NHTSA ID Number: 10141862
Manufacturer Communication Number: 0404-18
TSB/Document Date: 2018-06-18
Summary
0404-18 GHG17 DD8 - Aftertreatment Systems - Diesel Particulate Filter End Cap
04 04-18
1
04 04-18
SUBJECT
DATE
GHG17 DD8 - Aftertreatment Systems - Diesel Particulate Filter End
Cap
April 2018
Additions, Revisions, or Updates
Publication Number / Title
Platform
Section Title
Change
Description and Operation of the Diesel Particulate
Filter End Cap
Removal of the Diesel Particulate Filter End Cap Horizontal Configuration
Inspection of the Diesel Particulate Filter End Cap
DDC-SVC-MAN-0198
GHG17
DD8
Installation of the Diesel Particulate Filter End Cap Horizontal Configuration
New Sections
Removal of the Diesel Particulate Filter End Cap Understep Configuration
Inspection of the Diesel Particulate Filter End Cap
Installation of the Diesel Particulate Filter End Cap Understep Configuration
All information subject to change without notice.
04 04-18
Copyright © 2018 DETROIT DIESEL CORPORATION
3
2 Description and Operation of the Diesel Particulate Filter End Cap
2
Description and Operation of the Diesel Particulate Filter End Cap
The Diesel Particulate Filter (DPF) end cap (3) directs filtered exhaust exiting the DPF in to the Selective Catalytic
Reduction (SCR) hydrolysis chamber (4).
1. Diesel Oxidation Catalyst (DOC)
2. Diesel Particulate Filter (DPF)
3. DPF End Cap
4. Selective Catalytic Reduction (SCR) Hydrolysis Chamber
5. SCR Catalyst
Figure 1. Diesel Particulate Filter (DPF) End Cap
4
All information subject to change without notice.
Copyright © 2018 DETROIT DIESEL CORPORATION
04 04-18
04 04-18
3
Removal of the Diesel Particulate Filter End Cap - Horizontal
Configuration
Table 1.
Service Tools Used in the Procedure
Tool Number
Tool Name
Locally Sourced
ATD Lifting Device
1.
2.
3.
4.
Diesel Oxidation Catalyst (DOC)
Diesel Particulate Filter (DPF)
DPF End Cap Clamp
Selective Catalytic Reduction (SCR) Hydrolysis Chamber
Picture
5. SCR Clamp
6. SCR Catalyst
7. DPF End Cap
Removal as follows:
1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.
All information subject to change without notice.
04 04-18
Copyright © 2018 DETROIT DIESEL CORPORATION
5
3 Removal of the Diesel Particulate Filter End Cap - Horizontal Configuration
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
2.
3.
4.
5.
Disconnect the batteries.
Allow the Aftertreatment System (ATS) time to cool.
Disconnect the exhaust system inlet pipe by loosening the clamp and relocating the inlet pipe away from work area.
Remove the Diesel Particulate Filter (DPF) outlet temperature sensor. Refer to section "Removal of the Diesel
Particulate Filter Outlet Temperature Sensor".
6. Remove the DPF outlet pressure tube. Refer to section "Removal of the Diesel Particulate Filter Outlet Pressure
Tube".
7. Note the orientation of the DOC, DPF, DPF end cap and associated clamps to ensure proper installation.
8. Disconnect the 18-pin chassis harness electrical connector (4) from the DPF mounted aftertreatment harness.
9. Lightly position the ATD lifting device under the DOC and DPF without enough force to lift the DOC, DPF or the
vehicle. Attach the safety strap to the lifting device.
10. Loosen the clamps securing the DOC, DPF and DPF end cap to the frame rail mounting bracket.
11. Remove the DPF clamp (1) and gasket securing the DPF to the DPF end cap. Discard the clamp and gasket.
6
All information subject to change without notice.
Copyright © 2018 DETROIT DIESEL CORPORATION
04 04-18
04 04-18
12. Carefully slide the DOC and DPF away from the DPF end cap.
13. Remove the DPF end cap clamp (2) and gasket securing the Selective Catalytic Reduction (SCR) hydrolysis chamber
(3) to the DPF end cap (1). Discard the clamp and gasket.
14. Carefully remove the DPF end cap from the SCR hydrolysis chamber.
All information subject to change without notice.
04 04-18
Copyright © 2018 DETROIT DIESEL CORPORATION
7
4 Inspection of the Diesel Particulate Filter End Cap
4
Inspection of the Diesel Particulate Filter End Cap
Inspect as follows:
1. Inspect the Diesel Particulate Filter (DPF) end cap for damage. Replace as necessary.
8
All information subject to change without notice.
Copyright © 2018 DETROIT DIESEL CORPORATION
04 04-18
04 04-18
5
Installation of the Diesel Particulate Filter End Cap - Horizontal
Configuration
Table 2.
Service Tools Used in the Procedure
Tool Number
Tool Name
Locally Sourced
ATD Lifting Device
1.
2.
3.
4.
Diesel Oxidation Catalyst (DOC)
Diesel Particulate Filter (DPF)
DPF End Cap Clamp
Selective Catalytic Reduction (SCR) Hydrolysis Chamber
Picture
5. SCR Clamp
6. SCR Catalyst
7. DPF End Cap
Install as follows:
1. Clean the mating surfaces of the Diesel Particulate Filter (DPF) end cap.
2. Using a new DPF end cap clamp (2) and gasket, install the DPF end cap (1) into the Selective Catalytic Reduction
(SCR) hydrolysis chamber (3). Torque the clamp to 20 N·m (15 lb·ft).
All information subject to change without notice.
04 04-18 Copyright © 2018 DETROIT DIESEL CORPORATION
9
5 Installation of the Diesel Particulate Filter End Cap - Horizontal Configuration
3. Install a new DPF clamp (1) and gasket onto the outlet side of the DPF.
4.
5.
6.
7.
8.
9.
10
Using the aftertreatment lifting device, carefully raise the Diesel Oxidation Catalyst (DOC) and DPF into place.
Carefully slide the DOC and DPF onto the DPF end cap.
Ensure the DOC, DPF, DPF end cap and associated clamps are installed in the correct orientation.
Torque the DPF clamp securing the DPF to the DPF end cap to 32 N·m (24 lb·ft).
Torque the clamps securing the DOC, DPF and DPF end cap to the vehicle frame to 40 N·m (30 lb·ft).
Carefully lower the ATD lifting device away from the DOC and DPF.
All information subject to change without notice.
Copyright © 2018 DETROIT DIESEL CORPORATION
04 04-18
04 04-18
10. Connect the 18-pin chassis harness electrical connector (4) to the DPF mounted aftertreatment harness.
11. Install the DPF outlet pressure tube. Refer to section "Installation of the Diesel Particulate Filter Outlet Pressure
Tube".
12. Install the DPF outlet temperature sensor. Refer to section "Installation of the Diesel Particulate Filter Outlet
Temperature Sensor".
13. Connect the exhaust system inlet pipe by installing the clamp. Torque to 25 N·m (18 lb·ft).
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
14. Connect the batteries.
WARNING: PERSONAL INJURY
Diesel engine exhaust and some of its constituents are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
• Always start and operate an engine in a well ventilated area.
• If operating an engine in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system or emission control system.
WARNING: PERSONAL INJURY
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level
surface, parking brake is set, and the wheels are blocked.
All information subject to change without notice.
04 04-18
Copyright © 2018 DETROIT DIESEL CORPORATION
11
5 Installation of the Diesel Particulate Filter End Cap - Horizontal Configuration
WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
15. Start the engine.
16. Check for any exhaust leaks.
12
All information subject to change without notice.
Copyright © 2018 DETROIT DIESEL CORPORATION
04 04-18
04 04-18
6
Removal of the Diesel Particulate Filter End Cap - Understep
Configuration
1. Diesel Particulate Filter (DPF) end cap
2. DPF Clamps
3. Diesel Oxidation Catalyst (DOC)
4. DPF
Removal as follows:
1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
2.
3.
4.
5.
6.
Disconnect the batteries.
Remove the right side fairing. Refer to the Original Equipment Manufacturer (OEM) procedures.
Remove the right side steps and mounting brackets.
Allow the Aftertreatment System (ATS) time to cool.
Disconnect the exhaust system inlet pipe (1) by loosening the clamp (2) and relocating the inlet pipe away from work
area.
All information subject to change without notice.
04 04-18
Copyright © 2018 DETROIT DIESEL CORPORATION
13
6 Removal of the Diesel Particulate Filter End Cap - Understep Configuration
7. Remove the Diesel Particulate Filter (DPF) outlet temperature sensor. Refer to section "Removal of the Diesel
Particulate Filter Outlet Temperature Sensor".
8. Remove the DPF outlet pressure tube. Refer to section "Removal of the Diesel Particulate Filter Outlet Pressure
Tube".
9. Remove the Diesel Oxidation Catalyst (DOC) inlet pressure tube. Refer to section "Removal of the Diesel Oxidation
Catalyst Inlet Pressure Tube".
10. Note the orientation of the DOC, DPF, DPF end cap and associated clamps to ensure proper installation.
11. Loosen the clamps (1) securing the DOC, DPF and DPF end cap to the frame rail mounting bracket.
14
All information subject to change without notice.
Copyright © 2018 DETROIT DIESEL CORPORATION
04 04-18
04 04-18
12. Remove the DPF clamp (2) securing the DPF (3) to the DPF end cap (1). Discard the clamp and gasket.
13. Carefully slide the DOC (4) and DPF (3) away from the DPF end cap (1). Ensure the DOC and DPF are still secured
to the frame rail mounting bracket.
14. Remove the clamp and gasket securing the Selective Catalytic Reduction (SCR) hydrolysis chamber to the DPF end
cap. Discard the clamp and gasket.
15. Carefully remove the DPF end cap from the SCR hydrolysis chamber.
All information subject to change without notice.
04 04-18
Copyright © 2018 DETROIT DIESEL CORPORATION
15
7 Inspection of the Diesel Particulate Filter End Cap
7
Inspection of the Diesel Particulate Filter End Cap
Inspect as follows:
1. Inspect the Diesel Particulate Filter (DPF) end cap for damage. Replace as necessary.
16
All information subject to change without notice.
Copyright © 2018 DETROIT DIESEL CORPORATION
04 04-18
04 04-18
8
Installation of the Diesel Particulate Filter End Cap - Understep
Configuration
Table 3.
Service Tools Used in the Procedure
Tool Number
Tool Name
Locally Sourced
ATD Lifting Device
1. Diesel Particulate Filter (DPF) end cap
2. DPF Clamp
Picture
3. Diesel Oxidation Catalyst (DOC)
4. DPF
Install as follows:
1.
2.
3.
4.
Clean the mating surfaces of the Diesel Particulate Filter (DPF) end cap.
Install a new clamp and gasket on the outlet of the Diesel Particulate Filter (DPF) end cap.
Slide a new DPF clamp and gasket inward on the DPF.
Carefully install the Diesel Particulate Filter (DPF) end cap onto the Selective Catalytic Reduction (SCR) hydrolysis
chamber.
5. Install the clamp securing the DPF end cap to the SCR hydrolysis chamber. Hand-tighten the clamp.
6. Carefully slide the Diesel Oxidation Catalyst (DOC) (4) and DPF (3) on to the DPF end cap (1).
All information subject to change without notice.
04 04-18
Copyright © 2018 DETROIT DIESEL CORPORATION
17
8 Installation of the Diesel Particulate Filter End Cap - Understep Configuration
7. Ensure the DOC, DPF, DPF end cap and associated clamps are installed in the correct orientation.
8. Install the DPF clamp (2) and gasket securing the DPF (3) to the DPF end cap (1). Torque the clamp to 32 N·m (24
lb·ft).
9. Torque the clamp securing the DPF end cap to the SCR hydrolysis chamber to 20 N·m (15 lb·ft).
10. Torque the clamps (1) securing the DOC, DPF and DPF end cap to the vehicle frame to 40 N·m (30 lb·ft).
11. Install the DOC inlet pressure tube. Refer to section "Installation of the Diesel Oxidation Catalyst Inlet Pressure
Tube".
18
All information subject to change without notice.
Copyright © 2018 DETROIT DIESEL CORPORATION
04 04-18
04 04-18
12. Install the DPF outlet pressure tube. Refer to section "Installation of the Diesel Particulate Filter Outlet Pressure
Tube".
13. Install the DPF outlet temperature sensor. Refer to section "Installation of the Diesel Particulate Filter Outlet
Temperature Sensor".
14. Connect the exhaust system inlet pipe (1) by installing the clamp (2). Torque to 25 N·m (18 lb·ft).
15. Install the right side steps and mounting brackets. Refer to the Original Equipment Manufacturer (OEM) procedures.
16. Install the right side fairing. Refer to OEM procedures.
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
17. Connect the batteries.
WARNING: PERSONAL INJURY
Diesel engine exhaust and some of its constituents are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
• Always start and operate an engine in a well ventilated area.
• If operating an engine in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system or emission control system.
WARNING: PERSONAL INJURY
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level
surface, parking brake is set, and the wheels are blocked.
All information subject to change without notice.
04 04-18
Copyright © 2018 DETROIT DIESEL CORPORATION
19
8 Installation of the Diesel Particulate Filter End Cap - Understep Configuration
WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
18. Start the engine.
19. Check for any exhaust leaks.
20
All information subject to change without notice.
Copyright © 2018 DETROIT DIESEL CORPORATION
04 04-18
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TSB/Document ID: 0404-18
Replacement Service Bulletin Number:
MFR Communication Date: 2018-04-04
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING:ENGINE:DIESEL
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