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.
6. Re-thread the plug onto the drain plug port by screwing in the clockwise
direction. Tighten the plug 40 - 60 in. lbs. (4.5 – 6.7 N m) of torque.
7. Refill the tank to verify no leakage occurs.
3.0
REMOVAL AND INSTALLATION INSTRUCTIONS
The following sections provide instructions for removing and/or installing various
components of the DEF tank assembly.
3.1
DEF TANK MOUNTING BRACKET
Example of DEF Tank assembly w/ mounting brackets and tank hanger assembly
Positioning of DEF tank assembly on vehicle:
When mounting the DEF tank assembly onto a vehicle the following
criteria should be verified to prevent potential damage or impaired functionality to
the DEF tank assembly.
Avoid mounting DEF tanks in areas that are debris prone or exposed to high
temperatures as this may damage the DEF tank and/or contaminate the DEF.
The bracket material should be compatible with intermittent exposure to DEF
such as splash.
Ensure the tank assembly is protected from projectile debris during vehicle
operation. The degree of protection will vary with vehicle applications.
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
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Ensure any hoses being routed in close proximity to the mounting brackets are
protected against any sharp edges, movement, and friction against the brackets,
as this could cause a leak and/or damage to the SCR System.
Ensure the tank assembly is not a step point.
Ensure the nozzle clearance meets ISO-22241 allowing for easy access for
filling and avoid areas where the DEF tank could be exposed to service fluids.
The DEF tank assembly should be mounted with easy access to the drain port
on the bottom corner of the tank in the instance the tank may need to be drained.
Additionally, the drain port should be away from critical components on the
vehicle.
The tank should never be mounted in such a way that the tank becomes
deformed (i.e. concave/convex sidings, indentation, etc.)
If the DEF Tank Assembly is
mounted against a wall or on
multiple sides, a minimum of 9
mm standoff should be available
between the tank’s strap
grooves with the mounting
bracket wall or sides, and strap
bolts with mounting bracket wall
and sides, to allow room for
expansion.
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
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Page 38 of 60
TB – 3019 Rev A
3.2
COOLANT HOSES
The coolant fittings used for the coolant hose interface on the Multifunction Head
Unit are hose bead fittings. The hose bead design enables easy disassembly for
servicing. (Refer to images below for visual aid)
Top view of MFHU w/ Hose Beaded Coolant Fittings
Procedure for installing Coolant Hoses:
The following procedure provides instructions for properly installing the coolant
hoses onto the coolant fittings of the head unit. This procedure displays the use
of worm clamps; however other forms of fasteners can be used.
NOTE: During initial installation, avoid removal of the fitting caps until the coolant hoses
are ready for installation. This prevents debris from entering the coolant lines.
1) Slide the hose clamp over the hosing before installing on the head unit.
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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Page 39 of 60
TB – 3019 Rev A
2) Push the hosing onto its respective coolant fitting indicated by the arrows.
The hose should be pushed up onto the stopping point of the fitting.
3) Slide the hose clamp over the hose covering the fitting up to
approximately 2/3 the length of the fitting.
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
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TB – 3019 Rev A
4) Tighten with a flathead screwdriver until the clamp feels snug.
DO NOT over tighten the hose clamp as this may cut through the hosing and
may cause a fluid leak.
Ensure the clamp is oriented in such a way that does not conflict with the
installation of the other coolant and DEF hoses and for ease of future servicing.
After assembly, confirm the hoses themselves aren’t kinked in any location, are
free of debris, and aren’t close to any kind of heat source and sharp edges.
3.3
DEF HOSES
The purpose of this section is to demonstrate the proper procedure for removing
and installing the DEF hoses. The DEF Hoses vary in length and connector size
and are in accordance with SAE J2044 fittings. Additionally, some DEF hoses
are electrically heated to prevent icing inside the hoses in cold environments. It is
important to verify hose length, quick connector size, and wire connector are all
correct prior to installation.
After assembly, confirm the hoses themselves aren’t kinked in any location, are
free of debris, and aren’t close to any kind of heat source and sharp edges.
Install of DEF Hoses (Outward facing release tab):
1) Turn the hose so that the DEF fitting release tab can be accessed
Hose
Release Tab
2) Place thumb over the tab and push inwards, while simultaneously
applying a pulling force on the hose connector. Completely remove the
hose off the fitting.
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
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Page 41 of 60
TB – 3019 Rev A
DO NOT use any tools to pop out the hose release tabs as this may cause
damage or breakage of the tabs.
3) Replace with new hose and connector, pushing onto the fitting until an
audible click can be heard and the hose and connector are locked into
place.
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 42 of 60
TB – 3019 Rev A
3.4
FILL PORT STRAINER
This section demonstrates how to properly remove and install the fill port strainer
assembly from the DEF tank.
Fill Port Strainer Removal Procedure:
Use two flat-headed screwdriver’s to carefully lift up/remove the strainer assembly from
the tank adapter, while pressing on both the strainer tabs inwards simultaneously. See
below photographs for reference.
It is important to make sure that the DEF tank is clean before and after the
strainer replacement process, to reduce debris intrusion into the tank. For
instructions on cleaning the DEF tank refer to sections 2.1.1 and 2.1.2
Fill Port Strainer Installation Procedure:
Remove the DEF cap and insert the strainer assembly into the DEF tank adapter per
the orientation shown below. Push the strainer until it clicks into place.
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
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Page 43 of 60
TB – 3019 Rev A
3.5
MULTIFUNCTION HEAD UNIT ASSEMBLY
The purpose for this procedure is to demonstrate the proper steps for installing
the Multi-Function Head Unit (MFHU) in a DEF tank and post testing the tank
assembly. Failure to adhere to the following procedure increases the risk of
damaging the DEF tank assembly and/or personnel. Below is a list of terms used
to describe different components of the MFHU.
It is important to make sure that the DEF tank is clean before and after the
MFHU replacement process, to reduce debris intrusion into the tank. For
instructions on cleaning the DEF tank refer to sections 2.1.1 and 2.1.2
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
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TB – 3019 Rev A
DEF Multifunction Head Unit Components Terminology
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
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TB – 3019 Rev A
Section A: MFHU Removal Instructions
Removal and installation of the Multifunction Head unit requires the use of
Personal Protective Equipment including but not limited to goggles and gloves.
1) Using a T25 Torx Driver, unscrew the retention screws that secure the
Retaining Ring to the DEF tank.
2) Using a flathead screwdriver, gently pry around where the head unit is
connected to the DEF tank while simultaneously pulling on the top of the
unit. Continue until DEF mounting base is free from the tank.
DO NOT pull on the wires or fittings.
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
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Page 46 of 60
TB – 3019 Rev A
3) Pull the DEF head unit out until the bottom of the header is at the bottom
of the tank bore.
4) Angle the heel of Tri-function sensor foot upward and rotate the header
until the bottom of the header is positioned inside the tank bore. When the
bottom of the header is in the tank bore, fold the filter downward towards
the interior of the tank. Continue to carefully remove the header out of the
tank bore until completely freed.
DO NOT pull directly out as this might damage the DEF head and bore seal.
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
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Page 47 of 60
TB – 3019 Rev A
Section B: MFHU Installation Instructions
5) Apply a thin layer of DOW UCON LB-625 or Shaw Product Engineering
Approved Equivalent O-ring lubrication to the Bore seal O-ring.
6) Tilt the header to an approximate 45˚ angle, with respect to the top of the
tank. With the heel of the Tri-Function Sensor foot angled upward, place
the toe of the heater coil into the tank bore. Gradually work the bottom
portion of the DEF head into the bore opening until completely inserted in
the tank.
DO NOT push the MFHU directly into the tank as this could damage the unit.
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
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Page 48 of 60
TB – 3019 Rev A
7) Position the DEF head unit in the desired orientation (lugs on the MFHU
should align with the cut out/recess on the tank bore and the Coolant and
DEF Fittings should orient as shown in the image below) and press on the
top of the blue mounting base until it is completely seated in the tank
bore.
Orientation of the MFHU fittings on DEF tank:
90° and 135° fitting orientations are not available for 5 gallon Portrait tank
(DR502) configuration.
135°, 180° and 225° fitting orientations are not available for 10 gallon cube tank
(DR507) configuration.
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 49 of 60
TB – 3019 Rev A
DO NOT push down on top of the blue mounting base until the MFHU is oriented
correctly to align with the tank bore.
DO NOT press directly on the fittings.
8) Position the retaining ring on head unit to align with the tank mounting
holes and install the retention screws using the T25 Torx driver.
Recommended torque on screws is 20 - 30 in-lbs (2.26 – 3.38 N m).
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 50 of 60
TB – 3019 Rev A
3.6
DEF SUCTION FILTER
This section demonstrates the proper steps for removing and installing the DM5
series DEF Multifunction Head Unit DEF suction filter. As mentioned previously,
the DEF Suction Filter is located at the bottom of the Multifunction Head Unit
assembly thus requiring the head unit to be removed from the DEF tank. For
better visibility of the top and bottom strainer bracket locations, see the second
image below. For instructions on how to remove the MFHU, please refer to
Section 3.5A.
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
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TB – 3019 Rev A
Suction Filter Removal Procedure:
NOTE: The following procedure begins after the MFHU has been removed from the
DEF tank. For instructions on removing the MFHU, please refer to Section 3.5A.
1) Locate the suction filter retention screw and remove using the #2 drive. Discard
the screw.
2) Discard the strainer top and bottom brackets.
3) Pull the old suction filter off of the suction tube and discard.
Note: All the above described/labeled items are included in the suction filter
replacement kit.
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
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Page 52 of 60
TB – 3019 Rev A
Suction Filter Installation Procedure:
4) Insert the top strainer bracket through the gap between the heat exchanger coil
and bottom of tri-function sensor. While the top bracket is sitting on the heat
exchanger, position the bottom strainer bracket at the bottom of the heat
exchanger coil and hold parallel to the top bracket.
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
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Page 53 of 60
TB – 3019 Rev A
5) Position the new filter’s suction tube housing onto the bottom of the suction tube
and press the filter flush towards the bottom of the tri-function sensor boot.
6) Align the filter, top and bottom brackets so that the filter retention screw can
screw into the retention screw housing. Install the new retention screw using #2
drive. Recommended torque on screw is 14 - 18 in-lbs (1.58 – 2.03 N m).
7) Once the retention screw is installed, the MFHU will be ready to be installed into
the tank. Refer to Section 3.5B for MFHU installation instructions.
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 54 of 60
TB – 3019 Rev A
3.7
TRI-FUNCTION SENSOR
This section demonstrates how to properly remove and install the Tri-function
sensor. It is crucial that these steps are followed to avoid performance issues
with the DEF system.
Tri-function Sensor Removal Procedure:
NOTE: The following procedure begins after the MFHU has been removed from the
DEF tank. For instructions on removing the MFHU, please refer to Section 3.5A.
1) Loosen and remove the Tri-Function Sensor nut using a box wrench or pliers.
Set the Sensor nut and the O-ring to the side.
2) Remove the suction filter. Refer to section 3.6 for DEF suction filter removal
instructions. Using a T15 Torx Driver, unscrew the retention screws that secure
the sensor clamp to the MFHU tubes/Sensor Bracket.
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
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TB – 3019 Rev A
3) Remove the retention screws and the sensor bracket and slide the Tri-Function
Sensor from the DEF head mounting base (Refer to image below). Do not
damage the MFHU coil/suction tubes while removing the 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 56 of 60
TB – 3019 Rev A
4) Inspect the Tri-Function Sensor for signs of damage. Verify an O-Ring is located
below the threading at the top of the sensor (Refer to image below).
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
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TB – 3019 Rev A
Tri-function Sensor Installation Procedure:
5) Make sure the new Tri-Function Sensor has an O-ring preinstalled on top as
shown in the previous image.
6) Feed the new Tri-Function Sensor’s cable into the bottom of the mounting base
through the sensor opening. Press the Tri-Function Sensor clamp into the MFHU
tubes to align with the sensor bracket and the foot of the sensor parallel with the
heater Element. The gap between bottom of the sensor clamp and top of the
sensor boot should not be more than 0.25 inch. Install the retention screws using
T15 Torx Driver. Recommended torque on screws is 18 - 24 in-lbs (2.03 – 2.71 N
m) (Refer to image below).
7) Position the top of the sensor through the mounting base such that the upper
threaded portion of the sensor is seen. Ensure the top surface of the header is
cleaned.
8) Install the Sensor O-ring on the top through the upper threaded portion of the
sensor by feeding the cable through the O-ring. The O-ring should sit in the
MFHU mounting base groove. Do not apply O-ring lube on this O-ring.
9) Install the Tri-Function Sensor nut on the top by feeding the cable through the
sensor nut and screwing down the nut on the sensor down to the mounting base.
Tighten nut to 40 - 44 in. lbs (4.5 - 4.97 N m).
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 58 of 60
TB – 3019 Rev A
10) Install the DEF suction filter. Refer to section 3.6 for DEF suction filter installation
instructions.
11) Once the DEF suction filter is installed, the MFHU is ready to be installed into the
tank assembly. Refer to section 3.5B for MFHU installation instructions.
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 59 of 60
TB – 3019 Rev A
4.0
FREQUENTLY ASKED QUESTIONS (FAQ’s)
What information should be collected before calling Shaw for troubleshooting
related issues?
Providing the following
troubleshooting process.
information
will
help
in
expediting
the
1. All Fault Codes related to the incident
2. DEF tank assembly part number
3. MFHU serial number (reference image below for location)
4. Location of failure (City, State, Territory)
5. Failure Date
How can I troubleshoot the Tri-Function Sensor?
Request for Shaw’s DEF gauge tool kit. The Part Number for this kit is
960-0231-01-KIT. This kit consists of the following 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 60 of 60
TB – 3019 Rev A
Shaw’s DEF gauge is capable of displaying all the DEF Tri-Function sensor
outputs and their associated Failure Mode Indicators (FMI). This gauge plugs in
between the J1939 connector on the Shaw’s DEF SCR system and the
Vehicle’s Harness. Technical Bulletin TB-2989 is a quick start guide that
describes the diagnostics process.
Can I orient the Multi-Function Head Unit?
Refer to page 48 for the header orientation options.
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.
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TSB/Document ID: SM1604
Replacement Service Bulletin Number:
MFR Communication Date: 2016-07-05
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