Product Support Program For Relocating The Air Conditioner Accumulator On Certain 938G Wheel Loaders And IT38G Toolcarriers Caterpillar

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 "PS4798" 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.

Termination Date

Problem

The air conditioning accumulator needs to be relocated on certain 938G Wheel Loaders and IT38G Toolcarriers. The air conditioning accumulator may interfere with the service letter program for installing the new belt drive system on certain 938G Wheel Loaders and IT38G Toolcarriers. Machines included in Service Letter PS4774 will require the relocation of the Air Conditioning Accumulator off the engine near the hydraulic tank. PS4774 should be performed immediately after completion of this letter.

Affected Product
Model & Identification Number

Group 1

938G (4YS1-469, 6WS1-393, 8RS1-190 )

IT38G (7BS1-373, 1CW1-324 )

Group 2

938G (4YS470-626, 6WS394-1340, 8RS191-295, 9HS1-451 )

IT38G (7BS374-505, 1CW325-342 )

Parts Needed

Group 1

2 - 8T4123 Washer - Plate

1 - 8T4133 Nut

3 - 8T4139 Bolt

3 - 8T4223 Washer - Plate

1 - 8T4244 Nut

1 - 6V4356 Clip

1 - 6V4357 Bracket

1 - 4W1683 Plate - Lifting

1 - 7X0589 Washer - Hard

2 - 9X7382 Seal - O-ring

2 - 9X7383 Seal - O-ring

1 - 1594589 Hose Assembly

1 - 1608742 Bolt - Hex Head

1 - 1730272 Hose Assembly

1 - 1736675 Bracket Assembly

Group 2

3 - 8T4139 Bolt

3 - 8T4223 Washer - Plate

1 - 6V4356 Clip

1 - 6V4357 Bracket

1 - 4W1683 Plate - Lifting

2 - 9X7382 Seal - O-ring

2 - 9X7383 Seal - O-ring

1 - 1594589 Hose Assembly

1 - 1720154 Plate Assembly

1 - 1730272 Hose Assembly

Action Required

See the attached rework procedure.

Service Claim Allowances

NOTE: This is a 2-hour job.

Parts Disposition

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

Attach.

(1 - Rework Procedure)

Rework Procedure

For Both Groups 1 and 2

1. The refrigerant must be recovered before removing the accumulator. Refer to the Service Manual, SENR5664, "Refrigerant Recovery" section in testing and adjusting.

2. Refer to the Service Manual, SENR5664, "Machine Preparation for troubleshooting" section in testing and adjusting before service work is performed.

3. Recover refrigerant from the Air Conditioning system and store for reuse.

4. Remove and retain 1522823 Air Conditioning Accumulator for reuse.

5. Remove and discard the 1298190 Plate Assembly including 1188064.

6. Remove and discard 1304667 and 1178311 Hoses that connect the accumulator to the compressor and the evaporator located in the cab with connections under the cab left of the centerline of the machine facing forward.

Group 1

7. For Group 1 machines - perform steps 8 through 13. For Group 2 machines proceed to step 15 and continue.

8. Install 1736675 Bracket per Illustration 1.

9. Install 1522823 Accumulator with 6V4357 and 6V4356 Clips using (1) 8T4223 Washer and (1) 8T4139 Bolt. Reference Illustrations 1 and 3.

10. Install (1) 9X7382 O-ring and (1) 9X7383 O-ring in each end to the 1594589 and 1730272 Hose Assemblies.

11. Install 1594589 Hose Assembly to the top port of the accumulator and the other end to the evaporator connection located under the cab.

12. Install 1730272 Hose Assembly to the bottom port on the accumulator and connect to the compressor.

13. Recharge the system. Refer to the Service Manual, SENR5664, "Refrigerant System - Evacuate" section in testing and adjusting. Refer to the Service Manual, SENR5664, "Refrigerant System - Charge" section in testing and adjusting.

14. Install the 4W1683 Engine Lifting Eye using hardware from letter PS4774.

Illustration 1.

Group 2

15. For Group 2 machines - perform steps 16 through 22. See Illustration 2.

16. Install 1720154 Plate Assembly. See Illustration 2.

17. Install 1522823 Accumulator with 6V4357 and 6V4356 Clips using (1) 8T4223 Washer and (1) 8T4130 Bolt.

18. Install (1) 9X7382 and (1) 9X7383 O-rings in each end to the 1594589 and 1730272 Hose Assemblies.

19. Install 1594589 Hose Assembly to the top port of the accumulator and the other end to the evaporator connection located under the cab.

20. Install 1730272 Hose Assembly to the bottom port on the accumulator and connect to the compressor.

21. Recharge the system. Refer to the Service Manual, SENR5664, "Refrigerant System - Evacuate" section in testing and adjusting. Refer to the Service Manual, SENR5664, "Refrigerant System - Charge" section in testing and adjusting.

22. Install one standard 4W1683 Lifting Eye for engine using bolts and washers provided in the letter PS4774.