only, remove front floorplate1722104. Pull some of the heater hose up through the floorplate. Apply2 hand clamps approximately 150 mm apart to stop the flow. Cut the hoseand install (2) 2152265 Plugs and (2) 5D1026 Clamps to seal the open ends.