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

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

Usage:

TEBE3512-01

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02Sep2015

(Revised 17Mar2016)

U-474

A-343

D-404

O-406

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REPLACING COUPLER ASSEMBLY ON CERTAIN 236D AND 242D SKID STEER LOADERS, 257D MULTI TERRAIN LOADERS, AND 259D COMPACT TRACK LOADERS
6129		PS53024

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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 "PS53024" 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 02Sep2015 Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

30Sep2017

PROBLEM

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The existing coupler cross tube may develop a structural failure on certain 236D and 242D Skid Steer Loaders, 257D Multi Terrain Loaders, and 259D Compact Track Loaders. A crack may develop where the cross tube is attached to the side plates on the coupler, resulting in total loss of the coupler function.

AFFECTED PRODUCT

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Model	Identification Number
236D	BGZ00100, 200-1106, 1108-1109, 1111-1938, 1940, 1942, 1944, 1946, 1948, 1950, 1952, 1974, 1976 MPW00190-00191, 290-756, 769-1064 SEN00100, 200-607
242D	A9W00110-00464 DML00115-00328 DZT00105-00106, 205-1765, 1767, 1769, 1771, 1773, 1797, 1799, 20963, 91276
257D	EML00120-00124 EZW00110, 210-1335 FMR00125-00320
259D	FTK00135, 235-780 FTL00115-00117, 215-2259, 2261-5093, 5095-5100, 5103, 5106, 5108, 5110, 5114, 5116, 5118, 5121, 5123, 5125, 5127, 5130, 5133, 5135, 5178, 5180, 5182, 5184, 5186, 5188, 5190, 33680, 52992 GTK00130-00154

PARTS NEEDED

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Qty	Part Number	Description
1	4766881	COUPLER 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%
0-1500 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 3.5-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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1. Follow UENR3731, Disassembly and Assembly, "Coupler Cylinder - Remove and Install" in order to remove the failed coupler and install the new coupler assembly. Ensure that the actuator is oriented as shown, with the electric motor pointing downwards. Refer to Image1.1.1

Image1.1.1

2. On certain 236D, 242D, 257D, and 259D machines, the coupler cover plate may not fit on the new coupler. If machine is equipped with a closed step cover plate shown in Image1.2.1, then the cover plate needs to be cut along the marking shown in the Image1.2.2.

Image1.2.1

Image1.2.2

3. Cycle the coupler tilt cylinders two times, each time ensuring that the coupler hits the lift arm rack stops. On the third time, operate the tilt cylinder gently until only one side is barely touching the coupler and measure the largest gap on the other side. Refer to Image1.3.1.

Image1.3.1

Note: If the measured gap is less than 3mm then no rework is needed.

4. If the gap is between 3 and 6mm, remove material either on the lift arm or on the coupler to ensure the gap is less than 3mm. Use appropriate method to remove material from coupler or lift arm on the opposite side of where it made contact. Refer to Image1.4.1. Ensure that no more than 2mm is removed from the coupler cast surface.