Built my Def Sensor Simulator

[redbaron]

As I plan to take delivery of my 2022 London Aire very soon, I decided it was time to build by Def Sensor simulator.

The instructions I followed where the original from the quick build (DEF Sensor Simulator – Quick Build – DEF Sensor Simulator)

I had purchased all of the components many months ago, and played a lot with the simulator on a simulated network, but never built one that was designed for the actual production use.

When I went to assemble the arduino DUE to the case, I discovered a problem with the fit. I assume that most people would use some 2 sided tape to get the due to hold in place, which would be fine.

Since I have several projects that will be using the DUE, including my new and improved RV-C control system for lights, shades, tank sensors, and tank flush, I decided that I would take the time design a platform that was purpose built for the case.

This is a view of the case with the weather-proof cable pass thru.

This shows the platform installed.

You will see that the platform is secured to the case with 2 screws.
The platform has 6 stands to keep the DUE board from touching the screws. 2 of those are threaded with a M3 thread to secure the board to the platform.

This shows the DUE screwed to the platform.

I also applied some silicon around each of the wires so that the strands wouldn't work their way loose and become a short circuit. I used a very thick wire (14 awg) which was overkill for the application. Next time I will use a 18awg.


This is the kit ready to be installed as soon as the summer heat kills my DEF head.

 

[Fatboy2004]

As I plan to take delivery of my 2022 London Aire very soon, I decided it was time to build by Def Sensor simulator.

The instructions I followed where the original from the quick build (DEF Sensor Simulator – Quick Build – DEF Sensor Simulator)

I had purchased all of the components many months ago, and played a lot with the simulator on a simulated network, but never built one that was designed for the actual production use.

When I went to assemble the arduino DUE to the case, I discovered a problem with the fit. I assume that most people would use some 2 sided tape to get the due to hold in place, which would be fine.

Since I have several projects that will be using the DUE, including my new and improved RV-C control system for lights, shades, tank sensors, and tank flush, I decided that I would take the time design a platform that was purpose built for the case.

This is a view of the case with the weather-proof cable pass thru.

View attachment 10633

This shows the platform installed.

You will see that the platform is secured to the case with 2 screws.
The platform has 6 stands to keep the DUE board from touching the screws. 2 of those are threaded with a M3 thread to secure the board to the platform.

View attachment 10634

This shows the DUE screwed to the platform.

View attachment 10635

I also applied some silicon around each of the wires so that the strands wouldn't work their way loose and become a short circuit. I used a very thick wire (14 awg) which was overkill for the application. Next time I will use a 18awg.


This is the kit ready to be installed as soon as the summer heat kills my DEF head.

View attachment 10636

Nice, but for us gas people. What does it do ?

 

[redbaron]

Nice, but for us gas people. What does it do ?

NOTHING!!

Gas coaches, and those diesel coaches built on Freightliner Chassis don't have to worry about this problem.
Only spartan with their terribly DEF Head sensors have to worry about this issue, and only in the summer months.

 

[Joe Hogan]

Very creative solution! Hope all goes as planned.

 

[J&JD]

NOTHING!!

Gas coaches, and those diesel coaches built on Freightliner Chassis don't have to worry about this problem.
Only spartan with their terribly DEF Head sensors have to worry about this issue, and only in the summer months.

Except for a few unlucky Freightliner owners

 

[redbaron]

Except for a few unlucky Freightliner owners

Correct me if I am wrong, but the failure for the freightliner was not related to the sensor itself, and parts are readily available?

I remember you had an issue...just not the details.

 

[J&JD]

Total derate due to bad DEF sensor. Entire DEF head replaced. Part was acquired within a few days. Unfortunately the Freightliner dealer took almost 3 weeks to have a tech available to replace the unit. All done under warranty. Freightliner also paid most of a $3000 tow bill after much arm twisting

 

[redbaron]

Total derate due to bad DEF sensor. Entire DEF head replaced. Part was acquired within a few days. Unfortunately the Freightliner dealer took almost 3 weeks to have a tech available to replace the unit. All done under warranty. Freightliner also paid most of a $3000 tow bill after much arm twisting

Ouch...honestly that sounds every bit as bad as what I am hearing on spartan.

 

[Neemer]

From all accounts, FL is not immune, but the frequency of occurrence is less than Spartan. I have a DEF sensor simulator tucked away in my storage compartment.

 

[FLSteve]

@redbaron ... once you build one of these units, what it the best method of field testing it to make sure it works before hitting the road? I am getting ready to order the parts.

FLSteve

 

[redbaron]

@redbaron ... once you build one of these units, what it the best method of field testing it to make sure it works before hitting the road? I am getting ready to order the parts.

FLSteve

The only test you can do without a donor coach is a continuity test between pins and the board with a multimeter.

Also verify no shorts between pins.

 

[FLSteve]

The only test you can do without a donor coach is a continuity test between pins and the board with a multimeter.

Also verify no shorts between pins.

I was thinking once I get my coach, maybe just unplugging the DEF head and plugging this in and see if I can start it ... but am almost afraid to do that in case it causes lots of codes and I get stranded.

FLSteve

 

[KR1973]

As I plan to take delivery of my 2022 London Aire very soon, I decided it was time to build by Def Sensor simulator.

The instructions I followed where the original from the quick build (DEF Sensor Simulator – Quick Build – DEF Sensor Simulator)

I've gotten all the parts to assemble mine but I wasn't sure about downloading the software on my work PC. I was going to try to get a used laptop so as not to create virus problems on this PC. I assume there was no issue for you downloading the software, is that correct?

 

[redbaron]

I was thinking once I get my coach, maybe just unplugging the DEF head and plugging this in and see if I can start it ... but am almost afraid to do that in case it causes lots of codes and I get stranded.

FLSteve

That is the correct test. You do this with the chassis power off.

From this page:

DEF Sensor Simulator – Quick Build – DEF Sensor Simulator

Connecting to your motorhome CAN network:​

1. Make sure that before you unplug your def head that the ignition is turned off, then unplug your def head. You may need to cut a zip tie to provide working slack in the wiring.
   
2. Plug the simulator into the connection to your chassis wiring where the def head was plugged in.
3. Turn on your ignition, some or all of the fault codes should go away and the Check Engine and MIL (Malfunction Indicator Lamp) lights should extinguish within a few minutes.
4. If some codes remain, to clear your codes you will need to turn your ignition on (let all systems come up, about 20 seconds), then start your engine and fast idle for 5-6 minutes, shut down for 90 seconds, turn ignition on (wait for systems to boot 20 sec) start engine and fast idle for 5 min. You will do this a total of 3 times on the 4 cycle the codes should clear to the inactive status.
   Note: on older engines or engines with older ECM software, some codes may not completely clear on their own. In this case code clearing intervention may be required. This is something that is still under study, see the Troubleshooting section for more info.

 

[redbaron]

I've gotten all the parts to assemble mine but I wasn't sure about downloading the software on my work PC. I was going to try to get a used laptop so as not to create virus problems on this PC. I assume there was no issue for you downloading the software, is that correct?

This software is not a virus. It is an executable, and modern browsers will scare you into not running it.

If you take it from the website: DEF Sensor Simulator – Quick Build – DEF Sensor Simulator then you are safe.

 

[KR1973]

This software is not a virus. It is an executable, and modern browsers will scare you into not running it.

If you take it from the website: DEF Sensor Simulator – Quick Build – DEF Sensor Simulator then you are safe.

Thanks Now I have the confidence!

 

[NWIP]

That is the correct test. You do this with the chassis power off.

From this page:

DEF Sensor Simulator – Quick Build – DEF Sensor Simulator

Connecting to your motorhome CAN network:​

1. Make sure that before you unplug your def head that the ignition is turned off, then unplug your def head. You may need to cut a zip tie to provide working slack in the wiring.
   
2. Plug the simulator into the connection to your chassis wiring where the def head was plugged in.
3. Turn on your ignition, some or all of the fault codes should go away and the Check Engine and MIL (Malfunction Indicator Lamp) lights should extinguish within a few minutes.
4. If some codes remain, to clear your codes you will need to turn your ignition on (let all systems come up, about 20 seconds), then start your engine and fast idle for 5-6 minutes, shut down for 90 seconds, turn ignition on (wait for systems to boot 20 sec) start engine and fast idle for 5 min. You will do this a total of 3 times on the 4 cycle the codes should clear to the inactive status.
   Note: on older engines or engines with older ECM software, some codes may not completely clear on their own. In this case code clearing intervention may be required. This is something that is still under study, see the Troubleshooting section for more info.

Are you planning on testing once you get your coach? I want you to lead the way

 

[redbaron]

Are you planning on testing once you get your coach? I want you to lead the way

Yes. I will be plugging it in as soon as possible.

 

[NWIP]

Well I finished mine up, got brave and tested. Worked as advertised and no fault codes. I am going to carry in my spare parts bin and hope I never need it

 

[FLSteve]

Well I finished mine up, got brave and tested. Worked as advertised and no fault codes. I am going to carry in my spare parts bin and hope I never need it

@NWIP ... did you order the parts very recently. Need to get my stuff ordered tonight. Just wondering if there is a backlog.

FLSteve