PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REWORKING THE DEF HEATER HOSE AND AFTER TREATMENT CONTROL UNIT HARNESS ROUTING ON CERTAIN 272D2/27D2 XHP SKID STEER LOADERS, 297D2/297D2 XHP MULTI TERRAIN LOADERS, AND 299D2/299D2 XHP COMPACT TRACK LOADE Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REWORKING THE DEF HEATER HOSE AND AFTER TREATMENT CONTROL UNIT HARNESS ROUTING ON CERTAIN 272D2/27D2 XHP SKID STEER LOADERS, 297D2/297D2 XHP MULTI TERRAIN LOADERS, AND 299D2/299D2 XHP COMPACT TRACK LOADE

Usage:

TEBE3967-00

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29Jan2016

U-52

D-51

O-48

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Priority	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REWORKING THE DEF HEATER HOSE AND AFTER TREATMENT CONTROL UNIT HARNESS ROUTING ON CERTAIN 272D2/27D2 XHP SKID STEER LOADERS, 297D2/297D2 XHP MULTI TERRAIN LOADERS, AND 299D2/299D2 XHP COMPACT TRACK LOADERS
1000 1408		PI32600

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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 must be administered as soon as possible. When reporting the repair, use "PI32600" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI32600" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "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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COMPLETION DATE	TERMINATION DATE
31Jul2016	31Jan2017

PROBLEM

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The DEF heater hose assemblies and After Treatment Control Unit (ACU) harness needs to be inspected and reworked on certain 272D2/27D2 XHP Skid Steer Loaders, 297D2/297D2 XHP Multi Terrain Loaders, and 299D2/299D2 XHP Compact Track Loaders. The existing DEF heater hose assembly and ACU harness assembly may have been incorrectly routed, causing rub and may lead to component damage. If DEF heater hose fails, the machine may experience some fault codes: 4354-4, 4355-4, 4356-4, and 4357-4.

AFFECTED PRODUCT

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Model	Identification Number
272D 2	BL200100-00101, 200-279, 282-312, 315-322, 325-330, 332-350, 355-374
272D 2 XHP	MD200130-00131, 230-261, 268-272
297D 2	BL700220-00224, 228-235
297D 2 XHP	HP200110-00111, 230-250, 252-256
299D 2	FD200120-00121, 220-360, 363-443, 445-447, 458, 460, 465, 471-512
299D 2 XHP	DX200100, 200-250, 252-313, 315, 317-318, 320-384, 388, 390, 392, 406-449

PARTS NEEDED

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Qty	Part Number	Description
6	7K1181	STRAP-CABLE
1	4414797	HARNESS AS (After Failure Only)
1	4656885	HOSE AS (After Failure Only)
1	4656887	HOSE AS (After Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 1.0-hour job
Note: An additional 3.0 hours of labor will be allowed for hose assembly replacement.

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PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REWORKING THE DEF HEATER HOSE ROUTING

MODELS INVOLVED - CERTAIN 272D2/27D2 XHP SKID STEER LOADERS, 297D2/297D2 XHP MULTI TERRAIN LOADERS, AND 299D2/299D2 XHP COMPACT TRACK LOADERS

Dear Cat Product Owner:

The DEF Heater Hose Assemblies and After Treatment Control Unit Harness needs to be inspected and reworked on the products listed below. The existing DEF hose assembly and After Treatment Control Unit Harness may have been incorrectly routed, and may cause hose or harness failures. The machine may show fault codes when such a problem occurs. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 29Jan2016 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 29Jan2016 Service Letter

Rework Procedure

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1. Locate and identify the SCR mixing tube from the rear of the machine.

Note: Use caution as Catalyst (SCR) tube may be very hot.

Image1.1.1

2. Locate the DEF delivery hose from DEF pump to DEF injector and the DEF return hose from DEF injector to DEF Tank as indicated in the Image1.2.1.

Image1.2.1

3. Inspect the hoses for any damage. If hose assembly is damaged, a complete replacement of the hose assembly is recommended. Refer to Disassembly and Assembly manual, for your machine, for additional instructions.

4. If no hose damage has occurred, then use a new 7K-1181 Cable Strap to secure the hose assemblies to the tube assembly, ensuring the DEF hoses are away from the SCR tube, as shown in the Image1.4.1 and 1.4.2.

Image1.4.1

Image1.4.2

5. Refer to UENR3731, Disassembly and Assembly, "Cab ? Tilt". Locate the After Treatment Electronic Control unit harness. Refer to Image1.5.1.

Image1.5.1

6. Inspect the harness and CAB HVAC box for any damages due to rubbing. Refer to Image1.6.1 that shows damage to the harness. Replace components if damaged excessively.

Image1.6.1

7. Re-strap the ACU harness assembly in order to eliminate any rub to the CAB heater box. Add additional cable straps as shown by Note "A". Relocate the existing cable straps to the location indicated by Note "B" and replace the dual cable strap as indicated by Note "C". Refer to Image1.7.1.