PRODUCT SUPPORT PROGRAM FOR REPLACING THE ENGINE OIL DIPSTICK TUBE ASSEMBLY ON CERTAIN 236D/242D/246D/262D SKID STEER LOADERS, 257D/277D/287D MULTI-TERRAIN LOADERS, AND 259D/279D/289D COMPACT TRACK LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE ENGINE OIL DIPSTICK TUBE ASSEMBLY ON CERTAIN 236D/242D/246D/262D SKID STEER LOADERS, 257D/277D/287D MULTI-TERRAIN LOADERS, AND 259D/279D/289D COMPACT TRACK LOADERS

Usage:

TEBE7689-01

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18Oct2018

(Revised 26Nov2018)

U-588

A-425

D-514

O-520

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE ENGINE OIL DIPSTICK TUBE ASSEMBLY ON CERTAIN 236D/242D/246D/262D SKID STEER LOADERS, 257D/277D/287D MULTI-TERRAIN LOADERS, AND 259D/279D/289D COMPACT TRACK LOADERS
1326		PS46043

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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 "PS46043" 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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NOTE:	This Revised Service Letter replaces the 18Oct2018 Service Letter. Changes have been made to the Action Required and Rework Instructions, added new Step 3.

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TERMINATION DATE

31Oct2020

PROBLEM

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The existing engine oil tube assembly can wear in the engine block on certain 236D/242D/246D/262D Skid Steer Loaders, 257D/277D/287D Multi-Terrain Loaders, and 259D/279D/289D Compact Track Loaders. If the existing tube assembly wears, it can allow dirt ingress into engine.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
236D	BGZ03502, 3504, 3507-4375
242D	DZT03445, 3447-3449, 3451-3473, 3482-4355
246D	BYF03518-04360
257D	EZW02096, 2100, 2103-2113, 2122-2493
259D	FTL12406, 12408-12418, 12420, 12423, 12425, 12428-12430, 12432, 12434, 12436-12529, 12563, 12565-12823, 12825-15243, 15246, 15248, 15250-16386, 16388-16744, 16746-17549
262D	DTB06883-08695
277D	FMT00849-00971, 10774
279D	GTL04296-05587
287D	HMT00974-01134
289D	TAW07480-10241

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*****Group 2*****
236D	BGZ00100, 200-1106, 1108-1109, 1111-3175, 3189-3501, 3503, 3505-3506
242D	DZT00105-00106, 205-3137, 3141-3142, 3144-3444, 3446, 3450, 3474-3481
246D	BYF00100, 200-3229, 3231-3232, 3234-3239, 3241-3517
257D	EZW00110, 210-1931, 1936-2095, 2097-2099, 2101-2102, 2114-2121
259D	FTL00061, 115-117, 215-2259, 2261-10244, 10296-10341, 10343-10347, 10349-10361, 10363, 10365-10367, 10371, 10373, 10376, 10378-10384, 10386-10389, 10391-10393, 10395, 10397-10398, 10400-12405, 12407, 12419, 12421-12422, 12424, 12426-12427, 12431, 12433, 12435, 12530-12562, 12564, 12824
262D	DTB00105-00106, 205-6321, 6323-6326, 6329-6340, 6342-6348, 6350-6355, 6357-6359, 6361-6366, 6368-6373, 6375-6376, 6379-6386, 6389-6882
277D	FMT00210-00848
279D	GTL00115, 215-4295
287D	HMT00120, 220-224, 227-973
289D	TAW00125-00126, 225-6284, 6287-6289, 6291-6301, 6303-7479

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3776969	FILTER-LUBE (After Failure Only)
1	3830256	GASKET
1	4308499	GASKET (After Failure Only)
1	4373432	GAUGE-OIL LEVEL (After Failure Only)
1	5616322	TUBE AS-OIL
1	5616325	TUBE-OIL
1	BULK_OIL	DIESEL ENG OIL (ULS) (3 GAL) (After Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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	3776969	FILTER-LUBE (After Failure Only)
1	3830256	GASKET
1	3887435	PLUG
1	4308499	GASKET (After Failure Only)
1	4373432	GAUGE-OIL LEVEL (After Failure Only)
1	5616322	TUBE AS-OIL
1	5616325	TUBE-OIL
1	BULK_OIL	DIESEL ENG OIL (ULS) (3 GAL) (After Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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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All machines listed may not need this Service Letter program. If the engine has been replaced it may already have these improvements.

Refer to REHS7930, Special Instruction, "Interpretation of Serial Number Format on C1.8, C2.4, C2.6, C3.3B, and C3.8 Engines", for details on the engine serial number format.

- If the Engine Serial number is 8JE0001 or newer it contains the improvements, NO further action is needed.

- If the Engine Serial number is prior to 8JE0001, 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*****
0-2000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
2001-3000 hrs, 37-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 0.5-hour job for Group 1
Note: 0.5 hour is allowed for replacing the tube assembly. Note: An additional 0.5 hours of labor is allowed to replace the dipstick, change the oil and oil filter, and submit oil sample for an After Failure repair of excessive wear, as defined in Rework Procedure. Note: $23 US Dollars is allowed for Reusable Dealer Tool 558-4613. Tool purchases should be limited by Dealer Branch to the number of mechanics needing the tool.

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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*****
0-2000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
2001-3000 hrs, 37-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 0.5-hour job for Group 2
Note: 0.5 hour is allowed for replacing the tube assembly and fill plug. Note: An additional 0.5 hours of labor is allowed to replace the dipstick, change the oil and oil filter, and submit oil sample for an After Failure repair of excessive wear, as defined in Rework Procedure. Note: $23 US Dollars is allowed for Reusable Dealer Tool 558-4613. Tool purchases should be limited by Dealer Branch to the number of mechanics needing the tool.

PARTS DISPOSITION

NACD:

Hold all failed parts for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork. Handle all other parts in accordance with your Warranty Bulletin on warranty parts handling.

If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.

EAME, LACD, and APD:

Hold all failed parts for 30 days for a possible Parts Return Request (PRR). Make sure to list the service letter program number on the packing slip and include the closed work order paperwork. Handle all other parts in accordance with your Warranty Bulletin on warranty parts handling.

If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.

Rework Procedure

Dealer Tool 558-4613 is needed for installation of the 561-6325 Oil Tube. The tool is reusable and should be used to rework multiple machines. It is recommended to limit the number of tools ordered per each Dealer Branch to only the quantity necessary.

1. Wash area where the dipstick tube enters the engine block using a pressure washer, compressed air, or other reasonable cleaning method to prevent dirt from entering the engine block when the dipstick tube is removed. Refer to Image1.1.1.

2. Remove the bolt from the dipstick tube bracket and remove the tube from the engine block. Retain the bolt for later reuse.

Image1.1.1

3. Before installing the 561-6325 Short Tube, confirm there is not already one in the engine block. Refer to Image1.2.1. Do not install another 561-6325 Tube if there is already one in the engine block.

Image1.2.1

4. If there are signs of severe wear at end of tube, the O-ring is missing or torn, or signs of dirt bypassing the O-ring as shown in Image1.3.1, then obtain and submit an oil sample, change the oil, and change the oil filter. Follow normal protocol based on results of the oil sample.

Image1.3.1

5. If the oil level gauge (dipstick) has any wear, as shown in Image1.4.1, replace with a new 437-3432 Oil Level Gauge.

Image1.4.1

6. For machines in Group 2 only - Locate the engine oil fill cap in area A shown in Image1.5.1. If the cap is plastic, clean area around cap, remove and replace with a steel 388-7435 Plug. Tighten the steel plug to a specified torque of 118 N.m (87 lb. ft).

Image1.5.1

7. Disconnect the harness blade terminal from the oil pressure switch.

8. Remove the oil pressure switch and adapter together, retain for later reuse.

9. Place the 561-6325 Oil Tube (Sleeve) on the end of the assembly tool and align with the hole in the engine block. Use hammer to tap the tool and drive the sleeve into place. Refer to Image1.6.1. The sleeve should be pressed into the block up to the shoulder on the sleeve, as shown in Image1.6.2.

Image1.6.1

Image1.6.2

10. Remove the existing 383-0256 Gasket from the oil pressure switch adapter and replace with a new 383-0256 Gasket. Install the switch and gasket, tighten to a specified torque of 17 +/- 2 N.m (12.5 +/- 1.5 lb. ft).

11. Reconnect the harness wire to the oil pressure switch.

12. Install a new 561-6322 Oil Tube Assembly, tighten the bolt to a specified torque of 25 +/- 2 N.m (18.5 +/- 1.5 lb. ft).

13. Insert gauge and check for appropriate oil level.