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Scania CV AB 2011, Sweden

01:07Issue 2 en

SCR system

Installation instructions

Industrial engines

DC 9, DC 13, DC 16

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2 Scania CV AB 2011, Sweden 01:07

Contents

General Reductant.................................................................. 3

System overview, mechanics .................................................................................. 4

System overview, electrics .................................................................................. 5

Reductant unit Dimensions............................................................... 6Placement and fitting................................................ 7Connection of reductant unit.................................... 9

Hydrolysis and SCR catalyticconverter Dimensions............................................................. 10

Placement and fitting.............................................. 11Fitting and connection of reductant doser .............. 15

Coolant connections, engine ................................................................................ 16

Warnings and torque reduction ................................................................................ 18

Contents

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01:07 Scania CV AB 2011, Sweden 3

General

SCR (Selective Catalytic Reduction) is a

system whereby urea is added to the exhaustgases in order to reduce NOx. This documentdescribes SCR system component parts andhow they should be connected.

Reductant

Reductant contains 32.5% urea and freezes at-11C. It is easy to handle and it is non-toxic atthis mixture. However, reductant is a highly

corrosive fluid which must not come intocontact with materials that are sensitive tocorrosion. It is therefore important to bear thefollowing in mind:

Rinse off reductant spillages with plenty ofwater.

If reductant seeps into electricalconnections or electrical cables, these must

be renewed.

General

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System overview, mechanics

Below is an overview of the components in the SCR system.

Pos. Component Supplied from thefactory

Fitted by fitter

1 Reductant unit X X

2 Return hose, reductant X X

3 Coolant valve X

4 Pressure hose for reductant X X

5 Coolant hose for heating of tank and pump X

6 Hydrolysis catalytic converter withreductant doser

X X

7 NOx sensor with control unit X X

8 SCR catalytic converter X X

9 Temperature sensor X X

10 Coolant hose, return from heating of tankand pump

X

6

1

9

2

8

3

7

5

10

4

3046

07

System overview, mechanics

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System overview, electrics

Below is an overview of the electrical connections in the SCR system.

Pos. Component Supplied from thefactory

Fitted by fitter

1 Customer interface, SCR system X

2 Cable harness between engine and SCRcontrol unit

X X

3 Electrical connection to SCR system X

4 Electrical cable for temperature sensor X X

5 Electrical cable for reductant doser X X

6 Electrical cable for NOx sensor X X

3

1

2

6

5

4

304

608

System overview, electrics

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Reductant unit

The reductant unit contains a reductant tank,

reductant pump and control unit. The reductantunit is heated via the engine's cooling system.

Note: Scania advises against manufacture ofown reductant tank.

The reductant tank and reductant pick-up unitare designed to withstand freezing; the logicfor heating, for example, is also adapted for aspecial tank design.

IMPORTANT!

The tank must not be filled to its total volumeso as to withstand reductant expansion underfreezing conditions. See below for the fillvolume.

Dimensions

38 litre tank

Total volume 50 litres

Fill volume max. 38 litres

570

675 280

3046

46

60 litre tank

Total volume 70 litres

Fill volume max. 60 litres

700

675 280

3046

47

Reductant unit

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Placement and fitting

To be able to perform inspection and repairwork expediently, the reductant unit must be

positioned so that the clearance A is at least

150 mm.

Obs! The tank must be removed in order tocarry out repair work on the pump and thecontrol unit.

The reductant tank must not be positioned closeto the exhaust system or any sources of heatthat may cause the reductant to be heated toabove 50C.

308

577

A

IMPORTANT!

The tank must not be twisted or tipped inrelation to the lode line.

3052

58

Reductant unit

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Attachment

The reductant unit is fitted using 6 M14 studs.The bracket is threaded so that screws withoutnuts can be used if the studs are removed.

3215

23

Reductant unit bracket.

3119

78

100

100

20

250

Reductant unit

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Connection of reductant unit

Pos. Connector Connection

1 C316 Reductant doser

2 C4012 Temperature sensor 3 Nipple 16 mm Coolant from engine

4 C7 Voltage supply from engine. CAN connection

5 C4011 NOx sensor

6 Nipple 16 mm Coolant return to engine

7 SAE J2044 7.89 mm

Reductant return hose to reductant doser

8 SAE J2044 6.30 mm

Reductant pressure hose to reductant doser

1 2 3 4 65 7

3210

298

Reductant unit

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Hydrolysis and SCR catalytic converter

Dimensions

Hydrolysis catalytic converter with reductantdoser.

450

185

190

3046

51

The SCR catalytic converter is available inthree different versions.

Engine Powerhp

Volumelitres

Dimension Amm

DC 9 200-400 24 765

DC 13 350-550 33 857

DC 16 550-700 48 1,060

A

348,

5

3214

19

There is also an SCR catalytic converter withsilencer, volume 33 litres.

Note: The SCR catalytic converter withsilencer cannot be used for DC 16.

For more information on weld flanges for thecatalytic converters, see the installationinstructions for the exhaust system.

768

597

3214

20


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Placement and fitting

The hydrolysis catalytic converter must berotated so that the reductant doser 1 is

positioned in area 2.

IMPORTANT!

The hydrolysis catalytic converter must not berotated so that the reductant doser is positionedin area 3.

- 85+ 85

- 45

+ 45

2

13

305

261

The hydrolysis catalytic converter must befitted in the direction of the exhaust gases asillustrated. The hydrolysis catalytic convertershould be positioned in a space where the

ventilation is as good as possible. Maximumpermitted ambient temperature 115C.

3052

79

A temperature sensor must be fitted on the inlet

side of the SCR catalytic converter. Thetightening torque for the temperature sensor is35-40 Nm.

321

421


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A pipe section must be fitted on the outlet sideof the SCR catalytic converter. The pipesection must have an outlet for fitting the NOxsensor. Refer to the illustration, which alsoillustrates the direction of exhaust gasesthrough the pipe section.

100 3161

46

The NOx sensor has a separate control unitwhich is connected to the SCR control unit.The length of the electrical cable between thesensor and the control unit is 600 mm, and itmust not be jointed.

The control unit must be fitted on the chassis,protected from radiant heat and knocks andwith the air hole facing down.

Tightening torque for sensor: 50 10 Nm.

IMPORTANT!

The sensor and control unit must not bepainted.

1

08

M20

148

108

65

304

652

The sensor must be fitted so that there is no riskof it coming into contact with collectedcondensation.

max 80 max 80

0

310

822


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There must always be a flexible connectionbetween the turbocharger and hydrolysiscatalytic converter. See the installationinstructions for the exhaust system.

The distance between the turbocharger and the

hydrolysis catalytic converter must be 5001,500 mm.

The distance between the hydrolysis catalyticconverter and the SCR catalytic converter must

be 7003,000 mm.

Material

The exhaust pipe between the hydrolysiscatalytic converter and the SCR catalyticconverter must be made from stainless metaltype 2333 or US grade 316L or equivalent.Scania also recommends that this be used forother exhaust pipes downstream of the SCRcatalytic converter.

For other instructions on the design and fittingof exhaust systems, see the installationinstructions for the exhaust system.

500 - 1500 mm700 - 3000 mm

3052

80


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Attachment

Hydrolysis catalytic converter bracket Theattachment holes have 13 mm.

Use an M12 flange screw or a normal screw of

a suitable length for attaching the bracket. Usean M12 flange nut if necessary. Tighteningtorque for M12: 70 Nm

Tightening torque for retaining straps: 39 Nm.

321

903

80

SCR catalytic converter bracket. Theattachment holes have 13 mm.

Use an M12 flange screw or a normal screw ofa suitable length for attaching the bracket. Usean M12 flange nut if necessary. Tighteningtorque for M12: 70 Nm.

Tightening torque for retaining straps: 39 Nm.

3219

02

130

Bracket for SCR catalytic converter bracket

with silencer. The bracket houses 3 off M12press screws for attachment.

Tightening torque for M12 flange nut: 70 Nm.

Tightening torque for retaining straps: 70 Nm.Use an M12 internal hexagon screw.

233,

3

116,

7

316

147


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Fitting and connection ofreductant doser

Fit the bracket for the reductant doser on thehydrolysis catalytic converter using 2 off M8

8/8 screws. Tightening torque 20 Nm.

Fit the reductant doser using 3 off M6 8/8screws and nuts. Tightening torque 8 Nm.

Connect the reductant pressure hose to nipple1.

Connect the reductant return hose to nipple 2.

Connect the electrical cable to connector 3(V117).

304

629

1

2

3


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Coolant connections, engine

The illustrations show coolant connections on

the engine for heating the reductant unit of therespective engine type.

1 Coolant to engine

2 Coolant from engine

Use a hose with an inside diameter of 16 mmfor connection to the nipples.

The hoses must be made from coolant-resistantmaterial, type EPDM or similar, and must be

able to withstand a working pressure of at least3.5 bar.

DC 9

DC 13

3057

42

1

2

305

7411

2


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DC 16

3214

18

2 1


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Warnings and torque reduction

The system provides a warning if there are

faults in the SCR system or if the level ofreductant in the reductant tank is too low.

Symbol for low reductant level

319

562

Reaction at low reductantlevel

The engine resumes normal torque afterreductant has been topped up so that the level inthe reductant tank is at least 20%.

Reductant

level

Warning lamp Torque reductiona

a. Applies only to engines certified according to Tier 4

20% Constant light

10% Flashes slowly( Hz)

Torque is reduced by1% per minute to 70%of the highest torque

0% Flashes rapidly(2 Hz)

Torque is reduced to0% (low idling) within2-10 minutes


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Reaction to fault in SCR system

Symbol for fault in SCR system

319

563

Once the fault has been remedied and theengine control unit received indication that it isworking, torque returns to the normal level.

If a new fault occurs within 40 hours ofoperation since the first fault, the warning lampwill come on. After 30 minutes of operation,the warning lamp will flash rapidly and torquewill be reduced to 0% (low idling) within30 minutes.

For more information on connection, see the

installation instructions for CAN interface.

Time Warning lamp Torque reductiona

a. Applies only to engines certified according to Tier 4

Fault detected Constant light

After 30 minutes Flashes slowly( Hz)

Torque is reduced by1% per minute to 70%of the highest torque

After 4 hours Flashes rapidly(2 Hz)

Torque is reduced to0% (low idling) within2-10 minutes


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