Dongfeng Xinjiang truck parts Installation process assembly of urea tank and sensor 1205910-LAPF20Y

Built to simplify the urea tank and sensor installation process, this assembly features a pre-configured, all-in-one design that eliminates component matching troubles. It includes 4 high-strength steel mounting brackets, 16 grade 10.9 galvanized bolts (M12×40), 8 rubber shock absorbers, 2 sensor seal gaskets (FKM material), and a 1.5m dedicated wiring harness. Each component is pre-sized and labeled—brackets are marked with “FRONT/REAR” to ensure correct orientation, and bolts are sorted by length for different mounting positions. The integrated design reduces the number of separate parts by 60% compared to non-assembled kits, cutting down installation preparation time from 2 hours to 30 minutes. This streamlines the workflow for maintenance teams, especially in fleet repair scenarios

Engineered to mitigate the impact of road vibrations on the urea tank and sensor, the assembly incorporates a multi-layer shock absorption structure. The rubber shock absorbers (Shore hardness 50±5) placed between the brackets and chassis reduce vibration transmission by 70%, preventing urea tank deformation and sensor connector loosening. The mounting brackets are made of Q355B high-strength steel with a 5mm thickness, featuring integrated reinforcing ribs that distribute vibration loads evenly. Finite element analysis (FEA) verifies the assembly can withstand 500,000 vibration cycles (5-2000Hz, ISO 16750-3) without structural damage. This vibration damping ensures the urea sensor maintains stable data collection (urea level, temperature, quality) and prevents urea leakage from tank-seal failures caused by excessive shaking

Designed for the harsh operating environments of commercial trucks, the assembly’s components feature exceptional sealing and corrosion resistance. The sensor seal gaskets (FKM material) withstand urea fluid corrosion and operating temperatures of -40℃ to 120℃, ensuring a leak-tight seal that passes 24-hour pressure testing at 0.3MPa. Mounting bolts and brackets undergo triple anti-corrosion treatment (zinc phosphate + electrophoretic coating + powder coating), passing 1500-hour neutral salt spray testing (ASTM B117) with no red rust. The wiring harness uses urea-resistant PVC insulation and a braided stainless steel shield, preventing damage from urea splashes and electromagnetic interference. These features ensure the assembly’s service life of ≥200,000km, matching the truck’s SCR system durability

Optimized for operators of varying skill levels, the assembly includes detailed, actionable installation guidance integrated into its design. Each component is paired with color-coded labels that correspond to a simplified installation flowchart (printed on the packaging). The wiring harness features pre-crimped connectors with “SENSOR” and “ECU” markings, eliminating wiring errors. Torque specifications (45-50N·m for bracket bolts, 15-20N·m for sensor bolts) are laser-etched on the fasteners, ensuring proper tightening without over-torque damage. A built-in alignment pin on the mounting brackets ensures the urea tank is positioned correctly (within ±2mm) relative to the fill port and sensor. With this design, a team of two technicians can complete the entire urea tank and sensor installation in 1.5 hours—40% faster than using non-integrated parts—reducing fleet downtime significantly