FPT - SCR System Installation Guideline to

meet Emission Standards Euro IV/V & Tier4A

with Bosch DNOx-2.1
without Coolant Control Valve (CCV-less version)

Version 7.3
Arbon / Turin, 21-05-2013

M. F. Pidria, S. Neggia
Aftertreatment Systems
20 Novembre, 2010
Table of contents

page content
3 SCR system description, configurations, chemical reactions
6 AdBlue/DEF – urea/water solution as reducing agent, specifications
9 SCR system overview, layout
12 Urea Dosing System (UDS) - Bosch Denoxtronic 2 (DNOx-2.1) overview
19 Supply module (SM) installation instructions
28 Dosing module (DM) installation instructions
34 Dosing / mixing unit and SCR muffler installation (Cursor engine)
44 Dosing / mixing unit and SCR muffler installation (NEF engine)
56 Instructions for modified exhaust pipe / SCR muffler layouts
61 AdBlue/DEF tank and WEMA combination unit
70 Material requirement for exhaust pipes and AdBlue/DEF tank
72 AdBlue/DEF pipes, hoses, connectors and filter
86 SCR control layout
88 Electrical layout and schemes
91 Exhaust temperature, NOx and humidity sensors
101 Parts list
102 Revisions
103 Contacts

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 2

SCR system description

• FPT has chosen SCR (selective catalyst reduction) for the medium engine (NEF) and
heavy engine (Cursor) ranges to meet present and future on-road and off-road emission
standards Euro V/VI and Tier 4A/B. Alternative emission reduction strategies by means of
EGR (exhaust gas recirculation) partly in combination with a particular trap and SCR are
applied on the light duty applications (F1 engines range)
• Why Selective Catalyst Reduction ?
 Selective Catalytic Reduction (SCR) is a widely used technology for removing
Nitrogen Oxides (NOx) from lean exhaust gases
 To enable the catalytic reduction of NOx to N2, the presence of ammonia is needed
 As ammonia is a toxic compound, usually an ammonia-releasing reagent is used
instead of pure ammonia
 AdBlue (trade name for Europe) or DEF (Diesel Exhaust Fluid, trade name for USA)
is a non-toxic aqueous urea solution. AdBlue/DEF is classified under the minimum
risk category of transportable fluids. AdBlue/DEF is guaranteed to meet the
Standards of ISO 22241 and the CEFIC regulations to safeguard the correct
functioning of your vehicle’s SCR system
 AdBlue/DEF is injected into the exhaust system with a specific dosing module.
 In the exhaust system the liquid has to be atomized and distributed homogeneously
in the exhaust pipe or across the catalyst cross-section respectively
 EN590 Diesel fuel has to be used, anyhow up to 2000 ppm S can be tolerated
by SCR only aftertreatment, while ULSD is necessary in combination with CRT

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 3

SCR configurations

SCR SCR cat only

configuration selected by FPT

SCR cat
SCR C
+ clean-up cat

SCR cat
O SCR C + pre-oxidation cat
+ clean-up cat

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 4

SCR chemical reactions

8 NH3 + 6 NO2  7 N2 + 12 H2O

Hydrolysis
4 NH3 + 4 NO + O2  4 N2 + 6 H2O
CO(NH2)2 + H2O  2 NH3 + CO2

2 NH3 + NO + NO2 2 N2 + 3 H2O

EXHAUST GAS
SCR Catalyst

SCR

UREA injection

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 5

AdBlue/DEF physical properties

60
 Concentration of 32.5% was chosen
because at this mixing ratio the 50
solution has its lowest freezing point

ea
40

ur
of -11°C (eutectic mixing ratio)

-
30
 To maintain correct system operation

T [°C]
20
under cold conditions, AdBlue/DEF

a
re
tank, pipes, pump module and dosing

-u
10


module need a de-freezing system
0

a
H2O

e
-ur
 ... likewise, the complete AdBlue/DEF


-10
distribution network requires -11.5°C
precautions against freezing
0 10 20 30 40 50 60 70
Urea concentration [°C]

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 6

AdBlue/DEF infrastructure

 The required network of AdBlue/DEF filling

stations in Europe is currently being
growing up by companies from the mineral
oil business and chemical industry
 Infrastructure has been set up in 3 steps:
1) Filling stations on the yard of large
fleet owners and any workshops of
truck companies (... open to all
AdBlue/DEF users)
2) Public filling stations along
expressways in Europe
3) Public filling stations covering
distribution throughout Europe
 AdBlue/DEF filling stations in Europe can
be found via internet link:
www.findadblue.com

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 7

AdBlue/DEF specification
®
Air1 Specifications
ISO 22241 / AUS32 / DIN V 70070
Product properties for AdBlue®

Urea 32,5 % - solution in water

Min. Max.
Urea content 31.8 33.2 % by weight
Density at 20°C 1.087 1.093 g/cm³
Refracting index at 20°C 1.3814 1.3843
Alkalinity as NH3 0.2 %
Biuret 0.3 %
Aldehyde 5 mg/kg
Insolubles 20 mg/kg
Phosphate (PO4) 0.5 mg/kg
Calcium 0.5 mg/kg
Iron 0.5 mg/kg
Copper 0.2 mg/kg
Zinc 0.2 mg/kg
Chromium 0.2 mg/kg
Nickel 0.2 mg/kg
Aluminium 0.5 mg/kg
Magnesium 0.5 mg/kg
Sodium 0.5 mg/kg
Potassium 0.5 mg/kg

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 8

SCR system overview main components

Supply Module

Urea tank

SCR muffler
Dosing
Module
21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 9
SCR system overview

 For the selective catalytic reduction of NOx, the presence of ammonia is needed. As
ammonia is a very toxic compound, usually an ammonia-releasing reagent is used
instead of pure ammonia. The reagent is introduced into the exhaust system upstream
the SCR catalyst. Achieving high NOx conversion and avoiding ammonia slip in the
exhaust gas requires very accurate dosing of a reducing agent
 Despite of several technical disadvantages (freezing point, dosing temperature threshold,
urea deposits, storage volume, etc.) European manufactures of HD trucks agreed to use
urea/water solution as reducing agent for SCR mainly for safety and handling reasons:
 Trade names for the urea/water solution (32.5%w): AdBlue/DEF
 Product composition, quality and properties of AdBlue/DEF have been
standardized by ISO 22241 / AUS32 / DIN V 70070
 FPT has chosen the Bosch urea dosing system (UDS) DNOx1 or DNOx-2.1 for it’s
SCR current production systems. The UDS consist mainly of a supply module (SM) and a
dosing module (DM). The SM integrates a pump, valves, filters, sensors, pressure
controller and the dosing control unit (DCU) within an environmentally secure box. The
DM contains mainly the a PWM dosing valve and is located close to the exhaust pipe
upstream the SCR catalyst. Mid of 2005 the 1st air-assisted UDS DNOx1 was introduced
by IVECO for heavy trucks and busses. Wherever possible the DNOx1 system was then
replaced by the air-less DNOx-2.1 system during 2006

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 10

System layout: air-less UDS (DNOx-2.1)

VERY IMPORTANT!
Intake air Bosch re-branded the system
humidity
& temp. DNOx-2.0 ST10 CCV-less as
sensor
Air DNOx-2.1
filter
Dosing
Module

Supply
ECU Module
DEF mixer

DCU

NOx AdBlue/DEF
Temperature sensor Temperature sensor
sensor level &
downstream upstream
temperature
sensor
SCR

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 11

DNOx-2.1 Supply Module (SM) 1/7

For prototype and final installation layouts please ask for detailed supplier customer information

Pressure sensor

Temperature sensor

Filter

4/2-way valve
Supply pressure: 5 bar
Actuator control: DCU 15
Software P910

Diaphragm pump

FPT p/n 504374326, CNH p/n 84246892, Bosch p/n 0444022021

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 12
DNOx-2.1 system overview 2/7

previous CCV new CCV-less

version version

Relevant note according to DNOx-2.1 TCD (KQ44023107, Rel. 5, p. 6; KQ44022108, Rel. 5, p. 8), “Used
parts: Close all NOx reduction agent AUS 32 connectors with caps”:
Usage of protection caps for the hydraulic connectors is absolutely mandatory if Denoxtronic 2.1
components are stored, disassembled from the vehicle and/or hydraulic hoses are disconnected.
Hydraulic connectors of the Denoxtronic 2.1 components must be covered to prevent ingress of dirt and
crystallisation
21-05-2013
of residual DEF, which might
CONFIDENTIAL result in malfunctions of the Denoxtronic 2.1 system.
SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 13
DNOx-2.1 CCV-less filters 3/7

Filter in DEF/AdBlue filer neck

SM main filter
10 μm
Filter in DEF/Adblue
supply line (Voss)
100 μm

Prefilter
100 μm

2 filters in Dosing Module

100 μm

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 14

DNOx-2.1 CCV-less filters 4/7

Filters in Euro V - Tier4A DEF/AdBlue circuit with DNOx-2.1 dosing system

filter type filter location p/n maintenance
DEF/AdBlue
Tank mesh coarse 41272413 cleaning if needed
tank
Filter in DEF/AdBlue tank to Supply - Euro V: linked to SM filter change
100 mm 42555466
supply line (Voss) Module - Tier4A: cleaning @ every oil change interval
SM prefilter coarse Supply Module na
no maintenance to be performed
- Euro V: 180,000 km or before 2 years or
SM filter (Bosch)
before 3,600 working hours
kit p/n 1457436006 10 mm Supply Module 42561605
(Bosch)
- Tier4A: before 2 years or before 3,600
working hours
Dosing Module
100 mm na no maintenance to be performed
inlet
DM prefilters
Dosing Module
100 mm na no maintenance to be performed
outlet

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 15

SM filter kit p/n 1457436006 5/7

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 16

SM filter kit p/n 1457436006 6/7

ATTENTION!
It is not allowed to install a
used and/or wet filter, due
to danger of damage and
malfunctions
Note:
Do not dispose parts (filter) in
household refuse

Main filter maintenance:

 3 Filter cover: open it to the left, take off filter cover
 2 Filter cartridge: unscrew it from filter cover.
 4 O-sealing ring: needs to be renewed after each filter
cartridge change. Lubricate with glycerin for easy
mounting.
 2 Filter cartridge: tighten it by hand until you feel a
resistance (around 1/4 rotation)
 3 Filter cover: attach it to SM and tighten it with a
torque of 20 Nm, + 5 Nm

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 17

DNOx-2.1 Dosing Module (DM) 7/7
For prototype and final installation layouts please ask for detailed supplier customer information

Dosing quantity: Min. 200 g/h

Max. 6 / 9kg/h.
Heat shield
Spray angle α: 54°
Spray holes: 1
Cooling concept: Active cooling

Dosing valve Cooling line

(return to SM)
Metal sheet body Pressure line
for heat isolation (from SM)
Filter
100μm
Sectional view of half holder

Elect. Connector
to dosing valve
6,5÷7,5 Nm

Bosch p/n 0444023058

All NEF & Cursor
504374327 (up to June 2013)
8/9/10/11/13 FPT p/n
DM 6 kg/h (Euro IV/V only)
5801730656 (since June 2013)
engines 84247021 (up to June 2013)
Fix throttle with CNH p/n
47511724 (since June 2013)
backpressure valve
Bosch p/n 0444023062

504381866 (up to June 2013)

All Tier4A Cursor 13 FPT p/n
DM 9 kg/h engines
5801730657 (since June 2013)

84248058 (up to June182013)

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt
CNH p/n
47511725 (since June 2013)
SM installation instructions 1/9

For prototype and final installation layouts please ask for detailed supplier customer information

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 19

SM installation instructions 2/9

For prototype and final installation layouts please ask for detailed supplier customer information

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 20

SM installation instructions 3/9
For prototype and final installation layouts please ask for detailed supplier customer information

DCU 15
35 pins
connector

filter

drain plug pressure

compensation

BACKFLOW OUTLET
to tank INLET
from tank

BACKFLOW INLET
from DM
pre-filter
OUTLET to DM

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 21

SM installation instructions 4/9
For prototype and final installation layouts please ask for detailed supplier customer information

Usually the SM can be

installed without rubber
mounts. However, vibration
measurements have to be
carried out before FPT /
Bosch can give a
production release

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 22

SM installation instructions 5/9
For prototype and final installation layouts please ask for detailed supplier customer information

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 23

SM installation instructions 6/9

For prototype and final installation layouts please ask for detailed supplier customer information

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 24

SM installation instructions 7/9

For prototype and final installation layouts please ask for detailed supplier customer information

The specification of the pump limits the suction

height (negative pressure) of the inlet line (IL).
In this configuration maximum suction height is
reached when AdBlue/DEF level is at minimum level
(MAL) or reaches the begin of the inlet line (BIL).

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 25

SM installation instructions 8/9
For prototype and final installation layouts please ask for detailed supplier customer information

• After shut-off, unwanted flow of AdBlue/DEF

from Supply Module to Dosing Module must
be avoided. In this configuration a routing of
AdBlue/DEF pressure line with a siphon
close to Dosing Module can avoid this
• The length of line between siphon and DM
shall be minimum to limit the volume of
AdBlue/DEF that may flow back to DM
• A test has to show that the remaining
AdBlue/DEF after after-run in the pressure
line matches siphon volume
• A flat siphon can avoid blocking of line by ice
if not complete cross section is frozen

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 26

SM installation instructions 9/9

For prototype and final installation layouts please ask for detailed supplier customer information

• After shut-off unwanted flow of

AdBlue/DEF to Dosing Module
must be avoided
• A routing of AdBlue/DEF pressure
line higher than max. level of
AdBlue/DEF in tank can avoid
this

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 27

DM installation instructions 1/6

For prototype and final installation layouts please ask for detailed supplier customer information

Horizontal 5
°

FPT recommends a
minimum inclination of 5
degrees above the horizon

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 28

DM installation instructions 2/6
For prototype and final installation layouts please ask for detailed supplier customer information

0
°
Heat

In cases where the DM is

installed on an inclined
exhaust pipe it is
suggested that the axis of
spray direction is pointing
towards the ground. FPT
recommends a minimum
inclination of 5 degrees
above the horizon (see
previous pages).
To keep the temperatures
of the DM connections as
low as possible the body Deposits
should be exposed toward
the driving wind or
ventilation cooling
whenever possible.

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 29

DM installation instructions 3/6

For prototype and final installation layouts please ask for detailed supplier customer information

Good Deposits Heat

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 30

DM installation instructions 4/6

For prototype and final installation layouts please ask for detailed supplier customer information

Air stream

Heat insulation

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 31

DM installation instructions 5/6

For prototype and final installation layouts please ask for detailed supplier customer information

Air stream

Air stream

Heat shield

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 32

DM installation instructions 6/6

For prototype and final installation layouts please ask for detailed supplier customer information

min.5°

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 33

Dosing & mixing unit installation (Cursor)
Version for Cursor engine (FPT patent), FPT p/n 4129 6199

Reference point (RP)

flow direction

105 111 110

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 34

Dosing & mixing unit installation (Cursor)

Exhaust pipe
with integrated
mixer unit for
Cursor engine
(Iveco Stralis)
FPT p/n
4129 6197

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 35

Truck SCR muffler installations (Cursor)

urea injection positions

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 36

Truck SCR muffler installations (Cursor)

temperature sensor
SCR inlet

NOx sensor

temperature sensor
SCR outlet

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 37

Faurecia horizontal Cursor SCR mufflers (LHD)

Note: latest production SCR mufflers

are equipped with NOx sensor boss

Cursor 8: 4129 8537 Cursor 10: 4129 8536

Cursor 13 < 368 kW: 4127 2365 Cursor 13 412 kW: 4127 2447

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 38

Faurecia horizontal Cursor SCR mufflers (RHD)

Note: latest production SCR mufflers

are equipped with NOx sensor boss

Cursor 8: 4129 8541 Cursor 10: 4129 8540

Cursor 13 < 368 kW: 4127 2366 Cursor 13 412 kW: 4127 2448
21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 39
Faurecia vertical Cursor SCR mufflers

Can be installed also horizontally

Note: latest production

SCR mufflers are
equipped with NOx
sensor boss

Cursor 8: 4127 2370 Cursor 13: 4127 2369

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 40

Cursor SCR muffler installation

StepSeal clamp for Cursor exhaust pipe/muffler connection, FPT p/n

4128 8279, tightening torque 50÷60 Nm

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 41

SCR mufflers Tier4i for free market
Cursor 9 & Cursor 10

Donaldson (24,4 L) Faurecia (30,2 L)

• CNH p/n 84325387 • CNH p/n 84160734
• FPT p/n 5801472311 • FPT p/n 5801472301

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 42

SCR mufflers Tier4i for free market
Cursor 13

Donaldson (33,3 L)
• CNH p/n 84366819
• FPT p/n 5801472213

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 43

Dosing & mixing unit installation (NEF)
Version for NEF engine (FPT patent), FPT p/n 804 7376

Reference point (RP)

flow direction

110.5 102.5

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 44

Dosing & mixing unit installation (NEF)
Two exhaust pipes with integrated mixer available for NEF engine (Iveco Eurocargo)

FPT p/n 504148370 504148371

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 45

Truck SCR muffler installations (NEF)

urea injection positions

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 46

Cortubi NEF 4 - 6 SCR horizontal mufflers

Motore Rif. Iveco/Iveco nr. Rif. Iveco/Iveco nr. n° di elementi Dimensioni Volume totale
Engine sul certificato/on certificate Acquisto/Buy n. of elements Dimensions Total Volume

5801268980 KZ (EURO4 AISI 439)

TECTOR
NEF 4 4 504135181 UB 1 9,5"x10" 11,6 l
5801269042 (MY08 AISI 439)

TECTOR
NEF 4 V4 V 504135189 UB 5801269081 KZ (AISI 439) 1 9,5"x10" 11,6 l

5801269056 KZ (EURO4 AISI 439) 9,5"x11"

TECTOR
NEF 6 6 504135186 UB 1+1 17,2 l
5801269048 KZ (MY08 AISI 439) 5,66"x11"

9,5"x11"
TECTOR
NEF 6 V6 V 504135192 UB 5801269066 KZ (AISI 439) 1+1 17,2 l
5,66"x11"

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 47

Cortubi NEF 4 SCR muffler - horizontal tailpipe

5041 35181

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 48

Cortubi NEF 4 SCR muffler - vertical tailpipe

Note: NOx sensor

has to be installed
in tailpipe close to
muffler outlet

5041 35189

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 49

Cortubi NEF 6 SCR muffler - horizontal tailpipe

5041 35186

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 50

Cortubi NEF 6 SCR muffler - vertical tailpipe

Note: NOx sensor

has to be installed
in tailpipe close to
muffler outlet

5041 35192

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 51

Cortubi NEF 4 - 6 SCR vertical mufflers

8424 7696
CNH combines

Can be installed also

horizontally

8425 6315
CNH wheel loader

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 52

NEF SCR muffler installation

V-clamp for NEF exhaust pipe/muffler connection, FPT p/n 504 105 924,
tightening torque 7 Nm

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 53

SCR mufflers Tier4i for free market
NEF 4 cyl.

CorTubi (11,6 L) DineX (12,4 L)

• CNH p/n 84298781 • CNH p/n 84489586
• FPT p/n 5801527893 • FPT p/n 5801526886

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 54

SCR mufflers Tier4i for free market
NEF 6 cyl.

Faurecia (20,9 L) Donaldson (17,4 L)

• CNH p/n 84170932 • CNH p/n 84328272
• FPT p/n 5801471839 • FPT p/n 5801471673

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 55

General instructions for modified exhaust pipe layouts 1/5

 Iveco standard SCR muffler in combination with Iveco standard exhaust pipes
have been intensively tested and are released for best NOx conversion and
the avoidance of urea deposits
 For custom made exhaust pipes pay attention to the following boundary Reference point mixer
(RP, see pages 34/42)
conditions:
 Minimum pipe length between turbine outlet flange and dosing module
(DM) reference point (RP) is 230 mm
 Straight pipe distances from inlet bend to the dosing module (RP) and
DM (RP) to outlet bend should exceed following values:
 30 deg. bend > 150 mm
 45 deg. bend > 200 mm
 90 deg. bend > 300 mm
For more details see next pages
 Adopting std. on-road IVECO SCR mufflers, following min. distances
between DM (RP) & SCR muffler inlet have to be respected:
 320 mm for NEF rectangular mufflers (504135 181/189/186/192)
 1200 mm for Cursor horizontal & vertical mufflers
 An insulated elbow/exhaust piping downstream of the DEF mixer is
recommended if the above values cannot be accommodated
 Depending on engine rating, application and operation profile an exhaust pipe
insulation might be necessary (e.g. garbage collector)
 To prevent urea deposits, bad designed / manufactured V-clamps, sharp
edges or welding seams, creating cold spots / flow disturbances directly after
the mixer outlet, have to be avoided in the exhaust pipes
 Any installation has to be checked and approved by FPT
21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 56
General instructions for modified exhaust pipe layouts 2/5

Dosing
valve axis
Reference
α L_in  L_out point (RP)
minimum minimum

90° 300 mm 90° 300 mm

45° 200 mm 45° 200 mm

Gas
flow
30° 150 mm 30° 150 mm
L_in minimum from turbine flange to RP = 230 mm L_in L_out
End of Begin of
bend bend

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 57

Specific installation instruction for Cursor mixer 3/5

SCR inlet
Dosing
valve axis Mixer flange
α
Mixing unit

Mixer

Gas flow

Begin of bend
End of bend L_in* L_out*

α L_in*  L_out* L_min

90° >189 mm 90° >195 mm > 1200 mm
45° >89 mm 45° <95 mm
30° >39 mm 30° >45 mm

No change of diameter on the whole tube / no edges inside the tube (welding to be cleaned)

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 58

Specific installation instruction for NEF mixer 4/5

 standard max length of downpipe: 2400 mm  longer installations to be verified in

NRTC
 no thermal insulation for downpipes with a length below 1500 mm
 thermal insulation mandatory for downpipes with length between 1500 and 2400
mm Dosing
valve axis Mixer flange SCR inlet
α
Mixing unit

Mixer

Gas flow

Begin of bend
End of bend L_in* L_out*

α L_in*  L_out*
90° >198 mm 90° >190 mm
45° >98 mm 45° >90 mm
30° >48 mm 30° >40 mm

No change of diameter on the whole tube / no edges inside the tube (welding to be
cleaned)
21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 59
Instructions for modified pipe / muffler layouts 5/5

Layout recommendation for new SCR muffler designs

20
1)
18
mixing chamber volume [l/100kW]

mixing SCR
mixing pipe
chamber catalyst
16

14
range to be
used
12 2)
mixing SCR
chamber catalyst
10

mixing pipe
6 gas inlet, mixer &
dosing module

4
0.5 1.5 2.5 3.5 4.5 5.5 6.5 7.5
mixing pipe volume [l/100kW]
3)
Additional exhaust pipe limitations: SCR
mixing catalyst
1) mixing pipe not shorter than 650 mm*) for systems with axial gas inlet! chamber
2) mixing pipe not shorter than 550 mm*) for systems with 90° gas redirection!
3) mixing pipe not shorter than 450 mm*) for systems with 180° gas redirection!
*) includes L_out as shown on page 53
mixing pipe
Ask FPT support (last page) for detailed design layout instructions!

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 60

AdBlue/DEF tank layout recommendations 1/9

FPT recommends maintaining AdBlue/DEF temperature below 50 °C in the tank during operating
conditions. For storage and none operating conditions the limits are specified in ISO DIS 22241-3 standard.

Based on experiences on different applications FPT & Bosch recommend:

 not to install the AdBlue/DEF tank in the engine
compartment (if applicable)
 to avoid direct blowing of hot engine cooling air or other
hot stream towards the AdBlue/DEF tank
 to protect the AdBlue/DEF tank from direct sunlight
 Tank ventilation:
 must be protected from dust / debris entry into the circuit
 Position in a place where contamination with dirt is
minimized. If this is not possible a filter is mandatory to
protect vent line from clogging.
 Do not use corrugated pipes. A minimum ID of 8 mm is
strongly recommended
 make sure that in any extreme inclination DEF will not
flow into vent line and crystallize  No submerging
 tank filler cap has to be positioned below the ventilation
on tank unit to achieve an expansion volume of 12%
(volume increase for liquid to frozen AdBlue/DEF)

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 61

AdBlue/DEF tank layout recommendations 2/9

 For sufficient cooling of the dosing module,  To obtain a correct after-run at

the suction port has to submerge in a engine shut-off with full tank, the
minimum of 5 litres AdBlue/DEF which return pipe must not submerge
should be contained in a single suction into fluid under all operating
volume of the tank when sensor level conditions / inclinations
indicates zero in all operating conditions
and inclinations positions.
return pipe

suction port

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 62

AdBlue/DEF tank 65 litres 4129 8226 3/9

65 litres AdBlue/DEF standard tank as installed on IVECO Stralis truck on right hand side, available also with
45 litres (4129 8229) and 120 litres (4127 8669). Part numbers refer to complete tank including filler cap with
strainer & WEMA unit with coolant heater coil. Iveco truck tanks are produced by Nova Simplast, 12046 Monta
(CN), Italy

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 63

AdBlue/DEF tank 45 litres 4129 8229 4/9

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 64

AdBlue/DEF tank 65 litres 4129 8226 5/9

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 65

AdBlue/DEF tank 120 litres 4129 8669 6/9

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 66

AdBlue/DEF tank 27 litres 7/9

27 litres L-shape AdBlue/DEF tank as installed on IVECO Eurocargo truck on right

hand side

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 67

AdBlue/DEF tank 27 litres 8/9

Part numbers for complete tank including filler cap and WEMA tank unit with
heater: 5801345829. WEMA tank unit with heater only: 504349967
21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 68
AdBlue/DEF tank with WEMA multi-function tank unit 9/9

coolant
heater coil
connections
 The WEMA multi-function unit contains urea tank level sensor,
level & temp. temperature sensor, suction and return pipe. Frozen AdBlue/DEF can
sensor connection be melted by means of a coolant heater coil. A solenoid which is
actuated by the DCU (Dosing Control Unit) of the DNOx-2.1 SM
controls the engine coolant flow through the heater
urea suction &
return connection  Depending on climatic & operating conditions, the tank unit is available
also w/o heater coil. For new tank layouts a custom tailored tank unit is
necessary
 For further information please contact: Mr Torsten Artz, Wema-
System AS, +47 55 60 37 52, [email protected]
To keep the application demand for different custom made tank units at a an acceptable
level, the following layout constraints should be met:
Temperature sensor: NTC type; 1kOhm +/-5% @ 25°C
Level sensor recommended characteristic: 70 Ohm at low level; 20kOhm at high level
level Electrical connections:
sensor

coolant
heater
coil

NTC
temperature
sensor

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 69

Material requirements (metallic) 1/2

Exhaust pipes
 all exhaust pipes downstream the urea injection point have to be manufactured in stainless steel to
prevent corrosion, see table below.
 all internal surfaces of exhaust pipes have to be cleaned from additives used for the production
process (e.g. lubricants on bending machines) to prevent SCR catalysts poisoning.
 Experiments have shown a strong poisoning effect of alkaline- and alkaline earth metals and phosphor
to the SCR- and NO-oxidation catalysts. Zinc also strongly inhibits the activity of SCR-catalysts.
(Chemische Desaktivierung von SCR – Katalysatoren, FVV Informationstagung, Technische Universität Darmstadt, Prof. Dr. rer. nat. habil. P.
Claus / Dipl.-Ing. M. Lucas).

Other machined metallic parts in contact with AdBlue/DEF

 can be made from the following stainless steels 1.4571, 1.4541, 1.4112, 1.4310, 1.4404

DIN AISI Name C Cr Mo Ni typ Application

1.4526
436 X6CrMoNb17-1 <=0.08 16-18 0.4-1.4 - ferritic Passive reg
(SUS436M)
1.4509 441 X2CrTiNb 18 <=0.03 17.5-18.5 ferritic Passive reg
1.4510 439 X3CrTi17 <=0.05 16-18 ferritic Passive reg
Bold = preferred stainless steel grade

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 70

Material requirements (plastic and metallic) 2/2

AdBlue/DEF tanks
 most plastic fluid tank materials can Material AdBlue/DEF Ammonia
Material type
be selected for AdBlue/DEF resistant resistant
 recommended material is Thermoplastic IXEF yes yes
Polyethylene (PE) PA66 yes yes
 depending on production volume PTFE yes yes
different processes are selected by PEEK yes yes
the suppliers (blow or rotation PPS-compounds yes yes
moulding) PVDF Yes yes
 depending on the production volume Elastomeric BR yes yes
it is recommended to use one of the CR yes no
Iveco AdBlue tanks combined with HNBR yes no
the adapted WEMA multi-function NR yes yes
unit to avoid customized datasets FPM yes no
EPDM yes yes
 Metallic tanks: Austenitic/Martensitic
NBR yes no
Stainless Steels: 1.4571, 1.4541,
Metallic DIN 1.4571 AISI 316Ti yes yes
1.4112, 1.4310.
DIN 1.4541 AISI 321 yes yes
DIN 1.4112 AISI 440B yes yes
Plastic parts in contact with DIN 1.4310 AISI 301 yes yes
AdBlue/DEF
 following table shows the suitability
of the different materials
 VOSS tubes MLT 8.8x1.4, PA562
are recommended for AdBlue/DEF
21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 71
AdBlue/DEF pipes, hoses and connectors 1/14

 Urea lines can be heated by means of engine coolant or electrically (both systems have pros and cons)
 There are different suppliers on the market which offer these parts, however it’s important to chose high quality
products as UDS is very sensitive with regard to leakages in the suction pipes
 Experiences have shown that not only hoses but also all connectors have to be heated.
 Connectors with straight shape are recommended for faster defrosting than with differently shaped connectors
 FPT recommends VOSS as sub-system supplier for coolant & electrically heated urea pipes
Contact: Mr M. Karlicsek, +49 22 67 63-5485, [email protected], Mr. P. Quagliotti, +39 011 2673060,
[email protected]
 Quality electrically heated hoses can be supplied also by Contitech.
Contact: Mr H. Koch, +49 5631 58-1510, [email protected], Mr H. Dude, +49 5631 58-1119,
[email protected]

Example of a electrically heated AdBlue/DEF hose Section of a coolant heated AdBlue/DEF hose

Heated hydraulic Insulation hose

connector

AdBlue/DEF lines
Heated Line

Connector or
electric power Coolant water pipes

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 72

Electrical AdBlue/DEF pipes 2/14

Requirements and Recommendations for a electrical heated AdBlue/DEF pipe:

Item Subject General Specification

Electrical Battery voltage 22V – 32V (nominal 28V)*

System Heating Currents See table 1
Defreezing performance De-freezing time 10min@-30°C lines fully filled with AdBlue/DEF
De-freezing
De-freezing concept Adblue/DEF line + hydraulic connectors electrical heated

* Values refer to a 24V electrical system. If a DC/DC converter is used for the power supply of the DCU, follow DC/DC converter output
specification

Table 1: Maximum heating currents of DCU 15 (Source: Bosch DCU I/O Description No: 0 281 Y03 5AF)
DCU-connector-Pin Max Current for each power Over current threshold for
Base function
(standard assignment) stage for 100% duty cycle switching off for each power stage

122 Suction line heater Power stage 2A 2.7 A

132 Pressure line heater Power stage 3A 4.6 A
134 Cooling line heater Power stage 3A 4.6 A

135 Backflow line heater Power stage 2A 2.7 A

 The max current of DCU power switches must not be exceeded

 A heating power of 15 – 25W/m (depend on the hose material and pipe diameter) are normally sufficient for the
urea de-freezing
 A heating device in the urea line house and at the hydraulic connectors is recommended

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 73

Electrical AdBlue/DEF pipes 3/14

Maximum possible length for electrical heated AdBlue/DEF pipes:

Max. Pipe length at 2A power stage (PIN 122/135) Max. Pipe length at 3A power stage (PIN 132/134)
6.0 6.0
5.5 5.5
5.0 24V U-supply 5.0
4.5 26V U-supply 4.5
Pipe length [m]

Pipe length [m]

4.0 28V U-supply 4.0
3.5 3.5
3.0 3.0
2.5 2.5
24V U-supply
2.0 2.0
26V U-supply
1.5 1.5
28V U-supply
1.0 1.0
14 15 16 17 18 19 20 21 22 23 24 25 26 14 15 16 17 18 19 20 21 22 23 24 25 26
Pipe heater Power [W/m] Pipe heater Power [W/m]
* Calculation of max pipe length is valid for resistance wire heater. For pipes with PTC heater a additional evaluation is necessary

Example for electrical heated SAE J2044 Quick connector:

Sectional view:
Outside view
Heating wire
around connector

Outer contour for heating wire

Source: Voss
21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 74
AdBlue/DEF pipes, hoses and connectors 4/14

Coolant heated SCR systems are controlled by a WABCO water

shut-off valve controlled by the DNOx-2.1 Supply Module
FPT p/n 4124 1093

Coolant hose
connector
Normaquick 90°
0702 8008 012

Normaquick 0°
0702 8009 012

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 75

AdBlue/DEF pipes, hoses and connectors 5/14

Sample of a coolant heated

AdBlue/DEF hose from tank to
supply module (Stralis AS/AT)
FPT p/n 4124 1931

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 76

AdBlue/DEF pipes, hoses and connectors 6/14

FPT p/n
4124 1950 2nd pre-filter FPT p/n
4124 1949

Available coolant heated

AdBlue/DEF connection
sets for supply module

FPT p/n
FPT p/n
4124 1950
4124 1948
21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 77
AdBlue/DEF pipes, hoses and connectors 7/14

Sample of a coolant heated AdBlue/DEF Recommended

hose from SM to DM coolant pipe routing
FPT p/n 4124 1956 for good DM
connector de-
freezing
For good X
de-
freezing,
coolant
pipe loop
clip
attached to
urea pipe
connectors

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 78

AdBlue/DEF connector (3/8”) 8/14

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 79

AdBlue/DEF connector (5/16”) 9/14

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 80

AdBlue/DEF pre-filter between tank and SM 10/14

Preferred filter position on top

of WEMA tank unit or on SM
near coolant hose (for heat
radiation during defrosting!)

AdBlue pre-filter spare part:

Iveco p/n 420555466
FPT p/n 5801398799
VOSS p/n. 5466160100

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 81

Connectors & tubes for tank module 11/14

VOSS connecter system SV 246

Urea tank outlet (NG8)
Voss no. 5 2 46 02 71 00 (black/white)

Urea tank return (NG8)

Voss no. 5 2 46 03 28 00 (black/black)

Coolant tank - engine (NG12)

Voss no. 5 2 46 03 30 00 (black/white)

Coolant SM – tank (NG12)

Voss no. 5 2 46 03 32 00 (black/blue)

VOSS tubes
Urea: MLT 8.8x1.4, PA562/PUR2621
Coolant: Grilamid 13x1.5 for pre-moulded
tubing (high production volumes!)
or standard coolant hoses for low
production volumes

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 82

Coolant pipes to AdBlue/DEF tank, SM & DM 12/14

SM
recommended coolant flow
coolant flow from ~300 l/h @ rated engine speed
crankcase / air
compressor

AdBlue tank pipe WABCO shut-

harness off valve

return to water pump inlet

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 83

Coolant pipes to AdBlue/DEF tank, SM & DM 13/14

coolant from ECU DCU

crankcase / air
compressor

WABCO shut-
off valve

SM 1 2
DM

return to
water
pump inlet

AdBlue tank

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 84

AdBlue/DEF pipes, hoses and connectors 14/14

On FPT drawing p/n 4128 3732

all necessary AdBlue/DEF and
coolant hoses with matching
connectors are listed for
custom made installations

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 85

 SCR system – DNOx-2.1 control layout 1/2
- Machine Interface
- Pedal assembly
- Machine components

4 6 7 48
Vehicle CAN 1.Fuel Tank
3 2. Engine Control Unit Bosch EDC7UC31/EDC17CV41
Engine CAN 3. Heated fuel pre-filter with water separator & WIF
switch
2 4. Fuel Filter with Fuel Temperature Sensor
5. Damper Volume
8 9 6. igh Pressure Pump with gear pump
7. Fuel metering Valve
8. Rail
5 9. Rail Pressure Sensor
10. Over Pressure Valve
10 11. Solenoid Injectors
12. Air Filter
13. Humidity and T sensor
1 14. eVgt actuator on C9
19 11 15. Compressor
23 16. Intercooler
18. Turbine
Vehicle CAN 60 19. Camshaft Position Sensor
20 20. Oil Pressure and Temperature Sensor
21. Coolant Temperature Sensor
engine coolant 22. Oil Level Sensor (to dashboard, opt.)
42 23. Crankshaft Position Sensor
29. Grid heater via rele
45 30. Exhaust flap (opt.not connected to ECU)
38. SCR T sensor upstream
21 39. SCR T sensor downstream
Engine CAN 40. Wastegate (if not eVGT)
55 42. DCU + supply module DNOx-2.1
54 14 43. DEF level & T sensor
Engine 22
43 CAN
44. DEF injector
61 45. DEF tank
29 46. DEF mixer
49 56 40 48. Boost pressure sensor + air T sensor
13 49. NOx sensor + ECU via CAN
39 12 51. Downpipe
44 52. Tailpipe (with or w/o silencer)
54. Crankcase pressure sensor (for oil dilution ONLY
CURSOR)
SCR 56. Urea Quality sensor TBC
60. DEF heating from engine coolant shut off valve

52 51 18 15 61. DEF tank heater

46 30
In black: engine mounted 38
In blue: vehicle mounted
16
21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 86
SCR system – DNOx-2.1 control layout 2/2

4
Vehicle CAN
5

1. DEF Tank
2. DEF level & temperature sensor
15
3. Tank heater
4. DCU15
5. Supply module DENOXTRONIC2.0 1
6. Filter 6
7. DEF dosing module
8. SCR temperature sensor 1 3 17
9. SCR Catalyst 15 2
10. DEF mixer
11. Dowpipe
12. SCR temperature sensor 2 Engine CAN
13. NOx sensor
14. NOx sensor ECU 14
15. Pipes Heaters
16. Tailpipe (with or w/o silencer) 8
17. Urea Quality sensor+ ECU (TBC) 7
12 13

9
11 16
10

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 87

Electrical layout 1/3

Bosch, Y 462 U04 697, Terminal diagram,

DCU15D2-2.x, Denoxtronic 2 (C1-sample).pdf

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 88

Electrical layout 2/3

Bosch, Y 462 U02 463, Connector Set, DCU15D2-2.x,

Denoxtronic 2 (C-sample).pdf

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 89

Electrical layout 3/3

ROBERT BOSCH GMBH Terminal diagram DCU15D2 0 462 YU4 01T

STUTTGART Denoxtronic 2
Pos. Pin Abbrev. Name Wire-size
No. No. [mm2]
15 1 V_V_BAT+R Battery + via main relay (output) 2,5
16 2 V_V_BAT+R Battery + via main relay (output) 2,5
1) Proposal for CAN (and SAE) cable:
4 3 V_V_BAT+ Battery plus 2,5
6 4 V_V_BAT+ Battery plus 2,5 Twisted pair cable 2 x 0,75 mm2
6 5 B_D_CANH1 Controller Area Network 1 (high) 0,75 1)
7 6 B_D_CANL1 Controller Area Network 1 (low) 0,75 1)
twist length  40 mm (= 25/m).
9 7 B_D_CANH2 Controller Area Network 2 (high) 0,75 1)
10 8 B_D_CANL2 Controller Area Network 2 (low) 0,75 1)
9 dnc do not connect -
36 10 O_S_CLH Compensation line heating 1.5
40 11 O_S_RAMV Reduction agent metering valve 2,5
39 12 O_V_RAMV Reduction agent metering valve supply (BAT+ ) 2,5
13 dnc do not connect -
3 14 G_G_BAT- Battery minus 2.5
4 15 G_G_BAT- Battery minus 2.5
16 dnc do not connect -
29 17 G_R_CATTSPRE Catalyst temperature sensor ground (upstream) 0,75
20 18 I_A_RALS Reduction agent level sensor signal 0,75
21 19 G_R_RALS Reduction agent level sensor ground/Reduction agent tank temperature sensor ground 0,75
20 dnc do not connect -
19 21 O_S_SVS Service soon available 0.75
28 22 O_S_HH1 Hose heating 1 (Suction line heating) 1,5
24 23 O_S_RATH Reduction agent tank heating 1,5
3 24 I_S_T15 Terminal 15 (switched BAT+) 0,75
32 25 G_R_CATTSPOST Post-catalyst temperature sensor ground (downstream) 0,75
31 26 I_A_CATTSPOST Post-catalyst temperature sensor signal (downstream) 0,75
27 dnc do not connect -
28 28 I_A_CATTSPRE Catalyst temperature sensor signal (upstream) 0.75
22 29 I_A_TRATS Reduction agent tank temperature sensor signal 0,75
19 30 V_V_5VRALS Reduction agent level sensor supply 0.75
13 31 B_D_ISOK ISO-K interface 0.75
32 32 O_S_HH3 Hose heating 3 (Pressure line heating) 1,5
33 dnc do not connect -
34 34 O_S_HH4 Hose heating 4 (Back flow to supply module line heating) 1,5
30 35 O_S_HH2 Hose heating 2 (Back flow to tank line heating) 1,5

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 90

Exhaust temperature sensor for SCR muffler

 Two temperature sensors have to be installed on the SCR muffler.

Installation bosses exist on inlet / outlet housing, located in a
position representative for the SCR temperature.
 To avoid incorrect values the sensor on the inlet should be
mounted at least 300mm downstream of the dosing module
(injection position RP).
 Mounting positions from top between +/-90° from vertical axis.
Different colour coded connectors to avoid a mix-up of in & out
For prototype and final installation layouts please
temperatures: FPT p/n 504102603 (SCR in, black, to be connected
ask for detailed supplier customer information to female connector p/n 1/01621/87), 504109529 (SCR out, brown,
to be connected to female connector 1/01621/88).
21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 91
NOx sensor installed in SCR muffler end pipe 1/6

For prototype and final installation layouts please ask for detailed supplier customer information
21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 92
NOx sensor installed in SCR muffler end pipe 2/6

FPT-Iveco CNH Continental HW Cable

Voltage Cap Elem.
p/n p/n p/n Gen. length
41271167 - 5WK96615C Gen2.0 24V-b HD std 608
5801424181 - 5WK96615D Gen2.5 24V-c HD std 608
Euro V
5801443022 - 5WK96734 Gen2.5 24V-c HD std 408
5801443021 - 5WK96733 Gen2.5 24V-c HD std 908
- 87482356 5WK96710 Gen2.0 24V-b HD std 608
- 84292579 5WK96711 Gen2.0 24V-b HD std 908
Tier4A
- 84422745 5WK96710A Gen2.5 24V-c HD std 608
- 84414466 5WK96711A Gen2.5 24V-c HD std 908

Relevant note: production up to 05/2011 with Gen2.0 HW,

since 06/2011 onwards Gen 2.5 HW to be mandatorily
introduced (modification declared transparent by Continental)
21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 93
NOx sensor installed in SCR muffler end pipe 3/6

Sensor boss, recommended material

Sensor ECU mounting positions
304 (AISI) / 1.4301 (DIN)

Sensor installation
orientation

For prototype and final installation layouts please ask for detailed supplier customer information
21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 94
NOx sensor installed in SCR muffler end pipe 4/6

For prototype and final installation layouts please ask for detailed supplier customer information
 Note: cable length can not be freely changed!
FPT p/n 41271167 has cable length of 608 mm,
CNH p/n 8429 2579 has a cable length of 908 mm

 NOx sensor ECU has to be installed on suitable place. Refer to detailed installation
instructions.
 The sensor has to be positioned in provided boss on SCR muffler or on exhaust end
pipe where uniform gas mixture is guaranteed.
 NOx sensor has to be mounted in a way, that no condensed water is collected inside
the protection tube of the sensing element. Especially in applications with vertical
exhaust pipes additional protection measures against external water intrusion might
be necessary.

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 95

NOx sensor installed in SCR muffler end pipe 5/6

For prototype and final installation layouts please ask for detailed supplier customer information
 Requirement for flow & velocity distribution before the NOx sensor: γ > 0.96

good

not good

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 96

NOx sensor installed in SCR muffler end pipe 6/6

For prototype and final installation layouts please ask for detailed supplier customer information
 NOx sensor is very sensitive with regard to water. Ceramic part
could crack and/or the sensor cell may be poisoned. Therefore
any contact with water due to rain or washing has to be avoided.
 Some design samples to avoid water contact on the NOx sensor
are shown here
NOx sensor
positions

drain
holes

NOx
sensor

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 97

Humidity & temperature sensor 1/3

For prototype and final installation layouts please ask for detailed supplier customer information
2- %RH
3- Gnd

1- VCC
4- °T

FPT p/n
504 101 690

Flow
direction

Mounting torque: typical 12

Nm and maximum 17 Nm

Any installation has to be released by

Humirel. Contact address:
Romuald GALLORINI
Product Development Manager
phone: +33(0) 561 194 079
[email protected]

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Humidity & temperature sensor 2/3

For prototype and final installation layouts please ask for detailed supplier customer information
Humidity & temperature sensor to be installed on
suitable place with high air velocity (no dead zones) after
air filter, but before blow-by / air compressor
connections.

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Humidity & temperature sensor 3/3

Recommended installation examples on not horizontal air pipes:

 On the installation (image on the right) location (2) is recommended for

the sensor. The tip has to point down with a minimum angle of 40° and
a maximum of 89° according to the detailed the installation guideline. If
location (1) is necessary, the tip has to point down too (minimum 1°)
• With a bend a ‘dead flow zone’ should be avoid (B) on the drawing
below). In this case position (A) is preferred

• It is recommended orienting the sensor facing the air stream to help fluid
/ moisture / soot / particles being drained out

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SCR system main components list

Pos. Part FPT p/n Supplier p/n No. of

1 DNOx-2.1 Supply Module (SM) without CCV 504 374 326 0 444 022 021 1
2 DNOx-2.1 Dosing Module (DM) for CCV less SM, 6 kg/h 504 374 327 (up to June 2013) 0444 023 058 1
580 1730 656 (since June 2013)
9 kg/h 504 381 866 (up to June 2013) 0444 023 062
580 1730 657 (since June 2013)
3 AdBlue/DEF tank 45 litres including WEMA tank unit 4129 8229 1
AdBlue/DEF tank 65 litres including WEMA tank unit 4129 8226
AdBlue/DEF tank 120 litres including WEMA tank unit 4129 8669
4 90° exhaust temperature sensor, SCR inlet (black connector) 504 102 603 500 349 00 1
(504 109 525 family drawing)
5 90° exhaust temperature sensor, SCR outlet (brown connector) 504 109 529 500 350 00 1
(504 109 525 family drawing)
6 Humidity sensor 504 101 690 (plastic) HTM2500 B6C6 1
504 253 912 (metallic) HTM2500 B3C4
8 NOx sensor (24 V, 608 mm cable) – Gen. 2.0 ( 05/2011) 4127 1167 5WK96615C 1
NOx sensor (24 V, 608 mm cable) – Gen. 2.5 (06/2011 ) 5801424181 5WK96615D
9 Coolant shut-off valve 4124 1093 4460913010 (WABCO) 1
10 Electrical connector for DNOx-2.1 Supply Module 804 5173 1
11 Electrical connector for DNOx-2.1 Dosing Module 804 5171 1
12 Electrical connector for Exhaust temperature sensor, SCR inlet 804 5169 1
13 Electrical connector for Exhaust temperature sensor, SCR outlet 804 5170 1
14 Electrical connector for Humidity & temperature sensor 804 5175 1
15 Electrical connector for NOx sensor 804 5174 1
16 Electrical connector for coolant shut-off valve (WABCO) 804 5172 1
17 Electrical connector for WEMA tank unit 803 1989 1
18 External pre-filter 100 micron in urea suction line 5801398799 5466160100 (Voss) 1

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Revision History

Version File name Authors Date Changes, Remarks

Remark on Diesel quality (p.3); AdBlue/DEF flow orientation corr. (p.11); SM add. information (p.12);
DNOx filters (p.15); DM new & add. information (p.18); new cylindrical mufflers with radial inlet, axial
SCRsystemInstallationGuideLi F. Papst inlet deleted (p.50); 1000mm exhaust pipe NEF cylindrical muffler removed, FPT approval (p.54);
V6.2 25-02-2010
neDNOx-2_V6.2.ppt M. Pidria AdBlue/DEF tank 27 litres (p.65); material requirements (p.68-69); coolant pipe routing (p.79-80);
integration in the SM corrected (p.84); SCR inlet temperature sensor position (p.87); NOx sensor
add. cable length, positioning & water protection (p.89-90)

DNOx filters maintenance (p.15); SM filter kit and installation info (p. 16-17); inclination of 5 degrees
F. Papst above the horizon on p.26 not 24 (p.27); new Cursor mixer drawing (p.32-33); add comment on tank
SCRsystemInstallationGuideLi
V6.3 M. Pidria 25-10-2010 design (p.57/58); tank unit add info (p.65); corrected & additional Contitech address, add info (p.68);
neDNOx-2_V6.3.ppt
L.Ferraris FPT p/n pre-filter VOSS (p.75); Mounting interface humidity sensor and mounting position (p.90-91)

F. Papst New FPT Industrial template, increased main filter maintenance for off-road applications (p. 15),
SCRsystemInstallationGuideLi bugs correction, insert note about the new Bosch brand DNOx-2.1 (p. 11), added SCR mufflers
V7.0 M. Pidria 03-05-2011
neDNOx-2_V7.0.ppt Stage IIIB / Tier4i free market (p. 52), Gen. 2.5 NOx sensor (p. 88), notes on NEF downpipes (p. 56)
L.Ferraris

Usage of protection caps (p. 13); added image of sectional view of DM half holder (p. 18); SCR
SCRsystemInstallationGuideLi M. Pidria mufflers Tier4i for free market Cursor (p. 42-43) and NEF (p. 54-55); added metallic tanks (p. 71);
V7.1 29-11-2011
neDNOx-2_V7.1.ppt S. Neggia Update on electrical heated DEF hose and pipes requirements (p. 72-73-74)

SCRsystemInstallationGuideLi Updated AdBlue/DEF tank recommendation (p. 61)

V7.2 S. Neggia 28-01-2013
neDNOx-2_V7.2.ppt

SCRsystemInstallationGuideLi Updated dosing modules PNs (p.18-101)

V7.3 S. Neggia 21-05-2013
neDNOx-2_V7.3.ppt

21-05-2013 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx-2_V7.2.ppt 102

Contacts

For further general information and installation support please contact:

Ing. Marco Federico Pidria
Product Engineering
Aftertreatment Systems
FPT Industrial S.p.A.
Str. Delle Cascinette 424/34, 10156 Torino, Italia
Cell +39 335 7513831
[email protected]

Dr. Sabrina Neggia

Product Engineering
Aftertreatment Systems
FPT Industrial S.p.A.
Str. Delle Cascinette 424/34, 10156 Torino, Italia
Telephone: +39 011 0078510
[email protected]

For more detailed dosing system information please contact:

Mr. Sebastian Schwarz
Aftertreatment Systems
FPT POWERTRAIN TECHNOLOGIES
Iveco Motorenforschung AG
Schlossgasse, Postfach 80
CH-9320 Arbon, Switzerland
Telephone: +41 (0)71 44 77 252
Telefax: +41 (0)71 44 63 165
[email protected]

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