PRODUCT SUPPORT PROGRAM FOR THE INSTALLATION OF AFTERTREATMENT ON CERTAIN 3126E ON-HIGHWAY TRUCK ENGINES MANUFACTURED IN 2002 AND USED IN INDUSTRIAL YARD JOCKEY APPLICATIONS Caterpillar

PRODUCT SUPPORT PROGRAM FOR THE INSTALLATION OF AFTERTREATMENT ON CERTAIN 3126E ON-HIGHWAY TRUCK ENGINES MANUFACTURED IN 2002 AND USED IN INDUSTRIAL YARD JOCKEY APPLICATIONS

Usage:

REBE2546-01

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05Oct2007

(Revised 22Oct2007)

U-509

TT-36

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR THE INSTALLATION OF AFTERTREATMENT ON CERTAIN 3126E ON-HIGHWAY TRUCK ENGINES MANUFACTURED IN 2002 AND USED IN INDUSTRIAL YARD JOCKEY APPLICATIONS
1091 1062		PS42532

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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 "PS42532" 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 O5Oct2007 Service Letter. Changes have been made to the title to state Product Support Program.

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TERMINATION DATE

31Oct2015

PROBLEM

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

AFFECTED PRODUCT

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Model	Identification Number
3126E	CKM20186, 48301, 48390, 48472, 48730, 50441, 50763, 50793, 63715, 63977, 63982, 63996

PARTS NEEDED

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Qty	Part Number	Description
4	0T0573	BOLT
1	5M6213	PLUG-PIPE
1	2547263	CONV/MUFFLER AS

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%
0-10000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 4.0-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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PARTS NEEDED IF OTTAWA TRUCK
NOTE: Order non-CAT parts from the respective Ottawa dealer in your area or may obtain components locally

Image1.1.1

** Select the appropriate converter/muffler from the
attached aftertreatment system chart.

Image1.2.1

Image1.2.2

Image1.2.3

Image1.2.4

Aftertreatment Chart Notes:
- All schematics are oriented with the inlet on right
- Piping distance limitation (set-back from turbo outlet to converter inlet): 1000 mm (39") MIN ? 3658 mm (144") MAX
- Dimensions are in millimeters

Image1.3.1

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PARTS NEEDED IF CAPACITY TRUCK
NOTE: Order non-CAT parts from the respective Capacity dealer in your area or may obtain components locally

Image1.4.1

ACTION REQUIRED
OTTAWA TRUCK INSTALLATION PROCEDURE
. Remove clamp and pipe from top of muffler.
. Remove lower clamp holding elbow going into bottom of muffler.
. Tap elbow down and remove from muffler.
. Remove last 3 clamps holding muffler to bracket and remove muffler.
. Remove 2 bolts securing guard to muffler.
. Remove guard.
. Put guard on new converter muffler using 2 new 6inch bolts and nuts.
. Slide 1 adapter into each end of converter muffler.
. Install 3 clamps (5 inch) on converter muffler and secure to brackets, tighten clamps.
. Install elbow into inlet (lower) of converter muffler.
. Install 4 inch clamp and tighten.
. Install outlet pipe into top of converter muffler.
. Install 4 inch clamp and tighten.
. Look over to make sure all fasteners are tight.
. Start engine and confirm no exhaust leaks.

CAPACITY TRUCK INSTALLATION PROCEDURE
. Remove muffler inlet end U clamp and discard. Loosen exhaust pipe.
. Remove 4 bolts and straps holding muffler to upright support. Do not reuse the 4 bolts. Reuse nuts and washers.
. Lift muffler up and off exhaust pipe and support. Do not separate stack from muffler.
. Clean exhaust pipe and install new converter/muffler. Use a ratcheting strap to hold the converter/muffler in place while securing the inlet clamp and mounting straps. Line up pipe tap in converter/muffler away from support. Aim tap towards the rear of the truck. Install a plug in the pipe tap.
. Install exhaust pipe properly into converter/muffler and tighten clamp. The new converter/muffler comes with an inlet clamp attached.
. Install lower mounting strap. Strap is slightly smaller due to diameter differences between old muffler and new converter/muffler.
. Bend the strap around the converter/muffler so bolt holes line up with mounting tabs on the upright support. Install longer bolts with old washers and locknuts. Do not tighten yet.
. Use the ratcheting strap to pull converter muffler tight to the support.
. Install the upper strap the same as the lower strap and then tighten all strap bolts together.
. Install the new larger diameter 5" stack with a new Seal Clamp.
. Start engine and confirm no exhaust leaks.