A Hydraulic Oil Cooler Core Is Needed To Prevent Hydraulic Oil Overheating On Certain 938F Wheel Loaders And IT38F Integrated Tool Carriers Caterpillar

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 Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS8394" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

NOTE: COSA mail code O-116 is not in order since it was added at Revision SEBE5480-02 in November 1995.

NOTE: This Revised Service Letter replaces the August 2, 1995 Service Letter (Revised October 1995). Changes have been made to the Mail Codes.

Termination Date

Problem

A hydraulic oil cooler core needs to be added to prevent hydraulic oil overheating on certain 938F Wheel Loaders and IT38F Integrated Tool Carriers used in moderately intensive applications. Those machines which experience extended periods of intense hydraulic usage should have the 1037397 Hydraulic Oil Cooler installed.

NOTE: If the 1037397 Hydraulic Oil Cooler (attachment) has been installed on the machine, do not administer this program.

Affected Product
Model & Identification Number

Group 1

938F (1KM1-1018 2RM1-562 8SM149-155 , 8SM163, 8SM164, 8SM169-174, 8SM180, 8SM186, 8SM187, 8SM189, 8SM191, 8SM194, 8SM196, 8SM199, 8SM203, 8SM204, 8SM208)

IT38F (6FN1-267)

Group 2

938F (2RM563-742 )

Parts Needed

Group 1

4 - 6D1641 Clip

1 - 4E9271 Hose Assembly

1 - 3J1907 Seal - O-Ring

1 - 3K0360 Seal - O-Ring

4 - 2M9780 Seal - O-Ring

1 - 7M8485 Seal

1 - 9M4136 Spacer

1 - 4Q5614 Core As.

1 - 8T0249 Elbow - Swivel

13 - 8T4121 Washer - Plate

4 - 8T4133 Nut

1 - 8T4137 Bolt

1 - 8T4186 Bolt

8 - 8T4195 Bolt

1 - 6V7420 Adapter - Straight

1 - 6V8397 Seal - O-Ring

7 - 6V8398 Seal - O-Ring

1 - 6V8624 Elbow - Face

2 - 6V8721 Elbow - Face

1 - 6V9873 Connector

2 - 1272180 Plate

1 - 1272228 Valve Group - Check

1 - 1272913 Hose Assembly

1 - 1272914 Hose Assembly

1 - 1274874 Manifold Assembly

Group 2

2 - 6D4246 Clip

1 - 4E9271 Hose Assembly

4 - 7J9108 Seal - O-Ring

1 - 3K0360 Seal - O-Ring

4 - 2M9780 Seal - O-Ring

1 - 4Q5614 Core Assembly - Oil

1 - 8R0831 Hose Assembly

1 - 8T0249 Elbow - Swivel

14 - 8T4121 Washer - Plate

4 - 8T4133 Nut

2 - 8T4137 Bolt

8 - 8T4195 Bolt

1 - 6V7420 Adapter

3 - 6V8398 Seal - O-Ring

2 - 6V8642 Connector

1 - 6V8721 Elbow

2 - 1272180 Plate

1 - 1272228 Valve Group - Check

Action Required

See attached Rework Procedure

Service Claim Allowances

NOTE: This is a 3-hour job.

Parts Disposition

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

Attach.

(1-Rework Procedures)

(2-Illustrations)

Rework Procedure

Rework Procedures for Group 1

1. Relieve the line and tank hydraulic pressure and drain the hydraulic tank.

2. While the tank is draining, mount the 4Q5614 Core Assembly with the (2) 1272180 Plates using (8) 8T4195 Bolts, (4)8T4133 Nuts and (12) 8T4121 Washers at the rear of the machine.

3. Install the various fittings, hoses, and seals at each corner of the 4Q5614 Core Assembly per Illustration 2.

4. Remove the 1116951 Manifold Assembly. Install 1274874 Manifold Assembly in the same location with a 7M8485 seal. Install 1272914 Hose Assembly to the lower right corner of the core assembly as shown in Illustration 2. Install the pump drain line and brake valve return line to the new manifold assembly using 6V8398 and 6V8397 Seals.

5. Remove 6V8636 Connector and 4E3443 Hose Assembly from the 8R3584 Valve Group - Accumulator. Install the 6V9873 Connector and the 1272913 Hose Assembly using the 3J1907 and 6V8398 Seals to the accumulator valve group. Route the 1272913 Hose Assembly to the lower left corner of the core assembly as shown in Illustrations 1 and 2.

6. Clip each new hose assembly along the left hand side of the machine per Illustrations 1 and 2.

Rework Procedures for Group 2

1. Relieve the line and tank hydraulic pressure and drain the hydraulic tank.

2. While the tank is draining, mount the 4Q5614 Core Assembly with the (2) 1272180 Plates using (8) 8T4195 Bolts, (4) 8T4133 Nuts and (12) 8T4121 Washers at the rear of the machine.

3. Install the various fittings, hoses, and seals only at the top corners of the 4Q5614 Core Assembly per Illustration 2. Install (2) 6V8642 Connectors using 2M9780 and 7J9108 Seals at the bottom corners of the 4Q5614 Core Assembly.

4. Disconnect the end of the looped 8R0832 Hose Assembly from the lower of the two 1066512 Tube Assemblies, just below the new 4Q5614 Core Assembly.

5. Connect the loose end of the 8R0832 Hose Assembly to the bottom right hand corner of the 4Q5614 Core Assembly.

6. Install the 8R0831 Hose Assembly from the bottom left hand corner of the 4Q5614 Core Assembly to the lower of the two 1066512 Tube Assemblies.

7. Secure each hose assembly with a 6D4262 Clip, 8T4137 Bolt and 8T4121 Washer.

Illustration 1

Illustration 2