PRODUCT SUPPORT PROGRAM FOR UPDATING THE CATERPILLAR REGENERATION SYSTEM ON CERTAIN C15 ON-HIGHWAY TRUCK ENGINES EQUIPPED WITH 24 VOLT PURGE AIR PUMP AFTERTREATMENT REGENERATION DEVICES Caterpillar

PRODUCT SUPPORT PROGRAM FOR UPDATING THE CATERPILLAR REGENERATION SYSTEM ON CERTAIN C15 ON-HIGHWAY TRUCK ENGINES EQUIPPED WITH 24 VOLT PURGE AIR PUMP AFTERTREATMENT REGENERATION DEVICES

Usage:

REBE5279-00

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24Aug2009

U-303

O-277

TT-38

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR UPDATING THE CATERPILLAR REGENERATION SYSTEM ON CERTAIN C15 ON-HIGHWAY TRUCK ENGINES EQUIPPED WITH 24 VOLT PURGE AIR PUMP AFTERTREATMENT REGENERATION DEVICES
1743 108B 107P		PS42959

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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 "PS42959" 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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TERMINATION DATE

31Aug2010

PROBLEM

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The existing components on the Caterpillar Regeneration System can fail causing the system to not regenerate properly. This failure results in the check engine lamp being illuminated and a possible engine derate. This service letter only applies to Model Year 07 On-Highway Truck engines that are equipped with a 24 volt Purge Air Pump for the regeneration cleaning system.

AFFECTED PRODUCT

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Model	Identification Number
C15	B5R00153, 156-160, 173-302, 304-339

PARTS NEEDED

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Qty	Part Number	Description
2	0S1614	BOLT
6	3S2093	STRAP-CABLE
2	5M2894	WASHER-HARD
4	5P0537	WASHER-HARD
1	8T9405	BOLT-SOCKET HEAD
2	9F7022	BOLT
1	9S5518	PLUG
1	9S8004	PLUG-HEX SOCKET
2	9S8752	NUT-FULL
3	1261768	SOCKET-CONNECTOR
2	1566175	CLIP-LADDER
1	2147568	SEAL-O-RING-STOR
2	2808911	CLAM-BAND
1	2893107	GASKET
2	2901993	STRAP-CABLE
1	2953099	PLUG-SPARK
2	2967780	GASKET
1	3120092	WIRE AS-HEATER
1	3121080	RELAY AS-SS (24 volt)
1	3147660	BRACKET
1	3150225	CLAMP-WIRE
1	3170642	WIRING KIT
1	3232205	CONNECTOR AS.
1	3232206	CONNECTOR AS.
1	3270363	HOSE
1	3341387	SENSOR-TEMP
1	3341390	SENSOR-TEMP
1	3343103	VALVE GP-SOL
1	3343104	VALVE GP-SOL
1	3373970	HEAD AS-COMB (24 Volt)
1	3486571	SOFTWARE GP-ELEK
1	3486572	SOFTWARE GP-ELEK
1	3486573	SOFTWARE GP-ELEK
1	LEDT8906	Drive Regeneration Card
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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

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1. Review records and SIMSi for a claim containing "RP9712" or "RP9709" or other information indicating the regeneration system has been previously updated under another program. If the Caterpillar Regeneration System has been previously updated, no further rework is required. If research of the records does not indicate a previous update has been completed, proceed to Step 2.

2. Inspect for a purge pump.

- If inspection shows that there is not a purge pump, the engine has been previously updated and no further rework is required. Enter an inspection claim against the service letter and 0.5 hours for the inspection time.

- If a purge pump is still installed on the engine, proceed to Step 3.

3. Update the Caterpillar Regeneration System. Refer to attached Rework Procedure and Special Instruction REHS4801.

NOTE 1: The technician making the repairs as outlined in this instruction MUST have completed all required technician certification training and EPA07 Update assessment training and testing. The required EPA07 assessment video and test are posted on DLMS (Global On-Highway Campus). Dealer MUST submit the Technician?s CWS ID on each Cat ET warranty report (required). The CWS ID must be placed in the "Technician Name" section of the warranty report in Cat ET (see example below). Dealer claim submittal for repairs in this update signifies that the repairs have been done completely by a trained technician. All claims that do not follow this requirement will be DENIED.

NOTE 2: It is critical that all special instructions referenced in REHS4801 are downloaded from SIS web and followed. Do not use old paper copies that are outdated. Some of the referenced special instructions will include:

REHS3848, REHS3822, and REHS3826

NOTE 3: DPF ASH Cleaning

It is recommended that the diesel particulate filter cleaning maintenance should be performed before 250,000 miles for the C15.

If the engine is at or above the recommended ash cleaning service interval, strongly recommend to the customer to complete this maintenance while the truck is in the shop for this service letter. If the Ash Cleaning Service tool is not available, assist the customer to schedule a cleaning at another location.

Ash cleaning will allow optimum fuel economy and engine performance.

Refer to special instruction REHS3826 for specific instructions on cleaning a DPF.

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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%
0-500000 miles, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 8.5-hour job If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
If the engine was inspected and no purge pump found there is no need to apply the Service letter; the truck has been updated and no further rework is required. Enter a claim against this service letter and charge 0.5 hours for the inspection time. If the engine that is updated during this program is installed in a difficult chassis, more time will be allowed. In order for additional time to be allowed a separate segment with code 500 must be itemized. The information must include chassis make/model and components that were removed and installed. Itemize additional time necessary per component. Extra labor time not itemized will not be paid.

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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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1. Follow instructions outlined in REHS4801.
* It is critical that all special instructions referenced in REHS4801 are downloaded from SIS web and followed. Do not use old paper copies that are outdated.

NOTE: The seating of the heater wire to the ARD head is critical. There have been some cases of the heater wire interfering with the ARD head and not allowing it to seat properly. Refer to Image 1.1.1 for an example of proper seating.

If the heater wire hex interferes with the ARD head, use a file on the heater wire hex to allow proper seating (Image 1.1.2). DO NOT USE any cleaner after removing material from the hex as it can cause a heater failure. Usually less than 2mm reduction is necessary if proper seating does not take place.

Image1.1.1

Image1.1.2

2. Attach to the Warranty Report:
- Data Log of a successful regeneration.
- Air Systems Verification Test Report.

NOTE: Also add the Technician's CWS or SSO ID in the Technicians Name field of the "Warranty Report - User Information" screen. See example in illustration of warranty report in REHS4801.