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/m
2
.
• 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.
A&I manual Publication TPD 1832 – Production issue 3. Page 7 of 41
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