Aftertreatment Diesel Exhaust Fluid Dosing Unit Air Side Flushing

8/19/24, 10:30 AM Aftertreatment Diesel Exhaust Fluid Dosing Unit Air Side Flushing
Trainings
General Information
 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 DEF is ingested,
contact a physician immediately. Reference the materials
safety data sheet (MSDS) for additional information.
 WARNING 
The catalyst reagent contains urea. Do not get the
flood eyes with large amounts of water for a minimum of 15
minutes. Avoid prolonged contact with skin. In case of
contact, immediately wash skin with soap and water. Do not
swallow internally. In the event the catalyst reagent is
ingested, contact a physician immediately. Refer to the
Materials Safety Data Sheet (MSDS) for additional
information.
Note : The aftertreatment DEF dosing unit is not

serviceable. Do NOT open the case.
This procedure is used to flush DEF crystals that have built
up in the air circuit of the aftertreatment DEF dosing unit. A
blockage in the DEF circuit can result in DEF entering the air
circuit. Over time, urea crystal growth in the air circuit leads
to a reduction or total loss of air flow and a malfunction of
the component. It is also possible to trigger active Fault
Codes 4283, 4239 and 4271.
https://quickserve.cummins.com/qs3/pubsys2/xml/en/procedures/379/379-011-082-tr.html 1/7
Initial Check
Check the plumbing going to and returning from the DEF
dosing unit for any signs of a leak. DEF will form white
deposits around leaky fittings. If deposits are found, inspect
the DEF line connection fittings for damage. See equipment
manufacturer service information for assistance with DEF
lines.
For visible leaks from the aftertreatment DEF dosing unit
connectors, use the Clean and Inspect for Reuse step in the
following procedure. Refer to Procedure 011-058 in Section
11. (/qs3/pubsys2/xml/en/procedures/379/379-011-
058.html)
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.
 WARNING 
Acid is extremely dangerous and can damage the
machinery and can also cause serious burns. Always
provide a tank of strong soda water as a neutralizing agent
when servicing the batteries. Wear goggles and protective
clothing to reduce the possibility of serious personal injury.
 WARNING 
Wear appropriate eye and face protection when using

compressed air. Flying debris and dirt can cause personal
injury.
 WARNING 
The air solenoid and coolant lines connecting to the

aftertreatment DEF dosing unit are hot and can be under
pressure and must not be disconnected while the engine is
running or before the system has cooled down after engine
shutdown. Heated coolant spray can cause personal injury.
To reduce the possibility of personal injury, use eye and
face protection, gloves and appropriate personal protective
equipment.
Disconnect the batteries. See equipment manufacturer

service information.
Release the pressure in all vehicle air tanks. See
equipment manufacturer service information.
Remove the aftertreatment nozzle. Make sure the
aftertreatment nozzle and DEF line are completely clear
of blockage. Refer to Procedure 011-040 in Section 11
(/qs3/pubsys2/xml/en/procedures/379/379-011-
040.html) and the equipment manufacturer service
information.
The aftertreatment DEF dosing unit must be wiped with a

clean damp cloth and warm water with a mild detergent. Use
a clean damp cloth to remove any contamination and reduce
the risk of contamination entering the DEF dosing unit.
Flush
 WARNING 
 WARNING 

injury.
Note : Make sure the vehicle air supply to the DEF

dosing unit is either drained down or isolated before
removing the air supply line.
Disconnect the air supply line to the DEF dosing unit.
Coil the polytetrafluoroethylene tube, Part Number

5296513, from the doser pump cleaner kit, Part Number
5296510, and fasten using tape. Inject and fill the tube
completely with warm +40 °C [104°F] distilled water. Use
the syringe from service tool kit, Part Number CC-2602.
Connect one end of the coiled polytetrafluoroethylene

pipe to the aftertreatment DEF dosing unit air supply
port (1), and the opposite end to the vehicle air supply
(2). Use the barrel connector from the doser pump
cleaner kit, Part Number 5296510.
Connect the DEF transfer line to the outlet of the
aftertreatment DEF dosing unit (3) and the
aftertreatment nozzle (4).
Place the aftertreatment nozzle in a clean container.
 WARNING 

Note : It can be necessary to run the engine at idle for

several minutes build up the air pressure in the air
tank.
Connect the batteries. See equipment manufacturer
Connect INSITE™ electronic service tool. Perform the air
flow test within Diesel Exhaust Fluid Doser Pump Air
Solenoid Click Test to toggle the air solenoid to flush the

water through the system.
Collect the fluid from the aftertreatment nozzle in a
clean container.
Once all the water has been forced out of the
aftertreatment nozzle, wait another 30 seconds for clear
air flow before stopping the Diesel Exhaust Fluid Doser
Pump Air Solenoid Click Test.
Note : While the test is running, make sure that air is

flowing out of all four holes of the aftertreatment
nozzle. Otherwise, the aftertreatment nozzle may be
blocked. Refer to Procedure 011-040 in Section 11.
(/qs3/pubsys2/xml/en/procedures/379/379-011-
040.html)
Note : When flushing is being performed, the
aftertreatment nozzle will spray a very fine mist of
fluid. To prevent fine mist from escaping into the air,
place a clean shop towel or cover over the nozzle and
container. Dispose of the fluid in accordance with
local environmental regulations.
Note : Make sure the vehicle air supply to the DEF

dosing unit is either drained down or isolated before
removing the air supply line.
Remove the coiled polytetrafluoroethylene pipe and
barrel connector from the DEF dosing unit air supply
line.
Connect the original equipment manufacturer (OEM) air
supply line to the DEF dosing unit and vehicle air supply.
Test
 WARNING 

 WARNING 
injury.
Turn keyswitch ON.

Connect INSITE™ electronic service tool.
Start and operate the engine. The DEF dosing unit will go
through its priming cycle. After a maximum of 5
minutes, air should flow through the system.
Use INSITE™ electronic service tool to measure the
aftertreatment diesel exhaust fluid air mixture pressure.
Aftertreatment Diesel Exhaust Fluid Air Mixture

Pressure Specifications
kpa psi
320 MIN 46
410 MAX 59
If the air pressure is outside of the specification after

performing Flush step three times:
Check for air leaks from the air solenoid valve. Replace the
air solenoid if a leak is detected. Refer to Procedure 011-058
in Section 11. (/qs3/pubsys2/xml/en/procedures/379/379-
011-058.html)
Check the DEF dosing line for blockages or restrictions.

If blockages or restrictions, repair or replace the DEF
dosing line.
Check the DEF nozzle for blockages or restrictions. If
blockages or restrictions, repair or replace the DEF
nozzle.
If none of the above is causing the issue, replace the DEF

dosing unit. Contact a Cummins® Authorized Repair
Location. Refer to Procedure 011-058 in Section 11.
(/qs3/pubsys2/xml/en/procedures/379/379-011-058.html)
Finishing Steps
 WARNING 

Install the aftertreatment nozzle on the exhaust system.

Connect the batteries. See equipment manufacturer
Start and operate the engine to build up air pressure.
Check for air or DEF leaks.
Check for active fault codes.
Last Modified: 04-Jun-2020

Aftertreatment Diesel Exhaust Fluid Dosing Unit Air Side Flushing

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8/19/24, 10:30 AM Aftertreatment Diesel Exhaust Fluid Dosing Unit Air Side Flushing

Note : The aftertreatment DEF dosing unit is not

Wear appropriate eye and face protection when using

The air solenoid and coolant lines connecting to the

Disconnect the batteries. See equipment manufacturer

The aftertreatment DEF dosing unit must be wiped with a

Wear appropriate eye and face protection when using

Note : Make sure the vehicle air supply to the DEF

Coil the polytetrafluoroethylene tube, Part Number

Connect one end of the coiled polytetrafluoroethylene

Batteries can emit explosive gases. To reduce the

Note : It can be necessary to run the engine at idle for

Solenoid Click Test to toggle the air solenoid to flush the

Note : While the test is running, make sure that air is

Note : Make sure the vehicle air supply to the DEF

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

Turn keyswitch ON.

Aftertreatment Diesel Exhaust Fluid Air Mixture

If the air pressure is outside of the specification after

Check the DEF dosing line for blockages or restrictions.

If none of the above is causing the issue, replace the DEF

Batteries can emit explosive gases. To reduce the

Install the aftertreatment nozzle on the exhaust system.

Last Modified: 04-Jun-2020

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