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PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE CONVERTER MUFFLER HANGER CLAMPS ON CERTAIN 3126E TRUCK ENGINES Caterpillar


PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE CONVERTER MUFFLER HANGER CLAMPS ON CERTAIN 3126E TRUCK ENGINES

Usage:

SEBE8909-01

September 14, 2004
(Revised November 2006)

U-266
O-231
TT-22


 
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PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE CONVERTER MUFFLER HANGER CLAMPS ON CERTAIN 3126E TRUCK ENGINES
1050
PI10337
NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI10337" 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 "PI10337" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: This Revised Service letter replaces the September 14, 2004 Service Letter. Changes have been made to the Customer Notification Letter.

PROBLEM

The converter muffler hanger clamps need to be replaced on certain 3126E truck engines. On the affected vehicles built with Caterpillar 3126E 7.2L engines, one or both of the converter muffler clamps may crack or break along a weld bead used to hold the converter muffler assembly to the clamps. If both clamps fail completely, the potential exists that the converter muffler assembly may come loose and fall off the truck.
 

AFFECTED PRODUCT

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Model Identification Number
C7 KAL00282
3126E HEP7843, 7861, 7894, 9557, 9557, 9636, 9650, 9657, 12212, 12238, 12255, 12258, 12275, 12300, 12314, 12329, 12340, 12341, 12350, 12358, 12393, 12409, 12431, 12449, 12459, 12470, 12540, 12542, 12543, 12544, 12545, 12547, 12548, 12550, 12551, 12557, 12620, 12634, 12644, 12650, 12725, 12753, 12782, 12812, 12840, 12843, 12845, 12876, 12895, 12898, 12933, 12935, 12937, 12974, 12978, 12986, 13007, 13029, 13031, 13039, 13054, 13081, 13083, 13085, 13086, 13094, 13105, 13109, 13116, 13126, 13149, 13150, 13154, 13155, 13158, 13196, 13204, 13209, 13212, 13218, 13221, 13231, 13239, 13241, 13255, 13263, 13273, 13287, 13311, 13317, 13320, 13328, 13331, 13359, 13371, 13386, 13389, 13406, 13411, 13420, 13466, 13468, 13474, 13475, 13487, 13488, 13500, 13512, 13519, 13532, 13540, 13548, 13559, 13573, 13575, 13584, 13590, 13604, 13605, 13607, 13608, 13617, 13622, 13628, 13629, 13632, 13642, 13644, 13651, 13658, 13663, 13672, 13675, 13686, 13697, 13700, 13703, 13708, 13711, 13714, 13726, 13741, 13748, 13749, 13764, 13765, 13770, 13781, 13786, 13798, 13799, 13801, 13803, 13805, 13824, 13834, 13840, 13842, 13844, 13849, 13854, 13857, 13860, 13863, 13866, 13873, 13879, 13888, 13892, 13896, 13901, 13905, 13909, 13914, 13918, 13922, 13928, 13939, 13941, 13949, 13951, 13953, 13955, 13968, 13972, 13976, 13979, 13989, 13999, 14008, 14017, 14020, 14026, 14032, 14035, 14041, 14044, 14052, 14058, 14062, 14065, 14067, 14070, 14072, 14075, 14076, 14077, 14079, 14080, 14083, 14084, 14085, 14086, 14087, 14088, 14089, 14090, 14092, 14093, 14094, 14095, 14096, 14097, 14099, 14100, 14101, 14102, 14103, 14104, 14215, 14217, 14221, 14226, 14228, 14231, 14234, 14237, 14240, 14242, 14248, 14250, 14255, 14263, 14265, 14267, 14269, 14271, 14273, 14275, 14278, 14281, 14285, 14291, 14293, 14298, 14300, 14302, 14304, 14306, 14308, 14311, 14313, 14315, 14317, 14319, 14321, 14323, 14325, 14327, 14329, 14332, 14335, 14337, 14339, 14341, 14342, 14343, 14346, 14347, 14349, 14352, 14353, 14354, 14364, 14369, 14372, 14373, 14377, 14381, 14382, 14383, 14385, 14387, 14390, 14391, 14395, 14401, 14402, 14403, 14408, 14410, 14411, 14416, 14420, 14427, 14429, 14435, 14436, 14441, 14444, 14450, 14455, 14456, 14460, 14468, 14470, 14477, 14478, 14496, 14498, 14506, 14510, 14511, 14521, 14526, 14531, 14534, 14538, 14549, 14551, 14555, 14566, 14568, 14571, 14580, 14585, 14595, 14604, 14608, 14613, 14614, 14620, 14630, 14639, 14641, 14642, 14646, 14653, 14658, 14659, 14660, 14661, 14664, 14665, 14667, 14675, 14679, 14681, 14682, 14686, 14699, 14703, 14704, 14707, 14710, 14713, 14714, 14723, 14727, 14728, 14731, 14739, 14740, 14751, 14752, 14754, 14759, 14761, 14766, 14767, 14768, 14769, 14775, 14780, 14782, 14801, 14810, 14812, 14814, 14824, 14826, 14828, 14840, 14843, 14845, 14847, 14850, 14866, 14874, 14880, 14889, 14895, 14912, 14915, 14917, 14919, 14921, 14925, 14927, 14966, 14969, 14971, 14976, 14991, 14995, 15000, 15006, 15020, 15021, 15029, 15041, 15047, 15049, 15058, 15063, 15071, 15085, 15088, 15129, 15149, 15151, 15154, 15157, 15178, 15179, 15180, 15182, 15184, 15186, 15191, 15192, 15193, 15211, 15214, 15221, 15230, 15234, 15236, 15241, 15248, 15257, 15265, 15275, 15283, 15292, 15296, 15311, 15312, 15314, 15334, 15342, 15344, 15346, 15347, 15358, 15363, 15367, 15371, 15373, 15377, 15379, 15382, 15384, 15386, 15392, 15394, 15396, 15399, 15400, 15402, 15404, 15406, 15411, 15412, 15414, 15416, 15421, 15423, 15424, 15427, 15428, 15430, 15432, 15434, 15436, 15441, 15443, 15445, 15447, 15448, 15450, 15452, 15454, 15456, 15458, 15462, 15463, 15465, 15495, 15497, 15503, 15507, 15509, 15518, 15520, 15523, 15531, 15532, 15539, 15548, 15549, 15553, 15562, 15563, 15567, 15573, 15576, 15579, 15580, 15582, 15585, 15589, 15592, 15599, 15602, 15606, 15609, 15613, 15616, 15617, 15620, 15624, 15626, 15628, 15629, 15632, 15640, 15643, 15660, 15662, 15665, 15670, 15672, 15679, 15686, 15696, 15706, 15709, 15712, 15715, 15717, 15720, 15724, 15726, 15731, 15735, 15739, 15745, 15757, 15760, 15763, 16718, 16724, 16802, 16831, 16883, 16888, 16890, 16897, 16912, 16924, 16929, 16940, 16955, 16959, 16975, 16977, 16988, 16995, 17006, 17023, 17045, 17047, 17087, 17104, 17117, 17144, 17155, 17159, 17172, 17186, 17193, 17203, 17205, 17211, 17234, 17236, 17247, 17261, 17282, 17286, 17290, 17302, 17312, 17326, 17328, 17359, 17374, 17383, 17393, 17409, 17415, 17417, 17419, 17474, 17482, 17494, 17510, 17513, 17518, 17520, 17525, 17527, 17555, 17591, 17597, 17600, 17606, 17621, 17627, 17644, 17648, 17652, 17655, 17658, 17661, 17665, 17672, 17675, 17679, 17683, 17690, 17698, 17704, 17712, 17716, 17719, 17723, 17749, 17761, 17797, 17821, 17834, 17844, 17856, 17862, 17881, 17884, 17887, 17889, 17893, 17901, 17903, 17911, 17925, 17928, 17930, 17945, 17969, 17981, 17984, 17987, 18006, 18009, 18016, 18018, 18024, 18026, 18028, 18050, 18054, 18072, 18078, 18080, 18095, 18098, 18116, 18119, 18125, 18127, 18157, 18189, 18219, 18232, 18262, 18264, 18272, 18286, 18306, 18321, 18323, 18340, 18353, 18356, 18370, 19343, 20314, 20330, 20369, 20414, 20426, 20453, 20482, 20485, 20506, 20509, 20513, 20521, 20531, 20550, 20553, 20584, 20599, 20627, 20631, 20653, 20663, 20666, 20681, 20695, 20697, 20722, 20735, 20757, 20772, 20783, 20790, 20799, 20802, 20809, 20815, 20835, 20838, 20865, 20878, 20884, 20896, 20905, 20920, 20924, 20938, 20957, 20966, 20972, 20980, 21003, 21020, 21034, 21042, 21050, 21053, 21055, 21061, 21078, 21084, 21092, 21102, 21105, 21120, 21129, 21160, 21163, 21173, 21206, 21214, 21234, 21260, 21263, 21279, 21287, 21298, 21308, 21309, 21312, 21328, 21332, 21334, 21335, 21340, 21385, 21387, 21388, 21393, 21396, 21403, 21405, 21422, 21426, 21436, 21442, 21450, 21461, 21463, 21476, 21480, 21492, 21537, 21542, 21553, 21554, 21564, 21567, 21575, 21600, 21615, 21621, 21648, 21649, 21654, 21658, 21660, 21663, 21666, 21667, 21669, 21670, 21673, 21675, 21679, 21699, 21709, 21717, 21756, 21775, 21802, 21803, 21820, 21847, 21859, 21875, 21877, 21889, 21915, 21929, 21934, 21937, 21943, 21946, 21952, 21955, 21957, 21969, 21971, 21975, 21982, 21989, 22028, 22051, 22055, 22078, 22088, 22093, 22109, 22113, 22164, 22184, 22196, 22207, 22214, 22218, 22235, 22238, 22298, 22377, 22383, 22389, 22395, 22398, 22405, 22408, 22411, 22420, 22442, 22455, 22466, 22482, 22485, 22487, 22493, 22511, 22519, 22528, 22545, 22562, 22567, 22576, 22591, 22598, 22599, 22604, 22610, 22630, 22635, 22684, 22696, 22719, 22750, 22752, 22762, 22763, 22764, 22772, 22790, 22793, 22804, 22837, 22843, 22867, 22871, 22875, 22881, 22884, 22894, 22925, 22935, 22941, 22942, 22948, 22957, 22971, 22976, 22982, 23002, 23005, 23056, 23068, 23077, 23093, 23098, 23125, 23135, 23174, 23184, 23203, 23214, 23237, 23240, 23246, 23263, 23278, 23294, 23298, 23305, 23334, 23336, 23347, 23352, 23383, 23400, 23401, 23412, 23413, 23425, 23432, 23446, 23448, 23454, 23470, 23483, 23506, 23562, 23578, 23584, 23608, 23651, 23659, 23669, 23691, 23694, 23699, 23705, 23719, 23720, 23724, 23736, 23749, 23771, 23778, 23823, 23837, 23839, 23855, 23873, 23892, 23905, 23914, 23920, 23924, 23935, 23939, 23967, 23973, 23980, 24013, 24026, 24045, 24047, 24059, 24073, 24127, 24130, 24138, 24147, 24162, 24173, 24187, 24190, 24200, 24203, 24209, 24242, 24243, 24249, 24303, 24307, 24309, 24313, 24324, 24331, 24334, 24346, 24355, 24357, 24372, 24390, 24404, 24434, 24437, 24438, 24441, 24452, 24461, 24464, 24466, 24474, 24478, 24498, 24500, 24502, 24513, 24524, 24534, 24538, 24552, 24556, 24560, 24562, 24565, 24571, 24577, 24591, 24595, 24608, 24612, 24632, 24647, 24654, 24662, 24669, 24672, 24674, 24680, 24687, 24699, 24702, 24707, 24724, 24729, 24761, 24788, 24795, 24805, 24829, 24852, 24858, 24864, 24871, 24876, 24883, 24888, 24895, 24901, 24907, 24913, 24932, 24940, 24946, 24963, 24968, 24975, 24981, 24987, 24995, 25012, 25021, 25032, 25039, 25045, 25052, 25058, 25065, 25071, 25084, 25092, 25096, 25100, 25106, 25110, 25117, 25125, 25132, 25137, 25141, 25145, 25150, 25154, 25160, 25162, 25168, 25171, 25177, 25183, 25188, 25194, 25199, 25206, 25211, 25215, 25218, 25222, 25229, 25233, 25238, 25242, 25245, 25250, 25252, 25255, 25259, 25263, 25268, 25273, 25277, 25280, 25284, 25288, 25297, 25299, 25304, 25307, 25311, 25318, 25322, 25331, 25338, 25344, 25350, 25361, 25367, 25379, 25388, 25426, 25430, 25435, 25439, 25443, 25447, 25451, 25455, 25459, 25463, 25467, 25473, 25477, 25482, 25492, 25496, 25501, 25505, 25510, 25517, 25525, 25529, 25533, 25537, 25541, 25544, 25549, 25553, 25557, 25561, 25564, 25568, 25572, 25576, 25581, 25585, 25590, 25594, 25598, 25602, 25606, 25612, 25615, 25620, 25623, 25628, 25635, 25642, 25651, 25661, 25670, 25677, 25685, 25696, 25704, 25710, 25722, 25730, 25750, 25758, 25768, 25777, 25785, 25790, 25799, 25815, 25822, 25831, 25837, 25843, 25850, 25861, 25873, 25879, 25884, 25890, 25896, 25902, 25908, 25913, 25918, 25924, 25930, 25937, 25950, 25956, 25962, 25968, 25974, 25980, 25986, 25992, 25998, 26009, 26014, 26022, 26026, 26030, 26035, 26041, 26045, 26049, 26053, 26056, 26060, 26064, 26071, 26075, 26078, 26083, 26087, 26091, 26095, 26098, 26101, 26105, 26111, 26115, 26119, 26123, 26127, 26131, 26135, 26142, 26147, 26151, 26158, 26161, 26166, 26170, 26173, 26178, 26181, 26189, 26192, 26197, 26201, 26204, 26208, 26212, 26215, 26218, 26223, 26226, 26230, 26234, 26237, 26241, 26244, 26247, 26249, 26259, 26262, 26268, 26272, 26274, 26278, 26286, 26293, 26300, 26306, 26311, 26317, 26320, 26325, 26328, 26332, 26337, 26341, 26345, 26349, 26352, 26355, 26361, 26367, 26370, 26374, 26383, 26389, 26392, 26395, 26401, 26405, 26407, 26416, 26419, 26422, 26426, 26429, 26431, 26435, 26439, 26443, 26449, 26455, 26458, 26462, 26466, 26475, 26478, 26481, 26488, 26491, 26497, 26501, 26504, 26510, 26512, 26514, 26518, 26522, 26530, 26533, 26538, 26547, 26550, 26555, 26560, 26567, 26570, 26574, 26578, 26581, 26584, 26587, 26591, 26594, 26599, 26603, 26608, 26612, 26615, 26618, 26621, 26624, 26628, 26632, 26641, 26643, 26646, 26649, 26653, 26655, 26657, 26659, 26661, 26663, 26665, 26677, 26682, 26687, 26691, 26695, 26699, 26704, 26708, 26718, 26723, 26727, 26732, 26737, 26742, 26747, 26755, 26765, 26770, 26779, 26784, 26788, 26793, 26798, 26813, 26818, 26823, 26828, 26832, 26836, 26841, 26846, 26851, 26864, 26871, 26875, 26881, 26889, 26896, 26903, 26911, 26918, 26932, 26937, 26944, 26957, 26963, 26970, 26978, 26985, 26999, 27011, 27017, 27023, 27030, 27037, 27058, 27065, 27071, 27078, 27085, 27091, 27096, 27098, 27103, 27110, 27122, 27128, 27135, 27147, 27154, 27168, 27173, 27178, 27185, 27192, 27197, 27206, 27213, 27221, 27226, 27239, 27246, 27259, 27265, 27272, 27277, 27282, 27289, 27296, 27308, 27321, 27327, 27337, 27341, 27346, 27350, 27355, 27360, 27364, 27369, 27374, 27379, 27386, 27391, 27398, 27404, 27408, 27418, 27424, 27428, 27433, 27438, 27448, 27452, 27457, 27462, 27467, 27471, 27476, 27481, 27484, 27494, 27497, 27502, 27506, 27513, 27530, 27536, 27547, 27551, 27569, 27575, 27580, 27584, 27590, 27601, 27615, 27620, 27627, 27635, 27641, 27653, 27665, 27684, 27689, 27696, 27770, 27705, 27711, 27725, 27734, 27738, 27747, 27754, 27762, 27770, 27777, 27784, 27791, 27799, 27807, 27819, 27827, 27834, 27852, 27860, 27886, 27893, 27895, 27898, 27903, 27907, 27910, 27913, 27917, 27919, 27924, 27927, 27931, 27934, 27938, 27941, 27946, 27949, 27952, 27957, 27960, 27963, 27968, 27971, 27975, 27978, 27982, 27985, 27989, 27993, 27996, 28000, 28004, 28008, 28013, 28016, 28020, 28024, 28027, 28032, 28035, 28039, 28042, 28047, 28051, 28057, 28060, 28063, 28066, 28070, 28073, 28079, 28087, 28091, 28096, 28100, 28104, 28108, 28112, 28117, 28121, 28132, 28137, 28142, 28147, 28151, 28156, 28161, 28165, 28171, 28176, 28181, 28184, 28188, 28192, 28198, 28202, 28206, 28206, 28218, 28221, 28225, 28230, 28235, 28239, 28243, 28247, 28251, 28253, 28260, 28267, 28275, 28281, 28287, 28293, 28304, 28318, 28324, 28331, 28347, 28356, 28394, 28403, 28475, 28542, 28575, 28592, 28606, 28622, 28678, 28682, 28688, 28693, 28708, 28714, 28719, 28729, 28734, 28739, 28745, 28750, 28755, 28760, 28765, 28770, 28781, 28786, 28791, 28796, 28802, 28807, 28819, 28825, 28833, 28837, 28843, 28851, 28857, 28860, 28864, 128867, 28871, 28873, 28877, 28879, 28883, 28886, 28889, 28892, 28898, 28902, 28906, 28909, 28912, 28917, 28929, 28931, 28934, 28937, 28941, 28944, 28949, 28953, 28957, 28960, 28969, 28974, 28981, 28984, 28987, 28990, 28993, 28999, 29003, 29006, 29015, 29019, 29023, 29027, 29029, 29033, 29037, 29044, 29047, 29052, 29056, 29066, 29072, 29076, 29087, 29090, 29094, 29098, 29102, 29110, 29115, 29120, 29125, 29129, 29136, 29140, 29144, 29149, 29155, 29160, 29169, 29174, 29178, 29182, 29186, 29190, 29196, 29200, 29207, 29216, 29220, 29224, 29229, 29235, 29240, 29243, 29248, 29252, 29255, 29259, 29264, 29268, 29273, 29277, 29284, 29287, 29291, 29295, 29299, 29305, 29309, 29314, 29319, 29323, 29326, 29333, 29337, 29340, 29344, 29351, 29355, 29358, 29362, 29366, 29374, 29377, 29382, 29386, 29389, 29393, 29397, 29400, 29403, 29407, 29411, 29420, 29425, 29429, 29433, 29438, 29443, 29448, 29452, 29456, 29461, 29464, 29466, 29475, 29482, 29497, 29512, 29522, 29528, 29536, 29544, 29553, 29562, 29572, 29591, 29601, 29620, 29637, 29646, 29654, 29663, 29669, 29678, 29687, 29693, 29701, 29706, 29712, 29717, 29725, 29729, 29734, 29740, 29745, 29752, 29759, 29772, 29785, 29798, 29803, 29810, 29817, 29829, 29835, 29840, 29847, 29854, 29865, 29876, 29882, 29886, 29890, 29895, 29899, 29909, 29919, 29925, 29929, 29941, 29944, 29949, 29954, 29959, 29970, 29980, 29989, 29995, 30003, 30008, 30013, 30015, 30019, 30033, 30037, 30041, 30042, 30048, 30072, 30081, 30110, 30125, 30133, 30141, 30165, 30174, 30189, 30195, 30201, 30210, 30225, 30233, 30240, 30278, 30292, 30299, 30307, 30313, 30336, 30343, 30349, 30355, 30361, 30372, 30385, 30403, 30409, 30415, 30450, 30457, 30495, 30522, 30612

PARTS NEEDED

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Qty

 Part Number Description
1 2405916 SERVICE KIT

ACTION REQUIRED

See the attached Rework Procedure.

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
 
 

IMPORTANT: SAFETY NOTICE


 
 

SAFETY ? RECALL FOR REPLACING THE CONVERTER MUFFLER HANGER CLAMPS

MODELS INVOLVED - CERTAIN 3126E TRUCK ENGINES
 

Dear Caterpillar Product Owner:

This notice is sent to you in accordance with the requirements of the US National Traffic and Motor Vehicle Safety Act. This notice is also in accordance with the requirements of the Canadian Motor Vehicle Safety Act. Caterpillar has decided that a defect, which relates to motor vehicle safety, exists in Ford trucks equipped with certain Caterpillar 3126E engines.

The converter muffler hanger clamps need to be replaced on the Products listed below. The converter muffler hanger clamps used to attach the catalytic converter muffler (CCM) to the chassis on your Ford Super Duty equipped with a Caterpillar 3126E engine may crack and / or break along a weld bead used to hold the converter muffler assembly stationary to the clamps. If both straps fail completely, the potential exists that the converter muffler assembly may come loose and separate from the truck. A Converter Muffler on a road may result in a situation where a vehicle crash could occur. You will not be charged for the service performed.

If you elect to install the CCM hanger clamps yourself rather than having your local Authorized Ford TEPS (Truck Engine Product Support) or Authorized Caterpillar dealer install the hanger clamps, please contact Caterpillar at this toll free number (800) 321-7332. Caterpillar will send you the CCM hanger clamps and installation instructions so that you can install the hanger clamps. After that, you will not receive further notification of this recall.

If you are a lessor of these vehicles, you must forward this letter to your lessee within ten days.

If you have had your vehicle repaired prior to receipt of this notice and incurred any costs, you may be eligible for reimbursement. Please contact Caterpillar at this toll free number (800) 447-4986.

If you no longer own the truck with this engine, please contact Caterpillar at this toll free number (800) 321-7332.

Contact your local Authorized Ford TEPS (Truck Engine Product

Support) dealer or any Authorized 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 September 14, 2004 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to do the inspection and have this service performed for your added safety and satisfaction.

Caterpillar Inc.



Identification #(s)
 
 

Attached to September 14, 2004 Service Letter

If the dealer is unable to have the inspection and repair made, please contact:

Caterpillar Inc.

PO Box 610

Mossville, IL 61552-610

Attn: Engine Products Division

Truck Engine Call Center

Telephone: (800) 447-4986
 
 

If you are unable to have the inspection and repair made within 60 days or without charge, you may submit a complaint to:
 
 

In the U.S.

Administrator

National Highway Traffic Safety Administration 400 Seventh Street, S.W.

Washington, D.C. 20590

Telephone: 1-888-327-4236 (TTY:1-800-424-9153)or go to http://www.safercar.gov
 
  In Canada

Transport Canada

Road Safety and Motor Vehicle Regulation

Ottawa, Ontario KIA 0N5
Telephone: (613) 993-9851
Caterpillar Inc.

Rework Procedure

The proposed field service should be able to be completed without removing the converter muffler from the vehicle. The overall process will be to remove the band furthest from the inlet, replace it with a new band assembly, and repeat with the second band.

Band removal

  1. Cut the band with a grinding wheel at the overlap of the band on the bottom side of the muffler. Cutting the band at the overlap will reduce the potential of damaging the muffler body.


    2. Illustration 1

    Illustration 2

  2. Remove the band completely from the muffler by grinding away the weld between the band and the muffler body. Make sure that care is taken not to damage the outer muffler body while removing this weld.


    3. Illustration 3

    Illustration 4

  3. Remove the band and clip from the muffler by removing the bolt holding the isolator assembly to the clip.

Installing new band assembly

  1. Slide the new band assembly into place and reinstall the bolt that holds the isolator to the clip.


    2. Illustration 5

     
  2. Orient the new band assembly so the bolt-together joint is on the bottom side of the muffler opposite the clip and isolator. Hand-assemble the 5/16-18 bolt and nut provided to temporarily hold the new band assembly in place. Torque the bolt holding the rubber isolator to the clip to 30-40 ft-lb. Torque the bolt holding the band assembly together to 14-18 ft-lb. The band assembly should come together fully, but not be deformed excessively.

Illustration 6

Repeat steps for the band nearest the inlet of the muffler.

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PRODUCT SUPPORT PROGRAM FOR CORRECTING THE BOLT HOLE ALIGNMENT ON THE PADS OF THE TRUCK BODIES FOR CERTAIN 773 AND 775 OFF-HIGHWAY TRUCKS PRODUCT SUPPORT PROGRAM FOR CORRECTING THE BOLT HOLE ALIGNMENT ON THE PADS OF THE TRUCK BODIES FOR CERTAIN 773 AND 775 OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR IMPROVING ACCELERATION ON 525HP C13 TRUCK ENGINES PRODUCT SUPPORT PROGRAM FOR IMPROVING ACCELERATION ON 525HP C13 TRUCK ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE INJECTION ACTUATION PRESSURE SENSOR ON CERTAIN 3126E ENGINES PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE INJECTION ACTUATION PRESSURE SENSOR ON CERTAIN 3126E ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE ROTOR IN THE ALTERNATOR ON CERTAIN 3116 AND 3126E TRUCK ENGINES PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE ROTOR IN THE ALTERNATOR ON CERTAIN 3116 AND 3126E TRUCK ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING THE FUEL CONTROL ASSEMBLY ON SOME 3161 GOVERNORS PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING THE FUEL CONTROL ASSEMBLY ON SOME 3161 GOVERNORS
PRODUCT SUPPORT PROGRAM FOR UPDATING SOFTWARE FILES ON CERTAIN C10, C12, C15, AND C16 INDUSTRIAL ENGINES PRODUCT SUPPORT PROGRAM FOR UPDATING SOFTWARE FILES ON CERTAIN C10, C12, C15, AND C16 INDUSTRIAL ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE TURBO OIL SUPPLY LINES ON CERTAIN C15 ON-HIGHWAY TRUCK ENGINES PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE TURBO OIL SUPPLY LINES ON CERTAIN C15 ON-HIGHWAY TRUCK ENGINES
PRODUCT SUPPORT PROGRAM FOR REPLACING A CONTROL GROUP AND RECALIBRATING THE RACK POSITION SENSOR ON CERTAIN 3512 ENGINES PRODUCT SUPPORT PROGRAM FOR REPLACING A CONTROL GROUP AND RECALIBRATING THE RACK POSITION SENSOR ON CERTAIN 3512 ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR INSTALLATION OF A CHECK VALVE KIT ON CERTAIN C7 AND C9 ENGINES PRODUCT IMPROVEMENT PROGRAM FOR INSTALLATION OF A CHECK VALVE KIT ON CERTAIN C7 AND C9 ENGINES
PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST ROCKER ARMS ON CERTAIN C15 TRUCK ENGINES EQUIPPED WITH COMPRESSION BRAKES PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST ROCKER ARMS ON CERTAIN C15 TRUCK ENGINES EQUIPPED WITH COMPRESSION BRAKES
PRODUCT SUPPORT PROGRAM FOR REPAIRING A BROKEN CRANKSHAFT ON CERTAIN 3406E TRUCK ENGINES PRODUCT SUPPORT PROGRAM FOR REPAIRING A BROKEN CRANKSHAFT ON CERTAIN 3406E TRUCK ENGINES
PRODUCT SUPPORT PROGRAM FOR UPDATING SOFTWARE ON CERTAIN 3500B ENGINES PRODUCT SUPPORT PROGRAM FOR UPDATING SOFTWARE ON CERTAIN 3500B ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR PREVENTING POSSIBLE FUEL OR OIL LINE FAILURES ON CERTAIN C12 MARINE ENGINES PRODUCT IMPROVEMENT PROGRAM FOR PREVENTING POSSIBLE FUEL OR OIL LINE FAILURES ON CERTAIN C12 MARINE ENGINES
PRODUCT SUPPORT PROGRAM FOR REPLACING EXHAUST ROCKER ARMS ON CERTAIN C15 AND C16 TRUCK ENGINES EQUIPPED WITH JACOBS 340D COMPRESSION BRAKES PRODUCT SUPPORT PROGRAM FOR REPLACING EXHAUST ROCKER ARMS ON CERTAIN C15 AND C16 TRUCK ENGINES EQUIPPED WITH JACOBS 340D COMPRESSION BRAKES
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING 185-6134 STUDS FROM DEALER PARTS STOCK PRODUCT IMPROVEMENT PROGRAM FOR REMOVING 185-6134 STUDS FROM DEALER PARTS STOCK
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING 9M6193 CARTRIDGE SPRINGS FROM DEALER PARTS STOCK PRODUCT IMPROVEMENT PROGRAM FOR REMOVING 9M6193 CARTRIDGE SPRINGS FROM DEALER PARTS STOCK
PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW FLASH FILES FOR CERTAIN C15 TRUCK ENGINES PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW FLASH FILES FOR CERTAIN C15 TRUCK ENGINES
PRODUCT SUPPORT PROGRAM FOR REPLACING THE HIGH PRESSURE OIL PUMP AND / OR REFLASHING SOFTWARE ON CERTAIN C9 ENGINES IN RV APPLICATIONS PRODUCT SUPPORT PROGRAM FOR REPLACING THE HIGH PRESSURE OIL PUMP AND / OR REFLASHING SOFTWARE ON CERTAIN C9 ENGINES IN RV APPLICATIONS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL PRESSURE SENSOR ON CERTAIN C7 MARINE ENGINES PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL PRESSURE SENSOR ON CERTAIN C7 MARINE ENGINES
PRODUCT SUPPORT PROGRAM FOR INSTALLING VIBRATION ISOLATORS FOR POWER DISTIBUTION PANELS ON CERTAIN 3500B SERIES II MARINE ENGINES PRODUCT SUPPORT PROGRAM FOR INSTALLING VIBRATION ISOLATORS FOR POWER DISTIBUTION PANELS ON CERTAIN 3500B SERIES II MARINE ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR SAMPLING THE ENGINE OIL AND IF NECESSARY REPLACING THE IDLER GEAR ASSEMBLY ON 3054C ENGINES INSTALLED IN CERTAIN ASV RC85 AND RC100 MACHINES PRODUCT IMPROVEMENT PROGRAM FOR SAMPLING THE ENGINE OIL AND IF NECESSARY REPLACING THE IDLER GEAR ASSEMBLY ON 3054C ENGINES INSTALLED IN CERTAIN ASV RC85 AND RC100 MACHINES
PRODUCT SUPPORT PROGRAM FOR REPLACING THE ENGINE ACCESSORY DRIVE TENSIONER ON CERTAIN C15 TRUCK ENGINES PRODUCT SUPPORT PROGRAM FOR REPLACING THE ENGINE ACCESSORY DRIVE TENSIONER ON CERTAIN C15 TRUCK ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR INSTALLATION OF A CHECK VALVE KIT ON CERTAIN 3126E ENGINES PRODUCT IMPROVEMENT PROGRAM FOR INSTALLATION OF A CHECK VALVE KIT ON CERTAIN 3126E ENGINES
PRODUCT SUPPORT PROGRAM FOR REFLASHING ENGINE SOFTWARE TO ELIMINATE A TIMING KNOCK ON CERTAIN C15 TRUCK ENGINES PRODUCT SUPPORT PROGRAM FOR REFLASHING ENGINE SOFTWARE TO ELIMINATE A TIMING KNOCK ON CERTAIN C15 TRUCK ENGINES
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