W49.20-A106-79
Shown: Model 963 with code K7D (Exhaust system, tailpipe to right and outwards) |
1 | Exhaust aftertreatment unit | 7 | Air cleaner housing | 13 | Heat shield (upper) | ||
2 | AdBlue® return line | 8 | Air intake pipe (depends on vehicle equipment) | 14 | Bracket | ||
3 | AdBlue® pressure line | 9 | Fender liner segment | 15 | Crossmember (depends on cab equipment) | ||
4 | Conductor rail | 10 | Fender section | 16 | Exhaust tailpipe | ||
5 | Line package | 11 | Heat shield (right) | A60a | Aftertreatment control module (ACM) 3.0 | ||
6 | Electrical connector | 12 | Heat shield (rear) | A67 | AdBlue® metering device |
17 | Screw |
18 | Fastening bracket |
20 | Carrier |
A | Removal variant (carriers remain on exhaust gas aftertreatment unit) |
W49.20-A203-76
18 | Fastening bracket |
19 | Screw |
20 | Carrier |
B | Removal variant (carriers remain on vehicle) |
W49.20-A204-76
Shown: equipped and unequipped EATU |
1 | Exhaust aftertreatment unit |
C | Unequipped EATU (delivery condition) |
D | Equipped EATU |
W49.20-A108-76
Warning | Risk of injury. Skin or eye injuries may result when handling hot or glowing objects. | Wear protective gloves, protective clothing and safety glasses, if necessary. | |
Warning | Risk of burn injuries and scalding when working at AdBlue lines and the components attached to them. Risk of injury to skin and eyes when handling AdBlue. Risk of poisoning caused by swallowing AdBlue | Pour AdBlue into suitable containers only. Wait until the pressure is released before starting any work on the exhaust aftertreatment system. | |
Warning | Risk of injury caused by body parts being pinched or crushed as cab is tilted | Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure it with the safety strut. | |
Caution | Risk of injury caused by scraping or cutting body parts on sharp vehicle parts | Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. | |
Topical note | Notes on tilting the cab | ||
Topical note | Notes on self-locking nuts and bolts | ||
Notes on use, material properties and handling of AdBlue® | |||
Note on calculation of tightening torque when using insertion or socket tools with various effective lengths | |||
Remove exhaust aftertreatment unit | |||
1 | Align vehicle so that as horizontal as possible. | The straightening out facilitates the removal/installation of exhaust gas aftertreatment unit (1). This is, in particular, relevant for air-sprung vehicles. | |
2 | Switch off ignition. | ||
3 | Tilt cab. | ||
4 | Remove right side trim. | Only on vehicles with code C8Z (Side trim, aerodynamic) | |
5 | Remove air intake pipe (8) together with bracket (14). | As-built configuration can vary depending on vehicle equipment. | |
6 | Remove rear heat shield (12). | ||
7 | Remove upper heat shield (13). | ||
8 | Remove right heat shield (11). | Only for vehicles without code C8Z (Side trim, aerodynamic) | |
9 | Remove exhaust flex pipe. | ||
10 | Remove AdBlue® return line (2) and AdBlue® pressure line (3) at AdBlue® metering device (A67). | Catch escaping AdBlue® in a suitable container and dispose of it in an environmentally friendly member. | |
11 | Open conductor rail (4) and release line package (5) in this area. | ||
12 | Disconnect electrical connector (6) at aftertreatment control module 3.0 (A60a). | ||
13 | Support exhaust gas aftertreatment unit (1) by means of a pallet forklift. | | |
The removal/installation of exhaust gas aftertreatment unit (1) is facilitated if this is supported so that tilted slightly towards vehicle frame during lifting. | |||
14.1 | Unscrew screws (17) and remove mounting plates. | If removal variant (A) is used. | |
14.2 | Remove screws (19). | If removal variant (B) is used. | |
15 | Remove exhaust gas aftertreatment unit (1) outwards using pallet forklift. | ||
Mechanical work in case of replacement – Operation step 16 is only to be performed in this case | |||
16 | Detach/attach component parts of exhaust gas aftertreatment unit (1). | ||
New exhaust gas aftertreatment units (1) are delivered without detachable parts. These must accordingly be removed from the old EATU and installed on the new EATU. | |||
AdBlue® metering device to EATU | |||
Exhaust temperature sensor to exhaust aftertreatment unit | |||
NOx sensor to exhaust aftertreatment unit | |||
NOx sensor control unit to bracket | |||
NOx sensor control unit bracket to exhaust aftertreatment unit | |||
Carrier at exhaust aftertreatment unit | |||
Differential pressure sensor to bracket | |||
Exhaust gas aftertreatment control unit to holder | |||
Install EATU | |||
17 | Position exhaust gas aftertreatment unit (1) at installation location using pallet forklift. | | |
18.1 | Fit mounting plates and screw in screws (17). | If removal variant (A) was used. | |
18.2 | Screw in screws (19). | If removal variant (B) was used. | |
19 | Connect electrical connector (6) to aftertreatment control module 3.0 (A60a). | ||
20 | Attach AdBlue® return line (2) and AdBlue® pressure line (3) to AdBlue® metering device (A67). | ||
21 | Attach line package (5) and close conductor rail (4). | ||
22 | Install exhaust flex pipe. | ||
23 | Install air intake pipe (8) together with bracket (14). | As-built configuration can vary depending on vehicle equipment. | |
24 | Install right heat shield (11). | Only for vehicles without code C8Z (Side trim, aerodynamic) | |
25 | Install upper heat shield (13). | ||
26 | Install rear heat shield (12). | ||
27 | Install right side trim. | Only on vehicles with code C8Z (Side trim, aerodynamic) | |
28 | Tilt back cab. | ||
Additional work in case of replacement – Only perform operation steps 29 to 31 in this case | |||
29 | Update VeDoc documentation. | ||
The VeDoc documentation must be updated before the following operation steps was updated. | |||
30 | "Re-hook" control unit or link to the exhaust gas aftertreatment unit (1). | ||
| Notes on: Linking exhaust aftertreatment (ACM) control unit and exhaust aftertreatment unit, form | ||
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To do this the filled out form must be scanned in and sent as an attached file together with an XSF ticket to the central VeDoc team. | |||
31 | Update software in aftertreatment control module and perform teach-in processes at aftertreatment control module. | ||
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First update software in aftertreatment control module and then perform teach-in processes. |