NHTSA ID Number: 10128904
Manufacturer Communication Number: SM1604
TSB/Document Date: 2018-02-21
Summary
New Diesel Exhaust Fluid (DEF) Tank Assemblies (Gen 5 Tri-Function Sensor): Dealer Memo to provide service related information for buses equipped with new Diesel Exhaust Fluid (DEF) tank assemblies. Blue Bird buses equipped with new (DEF) tank assemblies have a Gen 5 Tri-Function Sensor. The Gen 5 Tri-Function Sensor provides the level, concentration, and temperature of the (DEF) Diesel Exhaust Fluid in the reservoir and returns a defined CAN message for these values. The sensor and controller communicates on a ?Private? J1939 data link with the Cummins
ECM.
July 05, 2016
SERVICE MEMORANDUM
NO:
SM1604
SUBJECT:
New Diesel Exhaust Fluid (DEF) Tank Assemblies (Gen 5 Tri-Function Sensor)
MODELS AFFECTED:
Vision, All American, and TX4, with New 2016 Cummins
Engine Features
Blue Bird Production Date Begin: January 18, 2016
The intent of SM1604 is to provide service related information for buses equipped with new Diesel
Exhaust Fluid (DEF) tank assemblies. This change ONLY affects Blue Bird buses with Cummins diesel
engines that are EPA/CARB certified on highway built by Cummins on January 1, 2016 or later (Blue
Bird production date January 18, 2016).
Blue Bird buses equipped with new (DEF) tank assemblies have a Gen 5 Tri-Function Sensor.
The Gen 5 Tri-Function Sensor provides the level, concentration, and temperature of the (DEF) Diesel
Exhaust Fluid in the reservoir and returns a defined CAN message for these values. The sensor and
controller communicates on a “Private” J1939 data link with the Cummins ECM.
Please see the attached DEF Tank Assembly Service Manual Gen 5 (Tri-Function Sensor) for
maintenance, filling, draining, removal, and installation instructions.
If you need service technical support, or have any service related questions, please contact your Blue Bird
Field Service Engineer.
Gen 5 Tri-Function Sensor
Important service note: See service memorandum SM1304 for all EPA/CARB certified buses built
before January 18, 2016 with Diesel Exhaust Fluid (DEF) tank assemblies. These buses are
equipped with DEF tank assemblies that use Gen 4 “Analog” type level, and temperature sensors.
BLUE BIRD BODY COMPANY
P.O. Box 937 – 402 Blue Bird Blvd – Fort Valley, Georgia – (478) 825-2021
25190 Bernwood Drive
Bonita Springs, FL 34135
239-405-6100
www.shawdev.com
ISO 9001 & 14001 Registered
TB-3019 Rev-A
DEF TANK ASSEMBLY SERVICE MANUAL
Gen 5 (Tri-Function Sensor)
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 2 of 60
TB-3019 Rev A
APPROVAL SUMMARY
Written by:
Kiran Muggulla
____________________________12/14/2015
Project Engineer
Shaw Development, LLC
Approved by:
Michael O’Hara
____________________________01/11/2016
Chief Technologist
Shaw Development, LLC
James Carter
____________________________01/11/2016
Engineering-Technology
Shaw Development, LLC
Chris Godfrey
____________________________01/11/2016
Engineering Group Leader
Shaw Development, LLC
Michael Ostertag
____________________________01/11/2016
DEF Business Development Manager
Shaw Development, LLC
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 3 of 60
TB – 3019 Rev A
INDEX OF REVISIONS
REVISION
A
DESCRIPTION
INITIAL RELEASE
APPROVED BY/ DATE
KM/ 01/11/2016
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 4 of 60
TB – 3019 Rev A
TABLE OF CONTENTS
1.0
INTRODUCTION TO SHAW DEF SYSTEM ...................................................... 6
1.1
1.2
2.0
GENERAL INFORMATION ........................................................................... 7
1.1.1
SCR SYSTEM ........................................................................................ 7
1.1.2
DIESEL EXHAUST FLUID ..................................................................... 7
SHAW DEF COMPONENTS......................................................................... 7
1.2.1
DEF MULTIFUNCTION HEAD UNIT ..................................................... 8
1.2.2
DEF CAP.............................................................................................. 13
1.2.3
TANK AND ADAPTER ASSEMBLY ..................................................... 15
1.2.4
DEF DRAIN PLUG ............................................................................... 22
MAINTENANCE ............................................................................................... 23
2.1
2.2
2.3
3.0
CLEANING .................................................................................................. 23
2.1.1
CLEANING THE EXTERIOR OF THE TANK ASSEMBLY .................. 23
2.1.2
CLEANING THE INTERIOR OF THE TANK ASSEMBLY.................... 24
2.1.3
CLEANING THE DEF CAP .................................................................. 25
FILLING THE DEF TANK ............................................................................ 31
2.2.1
STATION OR BULK FILLING VIA PUMP AND NOZZLE..................... 32
2.2.2
BOTTLE FILLING................................................................................. 33
DRAINING THE DEF TANK ASSEMBLY.................................................... 34
REMOVAL AND INSTALLATION INSTRUCTIONS ......................................... 36
3.1
DEF TANK MOUNTING BRACKET ............................................................ 36
3.2
COOLANT HOSES ..................................................................................... 38
3.3
DEF HOSES................................................................................................ 40
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 5 of 60
TB – 3019 Rev A
4.0
3.4
FILL PORT STRAINER ............................................................................... 42
3.5
MULTIFUNCTION HEAD UNIT ASSEMBLY .............................................. 43
3.6
DEF SUCTION FILTER............................................................................... 50
3.7
TRI-FUNCTION SENSOR ........................................................................... 54
FREQUENTLY ASKED QUESTIONS (FAQ’s) ................................................. 59
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 6 of 60
TB – 3019 Rev A
1.0
INTRODUCTION TO SHAW DEF SYSTEM
This manual was created for the purpose of familiarizing users with the Shaw
DEF Tank Assembly and its components. Furthermore, this manual provides proper
maintenance and installation instructions for the DEF tank assembly. After reviewing
this document, readers should gain a clearer understanding of how the Shaw DEF
system operates, and what preventive maintenance practices can be performed to
extend the life of DEF system.
This document is categorized into four (4) main sections: Introduction to the
Shaw Development DEF System, Operations & Maintenance, Removal & Installation
Procedures, and Frequently Asked Questions (F.A.Q.s). These sections provide
instructions for installation & disassembly (with step by step image assistance),
troubleshooting, and cleaning. For quick reference, refer to the Table of Contents for
the page locations of applicable topics. If after reviewing this document, there are
unanswered question, please feel free to contact us via the following methods.
Mailing Address:
Phone: (239) 405-6100
Shaw Development, LLC
25190 Bernwood Drive
Bonita Springs, FL 34135
Web Address: www.ShawDev.com.
NOTE: [Warnings (
) & Notes (NOTE)] These adjuncts are used throughout the
entirety of the document. These points are utilized for the purpose of simplicity and to
highlight/emphasize important points to be considered. Warnings call attention to use
of materials, processes, methods, procedures, or limits which must be followed
precisely to avoid injury to persons and/or damage to the components/equipment.
Notes call attention to methods to ease the task at hand.
NOTE: All weights and measurements are in US units and their standard Metric
conversions are enclosed in parenthesis. Temperature is called out in degree
Fahrenheit, indicated by an F, with Celsius conversion, indicated by a C, following in
parentheses.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 7 of 60
TB – 3019 Rev A
1.1
GENERAL INFORMATION
The following subsections provide brief descriptions of the diesel exhaust fluid
system and its components.
1.1.1 SCR SYSTEM
The Selective Catalytic Reduction (SCR) system helps to reduce the
emission levels of nitrogen oxides released from the exhaust of diesel engines.
This is accomplished when Diesel Exhaust Fluid (DEF) is injected into the engine
exhaust system of the vehicle. Once injected, the DEF will undergo a series of
reactions that converts Nitrogen Oxides (NO & NO2) in the exhaust into nitrogen
(N2) and water vapor. Some of the adverse effects caused by increased
atmospheric nitrogen oxides concentrations include: promotes acid rain,
hampers the growth of plants, and can form with other pollutants to create toxic
chemicals.
1.1.2 DIESEL EXHAUST FLUID
Diesel Exhaust Fluid (DEF), also known as AdBlue or AUS32 (Aqueous
Urea Solution 32.5%), is manufactured per ISO-22241. DEF system users are
highly recommended to familiarize themselves with this ISO specification. The
list below provides a few physical properties of DEF. If further information is
required, refer to ISO-22241.
Freezing point of DEF ≈ -11° C (12.2° F)
Maximum Temperature Exposure ≈ 50° C (122° F)
Urea Concentration: ≈ 32.5%, Water Concentration ≈ 67.5%
DEF is considered a slight irritant. Avoid contact with skin, clothing, or eyes. If it
has come into contact with skin, wash the affected area thoroughly with soapy
water. If irritation persists, seek medical attention. If it has come into contact with
eyes, flush thoroughly with water and seek medical attention if irritation persists.
If DEF is ingested, do not induce vomiting, drink plenty of water, and contact a
physician if symptoms become present.
1.2
SHAW DEF COMPONENTS
The following section provides a component level breakdown and
descriptions of each component. The Shaw Development tank assembly and
components will vary from vehicle to vehicle. For detailed descriptions regarding
a specific tank assembly model, please refer to the drawing of the part.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 8 of 60
TB – 3019 Rev A
DEF Tank Assembly Components
1.2.1 DEF MULTIFUNCTION HEAD UNIT
The Shaw DEF Multifunction Head Unit Assembly (MFHU) can be found
on the top surface of the tank in the DEF tank assembly. It is fixed in place by a
retaining ring and fastened down by 2 #10-32 screws. While installed in tank, the
upper portion of the MFHU can be seen. This upper portion consists of a DEF
Suction fitting, a DEF Return fitting, a Coolant Inlet fitting, a Coolant Return
fitting, the top portion of the Tri-Function Sensor, and a 6 digit serial number data
matrix code positioned right behind the coolant outlet fitting. (Refer to image
below for visual aid)
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 9 of 60
TB – 3019 Rev A
Top view of Multifunction Head unit
COOLANT OUTLET
DEF RETURN
MFHU Retention
Screws
DEF MFHU Serial #
DEF SUCTION
Tri-Function Sensor
COOLANT INLET
MFHU Retaining Ring
Note: To see the actual image of DEF MFHU Serial number, refer to FAQ’s
The bottom assembly of the MFHU consists of a coolant heater tube, a
DEF Suction Tube, the bottom portion of the Tri-function Sensor with Spacer,
and the 40 micron gradient filter with retention screw. The diagram below
identifies each component of the MFHU and provides a description of its
purpose. The Tri-function sensor and DEF Suction Filter are described in greater
detail in Sections 1.2.1.1 and 1.2.1.2, respectively. The MFHU is designed as a
replaceable item. For instructions on removing and installing the MFHU, please
refer to section 3.5.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 10 of 60
TB – 3019 Rev A
Side view of Multifunction Head Unit
1.2.1.1 TRI-FUNCTION SENSOR
The Tri-Function Sensor is the electrical component of the tank assembly
responsible for communicating the temperature, concentration, and level of
diesel exhaust fluid in the tank to the engine computer. The sensor is designed
and manufactured in accordance with SAE J1939-15 (Reduced Physical Layer)
specification. Additionally, the sensor has been designed as a replaceable item
for the DEF Tank assembly. For Removing and Installing the Tri-function sensor,
please refer to Section 3.7.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 11 of 60
TB – 3019 Rev A
Image of Tri-Function Sensor
The power circuit requires a 2 amp fuse and must not share its power circuit with
unsuppressed inductive loads. Relay coils and DC motors (fans) on the same
power circuit should be avoided. The unit utilizes a Deutsch DT04-4P connector
with gold plated terminals. The mating connector is the Deutsch DT06-4S (not
supplied by Shaw Development)
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 12 of 60
TB – 3019 Rev A
Image of Tri-function sensor connectors
Wiring Pin-Out for Sensor Connector
Pin Number
Description
1
CAN LOW
2
CAN HIGH
3
GROUND
4
9-32 VDC
4
3
1
2
1.2.1.2 DEF SUCTION FILTER
The DEF Suction Filter is responsible for maintaining the cleanliness of
the DEF circulating in the SCR system. Utilizing proper refilling practices is the
best method for preventing clogging issues and extending the life of the filter. In
the event the tank interior has become contaminated, the suction filter is
replaceable. For instructions on replacing the suction filter, refer to Section 3.6.
For instructions on cleaning the DEF tank refer to Section 2.1.1.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 13 of 60
TB – 3019 Rev A
Image of DEF Suction Filter
1.2.2 DEF CAP
Shaw Development provides 2 standard DEF caps, Locking and Nonlocking. The caps include a hydrophobic membrane to allow the tank to vent
freely. The membrane prevents DEF fluid from escaping the tank and ingress of
other contaminating fluids from the external environment.
The DEF caps are also designed to create a sealing surface interface with
the inlet adapter. The seal also prevents DEF leakage and contamination.
Cleanliness of the DEF cap is crucial to maintaining the cleanliness of the DEF
and protecting the DEF/SCR system. Proper refilling practices and regular
scheduled cleanings can greatly reduce the potential for tank contamination. If
the DEF cap appears dirty, refer to Section 2.1.3 for directions on cleaning the
DEF cap. The DEF cap is a replaceable item in the event the cap becomes
damaged.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 14 of 60
TB – 3019 Rev A
Non-Locking DEF Cap
Hydrophobic
Membrane
Locking DEF Cap
Hydrophobic
Membrane
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 15 of 60
TB – 3019 Rev A
DEF Cap Ventilation Pathway
Outward Venting
Inward Venting
1.2.3 TANK AND ADAPTER ASSEMBLY
Shaw Development offers three tank inlet adapter configurations: Buttress
Threaded, Bolt-on, and Remote Fill. All three styles are designed in accordance
with ISO-22241. Additionally, each adapter is designed with a magnetic
interface; enabling refilling at all ISO-22241 approved fill stations. The following
sections provide important information regarding the different fill adapters and
their performance.
Buttress Thread / Bolt-on Adapters
The Buttress Threaded adapter and Bolt-on adapter differ in how they are
fastened to the tank. The Buttress Threaded adapter is threaded onto the tank fill
inlet and fixed by 2 screws. The buttress threaded adapter seals the
tank/adapter interface with an O-ring located in the upper interior portion of the
adapter. The O-ring prevents DEF from seeping out in the event of sloshing. The
Bolt-on adapter is fastened to the tank with 6 bolts and sealed with a gasket.
Refer to the images below for visual aid. Please note that the adapter
assemblies on the DEF tank assembly are not replaceable items.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 16 of 60
TB – 3019 Rev A
Buttress Threaded Adapter
Bolt-On Adapter
The Buttress Threaded and Bolt-on Adapters perform identically in
regards to venting and enabling magnetic actuation of the DEF magnetic fill
nozzle. Both adapters are equipped with fill restrictors as indicated in the picture
below. The purpose of the fill restrictor is to decrease the potential of overfilling
the DEF tank. Overfilling the DEF tank could adversely affect the tank’s
performance and potentially damage to tank assembly in cold environments
[ambient temperature ≤ -11°C (12°F)]. In cold environments, DEF can
experience an expansion of up to 15-20%. This expansion will deform and
potentially damage the internal components of the assembly. For information on
proper refilling techniques, please refer to Section 3.1.
DEF Inlet Adapters
Fill Restrictor
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
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TSB/Document ID: SM1604
Replacement Service Bulletin Number:
MFR Communication Date: 2016-07-05
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Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, DIESEL
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- Full Bi-Directional Control & 3000+ Active Tests: Take control and test components like actuators, fuel injectors, relays, and cooling fans in real time. You’ll quickly see if the problem is in the part itself or the control module — saving you hours of guesswork and frustrating trial-and-error.
- Advanced ECU Coding Capabilities: Handle module matching and hidden feature activation with confidence. When you replace an ECU or want to customize settings, this obd2 scanner diagnostic bi directional tool gives you the professional-level capabilities you need without the dealership price tag.
- 34+ Useful Reset and Maintenance Functions: Complete everyday service tasks smoothly with a wide range of helpful reset and maintenance functions. Whether you’re keeping up with regular upkeep or tackling a specific job, this scanner makes maintenance simpler and less stressful for both DIYers and pros.
- Comprehensive Full System Diagnostics: Diagnose every major system — Engine, Transmission, ABS, SRS, TPMS, and more — all in one place. Finally stop wondering if you’re missing something important; get the full picture and clear codes with ease.
- Top Reasons to Choose the D7S OBD2 Scanner: XTOOL D7S car scan tool, an upgrade of XTOOL D7, offers comprehensive features for automotive technicians, workshops, and DIY enthusiasts 1. Upgraded Hardware: 2+64GB memory, rear camera, intuitive interface, foldable bracket 2. Complete Diagnostics: FCA
Autoauth, OE-level all system scan, 39+ maintenance services, 4K+ bidirectional, CANFD/DoIP protocol 3. Advanced Capabilities: ECU c0ding, PMI functions 4. Wide Compatibility: Support 10,000+ models, covering 99% vehicle brands 5. Multi-language: Available in 22+ languages, No IP Restrictions 6. 3-Year Updates: Save 300 bucks on software updates for the latest features and optimizations - 2026 Upgraded D7S Car Scanner Features: The newly 2026 D7S V2.0 scanner for car brings exciting features for advanced vehicle diagnostics and enhanced user experience 1. FCA AutoAuth: Now supports FCA SGW module for Chrysler, for Jeep, for Dodge (2018+), for Fiat (2017+), enabling faster vehicle communication without gateway restrictions 2. PMI (Offline ECU Pr0gramming): Allows for Ford, for Lincoln, and for Mazda ECU pr0gramming for new modules 3. Optimized Diagnostic Report 2.0: Personalized reports with logos and customer info for auto shops. Note: Compatibility varies by cars, please check before order
- 39+ Services/Resets/Adaptations/Relearns/Calibrations: XTOOL D7S full system car scanner diagnostic tool tackles 99% of common car issues through its 36+ special functions, including Oil Reset, EPB, SAS, BMS, Throttle Reset, Injector C0ding, ABS Bleed, TPMS Reset, Power Balance, etc and also covers specific-vehicle functions like Crank Sensor Relearn, ABS Initialization, Cylinder Power Balance, Fuel Trim Reset, Idle Relearn etc. This car diagnostic scanner enhances efficiency, making repairs and maintenance hassle-free. Tip: DO NOT for All vehicles, please check compatibility first
- Cost-effective ECU C0ding Scan Tool for Specific Brands: Enhance your vehicle's performance with XTOOL D7S! This obd2 scanner all systems bidirectional offers advanced capabilities at an affordable price, supports online for BMW, for Benz and offline for BENZ, for MIT, along with PMI functions for Ford, for Mazda, and for Lincoln. Ideal for technicians and DIY enthusiasts, this automotive scanner diagnostic tool optimizes vehicle performance and enhances the driving experience. Note: Not for all cars and modules, please send car VIN to check the compatibility before purchase
- OE All System Diagnostic & 8 Pids Graphing: XTOOL D7S is a comprehensive all system bi directional obd2 scanner that delivers dealer-level diagnostics, completely controlling over your vehicle’s performance and health. This automotive scan tool can read and clear DTCs, view live data and ECU information, retrieve freeze frames, and perform active tests and full obd2 functions. This bi-directional scan tool can can identify your vehicle's make, model, and year information with just one click and show up to 8 PIDs live data with options for CSV viewing, playback, and recording for in-depth analysis. It is easy-to-use for both professionals and beginners, helping pinpoint issues efficiently
- 【✅Compared to BOSSCOMM IF742, IF745 Offers Full-System Diagnostics】The BOSSCOMM IF745 car diagnostic scanner is an upgraded model of IF742. In addition to supporting all OBD2 Code Reader functions and 6 reset options (ABS/EPB/SAS/BMS/Oil/Throttle), it expands diagnostics from 4 systems (Check Engine/ABS/SRS/Transmission) to vehicle All systems, including Steering, Suspension, and Body Electronics. This provides deeper, more comprehensive diagnostic capabilities.
- 【✨10 OBD2 Functions】The BOSSCOMM IF745 scan tool’s DTC Lookup instantly translates fault codes into user-friendly explanations, its I/M Readiness feature streamlines emissions testing with a single tap, and Freeze Frame lets you pinpoint the exact moment of a fault for in-depth root-cause diagnosis. Combined with a live data dashboard and advanced diagnostics (O2S, OBMon, EVAP), it delivers comprehensive insights for confident troubleshooting.
- 【✨Deep Diagnostics for All Vehicle System Modules】Beyond code reading/clearing and ECU information retrieval, our all-in-one data stream feature lets you inspect all current fault codes and their locations across the vehicle’s systems. This vehicle code reader helps you turn off dashboard warning lights and perform a comprehensive self-check of your car at home—no more back-and-forth trips to the repair shop or hefty inspection fees.
- 【✨6 Essential Resets: ABS Bleeding, Oil, EPB, SAS, Throttle, BMS】The BOSSCOMM IF745 obd2 scanner diagnostic tool swiftly purges air from brake lines to restore braking sensitivity, fine-tunes maintenance cycles to eliminate false alerts, resolves parking brake issues with one-click control, recalibrates steering sensors for stability, optimizes engine idling/acceleration for smoother performance, and deeply resets battery systems to extend lifespan and range via precise parameter adjustments.❗NOTE: Does NOT support bidirectional control, coding, or programming.
- 【✨10,000+ Car Models, AutoVIN, 13 Languages】The BOSSCOMM IF745 vehicle scanner diagnostic tool covers 73+ global car brands and offers support in 13 languages, making it perfect for DIYers, auto mechanics, or as a thoughtful gift. With a single-click AutoVIN feature, it instantly retrieves vehicle serial numbers, streamlining diagnostics for users globally. This adaptable tool balances user-friendliness with precision, catering to both personal and professional requirements.✅Unsure about compatibility? Compatibility will vary on vehicles' model and year, pls reach us via 📧 [email protected] 📧 before purchase.
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