Cummins ISX11.9 CM2250 – Service Manual 011-050   Aftertreatment System

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 the number of exhaust aftertreatment applications, this procedure has been written to be generic. Illustrations within this procedure will not represent all applications. The aftertreatment system is composed of seventeen main components.

Use the following procedure to view callouts of the aftertreatment system components. Refer to Procedure 100-002 in Section E.

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

WARNING  Coolant is toxic.  Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

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 first.

NOTE: Refer to the OEM service manual for aftertreatment system removal instructions. The OEM will designate whether aftertreatment system components are to be removed as individual components or as a complete system for service.

• Disconnect the batteries. Refer to the OEM service manual.
• Drain the engine coolant. Refer to Procedure 008-018 in Section 8.
• Disconnect the diesel exhaust fluid supply line from the aftertreatment diesel exhaust fluid dosing valve. Refer to Procedure 011-059 in Section 11.
• Disconnect the coolant lines from the aftertreatment diesel exhaust fluid dosing valve. Refer to Procedure 011-059 in Section 11.
• Disconnect the aftertreatment diesel particulate filter temperature sensor wiring harness connector. Refer to Procedure 019-462 in Section 19.
• Disconnect the aftertreatment SCR catalyst temperature sensor wiring harness connector. Refer to Procedure 019-464 in Section 19.
• Disconnect the aftertreatment SCR outlet NOx sensor wiring harness connector. Refer to Procedure 019-451 in Section 19.
• Mark the direction of the exhaust flow on the outside of the aftertreatment system components to aid in installation.
• Mark the location of the aftertreatment diesel particulate filter temperature sensor interface module.
• Mark the location of the aftertreatment SCR catalyst temperature sensor interface module.

NOTE: Use the following procedures to remove the aftertreatment system as a complete assembly.

Remove the V-band from the inlet of the aftertreatment system. Refer to Procedure 011-049 in Section 11.

Remove the clamp from the outlet of the aftertreatment system. Refer to Procedure 011-036 in Section 11.

Remove the straps or bolts securing the aftertreatment system to the vehicle chassis. Refer to the OEM service manual.

NOTE: Use the following procedures to remove the aftertreatment system by components.

Use this procedure to remove the aftertreatment diesel oxidation catalyst. Refer to Procedure 011-049 in Section 11.

Use this procedure to remove the aftertreatment diesel particulate filter. Refer to Procedure 011-041 in Section 11.

Use this procedure to remove the aftertreatment diesel particulate filter outlet section. Refer to Procedure 011-063 in Section 11.

Use this procedure to remove the aftertreatment decomposition tube and decomposition inlet and outlet elbows. Refer to Procedure 011-062 in Section 11.

Use this procedure to remove the aftertreatment SCR catalyst. Refer to Procedure 011-036 in Section 11.

NOTE: Use the following procedures to disassemble the aftertreatment system.

Use this procedure to disassemble the aftertreatment diesel oxidation catalyst. Refer to Procedure 011-049 in Section 11.

Use this procedure to disassemble the diesel particulate filter. Refer to Procedure 011-041 in Section 11.

Use this procedure to disassemble the aftertreatment diesel particulater filter outlet section. Refer to Procedure 011-074 in Section 11.

Use this procedure to disassemble the aftertreatment decomposition tube and decomposition inlet and outlet elbows. Refer to Procedure 011-062 in Section 11.

Inspect the diesel oxidation catalyst. Refer to Procedure 011-049 in Section 11.

Inspect the aftertreatment diesel particulate filter canister. Refer to Procedure 011-041 in Section 11.

Use the following procedure for aftertreatment diesel particulate filter cleaning instructions. Refer to Procedure 011-041 in Section 11.

Inspect the aftertreatment diesel particulate filter outlet. Refer to Procedure 011-074 in Section 11.

Inspect the aftertreatment decomposition tube and elbows. Refer to Procedure 011-062 in Section 11.

Inspect the aftertreatment diesel exhaust fluid dosing valve.Refer to Procedure 011-059 in Section 11.

Inspect the aftertreatment SCR catalyst. Refer to Procedure 011-036 in Section 11.

Inspect the exhaust gas temperature sensors. Refer to Procedure 019-449 in Section 19.

Inspect the differential pressure sensor. Refer to Procedure 019-443 in Section 19.

Inspect the differential pressure sensor tubes. Refer to Procedure 011-047 in Section 11.

Inspect the aftertreatment diesel particulate filter temperature sensor interface module. Refer to Procedure 019-462 in Section 19.

Inspect the aftertreatment SCR temperature sensor interface module. Refer to Procedure 019-464 in Section 19.

Inspect the aftertreatment diesel particulate filter temperature sensor wiring harness and connector. Refer to Procedure 019-462 in Section 19.

Inspect the aftertreatment SCR temperature sensor wiring harness and connector. Refer to Procedure 019-464 in Section 19.

Inspect the aftertreatment SCR outlet NOx sensor wiring harness connector. Refer to Procedure 019-451 in Section 19.

Inspect the exhaust clamps for leaks. Refer to Procedure 010-024 in Section 10.

NOTE: Use the following procedures to disassemble the aftertreatment system.

Assemble the aftertreatment decomposition tube and the decomposition inlet and outlet elbows. Refer to Procedure 011-062 in Section 11.

Assemble the aftertreatment diesel particulater filter outlet section. Refer to Procedure 011-074 in Section 11.

Assemble the diesel particulate filter. Refer to Procedure 011-041 in Section 11.

Assemble the aftertreatment diesel oxidation catalyst. Refer to Procedure 011-049 in Section 11.

NOTE: Use the following procedures to install the aftertreatment system by system.

Make sure the aftertreatment system is oriented so that the aftertreatment diesel particulate filter differential pressure sensor is installed in the same orientation noted during disassembly.

The aftertreatment system must be installed so that the aftertreatment diesel particulate filter differential pressure sensor tubes slope downward to drain condensation away from the differential pressure sensor.

Make sure the differential pressure sensor tubes are not making contact with each other or any other vehicle components prior to tightening the clamps.

Install the straps or bolts that secure the aftertreatment system to the vehicle chassis. Refer to the OEM service manual.

Install the V-band to the inlet of the aftertreatment system. Refer to Procedure 011-049 in Section 11.

Install the clamp to the outlet of the aftertreatment system. Refer to Procedure 011-036 in Section 11.

Install the aftertreatment diesel particulate filter temperature sensor interface module. Refer to Procedure 019-462 in Section 19.

Install the aftertreatment SCR temperature sensor interface module. Refer to Procedure 019-464 in Section 19.

Connect the aftertreatment diesel particulate filter differential pressure sensor wiring harness connector. Refer to Procedure 019-443 in Section 19.

Connect the aftertreatment diesel particulate filter temperature sensor wiring harness connector. Refer to Procedure 019-462 in Section 19.

Connect the aftertreatment SCR temperature sensor wiring harness connector. Refer to Procedure 019-464 in Section 19.

Connect the aftertreatment SCR outlet NOx sensor wiring harness connector. Refer to Procedure 019-451 in Section 19.

NOTE: Use the following procedures to install the aftertreatment system by components.

Use this procedure to install the aftertreatment diesel oxidation catalyst. Refer to Procedure 011-049 in Section 11.

Use this procedure to install the aftertreatment diesel particulate filter. Refer to Procedure 011-041 in Section 11.

Use this procedure to install the aftertreatment diesel particulate filter outlet section. Refer to Procedure 011-074 in Section 11.

Use this procedure to install the aftertreatment decomposition tube and the decomposition inlet and outlet elbows. Refer to Procedure 011-062 in Section 11.

Use this procedure to install the aftertreatment SCR catalyst. Refer to Procedure 011-036 in Section 11.

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 first.

• Connect the battery. Refer to the OEM service manual.
• Fill the cooling system. Refer to Procedure 008-018 in Section 8.
• Use INSITE™ electronic service tool to perform the Aftertreatment Maintenance Filter Installation procedure, found under the Advanced ECM Data Section.
• If the aftertreatment system was being serviced for an aftertreatment diesel particulate filter cleaning, use INSITE™ electronic service tool to clear related fault codes.