ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 011-036   Aftertreatment Selective Catalytic Reduction (SCR) Catalyst

WARNING  The exhaust and exhaust components can remain hot after the vehicle stopped moving. To reduce 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.

• Disconnect the exhaust gas temperature sensor, if necessary. Refer to Procedure 011-037 in Section 11.
• Disconnect the exhaust gas pressure sensor, if necessary. Refer to Procedure 011-039 in Section 11.

WARNING  The exhaust and exhaust components can remain hot after the vehicle stopped moving. To reduce 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.

• Disconnect the exhaust gas temperature sensor, if necessary. Refer to Procedure 011-037 in Section 11.

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.

Remove the exhaust gas filter assembly from the vehicle. Refer to the vehicle manufacturer’s service manual.

NOTE: It may be possible to remove the V-band clamps and separate the exhaust gas filter as listed in the Disassemble step with the exhaust gas filter assembly still installed in the vehicle.

Disconnect the OEM exhaust connections. 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.

Lower the exhaust catalyst from the underside of the vehicle/application.

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

Remove the V-band clamps holding the sections together. Separate the mating sections by approximately 13 mm [0.5 in] to allow removal over the gasket retainer rings.

Discard the gaskets.

Check the inlet and outlet sections for any cracks or damage. Replace if necessary.

Check the inlet and outlet face of the catalyst section for:

Fuel, oil, or coolant buildup. A fluid soaked exhaust gas catalyst will have a glossy sheen and a strong fuel or oil odor. Replace the exhaust gas filter catalyst section if any damage is found.

Cracks or gouges deeper than 4 mm [0.156 in]. Replace the exhaust gas filter catalyst section if any damage is found.

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

Inspect the exhaust gas filter for any cracks or gouges. Replace the exhaust gas filter section if any damage is found.

Inspect the outlet face of the exhaust gas filter for any black areas. Replace the exhaust gas filter section if there are more than 20 damaged cells.

Return the exhaust gas filter section to the nearest Cummins® Authorized Repair Location for cleaning.

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

Inspect the V-band clamp threads for damage.

Replace the V-band clamp if damage is found.

WARNING  The catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State of California to cause cancer. Always wear protective gloves, dust mask and eye protection when handling the catalyst assembly. Do not get the catalyst material in your eyes. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. Avoid prolonged contact with skin. In case of contact, immediately wash skin with soap and water. Refer to the Materials Safety Data Sheet (MSDS) for additional information.

Remove any loose paint, corrosion, from exhaust catalyst sealing surfaces with a wire brush.

Excessive fuel or oil buildup will damage the exhaust catalyst. If oil from an upstream engine failure is visible in the exhaust plumbing, replace the catalyst. If evidence of fuel in the exhaust stream is apparent and Fault Code 1687 occurs, replace the catalyst.

NOTE: Prior to the replacement of the exhaust catalyst, the source of the upstream failure must be identified and corrected. If the exhaust catalyst is replaced due to progressive damage from engine oil or fuel contamination, clean the tailpipe from the turbocharger outlet to the exhaust catalyst.

Inspect exhaust catalyst for:

• Loose paint
• Excess Corrosion
• Damage to the body of exhaust catalyst, i.e. splits or cracks to the body of the exhaust catalyst or connecting pipe work.

Inspect exhaust catalyst for signs of catalyst solution leaks.

Check/inspect all fittings and supports brackets before reuse.

Assemble the sections of the exhaust gas filter. Use the V-band clamps and new gaskets. Make sure marks on the exhaust side of the catalyst and filter sections are aligned with the outlet.

Tighten the V-band clamp.

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 the exhaust gas filter assembly into the vehicle. Refer to the OEM service manual.

NOTE: Check the correct catalyst part number is selected.

The exhaust catalyst is marked with “INLET” for assembly, (INLET to engine).

Lift catalyst into position.

Connect OEM holding clamps.

Connect each end of exhaust catalyst to the vehicle exhaust pipe work.

Use INSITE™ electronic service tool to initiate a aftertreatment SCR catalyst efficiency test.

• Connect the exhaust gas temperature sensor, if necessary. Refer to Procedure 011-037 in Section 11.
• Connect the exhaust gas pressure sensor, if necessary. Refer to Procedure 011-039 in Section 11.
• Operate the vehicle and check for leaks.

WARNING  The catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State of California to cause cancer. In the event the catalyst is being replaced, dispose of in accordance with local regulations. Do not cut open the exhaust catalyst assembly.

• Connect the exhaust gas temperature sensor, if necessary. Refer to Procedure 011-037 in Section 11.
• Operate the vehicle and check for leaks.