Cummins ISX11.9 CM2250 – Service Manual 011-074   Aftertreatment Outlet

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 the number of various exhaust aftertreatment applications, this procedure has been written to be common. Illustrations within this procedure will not represent all applications.

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

1. Aftertreatment diesel oxidation catalyst
2. Aftertreatment diesel particulate filter
3. Outlet.

NOTE: The diesel oxidation catalyst is integrated into the inlet of the exhaust aftertreatment system. Use the following procedure for the aftertreatment inlet service guidelines. Refer to Procedure 011-049 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 last.

CAUTION  The aftertreatment diesel particulate filter differential pressure sensor will not operate properly if the differential pressure sensor tubes are not connected to the correct port. Mark the differential pressure sensor tube connection locations before disconnecting.

• Disconnect the batteries. Refer to the OEM service manual.
• Mark the direction of exhaust flow to aid in assembly.
• Draw an orientation reference line across each of the V-band clamps, aftertreatment canister sections, and connection points. This will aid in returning the sections and the V-band clamps to their original orientation during installation.
• Remove the mounting straps or bolts from the inlet, if necessary. Refer to the OEM service manual.
• Remove the mounting straps or bolts from the outlet, if necessary. Refer to the OEM service manual.

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 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.

Support the aftertreatment diesel oxidation catalyst and aftertreatment diesel particulate filter to avoid applying a cantilevered load on the V-band joints.

Remove the V-band clamp used to connect the aftertreatment system to the aftertreatment decomposition tube.

Remove the V-band clamp connecting the outlet to the aftertreatment diesel particulate filter.

Remove and discard the gaskets.

Inspect the aftertreatment diesel particulate filter outlet canister for cracks or other damage

Flange Preparation – Use a putty knife to remove any residual gasket material from the flanges on the aftertreatment diesel particulate filter.

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

Do not use compressed air to remove fragments of gasket material that have fallen into the filter during gasket removal.

Do not grind on the flange surface. Grinding on the surface can damage the flange and cause the connection to leak.

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 clamp and mounting strap threads for damage.

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

Apply a coat of anti-seize compound on the threads of the V-band clamps.

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

Install a new gasket between the V-band clamp joints that have been disconnected.

Install and tighten the V-band clamp used to secure the outlet of the aftertreatment to the aftertreatment decomposition tube.

Install and tighten the V-band clamp used to connect the diesel particulate filter to the catalyst, if necessary.

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 mounting straps or bolts to the inlet, if necessary. Refer to the OEM service manual.
• Install the mounting straps or bolts to the outlet, if necessary. Refer to the OEM service manual.
• Connect the vehicle batteries. Refer to the OEM service manual.
• Operate the vehicle on a 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.