PRODUCT SUPPORT PROGRAM FOR REPLACING EXHAUST PIPE ON CERTAIN 236D AND 242D SKID STEER LOADERS, 257D MULTI TERRAIN LOADERS, AND 259D COMPACT TRACK LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING EXHAUST PIPE ON CERTAIN 236D AND 242D SKID STEER LOADERS, 257D MULTI TERRAIN LOADERS, AND 259D COMPACT TRACK LOADERS

Usage:

TEBE2511-02

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09Jun2015

(Revised 22Jan2016)

U-299

D-244

O-248

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REPLACING EXHAUST PIPE ON CERTAIN 236D AND 242D SKID STEER LOADERS, 257D MULTI TERRAIN LOADERS, AND 259D COMPACT TRACK LOADERS
1061		PS52959

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NOTE:	Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
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 "PS52959" 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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NOTE:	This Revised Service Letter replaces the 09Jun2015 (Revised 12Jun2015) Service Letter. Changes have been made to the Affected Product, Parts Needed, and Service Claim Allowances to add a Group 2.

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TERMINATION DATE

30Jun2017

PROBLEM

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The existing exhaust stack pipe from the engine may not be centered to the upper exhaust pipe assembly (Venturi Pipe), causing exhaust gas to blow back into the engine compartment on certain 236D and 242D Skid Steer Loaders, 257D Multi Terrain Loaders, and 259D Compact Track Loaders. If the exhaust gas blows back into the engine it may result in damage to engine harness.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
236D	BGZ00200-00209, 211-478
242D	DZT00205-00466
257D	EZW00210-00304
259D	FTL00061, 215-1158

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*****Group 2*****
236D	BGZ00479-01106, 1108-1109, 1111-1494
242D	DZT00467-01490
257D	EZW00305-01130
259D	FTL01159-02259, 2261-4434

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3453579	GASKET-EXHAUST
1	3616381	HARNESS AS
1	4165802	PIPE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 2*****
1	3453579	GASKET-EXHAUST
1	4165802	PIPE AS
1	4509634	HARNESS AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

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%
*****Group 1*****
0-1500 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-hour job for Group 1
Note: An additional 3.0 hours will be allowed for replacement of the engine harness.

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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%
*****Group 2*****
0-1500 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-hour job for Group 2
Note: An additional 3.0 hours will be allowed for replacement of the engine harness.

PARTS DISPOSITION

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

Rework Procedure

1. If the engine harness is melted near the Diesel Particulate Filter (DPF) Differential Pressure sensor or Boost sensor, then misalignment of the Venturi pipe assembly (Image 1.1.1, Item 1) and pipe assembly (Image 1.1.1, Item 2) maybe the cause of exhaust blow back onto the harness. (No rework is necessary if there is no visible damage to the engine harness). Refer to Image 1.1.1 and 1.1.2 for examples of harness damage.

Image1.1.1

Image1.1.2

2. Open the rear door and disconnect the grill strap and gas strut. Refer to Image 1.2.1, the gas strut is not shown.

3. Remove two bolts. Refer to Image1.2.2. Two people should be used to remove the grill assembly. The weight of grill assembly is approximately 23 kg (50 lb).

Image1.2.1

Image1.2.2

4. Locate four bolts that hold the grill support plate assembly. Refer to Image1.3.1.

Image1.3.1

5. Locate and loosen two bolts in order to remove the Venturi pipe assembly. Refer to Image1.4.1.

Image1.4.1

6. Remove the exhaust pipe assembly on the engine by loosening four bolts, washers, and nuts. Refer to Image1.5.1.

Image1.5.1

7. Replace the gasket with the new gasket. Install the new pipe assembly to the DPF exhaust. Tighten to a specified torque of 55 N.m (40.5 ft lb).

8. Reinstall the Venturi pipe assembly, ensure that the pipe is centered and has a minimum of 10mm gap between the pipes. Tighten the two bolts to a specified torque of 28 N.m (20.6 ft lb).

9. Install the grill support plate assembly using four bolts. Refer to Image1.3.1. Tighten to a specified torque of 28 N.m (20.6 ft lb).

10. Install the grill assembly and connect gas strut. Refer to Image1.2.2. Tighten to a specified torque of 28 N.m (20.6 ft lb).

Important: If there is evidence of severe harness melting, the engine harness should be replaced with a new harness assembly. Follow existing harness routing and clip points to secure the new harness assembly.