PRODUCT SUPPORT PROGRAM FOR REWORKING THE HEATER AND AIR CONDITIONER SYSTEM ON CERTAIN 904B COMPACT WHEEL LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE HEATER AND AIR CONDITIONER SYSTEM ON CERTAIN 904B COMPACT WHEEL LOADERS

Usage:

REBE2162-00

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29Oct2007

U-544

A-445

D-444

O-476

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE HEATER AND AIR CONDITIONER SYSTEM ON CERTAIN 904B COMPACT WHEEL LOADERS
7304 7320		PS51379

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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 "PS51379" 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.

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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.

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TERMINATION DATE

31Oct2009

PROBLEM

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The existing heater, defrost, and air conditioner system does not perform as expected on certain 904B Compact Wheel Loaders. The heater capacity and air flow from the vents is not enough to keep the cab windows defrosted and the operator at a comfortable working temperature in cold operating conditions. Also, the weak air flow from the vents is not enough to keep the operator at a comfortable working temperature in warm operating conditions.

AFFECTED PRODUCT

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Model

Identification Number

904B

B4L00166-00167, 170-172, 174, 176-184, 186-188, 191-193, 196-198, 201-202, 205-209, 212-215, 218-221, 223-229, 232-235, 238-241, 244-247, 249, 251-252, 254-256, 259-262, 265-266, 269-273, 276-280, 283-286, 288-292, 295-298, 302-305, 309-310, 312, 314-319, 323-326, 330-332, 336-339, 343-346, 350-352, 355-358, 362-365, 369-373, 377-379, 382-384, 388-398, 401-411, 413-414, 417-419, 422-425, 429-437, 442-445, 447-451, 453-469, 471-473, 475-477, 479-503, 506-508, 516-520, 525, 531-532, 536-537, 541-542, 546-547, 549-551, 553-561, 567-569, 572-578, 580, 582, 584-585, 588-605, 608-619, 621-622, 626-627, 629-631, 633-640, 643-663, 665, 670, 675, 677-693, 696-697, 699-700, 702-707, 709-755, 757-787, 789-794, 796-808, 810-813, 815-858, 860-864, 866-874, 877-921, 923-924, 926-933

PARTS NEEDED

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Qty	Part Number	Description
1	6V2495	SEAL
2	9X2044	SCREW-TRUSS HEAD
4	2014440	SCREW
1	2057048	INSERT-THREADED
1	2354960	THERMOSTAT
1	2424885	HOSE
1	2698438	SEAL
1	3082243	COVER AS
1	3114219	DUCT AS
1	3127464	COVER AS
1	3127491	COVER AS
1	3161513	DUCT

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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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%
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
3001-5000 hrs, 37-48 mo	33.3%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 3.0-hour job

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PARTS DISPOSITION

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

Rework Procedure

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Complete steps 1-4 before beginning rework procedure for installing new heater air ducts:

Step 1: Replace the water temperature regulator with a 235-4960 Water Temperature Regulator.

Step 2: Open the access door on the right side of the machine.

Step 3: Check the routing of the air hose to the rear defroster to ensure the hose has not been crushed or collapsed by a harness. Reroute the hose if necessary. Ensure both ends of the hose are still connected. (Image 1.1.1)

Image1.1.1

Step 4: Check that the 2 9X-2045 Screws for mounting the blower motor are tight. Tighten the screws to a torque of 12 +/- 3 Nm. (Image 1.2.1)

Image1.2.1

Rework procedure for installing new ducts for improved heater defrost performance: (Image 1.3.1)

Image1.3.1

Step 5: Remove 2 bolts that retain the wrist rest and remove the wrist rest.

Step 6: Remove plastic control panel so it is loose. (Image 1.4.1)

Image1.4.1

Step 7: Remove 2 236-5075 Knobs that attach the 236-5082 Recirculation Filter Cover. (Image 1.5.1)

Step 8: Remove the 4 9X-6042 Screws that attach the top outer plate surrounding the B post. (Image 1.5.1)

Step 9: Remove the 2 screws that attach the HVAC switches to the right hand console. (Image 1.5.1)

Image1.5.1

Step 10: Remove the temperature select knob. (Image 1.6.1)

Step 11: Remove 6 screws that attach the HVAC top plate to the right hand console. (Image 1.6.1)

Image1.6.1

Step 12: Remove 1 screw on the side plate to allow the plate to tilt back for easier access to heater box. (Image 1.7.1)

Image1.7.1

Step 13: Apply a ring of silicone sealant around the small round end of the 316-1513 Diffuser (reference item 2 Image 1.3.1) prior to installation. (Image 1.8.1)

Step 14: Position diffuser into the heater box ensuring that the round end fits into the hole to the front air vent in the bottom of the heater box. (Image 1.8.2 and 1.8.3)

Step 15: Reassemble the heater box by reversing the disassembly.

Image1.8.1

Image1.8.2

Image1.8.3

Rework procedure for installing the front air vent:

Step 16: Remove the 242-4885 Hose from the front window air vent on the front of the steering column. (Image 1.9.1)

Step 17: Remove the 271-4127 Front Window Duct Assembly from behind the steering column by removing 2 5C-9553 Bolts and 2 9X-8256 Washers. (Image 1.9.1)

Step 18: Remove the 8Y-6388 Plastic Louver Assembly from the removed air vent in Step 17. (Image 1.9.1)

Image1.9.1

Step 19: Reinstall the 8Y-6388 Louver Assembly from old duct assembly into the new 311-4219 Duct Assembly (reference item 3 Image 1.3.1). (Image 1.10.1)

Step 20: Install the new 311-4219 Duct Assembly behind the steering column with 2 5C-9553 Bolts and 2 9X-8256 Washers. (Torque bolts to 12 +/- 3 Nm)

Step 21: Reinstall the 242-4885 Hose from Step 16 to new 311-4219 Duct Assembly. (Image 1.10.2)

Image1.10.1

Image1.10.2

Rework procedure for installing the new floor vent:

Step 22: Remove the floormat. (Image 1.11.1)

Step 23: Remove the cab floorplate. (Image 1.11.1)

Image1.11.1

Step 24: Remove hose from the existing foot vent. (Image 1.12.1)

Step 25: Remove the existing louver assembly from the hole in the kickplate. (Image 1.12.1)

Image1.12.1

Step 26: Open up the existing hole in the kickplate with a grinder in order to provide clearance for the hose clamp. (Image 1.13.1)

Image1.13.1

Step 27: Drill a 9.5mm +0.3/-0.1 hole in the removed floorplate in location shown in Image 1.14.2. Install the 205-7048 Insert into the hole. (Image 1.14.1)

Step 28: Drill and tap for an M6 9X-2044 Screw in location shown in Image 1.14.2.

Image1.14.1

Image1.14.2

Step 29: Add 6V-2495 Adhesive Backed Seal to bridge the 2 surfaces. Trim seal to fit flush between the plates as shown in Image 1.15.1.

Image1.15.1

Step 30: Install existing 271-5319 Louver Assembly into the 312-7491 Cover Assembly. Install a new 242-4885 Hose cut to a length of .35 m onto the 271-5319 Louver Assembly reusing the 140-4767 Hose Clamp. (Image 1.16.1)

Image1.16.1

Step 31: Install the 312-7491 Cover Assembly into cab using 2 9X-2044 Screws. (Image 1.17.1)

Image1.17.1

Step 32: Reinstall the floormat. (Image 1.18.1)

Image1.18.1

Step 33: Remove the 6 9X-2043 Screws and 308-2244 Cover Assembly and 269-8438 Seal. Install new 269-8438 Seal and 312-7464 Cover Assembly and secure with the 6 9X-2043 Screws. (Image 1.19.1)