Procedure to Install Waste Handling Arrangement on Series D Wheeled Excavators{1353, 1356, 1360, 1386, 1387, 1408, 1931, 5057, 5061, 7000, 7255, 726A, 7272, 7490, 7600, 7601, 7610, 7620} Caterpillar

Excavator:

M318D (S/N: D9X1-UP)

M322D (S/N: D3X1-UP)

Introduction

This Special Instruction will provide the parts and the procedures that are required for installation of the Waste Handling Arrangement on M318D-Update and M322D-Update Wheeled Excavators.

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

Required Kits for Waste Handling Arrangement

Table 1

Waste Handling Arrangements
Model	Serial Number Prefix	Part Number
M318D HCR	S/N:D9X	365-5449
M322D HCR	S/N:D3X	369-2444

Waste Handling Arrangement (Kits)

Table 2

365-5449 Waste Handling Special Ar M318D-Update HCR
Part Number	Description	Qty
308-2429	Radiator Enclosure	1
330-9136	Fan Motor Gp	1
330-9137	Radiator Gp	1
330-9140	Fan Guard	1
338-9384	Walkway Gp	1
330-9146	Cover Gp	1
339-0885	Hydraulic Fan Lines Gp	1
297-1603	Fan Wiring Gp (REVERSING, CAB)	1
314-2878	Fan Wiring Gp (REVERSING, CHASSIS)	1
314-2880	Fan Wiring Gp (REVERSING, RADIATOR)	1
314-2882	Cab Riser Wiring Gp (REVERSING FAN)	1
330-9177	Radiator Hose (OUTLET)	1
330-9178	Radiator Hose (INLET)	1
096-0061	Cable Strap	1
8T-4984	Hose Clamp	2
5P-4961	Hose Clamp	2
164-5562	Connector As	1
185-8196	Grommet	1
5P-1442	Hose	211.8 cm (83.4 inch)
8T-6703	Clamp	2

Table 3

369-2444 Reversible Fan Ar M322D-Update HCR
Part Number	Description	Qty
308-2429	Radiator Enclosure	1
297-1571	Fan Motor Gp	1
297-1576	Reversible Fan Gp	1
297-1579	Fan Guard	1
320-2940	Hydraulic Fan Lines Gp	1
297-1603	Fan Wiring Gp	1
314-2878	Fan Wiring Gp	1
314-2880	Fan Wiring Gp	1
314-2882	Cab Riser Wiring Gp	1
259-6812	Plate As	1

Kits

Table 4

308-2429 Radiator Enclosure
Part Number	Description	Qty
297-1566	Radiator Enclosure	1
253-7123	Precleaner Assembly	2

Table 5

297-1571 Fan Motor Gp
Part Number	Description	Qty
197-4858	Plate	1
297-1572	Gear Motor Gp	1
8T-4224	Hard Washer	4
7X-7729	Washer	4
8T-4136	Bolt	4
8T-4189	Bolt	4

Table 6

297-1576 Reversible Fan Gp
Part Number	Description	Qty
197-6548	Fan Spider As	1
297-1577	Adapter	1
8T-4224	Hard Washer	4
8T-4189	Bolt	4

Table 7

297-1579 Fan Guard
Part Number	Description	Qty
239-3798	Spacer	2
262-4729	Shroud	1
278-6964	Gas Spring	1
297-1580	Grill As	1
303-2185	Brush	2
303-2186	Brush	1
303-2187	Brush	2
308-2422	Bracket As	2
357-0119	Retainer	2
4P-7581	Clip-Ladder	1
5C-2874	Nut	11
5W-1120	Fastener	2
7X-7729	Washer	8
7Y-7388	Screw-Button	11
8T-0328	Washer-Hard	11
8T-4137	Bolt	8
8T-4179	Bolt	4
8T-4223	Washer-Hard	4

Table 8

320-2940 Hydraulic Fan Lines Gp
Part Number	Description	Qty
308-1191	Solenoid Valve Gp (REVERSIBLE FAN)	1
311-4530	Hose As	1
311-4531	Hose As	1
311-4534	Hose As	1
311-4535	Hose As	1
148-8315	Connector	1
148-8340	Connector As	3
4P-7581	Clip	1
8T-4121	Hard Washer	2
8T-5005	Bolt	2

Table 9

297-1603 Fan Wiring Gp (Cab)
Part Number	Description	Qty
269-0474	Switch Harness As	1
161-3128	Relay	1
3S-2093	Cable Strap	2

Table 10

314-2878 Fan Wiring Gp
Part Number	Description	Qty
314-2879	Solenoid Harness As	1
3S-2093	Cable Strap	9

Table 11

314-2880 Fan Wiring Gp (Radiator)
Part Number	Description	Qty
314-2881	Solenoid Harness As	1
276-8614	Sensor Harness As	1
3S-2093	Cable Strap	5

Table 12

314-2882 Cab Riser Wiring Gp
Part Number	Description	Qty
314-2883	Wiring Harness	1
3S-2093	Cable Strap	6

Table 13

330-9140 Fan Guard
Part Number	Description	Qty
330-9141	Grill As	1
8T-4121	Hard Washer	4
8T-4191	Bolt	4
117-0121	Seal-Bulk	84.5 cm (33 inch)

Table 14

330-9146 Cover Gp
Part Number	Description	Qty
330-9180	Plate	1
8T-4137	Bolt	3
8T-4121	Hard Washer	3
148-9561	Seal	84 cm (33 inch)

Table 15

338-9384 Walkway
Part Number	Description	Qty
330-9143	Walkway As	1
8T-6467	Fastener	4

Table 16

339-0885 Hydraulic Fan Lines Gp
Part Number	Description	Qty
8U-0215	O-Ring Seal	1
8U-0216	O-Ring Seal	1
8U-0234	Elbow	1
8U-0235	Elbow	1
113-0453	Hose As	1
191-2356	Hose As	1
205-3930	Connector As	1
227-6000	Oil Filter Gp	1
233-9613	Hose As	1
242-9890	Hose As	1
267-8828	Grommet	1
289-4232	Bolt	2
293-8293	Hose As	1
308-1191	Solenoid Valve Gp (REVERSIBLE FAN)	1
313-5874	Hose As	1
332-4523	Tube As	1
332-6850	Hose As	1
332-6851	Hose As	1
105-3487	Bolt	2
148-8335	Connector As	1
148-8336	Connector As	1
148-8340	Connector As	1
148-8352	Elbow As	1
148-8354	Elbow As	1
148-8358	Elbow As	1
148-8364	Elbow As	2
148-8370	Elbow As	1
148-8372	Elbow As	1
148-8375	Elbow As	1
148-8415	Reducer As	1
148-8444	Tee As	1
171-6728	Elbow As	1
1M-4543	Grommet	1
1P-4577	Half Flange	2
1P-4578	Half Flange	2
283-5684	Bolt	2
4J-0520	O-Ring Seal	2
4J-0522	O-Ring Seal	1
4P-7581	Clip	1
5K-9090	O-Ring Seal	1
6P-0699	Grommet	1
6V-8398	O-Ring Seal	1
6V-9169	Bulkhead Nut	1
7K-1181	Cable Strap	2
8T-4121	Hard Washer	8
8T-4195	Bolt	4
8T-4196	Bolt	8
8T-5005	Bolt	2
8T-8442	Bolt	2
9X-7345	Grommet	1
7J-9108	Seal-O-Ring	1

Table 17

330-9136 Fan Motor Gp
Part Number	Description	Qty
297-1572	Gear Motor Gp	1
336-1233	Bracket As	1
7X-7729	Washer	4
8T-4196	Bolt	4
8T-4224	Hard Washer	4
8T-7547	Bolt	4

Table 18

330-9137 Radiator Gp
Part Number	Description	Qty
125-0914	Bumper	4
280-7236	Washer	2
329-5922	Radiator As	1
330-9138	Support As	1
330-9165	Shroud	1
332-5639	Seal	2
332-5641	Seal	1
7X-2621	Bolt	2
8T-4121	Hard Washer	17
8T-4137	Bolt	4
8T-4191	Bolt	11
9D-3768	Grommet	2
117-0121	Seal	23 cm (9 inch)
201-8780	Seal	85 cm (34 inch)

Install The New Right Front Access Door and Precleaner Assemblies

Note: The following machines are applicable: M318D-Update HCR and M322D-Update HCR.

Note: Illustrations in the following steps show a basic waste handling arrangement. Contents of the kits for each machine will vary. The parts in the illustrations may differ in appearance to the parts in the kits. The kits will indicate the correct part number that should be used for cross-referencing the contents that are in the tables in ""Waste Handling Kit Arrangements" ".

Note: The parts that are pictured in the illustrations are not required on all of the machine arrangements. Reference the contents of the kits in the tables that are located in ""Waste Handling Arrangement (Kits)" ".

1. Open the right front access door.

2. Support the access door in the open position.

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Illustration 1	g01741286
(1) Gas springs

3. Remove two gas springs (1) .

4. Lower the access door into the closed position.

5. Open the top engine access door.

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Illustration 2	g01741290
(2) Bolts

6. Remove four bolts (2) .

7. Remove the front right access door.

8. Assemble the new right front access door by applying Steps 1 through 7 in the reverse order.

   Note: Refer to Table 4.

9. Assemble the precleaner assemblies to the new access door.

   Note: Refer to Table 4.

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Illustration 3	g01741291
(3) Clamps

10. Orient the precleaners so that the drain valves do not come into contact with the enclosure. Refer to Illustration 3.

11. Tighten clamps (3) to a torque of 5 N·m (44 lb in).

Disassemble the Standard Fan and the Fan Guard

Note: The following machine is applicable: M322D-Update HCR.

Note: The following procedure is not applicable for the M318D-Update HCR machine.

1. Place the machine in the service position. Release the pressure from the hydraulic system.

2. Install the vacuum pump.

3. Place a suitable container under the machine in order to collect the hydraulic oil for storage or disposal.

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Illustration 4	g01741292
(4) Plate (5) Fasteners

4. Remove two fasteners (5) .

5. Open the radiator access door and secure the door in the open position.

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Illustration 5	g01741294
(6) Gas spring (7) Hose As (8) Hose clamps (9) Hose As

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Illustration 6	g01730038
(7) Hose As

6. Disconnect hose assembly (7) at the main valve. Refer to Illustration 5 and 6.

7. Disconnect hose assembly (9). Refer to Illustration 5.

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Illustration 7	g01741295
(10) Hose As (11) Adapter (12) Adapter

8. Disconnect hose assembly (10). Refer to Illustration 7.

9. Remove hose clamps (8). Refer to Illustration 5.

10. Support the radiator access door in the open position.

11. Remove gas spring (6). Refer to Illustration 5.

12. Remove the four mounting bolts from the door hinge.

13. Lift the radiator access door together with the fan and the fan motor from the machine.

14. Remove plate (4). Refer to Illustration 4.

    Note: Removing plate (4) is only required on the M322D-Update HCR.

Final Assembly of the Waste Handling Fan and the Fan Guard

Note: The following machine is applicable: M322D-Update HCR.

Note: The following procedure is not applicable for the M318D-Update HCR machine.

1. Disassemble adapter (11) and (12) together with the seals and mounting bolts from the standard fan motor and the fan guard. Refer to Illustration 7.

2. Assemble adapter (11) and (12) together with the seals to new 297-1571 Fan Motor Gp . Refer to Table 5.

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Illustration 8	g01741304
Refer to Table 19. (19) Hose As (20) Hose As (21) Hose As (22) Hose As

3. Connect the following hydraulic hoses to the new fan motor: (19), (20), (21) and (22). Refer to Tables: 17, 18, 19 and 20.
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   Table 19

   Hose Assembly
   	19	20	21	22
   M322D-Update HCR	311-4534	311-4535	311-4530	311-4531

Illustration 9	g01741302
Preassembled fan package

Reversible Fan Group

Note: The following machine is applicable: M322D-Update HCR.

Note: The following procedure is not applicable for the M318D-Update HCR machine.

Note: Refer to Table 3.

1. Components of the reversible fan group are preassembled. Refer to Table 6.

Install the New Waste Handling Fan and the Fan Guard

Note: The following machine is applicable: M322D-Update HCR.

Note: The following procedure is not applicable for the M318D HCR machine.

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Illustration 10	g01737713

1. Lift the preassembled group to the assembly position on the machine.

2. Assemble 259-6812 Plate As from the following Table 3.

   Note: 259-6812 Plate As is only required on the following machine M322D-UpdateHCR.

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Illustration 11	g01741305
(23) Clip

3. Install clip (23) .

4. Install the four mounting bolts to holes (A). Refer to Illustration 10.

5. Assemble the gas spring to weld nut (E). Refer to Illustration 10.

6. Connect hose assembly (10). Refer to Illustration 7.

7. Connect return hose assembly (20) to the main valve. Refer to Illustration 8.

8. Connect pressure hose assembly (19). Refer to Illustration 8.

9. Assemble hose clamps (8). Refer to Illustration 5.

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Illustration 12	g02481639
(24) Reverse fan group

10. Assemble reverse fan group (24) to the fan motor. Tighten the retaining bolt to a torque of 70 N·m (52 lb ft).

11. Close the fan guard and install two fasteners (5). Refer to Illustration 4.

Removal and Installation of the Cooling Package

Note: The following machine is applicable M318D-Update HCR.

Note: The following procedure is only applicable for the M318D-Update HCR machine.

1. Clear all personnel from the machine and from the area around the machine.

2. Start the engine.

3. Lower the left console.

4. Position the machine on level ground. Check the visibility and adjust the mirrors for the best vision close to the machine.

5. Lower the stabilizers and the blade tip.

6. Fully extend the bucket cylinder and place the bucket on the ground.

7. Stop the engine.

8. Release the pressure in the hydraulic system.

9. Raise the left console.

10. Attach 311-1362 Vacuum Cap onto the hydraulic tank. Attach an air supply hose onto the assembly. Apply 276 to 414 kPa (40 to 60 psi). This procedure will pull a vacuum on the hydraulic system.

Remove the Standard Cooling Package

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Illustration 13	g01730614
(25) Fasteners

1. Remove two fasteners (25) .

2. Open the radiator access door and secure the door in the open position.

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Illustration 14	g01730673
(26) Step and brackets (27) Hose As (28) Clamps (29) Hose As (30) Hose As (31) Hose As

3. Remove clamps (28) from fuel line.

4. Disconnect hose assembly (29) at the hydraulic tank.

5. Disconnect hose assembly (30) at the main valve.

6. Disconnect hose assembly (31) at the fan pump.

7. Disconnect hose assembly (27) at the main valve.

8. Remove the step with brackets (26) .

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Illustration 15	g01730994
(32) Vent hose (33) Coolant hoses

9. Disconnect coolant hoses at coolant tubes (33) .

10. Remove vent hose (32) from the radiator package.

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Illustration 16	g01730995
(34) Fan wiring Gp

11. Remove fan wiring group (34) from the machine harness.

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Illustration 17	g01731013
(35) Bolts

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Illustration 18	g01731014
(35) Bolts

12. Remove eight bolts (35) that attach the cooling package. Refer to Illustration 17 and 18.

13. Lift the radiator package out of the machine.

Prepare the New Package for Assembly

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Illustration 19	g01731073
(36) Hose as (37) Grommet (38) Cover (39) Sealants

1. Assemble grommet 1M-4543 Grommet (37) .

2. Assemble 293-8293 Hose As (36) and connect to port "P" of 308-1191 Solenoid Valve Gp (REVERSIBLE FAN) .

3. Assemble cover (38) and sealants (39) .

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Illustration 20	g01731074
(36) Hose As (40) Filter assembly

4. Assemble filter assembly (40) on the bracket .

5. Connect 293-8293 Hose As (36) to the filter.

Final Assembly of the Waste Handling Fan and the Fan Guard

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Illustration 21	g01731075
(41) Bolts

1. Install the package with nine bolts (41) .

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Illustration 22	g01731076
(42) Step with brackets

2. Install the step with brackets (42) .

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Illustration 23	g01731077
(43) Grommet (44) Vent line (45) Coolant lines

3. Install the following parts: 330-9177 Radiator Hose (Outlet) and 330-9178 Radiator Hose (Inlet) (45), 185-8196 Grommet (43) and 5P-1442 Hose (44) .

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Illustration 24	g01731078
(46) Hose As (47) Hose As (48) Hose As (49) Hose As (50) 45 degree coupling

4. Connect 233-9613 Hose As (46) and replace straight coupling with 148-8358 Elbow As (45 degree) (50) on the main valve .

5. Connect 332-6850 Hose As (48) .

6. Connect 242-9890 Hose As (49) .

7. Connect 313-5874 Hose As (47).
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   Table 20

   Item	Hose As	Connecting From this Component	Connecting to this Component
   (36)	293-8293	Oil Filter (Port "IN")	Solenoid Valve Gp (Port "P")
   (46)	233-9613	Solenoid Valve Gp (Port "T")	Main valve (Port "S53")
   (47)	313-5874	Radiator (Port "OUT")	Hydraulic Tank (Port Filter)
   (48)	332-6850	Radiator (Port "IN")	Main valve (Port "K")
   (49)	242-9890	Fan Pump (Port Pressure)	Oil Filter (Port "IN")

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Illustration 25	g01731079
(51) Hose clamps

8. Connect clamps (51) for fuel lines .

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Illustration 26	g01731080
(52) Outlet grill (53) Walkway

9. Assemble outlet grill (52) and walkway (53) .

10. Fill the tank with coolant.

Electrical installation

Note: The following machines are applicable: M318D-Update HCR and M322D-Update HCR.

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Illustration 27	g01736794
Harness Assemblies (54) 269-0474 Switch Harness As (55) Connector (56) Connector (57) Ring terminal (58) Connector (59) 276-8614 Sensor Harness As (60) Connector (61) Connector (62) Connector (63) 314-2883 Wiring Harness (64) Connector (65) Connector (66) 314-2881 Solenoid Harness As (67) Connector (68) Connector (69) Connector (70) Connector (71) 314-2879 Solenoid Harness As (72) Connector (73) Connector

Note: Refer to Illustration 27 for the identification of the harness connectors.

1. Install 297-1603 Fan Wiring Gp .

   1. Disassemble the lunch box inside the cab.
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   Illustration 28	g01736796
   Routing of 269-0474 Switch Harness As (55) Connector (56) Connector (57) Ring terminal (58) Connector

   2. Route 269-0474 Switch Harness As (54) according to Illustration 28. Strap 269-0474 Switch Harness As (54) to the existing main harness. Refer to Table 9.

   3. Connect ring terminal (57) to the ground point that is behind the fuse panel.

   4. Connect connector (58) to the 2-pin connector at the fuse and relay harness below the fuse panel.

   5. Mount connector (56) next to the wiper relay (dovetail guide). Refer to Illustration 17.

   6. Insert 161-3128 Relay to connector (56). Refer to Table 9.

2. Machines with a cab riser hydraulic system must install the 314-2882 Cab Riser Wiring Gp . Reference Table 12.
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   Illustration 29	g01736797
   Routing of 314-2883 Wiring Harness (64) Connector (65) Connector

   1. Route 314-2883 Wiring Harness (63) in Table 12 through the chain of the linkage. Refer to illustration 29.

   2. Connect connector (64) of 314-2883 Wiring Harness to connector (55) of 269-0474 Switch Harness As (54) .

3. Install 314-2878 Fan Wiring Gp . Refer to Table 10.
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   Illustration 30	g01736814
   Routing of 314-2879 Solenoid Harness As (72) Connector (73) Connector

   1. Route 314-2879 Solenoid Harness As (71) in Table 10 through the machine. Refer to illustration 30.

   2. Connect connector (72) of 314-2879 Solenoid Harness As (71) to connector (65) of 314-2883 Wiring Harness (63) .

   3. Connect connector (72) of 314-2879 Solenoid Harness As (71) to connector (55) of 269-0474 Switch Harness As (54) .

4. Install 314-2880 Fan Wiring Gp .
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   Illustration 31	g01736894
   Routing of 314-2881 Solenoid Harness As and 276-8614 Sensor Harness As The following machine is applicable: M322D-Update HCR. (59) 276-8614 Sensor Harness As (60) Connector (62) Connector (66) 314-2881 Solenoid Harness As (67) Connector (68) Connector (69) Connector (70) Connector (74) Fan speed sensor

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   Illustration 32	g01736895
   The following machine is applicable: M322D-Update HCR. (59) 276-8614 Sensor Harness As (60) Connector (62) Connector (66) 314-2881 Solenoid Harness As (67) Connector (68) Connector (69) Connector (70) Connector (71) 314-2879 Solenoid Harness As (72) Connector (73) Connector (74) Fan speed sensor (75) Solenoid Assembly (76) Solenoid Assembly (77) Connect to machine harness (78) Connect to machine harness

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   Illustration 33	g01736897
   Routing of 314-2881 Solenoid Harness As and 276-8614 Sensor Harness As Applicable for the M318D-Update HCR (59) 276-8614 Sensor Harness As (60) Connector (62) Connector (66) 314-2881 Solenoid Harness As (67) Connector (68) Connector (69) Connector (70) Connector (74) Fan speed sensor

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   Illustration 34	g01736898
   Applicable for the M318D-Update HCR (59) 276-8614 Sensor Harness As (60) Connector (62) Connector (66) 314-2881 Solenoid Harness As (67) Connector (68) Connector (69) Connector (70) Connector (71) 314-2879 Solenoid Harness As (73) Connector (74) Fan speed sensor (75) Solenoid Assembly (76) Solenoid Assembly (77) Connect to machine harness (78) Connect to machine harness

   1. Route 314-2881 Solenoid Harness As (66) through the fan compartment. Refer to Illustration 31 for the following machine: M322D HCR. Refer to Illustration 33 for the M318D HCR.

   2. Connect connector (68) of 314-2881 Solenoid Harness As (66) to connector (73) of 314-2879 Solenoid Harness As (71) .

   3. Connect connector (69) of 314-2881 Solenoid Harness As (66) to solenoid (76) of 308-1191 Solenoid Valve Gp .

   4. Connect connector (70) of 314-2881 Solenoid Harness As (66) to solenoid (75) of 308-1191 Solenoid Valve Gp .

   5. Connect connector (67) of 314-2881 Solenoid Harness As (66) to connector (78) of the machine harness.

      `

   6. Connect connector (62) of 276-8614 Sensor Harness As (59) to connector of fan speed sensor (74).

   7. Connect connector (60) of 276-8614 Sensor Harness As (59) to connector (77) of the machine harness.

Software Compliance

Make sure that the appropriate software has been installed on the machine. Table 21 shows the part numbers of the various control software that must be installed. This software will at least ensure that proper functionality of the waste handling package. If an earlier version of the software has been installed on the machine, then an update to at least the status mentioned in Table 21.

Table 21

Controller	Affected Models	Software
		Part Number	Description
Machine	M318D-Update HCR, and M322D-Update HCR	376-6647	Machine Software Gp
Implement	M318D-Update HCR, and M322D-Update HCR	370-5236	Machine Software Gp
Monitor	M318D-Update HCR, and M322D-Update HCR	364-2802	Monitor Software Gp

Enabling of functionality of the Reversing Fan

Note: The following machines are applicable: M318D-Update HCR and M322D-Update HCR.

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Illustration 35	g01737233
(82) Service tool connector

1. Connect a laptop computer to service connector (82).

2. Start Electronic Technician.

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Illustration 36	g01737234

3. Select Engine ECM (83) .

4. Select "OK" (84).

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Illustration 37	g01737235

5. Select "Service" (85) from the main menu.

6. Select "Configuration" (86).

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Illustration 38	g01737236

7. Select "Fan Control" (87).

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Illustration 39	g01737237

8. Double click on "Engine Fan Reversing Feature" (88) .

9. Select "Enabled" (89) in the drop-down menu.

10. Select "OK" (90).

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Illustration 40	g01737238

11. Select "YES" (91).

12. Leave ET.