SCRsystemInstallationGuideLineDNOx2 V6.11 PDF

FPT - SCR System Installation Guideline to meet Emission
Standards Euro IV/V & Tier 4A with Bosch Denoxtronic 2

without Coolant Control Valve (CCV-less version)
Version 6.1
Arbon, 19-11-2009
Fritz Papst / Marco Pidria

Aftertreatment Systems
Arbon, November 2009 CONFIDENTIAL

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 (DNOx2) overview
17 Supply module (SM) installation instructions
26 Dosing module (DM) installation instructions
32 Dosing / mixing unit and SCR muffler installation (Cursor engine)
40 Dosing / mixing unit and SCR muffler installation (Tector / NEF engine)
49 Instructions for modified exhaust pipe / SCR muffler layouts
54 AdBlue/DEF tank and WEMA combination unit
61 Material requirement for exhaust pipes and AdBlue/DEF tank
63 AdBlue/DEF pipes, hoses, connectors and filter
76 SCR control layout
77 Electrical layout and schemes
80 Exhaust temperature, NOx and humidity sensors
86 Parts list
87 Revisions
88 Contacts
Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 2

SCR system description
FPT has chosen SCR (selective catalyst reduction) for the medium engine (NEF/Tector)
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 particulate 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 very 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
The 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

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

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

AdBlue/DEF physical properties
60
The concentration of 32.5% was chosen
because at this mixing ratio the solution
50
has its lowest freezing point of -11°C
ea
(eutectic mixing ratio) 40
ur
γ-
To maintain correct system operation 30
under cold conditions, AdBlue/DEF tank,
T [°C]
pipes, pump module and dosing module 20
a
need a de-freezing system
re
-u
10
β
... likewise, the complete AdBlue/DEF 0
rea
distribution network requires precautions H2O
-u
α
against freezing -10
-11.5°C
0 10 20 30 40 50 60 70
Urea concentration [°C]

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 three 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 can be found via

internet link: www.findadblue.com

AdBlue/DEF specification 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

SCR system overview main components
supply module
urea tank
SCR muffler
dosing module

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 DNOx2 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 DNOx2 system during 2006

System layout: air-less UDS (DNOx-2)
Intake air
humidity
& temp.
sensor
Air
filter
Dosing
Module
Supply
ECU Module
DEF mixer
DCU
NOx
Temperature sensor Temperature sensor
sensor
downstream upstream
DEF level &
SCR temperature
Sensor

DNOx 2 supply module (SM) 1/5
For prototype and final installation layouts please ask for detailed supplier customer information
Pressure sensor
Temperature sensor
Filter
4/2-way valve
Diaphragm pump
FPT no. 504374326, CNH no. 84246892, Bosch no. 0444022021

DNOx 2 system overview 2/5
External
External
pre-filter
pre-filter
100 micron
100 micron
(VOSS)
(VOSS)
previous CCV new CCV-less

version version

DNOx-2.0 CCV-less filters 3/5
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

DNOx-2.0 CCV-less filters 4/5

DNOx 2 dosing module (SM) 5/5
6,5÷7,5 Nm
DM 6 kg/h for all NEF/Tector & Cursor 8/9/10/11/13 (Euro IV/V DM 9 kg/h for all Tier4A Cursor 13 engines:
only) engines: FPT no. 504381866, CNH no. 84248058,
FPT no. 504374327, CNH no. 84247021, Bosch no. 0444023058 Bosch no. 0444023062

SM installation instructions 1/9


DCU 15
35 pins
connector
filter
drain plug pressure

compensation
BACKFLOW OUTLET
to tank INLET
from tank
BACKFLOW INLET
from DM
OUTLET to DM pre-filter

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



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).

• 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

• 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

DM installation instructions 1/6
Horizontal 5°
FPT recommends a
minimum inclination
of 5 degrees above
the horizon

0
°
Heat
In cases where the DM is

installed on an inclined
+4
exhaust pipe it is
5°-
15
suggested that the axis of
85
°-3
°
spray direction is pointing
75
+2
towards the ground. FPT
recommends a minimum
inclination of 5 degrees
above the horizon (p.24).
In order to keep the
temperatures of the DM
Deposits
connections as low as
possible the body should
be exposed toward the
driving wind or ventilation
cooling whenever
possible.

Good Deposits Heat

Air stream
Heat insulation

Air stream
Air stream
Heat shield

min.5°
-XX°

Dosing and mixing unit installation (Cursor)
Version for Cursor engine (FPT patent), FPT drawing no. 4129 6199
Reference point (RP)
110
flow direction
105 111

Dosing and mixing unit installation (Cursor)
Exhaust pipe
with integrated
mixer unit for
Cursor engine
(Iveco Stralis)
FPT drawing
no. 4129 6197

Truck SCR muffler installations (Cursor)
urea injection positions

Truck SCR muffler installations (Cursor)
temperature sensor
SCR inlet
NOx sensor
temperature sensor
SCR outlet

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

Emcon 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 < 368kW: 4127 2366 Cursor 13 412kW: 4127 2448

Emcon vertical Cursor SCR mufflers
Note: latest production

SCR mufflers are
equipped with NOx
sensor boss
Cursor 8: 4127 2370 Cursor 13: 4127 2369

Cursor SCR muffler installation
StepSeal clamp for Cursor exhaust pipe/muffler connection, FPT drawing no. 4128 8279
tightening torque 50÷60 Nm

Dosing and mixing unit installation (Tector)
Version for Tector engine (FPT patent), FPT drawing no. 804 7376
Reference point (RP)
flow direction
110.5 102.5

Dosing and mixing unit installation (Tector)
Two exhaust pipe versions with integrated mixer unit are available for Tector engine
(iveco Eurocargo)
FPT no. 504148370 504148371

Truck SCR muffler installations (Tector)

Cortubi Tector 4 SCR muffler with horizontal tailpipe
5041 35181

Cortubi Tector 4 SCR muffler with vertical tailpipe
Note: NOx sensor

has to be installed
in tailpipe close to
muffler outlet
5041 35189

Cortubi Tector 6 SCR muffler with horizontal tailpipe
5041 35186

Cortubi Tector 6 SCR muffler with vertical tailpipe
Note: NOx sensor

has to be installed
in tailpipe close to
muffler outlet
5041 35192

Cortubi Tector 4 / 6 SCR cylindrical muffler
5041 84309
Note: NOx sensor has to

be installed in tailpipe
close to muffler outlet
Exhaust pipe samples for muffler in horizontal (left) and vertical (right) installation

Tector SCR muffler installation
V-clamp for Tector exhaust pipe/muffler connection, FPT drawing no. 504 105 924,
tightening torque 7 Nm

General instructions for modified exhaust pipe layouts 1/5
Iveco standard SCR muffler in combination with Iveco standard exhaust Reference point mixer
pipes have been intensively tested and are released for best NOx (RP, see page 30/38)
conversion and the avoidance of urea deposits.
For custom made exhaust pipes pay attention to the following
boundaries:
The minimum pipe length between turbine outlet flange and dosing module
L_in
(DM) reference point (RP) is 230mm.
The straight pipe distances from inlet bend to the dosing module (RP) and
DM (RP) to outlet bend should exceed the following values:
30 deg. bend > 150 mm
L_out
For more details see next page 45
For custom made exhaust pipes the following minimum distances between
DM (RP) and SCR muffler inlet have to be realised:
320 mm for the Tector rectangular muffler (504135 181/189/186/192)
1000 mm for the Tector cylindrical muffler (5041 84309)
1200 mm for the Cursor horizontal & vertical muffler versions
An insulated elbow/exhaust piping downstream of the mixer is
recommended if the above values cannot be accommodated.
Depending on application and operation profile an exhaust pipe insulation
might be necessary (garbage collector).
To prevent urea deposits, any disturbances like V-clamping, edges or
welding seams directly after the mixer outlet has to be avoided in the
exhaust pipes.
Any installation has to be checked by FPT

General instructions for modified exhaust pipe layouts 2/5
Dosing
valve axis
α L_in β L_out α Reference
minimum minimum
point (RP) β
90° 300 mm 90° 300 mm
45° 200 mm 45° 200 mm

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

Specific installation instruction for Cursor mixer 3/5
Dosing Mixer flange

valve axis
SCR inlet
α
Mixing unit
β
Mixer
Gas flow n
_mi
L
Begin of bend
End of bend L_in* L_out*
α L_in* β 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)

Specific installation instruction for Tector mixer 4/5
Dosing Mixer flange

valve axis
SCR inlet
α
Mixing unit
β
Mixer
Gas flow n
_mi
L
Begin of bend
End of bend L_in* L_out*
α L_in* β 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)

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!
2) mixing pipe not shorter than 550 mm*) for systems with 90°gas redirection! chamber
3) mixing pipe not shorter than 450 mm*) for systems with 180°gas redirection!
*) includes L_out as shown on page 48
Ask FPT support (p.86) for detailed design layout instructions! mixing pipe

AdBlue/DEF tank 65 litres 4129 8226 1/7
FPT recommends to maintain AdBlue/DEF

temperature < 50°C in the AdBlue/DEF tank during
operating conditions. For storage and none operating
conditions the limits of the ISO DIS 22241-3
recommendation have to be met.
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 sun light
tank ventilation must be protected from dust / debris
entry into the circuit
5 litres of AdBlue/DEF have to stay in the tank when
sensor level indicates zero, in all operating
conditions/inclinations & contained in a single
volume
65 litres AdBlue/DEF 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
shown refer to complete tank including filler cap with strainer and WEMA unit with coolant
heater coil. Iveco truck tanks are produced by Nova Simplast, 12046 Monta (CN), Italy




AdBlue/DEF tank 27 litres 5/7
27 litres L-shape AdBlue/DEF tank as installed on IVECO

Eurocargo truck on right hand side

AdBlue/DEF tank 27 litres 6/7
Part numbers for complete 504 168 563 with tank heater
tank including filler cap 504 192 241 without tank heater
and WEMA tank unit: 504 168 558 tank drawing only

AdBlue/DEF tank with WEMA multi-function tank unit 7/7
coolant heater coil

connections
level & temperature

sensor connection
urea suction &

return connection
level sensor
The WEMA multi-function unit contains urea tank level sensor, temperature
coolant sensor, suction and return pipe. Frozen AdBlue/DEF can be melted by
heater coil
means of a coolant heater coil. A solenoid which is actuated by the DCU
(Dosing Control Unit) of the DNOx supply module controls the engine coolant
flow through the heater
temperature Depending on climatic & operating conditions, the tank unit is available also
sensor 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, torsten.artz@wema.no

Material requirements 1/2
Exhaust pipes
all exhaust pipes downstream the urea injection point have to be manufactured in
stainless steel to prevent corrosion
recommended material is 304 (AISI) / 1.4301 (DIN), but also 1.4571, 1.4541 can be
used
all internal surfaces of exhaust pipes have to be cleaned from phosphor to
prevent SCR catalysts poisoning
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
AdBlue/DEF tanks
most plastic fluid tank materials can be selected for AdBlue/DEF
recommended material is Polyethylene (PE)
depending on production volume different processes are selected by the
suppliers (blow or rotation moulding)
depending on the production volume it is recommended to use one of the Iveco
AdBlue tanks combined with the adapted WEMA multi-function unit to avoid
customized datasets
any metallic tanks are not allowed!

Material requirements 2/2
Plastic parts in contact with AdBlue/DEF

the following table shows the suitability of the different materials
Material type Material AdBlue/DEF Ammonia resistant
resistant
Thermoplastics IXEF yes yes
PA66 yes yes
PTFE yes yes
PEEK yes yes
PPS-compounds yes yes
PVDF yes yes
Elastomeric BR yes yes
CR yes no
HNBR yes no
NR yes yes
FPM yes no
EPDM yes yes
NBR yes no
VOSS tubes MLT 8.8x1.4, PA562 are recommended for AdBlue/DEF

AdBlue/DEF pipes, hoses and connectors 1/13
Urea lines can be heated by means of engine coolant or electrically. Depending on

installation layout and production volumes both systems have pros and cons
There are different suppliers on the market which offer these parts, however it’s important to
choose high quality products as the UDS is very sensitive with regard to leakages in
suction pipes
FPT recommends VOSS as sub-system supplier for coolant & electrically heated urea pipes.
Contact: Mr M. Karlicsek, +49 22 67 63-5485, michael.karlicsek@voss.de
Mr. P. Quagliotti, +39 011 2673060, patrizio.quagliotti@it.voss.net
Quality electrically heated hoses can be supplied also by Contitech.
Contact: Mr H. Koch, +49 5631 58-1510, harld.koch@fluid.contitech.de
Samples of a
electrically heated
AdBlue/DEF hose
Section of a coolant
heated AdBlue/DEF hose

Coolant heated SCR systems are controlled by a WABCO water

shut-off valve controlled by the DNOx2 supply module
FPT no. 4124 1093
Coolant hose
connector
Normaquick 90°
0702 8008 012
Normaquick 0°
0702 8009 012

AdBlue/DEF pipe heating 3/13
Heat power vs. Heating up time vs. Temperature at Tamb = -25°C

Urea hose full & with total insulation & various ∅
110
100 09 - 14 W/m
90 11 - 17 W/m
12 - 17 W/m
14 - 22 W/m
80
70
Depending on heated hose insulation a
∅ 18mm w. tape
power of 10 to 15 W/m is needed to heat
time [min]
60
∅ 24mm w. tape
& 2 connectors
up a frozen hose within 30 minutes (FPT
50 target). For the final selection, it has to
∅ 24mm w. tape
be checked if compatible with the DCU
40 ∅ 34mm w. tape output stage
30
20
10
0
5 10 15 20 25 30
power [W/m]

Sample of a coolant heated

AdBlue/DEF hose from tank to
supply module (Stralis AS/AT)
FPT no. 4124 1931

FPT no. FPT no.

4124 1950 2nd pre-filter
4124 1949
Available coolant heated

AdBlue/DEF connection
sets for supply module
FPT no.
FPT no.
4124 1950
4124 1948

Sample of a coolant heated

AdBlue/DEF hose from supply
module to dosing module
FPT no. 4124 1956

AdBlue/DEF connector (3/8”) 7/13

AdBlue/DEF connector (5/16”) 8/13

AdBlue/DEF pre-filter between tank and SM 9/13
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 No. 420555466
VOSS No. 5466160100

Connectors & tubes for tank module 10/13
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

Coolant pipes to AdBlue/DEF tank, SM & DM 11/13
SM
recommended coolant flow
~300 l/h @ rated engine speed
coolant flow from
crankcase / air
compressor
AdBlue tank pipe

harness WABCO shut-
off valve
return to water pump inlet

Coolant pipes to AdBlue/DEF tank, SM & DM 12/13
coolant from
crankcase / air
ECU DCU
compressor
WABCO shut-
off valve
DM SM 1 2
return to
water
pump inlet
AdBlue tank

On FPT drawing no. 4128 3732

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

SCR system – DNOx2 control layout
Urea tank level

& temp sensor Humidity and temp sensor
Integrated in the AdBlue tank (WEMA unit) (intake air filter)
Integrated in the DNOx supply module
To be installed by OEM
Urea Engine Data

tank Bus - J1939
DCU15 EDC7UC31
Urea press
sensor Urea temp
sensor via CAN
Urea
Supply Module
Cat temp
Urea
upstream
Dosing NOx sensor
Module
SCR
Exhaust Mixer Cat temp
downstream
gas flow

Electrical layout 1/3
Bosch, Y 462 U04 697, Terminal diagram,

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

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

Denoxtronic 2 (C-sample).pdf

ROBERT BOSCH GMBH Terminal diagram DCU15D2 0 462 YU4 01T
STUTTGART Denoxtronic 2
Pos. Pin Abbrev. Name Wire-size
2
No. No. [mm ]
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
4 3 V_V_BAT+ Battery plus 2,5
6 4 V_V_BAT+ Battery plus 2,5
6 5 B_D_CANH1 Controller Area Network 1 (high) 0,75 1) 1) Proposal for CAN (and SAE) cable:
7 6 B_D_CANL1 Controller Area Network 1 (low) 0,75 1)
Twisted pair cable 2 x 0,75 mm2
9 7 B_D_CANH2 Controller Area Network 2 (high) 0,75 1)
twist length ≈ 40 mm (= 25/m).
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
3 14 G_G_BAT- Battery minus 2.5
4 15 G_G_BAT- Battery minus 2.5
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
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
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
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

Exhaust temperature sensor for SCR muffler
Two temp. sensors have to be installed on the SCR muffler.

Installation bosses exist on inlet / outlet housing, positioned
before and after the SCR catalyst, in a position well
representative of the exhaust flow
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
ask for detailed supplier customer information connected to female connector p/n 1/01621/87), 504109529 (SCR
out, brown, to be connected to female connector 1/01621/88)

NOx sensor installed in SCR muffler end pipe 1/3
NOx sensor ECU has to be installed on suitable place. Refer to detailed installation
instructions. Note: cable length can not be changed! FPT no. 41271167
The sensor has to be positioned in provided boss on SCR muffler or on exhaust
end pipe where uniform gas mixture is guaranteed
best NOx sensor measurements between 5 m/s and 60 m/s gas velocity; for 24V
NOx sensor (Cursor/NEF) it is possible a gas velocity of up to 80 m/s

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

Humidity & temperature sensor 1/2
2- %RH
3- Gnd
1- VCC
4- °T
FPT no.
504 101 690
Flow
direction
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.
Any installation has to be released by

Humirel. Contact address:
Romuald GALLORINI
Product Development Manager
phone: +33(0) 561 194 079
Romuald.Gallorini@meas-spec.com

Humidity & temperature sensor 2/2
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

SCR system main components list
pos. part FPT no. Supplier no No. of

1 DNOx2 supply module (SM) without CCV 504 374 326 0 444 022 021 1
2 DNOx2 dosing module (DM) for CCV less SM, 6 kg/h 504 374 327 0444 023 058 1
9 kg/h 504 381 866 0444 023 062
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) 4127 1167 5WK9 6615C 1
9 Coolant shut-off valve 4124 1093 4460913010 (WABCO) 1
10 Electrical connector for Denoxtronic 2 supply module 804 5173 1
11 Electrical connector for Denoxtronic 2 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 - 5466160100 (Voss) 1

Revision History
Version File name Author Date Changes, Remarks

DNOx2 installation instructions update (pages 15-), new cylindrical muffler for Tector
V4.4 SCRsystemInstallationGuideLineDnox2_V4-4.ppt F. Papst 20-11-2007
4&6 (page 40).
DM installation, page 26, Dosing / mixing unit and SCR muffler installations (Cursor /
Tector, pages 27-43), Instructions for modified exhaust pipe layouts (pages 44-46),
V4.5 SCRsystemInstallationGuideLineDnox2_V4-5.ppt F. Papst 16-12-2008
AdBlue/DEF pipes, hoses, connectors and filter (pages 56-68), Electrical layout (pages
70-72), Exhaust temperature, NOx and humidity sensors (pages 73-78).
Exhaust pipe samples for cylindrical Tector SDR muffler horizontal & vertical installation
V4.6 SCRsystemInstallationGuideLineDnox2_V4-6.ppt F. Papst 05-01-2009 (page 42), 27 litres AdBlue/DEF tank (page 52), urea pipes / 2nd pre-filter installation
(page 60), parts list (page 79).
Bosch drawings no. (pages 13, 14); added Bosch for production release (page 18);
F. Papst additional FPT spray axis recommendation (pages 25,26); additional limitation
V4.7 SCRsystemInstallationGuideLineDnox2_V4-7.ppt 02-02-2009
M. Pidria corrections (page 46); improved scheme (page 69); drawing references (page 70-71);
SCR components list (page 79).
F. Papst DM installation instructions (page 25-29); Instructions for modified exhaust pipe layouts
V5.0 SCRsystemInstallationGuideLineDnox2_V5.0.ppt 27-03-2009 Pages (47-50); AdBlue/DEF pipes, hoses and connectors (Page 61); AdBlue/DEF tank
M. Pidria 27 litres no. (page 57); Material requirements (page 59).
F. Papst SCR system description (p.3); pre-filter in scheme & parts list (p.12;84); additional DM
V5.1 SCRsystemInstallationGuideLineDnox2_V5.1.ppt 26-08-2009 9kg/h (p.14); exhaust pipe/mixer installations (p.47-51); AdBlue/DEF tank (p.52);
M. Pidria temperature sensor (p.78); NOx sensor (p.79-81); humidity sensor (p.82);
F. Papst Denoxtronic SM & DM with CCV less layout (p. 12-14); AdBlue/DEF filter (p.69); parts
V6.0 SCRsystemInstallationGuideLineDnox2_V6.0.ppt 04-10-2009
M. Pidria list (p. 84)
F. Papst DNOx filters (p.14); Removal of filter heater in SM (p. 19); AdBlue/DEF tank
V6.1 SCRsystemInstallationGuideLineDnox2_V6.1.ppt 19-11-2009 recommendations (p. 54); NOx sensor optimal gas velocity (p. 81)
M. Pidria

Contacts
For further general information and installation support please contact:
Mr. Fritz Papst Ing. Marco Federico Pidria

Aftertreatment Systems Product Engineering – EA&MS
FPT POWERTRAIN TECHNOLOGIES Aftertreatment Systems
Iveco Motorenforschung AG FIAT POWERTRAIN TECHNOLOGIES S.p.A.
Schlossgasse, Postfach 80 Corso Settembrini 40, 10135 Torino, Italia
CH-9320 Arbon, Switzerland Tel. +39 011 0036686, Fax +39 011 0035135
Telephone: +41 (0)71 44 77 230 Cell +39 335 7513831
Telefax: +41 (0)71 44 63 165 marcofederico.pidria@fptpowertrain.com
fritz.papst@fptpowertrain.com
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
sebastian.schwarz@fptpowertrain.com

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FPT - SCR System Installation Guideline to meet Emission

Standards Euro IV/V & Tier 4A with Bosch Denoxtronic 2

Fritz Papst / Marco Pidria

Arbon, November 2009 CONFIDENTIAL

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 2

Why Selective Catalyst Reduction ?

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 3

SCR SCR cat only

configuration selected by FPT

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 4

8 NH3 + 6 NO2 → 7 N2 + 12 H2O

2 NH3 + NO + NO2 → 2 N2 + 3 H2O

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 5

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 6

The required network of AdBlue/DEF filling

Infrastructure has been set up in three steps:

AdBlue/DEF filling stations can be found via

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 7

Product properties for AdBlue®

Urea 32,5 % - solution in water

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 8

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 9

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 10

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 11

FPT no. 504374326, CNH no. 84246892, Bosch no. 0444022021

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 12

previous CCV new CCV-less

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 13

Filter in DEF/AdBlue filer neck

2 filters in Dosing Module

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 14

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 15

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 16

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 17

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 18

drain plug pressure

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 19

Usually the SM can be

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 20

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 21

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 22

The specification of the pump limits the suction

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 23

• After shut-off unwanted flow of AdBlue/DEF

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 24

• After shut-off unwanted flow of

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 25

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 26

In cases where the DM is

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 27

Good Deposits Heat

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 28

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 29

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 30

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 31

Reference point (RP)

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 32

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 33

urea injection positions

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 34

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 35

Note: latest production SCR mufflers

Cursor 8: 4129 8537 Cursor 10: 4129 8536