EPA 2010 SCR System Training Center Introduction

EPA 2010 SCR System for
Customer Demo Vehicles

Training Center Introduction
1
Training Center Operation - Daily Schedule
Class Starts 8:00 AM
Break 9:30 AM
Class Resumes 9:45 AM
Lunch 11:15 AM
Class Resumes 12:15 PM
Break 2:15 PM
Class Resumes 2:30 PM
Class Ends 4:00 PM
2
Training Center Introduction
Conduct - Detroit Diesel prohibits the use of jokes, cartoons or pictures that
are directly or indirectly derogatory toward race, religion, national origin,
gender, age, disability, height, weight or marital status. All employees, visitors,
vendors or trainees must be sensitive to the diversity of all employees within
our workforce and treat each other with dignity and mutual respect at all times.
Undermining the dignity of others through inappropriate use of printed
material, comments or conduct and utilizing such available communication
methods such as email, facsimile and copier will not be tolerated.
3
EPA 2010 SCR System – Objectives / Outline
This course has been designed to provide students with the best information
available on Detroit Diesel’s implementation of the EPA 2010 SCR system allowing
them to provide service to the fleets participating in the Customer Demo program.
1) SCR System Introduction
2) DD15 Engine Changes for 2010
3) The Single Box Aftertreatment System
4) Individual SCR System Components
5) Electronic Service Tools for 2010
6) 2010 Vehicle Walk-around
4
EPA 2010 SCR System – Course Objectives / Outline (continued)
7) Overview of OBD for Heavy Duty Vehicles
8) 2010 Special Tools
9) Common Issues / System Diagnostics
10) Final Review Questions
5
Reimbursements
• Please keep all documentation for the following
- Airfare receipts and boarding passes
- Hotel receipts
- Does not include mini-bar, phone usage, movies, games
- Turn in gasoline receipts if driving from your location
- All the above information needs to be invoiced to Detroit Diesel
- Meals (including lunch) will not be reimbursed
- Please include your name and location
- Email to: john.evanoff@daimler.com
Mail to: Detroit Diesel Corporation
Attention: Jack Evanoff (A14)
13400 Outer Drive West
Detroit, MI 48239
6
Introduction to
7
Common Terms
•SCR = Selective Catalytic Reduction
9A vehicle emissions control technology to reduce diesel engine emissions for passenger cars, light &
heavy duty trucks. Reduces NOx using a reducing agent by converting NOx into nitrogen, water and
tiny amounts of carbon dioxide.
• BlueTec
9 Daimler’s branded SCR emissions solution
•DEF = Diesel Exhaust Fluid 32.5% Urea

100% DEF
9A solution of 67.5% purified water and 32.5% automotive-grade
urea are used in the SCR process; also referred to as AUS32
Diesel
67.5%
Exhaust
Water
•AdBlue Fluid
9 Registered trademark for DEF in Europe; North America will use the term
DEF
The website www.factsaboutscr.com is an excellent source of

information about the SCR system. It contains information from many
different companies.
8
22 Years of Truck Emission Changes
Particulate Matter - PM (g/bhp-hr) 1988
1991
2002/2004 1998 1994
0.01 2010 2007
Nitrogen Oxides - NOx (g/bhp-hr)

0.2
Over time the trucking industry has been asked to continually improve the Nitrogen Oxide
and Particulate Matter output levels of diesel engines. Particulate Matter output guidelines
were satisfied with the addition of the aftertreatment device in 2007. Nitrogen Oxide levels
are being dropped though the introduction of a second device, the SCR catalyst.
Note that both Particulate Matter and Nitrogen Oxides are both measured in Grams per
Brake Horse Power Hour.
9
• BlueTec offers better economics… with better fuel economy than equivalent
2007 engines BlueTec is the first emissions change to provide a cost benefit to
the customer.
• BlueTec is cleaner… SCR is the only technology that is able to meet NOx levels
of 0.2g/bhp-hr at the tailpipe. Customers will be proud to support
environmental improvements.
• BlueTec is convenient… Fewer active regenerations. DEF supply will not be an

issue and will become second nature to drivers when operating their vehicles.
• BlueTec is proven… With over 200,000 SCR vehicles operating in Europe and
over 15 Million BlueTec test miles run in the United States, customers can be
confident in BlueTec.
Engines using the SCR system are
more fuel efficient and cleaner than
those using the extreme EGR flow
strategy !
EGR Flow Rate Fuel Efficiency
10
How Does BlueTec Help Improve Fuel Economy?
• It allows Detroit Diesel to focus its 2010 NOx reduction efforts on the exhaust
gas after it has traveled downstream of the particulate filter.
•This allows Detroit Diesel to improve and optimize the performance efficiency of
the engine under the hood by actually reversing some of its operational
parameters, including NOx levels emitted before the aftertreatment device.
•Detroit Diesel’s 2010 engines will actually have better fuel economy than their
EPA2007 compliant predecessors!
Effects of BlueTec on engine operation
11
DEF Calculator
12
What is Diesel Exhaust Fluid (DEF)?
DEF will be heated DEF will be readily

in cold climates. The available through
EPA will allow the our Dealers and
engine to run for a Distributors, and
short period of time independent truck
without standard stops.
system monitors
while the DEF thaws
out.
DEF to Diesel Fuel

Consumption Ratio will be ~2%
DTNA has a dedicated person working with other OEM’s to establish

infrastructure. Arrangements are being worked out with Pilot and T/A
truck stops to carry DEF as well as all service locations of DEF
equipped vehicles.
13
What is Diesel Exhaust Fluid (DEF)?
> 32.5% urea concentration in

water
> Clear liquid
> Non-toxic and biodegradable
> Weight = 9.2lbs/gallon
> Freezing point = 12°F (-11°C)
1 gallon jug, 2.5 gallon jug, 55 gallon drum and 275 gallon IBC
> The 32.5% concentration is important. Urea is used in a variety of

chemical compounds that have many uses. That’s why it should be
referred to as DEF whenever possible and not just urea.
> Urea 31.8 – 33.2 % by weight
> Although DEF is heavier than water it will not separate out in the tank.
DEF needs high heat to break down it’s chemical bond.
> DEF has a shelf life of approximately 12 months provided certain
storage conditions are met.
> Prolonged storage above 86°F (30°C) will reduce shelf life.
> Avoid prolonged exposure to direct sunlight (to avoid growth of
algae).
> After expiration of the shelf life the batch should be tested for a
decision about further use.
> Further studies are being conducted on DEF shelf life
14
Which warning label refers to DEF?
Sheet B
Sheet A
There has been a considerable amount of erroneous information being circulated about the chemical
properties of DEF. Studies done by several industry trade publications have concluded that these
claims have been highly exaggerated. In fact, DEF is considerably less toxic than many fluids used on a
daily basis in the trucking industry.
Sheet A is the warning label that comes with common windshield washer fluid with sheet B is the label
for DEF.
15
Customer Terminal
IBCs, Jugs
IBC, 55-gallon drum, 2 gallon jug
Truck Stop Dealer / Distributor
Fuel island filling

Jugs
Oil / Fuel Jobber Fuel truck, IBCs, Urban / City

Drums
> The American Petroleum Institute

will certify manufacturers of DEF,
customers should look for the API
logo shown below when purchasing
DEF.
> Certified suppliers shall
demonstrate capabilities of producing
DEF to the ISO 22241 standard
> Certified suppliers will be able to
sell their product with the API – DEF
logo
> It is recommended that only API
certified DEF be utilized.
> One IBC will support 82,500 (275 x
300 miles) miles of truck utilization
16
DEF Infrastructure
• Progress continues in creating a distribution network to ensure a smooth
transition into 2010.
- Pilot Travel Centers, TA Travel Centers of America, and Petro Stopping
Centers have already committed to supplying DEF.
- Other partners are expected to make announcements throughout 2009.
17
Driving Range of DEF
Approximately Driving range of the

300 miles EPA 2010 vehicles
driven per with DEF is quite
gallon of DEF impressive. A 13
consumed. gallon DEF tank will
get drivers from Los
Angeles to
3 gallons 6 gallons 9 gallons 12 gallons
somewhere in the
middle of the
Atlantic Ocean.
18
•BlueTec is already in use all over the world
•Daimler has over 200,000 BlueTec units on the road today
•Daimler has over 15 MILLION miles of BlueTec validation

testing in North America
Nobody comes close to Daimler’s SCR experience
19
How Does BlueTec Work?
20
= Exhaust
= Diesel Exhaust Fluid (DEF)
Intake
Throttle Valve Particulate Matter (PM) is trapped
in the Diesel Particulate Filter DEF injected into the
(DPF) exhaust stream
NOx
PM HC Doser
DEF
PM
NOx
Ammonia (NH3) and Nitrogen
Oxides (NOx) react in the catalyst
Diesel Oxidation Catalyst (DOC) to form Nitrogen and Water
Diesel Particulate Filter
(DPF)
NH3
DEF solution ‘hydrolyzes’ into
ammonia gas (NH3) which mixes
with the exhaust
SCR
N2O
H Device
2
The catalysts used in the SCR after-treatment system consist of

catalytically active transition metal compounds, which are fixed onto
ceramic carriers. The ability of the SCR after-treatment system to
convert NOx into N2 and H2O depends to a large extent on the actual
activity of these active centers, and on the width of the pores in the
ceramic carrier. Pore size influences the diffusion rate of the exhaust
gases into the catalyst.
To ensure a high activity of the SCR after-treatment system over a long
period of time the quality of DEF has to be controlled very strictly, as
many of the components with limit values in ISO 22241 2008/9
irreversibly harm the catalyst system by physical blocking of the pores,
or deactivation of the reactive centers. Poor activity of the SCR after-
treatment system due to inactive catalysts may 1) result in an increase
in NOx emission, and 2) cause secondary damage in the engine itself
due to an exhaust gas pressure increase.
21
1. Exhaust from engine The process begins when
2. Hydrolysis segment the DPF out temperature
3. SCR catalytic converter reaches 180 degrees C
4. Exhaust after reduction (356 degrees F)
5. DEF injection
22
SCR Video
BlueTec_Animation_E.exe
23
2010 Regeneration Frequency
> The use of SCR will allow engineers to recalibrate the performance of the
DOC / DPF portion of the aftertreatment system.
> Intervals between regenerations will be extended leading to longer life for
these components and improved fuel economy.
+ +
SOLID FLASHING
FLASHING FLASHING
Zone 1 Trigger Zone 2 Trigger Zone 3 Trigger Zone 4 Trigger Zone 5 Trigger
(Auto Regen) (Auto Regen) (Auto Regen) (Parked Regen) (Parked Regen)
DD15 2007 NAFTA 8 Hrs 14 Hrs 15 Hrs 15.5 Hrs 20 Hrs
Customer
Demo:DD15 45 Hrs 58 Hrs 60 Hrs 61 Hrs 64 Hrs
initial release
Current 2010 demo calibration’s active regeneration interval will be 45 to 90 hrs

90 hrs is max interval (typical for over-the-road, long haul)
45 hrs is min interval (typical for P&D, stop & go)
Active regeneration temperature will be lowered to 752°F/400°C
Duration 3 hrs
High Exhaust System Temperature (HEST) lamp is not lit
Regeneration event is transparent to the driver
Every 5th regeneration will be at high temp 1112°F/600°C
Duration 2 hrs / HEST lamp lit at vehicle speeds below 5 mph only
Occurs every 11,250 – 22,500 miles @ average speeds of 50 mph
Hydrocarbon storage protection (auto-elevate feature) will still be needed in 2010
Used in applications with extended periods of idle time
Engineering is working on improvements, but times will be no worse than today for
EPA’07 engines 24
DD15 Engine Changes
for 2010
25
DD15 ISO LEFT VIEW
2007 2010
26
CYLINDER HEAD COVER
2007 2010
Changes from EPA07 DTNA Impact Actions/Solutions
Modified Design (shape) • None
27
CAM SHAFT HOUSING
2007 2010

Attachment Point
Modified Hole Dimensions • Air Suction Pipe for Air
Manufacturing Process allows Compressor
1.5xD
28
CRANKCASE HOT ENGINE SIDE
2007 2010
relocated added
Added Bosses
• Vehicle Wiring Harness
Elimination of Bosses • None
New Boss Location • None
29
CRANKCASE COLD ENGINE SIDE
2007 2010
added
relocated
• None (only for 2cyl Air compressor

New Boss Location
bracket)
• None (only for 2cyl Air compressor

Added Boss
bracket)
30
FLYWHEEL HOUSING
2010
2007
Added variant
• PSP
w/ PSP & w/o PTO
• Requested for
Added Attachment Points
Module: 125, 286, 290, undefined
31
CRANKCASE BREATHER
2007 2010
Added Bracket and Sensor • None
32
MCM ENGINE CONTROL UNIT
2007 2010

Modification electrical
characteristics
33
WIRING HARNESS
2007 2010

Changed Type of Connector
EPA07: 31PIN • Vehicle Wiring Harness
EPA10: 10PIN
Elimination of 31PIN
• Air line for fan clutch
Connector bracket
Added speed sensor for

• None
Crankcase breather
Misc. Wiring & Bracket

• None
Updates
34
AIR COMPRESSOR
SINGLE SINGLE
2007 2010

• New air compressor governor port
Remove governor mounting pad. faces forward instead of down.
• New plumbing required.
Air inlet port diameter decreases • Redesign of air compressor inlet
from 44mm to 35mm. tube.
New (common) air compressor to

• None.
engine flange.
35
AIR COMPRESSOR
DUAL DUAL
NOT AVAILABLE FOR 2007
2010
New component. • Packaging investigation required.
Compressor does not have a provision • DTNA to install safety valve on

for a safety valve. discharge plumbing.
Power steering pump and plumbing
• DTNA to define new plumbing and
different compared to single cylinder
investigate packaging.
compressor.
Governor port is in different location
compared to single cylinder • DTNA to define governor plumbing.
compressor.
Implementation of air compressor • Potential rerouting of vehicle
.
support bracket. harness necessary.
New (common) air compressor to
• None.
engine flange.
36
AIR COMPRESSOR COOLANT LINE
2010 – ADDITIONAL DUAL COMPRESSOR - 2010

COOLANT RETURN PORTS
• Packaging investigation required in

New component. combination with packaging of
compressor.
37
ACCESSORY BRACKET
2007 2010
Mounting for A/C compressor moved

outboard and down in order to • New A/C compressor, compressor
accommodate 160mm A/C plumbing and new belt necessary.
compressor pulley.
38
TURBOCHARGER
2007 2010
Minor Casting Updates • Minimal or None.
39
OIL-COOLANT FILTER MODULE
2007 2010
• No Engine Mounted Coolant Filter.

Removed Coolant Filter. • Provision for Penray Need Release
Element still available.
40
FRONT MOUNTING EYE
2007 2010
Relocated Radiator Bias

• New Bias Strut Rod required.
Strut Mounting Point.
Designed new Front Lifting

• New Lift Eye Access.
Eye Strategy.
41
REAR MOUNTING EYE
2007 2010
Changed Bracket Mounting

• Minimal or None
location from side to rear
Changed Bent Bracket the

Flat Bracket design (same as • Minimal or None
DD13)
42
43
Cascadia Sleeper w/ 1 box ATS
Additional notes on mounting the ATS:

> There must be a 7 inch gap between the fuel tank and ATS so a cover can be
placed over the DEF dosing unit and injection tube.
> The “U” shaped exhaust from the engine into the ATS is configured to
- Wrap around the vehicle frame
- Maintain proper back pressure
44
DEF Tank / Mounting Weight
23 gal
13 gal
6 gal
Tank Component Weight (in lbs.)
Component 13 Gallon 23 Gallon

Frame Castings 15.8 15.8
Hilite Pump 13.0 13.0
Pump Bracket 2.5 2.5
Cage Weldment 36.5 49.6
Retainer 0.6 1.0
Header Unit 3.5 3.5
Tank Assembly 10.4 13.5
DEF Fill 129.7 229.5
Total 212.0 328.4
45
Vehicle mounted DEF tank
The 23 gallon DEF tank from a customer demo vehicle.
46
2010 ATS Weight Component Total Weight (lbs.)
Upper Castings (2) 5.6
LWR Fwd Casting 10.9
LWR Aft Casting 10.5
1-Box 382
Total 1-Box & Casting 409
Component Total Weight (lbs.)

1-Box & Casting 409
2007 ATD 175
Increase over 2007 ATD 234

13 Gallon DEF tank (empty) 82
13 Gallon DEF (liquid) 130
Weight Increase over 2007 446
47
1-Box design details Flat Band
> Twin DPF’s in 1-box design

- On top row for serviceability
> Solid machined V-band halves (identical
to EPA’07 design) on DOC to DPF joint
> Torca flat band with integrated gasket
on lower-pressure DPF outlet
Note: The clamps and

gaskets pictured here are
undergoing some revisions.
The DPF filters are

serviceable.
The side-by-side filter design allows for approximately the same volume of exhaust
to flow in a more compact setup. Exhaust pressures / temperatures with the
2010 one box system are also approximately the same as those with the 2007
aftertreatment system.
48
DD15/DD16 1US ATS
Mounting
Top Inlet Plate
Sensor Box
DEF Front-face
Metering Inlet
Unit
In-board
Outlet
Rear-face Outer Heat
Outlet Shield
DEF Injection
Nozzle
On the training center C1 ATS we have:

6 temp sensors
1 x DOC inlet
2 x DOC out
1 x DPF out
1 x SCR inlet
1 x SCR outlet
2 NOx sensors
NOx raw inlet
NOx outlet
2 Pressure sensors
DOC in
DPF out
Note: C2 and later versions of the ATS (the ones on the customer demo units) will
contain only 1 DOC out temperature sensor. The C1 sensor box has a single 31 pin
connector. The C2 model has two 14 pin connectors.
49
Single box ATS mounted on vehicle
The single box ATS from a Customer Demo truck.
50
Step 1
1-Box Flow – Part 1
Step 2
Step 3
Step 4
Step 1 Engine exhaust enters the system
Step 2 The exhaust travels through the DOC/DPF filters toward the
rear of the system
Step 3 The exhaust is routed downward to the DEF injector
Step 4 DEF /compressed air is sprayed into exhaust stream at this

point
51
1-Box Flow – Part 2
Step 6
Step 7 Step 5
Step 5 The treated exhaust travels through the hydrolysis tube toward the front of the
system
Step 6 Treated exhaust enters the SCR catalyst filters where it undergoes a chemical
reaction while moving toward the rear of the system once more
Step 7 Water and Nitrogen by-products pass out of the SCR catalyst and into the exhaust
52
Current
training
engine
sensor box
has a single
31 pin
connector to
the vehicle
harness. The
next
generation
of sensor
boxes will
have two 14
pin
connectors.
The sensor box mounted on top of the 1 box ATS houses:

> DOC / DPF aftertreatment sensors associated with 2007 engine
> SCR in and SCR out temperature sensors
> NOx in (or raw) and out sensors.
The box has reflective tape in spots to cut down on heat.
53
NOx in sensor
The NOx in (or raw) sensor measures the NOx concentration prior to
the exhaust gas entering the SCR catalyst while the NOx out sensor
takes a similar measurement as the exhaust gas leaves the SCR
catalyst. The reduction of NOx will fall within a known range on a
properly operating system. The NOx sensors operate on 12 volts. This
sensor is considered a “smart” sensor.
Operation
Electro-chemical pumps adjust the oxygen concentration in the cavities
of the sensing element. The NOx concentration in the exhaust gas is
proportional to the electrical current controlling the pumps.
Based upon the physical measurement, the electronic control unit
generates 3 output signals (NOx, binary, linear).
The signals are transmitted digitally to the ACM.
54
ATS Single Box
Worksheet
At this point we will go to the engine room and perform 3 exercises:
1) The identification worksheet of sensors

2) Remove sensor pack
3) Remove DPF filter
55
Quick Check #1
1) There are ______ main methods being used to meet EPA 2010 emission standards.
2) Give two reasons for an expected increase in fuel economy for 2010 SCR equipped
vehicles.
__________________________________________________
__________________________________________________
3) A 2010 SCR equipped vehicle with a full 13 gallon DEF tank would weigh approximately
how much more than a vehicle with a 2007 aftertreatment system? ___________lbs.
4) What is the freezing point of DEF? ___________degrees F.
5) With the single box ATS design how many DPF filters are in use? _______________
56
SCR System
Components
57
The coolant valve and the DEF pump are both attached to the DEF tank
with the coolant from the engine first flowing through the DEF pump.
The heated DEF lines in the schematic are represented by the gray
border around the blue DEF lines.
58
Aftertreatment
Control Module
59
Aftertreatment Control Module (ACM)
Note: Cover not shown
> The ACM is the primary controller for both DPF and SCR
aftertreatment components.
> It has the same overall dimensions as the MCM2 engine control
module.
> The module’s labels will be color coded for easy identification.
All power supply lines from the vehicle and powertrain CAN are
connected with the 21–pin connector (1). The sensors and actuators
use the 120–pin connector (2).
60
Cascadia ACM Location
ACM mounting
behind driver’s fender
ACM Mounting
The ACM is mounted with four bolts and requires ISO mount damping elements.
When mounting the ACM keep the following points in mind:
> Headers or harness bundles should not point up to prevent potential water
pooling.
> Protect the plastic cover against mechanical damage to the maximum extent
possible.
> Isolator mounts are required for electrical, thermal, and vibration isolation from
the chassis.
> Harness bundle strain relief must be provided via the housing bosses.
> Do NOT ground the ACM housing. This can result in false codes being logged.
Cooling
The ACM does not use a liquid cooler so the cover of the cooler has been removed.
61
ACM Communications
> The ACM communicates with

the MCM2 and CPC2+ via a
dedicated CAN line
> Like DDEC VI modules it

transmits data messages via
the Unified Diagnostics
Services protocol.
> Electronic diagnostics will be

done using the DDDL / DDRS /
Drumroll family of tools
> Programming the ACM will

follow procedures similar to
MCM programming
62
Preliminary ACM2 /CPC2+
Wiring Diagram Review
63
DEF Tank
64
Line fitting for Line fitting for
13 Gallon DEF Tank DEF fill neck (will
be molded into
DEF (return line) DEF (feed line)
Components production tank)
DEF Line
temperature Line fitting
for coolant fitting for
and fill level coolant
combination (outlet)
(inlet)
sensor
DEF tank
Tank heater
Note: Tank connections may vary
depending upon the tank being used.
The DEF Tank

> DEF tanks are made of plastic
> Heating takes place by the engine coolant flowing through the tank
> A screen is installed on the DEF intake side
> Tank neck is sized so diesel fuel cannot be added by mistake.
65
Integrated Header
> D-level designs of urea tank
DEF return
Urea DEF
Urea supply
return supply headers with integrated coolant
Coolant
valve
valve finalized
Coolant
Coolant
supply
supply > Reduced complexity and
coolant connection points
> Same system is used for both
Coolant
valve
13 and 23 gallon DEF tank
Coolant
Coolant
return
sizes
return
66
DEF tank level and temperature combination sensor along with heater
DEF tank level

sensor float
A negative
temperature
coefficient DEF filter
resistor is elements
used to
measure the
temperature
of the DEF in
the tank.
Coolant
circulates
through the
bottom of the
tank
67
DEF Tank Filling and Freezing
> Installed on left side of vehicle

> Integrated heater using engine coolant to heat DEF in cold ambient
conditions
> DEF will freeze when the vehicle is parked in temperatures below
12ºF (- 11ºC).
> Vehicle is fully operational when DEF is frozen – Upon starting the
engine, coolant will thaw the DEF to allow the SCR system to operate
68
Heated DEF Lines
• Quick connect/disconnect.
• Lines are fixed length.
• Not repairable, must be replaced.
• Connector is also heated.
• Air gap between cover and line.
• Blue marking to identify from electrical
harnesses.
• Lines receive 12 volts
> Heated lines 1 and 2 go from DEF tank to DEF pump

> Heated line 3 goes from DEF pump to DEF dosing unit
> Heated line 4 is used for configurations other than the one box ATS
69
DEF Pump
70
Line to DEF dosing
unit
Line to DEF tank
Compressed air from

air supply unit
DEF pickup
tube
Electrical
connector
Coolant in Coolant out
Filter cap (behind

reservoir cover)
DEF pump module is mounted to the DEF tank. It will have a protective cover.
The DEF pump module:

> Filters the DEF
> Supplies the DEF dosing unit with DEF and pressure.
> The DEF pump module consists of a plastic housing and a bolted-on
aluminum block.
> The plastic housing contains the electrical pump for the DEF.
> The aluminum block contains an air bladder, a fill valve, and the DEF
filter.
> DEF Filter has a 300,000 mile change interval.
71
Inside the DEF Pump DEF feed line
DEF pressure (to dosing unit)
Pump Module pump filter
DEF return line
DEF intake line (to DEF tank)
Pneumatically controlled
switching valve
Compressed air connection
Pressure reservoir
Electrical
connector
Coolant Coolant
inlet outlet
Note: Items in red are
Pressure
the only ones the may
reservoir Note: The pressure at the
be serviced. compressed air connection
filling valve
and should be about 80 PSI (5.5
connection bar).
Operation:
The DEF pump draws the DEF from the DEF tank. The DEF is pre-
filtered via the intake filter which is integrated in the DEF line fitting.
The pump brings the DEF up to the operating pressure of approximately
5 bar (72 PSI) and pumps it on to the pressure filter and pressure
reservoir housing.
In order to eliminate any finer remaining dirt particles, the DEF passes
through the integral pressure filter before being pumped to the
metering device.
The pressure reservoir is basically a rubber bladder filled with gas,
which compensates for pressure fluctuations, reduces the cut-in
frequency of the DEF pump and protects against bursting if the DEF
freezes. It is factory-filled with nitrogen (N2).
To prevent frozen DEF from damaging the DEF pump module, after the
ignition is switched off the valve opens allowing DEF to flow back to the
tank.
72
DEF Dosing Unit
73
DEF Dosing Unit
The DEF dosing unit is
mounted to the ATS.
The unit mixes DEF with
compressed air and
meters this mixture into
the exhaust flow via the
DEF nozzle also
mounted on the ATS.
DEF dosing unit with cover
The ACM uses data from all the ATS sensors and engine operating
conditions to calculate the mixture of DEF and compressed air.
It also determines if the components are working properly within the
DEF dosing unit.
74
Compressed air
pressure sensor
DEF pressure
PTC heating
sensor element location
DEF temperature
sensor
Diffuser heating
element
DEF connection
DEF filter screen
Calibrating screw DEF / Air mix output

–DO NOT ADJUST
DEF dosing valve
The DEF dosing unit is attached to the 1 box ATS. One side
accommodates the DEF components, the other the compressed air
components. On the DEF side is a filter screen, a pressure and a
temperature sensor, a calibration screw, and the electrically controlled
dosing valve.
The compressed air side is equipped with a filter screen, a check valve,
a diffuser and a mixing zone beneath the diffuser, where DEF is added
to the compressed air. In the mixing chamber the pressure is detected
via an air pressure sensor. Pressure at the entry point of the
compressed air connection is about 5.5 bar (80 PSI).
The diffuser heater and DEF heating element removes crystal deposits
from the dosing unit and prevents them from building up.
75
3
Air
diffuser
heating
element
1
Functionality –
1) The pump module sends DEF to the DEF Dosing Unit. From the DEF
connection it passes the DEF filter screen and becomes available at
the closed DEF dosing valve at operating pressure.
2) The DEF dosing valve is controlled via signals from the ACM. Upon
opening the DEF flows through dosing valve.
3) Once the engine is started compressed air continually enters the
dosing unit from the air supply control unit. The compressed air passes
through the diffuser heater toward the mixing chamber. (note the
change in color of the flowing air)
4) The calculated amount of DEF mixes with the compressed air and is
carried along towards the DEF nozzle.
Because of the continuous flow of compressed air through the dosing
unit no DEF deposits will build up in unit.
76
Inspecting the DEF
Pump Module
77
Plastic
housing
side of the
DEF pump
module.
When the engine reaches SCR operating conditions (DPF Out Temp180
degrees C / 356 degrees F) the pump will become enabled until DEF
pressure reaches 72 PSI. Compressed air from the system’s air control
unit keeps the pneumatic valve closed sending DEF to the dosing unit.
The pump builds up operating pressure quickly. It will then turn off and
only get turned on again when DEF pressure drops sufficiently
(approximately 65 PSI). It will then turn back just long enough to build
sufficient operating pressure.
78
Aluminum housing
side of the DEF
pump module.
3 points of interest:
1) Filter element
2) Reservoir bladder
3) Air pressure
switching valve
mechanism
Please follow these guidelines regarding bladder pressure:

1) Pressure needs to be checked in the pump after installing it on the
truck. If pressure is low then bleed off the pressure and fill with clean,
oil free, water free air pressure.
2) Bladders are empty and need to be pressurized after installing them
in the pump housing.
3) Use a pressure regulator on the air line to avoid over charging the
bladder.
4) Bladder pressure needs to be check every 3 years.
5) Bladder pressure is 3.0 bar (about 44 PSI) + or – 2%
79
DEF Pump Module
Worksheet
80
Inspecting the DEF
Dosing Unit
81
The DEF Dosing
Unit Components
82
DEF pressure sensor
Air pressure sensor
DEF temperature
sensor
DEF Dosing Unit Sensors
1) Normal operating pressure at the DEF pressure sensor would be

approximately 5 bar (72.5 PSI).
2) A proper range of operating pressure read by the compressed air
pressure sensor is 1.23 bar to 2.5 bar (18 PSI to 36 PSI).
3) Both pressure sensors are standard 3 wire pressure sensors with a 5
volt operating range.
4) The DEF temperature sensor is a standard 2 wire sensor with a 3 volt
range.
83
DEF heating
element on
dosing unit
PWM
actuated
DEF dosing
valve on
dosing unit
Diffuser heating
element on
dosing unit
1) The 2 heating elements of the dosing unit are activated via the ACM
based readings from the DEF temperature sensor, the ambient air
temperature sensor, and other factors. The initial temperature is about
200 degrees C (392 degrees F) but gradually settles in to a
temperature just above the melting point of DEF crystals (about 135
degrees C / 275 degrees F).
2) The DEF dosing valve is a PWM controlled unit that receives it’s
instructions from the ACM. The amount of DEF allowed to flow into the
mixing chamber is a calculation based on values from the dosing unit
sensors, DEF tank conditions, and engine operation conditions.
84
DEF Dosing Unit
Worksheet
85
DEF Nozzle
86
DEF Nozzle
The DEF / air mix
coming from the
dosing unit is sprayed
through the nozzle as
uniformly as possible
into the exhaust flow.
The DEF nozzle is
made of stainless
steel. The nozzle tip
faces towards the flow
direction.
DEF flows
through a single
hole in the
center of the tip
87
DEF Nozzle
Note that the
length of the
DEF nozzle
and dosing
connection
will change
depending
upon the type
of SCR
catalyst being
used.
The DEF in the exhaust flow requires a certain amount of time for the
chemical process that converts DEF to ammonia (NH3). For this reason
it is mounted at a precisely-defined distance upstream of the SCR
catalyst.
88
DEF Flow
89
1 2 Step 2
Step 1
DEF
Driver Side
3 4
Passenger Side
Step 3 3
4 Step 4
DEF FLOW
Step 1. DEF is fed from the DEF tank and transferred to the DEF pump
Step 2. DEF Pump draws DEF from the DEF tank where it passes through a filter to remove
any particles. The operating pressure of the pump is approximately 72 psi and it consumes
12 volts as it cycles on / off to build operating pressure as required.
Step 3. DEF is mixed with compressed air in the DEF metering unit to create a fine mist of
DEF and air.
Step 4. DEF/compressed air mixture enters the BlueTec 1-Box at the DEF nozzle where it
meets the exhaust flow.
90
DEF Pressure Line Routing
> Be aware of incorrect DEF line

routing when making vehicle repairs.
Do not route DEF lines over the frame
rail. There must be consistent line
routing with a trap.
> DEF could drain back into metering
unit after vehicle shut down
potentially causing problems.
Urea line (crystallization, freezing)
routing over
frame rail
91
Integrated
Coolant Valve
92
1
3
2
Integrated Coolant Valve Coolant is branched off from the engine coolant
1 Electrical connector circuit via the Integrated Coolant Valve to heat the
2 Line fitting (coolant supply line) DEF line circuit and the DEF tank. The valve is
3 Line fitting (coolant working line) controlled by the ACM.
Activation conditions for opening the coolant valve:

The coolant valve will open allowing engine coolant to flow and heat the
system when the following conditions are met:
1 – The DEF in tank temperature is less than 36°F (2°C).
2 – The engine coolant temperature is greater than least 32°F (0°C).
93
Coolant Line Plumbing
Co
Co
o
lan
olan
t O
t I
U
N
T
94
SCR Coolant Flow
95
Step 1 Step 2 Step 3
1
2
CLT
4
Passenger Side 2 3
3
4
1
Step 4
Driver Side
Step 1. Coolant from the engine flows through the DEF pump
Step 2. Coolant travels through the DEF pump to heat the DEF and pump components.
Step 3. Coolant will flow through the integrated coolant valve when the system requires.
When not needed coolant will stop at the valve inlet.
Step 4. Coolant travels through the DEF tank to heat the DEF. The amount of coolant flow is
based on the temperature sensor in the DEF tank.
96
SCR Air Supply
97
Air Control
Unit
> The DEF air pressure regulation valve is actuated via ACM control
unit.
> The initial air pressure comes from the engine at about 8 bar (116
PSI) and is reduced in the air control unit to about 5.5 bar (80 PSI)
> Compressed air flows through the DEF air pressure regulation valve,
through a check valve and the pressure limiting valve before moving on
to the DEF pump and DEF doser.
> The compressed air ensures that the DEF is transported from the DEF
dosing unit to the DEF nozzle and that the DEF is sent back from the
DEF pump to the DEF tank.
98
Air System
Preliminary
Data Purge Cycles
140
Air Tanks
120
Delivered
Pressure at
100 Regulator
Pressure (psi)
80
60
40
20 Volume = 5,600 cu. in.
0
0 1 2 3 4 5 6 7
Time (min.)
When ignition is off the air system purges DEF from the lines to prevent
DEF from freezing within the lines during cold ambient conditions. Psi
drop is 9 – 12 psi, so drivers need to know this is not a leak.
99
SCR Air
System Flow
100
Step 1
Step 2
1
AIR 2 3
AIR Step 3-1:
Passenger Side
3
1 2
1
4
Step 3-2
Driver Side
5
5
4
Step 1. Compressed air from the air tanks flows to the air control unit engine at about 8 bar
(116 psi). The air control unit reduces air pressure to about 5.5 bar (80 psi)
Step 2. This frame mounted, 12 volt unit also ensures DEF is transported from the DEF
metering unit to the DEF nozzle and that DEF is sent back from the DEF Pump to the DEF
tank
Step 3 -1. Compressed air travels to the compressed air connection on the DEF pump,
during operation the valve keeps the pneumatically controlled switching valve closed
Step 3-2. Compressed air travels through the DEF metering unit where it mixes with DEF to
create a DEF/air mixture that is metered into the BlueTec 1-Box.
101
Quick Check #2
1) Identify three methods used to heat DEF in the 2010 system.
A. __________________
B. __________________
C. __________________
2) The new electronic control unit on the 2010 system is called the
_____________________________________.
3) The new electronic control unit on the 2010 system is cab mounted.
True False
4) The DEF nozzle is made of
_______________________________________.
102
Quick Check #2 (continued)
5) When the compressed air pressure is reduced to the pneumatic switching valve on the
DEF pump module DEF will flow back to the DEF tank. True False
6) How many sensors are located on the DEF dosing unit? _____________
7) What 2 temperatures are necessary for the integrated coolant valve to begin operation
to heat the SCR system? ____________________ and _______________________.
8) The air control unit reduces the air pressure from ________ Bar (PSI) to __________ Bar
(PSI).
9) The air control unit of the SCR system sends air to the ______________ and the
___________________.
103
Quick Check #2 (continued)
10) 70 PSI is a valid operating pressure for the DEF pressure sensor on the dosing unit to
read. True False
11) The DEF dosing valve is controlled by the ____________.
MCM2 CPC2+ ACM
12) The engine coolant temp is 40°C. The DEF tank temperature is 0°C. Would you expect
the coolant valve to be open? Yes No
104
Electronics and
Diagnostic Software
105
1 2
2010 Electronic Control Modules

3
1) Aftertreatment Control Module (ACM) –
shown in e-tools as ACM02T
2) Motor Control Module 2 (MCM2) –

shown in e-tools as MCM02T
3) Common Powertrain Controller 2+ (CPC2+) –

shown in e-tools as CPC02T
1) The ACM is a completely new module to the system. It will control

and monitor all the 2010 engine’s aftertreatment related sensors,
actuators, and general operations. It is mounted to the vehicle frame
enclosed in a box.
2) The MCM2 is the next generation of engine controller. It will control

and monitor all the engine functions it has in the past with the
exception of aftertreatment components. It is mounted on the engine.
3) The CPC2+ will oversee all vehicle related activity. It will interact with
the MCM2 and ACM via a dedicated CAN connection and interface with
all the other electronic control modules on the vehicle using J-1939
communications. The CPC2+ is mounted in the cab.
106
The diagnostic software for the customer demo vehicles will be either the
production release of DDDL or DDRS 7.04. There will be a second service pack
introduced in the 3rd Q. of 2009.
107
DDDL / DDRS 7.04
Functionality Review
for 2010 units
108
Instrument Panels
Panel Name EPA07 EPA 2010 S60 MBE HDEP HDEP
Trip Data X X X n/a
All Instruments X X X X
Chart X X X X
Cruise Control X X X X
EGR X X X X
Engine Brake X X X X
Mechanical X X X X
Switches X X X X
User Defined X X X X
X – Appears in Application Functional Not functional at this time For version 7.04 SP1
> All instrumentation panels for 2007 DDEC VI engine applications are functioning properly.
> For 2010 engines the green blocks indicate the panels are functioning properly while the
red blocks indicate there are issues with that panel.
109
Parameter Panels

All Parameters X X X X
Compare Parameters X X X X
Compare Server Data X X X X
Fuel Economy X X X X
Transfer Accumulators X X X tbd
Cruise Control X X X X
Engine Brake Config X X X X
Engine Protection X X X X
Idle and PTO Shutdown X X X X
Inputs and Outputs X X X X

Optimized Idle X X X X
Progressive Shift X X X X
PTO X X X X
Speed Limiter X X X X
For version 7.04 SP1
The “tbd” blocks for the 2010 engines have not been implemented yet
110
Service Routine Panels (1/2)

ATD Maximum Sensor Value Reset X X X tbd
ATD Test Pipe X X X tbd
Compression Test X X X X
DPF Ash Accumulation X X X ***
HC Doser X X X X
Injector Codes X X X X
Leak Detection n/a n/a X X
Pressure Limiting Valve (PLV) Change n/a n/a X X
Rating X X X X
Real Time Clock X X X X
Replace Quantity Control Valve n/a n/a X X
Set Engine Serial Number X X X X
Turbo Actuator X n/a n/a n/a
*** - Special 2010 Service Routine For version 7.04 SP1
Notes on the current production DD15 service routines when used on 2010 engines:
> The rating function returns values of all zeros on the 2010 engines.
> All the routines previously discussed work fine with all DDEC VI current production
engines.
111
Service Routine Panels (2/2)

Activate Outputs X X X X
Air Mass Adaptation n/a X n/a n/a
DPF System X X X X
Idle Speed Balance X X X X
Intake Throttle Valve X X X X
Voltages X X X X
Cylinder Cutout (Automatic) X tbd tbd tbd
Cylinder Cutout (Manual) X X X X
For version 7.04 SP1
Notes on 2010 engines the DPF system service routines:
> The stationary regen works properly
> The HC doser purge routine works properly
> The ability to set a driving regen flag is not working at this time
112
DDDL / DDRS 7.04
2010
Software Tips
113
Tips for using the 2010 diagnostic software
When you successfully connect to the 2010 modules you will see this message
appear under the identification window. If this message appears when
connected to production vehicles it alerts you to check the version numbers of
your MCM and CPC software for an incompatibility. The application is reading
from a production compatibility table of software versions and displays the
message when necessary.
When connected to pre-production software this message will always appear

because none of the versions we are using are in the compatibility table.
114
> The fault code window in the 2010 will work in much the same way as with production
software. There will be a description of the code, the number will be the J-1939 SPN, the
mode will refer to the J-1939 FMI for that code.
> Because of the pre-production nature of the software faults may occur that have not
been officially assigned a description or J-1939 values. Technical support will be able to
help you identify these faults.
> Pending faults will be discussed in the OBD section.
115
Special
diagnostics
panels for
viewing ACM
instrumentation
have not yet
been developed.
We will create
our own custom
panel of key SCR
system
parameters that
can be recalled
whenever
necessary.
To create your own user selection:

> Open the Instrumentation window and click on the “User” tab. All the
parameters from the CPC2, MCM2 and ACM will appear in a list on the
left.
116
As you check off values you want from the list they will automatically
appear in the blank white area. The amount of screen space used to
display a value will be automatically configured as new values are
selected.
117
2 3
When you have made all the selections you want save your panel by
clicking on the floppy disk icon, type in a file name in the dialog box
that appears, and then save the selection.
Your selection now may be retrieved if you are in the “User” tab or the
“Chart” tab of the Instrumentation window.
118
Using a 2010
Routine from the “All
Services” Panel
There is only two validated service routine specifically for SCR diagnostics as of
release 7.04 service pack 1. These routines do not have their own user panels and
must be accessed under the “All Services” tab in the “Service Routines” window. In
this section we’ll review how to run these routines.
119
Proposed Service Routines for SCR System:
> SCR Efficiency Test – proposal to create a test similar to high idle
regen; bring system up to dosing conditions, measure NOx in and NOx
out.
> Voltages Service Routine – create new SCR related sensor panel to
display voltage outputs
> SCR Heater Operation – proposal to control heating elements to
determine proper operation
> SCR Dosing Quantity Check – take over control of DEF dosing
unit for a given amount of time and measure the actual DEF flow
> Key Off DEF Bleed Test – proposal to monitor DEF pressure and air
pressure with key off
> System Pressure Check – routine to activate / turn off air valve
> User ACM Switch Control – allows the user to control digital outputs
> User ACM PWM Control – allows the user to control PWM outputs
These are example of routines that have been requested.

While some are currently under development the release
schedule for all these routines is not known at this time. The
routines in bold are available in version 7.04 of the electronic
tools service pack1
120
SCR
System
Pressure
Check
After making your initial connection with the vehicle select “Service Routines” from
the main function menu on the left of the screen.
121
SCR System Pressure Check
> Click on the “All Services” tab.
> The tab will open will display routines for all 3 modules. Click on the minus sign to
close the routine list for the CPC02T and MCM02Tleaving the ACM02T list open.
122
> Scroll through the ACM02T routines until you come to the “SCR Pressure System
Check: Start” routine and leave it highlighted.
> Once highlighted you’ll notice controls for running the routine will appear in the
lower half of the window.
123
This routine will pressurize the system as if it were under fully operational
conditions:
1) The compressed air control will be enabled
2) The DEF pump will be enabled till its pressure builds to its operational limit
3) DEF pressure and compressed air pressure will build to operating pressures
> To start the routine type in the amount of time you wish to run the routine for in
the “Value” column on the “Operation Time” line.
> Click on the “Execute” box in the lower right of the screen.
You will be able the hear the system become pressurized for the time designated
and then shut back off.
124
To best analyze the results of the test we’ll look at the log file that was created.
> Disconnect all the modules when the test is complete.
> Go to the “Open Log” item in the “File” drop-down menu, select the log you’ve
just created, and open it up.
125
Go into the “Instrumentation” window and select the “Chart” tab.

Select the parameters shown above to examine the test results.
126
SCR Pressure System
Check
> Pump is only enabled

long enough to build up
proper DEF operating
pressure.
> Compressed air

remains on the entire
length of the routine.
> The key values to

observe are DEF
pressure and
compressed air
pressure. Are their
readings within the
proper range?
You may now use the chart controls to adjust the size and scaling of the parameters
to analyze the results. We will now open up the log file and look at it live.
Was this this system functioning correctly?
Why or why not?
127
SCR Pressure System
Check
How do the key values

in this service routine
differ from the previous
slide?
Enable DEF pump?
DEF Pressure?
Enable compressed air?
Compressed air
pressure?
128
SCR Dosing Quantity Check
The “SCR Dosing Quantity Check” allows you to command the DEF
dosing unit to flow DEF for a specific amount of time. The DEF is
collected and then measured to see if the expected amount has flowed
through the dosing unit.
Important note: In order for this routine to work we must also activate
the SCR pressure system check routine at the same time.
Our test assumptions:
A) DEF flow is measured by g/hr
B) The suggested values to set for the routine are:
> Desired dosing quantity 2,000 g/hr
> Desired time 2 minutes (120 seconds)
129
1) Before the routine can begin you’ll to get disconnect the tube from
the bottom of the DEF dosing unit and the DEF nozzle. You’ll need to
set up a graduated container to collect the DEF as it flows from the
dosing unit.
2) From the “All Services” tab select the “SCR Dosing Quantity Check:
Start Status” item
3) Once selected the desired values will be input in the lower half of the
screen.
130
4) Per our test assumptions enter the values in the appropriate boxes.
Do not choose to execute the routine at point.
131
5
5) Go back up the “All Services” list and find the “SCR Pressure System
Check: Start Status” item and highlight it.
6) We need to have the SCR system working at operating pressure to
flow DEF from the dosing unit so we’ll activate this routine first. Set the
desired time in the lower half of the screen to 140 seconds. The
additional twenty second will allow us plenty of time to go back up the
list and activate the DEF quantity check routine for the full 120
seconds.
7) After filling in the time click on the “Execute Service” box in the
lower left of the screen.
132
8) You’ll hear the SCR air system activated. Return to the “SCR Dosing
Quantity Check: Start Status” panel and click on the “Execute Service”
box in the lower right of the screen.
9) The DEF / air mixture will now begin to spray into your container and
continue to do so for 2 minutes. You will be able to hear the DEF dosing
valve in the DEF dosing unit working as it measures the DEF and sends
it to the mixing chamber.
10) When the 2 minutes is up check the amount of DEF collected.
Given our initial assumptions of flow rate and time we should have a
collected about 52 milliliters (1.75 oz.) of DEF. Note that there may be
a + - variance with the amount of DEF collected. The final variance is
still undergoing evaluation but will be part of the production
troubleshooting material. For our test purposes it should be
approximately + or – 15%.
133
SCR Dosing
Quantity Check
Enable Compressed Air Pressure
Enable DEF Pump
DEF Pressure
DEF Air Pressure
Actual DEF Dosing Quantity
Requested DEF Dosing Quantity
Here is a look at the chart screen created from a log file of the “SCR
Dosing Quantity Check Test”.
This routine will become automated and have its own service routine
panel for the production version of 2010 diagnostic software.
134
OBD Diagnostics
A Preliminary 2010 Overview
135
What is OBD?
> We have always had service diagnostics
- Open circuit, short circuit, invalid signals
> We have also had protection diagnostics
- Oil temperature high / oil pressure low / exhaust temperature high
> Logic codes were introduced in 2002 with the EGR system and expanded with the
2007 aftertreatment system
- Faults appeared when values for certain parameters fell outside the expected
operating range
- Faults would become inactive if the conditions were no longer present
> Now the regulators require threshold diagnostics for all emissions related systems
- Example: NOx conversion efficiency is too low and emissions limits are being
exceeded
- For any emissions related component (sensor, actuator), an assessment must
be made of the impact on emissions resulting from a failed or improperly
functioning component. Regulators have identified certain failure modes that
must be detected. Diagnostics must be developed to detect these conditions.
136
What is OBD?
California’s Air Resources Board (CARB) and the EPA

legislated diagnostics
- First step was Engine Manufacturer Diagnostics (EMD) in
2007
- Second step is On-board Diagnostics (OBD) beginning in
2010, with phase-in across all engine platforms by 2013
Why is this being regulated?
- Ensures emission control components are working in-use
for the vehicle’s life
- Helps ensure that low emission standards are met
- Assists technicians in diagnosis & repair by pointing to
the faulty component
- Can be (will be) a potential tool for fleet and road-side
inspections
137
What vehicles have OBD today?
> All passenger cars, SUVs, and small
trucks
- Started in 1996 for gasoline
and 1997 for diesel
> Over 120 million OBD II -equipped
vehicles operating in the United
States today
138
Elements of OBD
139
Elements of OBD
1) Emission Monitors
2) Certification
3) General requirements for diagnostic

trouble codes (DTC)
4) Standardization
5) OBD/emissions service information

disclosure
6) Penalties defined for non-compliance to

OBD rules
1) Emission Monitors
2) Certification
Monitoring demonstration requirements
Certification documentation
3) General requirements for diagnostic trouble codes (DTC)
MIL
Some OBD related DTCs will cause mandatory vehicle / engine derates
Fault code memory
4) Standardization
5) OBD/emissions service information disclosure
Facilitates third party repair of emissions and OBD related problems
6) Penalties defined for non-compliance to OBD rules
Per-engine $ penalties beginning 2013 for OBD deficiencies
140
Monitors
141
What is a Monitor?
> A process used to detect when a

component or system is no longer
operating as expected.
> Monitors are basically developed
with the following considerations in
mind:
- What is the system or
component expected to do
or detect?
- Under what conditions
should the logic operate?
- What should the actions be
when it no longer meets that
condition?
142
Three types of monitors
> Service monitors
- Assist in troubleshooting of
defective components
- What can fail in the system, how
can it fail?
> Protective monitors
- To prevent damage to
components
- What condition can cause
damage to a system
> OBD monitors
- As defined in regulation(s)
- Can be threshold, functional,
plausibility
143
OBD Monitors
> EGR System

> Boost Pressure Control System
> Fuel System
> Misfire
> NMHC Converting Catalyst
> NOx Converting Catalyst
> Particulate Filter
> Exhaust Gas Sensor Including NOx Sensor
> Engine Cooling System
> Crankcase Ventilation System
> Comprehensive Components – Circuit continuity,
plausibility (drift/in range failure)
144
Malfunction Indicator
Lamp and Diagnostic
Trouble Codes
145
Malfunction Indicator Lamp
> Dedicated, single lamp for all OBD faults

- ISO engine symbol
- Consistent with NHTSA proposal
> MIL cannot be used for other purposes
- e.g., maintenance, non-emission faults...
> Manufacturer may only turn this light on or off based on government approval.
146
Drive Cycle
> Generally an engine start, engine

running, followed by engine off.
> If engine is running for more than 4
hours without key-off, the ECU
must start a new “drive cycle”.
> All diagnostic monitors try to run at
least once per drive cycle.
147
Pending DTC’s
> OBD diagnostic faults may use 1 or 2 drive cycle logic.
> Driver is not notified unless the fault condition has been detected in
two consecutive drive cycles.
> 1st detection results in a “Pending” DTC, no dash lights are
illuminated
> On next drive cycle (4 hours or ignition cycle) if the fault occurs again
the result is an “Active” DTC (with appropriate light).
> If the fault fails to appear in next cycle when monitoring occurs the
pending code is cleared.
> Vehicle displays generally do not show Pending DTC’s
> Diagnostic tools will display pending DTCs
148
Freeze Frame
> Captures a set of

parameter data at the
time a DTC trips
> Helpful for
troubleshooting
intermittent DTC’s
> Makes it easier to
duplicate the conditions
causing the problem
> You’ll be familiar with
freeze frame data in the
DDDL 7.x fault code
window termed
“extended data”
149
DTC Behavior for OBD
> DTC’s will no longer go

inactive (turn off MIL and
disappear from active
DTC’s list) when the
problem goes away.
> 3 passing drive cycles
required to go inactive.
> Active codes must be
cleared by a diagnostic
tool after the repair and
re-run the monitor to
confirm repair
> Both the pending and
active DTC’s should be
read by the diagnostic tool
to see if any problems still
exist
150
OBD Implementation
151
OBD Requirements will phased in over a period of years
Rating
Family A 2010 Engine Coverage
B
C
Rating
A 2013
Family
B
C
Rating
A 2016
Family
B Legend
C = Demonstrated OBD
= OBD extrapolated
= Non-OBD
By 2013 all ratings in the first family and the lead ratings for each other
engine family must be demonstrated. Thus the lead engine family will have
been shown to set every possible fault code within the proper emissions
threshold at each horsepower rating. The other families will have been fully
compliance tested for one rating each. The remaining ratings will run OBD
software but their compliance will be “extrapolated” from the tests done
on the lead ratings. In 2016, the remaining ratings of the all engine families
will need to be fully demonstrated and the rollout will be complete from a
coverage standpoint.
152
Overall Summary
> OBD rules add a significant amount of new regulation to the industry that
will affect vehicle maintenance
> Understanding how these diagnostic systems work will be critical to
proper troubleshooting
> Goal is to better maintain emission performance through the life of the
product
> OBD will bring many new DTCs and parameters for emission related
failures
- DTCs may trip without a customer complaint
> DTCs are set and cleared differently than in the past
- MIL will remain on until 3 consecutive drive cycles do not see the
failure again or unless cleared by a diagnostic tool
> Rules phase in over several years
153
Dash Gauge / Dash Lights
Preliminary 2010 Behaviour
154
DEF tanks will need to be There will be a warning indicator
monitored and filled as required as the tank gets low
Warning indicator
Engine may requirements are
experience a slight under review
de-rate at low DEF
levels
Strategies are
being developed
jointly with
Engine will commercial,
experience a heavy automotive and
de-rate when tank is engine
empty manufacturers
associations
EPA is currently requesting a de-
rate when DEF is found to be
contaminated.
DTNA and the EPA are currently negotiating the de-rate level and the point of any
de-rate. It is important to keep in mind that a 23 gallon DEF tank a truck will be
able to travel thousands of mile prior to requiring a refill of DEF.
155
Fault Code and Dash
Panel Reactions for
Customer Demo
Vehicles
In this section we’ll review a list of the fault codes associated with the MIL light in
the initial customer demo vehicle calibration and what impact they’ll have on engine
performance. We’ll also review the functionality of the Fuel / DEF gauge in the dash.
156
This is a partial listing of the SCR related faults turned on in the initial customer
demo calibration. Note that while the major negative driver inducements have not
been enabled there are slight de-rate involved for certain faults.
157
Representative example for new
fuel gauge and driver warning
• Single, integrated Fuel and DEF Gauge

• Fuel level gauge with low level indicator
• 4 LED level indicator DEF gauge below
LED lamp is bicolor w/ low level indicator F
amber / red
First 3 LED bars display

green
4th (low) LED bar is tricolor
green / amber / red
This gauge will be installed on the first 4 customer demo vehicles however in the initial
release of the calibration the 55 MPH and 5 MPH negative inducements because of no DEF
or contaminated DEF covered in the course will not be enforced.
158
DEF Issues / Driver Inducements
> All driver inducements discussed are
mandated by the EPA.
> Discussions with the EPA have progressed
significantly over the last several months to
a point where agreement is essentially in Malfunction Indicator Lamp
place for the “Driver Inducements” to ensure
that Diesel Exhaust Fluid (DEF) Levels are
maintained.
> Under no circumstances will the engine be
shut down due to running the vehicle out of
DEF or putting the improper fluid in the DEF
tank
Dual Purpose Dash Gage
159
DEF Level Display Sensor has 5% Resolution Notes
7 DEF Tank 77.5-100% • No lamps lit & Level Solid
6 DEF Tank 52.5-77.5% • No lamps lit & Level Solid
DEF Light Solid
3 DEF Tank 7.5-12.5% • DEF Light & Level Solid
• DTNA Dash Displays SPN/FMI
Level Yellow Solid
DEF Light Flashing • DEF Light & Level Flashing
DEF Tank 2.5-7.5% • AWL - Solid On
2 • 25% Derate
• Veh. Speed Limit = 55mph
Level Red Flashing • DTNA Dash Displays SPN/FMI

• AWL & MIL - Solid On
1 DEF Tank 0-2.5%
• 25% Derate
Empty • Veh. Speed Limit = 55mph
DEF Light Flashing • DEF Light and Level Flashing
• AWL, RSL, & MIL – Solid On
0 DEF Tank 0-2.5%
• 25% Derate
Empty & Ignored
• Veh. Speed Limit = 5mph
Criteria Met
This slide shows full production level set of lights, faults, and negative
inducements (derates and road speed limits) for running without DEF.
160
DEF Level Display Sensor has 5% Resolution Notes
7 DEF Tank 77.5-100% • No lamps lit & Level Solid
DEF Light Solid
3 DEF Tank 7.5-12.5% • DEF Light & Level Solid
Level Yellow Solid
DEF Tank 2.5-7.5% • AWL - Solid On
2 • DTNA Dash Displays SPN/FMI
Level Red Flashing

• AWL & MIL - Solid On
1 DEF Tank 0-2.5%
Empty
Level Red Flashing
DEF Light Flashing • DEF Light and Level Flashing

• AWL, RSL, & MIL – Solid On
0 DEF Tank 0-2.5%
Empty & Ignored
Criteria Met
Level Red Flashing
The customer demo vehicles will display the same lights and faults in
the dash when the vehicle runs out of DEF but the vehicle will not
experience any of the negative inducements (derates and road speed
limits) that will be part of the production software.
161
Driving with Contaminated DEF – Production Intent Strategy
> When the system detects that the improper fluid has been put
in the Diesel Exhaust Fluid tank the NOx sensors in the SCR
system will detect this condition and turn on the MIL light.
> The following action will be employed once this condition is

detected.
- 25% engine derate
- 55 mph speed limit imposed
> After 1000 miles or 20 hours of operation without remedy a
Note: These negative
more significant action will be initiated. Vehicle speed will be inducements will not
limited to 5 mph provided the vehicle is in a safe situation. A safe be part of the initial
V6/V7 Calibration
situation will be inferred by recent activities such as fuel tanks package on the first
just refilled, truck just started, or extended idle time. 4 customer demo
units
162
Customer Demo Online
Engine Documentation
Documentation on the EPA 2010 customer demo engines is available

through the DDCSN website. This site may be accessed by going to
WWW.DDCSN.com with your ID and password or by choosing a link to the
site from the G2 website or Access Freightliner.
Note to get more information on getting a DDCSN ID contact Detroit
Diesel Customer Support at 313-592-5800.
163
Type ESN
Click here
After logging into the main screen of DDCSN type in the complete engine
serial number of your EPA 2010 customer demo engine and click in the
radio button for “Engine Serial Number”.
164
2010
Information
on DDCSN as
of 6 –3 - 09
A new window will be appear on your screen with information on your EPA
2010 customer demo engine. The information on this screen is latest
available with updates occurring frequently. Check this location
frequently to make sure your information is up to date. To open a
selection from this site click on the link.
165
Once you’re selection is opened up scroll through the table of contents to
find the information you’ll need.
166
EPA 2010 SCR Parts List
2010Inter.BOM.exe
167
Here is a
preliminary
sample from
the 2010
troubleshooting
guide. Some
new graphics
are being
evaluated.
168
Quick Check #3
1) The “Flash” function is only available with which diagnostic software?
DDDL DDRS DDDE
2) With the introduction of OBD for heavy duty engines diagnostic systems must be
________________ by the EPA for the first time.
3) When did the auto industry begin to adopt OBD II standards? ____________ About
how many cars use OBD II diagnostics? _______________
4) A pending fault will turn on the MIL light. True False
5) A drive cycle will reset itself after ________ hours of continuous driving.
6) Degrees of de-rate and engine shutdown are negative inducements for driving without
DEF. True False
7) To view 2010 service documentation you need access to the DDCSN web site and the
ESN of the customer demo vehicle. True False
169
2010 Vehicle Walk-around
Worksheet
170
Special Tools for 2010
SCR System
171
DEF Test Kit
(W060589001900)
> Refractometer – used to check the mixture
of DEF
> Graduated cylinder – used to check the
pump flow
> Fluid extraction cylinder – used for taking
DEF samples
> Sample bottle
Refractometer view with good DEF mix.
172
DEF Quality Test
Worksheet
173
Lifting Jack
(W060589003100)
New 2010
> A new adaptor plate has been adaptor plate
validated for the 2007 DPF
lifting device (TLZ00785) to
remove the 1-box 2010 SCR
aftertreatment device.
> Because the 1-box ATD is

outboard of the frame rail,
removal procedure is improved
over EPA‘07
The DEF quality test kit and lifting jack adapter are now available at the
Canton Parts Warehouse.
174
Field Issues
175
Top Field Issues Based on European Operation
> Dosing units clogging
> Tips clogging
> Improper filling of DEF tank
> Running out of DEF on the road
> Pump fails
> DEF Corrosion
176
Dosing
unit Compressed air
pressure sensor
clogging
DEF pressure
PTC heating
sensor element location
DEF temperature
sensor
Diffuser heating
element
DEF connection
DEF filter screen
Calibrating screw DEF / Air mix output

–DO NOT ADJUST
DEF dosing valve
DEF clogs in the mixing area and passage just off this area have been
an issue. Crystallization can occur for a variety of reasons but a
malfunctioning purge of DEF from this passage will this cause
problems. If this section becomes clogged with DEF you will see a low
air pressure code from the compressed air pressure sensor.
177
DEF nozzle tip clogging
In this case high

temperatures within
the can where the
exhaust flows can
crystallize the DEF and
clog the tips of the
nozzle.
If the nozzle is spraying

insufficient fluid to
reduce the NOx you
would expect to see a
fault from the NOx out
sensor.
178
DEF Tank Filled Improperly
2 types of problems
> Wrong type or mixture of DEF fluid
> Diesel fuel put in DEF tank
Studies are currently underway to

determine how to handle particular
situations. In general diesel fuel is likely
to cause damage. If DEF contamination is
suspected gather as much information as
possible and contact customer support.
Running out of DEF on the road
Inducements we’ve previously discussed

will take effect.
179
DEF Pump failures
Sources of failures
vary:
> Electrical issues
> Parts in the pump

seize
> Damage from diesel

in DEF tank
> Damage from

contaminated DEF
180
DEF Tank Contamination
> Contamination in DEF tank can lead to issues of DEF pump (like flow
restriction in diaphragm housing).
> Improved header seals should eliminate harmful contamination
BUT: Certain amounts of DEF contamination must be expected for trucks

operated in typical automotive environment
181
DEF Creep and
Corrosion
DEF creeps up
copper lines
Experimental
setup: Three lines
of copper wire at
the end of approx.
1 cm stripped and
placed in DEF, a
cut was made
approximately a 1-
2 mm in the wire.
Different voltages
applied to the
lines.
182

EPA 2010 SCR System Training Center Introduction

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EPA 2010 SCR System Training Center Introduction

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EPA 2010 SCR System for

Customer Demo Vehicles

Class Starts 8:00 AM

Class Resumes 9:45 AM

Class Resumes 12:15 PM

Class Resumes 2:30 PM

Class Ends 4:00 PM

1) SCR System Introduction

2) DD15 Engine Changes for 2010

3) The Single Box Aftertreatment System

4) Individual SCR System Components

5) Electronic Service Tools for 2010

6) 2010 Vehicle Walk-around

7) Overview of OBD for Heavy Duty Vehicles

8) 2010 Special Tools

9) Common Issues / System Diagnostics

10) Final Review Questions

•DEF = Diesel Exhaust Fluid 32.5% Urea

The website www.factsaboutscr.com is an excellent source of

2002/2004 1998 1994

0.01 2010 2007

Nitrogen Oxides - NOx (g/bhp-hr)

• BlueTec is convenient… Fewer active regenerations. DEF supply will not be an

EGR Flow Rate Fuel Efficiency

Effects of BlueTec on engine operation

DEF will be heated DEF will be readily

DEF to Diesel Fuel

DTNA has a dedicated person working with other OEM’s to establish

> 32.5% urea concentration in

> Clear liquid

> Non-toxic and biodegradable

> Weight = 9.2lbs/gallon

> Freezing point = 12°F (-11°C)

> The 32.5% concentration is important. Urea is used in a variety of

Truck Stop Dealer / Distributor

Fuel island filling

Oil / Fuel Jobber Fuel truck, IBCs, Urban / City

> The American Petroleum Institute

Approximately Driving range of the

•Daimler has over 200,000 BlueTec units on the road today

•Daimler has over 15 MILLION miles of BlueTec validation

Nobody comes close to Daimler’s SCR experience

The catalysts used in the SCR after-treatment system consist of

DD15 2007 NAFTA 8 Hrs 14 Hrs 15 Hrs 15.5 Hrs 20 Hrs

Current 2010 demo calibration’s active regeneration interval will be 45 to 90 hrs

Changes from EPA07 DTNA Impact Actions/Solutions

Modified Design (shape) • None

Changes from EPA07 DTNA Impact Actions/Solutions

Changes from EPA07 DTNA Impact Actions/Solutions

Elimination of Bosses • None

New Boss Location • None

Changes from EPA07 DTNA Impact Actions/Solutions

• None (only for 2cyl Air compressor

• None (only for 2cyl Air compressor

Changes from EPA07 DTNA Impact Actions/Solutions

Changes from EPA07 DTNA Impact Actions/Solutions

Added Bracket and Sensor • None

Changes from EPA07 DTNA Impact Actions/Solutions

Changes from EPA07 DTNA Impact Actions/Solutions

Added speed sensor for

Misc. Wiring & Bracket

Changes from EPA07 DTNA Impact Actions/Solutions

New (common) air compressor to