Cummins ISX11.9 CM2250 – Service Manual 011-049   Aftertreatment Diesel Oxidation Catalyst

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 people. The exhaust and exhaust components can remain hot after the vehicle has stopped moving. To avoid the risk of fire, property damage, burns or other serious 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 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 catalyst element can result.

Due to number of exhaust aftertreatment applications, this procedure is generic. Illustrations within this procedure will not represent all applications.

The exhaust aftertreatment 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, or road debris is not covered by Cummins Inc. warranty.

NOTE: In most applications, the aftertreatment system must be removed from the chassis as an assembly in order to service the aftertreatment diesel oxidation catalyst.

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 arching, remove the negative (-) battery cable first and attach the negative (-) batter cable last.

CAUTION  The catalyst can remain hot for a long time after the engine has stopped.

• Disconnect the batteries. Refer to the OEM service manual.
• Disconnect the aftertreatment exhaust gas temperature sensor number 1 electrical connector from the aftertreatment diesel particulate filter temperature sensor interface module. Refer to Procedure 019-449 in Section 19.
• Remove the aftertreatment system as an assembly from the chassis. Refer to Procedure 011-050 in Section 11.

NOTE: Mark the direction of the exhaust flow on the outside of the aftertreatment system to aid in installation.

Draw an orientation reference line across each of the V-band clamps, aftertreatment canister sections, and connection points to the tailpipe. This will aid in linking up sections and V-band clamps to their original orientation during installation.

Mark the direction of the exhaust flow on both the catalyst section and the aftertreatment diesel particulate filter section to aid in assembly.

WARNING  The component weighs 23 kg [50 lbs] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift the component.

CAUTION  The 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 catalyst element can result.

CAUTION  Do not use air tools to remove or install the nut on the v-band clamp. Use of these tools can seriously damage the threads or the bolt and cause the camp to not be reusable.

Remove the V-band clamps from the inlet and outlet of the catalyst.

Separate the component sections by approximately 13 mm [1/2 inch] to allow removal over the gasket retainer rings.

NOTE: Rolling or sliding the aftertreatment diesel oxidation catalyst can cause damage to the catalyst canister and flanges.

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.

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.

Inspect the aftertreatment inlet canisters for cracks or other damage.

Inspect the exhaust gas temperature sensor boss threads for damage.

If thread damage is found on the exhaust gas temperature sensor boss threads, a helicoil must be used for repair.

Remove any residual gasket material from the mating surfaces on the aftertreatment diesel particulate filter and aftertreatment diesel oxidation catalyst with a putty knife.

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

NOTE: If the aftertreatment diesel oxidation catalyst is being inspected due to progressive damage that introduced coolant, engine oil, or excessive fuel into the exhaust, inspect the tailpipe from the turbocharger outlet to the aftertreatment diesel oxidation catalyst.

If a trail of coolant can be seen exiting the turbocharger outlet the diesel oxidation catalyst can be recovered without removing it for inspection. Refer to Procedure 014-013 in Section 14.

If a trail of coolant can be seen exiting the turbocharger outlet, the tailpipe between the turbocharger outlet and aftertreatment diesel oxidation catalyst must be cleaned. Refer to the OEM service manual.

If a trail of engine oil, or fuel can be seen exiting the turbocharger outlet, the tailpipe between the turbocharger outlet and aftertreatment diesel oxidation catalyst must be cleaned. Refer to the OEM service manual.

If a trail of liquid, engine oil, or fuel can be seen from the turbocharger outlet to the aftertreatment diesel oxidation catalyst, the aftertreatment diesel oxidation catalyst must be inspected.

WARNING  The material captured in a diesel particulate filter may contain elevated concentrations of metals, primarily zinc and molybdenum, and possibly polynuclear aromatic hydrocarbons that may be regulated. These materials must be characterized, handled, and disposed of according to applicable local regulations. In addition, due to the presence of the above-listed chemicals and other potentially toxic components such as oxides of calcium, zinc, phosphorous, silicone, sulfur, and iron, exhaust filter maintenance must be completed only by appropriately trained personnel.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Inspect the outlet of the aftertreatment diesel oxidation catalyst for loose debris and soot. Use a rag to wipe off any soot. Use a HEPA vacuum to remove any remaining loose debris.

NOTE: Use a vacuum bag, such as a drywall dust bag, to capture the soot that is removed.

Attach the Cummins® aftertreatment diesel particulate filter cleaning machine cone, Part Number 4918850, to the inlet and outlet sides of the aftertreatment diesel oxidation catalyst with the adapter rings, Part Number 4918847 and 4918848. Evenly space 4 to 5 spring clamps or C-clamps around the circumference of the aftertreatment diesel oxidation catalyst to seal the cone and adapter ring to the aftertreatment diesel oxidation catalyst.

Service tool kit, Part Number 4918877, contains the cones and rings needed for this procedure.

If the aftertreatment diesel oxidation catalyst is integrated into the aftertreatment inlet, use one cone only, and attach it to the outlet side of the unit.

Use tape to seal any open ports.

Obtain a 76 mm to 51 mm [3 in to 2 in] rubber pipe reducer from a local supplier. If the aftertreatment diesel oxidation catalyst is integrated into the aftertreatment inlet, obtain a 102 mm to 51 mm [4 in to 2 in] rubber pipe reducer.

Attach the vacuum hose to the 51 mm [2 in] end of the pipe reducer. Attach the larger end of the reducer to the aftertreatment diesel particulate filter cleaning machine cone attached to the inlet side of the diesel oxidation catalyst.

CAUTION  Use only a rubber-tipped air gun near the catalyst material. Damage will result if a metal air gun strikes the catalyst material.

Adjust the air supply for a rubber-tipped air gun to 621 kPa [90 psi].

Switch on the vacuum. The vacuum and service tool kit is properly installed if the air flow through the aftertreatment diesel oxidation catalyst is opposite to the exhaust flow. The exhaust flow is indicated by an arrow on the canister of the diesel oxidation catalyst.

Blow compressed air across the outlet face of the aftertreatment diesel oxidation catalyst for approximately 5 minutes.

After 5 minutes, remove the aftertreatment diesel particulate filter cleaning machine cone and continue blowing compressed air into the outlet of the diesel oxidation catalyst for an additional 10 to 15 minutes. Maintain a 13 mm to 25 mm [1/2 in to 1 in] distance between the air gun and diesel oxidation catalyst face. Use a sweeping motion across the entire face of the diesel oxidation catalyst and attempt to blow air through every cell.

Allow the vacuum to operate for 1 minute after blowing out the aftertreatment diesel oxidation catalyst. After the vacuum is switched off, disconnect the cleaning machine cone and inspect the cells of the diesel oxidation catalyst.

Inspect the cells of the diesel oxidation catalyst by looking through each cell. Shine a light on the opposite side of the diesel oxidation catalyst to aid inspection. If the cell is clear of soot, it is possible to see straight through the diesel oxidation catalyst.

If the aftertreatment diesel oxidation catalyst has a side inlet configuration, insert a shop light and an inspection mirror into the inlet of the diesel oxidation catalyst to aid inspection.

Upon inspection, if less than 50 percent of the cells are blocked (1) the aftertreatment diesel oxidation catalyst can be reused. If more than 50 percent of the cells remain blocked (2), repeat the cleaning procedure.

NOTE: It should not take more than two attempts to clean the face of the diesel oxidation catalyst.

If the catalyst section has shifted, moved, or is loose inside the canister, replace the catalyst section.

Inspect the inlet and outlet faces of the aftertreatment diesel oxidation catalyst for signs of damage. Refer to Additional Aftertreatment Diesel Oxidation Catalyst and Aftertreatment Diesel Particulate Filter Reuse Guidelines, Bulletin 4021600.

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

Replace the V-band clamps or catalyst mounting straps if damage is found.

Install the exhaust gas temperature sensor into the catalyst section, if necessary. Refer to Procedure 019-449 in Section 19.

NOTE: If the engine had turbocharger damage or any other damage that introduced foreign objects into the exhaust system, the aftertreatment exhaust gas temperature 1 sensor must be inspected for damage. If the sensor is broken or damaged it must be replaced.

WARNING  The component weighs 23 kg [50 lbs] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift the component.

Install new gaskets on the inlet and outlet of the aftertreatment diesel oxidation catalyst.

Loosely tighten the V-band clamps to allow rotation for final alignment.

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