Service Bulletin Number Date

4021600 07-JUL-2009

Service
Bulletin

Aftertreatment Diesel Oxidation Catalyst and

Aftertreatment Diesel Particulate Filter Reuse
Guidelines

This Service Bulletin provides reuse guidelines for the aftertreatment diesel oxidation
catalyst and aftertreatment diesel particulate filter, in conjunction with the information
provided in the ISB CM2100 and CM2150 Service Manual, Bulletin 4021578, the ISC
and ISL CM2150 Service Manual, Bulletin 4021569, the Signature™, ISX, and QSX15
Service Manual, Bulletin 3666239, and the ISM, ISMe, and QSM11 Service Manual,
Bulletin 3666322.

Use the following procedures in the Signature™, ISX, and QSX15 Service Manual,
Bulletin 3666239, or the ISM, ISMe, and QSM11 Service Manual, Bulletin 3666322 for
removal and installation information for ISX and ISM engines.

• Refer to Procedure 011-041 in Section 11.

• Refer to Procedure 011-049 in Section 11.

Use the following procedures in the ISC and ISL CM2150 Service Manual, Bulletin
4021569, for removal and installation information for the ISC and ISL engines, refer to
the following procedures.

• Refer to Procedure 011-041 in Section 11.

• Refer to Procedure 011-049 in Section 11.

Use the following procedures in the ISB CM2100 and CM2150 Service Manual, Bulletin
4021578, for removal and installation information for the ISB engines.

• Refer to Procedure 011-041 in Section 11.

• Refer to Procedure 011-049 in Section 11.
The aftertreatment diesel oxidation catalyst and the aftertreatment diesel particulate
filter housing must be free of dents.

Mounting flanges must be free of dents, cracks, or gouges to seal properly with
gaskets.

Replace any oil or fuel soaked aftertreatment diesel oxidation catalyst or diesel
particulate filter.

NOTE: Coolant or water intrusion into the diesel oxidation catalyst and/or diesel
particulate filter is acceptable and the component(s) can be recovered. After
correcting the cause of the coolant or water leak and troubleshooting any active
fault codes, use the following procedure for detailed instructions to recover the
diesel oxidation catalyst and/or diesel particulate filter. Refer to Procedure 014-
013.

The following are aftertreatment particulate filter inspection techniques for cracking and
melting.

An internally cracked or melted aftertreatment diesel particulate filter can show damage
in three ways.

1. The filter outlet channels can have soot stains. These stains will typically not
show on the face of the filter, but can be seen in the non-plugged channel walls
of the outlet. See “Aftertreatment Diesel Particulate Filter (DPF) Outlet - Soot
Stains” below for an example illustration of this. Other staining or marks that are
on the face of the filter are not indications of a cracked or melted filter. See
“Aftertreatment Diesel Particulate Filter (DPF) Outlet - New” below for an
example illustration of this.
2. The tail pipe outlet has excessive soot buildup. Normal operation of the vehicle
over its life will cause a very small amount of soot staining to appear in outlet of
the exhaust stack, but excessive soot is an indication of a damaged filter. If
excessive soot is found in the outlet of the exhaust stack, it must be cleaned if
the filter is replaced.
3. A customer complaint of black smoke during operation can also indicate a
damaged filter. This complaint should be verified by performing snap
acceleration. Refer to Procedure 014-013.

Of the three indications of damage to a filter above, number 1 is the most conclusive. If
number 1 does not exist, but numbers 2 and 3 can be confirmed together, the filter
should be replaced due to cracking or melting. The source of the excessive soot that
caused the cracking or melting must be investigated.

There are two primary reasons the outlet channels (number 1 above) would not have
soot staining, but numbers 2 and 3 may be present.
 1. If an active regeneration had been performed shortly before the filter was
removed and inspected, this could have removed the soot from the channels of
the outlet.
2. If the cracking or melting occurs close to the inlet face, the soot will not build up
in the outlet channel wall and therefore will not be visible. The illustration below
is a representation of this failure mode.

SMALL | MEDIUM | LARGE

Mechanism of Darkened Cell (in relation to the position of “Hole”)

Example Description

1. “Hole” exists near “outlet” face A. Gas with soot

2. “Hole” exists near “inlet” face. B. Inlet face

C. Outlet face

D. Hole

E. Soot leakage

F. Darkened

G. Not darkened.
Aftertreatment Diesel Oxidation Catalyst (DOC), Inlet - Melted

Appearance: Melted or deformed cells.

Cause: Excessive fuel or oil in exhaust.

Replace the aftertreatment diesel oxidation catalyst. Check the vehicle

Action: history for a past component malfunction which has allowed fuel or oil to
enter the exhaust.

SMALL | MEDIUM | LARGE

Aftertreatment Diesel Oxidation Catalyst (DOC), Inlet - Face Plugged

Light duty cycles, low exhaust temperatures, or combustion malfunction

Cause:
creating excessive engine smoke.

Action: Use compressed air to clean the diesel oxidation catalyst (DOC).

SMALL | MEDIUM | LARGE

Aftertreatment Diesel Oxidation Catalyst (DOC), Outlet - Melted

Appearance: Melted or deformed cells.

Cause: Excessive fuel or oil in exhaust.

Replace the aftertreatment diesel oxidation catalyst. Check the vehicle

Action: history for a past component malfunction which has allowed fuel or oil to
enter the exhaust.

SMALL | MEDIUM | LARGE

Aftertreatment Diesel Particulate Filter (DPF), Inlet - New

Appearance: Tan color, can have visible writing on the face.

Action: This is a new filter and is ready to use.

SMALL | MEDIUM | LARGE

Aftertreatment Diesel Particulate Filter (DPF), Inlet - Good (Dirty Number 1)

Appearance: Soot (black) or ash (grey) on the face and within the channels.

Cause: Normal engine operation.

Action: None, the filter can continue to be used.

SMALL | MEDIUM | LARGE

Aftertreatment Diesel Particulate Filter (DPF), Inlet - Good (Dirty Number 2)

Appearance: Soot (black) or ash (grey) on the face and within the channels.

Cause: Normal engine operation.

Action: None, the filter can continue to be used.

SMALL | MEDIUM | LARGE

Aftertreatment Diesel Particulate Filter (DPF), Inlet - Good (Clean)

Appearance: Very little soot (black) or ash (gray) within the channels.

Normal engine operation followed by a cleaning by the aftertreatment

Cause:
diesel particulate filter cleaning machine.

Action: None, the filter can continue to be used.

SMALL | MEDIUM | LARGE

Aftertreatment Diesel Particulate Filter (DPF), Inlet - Gouged

Appearance: Gouge in the face of the aftertreatment diesel particulate filter.

Face gouge created during manufacturing of aftertreatment diesel

Cause:
particulate filter, or an object scraped across the face.

Check if the gouge(s) in the substrate is more than 3 mm [1/8 in] deep. A
gouge 3 mm [1/8 in] deep or deeper is greater than the depth of the plugs.
Action: If the gouge is deeper than the specification, and there are more than 20
plugs missing due to this gouge, replace the aftertreatment diesel
particulate filter.

SMALL | MEDIUM | LARGE

NOTE: No plugs are missing from the gouge in the illustration above. This filter
can be reused.
Aftertreatment Diesel Particulate Filter (DPF), Inlet - Ash

Concentrated ash (white (1)) with dark wet (2) surrounding ring and
Appearance:
uneven soot streaks (3) across the inlet to the filter.

Cause: Excessive oil concentration in exhaust gases.

Investigate the cause of excessive oil in exhaust gases. Inspect the

turbocharger turbine outlet and aftertreatment inlet for oil. Investigate the
vehicle for engine component damage that has introduced excessive oil
Action:
into the exhaust. The oil contamination source must be corrected before
replacing the aftertreatment diesel particulate filter. The aftertreatment
diesel particulate filter must be replaced.

SMALL | MEDIUM | LARGE

Aftertreatment Diesel Particulate Filter (DPF), Inlet - Dark Soot Rings

Appearance: Dark soot rings (1).

Cause: Excessive water concentration in exhaust gases.

Check for active fault codes. Investigate coolant consumption. Investigate

the vehicle history for component damage that introduces excessive
Action:
coolant into the exhaust. The aftertreatment diesel particulate filter can be
recovered. Refer to Procedure 014-013.

SMALL | MEDIUM | LARGE

Aftertreatment Diesel Particulate Filter (DPF), Outlet - New

Appearance: Tan color, can have visible writing on the face.

Action: This is a new filter ready to use.

SMALL | MEDIUM | LARGE

NOTE: This staining in the illustration above is on the face of the outlet. This is
not an indication of a failure, but is more likely a smudge due to handling.
Aftertreatment Diesel Particulate Filter (DPF), Outlet - Soot Stains

Appearance: Black soot stains on the outlet.

Internal cracking or melting of the aftertreatment diesel particulate filter

Cause:
material.

Check for fault codes related to the aftertreatment system. Investigate the
engine service history. Determine if fuel or oil has been introduced into
the exhaust due to damage of another engine component. Inspect the
Action:
turbocharger turbine outlet and aftertreatment inlet for oil or fuel. Only
replace the aftertreatment diesel particulate filter after the cause of
excessive black smoke, fuel, or oil in the exhaust has been corrected.

SMALL | MEDIUM | LARGE

NOTE: The cells in the upper illustration (1) have soot staining in the channel
walls. This is a clear indication that the filter has internal cracking or melting.
NOTE: The cells in the lower illustration (2) have soot on the outlet face. This is
not an indication of failure, but likely staining due to handling.

Aftertreatment Diesel Particulate Filter (DPF), Outlet - Burn Marks from Welding
Process

Appearance: Brown staining on the outlet.

Cause: Part of the welding process during assembly of the part.

Inspect the filter for black soot stains in the outlet cell walls. If only brown
Action:
burn marks are visible, the filter can be reused.

SMALL | MEDIUM | LARGE

Aftertreatment Diesel Particulate Filter (DPF), Outlet - Excessive Soot Stains

Appearance: Black soot stains on the outlet.

Internal cracking or melting of the aftertreatment diesel particulate filter

Cause:
material.

Check for fault codes related to the aftertreatment system. Investigate the
engine service history. Inspect the turbocharger turbine outlet and
Action: aftertreatment inlet for oil or fuel. Only replace the aftertreatment diesel
particulate filter after the cause of the excessive black smoke, fuel, or oil
in the exhaust has been corrected.

SMALL | MEDIUM | LARGE

Aftertreatment Diesel Particulate Filter (DPF), Outlet - Face Cracked

Appearance: Crack across the face.

High soot in the aftertreatment diesel particulate filter reacted rapidly with
Cause:
the engine exhaust, creating a high temperature.

Check for fault codes related to the aftertreatment system temperature

and soot level. Investigate the vehicle history for damaged components
Action: that have introduced excessive fuel or oil into the exhaust. Inspect the
face of the aftertreatment diesel oxidation catalyst for blockage. Replace
the aftertreatment diesel particulate filter.

SMALL | MEDIUM | LARGE

Aftertreatment Diesel Particulate Filter (DPF), Outlet - Coolant Staining

Appearance: Dark streak on the face of the filter.

Cause: Excessive water concentration in exhaust gases.

Check for active fault codes. Investigate coolant consumption. Investigate

the vehicle history for component damage that introduces excessive
Action:
coolant into the exhaust. The aftertreatment diesel particulate filter can be
recovered. Refer to Procedure 014-013.

SMALL | MEDIUM | LARGE

NOTE: The brown staining in the illustration above is an indication of coolant

contamination in the diesel particulate filter.
Aftertreatment Diesel Particulate Filter (DPF), Outlet - Melted

Appearance: Melted or deformed cells.

Causes: Excessive fuel or oil in exhaust.

Check for fault codes related to the aftertreatment system. Investigate the
engine service history. Determine if fuel or oil has been introduced into
the exhaust from the damage of another engine component. Inspect the
Action:
turbocharger turbine outlet and aftertreatment inlet for oil or fuel. Only
replace the aftertreatment diesel particulate filter after the cause of
excessive fuel or oil in the exhaust has been corrected.

SMALL | MEDIUM | LARGE

Last Modified: 23-Oct-2009