24/11/23, 9:43 QuickServe Online | (5504583) X15 CM2450 X124B - Efficiency Series Service Manual

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Select Service Tools

Recommended Cummins® Service Tool
Anti-seize, Part Number 3824879, or equivalent
Aftertreatment Clean Care Kit, Part Number 5299193
Diesel Exhaust Fluid (DEF) Extension Kit, Part Number 5299873
Aftertreatment DEF Clean Care Kit, Part Number 5394236.

Additional Service Items

Synthetic grease such as Super Lube®.

General Information
The aftertreatment DEF dosing valve (1) is used to spray DEF
into the exhaust flow.

The aftertreatment DEF dosing valve is located on

the aftertreatment decomposition tube (2).

When the aftertreatment DEF dosing valve is dosing DEF into

the exhaust, there is a noticeable clicking sound. This is normal
and should not be replaced if heard.

There are three primary connections on the aftertreatment DEF

dosing valve.

1. 8 pin electrical connection

2. DEF supply line which connects the aftertreatment dosing
valve to the aftertreatment DEF dosing unit

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3. DEF return line which connects the aftertreatment dosing

valve to the aftertreatment DEF tank.

There are two different types of aftertreatment DEF dosing

valves, 12V and 24V, depending on the application. Confirm
that the correct part number (1) is used. The connections are
the same between the two different aftertreatment DEF dosing
valves.

Reference the Aftertreatment Diesel Exhaust Fluid (DEF)

Dosing Valve Identification Label Technical Service Bulletin,
TSB150139, for part number verification.

For information on handling incorrect or contaminated DEF,

Refer to Procedure 011-056 in Section 11.
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Initial Check
 CAUTION 

Do not use the flow test portion of INSITE™ electronic

service tool Aftertreatment Diesel DEF Dosing Unit
Override Test to check the system for leaks. This will
spray DEF into the exhaust system at temperatures too
low to evaporate, resulting in deposit formations in the
exhaust system.

Note : DEF deposits could possibly be left over from a

previous DEF spill or repair. Verify active leaks before
replacing any components.
Inspect the area around the DEF line connection location at the
aftertreatment DEF dosing valve.

Inspect for signs of leaks and/or white deposits.

Due to deposit buildups possibly masking the source of the

leak, it can be necessary to remove the deposits and clean the
area with warm water.

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Once the source of the DEF leaks and/or deposits are

identified, see the Clean and Inspect for Reuse section of this
procedure.

Inspect the body and around the base of the aftertreatment

DEF dosing valve. Check for signs of exhaust leaks and white
deposits.

If leaks and/or deposits are identified, see the Clean and

Inspect for Reuse section of this procedure.

Preparatory Steps
 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.

Allow the DEF to recirculate and depressurize after engine shut down and prior to DEF
system servicing. This can take up to 15 minutes.
Disconnect the batteries. See equipment manufacturer service information.

 WARNING 
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause personal
injury.

 WARNING 

Diesel exhaust fluid (DEF) contains urea. Do not get the

substance in your eyes. In case of contact, immediately
flush eyes with large amounts of water for a minimum of
15 minutes. Do not swallow. In the event the diesel

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exhaust fluid (DEF) is ingested, contact a physician

immediately. Reference the Materials Safety Data Sheet
(MSDS) for additional information.

Use compressed air to remove any debris from around the

aftertreatment DEF dosing valve and connections.

Remove any debris trapped in the gaps between the

aftertreatment DEF dosing valve and the aftertreatment
decomposition tube so that debris does not fall into the
aftertreatment decomposition tube upon removal of the
aftertreatment DEF dosing valve.

If there are any white deposits on the DEF line connection,

remove them by wiping with a clean shop towel soaked in
warm water.

 CAUTION 

Care should be taken when handling and/or

disconnecting the DEF line from the aftertreatment DEF
dosing valve. The DEF supply line connector of the
aftertreatment DEF dosing valve can be easily damaged.

There is always a chance of residual pressure being present.

Open fittings slowly to allow any pressure to bleed off before
removing any connections.

Disconnect the connections at the aftertreatment DEF dosing

valve in the following order:

Place a small plastic container under the aftertreatment DEF

dosing valve to catch any residual DEF prior to disconnecting
the DEF supply line.

1. Disconnect the DEF line. See equipment manufacturer

service information.
2. Pull the yellow locking tab on the connector to disconnect
the aftertreatment wiring harness from the aftertreatment
DEF dosing valve.

Plug the aftertreatment DEF lines with plugs from

Aftertreatment Clean Care Kit, Part Number 5299193, to
reduce the possibility of debris entering the system.

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After the electrical connection is disconnected, cover the

connection on the aftertreatment DEF dosing valve with
electrical tape to prevent DEF from getting into the electrical
connection.

Remove
 CAUTION 

Do not set the aftertreatment DEF dosing valve down on

the spray area of the aftertreatment DEF dosing valve.
Damage can occur.

Remove the capscrews (1).

Remove aftertreatment DEF dosing valve (2).

Remove and discard the thermal isolator (3).

Note : A small amount of DEF deposits is normal if

observed on the aftertreatment DEF dosing valve face
and around the ring seal of the aftertreatment DEF
dosing valve.

Use a pick to carefully remove the aftertreatment DEF dosing

valve nozzle ring seal.

Discard the ring seal.

Disassemble
 CAUTION 

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A small amount of dirt and debris can be very harmful to

the DEF dosing system. Dirt or other foreign objects must
not get into the aftertreatment DEF dosing valve.

Use a T-25 Torx™ socket drive to remove the capscrews from

the aftertreatment DEF dosing valve connector manifold.

Discard the capscrews.

Remove the connector cylinders with needle nose pliers.

Discard the connector cylinders.

Use needle nose pliers to remove the filter from the

aftertreatment DEF dosing valve connector manifold.

Discard the filter.

Clean and Inspect for Reuse

If leaks or deposits are found at the aftertreatment DEF dosing
valve joints between the valve and the valve assembly body
during the Initial Check section of this procedure, replace the
aftertreatment DEF dosing valve.

If leaks are suspected from the aftertreatment DEF dosing

valve nozzle tip, perform the Aftertreatment Diesel Exhaust
Fluid System Leak Test with the aftertreatment DEF dosing
valve removed. Refer to Procedure 011-080 in Section 11.
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Count the number of drops from the aftertreatment DEF dosing

valve within 30 seconds.

Aftertreatment DEF Dosing Valve Leak Test

Max Drops Seconds
3 30
If leaks or deposits are found at the DEF line connection during
the Initial Check section of this procedure, inspect the DEF line
connection port for cracks or pitting.

If damage or corrosion is found, also inspect the DEF line

connection. See equipment manufacturer service information.
Inspect the electrical connection and pins for damage and
corrosion. Refer to Procedure 019-361 in Section 19.
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If damage or corrosion is found, inspect the electrical

connector and pins on the vehicle harness. See equipment
manufacturer service information.

Replace the aftertreatment DEF dosing valve if damage is

found.

 CAUTION 
Use only warm water to clean the tip of the aftertreatment
DEF dosing valve. The use of a wire wheel or brass brush
or any other abrasive medium will cause permanent
damage to the aftertreatment DEF dosing valve.

Use a clean shop cloth soaked in warm water to dissolve and

wipe DEF deposits away on the aftertreatment DEF dosing
valve tip.

Inspect the aftertreatment DEF dosing valve tip for cracks or

other damage. Replace if damage is found.

If leaks or deposits are found at the base of the aftertreatment

DEF dosing valve during the Initial Check section of this
procedure, inspect the following:

Check the bottom of the aftertreatment DEF dosing valve

around the ring seal sealing surface for signs of heavy
corrosion, pitting, and/or surface damage. Replace the
aftertreatment DEF dosing valve if damage is found.
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Check the aftertreatment DEF dosing valve mounting

surface on the decomposition chamber.

If replacing the aftertreatment DEF dosing valve, make sure to

transfer the DEF Clean Care Kit, Part Number 5394236,
protective caps from the replacement aftertreatment DEF
dosing valve to the old aftertreatment DEF dosing valve prior to
putting it in the core return box.

Make sure to fill out any requested information (engine serial

number (ESN), hours, and vehicle identification number (VIN)).

Inspect the capscrews for damaged threads and corroded

surfaces.

Replace if damage is found.

Measure the resistance between the aftertreatment DEF dosing valve SIGNAL pin and
aftertreatment DEF dosing valve RETURN pin with aftertreatment DEF dosing valve
disconnected from the original equipment manufacturer (OEM) harness. Replace the
aftertreatment DEF dosing valve if measured resistance does not meet the following
specification:

Resistance (ohms)
System Voltage (VDC)
Minimum Maximum
12 4.5 9.5
24 12 22

Assemble
Install a new aftertreatment DEF dosing valve filter in the
bottom hole of the valve assembly. The filter will only fit in the
bottom hole.

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Apply synthetic grease onto the o-rings.

Install new connector cylinders into the connector manifold.

Make sure to press the cylinders until they contact the bottom
of the connector manifold. The cylinders are identical and can
go in either hole.

Install the connector manifold onto the aftertreatment DEF

dosing valve assembly using two new Torx™ capscrews.
Torque Value: 8 n•m [ 71 in-lb ]

Install
Install a new aftertreatment DEF dosing valve nozzle ring seal
onto the dosing nozzle.

Remove any protective caps.

Make sure the aftertreatment DEF dosing valve spray port is

free of debris.

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Apply a coat of high temperature anti-seize compound, Part

Number 3824879, to the threads of the aftertreatment DEF
dosing valve mounting capscrews.

Install the thermal isolator (3).

Install the aftertreatment DEF dosing valve (2).

Install and tighten the capscrews (1).

Torque Value: 10 n•m [ 89 in-lb ]

Finishing Steps
 CAUTION 
Do not use the flow test portion of INSITE™ electronic
service tool Aftertreatment Diesel DEF Dosing Unit
Override Test to check the system for leaks. This will
spray DEF into the exhaust system at temperatures too
low to evaporate, resulting in deposit formations in the
exhaust system.

Remove any protective caps and/or covers from the electrical,

coolant, and DEF ports immediately prior to making the
connection.

Connect the electrical connector (2) to the aftertreatment DEF

dosing valve.

Lubricate the DEF line fittings with a drop of synthetic grease

such as Super Lube®.
Connect the DEF lines (1). See equipment manufacturer
service information.
Note : DEF forms a white residue when allowed to dry.
This residue can prevent proper sealing of the fittings
when the DEF line is installed. Before making the DEF
line connection:
Dissolve DEF residue off the DEF line fittings with distilled
water.
Inspect the DEF line fitting o-rings for cuts or damage.
Replace the DEF lines if there is any damage to the o-
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rings.
Lubricate the DEF line fittings with a drop of synthetic
grease.

Once all connections are made, give each a slight pull to make
sure they are securely installed.

 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.

Connect the batteries. See equipment manufacturer service information.

Operate the engine. Check for leaks.

Last Modified: 13-Jan-2023

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