Centinel System – Repair Manual – 014-013   Aftertreatment Testing

General Information

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The Snap-Acceleration Test is used to check the aftertreatment diesel particulate filter for cracks or other progressive damage, without removing the filter system. It is used to test the functionality of the aftertreatment diesel particulate filter.

The INSITE™ electronic service tool Aftertreatment Diesel Particulate Filter Stationary Regeneration Test is used to:

  • Regenerate an aftertreatment diesel particulate filter
  • Recover the aftertreatment diesel oxidation catalyst and aftertreatment diesel particulate filter after coolant contamination
  • Check the aftertreatment diesel oxidation catalyst efficiency
  • Check for the correct installation of the aftertreatment temperature sensors
  • Reset the stored soot load in the engine ECM
  • Check the aftertreatment fuel injector, shutoff valve, and drive train functionality.

Check for active fault codes prior to performing either of these procedures. If any active fault codes are present, follow the appropriate fault code troubleshooting tree.

 
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The INSITE™ electronic service tool Aftertreatment Diesel Particulate Filter Stationary Regeneration Test can be used to regain functionality of the Aftertreatment Diesel Oxidation Catalyst (DOC) and Aftertreatment Diesel Particulate Filter (DPF) after either, or both, have been exposed to coolant.

NOTE: If the DOC and DPF are suspected of having coolant contamination, they do not need to be removed and inspected. Consult the Preparatory Steps section of this procedure for further details.

The temperatures that are achieved during the Regeneration are high enough to evaporate the coolant out of both components and return both components to normal operating specifications.

NOTE: If these components are suspected of having coolant contamination, do not perform the snap acceleration test before performing the regeneration.

 
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This section outlines the Exhaust System Outlet Inspection.

Inspection of the exhaust system outlet can reveal the condition of the aftertreatment diesel particulate filter. The exhaust system outlet should appear clean with little to no exhaust residue/soot buildup.

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.

To determine if the exhaust residue/soot accumulation on the exhaust system outlet is the result of a malfunctioning aftertreatment diesel particulate filter, perform one of the following:

  1. Snap Acceleration Test as outlined in this procedure.
  2. Clean the last 152 to 254 mm [6 to 10 in] of the exhaust system outlet. Operate the vehicle for one shift or trip and inspect the exhaust system outlet for exhaust residue/soot accumulation.
  3. Inspect the aftertreatment diesel particulate filter.
    1. For ISM engines, use the following procedure. Refer to Procedure 011-041 in Section 11.
    2. For ISX engines, use the following procedure. Refer to Procedure 011-041 in Section 11.
    3. For ISX11.9 engines, use the following procedure. Refer to Procedure 011-041 in Section 11.
    4. For ISX15 engines, use the following procedure. Refer to Procedure 011-041 in Section 11.
 
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Snap Acceleration Test

  • The vehicle transmission must be in neutral.
  • The vehicle parking brake must be applied.

Start and idle the engine.

Rapidly depress the accelerator pedal from 0 percent to 100 percent. This can be performed multiple times, if necessary.

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During this test, visually check for black smoke exiting the exhaust stack, as the engine is accelerated from low idle to high idle

NOTE: In some applications, a snap acceleration test may not provide the conditions necessary to reveal a malfunctioning aftertreatment diesel particulate filter. If there is a heavy buildup of exhaust residue/soot on the exhaust system outlet and a snap acceleration does not reveal a condition outlined in the following steps, it can be necessary to perform:

Refer to the Catalyst and Aftertreatment Particulate Filter Reuse Guidelines, Bulletin 4021600, for pass or fail guidelines.

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If gray smoke or faint black smoke is present, refer to the Catalyst and Aftertreatment Particulate Filter Reuse Guidelines, Bulletin 4021600, for pass or fail guidelines.

White smoke during the snap-acceleration test does not indicate a failure. No repair is necessary.

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Preparatory Steps

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 WARNING 

During regeneration, exhaust gas temperature could reach 800°C [1500°F] and exhaust system surface temperature can exceed 700°C [1300°F], which is hot enough to ignite or melt common materials, and cause severe burn injuries. The exhaust and exhaust components can remain hot after the vehicle 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.

To perform a stationary regeneration, connect INSITE™ electronic service tool and check for active fault codes. If any fault codes are present other than Fault Codes 2639 or 1921, go to Section TF for any fault code troubleshooting before proceeding. Do not perform a stationary regeneration with active fault codes other than Fault Codes 2639 or 1921, unless guided to do so by the fault code troubleshooting.

NOTE: If the stationary regeneration is being performed to recover either the DOC, the DPF, or both after coolant contamination, the DOC does not need to be removed or inspected unless there are active fault codes that require inspection as part of the fault code troubleshooting steps.

NOTEUnless there are complaints of black smoke during operation and the exhaust stack is black, the DPF does not need to be removed or inspected during this process.

Before performing a stationary regeneration, follow the steps listed below:

  1. Select an appropriate location to park the vehicle.
    1. On a surface that will not burn or melt under high temperatures (such as clean concrete or gravel, not grass or asphalt)
    2. Away from anything that can burn, melt, or explode
  • Nothing within 0.6 m [2 ft] of the exhaust outlet
  • Nothing that can burn, melt, or explode within 1.5 m [5 ft] (such as gasoline, wood, paper, plastics, fabric, compressed gas containers, hydraulic lines)
  • No gas or vapors nearby that could burn, explode, or contribute to a fire (such as LP gas, gasoline vapors, oxygen, nitrous oxide).
  • Park the truck securely.
    1. Set the parking brake.
    2. Place transmission in Park, if provided; otherwise in Neutral.
    3. Set wheel chocks at the front and rear of at least one tire.
  • Set up a safe exhaust area.
    1. If bystanders might enter the area, set up barriers to keep people at least 1.5 m [5 ft] from the exhaust outlet during regeneration.
    2. When indoors, attach an exhaust discharge pipe rated for at least 800°C [1500°F]
    3. Keep a fire extinguisher nearby.
  • Check exhaust system surfaces.
    1. Confirm that nothing is on or near the exhaust system surfaces (such as tools, rags, grease, or debris).
  • Prepare for engine speed changes during regeneration.
    1. Do not operate any PTO-powered devices. Disconnect these devices before starting regeneration.
    2. Stay clear of the engine compartment.
  • Begin the stationary regeneration. This can be performed in two ways:
    1. Vehicles equipped with a stationary regeneration switch in the cab must also have the stationary regeneration switch parameter enabled in the ECM. The stationary regeneration switch can be a stand-alone switch, or can be combined with a diagnostic switch, at the choice of the vehicle manufacturer.
    2. The INSITE™ electronic service tool can be used to perform regeneration by starting the Aftertreatment Diesel Particulate Filter Regeneration Test.
    3. In either case, the engine will create enough heat to regenerate the aftertreatment diesel particulate filter. Engine speed will increase and the turbocharger can whistle loudly during the regeneration process. Once the aftertreatment diesel particulate filter is regenerated, the engine will automatically return to normal idle speed.
  • Monitor the area.
    1. Make sure that the vehicle and surrounding area are monitored during regeneration. If any unsafe condition occurs, shut off the engine immediately.

    To stop a stationary regeneration, engage the clutch, brake, or throttle pedal; or turn off the engine.

    Once regeneration is complete, exhaust gas and exhaust surface temperatures will remain elevated for 3 to 5 minutes.

     
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    Setup

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    Start and idle the engine.

    Prior to the Aftertreatment Diesel Particulate Filter Regeneration Test, inspect the exhaust piping for leaks, cracks, and loose connections.

    Tighten the exhaust clamps if necessary.

    Consult the OEM specifications for the correct torque value.

    Any leaks in the exhaust system will cause the Aftertreatment Diesel Particulate Filter Regeneration Test to be less efficient in reducing the soot load of the filter.

     
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    Test

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    The Aftertreatment Diesel Particulate Filter Regeneration Test can be found under the ECM Diagnostic Test menu in the INSITE™ electronic service tool.

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    If INSITE™ electronic service tool is not available, some vehicles can be equipped with a stationary regeneration switch in the cab. The switch can be a stand-alone switch or can be combined with the diagnostic switch. Check with the OEM for the location and availability of the switch.

    NOTE: In order for the stationary regeneration switch to function, the stationary regeneration switch must be enabled in the ECM.

    Unlike the Aftertreatment Diesel Particulate Filter Regeneration Test with the INSITE™ electronic service tool, this switch will only start a stationary regeneration if the soot load of the filter is high enough. This is indicated by the aftertreatment lamp being illuminated or flashing.

    NOTE: A stationary regeneration can not be initiated through the use of the cab switch if regeneration inhibit is enabled. INSITE™ electronic service tool must then be used to initiate the stationary regeneration.

     
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    NOTE: If the Aftertreatment Diesel Particulate Filter Regeneration Test will not initiate, use the Stationary Regeneration – Will Not Start troubleshooting symptom tree.

    When the test is started, the engine idle speed will be raised automatically to the required level. Expected engine speed can reach between 1000 and 1500 rpm.

    The engine will then, through the engine controls, operate in a manner to build exhaust heat. The turbocharger can emit a slight “whining” noise during the test. This is normal.

    The Aftertreatment Diesel Particulate Filter Regeneration can take up to two and one half hours to complete, depending on the soot loading of the filter as well as conditions of the environment, such as but not limited to the temperature and humidity.

    Once the Aftertreatment Diesel Particulate Filter Regeneration Test is complete, the engine will automatically return to normal idle speed.

     
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    During the Aftertreatment Diesel Particulate Filter Regeneration Test, the following items will be monitored:

    • Aftertreatment Injector Status – Informs the user when fuel is being injected, in small quantity, into the exhaust system upstream of the diesel oxidation catalyst
    • Aftertreatment Diesel Particulate Filter outlet temperature
    • Aftertreatment Diesel Particulate Filter inlet temperature
    • Aftertreatment Diesel Oxidation Catalyst inlet temperature
    • Aftertreatment Diesel Particulate Filter Soot Load – Informs the user of the current soot load of the filter:
      • Normal – No regeneration is necessary
      • Above Normal; Least Severe Level – A stationary regeneration can be performed
      • Above Normal; Moderately Severe Level – A stationary regeneration can be performed
      • Above Normal; Most Severe Level – A stationary regeneration must not be performed unless the filter was cleaned or a new filter has been installed and the troubleshooting steps indicate to perform.
     
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     CAUTION 

    During the stationary regeneration, the exhaust gas temperature can reach 800°C [1500°F] and the surface temperature can exceed 700°C [1300°F].

    The stationary regeneration can take up to 2-1/2 hours to complete, depending on the soot loading of the filter. At any time the stationary regeneration can be aborted by clicking on the “Stop” button in the INSITE™ electronic service tool.

    The stationary regeneration will be aborted if:

    • A fault becomes active
    • The accelerator is depressed
    • The clutch pedal is depressed
    • The brake pedal is depressed
    • The transmission is put into gear.

    NOTE: If a stationary regeneration can not be initiated or is aborted, and the engine has a low power complaint, use the following procedures.

    Pass or Fail Criteria

    • Pass: Aftertreatment Testing Procedure 014-013 in Section 14 has passed, if there is no visible black smoke and the stationary regeneration completes with no aftertreatment fault codes being generated.
    • Fail: Aftertreatment Testing Procedure 014-013 in Section 14 has failed, if there is visible black smoke and/or aftertreatment fault codes are generated. Repair the cause of the black smoke and/or correct the fault codes.
     
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    Finishing Steps

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    Allow the engine and exhaust system to cool down. Temperatures can maintain an elevated state for several minutes.

    Check to make sure the diesel particulate filter lamp is not illuminated.

    NOTE: If the diesel particulate filter lamp is illuminated and Fault Code 2639 or 1921 are still active, a second regeneration will be needed. If the fault is still active after a second regeneration, the filter needs to be cleaned of ash or soot.

    Check for any active fault codes. If active fault codes are present, use Section TF for fault code troubleshooting.

    Use INSITE™ electronic service tool to clear all inactive fault codes.

     
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    Last Modified:  04-Aug-2010