Procedure to Install the 487-0165 Reversible Fan Kit on Certain Wheeled Hydraulic Excavators {1356, 1386, 1387, 138R} Caterpillar

Material Handler

MH3022 (S/N: FM21-UP)

MH3024 (S/N: FM41-UP)

Wheeled Excavator

M318F (S/N: F8B1-UP)

M320F (S/N: F2W1-UP)

M322F (S/N: F2Z1-UP)

Reference: Disassembly and Assembly, UENR6141, "Radiator, Aftercooler, and Hydraulic Oil Cooler - Remove and Install"

Introduction

This Special Instruction contains the procedure to install the 487-0165 Reversible Fan Kit on certain Wheeled Hydraulic Excavators.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety

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Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

Note: Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Required Parts

Machine Preparation

1. Place machine on level ground in the service position.

2. Stop the engine.

3. Release the pressure in the hydraulic system.

4. Drain engine coolant.

Removal Procedure

Removal of Radiator Enclosure

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Illustration 1	g06074095
Radiator enclosure location (A) Radiator enclosure (B) Engine compartment door

1. Open engine compartment door (B) on the right side of machine. Refer to Illustration 1.
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   Illustration 2	g06074100
   Hood unlocking cable location (A) Radiator enclosure (C) Hood unlocking cable

2. Pull hood unlocking cable (C) to open hood on radiator enclosure (A). Refer to Illustration 2.
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   Illustration 3	g06074112
   Gas spring locations (D) gas spring

3. Unfasten the two gas springs (D) from the mounting brackets. Refer to Illustration 3.

   Note: Save gas spring and hardware for install procedure.

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   Illustration 4	g06074137
   Front enclosure bolt location (E) Bolt (F) Washer

4. Remove bolt (E) and washer (F) from the front location of radiator enclosure (A). Refer to Illustration 4.

   Note: Save hardware for install procedure.

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   Illustration 5	g06074151
   Rear enclosure bolt locations (G) Bolts (H) Washers

5. Remove bolts (G) and washers (H) from the rear location of radiator enclosure (A). Refer to Illustration 5.

   Note: Save hardware for install procedure.

6. Remove radiator enclosure (A) from the chassis.

Removal of Fan Motor Group and Cooling Package

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Illustration 6	g06074236
Fan motor and hydraulic hose locations (J) Hose assembly (K) Hose assembly (L) Hose assembly (M) Motor group, 8T-7547 Bolt, 8T-4224 Hard Washer, 3S-2093 Cable Strap (N) 7J-9108 O-Ring Seal, 8U-0234 Elbow, 8U-0215 O-Ring Seal, 105-3487 Bolt, 283-5684 Bolt (P) 148-8367 Elbow As, 205-3930 Connector As (Q) 7J-9108 O-Ring Seal, 8U-0234 Elbow, 8U-0215 O-Ring Seal, 105-3487 Bolt, 283-5684 Bolt

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Illustration 7	g06074254
Cable strap and clamp locations (M) Motor group (T) Adapter (R) Cable straps (S) 437-9753 Clamps, 102-8705 Plate, 7X-0818 Bolt

1. Remove hose assemblies (J), (K), and (L) from motor group (M). Refer to Illustration 6.

   Note: Save hardware (N), (P), (Q), and o-ring seals for install procedure. Save hose assembly (L) for install procedure.

2. Remove cable straps (R) and clamps (S) from hose assemblies. Refer to Illustration 7.

   Note: Save clamps and hardware for install procedure.

3. Remove fan motor group (M) from adapter (T).

   Note: Save hardware for install procedure.

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   Illustration 8	g06074496
   Fan adapter location (T) Adapter (U) 8T-4200 Bolt (V) 8T-4224 Hard Washer

4. Remove the six bolts (U) and hard washer (V) that secure adapter (T), and remove adapter.

   Note: Save bolts (U) for install procedure.

   Note: Step 5 through Step 6 only applies to M318F, M320F, and M322F.

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   Illustration 9	g06074509
   Air channel location (W) Channel assembly (X) 117-0121 Seal, 8T-4200 Hard Washer, and 5P-4116 Hard Washer (Y) 5P-0599 Band Clamp

5. Remove channel assembly hardware (X).

6. Loosen band clamp (Y) and remove channel assembly (W)

   Note: Save hardware (X) and band clamp (Y) for install procedure.

7. Remove the cooling package. Refer to Disassembly and Assembly, UENR6141

   Note: Cooling package includes the radiator, aftercooler, and hydraulic oil cooler.

Install Procedure

Install Fan Motor Group

Note: Refer to Table 4 for the machines that require support assembly modification.

Note: Step 1 through Step 2 only applies to M318F, M320F, and M322F. For MH3022 and MH3024 replacement of channel assembly and pre-cleaner assembly is not required.

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Illustration 10	g06074544

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Illustration 11	g06076042
Air channel location (2) 070-0195 Precleaner As (5) 457-9506 Channel As (X) 117-0121 Seal, 8T-4200 Hard Washer, and 5P-4116 Hard Washer (Y) 5P-0599 Band Clamp (Z) 174-5414 Clamp

1. Install channel assembly (5) to the top of the machine. Reuse hardware (X) and band clamp (Y) to secure air channel assembly in position.

2. Install precleaner assembly (2) to the top of the air channel assembly (5). Use clamp (Z) to secure precleaner assembly in position.
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   Illustration 12	g06074560
   Fan adapter location (4) 454-2051 Adapter (U) 8T-4200 Bolt

3. Position adapter (4) on the fan as shown in Illustration 12. Reuse the six bolts (U) to secure adapter to fan. Tighten bolt to a torque of 28 ± 7 N·m (20.7 ± 5.2 lb ft)
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   Illustration 13	g06075431
   Fan adapter location (4) 454-2051 Adapter (AA) Shaft nut

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   Illustration 14	g06074600
   Fan motor and hydraulic hose locations (9) 486-7354 Motor Gear Gp, 8T-7547 Bolt, 8T-4224 Hard Washer, 3S-2093 Cable Strap (13) 466-1106 Hose As (14) 466-1107 Hose As (15) 466-1108 Hose As (16) 466-1109 Hose As (19) 148-8315 Connector As (N) 7J-9108 O-Ring Seal, 8U-0234 Elbow, 8U-0215 O-Ring Seal, 105-3487 Bolt, 283-5684 Bolt (P) 148-8367 Elbow As, 205-3930 Connector As (Q) 7J-9108 O-Ring Seal, 8U-0234 Elbow, 8U-0215 O-Ring Seal, 105-3487 Bolt, 283-5684 Bolt

4. Install motor group (9) reusing the hardware from the motor group (M). Tighten 8T-7547 Bolts to a torque of 28 ± 7 N·m (20.7 ± 5.2 lb ft). Tighten shaft nut (AA) to adapter (4) using a torque of 80 + 20 N·m (59 + 14.8 lb ft). Refer to Illustration 13.

5. Install the radiator, aftercooler, and hydraulic oil cooler. Refer to Disassembly and Assembly, UENR6141.

6. Install hose assemblies (L), (13), (14), (15), and (16) to motor group (9) reusing hardware (N), (P), and (Q) from the removal Step 1. Tighten bolts of hardware (N) and (Q) to a torque of 9 ± 1 N·m (6.6 ± 0.75 lb ft). Tighten connector assembly of hardware (P) to a torque of 33 ± 2 N·m (24.3 ± 1.5 lb ft). Refer to Illustration 14.

   Note: Ensure to reinstall o-ring seals before installing hose assemblies.

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   Illustration 15	g06075898
   Solenoid valve group without support assembly modification (12) 437-5021 Sleeves (17) 474-1720 Solenoid Valve Gp (22) 8T-4121 Hard Washers (24) 8T-6685 Bolts

7. Install solenoid valve group (17) using sleeves (12), hard washers (22), and bolts (24). Apply Locktite 243 on threads before installation. Tighten bolts to a torque of 55 ± 10 N·m (40.6 ± 7.4 lb ft). Refer to Illustration 15.

   Note: If the mounting plate does not have the bolt holes to install solenoid valve group (17), refer to Section "Support Assembly Modification". Refer to Table 4 for the machines that require bolt holes to be added.

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   Illustration 16	g06084336
   Solenoid valve group with support assembly modification - front view (12) 437-5021 Sleeves (17) 474-1720 Solenoid Valve Gp (22) 8T-4121 Hard Washers (27) 7X-2543 Bolts

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   Illustration 17	g06084322
   Solenoid valve group with support assembly modification - rear view (28) 8T-4121 Hard Washers (29) 344-5675 Nut

8. For the machines that required support assembly modification, install solenoid valve group (17) using sleeves (12), hard washers (22), bolts (27), hard washers (28), and nuts (29). Apply Locktite 243 on threads before installation. Tighten bolts to a torque of 55 ± 10 N·m (40.6 ± 7.4 lb ft). Refer to Illustrations 16 and 17. Refer to Table 3 for the required parts.
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   Illustration 18	g06076163
   Routing of 466-1108 Hose As (9) 486-7354 Motor Gear Gp (15) 466-1108 Hose As (17) 474-1720 Solenoid Valve Gp (21) 150-4048 Elbow As (S) 437-9753 Clamps, 102-8705 Plate, 7X-0818 Bolt (N) 8U-0234 Elbow, 8U-0215 O-Ring Seal, 105-3487 Bolt, 283-5684 Bolt

9. Route hose assembly (15) between motor group (9) and solenoid valve group (17) as shown in Illustration 18. Reuse hardware (S) from removal procedure to secure hose assembly, tighten to a torque of 28 ± 7 N·m (20.7 ± 5.2 lb ft).
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   Illustration 19	g06074886
   Routing of 466-1109 Hose As View A-A is the right side view of solenoid valve group (9) 486-7354 Motor Gear Gp (16) 466-1109 Hose As (17) 474-1720 Solenoid Valve Gp (18) 140-7598 Clamp (21) 150-4048 Elbow As (Q) 8U-0234 Elbow, 8U-0215 O-Ring Seal, 105-3487 Bolt, 283-5684 Bolt (BB) 20 degrees

10. Route hose assembly (16) between motor group (9) and solenoid valve group (17) as shown in Illustration 19. Use clamp (18) to secure hose assembly, tighten clamp to a torque of 28 ± 7 N·m (20.7 ± 5.2 lb ft).
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    Illustration 20	g06074922
    Routing of 466-1107 Hose As View B-B is the top side view of solenoid valve group (14) 466-1107 Hose As (17) 474-1720 Solenoid Valve Gp (19) 148-8315 Connector As (20) 148-8393 Elbow As (CC) Tube assembly (DD) 17 degrees

11. Route hose assembly (14) between tube assembly (CC) and solenoid valve group (17) as shown in Illustration 20.
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    Illustration 21	g06074935
    Routing of 466-1106 Hose As View C-C is the top side view of solenoid valve group (13) 466-1106 Hose As (17) 474-1720 Solenoid Valve Gp (21) 150-4048 Elbow As (S) 437-9753 Clamps, 102-8705 Plate, 7X-0818 Bolt (EE) Pump (FF) 20 degrees

12. Route hose assembly (13) between solenoid valve group (17) and pump (EE) as shown in Illustration 21. Reuse hardware (S) from removal procedure to secure hose assembly (13), tighten to a torque of 28 ± 7 N·m (20.7 ± 5.2 lb ft).
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    Illustration 22	g06075236
    Cable strap locations (9) 486-7354 Motor Gear Gp (17) 474-1720 Solenoid Valve Gp (26) 7K-1181 Cable Straps

13. Secure hose assemblies using cable straps (26). Refer to Illustration 22.

    Note: Ensure to strap the hoses to avoid any interference with the fan or other components.

Support Assembly Modification

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Illustration 23	g06084279
Support assembly before modification (GG) Modification area (HH) Support assembly

1. Locate modification area (GG) on support assembly (HH) as shown in Illustration 23.
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   Illustration 24	g06084308
   Hole dimensions (HH) Support assembly (JJ) 63 mm (2.48 inch) (KK) 11 mm (0.43 inch) hole diameter (LL) 16 mm (0.63 inch) (MM) 53 mm (2.09 inch)

2. Modify support assembly (HH) by drilling two 11 mm (0.43 inch) diameter holes (KK) through the support assembly. Refer to Illustration 24 for the hole dimensions.

Electrical Harness and Radiator Enclosure

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Illustration 25	g06075590
Routing of 476-0307 Solenoid Harness As (17) 474-1720 Solenoid Valve Gp (30) 3S-2093 Cable Straps (32) 476-0307 Solenoid Harness As (34) 277-1873 Clip (35) 344-5675 Nut (38) 8T-4121 Hard Washers (39) 8T-4136 Bolt (NN) Connector (PP) Connector (QQ) chassis wiring harness

1. Install clip (34) as shown in Illustration 25.

2. Route solenoid harness assembly (32) from solenoid valve group (17) to connector (PP) location as shown in Illustration 25. Use cable straps (30) to secure solenoid harness assembly (32). Connect harness assembly (32) to chassis wiring harness (QQ) using connector (PP). Connect harness assembly (32) to solenoid valve group (17) using connector (NN).
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   Illustration 26	g06075311
   Radiator enclosure location (6) Radiator enclosure

3. Position radiator enclosure (6) on chassis as shown in Illustration 26.
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   Illustration 27	g06074137
   Front enclosure bolt location (E) Bolt (F) Washer

4. Install bolt (E) and washer (F) to the front location of radiator enclosure (6).
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   Illustration 28	g06074151
   Rear enclosure bolt locations (G) Bolts (H) Washers

5. Install bolts (G) and washers (H) to the rear location of radiator enclosure (6).
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   Illustration 29	g06075340
   Gas spring locations (7) 472-6333 Gas Spring (D) gas spring

6. Install gas spring (7) between the hood enclosure and the bracket on the cooling system. Install gas springs (D) between the hood enclosure and the mounting bracket on the engine group. Refer to Illustration 29.
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   Illustration 30	g06075295
   Routing of 453-0860 Motor Assembly Harness (30) 3S-2093 Cable Straps (32) 476-0307 Solenoid Harness As (RR) 453-0860 Motor Assembly Harness (SS) Connector

7. Route motor assembly harness (RR) as shown in Illustration 30 and connect to solenoid harness (32) using connector (SS). Use cable straps (30) to secure motor assembly harness.

Radiator Enclosure Alignment

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Illustration 31	g06083706
Hood alignment (6) Radiator enclosure (TT) 10 + 5 - 3mm (0.4 + 0.2 - 0.12 inch) (UU) 10 ± 3 mm (0.4 ± 0.12 inch)

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Illustration 32	g06083709
Hood alignment (6) Radiator enclosure (VV) 12 ± 2 mm (0.5 ± 0.08 inch)

1. Correctly align radiator enclosure (6) with the gap dimensions shown in Illustrations 31 and 32.
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   Illustration 33	g06083710
   Sealing plates (XX) Sealing plates

2. Properly align sealing plates (XX) with radiator enclosure (6). Refer to Illustration 33.

Machine Configurations

Ensure that the correct machine configurations are set for the reversible fan. To set machine configurations, use Cat^® Electronic Technician (Cat ET) or the monitor.

Illustration 34	g06083712
Cat ET machine control settings

Using Cat ET, select machine control and set "Machine Application Configuration" to material handling and "Engine Fan Reversing Feature Installation Status" to installed. Refer to Illustration 34.

Illustration 35	g06083713
Cat ET fan control setting

Using Cat ET, set fan control "Engine Fan Reverse Operation Mode" to automatic and "Engine Fan Purge Cycle Interval" to 1200 seconds. Refer to Illustration 35.

Illustration 36	g06084018
Monitor fan control settings

Using the monitor, select the Reversible Fan menu from main menu and set "Mode" to automatic and "Interval" to 20 minutes. Refer to Illustration 36 .