Perkins 1200F Series Owner's manual

Tier 4F 1204F
Perkins 1200F Series
Models MT, MU, MV and MW
DEF SYSTEM SUPPLEMENT
1204F-E44TA Four cylinder diesel engines
1204F-E44TTA for agricultural, industrial,
construction applications
Developed to meet EEC off-road mobile machinery Stage IV and U.S. EPA off-road Tier 4 Final
legislation
1200
Series
Publication No.TPD1832 – Production Issue 3. May 2015

1204F - DEF System Supplement
This manual has been compiled to explain mandatory requirements, provide information for designers
and provide information on the application and installation of the 1204F Perkins engines into Industrial
equipment, to meet U.S. Environmental Protection Agency (“EPA”) Tier 4 Final regulatory
requirements and European Union (“EU”) Stage IV non-road mobile machinery emissions legislation.
We endeavour to provide information in this manual that is correct at the time of issue. Continuing
product developments and changing legal requirements will, however, continue to drive further
changes in installation requirements and therefore attention must be paid to ensure that the latest
information is utilised and valid data is obtained from the engine specification manual.
This manual is not an exhaustive source of instruction or data and should only be used in conjunction
with advice from your local application engineers, sales manager and or technical support
representative.
The following media publications for the relevant engine type should also be used for further technical
information:
•Tier 4 Final Mechanical A and I manual – TPD1830
•Tier 4 Final Electrical and Electronic A and I Manual – TPD1836
•Operator and maintenance manual (OMM)
•System Operation Test and Adjust (SOTA)
•Specifications (Specs)
•Disassembly and Assembly (D&A)
•Engine Specification Manual (ESM)
•Customer Assembly Requirements (CAR)
Correct practices, procedures and safety precautions should always be followed.
Please note:
The information provided may be subject to change.
Perkins has provided this information in good faith and are not liable for how this information is
interpreted or applied.
Perkins is not responsible for failures resulting from attachments, systems, accessory items, and
parts not sold nor approved by Perkins. Consult the applicable warranties for complete details of
Perkins warranty coverage.
The manufacturer and customer are reminded that it is their responsibility to ensure compliance with
the requirements of the Health & Safety at Work Act 1974 and any other applicable legislation, both
nationally and internationally, in relation to the engine installation applicable to the equipment
concerned. In giving notice of approval in respect of the installation, Perkins do not assume such
responsibilities on behalf of the manufacturer or customer and while engine installation approval and
advice is an opinion given in good faith, the equipment manufacturer and customer remain
responsible as detailed above and must act and insure accordingly.
Contents
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1204F - DEF System Supplement
1.1 SAFETY REQUIREMENTS ..............................................................................................................5
1.2 TERMINOLOGY.............................................................................................................................6
2.1 GENERAL REQUIREMENTS............................................................................................................7
2.2 CLEANLINESS ..............................................................................................................................7
2.3 PROHIBITED MATERIALS...............................................................................................................7
2.4 DEF SPECIFICATION ....................................................................................................................7
2.5 DEF TANK ..................................................................................................................................8
2.5.1 General ..............................................................................................................................8
2.5.2 Positioning .........................................................................................................................8
2.5.3 DEF Tank Mounting...........................................................................................................9
2.5.4 DEF filler neck extensions/Remote Fill..............................................................................9
2.6 TANK HEADER..............................................................................................................................9
2.7 PEU (WITH INTEGRATED DCU)...................................................................................................10
2.8 DEF COMPONENT RELATIVE POSITIONS ......................................................................................11
2.8.1 DEF tank to PEU..............................................................................................................11
2.8.2 PEU to DEF injector.........................................................................................................12
2.9 DEF COOLANT VALVE.................................................................................................................13
2.10 DEF TANK COOLANT SUPPLY LINES...........................................................................................14
2.11 DEF LINES ..............................................................................................................................15
3.1 PLATFORM TECHNOLOGIES.........................................................................................................16
3.2 DIESEL EXHAUST FLUID (DEF)...................................................................................................16
3.2.1 General DEF Information.................................................................................................16
3.2.2 Standards.........................................................................................................................16
3.2.3 DEF Quality......................................................................................................................16
3.2.3 DEF Storage....................................................................................................................16
3.3 REGULATIONS ...........................................................................................................................17
4.1 AT/ SCR SYSTEM SCHEMATIC...................................................................................................18
4.2 COMPONENTS ...........................................................................................................................20
4.2.1 DEF Tank.........................................................................................................................20
4.2.2 DEF Filler Cap .................................................................................................................21
4.2.3 DEF tank header..............................................................................................................21
4.2.4 Coolant Lines and valve ..................................................................................................22
4.2.5 DEF Pump .......................................................................................................................23
4.2.5 DEF Control Unit (DCU) ..................................................................................................23
4.2.6 DEF Lines ........................................................................................................................24
4.2.7 DEF injector .....................................................................................................................25
4.3 OPERATIONAL PARAMETERS ......................................................................................................26
4.3.1 DEF Component temperature Requirements..................................................................26
4.3.2 DEF Component Vibration Requirements .......................................................................27
5.1 DEF LINE AND COOLANT SCHEMATIC..........................................................................................28
5.2 CUSTOMER CONNECTIONS.........................................................................................................28
5.2.1 Coolant Connections........................................................................................................29
5.2.2 DEF Connection Detail ....................................................................................................31
5.3 MATERIALS................................................................................................................................33
5.3.1 Rubber Components (Seals, etc.) ...................................................................................33
5.3.2 Metallic Components .......................................................................................................33
5.4 DEF TANKS...............................................................................................................................34
5.4.1 DEF Tank Sizing..............................................................................................................34
5.4.2 DEF Tank Mounting and Installation................................................................................35
5.4.3 DEF Tank Straps .............................................................................................................35
1.0 INTRODUCTION........................................................................................................................... 5
2.0 MANDATORY INSTALLATION REQUIREMENTS..................................................................... 7
3.0 SCR SYSTEM FUNDAMENTALS.............................................................................................. 16
4.0 SCR SYSTEM.............................................................................................................................18
5.0 SCR SYSTEM DESIGN CONSIDERATIONS............................................................................28
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1204F - DEF System Supplement
5.4.4 Bulk Fuel and DEF Tanks................................................................................................37
5.5 DEF COMPONENT MOUNTING AND ISOLATION.............................................................................38
5.5.1 PEU/DCU Mounting Requirements .................................................................................38
5.5.2 DEF Component Relative Positioning .............................................................................39
5.6 DEF TANK SERVICE CONSIDERATIONS.......................................................................................39
5.6.1 DEF Tank Filling ..............................................................................................................39
5.6.2 Overfill Protection.............................................................................................................39
5.6.3 Remote Fill.......................................................................................................................40
5.6.4 DEF Tank Draining ..........................................................................................................40
5.7 PRODUCTION AND MANUFACTURING...........................................................................................40
6.1 CHANGES FROM ISSUE 1TO ISSUE 2...........................................................................................41
6.2 CHANGES FROM ISSUE 2TO ISSUE 3...........................................................................................41
6.0 RECORD OF AMENDMENT......................................................................................................41
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1204F - DEF System Supplement
1.0 Introduction
Tier 4 Final/Stage IV now includes the use of SCR technology to meet emissions legislation. DEF is
required as part of this technology selection and this document has been written to explain the
requirements of the 1204F DEF system. This document is supplementary to the Tier 4 Final/Stage
IV1200F Application and Installation Manual, which details the other engine system mandatory
requirements and recommendations.
The start of this document details the mandatory installation requirements relevant to the DEF
system. These mandatory requirements include emission related requirements and warranty
related requirements.
All mandatory requirements must be adhered to in order to ensure emission compliance and
attain full engine warranty.
For engines operated within the US the following statement applies:
‘Failing to follow these instructions when installing a certified engine in a piece of nonroad
equipment violates federal law (40 CFR 1068.105(b)), subject to fines or other penalties as
described in the Clean Air Act.’
For full details of the structure of the complete manual please refer to the table of contents.
For details of electronic and electrical systems please refer to the Tier 4 Final/Stage IV Electronic A
and I Manual.
1.1 Safety Requirements
Diesel Exhaust Fluid (DEF) is an aqueous urea solution blended with 32.5% high purity urea and
67.5% deionized water. DEF solution is used in selective catalytic reduction (SCR) to lower NOx
concentration in the exhaust emissions of diesel engines.
Diesel Exhaust Fluid Hazard Identification
Signal Word: CAUTION
Hazard Statement: May cause eye and skin irritation contains material that may cause target
organ damage, based on animal data.
Precautionary measures: Do not breathe vapor or mist. Do not eat, drink or smoke when using
this product. Avoid contact with eyes, skin and clothing. Wash thoroughly after handling.
Potential acute health effects
Inhalation: Exposure to decomposition products may cause a health hazard. Serious effects may
be delayed following exposure.
Ingestion: No known significant effects or critical hazards.
Skin: Moderately irritating to the skin. Not expected to produce significant adverse health effects
when the recommended instructions for use are followed.
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1204F - DEF System Supplement
1.2 Terminology
•SCR Selective Catalytic Reduction
•CDPF Catalysed Diesel Particulate Filter
•DEF Diesel Exhaust Fluid
•PETU Pump Electronic Tank Unit
•PEU Pump Electronic Unit
•DCU Dosing Control Unit
•ULSD Ultra Low Sulphur Diesel
•OEM Original Equipment Manufacturer
•CDV Coolant Diverter Valve
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1204F - DEF System Supplement
2.0 Mandatory Installation Requirements
‘Failing to follow these instructions when installing a certified engine in a piece of nonroad
equipment violates federal law (40 CFR 1068.105(b)), subject to fines or other penalties as
described in the Clean Air Act.’
2.1 General Requirements
•The DEF tank capacity must be chosen or designed to facilitate at least a 1:1 filling ratio with
the ULSD fuel tank.
•This can be achieved considering a maximum DEF consumption rate of 4% of fuel
•This should be calculated using the operational volume and taking into consideration the
maximum tilt angle of the machine under continuous operating conditions - ref 5.4.1.
•The DEF component temperatures in table 4.2, section 4.3.1 must be adhered to.
•The DEF system components must be isolated from excessive vibration and fall within the
component profile limits detailed in section 4.3.2.
•Vibration levels must be measured on applications subject to high vibration during
operation; including Rock Crushers, Tracked type Tractors and Pavers.
2.2 Cleanliness
•DEF Cleanliness must be adhered to as outlined in ISO 22241
•DEF system components are supplied with caps over hose connection points; these must
not be removed before final assembly to ensure cleanliness is maintained.
•The following DEF system component cleanliness requirements must be maintained during
the customer assembly process. In addition any components which have been supplied by
the customer must also meet these specifications.
•DEF lines – internal surfaces.
No more than 5 particles > 1200x500x150um and 170mg/m2.
•DEF Tank, Header assembly and DEF pump – In contact with DEF fluid:
50-100um = 600 particles;
100-200um = 80
200-500um = 8
>500um = 0
•The cleanliness of the coolant and coolant system must be maintained and protected to
ensure maintained operation of the coolant valve. Particles <1000 um.
2.3 Prohibited Materials
Any customer supplied metallic components expected to be in direct contact with DEF must not
be made of the following materials:
•Aluminium
•Brass
•Copper
•Zinc
Mild steel
2.4 DEF specification
•DEF must meet the requirements in section 3.2.2 , Standards
•The quality of the DEF must be maintained throughout the machine operation to maintain
acceptable machine performance and prevent frequent fluid replacement.
•The level of DEF in the tank must cycle from the DEF low level warning to the DEF
maximum fill level. This is required to provide an accurate indication of DEF quality,
required for emissions compliance.
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1204F - DEF System Supplement
2.5 DEF Tank
2.5.1 General
•The DEF tank is an emissions related component and should be selected from Perkins
product offering.
•The tank must be selected to suit the operational use of the machine- equivalent to a
minimum of 4% of fuel consumption (1:1 DEF to Diesel fuel refill rate). Ref 5.4.1
•The DEF tank should be identified with the correct symbol on the fluid container or Fill
point. The symbol markings should be in accordance to ISO 22241 and ISO 2575.
•The colour is to be associated with the DEF fill point or cap should be blue as
referenced in the standard.
•The DEF tank feed line must be submersed in all operating conditions.
•The DEF tank assembly must not be modified in any way from the supplied condition
2.5.2 Positioning
•The DEF tank must be mounted in a location to meet the temperature requirements of the
DEF fluid and the DEF tank as tabulated in section 4.3.1
•All temperatures must be tested in accordance with the defined test procedure
•The DEF tank must not be mounted in a location that is prone to dust or debris build up;
•Which could cause physical damage to the tank or attached components.
•Which could collect around the tank filler cap.
•The tank filler and drainage plug should be distanced or isolated from components which
are not resistant to DEF in the event of spillage.
•The DEF tank must be positioned so that it is easily accessible for servicing, replenishing,
draining and replacing the DEF.
•The DEF tank location must not risk contamination of the DEF with service fluids i.e. under
oil or fuel filters
•The DEF tank must be protected from impact and projectiles
•The DEF tank must be protected from side loading
•The DEF tank drainage plug must be accessible
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1204F - DEF System Supplement
2.5.3 DEF Tank Mounting
The following information is for tanks sourced and designed by Perkins. Tank mounting is the
OEM responsibility; the following must be adhered to for successful tank mounting.
•The bottom of the tank must be horizontal and fully supported by a structural platform
•Full support is defined as a continuous material that is at least as large as the tanks
base dimension.
•Structural is defined as being able to support full tank mass with application
dynamic loading without plastic deformation or failure.
•The tank mounting materials must be resistant to DEF
•The tank must be isolated from abrasive surfaces that may penetrate the tank material over
time.
•The tank must be retained in all ambient and operating conditions without stressing the
tank material while allowing for thermal expansion and contraction.
•The tank requires hold down straps to secure the tank to the structural platform in the
vertical plane.
•The pre-moulded tank grooves must be used for these hold down straps
•The straps must always sit flat within the pre moulded grooves and must be sized
considering the max and min strap and groove tolerances. Ref – table 5.6 in section
5.4.3
•The straps must pass over the top of the tank- Ref - figure 5.7 in section 5.4.3
•There must be sufficient clearance between the tank walls and any other component to
allow for thermo-cycling and tank mounting tolerances
•A minimum gap of 9mm should be maintained on all side and top faces.
•This 9mm space can be maintained by using spacers that are located in the tank
strap grooves on the tank. This can also be achieved by increasing tank hold-down
strap thicknesses to >9mm.
•Spacers must not be positioned elsewhere on the tank side walls.
•The tank side walls must not be mounted directly against any surfaces. Full coverage of
any side wall is prohibited. If this is a requirement then Perkins approval is required and a
full validation study conducted.
2.5.4 DEF filler neck extensions/Remote Fill
•A DEF tank filler extension must only be used with the compatible DEF tank option. Use of
a filler extension with any other factory supplied tank is prohibited.
•The filler extension must be designed to meet the requirements in IGB 99-05.1
2.6 Tank header
•The DEF tank header is an emissions related component and must be selected from
Perkins product offering.
•It is not permitted to re-orientate or modify the DEF tank header from its assembled position
on the DEF tank as supplied by Perkins.
•The tank header must be electrically connected in accordance with the requirements in the
Electronic Application and Installation manual.
•The tank header coolant inlet and outlet connections are identical in size and machine build
processes must be put in place to prevent incorrect matching of hose to connector. Refer to
section 4.2.3
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1204F - DEF System Supplement
2.7 PEU (with integrated DCU)
The PEU has an integrated DCU. It is supplied loose for customer fitment.
Fig 2.2 - PEU Dimensions and Clearance requirements.
•The PEU is an emissions related component and must be Perkins supplied.
•The PEU must be mounted vertically +/-5° with the two DEF connections at the bottom and
the filter at the top to ensure injection and purge functionality
•The PEU must be mounted internally or externally via all four M8 mounting through holes
ref section 5.5.1
•The mounting face between the four points must be flat within a tolerance of +/- 0.5mm
•The maximum tilt during operation is 45°
•The PEU must be mounted so that the vibration falls within the specified limits in section
4.4.2
•The PEU must not be engine mounted. It is recommended that the pump is mounted on
the machine chassis
•The PEU must be mounted in a location:
•that is protected from splash, stone chips, dirt and debris
oCare should be taken to ensure dust and debris does not build up on the box
and does not block the vent on the rear of the unit.
oMeasures should be taken to prevent dust/debris falling into the filter chamber
when removed for service
•where the pump temperature limits are not exceeded- ref section 4.3.1
oIn order to achieve this, the pump should not be mounted near any heat source
and there must be sufficient cool airflow round the pump.
•The following clearances are required for servicing:
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1204F - DEF System Supplement
•There must be a minimum of 150mm clearance above the filter cap to provide sufficient
space to service the filter.
oAccess for a 22mm hex socket is required to replace the filter cap (to 14Nm +/-
2Nm)
•Minimum clearance of 125mm must be given for DCU connector removal
•Minimum clearance of 65mm must be given for DEF inlet and outlet connector fit/removal
•Minimum clearance of 25mm should be given to the left and right side of the PEU
•The pump must be specified to the correct voltage of the machine and wired in accordance
with the Electronic A&I manual
•There is an M8x1.5 tapping (21mm depth) on the RHS top face of the DCU which should
be used for strain relief of the electrical harness. Torque limit is 15Nm=/-1.5Nm.
•The PEU must not be painted
2.8 DEF component relative positions
•All DEF system configurations require validation and approval to ensure the system
requirements are met.
2.8.1 DEF tank to PEU
There are limitations on the relative position of the tank base level to the PEU inlet
connection; these are detailed in fig 2.3 below.
Fig 2.3 – DEF Tank Relative Position to PEU
•The longest DEF suction line allowed is 2000 mm
•The lowest point on the DEF suction line, which attaches to the PEU, should be no more
than 190 mm ± 2 mm lower than the bottom of the standard tank.
•The highest point on the DEF suction line, which attaches to the PEU, should be no more
than 805 mm ± 2 mm higher than the bottom of the standard tank.
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1204F - DEF System Supplement
2.8.2 PEU to DEF injector
There are limitations on the relative position of the PEU outlet and the DEF injector inlet
connection; these are detailed in fig 2.4 below.
Fig 2.4 – PEU Relative Position to DEF Injector
•The longest DEF pressure line allowed is 4000 mm.
•The lowest point on the DEF pressure line, which attaches to the injector, should be no
more than 1000 mm lower than the bottom of the PEU.
•The highest point on the DEF pressure line, which attaches to the injector, should be no
more than 1500 mm higher than the bottom of the PEU
•A P-Trap should be used to prevent DEF pooling at the injector.
•This requires the lines lowest point to be at least 100mm lower than the injector
connection.
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1204F - DEF System Supplement
2.9 DEF coolant valve
•The DEF coolant valve is an emissions related component and must be selected from
Perkins product offering.
•The DEF coolant valve must be connected with an electrical harness by the OEM in
accordance with the Electronic A&I manual.
•The valve must be located on the inlet side of the of the tank header unit (between engine
and Tank header)
•The coolant valve may be mounted at any angle provided the maximum operating angle of
the valve, combined with the maximum machine operating tilt, is no greater than +/- 45deg
from vertical in any direction. See fig 2.5 below.
•It is recommended that the valve is mounted vertically (+/-5°).
•If the coolant valve is mounted in the reverse direction, 2 mm spacers must be
used between the mounting surface and the valve to prevent interference
Fig 2.5 – DEF Coolant Valve
•The valve must be mounted with three M8 bolts. The bolt pattern is as shown in fig 2.6
Fig 2.6 – Coolant Valve bolt pattern
•The temperature of the control valve must not exceed the limits detailed in Table 4.2
section 4.3.1.
•This must be tested in accordance with the relevant test procedure
•The coolant valve must not be mounted on the engine.
•The coolant valve must be mounted so that the vibration falls within the specified limits in
section 4.3.2
•The inlet and outlet are identical in size and machine build process must be in place to
prevent misconnection of these (flow direction arrows are visible on valve body)
•The valve is supplied with quick connectors providing a push fit for hoses, however it is
acceptable for the OEM to source 5/8” SAEJ2044 connectors if required.
•Side loading of the valve inlet/outlet should not exceed 10N in any direction and strain relief
of coolant lines should be used.
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1204F - DEF System Supplement
2.10 DEF tank coolant supply lines
•Only the designated coolant supply and return ports on the engine may be used as detailed
in section 5.2.1
•The correct hose fittings must be used to connect to the engine; ref section 5.2.1
•The correct hose fittings must be used to match the DEF coolant valve; ref section 5.2.1
•Reinforced hose must be used to minimise expansion when system is pressurised
•To achieve adequate thaw of the DEF tank a minimum of 2l/min coolant flow and temp of
80°C temp must be maintained. To ensure sufficient flow the following requirements must
be met:
•The total length of the coolant hoses (supply and return from tank) must be less than
8m, including a maximum of two 90° hose fittings.
•Use connectors and hoses with ID 16mm (5/8”).
•The maximum volume of coolant in the DEF tank coolant supply line must be such that:
For a Portrait tank
CV (litres) + 0.4 (litres) < RV (litres)
For a Landscape tank
CV (litres) + 0.6 (litres)< RV (litres)
Where
CV = Coolant Volume - the volume of coolant in DEF tank coolant supply line
RV = Reserve Volume - this is equal to the volume of coolant below the
minimum level in the coolant header tank added to the volume of coolant in
the fill line as shown in the diagram below.
•The coolant lines must:
•Be properly supported
•Not impose stress on the mating connectors
•Recommend support 150mm-250mm max from end connectors
•Be secured such as to avoid abrasion with touching surfaces
•Have minimal bends
•The coolant temperature drop (delta) between engine coolant temperature sensor and DEF
tank temperature sensor must not exceed 10°C.
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1204F - DEF System Supplement
2.11 DEF lines
•DEF lines are emissions related components and should be selected from Perkins product
offering.
•The total line length of the three DEF lines (pressure, suction and return) must not exceed:
•9.5m (12V)
•10 m (24V)
•The pressure drop across each of the DEF Lines must not exceed the limits shown in the
table below. This includes the head height plus bends plus the pressure drop due to the line
itself.
•To achieve this a maximum of 4 x 90deg bends is permissible
•The bend radius must not be less than 56mm
Table 2.1 – DEF line pressure requirements
•The DEF lines must;
•Be routed as direct as possible with no dips or sags
•Be secured such as to avoid abrasion with touching surfaces
•Be properly supported and not impose any side load or stress on mating connectors
oThe supports for the DEF lines must provide strain relief to the DEF injector and
DCU connections i.e. restrain on both sides of any bends in the DEF line.
•Be supported 150mm maximum from end connectors
•It is recommended that the lines are fully supported every 150-300mm along line length
•When DEF lines are mounted across surfaces with different relative movements, additional
line length should be considered to prevent line tension.
•SAE J2044 connectors should;
•be insulated where local air temperatures will exceed 120°C (reflective shield supplied
pre-fitted at injector connection by Perkins)
•be protected from airflow to prevent the connector from freezing
•The DEF lines must be electrically connected in accordance with the requirements detailed
in the Electronic A &I Manual.
DEF Line
∆P Limit (kPa)
Installed condition
Pressure Line
9.6
DEF Injector above PEU
13.8
DEF Injector below PEU
Suction Line
9.6
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1204F - DEF System Supplement
3.0 SCR System Fundamentals
3.1 Platform technologies
Overview of 1204F technology selection
3.2 Diesel Exhaust Fluid (DEF)
DEF fluid/Urea is made up of approximately 70% water which at temperatures below –11°C will
expand by approximately 10% to 15%.
3.2.1 General DEF Information
For Perkins diesel engines that are equipped with SCR equipment, meeting the mandated exhaust
emissions levels requires the use of diesel exhaust fluid (abbreviated DEF, also known as AdBlue or
AUS32). DEF is the only fluid recommended by Perkins for use in SCR systems in Perkins diesel
engines. DEF is available commercially, and its manufacture is regulated by the American Petroleum
Institute (API) to assure all DEF meets stringent quality specifications, as defined in “ISO 22241-1 -
NOx Reduction Agent AUS 32 – Part 1: Quality Requirements.”
3.2.2 Standards
•ISO 22241 – NOx reduction agent AUS 32
The ISO 22241 series provides the specifications for quality characteristics (22241-1), for test
method (22241-2), for handling, transportation and storage (22241-3), and for the refilling
interface (22241-4) as well as the test methods, needed by the manufacturers of motor vehicles
and their engines, by converter manufacturers, by producers and distributors of the DEF and by
fleet operators.
•DIN 70070 – NOx-Reduction agent AUS 32
This describes the quality requirements for the NOx deoxidizing agent AUS 32, required for the
deployment of catalytic converters with SCR in diesel engine powered automobiles.
•1200 Series engines and machines with DEF/SCR equipment used in the US, are required to
use API (American Petroleum Institute) certified diesel exhaust fluid.
•Warning: Use of fluids that are not recommended by Perkins can result in numerous problems
including damage to DEF/SCR equipment.
3.2.3 DEF Quality.
The quality of DEF is critical. Tight control on the individual constituents is necessary to:
•Maintain shelf life
•Prevent injector clogging
•Prevent formation of deposits
•Prevent poisoning of the catalyst
3.2.3 DEF Storage
•For DEF storage requirements refer to the OMM
•DEF has a finite storage life dependent on the fluids storage temperature and vessels type
used.
•DEF is not classified as dangerous or hazardous waste but care must still be taken in disposal.
•DEF should not be disposed of in drains or waterways where DEF may enter the ground water.
Refer to applicable local and national regulations regarding proper disposal for your location.
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1204F - DEF System Supplement
3.3 Regulations
The certification requirement on SCR systems can vary depending on the governing regulatory
body specifically between the EU and EPA.
The regulatory requirement for the SCR system is that the control system monitors DEF level and
detects control system malfunctions. The engine control system therefore, monitors the following
key SCR system parameters and applies various warnings and inducement levels to meet these
regulatory requirements.
•Low DEF level
•Degradation of DEF
•Interruption to DEF dosing (for reasons other than the tank is empty)
•Tampering or diagnostic system failure (to prevent unplugging of the level sensor for
example)
•Frozen DEF (this will be detected as interruption to DEF dosing, as frozen fluid will stop
injecting, however it is important to differentiate that the DEF is frozen as the timings and
severity of inducements are different.)
Inducement
Due to regulatory requirements, Tier 4 Final / Stage IV engines cannot be allowed to run when the
DEF system is not functioning correctly. There can be several reasons why the DEF system might
not be working properly.
Examples include poor quality DEF, lack of DEF in the tank, diagnostics, etc. In these cases, specific
actions will be taken to notify the operator. These actions will include lamps and J1939
communication. However, it must be understood that once a defined series of communications has
taken place, the engine will be required to shut down and in some cases, restart only briefly. This
strategy will not be configurable in Perkins EST. The Tier 4 Final Electronic A&I manual provides
specific information. This information is repeated here in the Mechanical Guide simply to emphasize
the issue.
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1204F - DEF System Supplement
4.0 SCR System
4.1 AT/ SCR System Schematic
*DOC and CDPF is option depending on rating.
Fig 4.1 - Aftertreatment and SCR Schematic
Fig 4.1 above shows the components and system arrangement required to meet Tier 4 Final / Stage
IV Emissions Legislation.
From Fig 4.1, it can be seen that DEF is drawn from the DEF tank through a ‘suction’ line to the DEF
pump where it is pumped through a heated ‘pressure’ line to the DEF injector. The DEF injector,
installed within the SCR mixer, then injects DEF into the exhaust gas to activate the reaction in the
SCR canister and reduce the exhaust NOx. Any excess DEF is returned from the DEF injector back
to the tank to create a continuous closed loop system.
Control of the DEF injection is managed by the DCU. The signal from the NOx sensor on the engine
exhaust outlet prior to the after treatment and in the exhaust tailpipe is used along with other sensor
inputs to meter the quantity and timing of DEF injection
To comply with the legislative freeze and thaw cycle requirements the temperature of the DEF is
monitored, with a sensor in tank, by the DCU. The DCU can then control the flow of coolant from the
engine through a diverter valve to heat the tank and the pump as required. The DEF lines are also
electrically trace heated to ensure these are thawed and free from blockages; this is also controlled
by the DCU.
DOC*
DCU and PUMP with heated
DEF feed and return lines
NH3
A&I manual Publication TPD 1832 – Production issue 3. Page 18 of 41

1204F - DEF System Supplement
As shown in Fig 4.1 the components required to meet the Tier 4 Final / Stage IV Emissions Legislation
consists of:
Aftertreatment
•DOC and CDPF Canister or DOC only (rating dependant)
•Flexpipe
•Nox sensor
•Mixer
•SCR canister
All the components within this system must be supplied by Perkins.
DEF system
•DEF tank
•DEF tank header
•DEF pump
•DEF Control Unit (DCU)
•DEF Lines
•Heated suction line
•Heated return line
•Heated pressure line
•DEF injector (supplied fitted in AT mixer tube)
•Coolant valve
•Coolant lines to DEF tank
The DEF pump and control unit assembly, DEF injector, DEF tank header and coolant valve must be
supplied by Perkins as these are emissions critical components. The coolant lines are customer
supplied.
A more detailed description of the DEF system components and their operation are all discussed
individually in section 4.2 below.
A&I manual Publication TPD 1832 – Production issue 3. Page 19 of 41

1204F - DEF System Supplement
4.2 Components
4.2.1 DEF Tank
The DEF tank is an emissions related component and should be selected from Perkins product
offering. These tanks have been fully validated as part of an integrated solution to ensure
durability, performance and adherence to legislative requirements.
The DEF tank is available in two sizes - a 19 litre tank available in portrait or landscape or a 38 litre
tank in landscape orientation only. Note this capacity is the total volume of the tank and not the
useable DEF volume which is required for tank sizing. Please also note that if remote fill is required
then a compatible tank must be selected.
The DEF tank requires heating and this is done by engine coolant which is controlled by the coolant
control valve (CCV.)
For maintenance of the DEF tank please refer to the engine OMM. Note for cleaning of the tank, it
can be reverse flushed with distilled or de-ionized water through the drain, then flushed with new
DEF just before use.
A typical DEF tank is shown in Fig 4.2. This shows the following features, which are incorporated
into the tank design:
•DEF tank header – ref section 4.2.3
•Drain plug
•Fill neck
Compatible with an ISO22241 compliant adapter and contains a serviceable 180 µ strainer.
All adapters supplied by Perkins include a magnetic toggle which when filled from a nozzle
with a magnetic safety switch will prevent DEF from being dispensed into a non-DEF tank.
The size of the neck is such that it prevents a standard diesel or gasoline fill nozzle from
being inserted into the tank resulting in a miss fill. There are, however, no devices in the
adapter preventing a determined party from inserting a non-standard fill hose and filling the
tank with fluids other than DEF. A remote fill adapter is also available as an option.
•Fill cap with filtered vent –ref section 4.2.2
The DEF cap is designed such that it cannot be installed on other type of tanks (fuel,
coolant, etc.) and conversely, other caps cannot be used on the DEF tank.
•Overfill protection device (incorporated into fill adapter)
This maintains the volume of expansion space and is done by simply extending a tube to
the required level then allowing the flow to back up in the nozzle activating its automatic
shutoff.
Fig 4.2 – Typical DEF Tank
A&I manual Publication TPD 1832 – Production issue 3. Page 20 of 41