PRODUCT SUPPORT PROGRAM TO INCREASE THE PERFORMANCE OF THE COOLING SYSTEM ON CERTAIN M312, M315, M318, AND M320 WHEELED EXCAVATORS EQUIPPED WITH LARGE MESH RADIATORS Caterpillar

PRODUCT SUPPORT PROGRAM TO INCREASE THE PERFORMANCE OF THE COOLING SYSTEM ON CERTAIN M312, M315, M318, AND M320 WHEELED EXCAVATORS EQUIPPED WITH LARGE MESH RADIATORS

Usage:

SEBE7930-01

March 9, 2002
(Revised April 2003)
U-48
A-37
AU-30
S-30
H-30
O-41

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*After failure only*	PRODUCT SUPPORT PROGRAM TO INCREASE THE PERFORMANCE OF THE COOLING SYSTEM ON CERTAIN M312, M315, M318, AND M320 WHEELED EXCAVATORS EQUIPPED WITH LARGE MESH RADIATORS
1353		PS50376

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 "PS50376" 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: 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 March 9, 2002 Service Letter. Changes have been made to the Parts Needed and Rework Procedure.

TERMINATION DATE

March 31, 2004

PROBLEM

Incidents of overheating have been reported on some M312, M315, M318, and M320 Wheeled Excavators. Long uphill operation can cause elevated engine coolant temperatures. NOTE: Before implementing this program assure all cooling-related systems are properly adjusted and operating correctly. This includes the following: - Proper machine operation during downhill travel (see TIB 8 September 1999) - Correct Functionality of the Overheating Alarm Switches: Hydraulic oil high temp. switch closes at 94+-3° C
Engine Coolant high temp. switch closes at 100+-3° C - Cleanliness of the Coolers Cores

- Correct Functionality of the Thermostat

- Maximum Driveshaft Speed within specification
(excessive driveshaft speed will significantly impact load on the cooling system)

AFFECTED PRODUCT

NOTE: This rework is NOT adaptable to M300 Series machines equipped with a Standard Mesh Radiator, but only to machines equipped with Large Mesh Radiator. The Part Number of the Radiator Gp is to be found on the id.plate located on the front of the reservoir.

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Chart of Radiator P/N	Standard Mesh	Large Mesh
M312/M315	1931026/1445980	1565670
M318	1931025/1445952	1565669
M320	1931017/1445993	1599569

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Model	Identification Number
Group 1
M312	6TL1-1709
M315	7ML1-2641, 2643-2737
Group 2
M318	8AL1-3369 6ES1-301 8SS1-610, 612-619
Group 3
M320	6WL1-919 9PS1-434, 436-456

PARTS NEEDED

Group 1 (M312/M315)

4 7X2539 Bolt
23 8T4224 Washer
1 1931028 Fan As.
1 1931029 Shroud
1 2079524 Reservoir
1 2246478 Plate
1 2274202 Adapter
1 1861338 Seal
2 7Y2292 Washer (use as required)
2 8R0126 Washer (use as required)
1 5H2471 Adhesive
1 1250914 Bumper
1 1597892 Plate As.
1 1597898 Plate
1 1597900 Plate
2 8T4121 Washer
1 8T4133 Nut
1 8T4191 Bolt
2 8T4223 Washer
2 8T4244 Nut
10 2Y5881 Washer spring
1 2078488 Bracket As

Group 2 (M318)

1 1250914 Bumper
1 1597894 Plate As.
1 1597900 Plate
1 1597904 Plate
2 8T4121 Washer
1 8T4133 Nut
1 8T4191 Bolt
2 8T4223 Washer
2 8T4244 Nut
6 7X2539 Bolt
6 8T4224 Washer
1 1931015 Fan As.
1 1931024 Shroud
1 2079524 Reservoir
2 7Y2292 Washer (use as required)
2 8R0126 Washer (use as required)
1 1861338 Seal
1 4P2843 Pulley (If equipped w/High Ambient Pulley Gp)*
1 9L1128 V-Belt (If equipped w/High Ambient Pulley Gp)*
1 5H2471 Adhesive
1 2078488 Bracket As
26 8T4224 Washer
20 2Y5881 Washer Spring
14 8T4189 Bolt
4 8T4908 Bolt
2 8T4200 Bolt
2 9X8256 Washer
2 5C9553 Bolt
2 5C2890 Nut-Hex
1 2108204 Adapter
1 2040690 Tube As
6 8T4177 Bolt

NOTE*: The 7C1390 High Ambient Fan Pulley of M318 has a diameter of 200mm (versus the 7C2515 Standard Pulley of diameter 230mm). Group 3 (M320)

1 1250914 Bumper
1 1597893 Plate As.
1 1597900 Plate
1 1597904 Plate
2 8T4121 Washer
1 8T4133 Nut
1 8T4191 Bolt
2 8T4223 Washer
2 8T4244 Nut
1 1931016 Adapter
1 1931015 Fan As.
1 1931020 Shroud
1 2079524 Reservoir
1 1861338 Seal
2 7Y2292 Washer (use as required)
2 8R0126 Washer (use as required)
1 5H2471 Adhesive
1 2078488 Bracket As
10 2Y5881 Washer Spring

ACTION REQUIRED

See attached rework procedure.

SERVICE CLAIM ALLOWANCES

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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
0-6000 0-60 mos	100%	5.0	0	0	0	0
NOTE: This is a 5.0-hr job.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)
(2-Illustrations)

Rework Procedure

Remove the Radiator and Hydraulic Oil Cooler using the Disassembly and Assembly section of the Service Manual. Do not disassemble the core assembly.

NOTE: For M318 equipped with High Ambient Pulley Group only Remove and discard the crankshaft pulley (190mm diameter) and fan belt. Save the hardware for reuse.

NOTE: The 7C1390 High Ambient Fan Pulley of M318 has a diameter of 200mm (versus the 7C2515 Standard Pulley of diameter 230mm).

NOTE: To ease radiator removal, dismount the bracket as plate in front of the radiator. See Illustration #1.

Dismount the fan guards, radiator shroud, fan adapter and fan assembly. Save the radiator shroud mounting hardware and the fan guards for reuse.

M318 equipped with High Ambient Pulley Group only, install a new 4P2843 Crankshaft Pulley (211mm diameter) and a new 9L1128 V-Belt.

Install a new fan adapter and new fan assembly, using new hardware (Reuse existing hardware for M320). See Illustration # 2, # 3, and # 4. Use the parts listed below.

M312/M315
1 1931028 Fan Assembly
1 2246478 Plate
1 2274202 Fan Adapter
4 7X2539 Bolt
4 8T4224 Washer

M318
1 1931015 Fan Assembly
1 2108204 Fan Adapter
6 7X2539 Bolt
6 8T4224 Washer

M320
1 1931015 Fan Assembly
1 1931016 Fan Adapter

NOTE: Reuse existing hardware for M320

Thoroughly and carefully clean both cooler cores with water or pressurized air.

NOTE: Make sure that the cleaning flow runs parallel to the cooler´s lamella (fins) to prevent cooler damages.

NOTE: Make sure the coolers are dry before running the machine again at the end of the rework procedure.

Install the components for a fourth radiator mounting point, using the parts listed below.

M312/M315 (See Illustration # 7)

1 1597892 Plate As.
1 1597898 Plate (this replaces the 1236740 Plate)
1 8T4121 Washer
1 8T4191 Bolt
2 8T4223 Washer
2 8T4244 Nut

M318 (See Illustration # 8)
1 1597894 Plate As.
1 1597904 Plate (this replaces the 1233653 Plate)
1 8T4121 Washer
1 8T4191 Bolt
2 8T4223 Washer
2 8T4244 Nut

M320 (See Illustration # 9)
1 1597893 Plate As.
1 1597904 Plate (this replaces the 1233653 Plate)
1 8T4121 Washer
1 8T4191 Bolt
2 8T4244 Nut

Disassemble and discard the Reservoir assembly from the radiator group and replace it with the new 2079524 Reservoir, and 2078488 bracket.
Install the new shroud onto the Radiator Group, using existing hardware. Note component configuration for M318 in Fig. 10.
Adjust the radiator position to meet the criteria shown in Illustration #5.
Install 1861338 Seal using 5H2471 adhesive. See Illustration # 6.

Illustrations

Illustration 1

Illustration 2: fan assembly

A = 1204709 Fan Assembly
B = 8T4177 Bolt
C = 8T4224 Washer
D = 1229087 Adapter
E = 7X2539 Bolt
F = 8T4224 Washer
G = 2274202 Adapter
H = 1931028 Fan Assembly
J = 2246478 Plate

Illustration 3: fan assembly

A = 1200301 Adapter
B = 1200300 Fan Assembly
C = 1082989 Bolt
D = 8T4224 Washer
E = 7X2539 Bolt
F = 8T4224 Washer
G = 1931015 Fan Assembly
2108204 adapter not shown

Illustration 4: fan assembly

A = 1340716 Adapter
B = 1200300 Fan Assembly
C = 8T4908 Bolt
D = 8T4224 Washer
E = 1931016 Adapter
F = 8T4908 Bolt (reuse C)
G = 8T4224 Washer (reuse D)
H = 1931015 Fan Assembly

Illustration 5: Fan (1), Shroud (2), Grill (3)

A: minimum 17mm for M312/M315; minimum 22mm for M318/M320

B: minimum 113mm for M312/M315; minimum 118mm for M318/M320

C: minimum 10mm for M312/M315 on the whole circumference; minimum 12mm for M318/M320 on the whole circumference

Illustration 6

A = 1861338 Seal
Note: = bond to radiator

Illustration 7: 4 point radiator mounting system on M312/M315

A = 1597892 Plate assembly
B = 8T4191 Bolt
C = 8T4121 Washer
D = 8T4223 Washer
E = 8T4244 Nut
F = 1597898 Plate
G = 1250914 Bumper
H = 1597900 Plate
I = 8T4133 Nut + 8T4121 Washer

Illustration 8: four-point radiator mounting system on M318

A = 8T4191 Bolt
B = 8T4121 Washer
C = 1597894 Plate Assembly
D = 1597904 Plate
E = 8T4223 Washer
F = 8T4244 Nut
G = 1250914 Bumper
H = 1597900 Plate
I = 8T4133 Nut + 8T4121 Washer

Illustration 9: 4 point radiator mounting system on M320

A = 8T4191 Bolt
B = 8T4121 Washer
C = 1597893 Plate Assembly
D = 1597904 Plate
E = 8T4223 Washer
F = 8T4244 Nut
G = 1250914 Bumper
H = 1597900 Plate
I = 8T4133 Nut + 8T4121 Washer