PRODUCT SUPPORT PROGRAM FOR INSPECTING AND CORRECTING, IF REQUIRED, THE DIESEL EMISSION FLUID (DEF) COOLANT SUPPLY AND RETURN HOSE INSTALLATION ON CERTAIN TL1055D AND TL1255D TELEHANDLERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSPECTING AND CORRECTING, IF REQUIRED, THE DIESEL EMISSION FLUID (DEF) COOLANT SUPPLY AND RETURN HOSE INSTALLATION ON CERTAIN TL1055D AND TL1255D TELEHANDLERS

Usage:

TEBE4560-00

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18Apr2016

U-184

A-140

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Before/After	PRODUCT SUPPORT PROGRAM FOR INSPECTING AND CORRECTING, IF REQUIRED, THE DIESEL EMISSION FLUID (DEF) COOLANT SUPPLY AND RETURN HOSE INSTALLATION ON CERTAIN TL1055D AND TL1255D TELEHANDLERS
7554 1380 108T		PS45047

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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 either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS45047" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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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TERMINATION DATE

30Apr2017

PROBLEM

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The Diesel Emission Fluid (DEF) Coolant lines may have been reversed during assembly on certain TL1055D and TL1255D Telehandlers.

AFFECTED PRODUCT

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Model	Identification Number
TL1055D	ML500372-00544 MNT00157-00163
TL1255D HRC	ML700319-00525
TL1255D LRC	MYW00150-00153

PARTS NEEDED

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Qty	Part Number	Description
5	3S2093	STRAP-CABLE
610	5P0767	HOSE (610CM)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 11% 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%
0-2000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 2.0-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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Use the procedures on the following pages in order to apply the updates to your machine.
- Park the machine on a firm, level surface.
- Fully retract and lower the boom.
- Place the travel select lever in the (N) NEUTRAL position.
- Apply Park Brake.
- Shut the engine off and remove the key from the MAIN switch located inside the engine compartment.
- Properly disconnect the battery.
- Place a Do Not Operate Tag on both the ignition key-switch and the steering wheel, stating that the machine should not be operated.
- Allow the engine area and antifreeze to cool down.
- Remove the cab rear cover.
- Use all applicable safety precautions while working on, around or under any machinery.

1. Locate DEF coolant supply hose (1) and DEF coolant return hose (2) on the engine. Refer to Image1.2.1.

Image1.2.1

2. Trace the routing of DEF coolant supply hose (1) on the engine to DEF coolant control valve (3) located in the middle of the frame. Refer to Image1.2.1 and 1.3.1.

Image1.3.1

3. Trace the routing of DEF coolant return hose (2) from the engine to DEF tank (4) located behind rear of the cab. Refer to Image1.2.1 and 1.4.1.

Image1.4.1

4. If the routing of DEF coolant supply hose (1) and DEF coolant return hose (2) are found to be correct, remount the cab rear cover and place the unit back in service.

5. If the routing of DEF coolant line (1) and DEF coolant return hose (2) are found to be incorrect, please continue the next steps to correct the DEF coolant line installation.

6. Remove all the cable straps that securing the two DEF coolant lines together or to other hoses. Refer to Image1.6.1. Some of the parts have been removed for clarity. Cut the 610cm of 5P-0767 Hose into two pieces: 330cm and 280cm.

Image1.6.1

7. Taking all precautions to minimize and contain any antifreeze spillage, disconnect DEF coolant supply hose (1) from DEF coolant control valve (3) and from the engine side DEF coolant supply port. The hose will not be reused. Retain the hose clamps for reuse. Refer to Image1.2.1 and 1.4.1.

8. Disconnect DEF coolant return hose (2) from DEF coolant tank (4) and from the engine side DEF coolant return port. The hose will not be reused. Retain the hose clamps for reuse. Refer to Image1.2.1 and 1.6.1.

9. Identify the new DEF coolant supply hose. It is the shorter of the two service hoses (280cm in length).

10. Connect the new DEF coolant supply hose to the DEF coolant supply port on the engine. Refer to Image1.2.1.

11. Reroute the new DEF coolant supply hose and connect it to DEF coolant control valve (3). Refer to Image1.4.1.

12. Identify the new DEF coolant return hose. It is the longer of the two service hoses (330cm in length).

13. Connect the new DEF coolant return hose to the DEF coolant return port on the engine. Refer to Image1.2.1.

14. Reroute the new DEF coolant return hose and connect it to DEF coolant tank (4). Refer to Image1.6.1.

15. Once both hoses have been rerouted and properly connected, secure them with new 3S-2093 Cable Straps.

16. Start the engine. Allow engine to come up to operating temperature, then shut off engine and check for leaks.

17. Remount the cab rear cover and place the unit back in service.