PIPE AS-AIR INLET 8S2383 - Caterpillar

REBE2546-01
05Oct2007
(Revised 22Oct2007)
U-509
TT-36
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
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 Numberand "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.
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.
This Revised Service Letter replaces the O5Oct2007 Service Letter. Changes have been made to the title to state Product Support Program.
TERMINATION DATE
31Oct2015
PROBLEM
Certain 3126E On-Highway Truck Engines Manufactured in 2002 and used in Industrial yard jockey applications need to have aftertreatment installed.
AFFECTED PRODUCT
Model Identification Number
3126E CKM20186, 48301, 48390, 48472, 48730, 50441, 50763, 50793, 63715, 63977, 63982, 63996
PARTS NEEDED
Qty
Part Number Description
4 0T0573 BOLT
1 5M6213 PLUG-PIPE
1 2547263 CONV/MUFFLER AS
ACTION REQUIRED
Refer to the attached Rework Procedure.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-10000 hrs 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 4.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
PARTS NEEDED IF OTTAWA TRUCK
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
Image1.3.2
PARTS NEEDED IF CAPACITY TRUCK
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.
.