BODYWORK FITTING GUIDE 1/400 English edition 07/2007 Recommendation "changing of position of AdBlue components" © RENAULT TRUCKS — 2007 1 / 35 9/13/2007 TABLE OF CONTENTS 1. Changing of position of AdBlue components - 1.1. Introduction ......................................................................................................................... 3/35 - 1.2. Changes to the regulations................................................................................................ 4/35 - 1.3. The RENAULT TRUCKS choice .........................................................................................6/35 - 1.4. General features of the AdBlue circuit..............................................................................9/35 - 1.5. Changing of position of the AdBlue pump .....................................................................16/35 - 1.6. Changing of position of the AdBlue reservoir................................................................21/35 - 1.7. Table of AdBlue pipes....................................................................................................... 25/35 - 1.8. Installation of AdBlue piping bundles.............................................................................28/35 - 1.9. Table of wiring harnesses ................................................................................................ 29/35 © RENAULT TRUCKS — 2007 2 / 35 9/13/2007 1. Changing of position of AdBlue components 1.1. Introduction The aim of this document is to supply all the information and recommendations necessary for bodybuilders to be able to proceed with changing the position of AdBlue components. There are different scales of pollution. Proximity pollution Interest has been shown in pollution of the air in large cities and densely populated areas since the last century, because that is where most of sources of pollution due to human activities are to be found and where most of the population breathes in polluted air. The majority of conventional atmospheric pollutants (SO2, NOx, CO, O3, lead and particulate matter) have effects on human health, ecosystems and monuments. Long distance pollution Pollutants emitted by human activities partly fall out not only in proximity to the sources, but also hundreds; even thousands of kilometres from their emitting sources. The main problems of long distance pollution are acidification, oxygen depletion and photochemical pollution. Planetary pollution This type of pollution was revealed during the eighties with observations by researchers on the greenhouse effect and destruction of the ozone layer. © RENAULT TRUCKS — 2007 3 / 35 9/13/2007 1.2. Changes to the regulations The 2005 pollution control standards and beyond relate more especially to the reduction of nitrogen oxides (NOx) and particulate matter. All diesel powered vehicles of more than 3.5 tonnes GVW circulating in Europe must be equipped with an exhaust gas treatment device to meet the pollution limits authorized by "Euro 4" Phase 1 as early as 01/10/2006 and by "Euro 5" Phase 2 as early as 01/10/2009. NOx - (g / kWh) P - Particulate matter (g / kWh) HC - Hydrocarbons (unburnt) CO - Carbon monoxide Values (in g/kWh) Date of application CO HC NOx PM Euro 4 10/2006 All types 1.5 0.46 3.5 0.02 Euro 5 incentive 10/2009 All types 1.5 0.46 2.0 0.02 © RENAULT TRUCKS — 2007 4 / 35 9/13/2007 Two solutions: EGR and SCR NOx (g / kWh) P - Particulate matter (g / kWh) Δ1 – Fuel efficiency Δ2 – Increased fuel consumption A – EGR (Exhaust Gas Recirculation system)+ DPF (Diesel Particulate Filter) Engine power setting with low NOx level but high fuel consumption + filter integrated in exhaust silencer to reduce particulate matter. B – SCR (Selective Catalytic Reduction) Engine power setting with low fuel consumption level and high particulate matter level + catalytic converter in exhaust silencer to reduce NOx. C – Cooled EGR D – Current graph of diesel powered heavy goods vehicles 1 – DPF 2 – SCR reduction 65% 3 – SCR reduction 80% © RENAULT TRUCKS — 2007 5 / 35 9/13/2007 1.3. The RENAULT TRUCKS choice To meet this goal, it has been necessary to innovate in exhaust gas post-treatment systems in order to treat nitrogen oxides and particulate matter, whence formulation of the SCR system. What is the SCR system? SCR = Selective Catalytic Reduction - This is an important technical stage for RENAULT TRUCKS. - It is the first time that users are going to be active in the action of vehicle pollution control (regulatorily, materially, financially…). The SCR system The most cost-effective solution in the matter of protecting the environment, sustaining engine performance and cutting fuel consumption. It is a durable solution that will allow Euro 5 requirements to be met. It is also the choice of the major players in the automotive, chemical and petroleum industries. © RENAULT TRUCKS — 2007 6 / 35 9/13/2007 NOx reduction principle To reduce NOx, the SCR system employs an aqueous solution of urea "AdBlue", which consists of ammonia (32.5%) and water (67.5%). The principal component of the SCR system is the catalytic converter. It contains the elements which, because of the injection of urea, serve to reduce NOx. The exhaust gases are treated in the catalytic converter in 4 phases: - Injection of AdBlue (1). An injector is installed at the inlet of the catalytic converter. The injector is pilot-controlled by the ADS (AdBlue Dosing System). The ADS very accurately calibrates the quantity of AdBlue to be injected on the basis of the different data that it has to process, such as quantity of NOx emitted by the engine and temperature of the exhaust gases. - Hydrolysis of AdBlue (2). The AdBlue frees the ammonia (NH3) by means of a chemical reaction (hydrolysis). - SCR catalytic converter (3). The oxidation catalyst uses the ammonia to reduce NOx. - Clean-up (4). The clean-up catalytic converter serves to reduce the re-emission of ammonia into the atmosphere by getting rid of the residue. © RENAULT TRUCKS — 2007 7 / 35 9/13/2007 System The layout of all these components is defined so as to not perturb bodybuilding and therefore avoid (as much as possible) having to work on these components. Furthermore, each position is subjected to various validations, which is why correct operation and reliability of the system is no longer guaranteed if the following instructions are not obeyed. If any of the proposals below do not suit your convenience, contact the Product Applications Department. 1 - SCR catalytic converter 2 - Pump (ADS) 3 - Injector 4 - Reservoir 5 - Heater 6 - Solenoid valve 7 - NOx sensor 8 - Exhaust gases temperature sensor 9 - Level and temperature sensor 10 - Engine coolant pipes 11 - AdBlue heating pipes 12 - Engine CAN © RENAULT TRUCKS — 2007 8 / 35 9/13/2007 1.4. General features of the AdBlue circuit AdBlue injector The AdBlue injector withstands a maximum temperature of 120°C. To resist the exhaust heat, the injector is fitted with a heat shield and is cooled by circulating AdBlue. Output ranges 9 kg / h injector 180 Æ 9000 g / h 6 kg / h injector 150 Æ 6000 g / h 3 kg / h injector 90 Æ 3000 g / h When in operation, the reservoirs must maintain a minimum volume of AdBlue in order to cool the injector. With such a minimum volume, the SCR system operates in fall-back mode and cuts off the injection of AdBlue to favour its circulation in the injector. Reservoir capacities (l) Non-injectable volume (l) 20 5 50 6.8 36 6.1 40 6.7 60 5.3 95 6.5 125 12 Each reservoir has a non-injectable volume. In practice, when work on the system requires drainage of the AdBlue, it is essential to fill the reservoir with this minimum content after finishing the work. Note: It is essential to fill the reservoirs with a minimum volume of 7 l, except for the 125 l reservoir, which must have a minimum content of 12 l. © RENAULT TRUCKS — 2007 9 / 35 9/13/2007 AdBlue circuit Pressure values Pump / Injector 5± 0.2 bars Pump to reservoir return ≤ 0.5 bars Checking the temperatures AdBlue freezes at –11°C. Operating temperatures At pump inlet -7 Æ +70°C At injector inlet -7 Æ +70°C Operation when hot Circuit temperatures +70 Æ +85°C Important: - Use only commercially available AdBlue for motor vehicles (Standard DIN 70070). - It is forbidden to replace AdBlue by any other product or add any other product to it or else vehicle pollution control will no longer be achieved and you will run the risk of damaging the post-treatment system. - In the event of changing of position/disconnection of one of the components, the quality of cleanliness of the AdBlue pipes and of the AdBlue reservoir must be ensured. - The AdBlue injector needs to be cooled while the engine is running to avoid its own overheating. - Circulating AdBlue is used for its own cooling. - AdBlue must always be handled with care – it is a corrosive product. - AdBlue must under no circumstance enter into contact with other chemical products. - AdBlue is a corrosive product for copper and magnesium based alloys (e.g. wiring harnesses). - If any AdBlue is spilt onto the vehicle or in the event of leakage, wipe it off with a cloth and rinse with plenty of water. - When working on AdBlue circuit components, protect unplugged electrical connectors and disconnected pipes against possible splashing of AdBlue with the blanking plugs kit available from the Spare Parts Department. - If any AdBlue is splashed: - onto an in-place connector: rinse with water, - onto an unplugged connector: replace the connector. WARNING If any AdBlue is splashed onto your skin or into