3516E Engine for Tier 4 Final 994K Wheel Loaders Caterpillar

Introduction

Use this procedure to flush the Diesel Exhaust Fluid (DEF) tank.

Required Tools

Flushing Procedure

1. Turn key switch off and allow Diesel Exhaust Fluid (DEF) system to purge. The orange light on the ground level battery disconnect will turn off. This will take a couple minutes after key switch is turned off.

2. Clean off top cover plate. Remove bolts and take off cover plate.

3. Hose off or clean out around filter headers that will be removed. Do not use high-pressure water.
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   Illustration 1	g06333315

   Note: All DEF drained or flushed during this procedure must be disposed of as per local regulations and mandates.

4. Drain existing DEF from tank.

   1. Remove plug on bottom of tank. Only remove outermost plug as shown.

   2. Install 2 ½ inch pipe in eco-valve to drain fluid.

5. Pinch off the 2 coolant lines from each header. Make sure that you do not clamp too close to the header coolant tubes.

6. Disconnect the 4 lines from the DEF header. These lines include: coolant inlet, coolant outlet, DEF suction line, and DEF backflow line.

7. Disconnect electrical connector to the header.

8. Remove the 6 bolts securing the DEF header to the tank. Remove the header from the tank.
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   Illustration 2	g06181078

9. Remove the DEF sock filter and discard. Remove the clamp shown and slide off sock filter.
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   Illustration 3	g06181080

10. Remove suction filter from bottom of DEF header and discard. Push tabs away while pulling filter toward you.

11. Position the suitable container under the DEF tank drain.

12. Flush the DEF tank with a hose (clean water). If a hose not available, use 19 L (5 US gal) of distilled water. Drain the tank. Reinstall plug on bottom of tank to 11 ± 3 N·m (8 ± 2 lb ft).
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    NOTICE
    Do not dry the inside of the DEF tank with any type of cloth or paper towel. Fibers left in the tank will clog the DEF filters.

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    Illustration 4	g06181078

13. Install new suction filter first and then sock filter. Install band clamp between arrows as shown. This will allow the clamp to align with the flat spot so that the header will go into tank properly. Tighten clamp to 4.5 ± 0.7 N·m (40 ± 6 lb in). Make sure that a new gasket is installed for the header.

14. Reinstall the DEF header into the DEF tank using a new header gasket. Tighten bolts in star pattern to 5 ± 1 N·m (44 ± 9 lb in) twice.

15. Reconnect all lines to the DEF pump and to the manifold (DEF heater).

16. Fill the DEF tank completely with new DEF. The new DEF must meet ISO 22241 standards.

17. Start the engine.

18. Connect to Cat ^® Electronic Technician (ET).

19. Use Cat ET to perform the "Aftertreatment System Functional Test". This test will verify that the DEF system is working correctly following the flush and filter replacement.