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Service LetterPRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE DIPSTICK TUBE ASSEMBLIES AND DPF DIFFERENTIAL PRESSURE SENSOR MOUNTING BRACKET ON CERTAIN 236D, 242D, 246D, 262D SKID STEER LOADERS, 257D, 277D, 287D MULTI TERRAIN LOADERS, AND 259D, 279D, 289D COMPACT TRACK LOADERS - MULTIPLE REPAIRSMedia Number -TEBE2581-02 Publication Date -06/04/2015 Date Updated -22/07/2015

Caterpillar: Confidential Yellow

TEBE2581-02

06Apr2015

(Revised 22Jul2015)

U-151A-104D-123O-123

Priority

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE DIPSTICK TUBE ASSEMBLIES AND DPF DIFFERENTIAL PRESSURE SENSOR MOUNTING BRACKET ON CERTAIN 236D, 242D, 246D, 262D SKID STEER LOADERS, 257D, 277D, 287D MULTI TERRAIN LOADERS, AND 259D, 279D, 289D COMPACT TRACK LOADERS - MULTIPLE REPAIRS

1326 PI32470

NOTE:Caterpillar: Confidential Yellow

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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 "PI32470" 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 "PI32470" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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.

NOTE:This Revised Service Letter replaces the 06Apr2015 (Revised 15May2015) Service Letter. Changes have been made to add GTL01473 to the Affected Product.

COMPLETION DATE TERMINATION DATE

31Oct2015 30Apr2016

PROBLEM

The existing dipstick tube assembly can fail on certain 236D, 242D, 246D, 262D Skid Steer Loaders, 257D, 277D, 287D Multi Terrain Loaders, and 259D, 279D, 289D Compact Track Loaders, equipped with a C3.3B engine. The new tube assembly contains a stronger support bracket.

The existing wiring harness for the Diesel Particulate Filter (DPF) differential pressure sensor can fail on certain 236D, 242D, 246D, 262D Skid Steer Loaders, 257D, 277D, 287D Multi Terrain Loaders, and 259D, 279D, 289D Compact Track Loaders, equipped with a HRC C3.3B engine. The existing mounting for the DPF differential pressure sensor can have excessive vibration causing wires in the engine harness to fail. This can lead to various fault codes: 3251-3, 3251-4, 523602-0 and frequent regen cycles. A new support bracket for the sensor needs to be installed.




AFFECTED PRODUCT

Model Identification Number*******Group 1*******236D BGZ00479-01099242D DZT00467-01075257D EZW00305-00700, 703, 705-708, 710-733, 735-749, 751-

753, 755-767, 769-773259D FTL01159-02259, 2261-3007, 3020

*******Group 2*******236D BGZ00100, 200-478242D DZT00105-00106, 205-466246D BYF00100, 200-1402, 1404-1411, 1441257D EZW00110, 210-304259D FTL00115-00117, 215-1158262D DTB00105-00106, 205-2470, 2472, 2474, 2500, 2536-2568,

2604-2605277D FMT00210-00466279D GTL00115, 215-1123, 1125-1126, 1128-1297, 1299-1396,

1398, 1400-1474, 1476-1485, 1487-1489, 1491-1493, 1495-1496, 1498-1655, 1707

287D HMT00120, 220-224, 227-506, 510289D TAW00125-00126, 225-2315, 2354-2357

PARTS NEEDED

QtyPart Number Description

*******Group 1*******

17 3S2093 STRAP-CABLE (After Failure Only)

9 7K1181 STRAP-CABLE (After Failure Only)

4 7X7729 WASHER-HARD (After Failure Only)

4 9X8912 BOLT (After Failure Only)

1 3776969 FILTER-LUBE (After Failure Only)

2 3830205 WASHER

1 3895365 BOLT-FLANGE HEAD Caterpillar: Confidential Yellow



1 4373432 GAUGE-OIL LEVEL (After Failure Only)

1 4509634 HARNESS AS (After Failure Only)

1 4589399 BRACKET

1 4674930 TUBE AS

1 4701071 WASHER

2 4804383 BOLT-FLANGE

In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 38% 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*******

13 3S2093 STRAP-CABLE (After Failure Only)

10 7K1181 STRAP-CABLE (After Failure Only)

4 7X7729 WASHER-HARD (After Failure Only)

4 9X8912 BOLT (After Failure Only)

1 3616381 HARNESS AS (After Failure Only)

1 3776969 FILTER-LUBE (After Failure Only)

2 3830205 WASHER

1 3895365 BOLT-FLANGE HEAD

1 4373432 GAUGE-OIL LEVEL (After Failure Only)

1 4589399 BRACKET




1 4674930 TUBE AS

1 4701071 WASHER

2 4804383 BOLT-FLANGE

In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 38% 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

Refer to the attached Rework Procedure.

OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

Caterpillar Dealer Suggested Customer Suggested

Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%

*******Group 1*******

100% 100% 0% 0% 0% 0%

NOTE: This is a 1.0-hour job for Group 1

Note: 1.0 hours is allowed for replacing tube assembly, installing DPF differential pressure sensor bracket, and checking the DPF mounting bolts.

For an After Failure repair, the following additional allowance is supported:1) For excessive tube assembly wear as per instructions, an additional 0.5 hours of labor to replace dipstick, change the oil and oil filter, and oil sampling costs.2) For DPF mounting bolts missing/loose, an additional 3.5 hours Caterpillar: Confidential Yellow



of labor and the new hardware as per instructions.3) For engine harness with a broken wire, an additional 3.0 hrs of labor and the harness as per instructions.

Caterpillar Dealer Suggested Customer Suggested

Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%

*******Group 2*******

100% 100% 0% 0% 0% 0%

NOTE: This is a 1.0-hour job for Group 2

Note: 1.0 hours is allowed for replacing tube assembly, installing DPF differential pressure sensor bracket, and checking the DPF mounting bolts.

For an After Failure repair, the following additional allowance is supported:1) For excessive tube assembly wear as per instructions, an additional 0.5 hours of labor to replace dipstick, change the oil and oil filter, and oil sampling costs.2) For DPF mounting bolts missing/loose, an additional 3.5 hours of labor and the new hardware as per instructions.3) For engine harness with a broken wire, an additional 3.0 hrs of labor and the harness as per instructions.

PARTS DISPOSITION

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

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

EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation3240 Arrow DriveAnywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE DIPSTICK TUBE ASSEMBLY AND DPF DIFFERENTIAL PRESSURE SENSOR MOUNTING BRACKET - MULTIPLE REPAIRS




257D, 277D, 287D MULTI TERRAIN LOADERS, AND 259D, 279D, 289D COMPACT TRACK LOADERS

Dear Cat Product Owner:

The dipstick tube assembly and diesel particulate filter differential pressure sensor bracket need to be replaced on the products listed below. The existing dipstick tube assembly and DPF differential pressure sensor bracket can fail due to vibration. 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 06Apr2015 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 06Apr2015 Service Letter

Rework Procedure

Tube Assembly Rework Procedure:

1. Download and save the Product Status Report for Dealer records and keep for possible follow-up action.

2. Record the oil level.

3. Check the dimensions of the bracket on the tube assembly on engine. Refer to Image1.1.1. - If the bracket measures 25mm wide, this is the improved tube assembly, skip to Step 6. - If the bracket measures 18mm wide, then replace tube assembly with new 467-4930 Tube Assembly. Reuse the existing bolt and tighten to a specified torque of 25 N.m (18.5 lb-ft).




Image1.1.1

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 Image1.2.1, 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.

Image1.2.1

5. If oil gauge (dipstick) has any wear as shown in Image1.3.1, replace with a new 437-3432 Oil Gauge.

Image1.3.1Caterpillar: Confidential Yellow



6. If machine has air conditioning, ensure that the a/c hose has clearance and it is not contacting the tube assembly or dipstick. Refer to Image1.4.1.

Image1.4.1

Diesel Particulate Filter (DPF) Differential Pressure Sensor Mounting:

Image1.5.1

1. Measure the distance from the back of the lifting eye to the front of the differential pressure sensor bracket. Refer to Images1.6.1 and 1.6.2. - If the distance is less than 18.5mm, washers (item 5) are required. - If the distance is greater than 18.5mm, do NOT use washers (item 5). Most machines will measure greater than 18.5mm.




Image1.6.1

Image1.6.2

2. Remove the two bolts mounting the differential pressure sensor and the bolt attaching the bracket to the lifting eye. These bolts will be replaced with new hardware. Refer to Image1.7.1.


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Image1.7.1

3. Mount bracket (item 1) and differential pressure sensor using bolts (item 4).

NOTE: Only use washers (item 5) if measurement from Step 1 is less than 18.5mm.Tighten to a specified torque of 10.5 +/-0.7 N.m (7.8 +/- 0.5 lb-ft). Secure the bracket (item 1) to the engine lifting eye using bolt (item 2) and washer (item 3). Tighten to a specified torque of 52 +/-3 N.m (39 +/-2 lb-ft). Refer to Image1.8.1.

Image1.8.1




The engine harness should be replaced with new harness assembly and tie straps.

- Group 1 requires the 450-9634 Harness Assembly- Group 2 requires the 361-6381 Harness Assembly

Check for DPF mounting bolts:

1. Confirm either visually with a mirror or by hand that the four mounting bolts for the DPF are in place and not loose. Refer to Image1.10.1.

Image1.10.1

2. If the bolts are tight, no further action is required.

3. If any of the bolts are loose or missing, replace all bolts one at a time. To access the bolts, remove the cooling pack. Refer to UENR3728, Disassembly and Assembly, "Remove and Install Radiator and Hydraulic Oil Cooler". Replace with 9X-8912 Bolt and 7X-7729 Washer. Tighten the bolts to a specified torque of 52 +/-3 N.m (39 +/- 2 lb-ft).

Copyright 1993 - 2015 Caterpillar Inc.

All Rights Reserved.

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Wed Jul 29 14:21:54 UTC+0200 2015

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