PRODUCT SUPPORT PROGRAM FOR UPDATING THE CATERPILLAR REGENERATION SYSTEM ON CERTAIN C13 ON-HIGHWAY TRUCK ENGINES EQUIPPED WITH 12 VOLT AND CERTAIN 24 VOLT PURGE AIR PUMP AFTERTREATMENT REGENERATION DEVICES Caterpillar

PRODUCT SUPPORT PROGRAM FOR UPDATING THE CATERPILLAR REGENERATION SYSTEM ON CERTAIN C13 ON-HIGHWAY TRUCK ENGINES EQUIPPED WITH 12 VOLT AND CERTAIN 24 VOLT PURGE AIR PUMP AFTERTREATMENT REGENERATION DEVICES

Usage:

REBE4704-04

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15Dec2008

(Revised 29Jan2010)

U-641

A-531

D-545

O-584

TT-40

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR UPDATING THE CATERPILLAR REGENERATION SYSTEM ON CERTAIN C13 ON-HIGHWAY TRUCK ENGINES EQUIPPED WITH 12 VOLT AND CERTAIN 24 VOLT PURGE AIR PUMP AFTERTREATMENT REGENERATION DEVICES
7755 107P 1743 108M		PS42851

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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 "PS42851" 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 15Dec2008 (Revised 27Mar2009) Service Letter. Changes have been made to Service Claims Allowance.

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TERMINATION DATE

31Dec2010

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 possible engine derate. This service letter only applies to Model Year 07 On-Highway Truck engines that are equipped with a Purge Air Pump for the regeneration cleaning system.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C13	LEE00868-00869, 886, 1022, 1046-1059, 1064-1068, 1070-1071, 1079, 1083, 1085, 1087, 1114, 1122, 1124, 1127-1128, 1132-1135, 1155, 1158, 1161, 1163, 1165, 1169, 1173-1174, 1177-1180, 1182, 1188, 1194-1196, 1201-1202, 1204-1207, 1213, 1215, 1217, 1222, 1228, 1231, 1239-1241, 1253, 1255-1259, 1261, 1263, 1265-1267, 1269, 1279, 1292, 1299, 1347, 1407, 1427, 1471, 1483, 1498, 1503, 1548-1549, 1562, 1567, 1574-1576, 1595, 1604, 1606, 1609, 1612, 1616, 1623, 1640, 1643, 1654, 1661, 1668, 1702, 1706, 1708, 1717, 1720, 1723, 1730-1731, 1734, 1739, 1743, 1749, 1751, 1791-1792, 1808, 1816-1817, 1823, 1831, 1842, 1846-1847, 1856-1858, 1860, 1868, 1890-1892, 1919, 1928, 1941, 1947, 1949, 1954-1955, 1959, 1966, 1972, 1977, 1980, 1987, 1994, 1998, 2003, 2006, 2011-2013, 2018, 2030, 2035, 2039, 2041, 2044, 2050, 2062, 2069, 2087-2088, 2090, 2097-2100, 2111, 2113-2114, 2116-2117, 2120, 2125, 2128-2130, 2132, 2136, 2164, 2181, 2193, 2225, 2232, 2237, 2242, 2254, 2257, 2260, 2272, 2285-2286, 2288, 2306-2307, 2310, 2317, 2321, 2326, 2334, 2338, 2340, 2342, 2346-2347, 2351-2352, 2361, 2374, 2381, 2385, 2388, 2395, 2403-2404, 2407, 2419, 2429, 2435, 2480, 2490, 2562, 2582, 2630, 2632, 2634-2635, 2637, 2644, 2651-2652, 2657-2658, 2663, 2668-2671, 2676, 2678-2680, 2687-2689, 2694-2695, 2698, 2701-2702, 2704, 2706, 2711-2713, 2715, 2717, 2720, 2723, 2726-2727, 2729, 2735, 2737, 2739, 2742, 2747-2749, 2752, 2755-2756, 2763, 2766, 2772-2773, 2776, 2780, 2783, 2792, 2801, 2804, 2806, 2811, 2814-2815, 2822, 2829-2830, 2832-2833, 2835-2843, 2848-2852, 2854-2860, 2862, 2864, 2866, 2869-2879, 2881-2898, 2900-2904, 2906, 2908, 2910, 2912-2914, 2916, 2919-2920, 2923, 2925-2931, 2934, 2936, 2944, 2947, 2949, 2952, 2955-2956, 2966, 3008, 3017, 3028, 3039, 3056, 3063, 3066, 3068, 3072-3073, 3075-3076, 3083, 3088-3091, 3093-3095, 3107, 3111, 3118-3121, 3129-3130, 3132, 3138, 3152-3153, 3156, 3159, 3170, 3174, 3176, 3178, 3180, 3184, 3189, 3200, 3205, 3207, 3218, 3222, 3225, 3227, 3230, 3232, 3245, 3249-3250, 3252, 3257-3258, 3260, 3266, 3277, 3280, 3283, 3285-3289, 3300, 3306, 3310, 3313, 3319, 3321, 3331-3332, 3337-3339, 3345, 3352, 3354, 3356, 3359-3360, 3362, 3366, 3374, 3391, 3393, 3395-3396, 3405, 3417, 3426, 3432, 3436, 3441, 3444, 3453, 3458-3459, 3465, 3470, 3483, 3492-3493, 3495-3496, 3501, 3521, 3526, 3531, 3537, 3541, 3551, 3557, 3560, 3562, 3570, 3574, 3593, 3610, 3616, 3647, 3652, 3662, 3664, 3680, 3682, 3714, 3724, 3770, 3775, 3782, 3794, 3818, 3944, 3956, 3961, 3988, 4076, 4095-4096, 4101, 4126, 4131-4132, 4134, 4141, 4151, 4182, 4186, 4190-4191, 4194, 4200, 4203, 4207, 4212, 4216, 4240, 4248, 4251, 4259, 4264, 4293, 4309, 4320, 4338, 4344, 4346, 4354, 4363, 4368, 4381, 4408, 4488, 4494-4495, 4572, 4588, 4604, 4646, 4670, 4673, 4679, 4681, 4690, 4695, 4707, 4734, 4737, 4739, 4747, 4756, 4774, 4792, 4795, 4821, 4848, 4853, 4876, 4897, 4907, 4909, 4917, 4921, 4930, 4934, 4946, 4957, 4962, 4965, 5047, 5227, 5284, 5389, 5397, 5401, 5407, 5423, 5428, 5432, 5436, 5442, 5444, 5456, 5459, 5461, 5468, 5470, 5477, 5481, 5500, 5504, 5516, 5521, 5526, 5529, 5535, 5537, 5542, 5545-5546, 5560, 5622, 5664, 5747-5748, 5750, 5752, 5758, 5763, 5794-5795, 5801, 5807, 5810, 5812, 5814, 5825, 5830, 5835, 5843, 5848, 5852, 5855-5857, 5859, 5861, 5868-5869, 5871, 5877, 5887, 5905, 5907, 5914-5915, 5917-5921, 5923, 5929-5930, 5938, 5962, 5964, 6083, 6178, 6377, 6384, 6389, 6398, 6400, 6406, 6413, 6416, 6422, 6485-6486, 6500, 6505, 6520-6521, 6529, 6536, 6540, 6548, 6552, 6556, 6647, 6694, 6710, 6822, 6832, 6834, 6842, 6844, 6846, 6852, 6890, 6906, 6922, 6930, 6936, 6946-6948, 6951, 7023, 7038, 7041-7042, 7044, 7047-7049, 7051, 7054-7055, 7060, 7064, 7069-7071, 7079, 7082, 7086, 7091, 7097, 7112, 7126, 7150, 7161, 7212-7213, 7215-7216, 7236, 7242, 7254, 7258, 7262, 7277, 7280, 7285-7287, 7326, 7393, 7414, 7425, 7438, 7441, 7446, 7458, 7467, 7476, 7495, 7498, 7500, 7520, 7544, 7549, 7559, 7564, 7617, 7626-7627, 7655-7656, 7664-7665, 7671, 7679-7680, 7690, 7696, 7701-7703, 7708, 7714, 7719, 7728, 7732, 7772, 7780, 7835, 7854, 7867-7868, 7871, 7877, 7893, 7918, 7924, 7926, 7934-7935, 7938-7939, 7942, 7968, 8006, 8059, 8138, 8201, 8229, 8248, 8584, 8642, 8645, 8647, 8662, 8829, 8831, 8842, 8853, 8858, 8864, 8867, 8883, 8887, 8899, 8923-8925, 8954, 8956, 8960, 8966, 8980, 8983, 9000, 9006, 9013, 9018-9019, 9094-9095, 9100, 9104, 9118, 9144, 9158, 9179-9180, 9188, 9196, 9212, 9215, 9335, 9341, 9357, 9362-9363, 9374-9375, 9418

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*******Group 2*******

C13

LEE00705, 2940, 2942, 5373, 5376, 5385, 5398-5399, 5409-5410, 5413, 5421, 5437, 5446, 5452, 5460, 5883, 6195, 6573, 6604, 6748, 6863, 6869, 6961, 6963, 6965, 6976, 6989, 6997, 7029, 7240, 7485, 7584, 7725, 7765, 7775, 7778, 7782, 7789, 7804, 7814, 7895, 7921, 8131, 8166, 8171, 8505, 9800, 9988, 9990, 10353-10354, 10456, 10462-10463, 10496, 10522, 10534, 10536, 10539, 10781, 10790, 11308, 11311, 11628, 11726, 11731, 11738, 11744, 11855, 11861, 11870, 11902, 11906, 11913, 11915, 11922, 11957, 11962, 11981, 11993, 12046, 12054, 12891, 12910, 12937, 12941, 12943, 12951-12952, 12957, 13104, 13135, 14302, 14505, 14570, 14604, 14633

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	1J9671	SEAL-O-RING
6	3S2093	STRAP-CABLE
2	6V4248	BOLT
1	6V5230	BOLT
2	6V5839	WASHER-HARD
1	7H7055	CLIP
2	8T0639	BOLT-HEX HEAD
1	8T9405	BOLT-SOCKET HEAD
1	9S5518	PLUG
1	9S8003	PLUG-STOR
2	9X8267	WASHER
1	0908747	SPACER
3	1261768	SOCKET-CONNECTOR
2	1566175	CLIP-LADDER
2	2302599	BOLT-FLANGE HD
1	2568753	FILTER AS-FWS
1	2802698	BASE-FILTER
1	2890704	TUBE AS-FUEL
1	2893107	GASKET
2	2901993	STRAP-CABLE
1	2953099	PLUG-SPARK
2	2967780	GASKET
1	3120092	WIRE AS-HEATER
1	3121079	RELAY AS (12 Volt)
1	3147659	BRACKET
1	3150225	CLAMP-WIRE
1	3170642	WIRING KIT
1	3232205	CONNECTOR AS.
1	3232206	CONNECTOR AS.
1	3341387	SENSOR-TEMP
1	3341390	SENSOR-TEMP
1	3343103	VALVE GP-SOL
1	3343104	VALVE GP-SOL
1	3377326	SOFTWARE GP-ELEK
1	3377327	SOFTWARE GP-ELEK
1	3377328	SOFTWARE GP-ELEK
1	3377329	SOFTWARE GP-ELEK
1	3377330	SOFTWARE GP-ELEK
1	3377331	SOFTWARE GP-ELEK
1	3377332	SOFTWARE GP-ELEK
1	3377333	SOFTWARE GP-ELEK
1	3377334	SOFTWARE GP-ELEK
1	3377335	SOFTWARE GP-ELEK
1	3377336	SOFTWARE GP-ELEK
1	3377337	SOFTWARE GP-ELEK
1	3377338	SOFTWARE GP-ELEK
1	3377339	SOFTWARE GP-ELEK
1	3377340	SOFTWARE GP-ELEK
1	3377341	SOFTWARE GP-ELEK
1	3377343	SOFTWARE GP-ELEK
1	3377344	SOFTWARE GP-ELEK
1	3377345	SOFTWARE GP-ELEK
1	3377346	SOFTWARE GP-ELEK
1	3377347	SOFTWARE GP-ELEK
1	3377348	SOFTWARE GP-ELEK
1	3377349	SOFTWARE GP-ELEK
1	3377350	SOFTWARE GP-ELEK
1	3377351	SOFTWARE GP-ELEK
1	3377352	SOFTWARE GP-ELEK
1	3377353	SOFTWARE GP-ELEK
1	3377354	SOFTWARE GP-ELEK
1	3377355	SOFTWARE GP-ELEK
1	3389241	HEAD AS.-COMB. (12 Volt)
1	LEDT8906	Driver 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.
*****Group 2*****
1	1J9671	SEAL-O-RING
6	3S2093	STRAP-CABLE
2	6V4248	BOLT
1	6V5230	BOLT
2	6V5839	WASHER-HARD
1	7H7055	CLIP
2	8T0639	BOLT-HEX HEAD
1	8T9405	BOLT-SOCKET HEAD
1	9S5518	PLUG
1	9S8003	PLUG-STOR
2	9X8267	WASHER
1	0908747	SPACER
3	1261768	SOCKET-CONNECTOR
2	1566175	CLIP-LADDER
2	2302599	BOLT-FLANGE HD
1	2568753	FILTER AS-FWS
1	2802698	BASE-FILTER
1	2890704	TUBE AS-FUEL
1	2893107	GASKET
2	2901993	STRAP-CABLE
1	2953099	PLUG-SPARK
2	2967780	GASKET
1	3120092	WIRE AS-HEATER
1	3121080	RELAY AS (24 Volt)
1	3147659	BRACKET
1	3150225	CLAMP-WIRE
1	3170642	WIRING KIT
1	3232205	CONNECTOR AS.
1	3232206	CONNECTOR AS.
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	3377326	SOFTWARE GP-ELEK
1	3377327	SOFTWARE GP-ELEK
1	3377328	SOFTWARE GP-ELEK
1	3377329	SOFTWARE GP-ELEK
1	3377330	SOFTWARE GP-ELEK
1	3377331	SOFTWARE GP-ELEK
1	3377332	SOFTWARE GP-ELEK
1	3377333	SOFTWARE GP-ELEK
1	3377334	SOFTWARE GP-ELEK
1	3377335	SOFTWARE GP-ELEK
1	3377336	SOFTWARE GP-ELEK
1	3377337	SOFTWARE GP-ELEK
1	3377338	SOFTWARE GP-ELEK
1	3377339	SOFTWARE GP-ELEK
1	3377340	SOFTWARE GP-ELEK
1	3377341	SOFTWARE GP-ELEK
1	3377343	SOFTWARE GP-ELEK
1	3377344	SOFTWARE GP-ELEK
1	3377345	SOFTWARE GP-ELEK
1	3377346	SOFTWARE GP-ELEK
1	3377347	SOFTWARE GP-ELEK
1	3377348	SOFTWARE GP-ELEK
1	3377349	SOFTWARE GP-ELEK
1	3377350	SOFTWARE GP-ELEK
1	3377351	SOFTWARE GP-ELEK
1	3377352	SOFTWARE GP-ELEK
1	3377353	SOFTWARE GP-ELEK
1	3377354	SOFTWARE GP-ELEK
1	3377355	SOFTWARE GP-ELEK
1	LEDT8906	Driver 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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STEP 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.

STEP 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.

NOTE: 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.

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

NOTE: 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: DPF ASH Cleaning

It is recommended that the diesel particulate filter cleaning maintenance should be performed by 250,000 miles for the C13 and 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%
*****Group 1*****
0-500000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 8.5-hour job for Group 1
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 OEM CGI Flex line is replaced then it should be billed to your local OEM dealership as follows: Cat Dealer Performs CGI Repair. - Cat dealer purchases parts from Peterbilt / Kenworth dealer @ retail. - Cat dealer performs repair (no charge to customer). - Cat dealer files sublet invoice to Peterbilt / Kenworth dealer for parts (CAT will not increase part price to Peterbilt / Kenworth dealer) and labor reimbursement. Invoice includes: 1) 17 digit VIN 2) Repair Order # 3) Vehicle mileage 4) Part pricing 5) Labor pricing . Peterbilt / Kenworth dealer pays Cat dealer . Peterbilt / Kenworth dealer files warranty claim (normal sublet) to Peterbilt / Kenworth NOTE: Peterbilt / Kenworth guarantees payment to Cat for the repairs performed.

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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%
*****Group 2*****
0-500000 miles, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 8.5-hour job for Group 2
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 OEM CGI Flex line is replaced then it should be billed to your local OEM dealership as follows: Cat Dealer Performs CGI Repair. - Cat dealer purchases parts from Peterbilt / Kenworth dealer @ retail. - Cat dealer performs repair (no charge to customer). - Cat dealer files sublet invoice to Peterbilt / Kenworth dealer for parts (CAT will not increase part price to Peterbilt / Kenworth dealer) and labor reimbursement. Invoice includes: 1) 17 digit VIN 2) Repair Order # 3) Vehicle mileage 4) Part pricing 5) Labor pricing . Peterbilt / Kenworth dealer pays Cat dealer . Peterbilt / Kenworth dealer files warranty claim (normal sublet) to Peterbilt / Kenworth NOTE: Peterbilt / Kenworth guarantees payment to Cat for the repairs performed.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

1. Follow instructions outlined in REHS4801.

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.