0583896 JOHNSON POWER PACK ASSEMBLY

Illustration 1 g06240261
Typical example
(1) Exhaust inlet
(2) Diesel Exhaust Fluid (DEF) injector
(3) Diesel Particulate Filter (DPF) and Selective Catalytic Reduction (SCR) canister
(4) Exhaust out
(5) Nitrogen Oxide (NOx) sensor
(6) Diesel Oxidation Catalyst (DOC)
(7) Diesel Exhaust Fluid (DEF) supply line
(8) Coolant return to engine line
(9) Diesel Exhaust Fluid (DEF) pump
(10) Coolant supply from engine line
(11) Coolant diverter valve
(12) Diesel Exhaust Fluid (DEF) tank
(13) Coolant supply connector
(14) Suction connector
(15) Backflow connector
(16) Coolant return connector
(17) DEF suction line
(18) DEF backflow lineThe purpose of Diesel Exhaust Fluid (DEF) is to create a Selective Catalytic Reduction (SCR) process to take place in the exhaust system to reduce Nitrogen Oxides (NOx).When the engine is keyed on but not running, DEF is not being injected into the system. When the engine is running, the DEF may be too cold or frozen to be injected. When the ambient or tank temperatures are cold enough, the engine ECM opens the coolant diverter valve to allow engine coolant to flow through the DEF tank to warm the system. The ECM also activates the heater circuits in the lines and pump to prevent DEF from freezing in the lines and pump. The time it takes to thaw the system depends on the tank temperature. Since the system always starts with empty lines, the pump activates to fill the lines with fluid before DEF injection begins.This is called DEF Priming mode. Once the system is primed, the DEF will be injected when the DEF tank and SCR temperatures are warm enough. If the system does not heat up after duration of time, a diagnostic code will become active.Note: Typical usage for DEF is 6-8% of diesel fluid.The DEF system has three operation modes:1. DEF Priming ModeSince the system always starts with empty lines, the pump activates to fill the lines with fluid before DEF injection begins. Priming will start when engine speed is greater than 450 rpm, DEF tank temp is greater than −6° C (21.2° F), and SCR inlet temperature is greater than 100° C (212° F). Once the system reads the appropriate pressures, priming is complete.2. DEF Injection ModeOnce the system is primed, the DEF will be injected when SCR inlet temperature is greater than 200° C (392° F). The DEF pump draws DEF from the tank and pressurizes the DEF to 900 kPa (130.5 psi). This pressure is constant throughout the operating cycle. The DEF injector sprays DEF into the exhaust before the SCR catalyst and continues spraying by pulsing on and off. The DEF injection rate is controlled by changing the duration of the DEF injector on time. If the engine is producing higher NOx, the DEF injector will turn on more frequently. To control the pressure to the DEF injector, a percentage of DEF will flow through the backflow line back to the tank.3. DEF Purge ModeWhen a DEF-related fault code becomes active or the engine is keyed OFF, the DCU enters purge mode. The system is designed to purge all DEF back to the DEF tank to prevent it from freezing in the pump and lines. The DEF injector opens and the DEF Reverting valve in the DEF pump reverses the flow of the DEF inside the pump. This removes the DEF from the pressure line and pumps it back to tank through the suction line. The purge takes approximately 2 minutes to remove DEF from the lines and pump. It is important NOT to turn off the battery disconnect switch during the purge process. If the purge process does not complete and the temperature of the DEF drops below −11° C (12° F,), then the pump and lines are at risk of damage. If the purge process does not complete, a diagnostic code will become active.NOx MonitoringThere are two NOx sensors supplied with the engine. One NOx sensor is installed in the exhaust inlet from the turbocharger (engine out). The other NOx sensor is installed in the exhaust pipe of the application (CEM out).The amount of DEF needed is based on NOx production. The engine produces NOx as the engine operates at a specific target to meet emission requirements. The engine out NOx sensor measures the amount and communicates that value to the ECM. The tailpipe out NOx sensor monitors the NOx level out of the catalyst and communicates that value to the ECM. Based on the engine out and the tail pipe out NOx sensor values, the flow rate of DEF will adjust to meet the NOx allowed per regulations.NOx Sensors
Illustration 2 g03364155
(21) Electrical connector
(22) Sensor electronic control unit
(23) Cable (black for engine out, gray for CEM out)
(24) Sensing unitThe NOx sensor contains a sensing element, a harness, and an electronic control unit. The sensing element is composed of two chambers and a heater. The first chamber measures the amount of oxygen and the second chamber measure the amount of NOx and Ammonia (NH3). Using electrochemistry, a ceramic material attracts ions at approximately 800° C (1472° F) and an electrode on the chamber wall measures the electrical charge in voltage or current. The voltage or current signal is then received by the NOx sensors electronic control unit and interpreted into a NOx concentration. The heater is used to maintain the sensing element temperature, as sensing element is sensitive to moisture. If the sensor sees any moisture while at 800° C (1472° F), then the moisture could quickly cool the element which would cause the element to crack. At engine start-up there is always some moisture within the exhaust pipes. So the sensors will not start working until the exhaust temperature around the sensors is greater than 100° C (212° F) for approximately two and a half minutes.Note: For information on handling the NOx sensors, refer to Special Instruction, REHS8151.Electric Components
Illustration 3 g06240619
(1) DEF fill port
(2) Coolant Return port
(3) DEF pump
(4) Coolant diverter valve
(5) DEF tankThe Pump Electronics Tank Unit (PETU) consists of the following components:Coolant Diverter ValveControls coolant flow to the tank and DEF pumpCoolant ReturnThe coolant will return to the engine water pump inlet through this