PRODUCT SUPPORT PROGRAM FOR INSTALLING SOFTWARE AND PURGE AIR CHECK VALVE ON CERTAIN C7 AND C9 ENGINES Caterpillar


PRODUCT SUPPORT PROGRAM FOR INSTALLING SOFTWARE AND PURGE AIR CHECK VALVE ON CERTAIN C7 AND C9 ENGINES

Usage:

REBE4472-04

30Oct2008
(Revised 06Mar2009)


U-552
A-457
D-469
O-506
TT-35

 
Before/After
  
  

PRODUCT SUPPORT PROGRAM FOR INSTALLING SOFTWARE AND PURGE AIR CHECK VALVE ON CERTAIN C7 AND C9 ENGINES

7755 5067 1130 1920 7620 1071 1901 5510 108N 5479
PS42819
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 "PS42819" 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.

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.

 
NOTE:

This Revised Service Letter replaces the 30Oct2008 Service Letter. Changes have been made to Termination Date, Parts Needed, Action Required, and Service Claims Allowance.


TERMINATION DATE

31Oct2009

PROBLEM

The existing software needs updated along with the purge air check valve on certain C7 and C9 engines. Updates to the software include regeneration system robustness and improved diagnostics to aid in troubleshooting. The current purge air check valve can stick shut causing problems with the regeneration system and is being updated with a stainless steel version.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
C7  C7S00500, 514-515, 520-527, 531, 534, 536-537, 543, 548, 553, 557-1375, 1377-1379, 1382-1383, 1385, 1387-1396, 1398-1407, 1409-1459, 1461-1467, 1469-1474, 1479, 1481-1483, 1485, 1487-1494, 1496-1497, 1500-1508, 1511-1566, 1568-1592, 1594-1610, 1612-1615, 1617-1944, 1946-2223, 2228, 2239, 2243, 2252, 2261-2262, 2264-2266, 2274, 2276, 2279, 2283, 2285-2286, 2289-2290, 2293, 2296, 2301-2792, 2794-2796, 2799-2800, 2802, 2804-2806, 2808-2811, 2814-2816, 2819-2820, 2822, 2825, 2827-2828, 2830-2836, 2839-2841, 2843-2846, 2848, 2850-2851, 2853, 2856-2858, 2863, 2868, 2874-2939, 2941-2953, 2955-3755, 3760, 3767-3768, 3778, 3785, 3787, 3790, 3799-3800, 3805-3807, 3809, 3813, 3816, 3820, 3823, 3828-3829, 3836, 3841, 3848, 3856, 3864-3865, 3868-3894, 3896-3902, 3904-3912, 3917, 3922, 3925, 3927, 3929-3930, 3932-3933, 3935-3936, 3938, 3940-3941, 3943-3946, 3949, 3952-3955, 3958-3959, 3964-3969, 3971, 3973-3977, 3979, 3981-3982, 3985, 3988-3992, 4433-4995, 4999, 5001-5002, 5004-5005, 5007-5033, 5038, 5047, 5049-6167, 6169-6181, 6183-6184, 6186-6199, 6201-6204, 6206-6208, 6210-6212, 6215-6216, 6218-6226, 6228-6230, 6232-6250, 6252-6253, 6255-6263, 6265, 6268-6331, 6333-6335, 6337-6338, 6340-6343, 6345-6356, 6358-6381, 6386-6388, 6390-7450, 7480-8985, 8988-9098, 9100-9549, 9551-9552, 9554-9555
*******Group  2*******
C9  C9S00500-00507, 522-523, 527, 531, 534-661, 664, 666, 668, 673-738, 740-741, 746-754, 756-762, 771, 782-841, 849-850, 852, 854-896, 898-902, 907-1006, 1009, 1015, 1017-1021, 1028-1032, 1034-1205, 1209-1319, 1324, 1328-1377, 1380-1381, 1394-1507, 1509, 1511, 1515-1532, 1534-1615

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
1 3042700 VALVE-CHECK
1 3106027 KIT-LINES F INJ (As Required)
1 3342353 SOFTWARE GP-ELEK
1 3342354 SOFTWARE GP-ELEK
1 3342355 SOFTWARE GP-ELEK
1 3342356 SOFTWARE GP-ELEK
1 3342357 SOFTWARE GP-ELEK
1 3342358 SOFTWARE GP-ELEK
1 3342359 SOFTWARE GP-ELEK
1 3342360 SOFTWARE GP-ELEK
1 3342361 SOFTWARE GP-ELEK
1 3342362 SOFTWARE GP-ELEK
1 3342363 SOFTWARE GP-ELEK
1 3342364 SOFTWARE GP-ELEK
1 3342365 SOFTWARE GP-ELEK
1 3342366 SOFTWARE GP-ELEK
1 3342367 SOFTWARE GP-ELEK
1 3342368 SOFTWARE GP-ELEK
1 3342369 SOFTWARE GP-ELEK
1 3342370 SOFTWARE GP-ELEK
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 3042700 VALVE-CHECK
1 3106031 KIT-LINES F INJ (As Required)
1 3342371 SOFTWARE GP-ELEK
1 3342372 SOFTWARE GP-ELEK
1 3342373 SOFTWARE GP-ELEK
1 3342374 SOFTWARE GP-ELEK
1 3342375 SOFTWARE GP-ELEK
1 3342376 SOFTWARE GP-ELEK
1 3342377 SOFTWARE GP-ELEK
1 3342378 SOFTWARE GP-ELEK
1 3342379 SOFTWARE GP-ELEK
1 3342380 SOFTWARE GP-ELEK
1 3342381 SOFTWARE GP-ELEK
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

1. Record Diesel Particulate Filter (DPF) serial number in the comments box of warranty report. Refer to Special Instruction REHS3849 for correct location of DPF serial number.

2. Download warranty report from Engine Electronic Control Module (ECM).

3. Flash latest software for correct engine rating.

NOTE: Engines installed in General Motors Chassis will turn on the oil service interval light on the dash after software flash and will need reset if this parameter is used by the customer. Refer to General Motors Operation & Maintenance manual for procedure to reset oil service interval light.

4. Inspect for active/logged diagnostic fault codes. Troubleshoot all active fault codes found.

5. Run the "Fuel System Functional Test" in Caterpillar Electronic Technician.
a) Re-time fuel injection pump if timing codes 157-7 or 157-17 set. A new warranty report must be submitted to the system that documents one of the above fault codes were present.

NOTE: The high pressure fuel line from the pump to the common rail is a one time use line only and must be replaced if the pump is removed for retiming. Refer to REHS3842 for C7 and REHS3846 for C9.

6. Replace purge air check valve with part number 304-2700 stainless steel check valve. If check valve removed was plugged ensure purge lines are not blocked, clean as needed. Refer to Disassembly and Assembly RENR9707. Purge valve is located close to ARD cleaning port on most arrangements (Image1).
Image1

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-250000 miles,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 1.0-hour job for Group 1
Claim 1.0 hour for software flash, R&I purge check valve, Fuel
System Functional Test and inspection portions.

Additional time will be allowed if retiming of the fuel injection pump is necessary. Claim additional time as recommended below:

Fuel Pump(Retime)_______4.0

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-250000 miles,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 1.0-hour job for Group 2
Claim 1.0 hour for software flash, R&I purge check valve, Fuel
System Functional Test and inspection portions.

Additional time will be allowed if retiming of the fuel injection pump is necessary. Claim additional time as recommended below:

Fuel Pump(Retime)_______4.0



PARTS DISPOSITION

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

Caterpillar Information System:

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