- Engine:
- C13 (S/N: LEE1-UP)
- C15 (S/N: SDP1-UP; B5R1-UP)
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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. |
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Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand. Cooling System Conditioner contains alkali. Avoid contact with skin and eyes. |
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| NOTICE |
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The technician making the repairs as outlined in this instruction MUST have completed all required training and testing. This includes any required technician certification training and EPA07 update assesment training and testing. The required EPA07 assesment video and test are posted on DLMS (Global On-Highway Campus). The Dealer MUST submit the technician's CWS ID on each Cat ET warranty report. 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 rerequirement will be DENIED. |
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| Illustration 1 | g01738938 |
Caterpillar Electronic Technician (ET) warranty report | |
- Review the SIMSi for any open Service Letters that can also be completed during this update. Do not perform any letters for software updates as you will be flashing new software in the Special Instruction.
- Download a warranty report to SIMSi.
- Document the serial number for the Diesel Particulate Filter (DPF) and record the serial number in the area for "Comments" of the Warranty Report. Refer to Illustration 1. Refer to Special Instruction, REHS3849 for the correct procedure.
- Utilize Caterpillar Electronic Technician (ET) for any active diagnostic fault codes or logged diagnostic fault codes. Troubleshoot and resolve all active fault codes that are found before proceeding.
- The inspection of the CGI actuator has been removed from the EPA07 Update Program. Due to the normal collection of debris around this actuator, the determination of a failure is not practical from a visual inspection alone. CGI actuators should not be replaced unless troubleshooting of the component identifies a failure of the CGI actuator.
- Thoroughly wash the engine. This step will ensure that the following components are cleaned for the steps that follow: ARD fuel manifold, secondary fuel filter base, primary fuel filter base and all fuel connections.
- Inspect the CGI flex pipe that is installed on all Kenworth and Peterbilt chassis. Check for a previous update to the CGI flex pipe under either a Peterbilt or Kenworth Technical Information Bulletin
This work should be charged to your local OEM dealer with instructions that are provided with the service letter.
- Peterbilt -Field Repair Notice 408-1 or newer Clean Gas Induction (CGI) and Main Exhaust Pipe Couplings
- Kenworth – Technical Information Bulletin Number 43-12 or newer
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| Illustration 2 | g01794313 |
(1) CGI flex pipe | |
- Drain and save the coolant. The saved coolant can then be reused. Draining the coolant is necessary in order to replace the ARD combustion head.
- Inspect the CGI coolant hose and clamps and replace the CGI coolant hose and clamps if it is necessary on S/N:SDP1-17026.
- Only replace the hose if the hose has not already been updated. Only black colored hoses should be replaced. The replacement hose is blue or green in color. The blue or green hose does not need to be replaced.
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| Illustration 3 | g01794358 |
(2) CGI coolant hose and clamps that are replaced on S/N:SDP1-17026 | |
- Replace the Pilot and Main Fuel Control Valves. The fuel control valves must not be overtorqued.
Torque for the two solenoid valve groups ... 50 ± 5 N·m (37 ± 4 lb ft)
Final installation torque for the two solenoid nuts ... 20 ± 3 N·m (15 ± 2 lb ft)
Note: There will be some coolant that is left in the line after draining.
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| Illustration 4 | g01794360 |
(3) Location of fuel control valves | |
- Inspect the primary fuel filter base and replace the primary fuel filter base if it is necessary.
Note: All Primary fuel filters MUST be 10 micron or less. Also, the fuel filter must have a minimum flow rate of 129 gallons per hour.
Note: Contact the OEM dealer in order to verify and obtain proper inlet fittings and outlet fittings. The fittings from the OEM can be JIC or SAE. The use of the incorrect fitting can cause air to enter the fuel system.
Note: Do not replace the special water separator and fuel filter assemblies such as a Davco or heated bases.
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| Illustration 5 | g01794379 |
(4) New high flow fuel filter base (5) Fuel filter base that needs to be replaced by new high flow fuel filter base | |
- Replace the existing fuel filter base with the 280-2698 Filter Base if a standard fuel filter base is used and if the threads for the inlet port into the base are "pipe thread". Also, replace the water separator and fuel filter assembly with 256-8753 Water Separator and Fuel Filter As . Inspect the fuel filter in order to verify that the filter has a stand pipe and an externally shipped O-ring seal. Charge any replacements to "NAT-PR-3 Heavy Duty Primary FWS & Base".
Note: Caterpillar will pay for a new 256-8753 Water Separator and Fuel Filter As under this Service Letter if a new filter base is installed per NAT-PR-3 or if proper base is already present, but a new 10 micron filter must be installed.
- Remove the ARD combustion head that utilizes the purge air and the associated pump. Replace the ARD combustion head that utilizes the purge air with an ARD combustion head that utilizes a heated nozzle. Refer to Special Instruction, REHS3822 for installation of the hardware only. Flashing of the software and regeneration are included in this special instruction.
Note: Do not install the fuel lines to the ARD Combustion head at this time. These lines will be installed after flushing the fuel system. Leave the protective shipping caps in the fuel ports of the ARD combustion head.
- In addition to the replacement of the ARD combustion head, install a new ARD flame detection temperature sensor. Refer to Special Instruction, REHS3794 for proper wire routing. If a stainless steel zip tie is removed a newstainless steel zip tie should be used.
Show/hide table
Illustration 6 g01794641
(6) ARD flame detection temperature sensor
- Replace the CGI temperature sensor. Refer to the Disassembly and Assembly Manual, RENR9706 and Disassembly and Assembly Manual, RENR9705 for the proper procedures. Proper wire routing should be followed. If a stainless steel zip tie is removed a new stainless steel zip tie should be used.
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| Illustration 7 | g01794647 |
(7) CGI temperature sensor | |
- Flush the ARD fuel system. Refer to Special Instruction, REHS3848 for the correct procedure.
- Flash the engine with the latest software. The release date of the software must be November 2008 or a newer date.
- Perform a verification test of the air system and save the file.
Note: Refer to Troubleshooting Guide, RENR9343, "Air System Verification Test" that is located on the Service Information System for the pass or fail criteria.
- Perform a stationary regeneration. Check for any fuel leaks.
Record a data log of the regeneration. The sample rate of the regeneration should be 20 samples in a minute. Use a duration of at least one hour.
Record the following variables:
- ARD Flame Detect Temperature
- ARD Outlet Temperature
- DPF Inlet Temperature
- DPF Outlet Temperature
- ARD Pilot Fuel Pressure
- ARD Main Fuel Pressure
- ARD Fuel Control Percentage
- ARD Air Pressure Control Command Percentage
- ARD Secondary Mass Air Flow
- CGI Mass Air Flow to ECM
- DPF Differential Pressure
- Attach the data log and the results from the verification test of the air system to a new warranty report.
- Verify that the serial number of the DPF is recorded in the box for comments in the Warranty Report. Refer to Special Instruction, REHS3849 for the proper procedure on obtaining the serial number of the DPF.
- Place the "Driver Regeneration Quick Reference Card" in the truck cab.
Note: This Special Instruction should be performed only through the authorization of a service letter. Order the parts that are specified in the Service Letter in order to complete this Special Instruction.
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| Illustration 8 | g01860434 |