TSB140105-010815

Fault Code(s) 1883, 1921, 1922, 1981, 2639, 3135, 3168 Caused by Incorrect Aftertreatm... Page 1 of 10
Technical Service Bulletin Number
TSB140105
Technical Service Bulletin
Subject
Fault Code(s) 1883, 1921, 1922, 1981, 2639, 3135, 3168 Caused by Incorrect
Aftertreatment Diesel Particulate Filter (DPF) Differential Pressure Sensor Orientation
Issue
The aftertreatment DPF differential pressure sensor is installed in the incorrect orientation.
This orientation of the sensor allows moisture to be trapped inside the sensor and/or sensor
tubes. The trapped moisture affects the signal processing of the sensor when reading the
pressure inside the DPF, and leads to incorrect pressure readings and Fault Code(s) 1883,
1921, 1922, 1981, 2639, 3135, and 3168 being set.
Figure 1: This image shows the incorrect orientation of the DPF differential pressure sensor
and sensor tubes for horizontally mounted DPFs, preventing moisture from draining out.
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Figure 1
1.
2.
3.
4.
5.
6.
7.
8.
Aftertreatment DPF assembly.
Aftertreatment DPF differential pressure sensor.
Aftertreatment DPF differential pressure sensor mounting bracket.
Aftertreatment DPF differential pressure sensor mounting bracket strap.
Aftertreatment DPF differential pressure sensor tubes.
Aftertreatment DPF differential pressure sensor port fittings.
Aftertreatment DPF differential pressure sensor elbow fittings.
Aftertreatment DPF differential pressure sensor tubes have upward slope away from
the sensor ports.
9. Moisture will collect and be trapped in these tube locations. During freezing conditions,
this moisture is likely to freeze causing fault codes.
Figure 2: This image shows the incorrect orientation of the DPF differential pressure sensor
and sensor tubes for vertically mounted DPFs, preventing moisture from draining out.
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Figure 2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Aftertreatment DPF assembly.
Aftertreatment DPF differential pressure sensor.
Aftertreatment DPF differential pressure sensor mounting bracket.
Aftertreatment DPF differential pressure sensor mounting bracket strap.
Upstream aftertreatment DPF differential pressure sensor tubes.
Upstream aftertreatment DPF differential pressure sensor elbow fittings.
Downstream aftertreatment DPF differential pressure sensor tubes.
Downstream aftertreatment DPF differential pressure sensor port fittings.
P-clips or tube clamps.
Aftertreatment DPF differential pressure sensor tubes have upward slope away from
the sensor ports.
11. Moisture will collect and be trapped in these tube locations.
12. During freezing conditions, this moisture is likely to freeze causing fault codes.
Verification
Reference INSITE™ electronic service tool to read the fault codes. Check for Fault Code(s)
1883, 1921, 1922, 1981, 2639, 3135, 3168 (active or inactive). Inspect the aftertreatment
DPF differential pressure sensor to confirm if it's installed in the incorrect orientation. If the
aftartreatment DPF differential pressure sensor is installed correctly, continue with published
troubleshooting.
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Resolution
The DPF differential pressure sensor tubes must have a continuous downward slope away
from the sensor ports whether in a vertical or horizontal aftertreatment configuration. A 10
degree sensor tube down angle is recommended to make sure that no cavity exists in the
tubes to collect moisture.
A video has been created to help illustrate the following adjustment procedure. Use the
following link to view the video.
NOTE: http://tsb.cumminsvirtualcollege.com/140105.aspx
To achieve a continuous downward sensor tube slope, the following adjustments can be
made:
• Align the temperature coupling on the diesel oxidation catalyst (DOC) inlet (stamped
T1) and the temperature coupling on the DPF (stamped T2). If they are not aligned,
loosen the band clamps and align the temperature sensor probes by rotating the
aftertreatment DPF canister. See Procedure 011-041 in Section 11 of the
corresponding service manual.
For canister mounted aftertreatment DPF differential pressure sensors on horizontally
mounted DPF applications:
• Loosen the DPF differential pressure sensor mounting bracket strap and allow the DPF
differential pressure tubes to locate the aftertreatment DPF differential pressure sensor
bracket on the aftertreatment DPF Canister.
• Mark the location of the DPF differential pressure sensor bracket on the aftertreatment
DPF canister by pressing the DPF differential pressure sensor bracket against the DPF
canister and tracing along the bottom of the DPF differential pressure sensor bracket.
(See Figure 3)
Figure 3
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Figure 3: This image shows the correct orientation of the DPF differential pressure sensor
mounting bracket and sensor tubes, which allows moisture to drain back to the DPF
assembly.
• Clock the DPF differential pressure sensor bracket by moving it toward the top of the
DPF canister to achieve a 10 degree sensor tube down angle. Do not move the sensor
mounting bracket more than 19 mm [3/4 in] above the reference mark.
• Tighten the aftertreatment DPF differential pressure sensor mounting bracket strap to
7 N•m [62 In-Lb]
• Adjust the DPF Differential pressure sensor port fittings to achieve the 10 degree down
angle. (See Figures 1 and 3) Tighten the DPF differential pressure sensor port fittings
after adjustment. Reference Procedure 011-046 in the appropriate service manual.
• Loosen the tube retention clips located at the aftertreatment DPF differential pressure
sensor elbow fittings. Rotate the DPF differential pressure sensor tubes to achieve a
10 degree sensor tube down angle.
• If needed, shorten the tubes to achieve a 10 degree sensor tube down angle. Up to 9.5
mm [3/8in] can be cut off the aftertreatment DPF differential pressure sensor elbow
fitting end of each DPF differential pressure sensor tube. Remove the same amount of
material from both tubes. Use a cutting tool that will make sure of a clean cut. See
Procedure 011-046 in Section 11 in the corresponding service manual.
For canister mounted aftertreatment DPF differential pressure sensors on vertically mounted
DPF applications:
• Mark the location of the DPF differential pressure sensor bracket on the aftertreatment
DPF canister by pressing the DPF differential pressure sensor bracket against the DPF
canister and tracing along the bottom of the DPF differential pressure sensor bracket.
• Loosen the DPF differential pressure sensor mounting bracket strap and the p-clip
holding the upstream aftertreatment DPF differential pressure sensor tubes.
• Adjust the downstream sensor port fittings to achieve a 5 degree down angle. (See
Figures 2 and 6) Tighten the DPF differential pressure sensor port fittings after
adjustment. See Procedure 011-046 in Section 11 in the corresponding service
manual.
• Move the DPF differential pressure sensor bracket toward the top of the DPF canister
to achieve a 5 degree down angle on downstream sensor tube. Do not move the
sensor mounting bracket more than 16 mm [5/8 in] above the reference mark. (See
Figure 4)
• Tighten the aftertreatment DPF differential pressure sensor mounting bracket strap to
7 N•m [62 in-lb]. Tighten the p-clip to 14 N•m [124 in-lb].
• If needed, shorten the upstream sensor tube to achieve a continuous down angle. Up
to 9.5 mm [3/8in] can be cut off the differential pressure sensor elbow fitting end of
upstream sensor tube. Do not shorten the downstream sensor tube. Use a cutting tool
that will make a clean cut. See Procedure 011-046 in Section 11 of the corresponding
service manual.
Figure 4: This image shows measuring the DPF differential pressure sensor bracket relative
to the reference mark.
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Figure 4
For remotely mounted aftertreatment DPF differential pressure sensors on horizontally
mounted DPF applications:
• Adjust the DPF differential pressure sensor port fittings to achieve the 10 degree down
angle. Tighten the DPF differential pressure sensor port fittings after adjustment. See
Procedure 011-046 in the corresponding service manual.
• If needed, shorten the tubes to achieve a 10 degree sensor tube down angle. Up to 24
mm [1 in ] can be cut off the aftertreatment DPF differential pressure sensor elbow
fitting end of each DPF differential pressure sensor tube. Remove the same amount of
material from both tubes. Use a cutting tool that will make sure of a clean cut. See
Procedure 011-046 in Section 11 of the corresponding service manual.
Figure 5: These images show the correct orientation of the DPF differential pressure sensor
mounting bracket and sensor tubes, which allows moisture to drain back to the DPF
assembly. A canister mounted aftertreatment DPF differential pressure sensor is shown on
the left and a remotely mounted aftertreatment DPF differential pressure sensor is shown on
the right.
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Figure 5
1. Aftertreatment DPF differential pressure sensor tubes have continuous downward
slope away from the sensor ports.
2. The sensor port fittings were rotated toward the DPF differential pressure sensor to
better achieve downward slope.
3. The sensor mounting bracket was rotated away from the sensor port fittings to better
achieve downward slope.
NOTE: When rotating the sensor mounting bracket, make sure to allow for clearance
with surrounding components. A minimum clearance of one inch is required around
the sensor mounting bracket and any surrounding components in order to prevent
damage.
Figure 6: This image shows the correct orientation of the DPF differential pressure sensor
mounting bracket and sensor tubes for vertically mounted DPFs, which allows moisture to
drain back to the DPF assembly.
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Figure 6
1. Aftertreatment DPF differential pressure sensor mounting bracket moved toward the
top of the DPF canister a maximum of 16mm [5/8 in] to achieve a 5 degree down angle
on the downstream sensor tube.
2. Aftertreatment DPF differential pressure sensor port fitting was rotated toward the DPF
differential pressure sensor to better achieve downward slope.
3. Aftertreatment DPF differential pressure sensor tubes have continuous downward
slope away from the sensor ports.
Figure 7: This image shows the incorrect orientation of the sensor port fittings for horizontally
mounted DPFs.
• Numbers 1 and 2 have poor fitting angles.
• The port angles are rotated away from the sensor.
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Figure 7
Figure 8: This image shows the correct orientation of the sensor port fittings for horizontally
mounted DPFs.
• Numbers 1 and 2 have good port fitting angles.
• The ports are rotated toward the sensor.
• The port angles should be 1 to 10 degrees from horizontal, angled toward the sensor.
Figure 8
Warranty Statement
The information in this document has no effect on present warranty coverage or repair
practices, nor does it authorize TRP or Campaign actions.
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Document History
Date
2014-8-15
2014-9-28
2015-1-8
Details
Module Created
none
Added vertically mounted DPF content.
Last Modified: 09-Jan-2015
Copyright © 2000-2010 Cummins Inc. All rights reserved.
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