PRODUCT IMPROVEMENT PROGRAM FOR PERFORMING BASIC ENGINE RECONFIGURATION ON CERTAIN 3126E ON HIGHWAY TRUCK ENGINES MANUFACTURED IN 2002 AND USED IN INDUSTRIAL YARD JOCKEY APPLICATIONS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR PERFORMING BASIC ENGINE RECONFIGURATION ON CERTAIN 3126E ON HIGHWAY TRUCK ENGINES MANUFACTURED IN 2002 AND USED IN INDUSTRIAL YARD JOCKEY APPLICATIONS

Usage:

SEBE9141-01

April 21, 2005
(Revised November 2005)
U-117
TT-5

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR PERFORMING BASIC ENGINE RECONFIGURATION ON CERTAIN 3126E ON HIGHWAY TRUCK ENGINES MANUFACTURED IN 2002 AND USED IN INDUSTRIAL YARD JOCKEY APPLICATIONS
1062		PI30640

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30640" 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 "PI30493" 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 April 21, 2005 Service Letter. Changes have been made to the Problem Statement, Parts Needed, and the Owner Notification Letter.

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COMPLETION DATE	TERMINATION DATE
October 31, 2005	April 30, 2006

PROBLEM

Certain 3126E On Highway Truck Engines Manufactured in 2002 and used in Industrial yard jockey applications need to have aftertreatment converter muffler installed.

AFFECTED PRODUCT

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Model	Identification Number
3126E	CKM20186, 48301, 48390, 48730, 48472, 50441, 50657, 50746, 50763, 50793, 59255, 59257, 59259, 59264, 59265, 59276, 59289, 59293, 59306, 59323, 59325, 59338, 59340, 59391, 63715, 63843-63847, 63977, 63982, 63996, 63998, 64334, 65631, 66187, 66188, 66191, 66192, 66195, 66196 HEP09610, 9596, 9578, 9592, 9544, 12207, 12203, 12186, 12170, 12221

PARTS NEEDED

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Part #	Description	QTY	List Price
127452	Clamp lap joint 5" ID	1	$19.53
130014	Strap Muffler	1	$18.43
109032	flat washer 3/8 std plated	1	$1.00
109245	bolt 3/8 x 2 nc	1	$1.00
109022	locknut 3/8 nc	1	$1.00
105275	elbow 90 degree	1	$49.49
	Aftertreatment Converter Muffler	1	N/C
500453	clamp lap joint 4"ID	1	$12.85
Total			$103.30

Contact Larry Aldridge @ Holt-Cat Power Systems to order the above parts. Ph: 903-234-4123

Submit your claim for the above amount plus shipping under misc expenses.

ACTION REQUIRED

The following people should be contacted for the engines sold by their dealerships:

Rick Staton (Warren Cat Power Systems) 405-641-6011 - Contact Rick for engines sold by West Texas Cat or Warren Power

Chris Bessemer (High Plains Power) 913-642-1300 - Contact Chris for those engines sold by High Plains Power

Paul Cosper(Holt Power Systems) 972-721-5822 ? Contact Paul for those engines sold by Darr or Holt Power.

See the attached Rework Procedure.

NOTE: For the parts to be installed see the parts needed section.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	1.0	0	0	0	0
NOTE: This is a 1.0-hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

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.

Attach. (1-Owner Notification)
(2-Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR PERFORMING BASIC ENGINE RECONFIGURATION

MODELS INVOLVED - CERTAIN 3126E ON HIGHWAY TRUCK ENGINES MANUFACTURED IN 2002 AND USED IN INDUSTRIAL YARD JOCKEY APPLICATIONS

Dear Caterpillar Product Owner:

Basic engine reconfiguration needs to be performed on the products listed below. Your dealer will install an aftertreatment device (converter muffler) in the exhaust system. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated April 21, 2005 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 April 21, 2005 Service Letter

Rework Procedure

Step 1: remove clamp and pipe from top of muffler.

Step 2: Remove lower clamp holding elbow going into bottom of muffler.

Step 3:Tap elbow down and remove from muffler.

Step 4:Remove last three clamps holding muffler to bracket and remove muffler.

Step 5: Remove two bolts securing guard to muffler.

Step 6: remove guard

Step 7: Put guard on new converter muffler using 2 new 6 inch bolts and nuts.