Cummins ISX11.9 CM2250 – Service Manual 011-041   Aftertreatment Diesel Particulate Filter

WARNING  During regeneration, exhaust gas temperature could reach 800°C [1500°F], and exhaust system surface temperature could exceed 700°C [1300°F], which is hot enough to ignite or melt common materials, and to burn the skin. The exhaust and exhaust components can remain hot after the vehicle has stopped moving. To avoid the risk of fire, property damage, burns or personal injury, allow the exhaust system to cool before beginning this procedure or repair and make sure that no combustible materials are located where they are likely to come in contact with hot exhaust or exhaust components.

CAUTION  The aftertreatment diesel oxidation catalyst elements contained in the aftertreatment system are made of brittle material. Do not drop or strike the side of the aftertreatment system as damage to the aftertreatment diesel oxidation catalyst element can result.

Due to the number of varying exhaust aftertreatment applications, this procedure contains generic information. Not all illustrations within this procedure will represent the applications being serviced.

The aftertreatment system is composed of three sections. These sections are:

1. Aftertreatment Diesel Oxidation Catalyst
2. Aftertreatment Diesel Particulate Filter
3. Outlet.

NOTE: Damage to the aftertreatment system due to mishandling, vehicle collision, and road debris is not covered by Cummins Inc. warranty.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Disconnect the vehicle batteries. Refer to the OEM service manual.
• Disconnect the aftertreatment diesel particulate filter differential pressure sensor tubes, if necessary. Refer to Procedure 011-047 in Section 11.
• Remove the aftertreatment exhaust gas temperature sensor from the bosses in the diesel oxidation catalyst. Refer to Procedure 019-449 in Section 19.
• Remove the aftertreatment junction connector from the aftertreatment diesel particulate filter differential pressure sensor mounting bracket. Refer to Procedure 011-046 in Section 11.
• Remove the aftertreatment diesel particulate filter differential pressure sensor mounting bracket. Refer to Procedure 011-046 in Section 11.

Mark the direction of the exhaust flow on the outside of the aftertreatment diesel praticulate filter to aid in installation.

Mark an orientation reference line across each of the v-band clamps, aftertreatment canister sections, and connection points to the tailpipe to align each piece of hardware to its original orientation during installation.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

CAUTION  The aftertreatment diesel oxidation catalyst elements contained in the aftertreatment system are made of brittle material. Do not drop or strike the side of the aftertreatment system as damage to the aftertreatment diesel oxidation catalyst element can result.

NOTE: If necessary, remove any additional mounting hardware to remove the aftertreatment diesel particulate filter from the vehicle.

Remove the V-band clamps from the inlet and outlet flanges of the aftertreatment diesel particulate filter.

Separate the flanges by approximately 25 mm [1 in] to allow removal over the gasket retainer rings.

Remove and discard the gaskets.

CAUTION  Do not use a grinder or abrasive air tool to remove residual gasket material, as this can damage the flange and cause the connection to leak. Do not use an open flame to burn off soot accumulation from the face of the aftertreatment diesel particulate filter. Do not scrape off soot accumulation from the face of the aftertreatment diesel particulate filter.

CAUTION  Do not use an open flame to burn off soot accumulation from the face of the aftertreatment diesel particulate filter.

CAUTION  Do not scrape off soot accumulation from the face of the aftertreatment diesel particulate filter.

NOTE: The aftertreatment diesel particulate filter relies on gas flow through the walls to collect soot. To accomplish gas flow through the walls of the filter, every other cell on the face of the filter is plugged with a ceramic material. Therefore it is not possible to see light straight through the holes in the aftertreatment diesel particulate filter.

Remove any residual gasket material from the flanges on the aftertreatment diesel particulate filter with a scraping tool.

Avoid dropping fragments of gasket material into the aftertreatment diesel particulate filter.

NOTE: It is not possible to inspect the outlet of the aftertreatment diesel oxidation catalyst and inlet of the aftertreatment diesel particulate filter on aftertreatment systems with a joined aftertreatment diesel oxidation catalyst – aftertreatment diesel particulate filter.

Refer to the Catalyst and Aftertreatment Particulate Filter Reuse Guidelines, Bulletin 4021600, to inspect the inlet and outlet faces of the aftertreatment diesel particulate filter for signs of damage. Replace the aftertreatment diesel particulate filter if damage is found.

If the aftertreatment diesel particulate filter has been removed for cleaning and is considered reusable according to the Catalyst and Aftertreatment Particulate Filter Reuse Guidelines, Bulletin 4021600, the filter can be cleaned using diesel particulate filter cleaner, Part Number 4918840 or 4919052, with adapter kit, Part Number 4919172, or other Cummins Inc. approved cleaning machines. Refer to the manufacturer’s service manual for appropriate cleaning procedures.

NOTE: If the aftertreatment diesel particulate filter was removed due to an active Fault Code 1981 or Fault Code 1922 and is contaminated with coolant, it must be replaced with a new aftertreatment diesel particulate filter.

Inspect the V-band clamps and mounting straps for signs of over extension. The band must not be bent or damaged.

Inspect the V-band clamps and mounting strap threads for damage.

Replace the V-band clamp or strap if damage is found.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

Install new gaskets on the inlet and outlet of the aftertreatment diesel particulate filter canister.

Loosely tighten the V-band clamps to allow rotation for final alignment of the differential pressure sensor tubes.

Use the orientation reference line drawn across each of the V-band clamps, aftertreatment canister sections, and connection points to the tailpipe, to align each piece of hardware to its original orientation.

Tighten the V-band clamps.

NOTE: The aftertreatment diesel particulate filter is not 100 percent efficient. Some accumulation of exhaust residue/soot is normal and does not indicate a malfunctioning aftertreatment diesel particulate filter.

A heavy buildup of exhaust residue/soot can indicate a malfunction of the aftertreatment diesel particulate filter.

If the aftertreatment diesel particulate filter is being replaced due to black smoke, and the exhaust stack is found to have heavy black soot accumulation, clean the last 152 to 254 mm [6 to 10 in] of the exhaust system outlet.

If the aftertreatment diesel particulate filter was replaced or cleaned due to Fault Code 1922, it will be necessary to reset the stored soot load in the engine’s ECM.

Advanced ECM Data

• Use INSITE™ electronic service tool to perform the Aftertreatment Maintenance Reset Procedure.
• Use INSITE™ electronic service tool or the in cab switch, if equipped, to perform a stationary regeneration. Refer to Procedure 014-013 in Section 14.
• In situations where Fault Code 1981 is active and Fault Codes 2639, 1921, and 1922 are not active, it is not necessary to perform a stationary regeneration after replacing the aftertreatment diesel particulate filter.
• In situations where Fault Code 1981 and/or 1922 are active and the aftertreatment diesel particulate filter was cleaned,a stationary regeneration must be performed after installing the filter on the vehicle.
• Aftertreatment diesel particulate filters that are replaced with new filters will require that the aftertreatment maintenance installation function in INSITE™ electronic service tool be reset.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Install the aftertreatment particulate filter differential pressure mounting bracket. Refer to Procedure 011-046 in Section 11.
• Install the aftertreatment junction connector from the aftertreatment diesel particulate filter differential pressure sensor mounting bracket. Refer to Procedure 011-046 in Section 11.
• Install the aftertreatment gas temperature sensor to the bosses in the diesel oxidation catalyst. Refer to Procedure 019-449 in Section 19.
• Connect the aftertreatment particulate filter differential pressure sensor tubes, if necessary. Refer to Procedure 011-047 in Section 11.
• Connect the vehicle batteries. Refer to the OEM service manual.
• Use INSITE™ electronic service tool to perform the Aftertreatment Maintenance Filter Installation procedure found under the Advanced ECM Data Section.
• Operate the vehicle on an engine dynamometer or perform a road test with the engine at rated load for a minimum of 5 minutes to make sure the aftertreatment system is performing properly. Refer to Procedure 014-005 in Section 14.
• Check for exhaust leaks.
• Check for fault codes.