The problems with the regen systems are nothing new. We had problems starting with the Columbia. They aren't unique to one power plant either. They've all had problems since '07. Detroit, Caterpillar, it doesn't matter. There are certain problems that cannot be avoided. However knowing your truck and paying close attention to it can help.
The problem is compounded by running these power units in the city. In town the unit never stays at speed long enough to do a regen automatically.
I haven't turned a wrench in over a year, but you do get warning notifications from the lights and have some time to run a regen. Too many guys see these lights and ignore them until it is too late. Check the manual because I can't recall the series of notifications for the different power plants. They are basically the same. Also variations on the notifications are slight. In my opinion they should have designated a separate light to say "Hey driver, you got about such and such time to run a regen".
Out of curiosity, does Con-Way have dedicated City trucks, or does the fleet rotate? I know everyone hates sharing trucks, but I always thought it would be good to have units rotating between line haul and city. From my experience this would likely help alleviate some of the reoccurring problems.
And it is common for these systems to go to the dealer for repair. There are tools/machines needed which are required that are very expensive. Not to mention the fact that the trucks are brand new and in warranty. Still it always pissed me off when we had to send ours out. I wanted to learn more about the regen systems. >:(
I had some pictures of a truck that a guy parked near some bushes to run a regen. He then went inside for a bite to eat. When he came back all he found was melted fiberglass and aluminum. ;D I'll have to see if I still have them. Don't park near plant life if you have to regen.