Scribd Logo
Upload

Welcome to Scribd!

  • 30 views

    2.5 Aftertreatment Device

    Uploaded by

    Luis Calla
    The aftertreatment device (ATD) uses selective catalytic reduction to convert nitrogen oxides from diesel exhaust into nitrogen and water using diesel exhaust fluid. The document provides step-by-step instructions for removing and installing the ATD, which involves disconnecting electrical and fluid lines, removing mounting hardware, and inspecting components. Safety precautions are noted throughout regarding electrical shock, exhaust inhalation, and ensuring the vehicle is securely parked.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    2.5 Aftertreatment Device

    Uploaded by

    Luis Calla
    30 views8 pages
    The aftertreatment device (ATD) uses selective catalytic reduction to convert nitrogen oxides from diesel exhaust into nitrogen and water using diesel exhaust fluid. The document provides step-by-step instructions for removing and installing the ATD, which involves disconnecting electrical and fluid lines, removing mounting hardware, and inspecting components. Safety precautions are noted throughout regarding electrical shock, exhaust inhalation, and ensuring the vehicle is securely parked.

    Original Title

    2.5  Aftertreatment Device

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    The aftertreatment device (ATD) uses selective catalytic reduction to convert nitrogen oxides from diesel exhaust into nitrogen and water using diesel exhaust fluid. The document provides step-by-step instructions for removing and installing the ATD, which involves disconnecting electrical and fluid lines, removing mounting hardware, and inspecting components. Safety precautions are noted throughout regarding electrical shock, exhaust inhalation, and ensuring the vehicle is securely parked.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    30 views8 pages

    2.5 Aftertreatment Device

    Uploaded by

    Luis Calla
    The aftertreatment device (ATD) uses selective catalytic reduction to convert nitrogen oxides from diesel exhaust into nitrogen and water using diesel exhaust fluid. The document provides step-by-step instructions for removing and installing the ATD, which involves disconnecting electrical and fluid lines, removing mounting hardware, and inspecting components. Safety precautions are noted throughout regarding electrical shock, exhaust inhalation, and ensuring the vehicle is securely parked.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    You are on page 1of 8

    DD Platform EuroV Workshop Manual (DDC-SVC-MAN-0205)

    2.5 Aftertreatment Device


    2.5.1 Description and Operation of the Aftertreatment Device
    The Aftertreatment Device (ATD) consists of a Selective Catalytic Reduction (SCR) hydrolysis chamber and two
    SCR catalysts that convert a mixture of nitrogen oxides and Diesel Exhaust Fluid (DEF) into nitrogen and water.
    DEF is pressurized by a pump and is then sprayed into the SCR hydrolysis chamber before reaching the SCR
    catalysts. No parts inside of the ATD are serviceable.

    2.5.2 Removal of the Aftertreatment Device

    Service Tools Used in the Procedure


    Tool Number Tool Name Tool Graphic
    Locally Sourced ATD Lifting Device

    Remove as follows:

    NOTICE
    To prevent Diesel Exhaust Fluid (DEF) flow issues, take note of the routing of the DEF
    lines. If removed, they MUST be installed according to manufacturer’s specifications to
    avoid DEF flow issues and leaks.

    1
    DD Platform EuroV Workshop Manual (DDC-SVC-MAN-0205)

    NOTICE
    Wait at least five minutes after shutting down the engine to disconnect the DEF lines.

    1. Shut off the engine and 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. Disconnect the batteries.
    3. Allow the aftertreatment device time to cool.
    4. Remove the passenger side fairing. Refer to the Original Equipment Manufacturer (OEM) procedures.
    5. Remove the passenger side fairing mounting bracket. Refer to OEM procedures.
    6. Note the location and orientation of the clamps. They will need to be installed in the same orientation. A
    paint marker can be used to mark the correct orientation.
    7. Remove the bolt securing SCR inlet pipe to the frame rail mounting bracket and disconnect the SCR inlet
    pipe at the turbocharger outlet connection.
    8. Disconnect the SCR inlet pipe by loosening the clamp and relocating the inlet pipe away from the
    aftertreatment.
    9. Remove the nylon straps securing the DEF lines to the ATD.
    10. Disconnect the DEF pressure (1) and return (2) line from the DEF dosing unit. Relocate the lines up and
    out of the way. See graphic below.

    2
    DD Platform EuroV Workshop Manual (DDC-SVC-MAN-0205)

    11. Disconnect both 18-pin electrical connectors (1). See graphic below.

    12. Disconnect the SCR outlet pipe by loosening the clamp. Remove the pipe and position aside.
    13. Using the ATD lifting device, lightly position the lifting device under the ATD without enough force to lift the
    ATD or the vehicle. Attach a safety strap to the lifting device. See graphic below.

    3
    DD Platform EuroV Workshop Manual (DDC-SVC-MAN-0205)

    14. Remove the three bolts and nuts attaching the ATD rear mounting bracket to the vehicle frame rail.
    15. Remove the four bolts and nuts attaching the ATD to the front mounting bracket. DO NOT remove the three
    bolts attaching the front mounting bracket to the frame.
    16. Carefully lower the ATD away from the vehicle ensuring that all exhaust, air, and electrical harness
    connections have been disconnected and that the ATD is free from the vehicle.

    2.5.3 Inspection of the Aftertreatment Device

    4
    DD Platform EuroV Workshop Manual (DDC-SVC-MAN-0205)

    Inspect as follows:
    1. Inspect the Diesel Exhaust Fluid (DEF) lines and connector fittings for damage. Repair or replace as
    needed.
    2. Inspect the DEF lines for blockages. Flush as needed.
    3. Inspect the 18-pin chassis electrical connector for damage to the pins or connector. Repair or replace as
    needed.
    4. Inspect the all electrical components for signs of damage. Repair or replace as necessary.
    5. Inspect the Aftertreatment Device (ATD) for physical damage. Repair as necessary.

    2.5.4 Installation of the Aftertreatment Device

    Service Tools Used in the Procedure


    Tool Number Tool Name Tool Graphic
    Locally Sourced Aftertreatment (ATD) Lifting Device

    Install as follows:
    1. Is the Aftertreatment Device (ATD) being replaced?
    1.a Yes; Go to step 2.
    1.b No; Go to step 4.
    2. Transfer rear mounting bracket over to the new ATD and hand-tighten the bolts.
    3. Transfer the following parts over to new ATD:
    • Side step brackets
    • Aftertreatment harness

    5
    DD Platform EuroV Workshop Manual (DDC-SVC-MAN-0205)

    • Front sensor bracket


    • Temperature and NOx sensors
    • Diesel Exhaust Fluid (DEF) dosing unit
    • Aftertreatment Control Module (ACM) and cover
    4. Using the ATD lifting device, carefully raise the ATD to the vehicle frame and align the ATD mounting
    brackets to the holes in the vehicle frame. See graphic below.

    5. Carefully align and install the SCR inlet pipe. Hand-tighten the clamps.
    6. Carefully align and install the SCR exhaust pipe. Hand-tighten the clamp.
    7. Install the four bolts and nuts on the front mounting bracket, attaching the aftertreatment to the front
    mounting bracket. Hand-tighten the bolts.
    8. Install the three bolts and nuts attaching the rear mounting bracket to the vehicle frame. Torque to 174 N·m
    (128 lb·ft).
    9. Torque the front mounting bracket bolts and nuts to 87 N·m (64 lb·ft).
    10. Connect both 18-pin electrical connectors. See graphic below.

    6
    DD Platform EuroV Workshop Manual (DDC-SVC-MAN-0205)

    11. Ensure that the DEF pressure and return lines are routed correctly under the frame rail of the vehicle.
    12. Connect the DEF pressure (1) and return lines (2) to the DEF dosing unit. See graphic below.

    7
    DD Platform EuroV Workshop Manual (DDC-SVC-MAN-0205)

    13. Install the nylon straps securing the DEF lines to the ATD.
    Note : The exhaust system outlet pipe clamps are directional; verify correct installation.
    14. Torque the SCR outlet pipe to 9 to10 N·m (79 to 88 lb·in.).
    15. Torque the SCR inlet pipe and turbocharger outlet clamps to 9 to 10 N·m (79 to 88 lb·in.).
    16. Remove the ATD lifting device.
    17. Install the passenger side fairing mounting bracket. Refer to the Original Equipment Manufacturer (OEM)
    procedures.
    18. Install the passenger 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.
    19. 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.

    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.

    WARNING
    ENGINE EXHAUST
    To avoid injury from inhaling engine exhaust, always operate the engine in a well-
    ventilated area. Engine exhaust is toxic.

    20. Start the engine.


    21. Check for any exhaust leaks.

    You might also like