C4.4 Engines for Caterpillar Built Machines Caterpillar

Required Tooling

Test Procedure

DEF Removal Procedure

Note: For Diesel Exhaust Fluid (DEF) handling and storage procedures, refer to Operation and Maintenance Manual, Fluid Recommendations for more information.

1. Clean the DEF tank of all debris prior to removal of any component. Contamination of the DEF can affect results of testing.
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   Illustration 1	g03706721
   Typical example (1) DEF tank fill cap (2) Filter screen

2. Remove fill cap (1) from the Diesel Exhaust Fluid (DEF) tank.

3. Use Tooling (J) to press and release the tabs. With the tabs released, remove the filter screen (2) from DEF tank neck adapter.
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   Illustration 2	g03706724
   Typical example (3) Vacuum pump nut (4) Tooling (D) ( 5) Tooling (H)

   Note: To ensure that the DEF sample is not contaminated during extraction, use a new piece of Tooling (H) every time this procedure is performed.

4. Remove Tooling (H) from the plastic bag and install into Tooling (D).

   1. Loosen nut (3) to install Tooling (H).

   2. Install Tooling (H) all the way through the cap of the vacuum pump as shown in Illustration 2.

   3. Tighten the nut on top of the vacuum pump down completely to prevent DEF leaks.

5. Remove Tooling (C) from the plastic bag. Remove the cap and install Tooling (C) onto Tooling (D).
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   Illustration 3	g03706727
   Typical example (5) Tooling (H) ( 6) DEF tank filler neck

   Note: The DEF sample must only be taken from the top level of fluid that is contained in the DEF tank. The top level of the DEF is where the contaminants will be located.

6. Place the other end of Tooling (H) into the filler neck of DEF tank (6).

7. Extract DEF from the top level of fluid in the tank using Tooling (D). Fill Tooling (C) to the "Fill Line" that is on the bottle.

8. Proceed to"Test Procedure For DEF Contamination" to begin contamination testing.

Test Procedure For DEF Contamination

1. Place Tooling (G) into Tooling (C) for 5 seconds.

   Note: The test strips should be able to detect for the presence of hydrocarbons.

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   Illustration 4	g03707382
   (7) Negative test result (8) Positive test result

2. Remove Tooling (G) and look for discoloring as shown in Illustration 4. Any discoloring of Tooling (G) indicates DEF contamination by an oil-based fluid. Contact the Dealer Solution Network (DSN) for further information.

   Note: If the test strips indicate no DEF contamination, proceed to step 3.

   Note: Clean water should be used to wash spilled DEF off machine components and surfaces.

   Note: Wear gloves when handling the DEF filter.

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   Illustration 5	g06278274
   (1) Protective cover

3. Remove protective cover (1).
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   Illustration 6	g06278289
   (2) DEF filter cap

4. Use a suitable tool to remove DEF filter cap (2).

   Remove protective cover (1).

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   Illustration 7	g06278325
   (3) Compensator

5. With the filter installed in the DEF pump, carefully remove compensator (3).
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   Illustration 8	g06278356
   (A) 38 mm (1.5 inch) (B) 97 mm (3.8 inch)

6. Check the measurements of compensator (3). Check if the measurements are greater than specified in Illustration 8. This condition indicates that the DEF pump is contaminated with hydrocarbons.

7. If the measurements indicate contamination, flush the DEF tank. Refer to Systems Operation, Testing and Adjusting, Diesel Exhaust Fluid Tank - Flush for the correct procedure.

8. If the measurements are within the specification, continue to follow the appropriate troubleshooting procedure to determine if the DEF pump has a fault.

   Note: If there is no DEF contamination, proceed to "Test Procedure For DEF Concentration".

Test Procedure For DEF Concentration

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Illustration 9	g03370564
A typical example of Tooling (A)

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Illustration 10	g03370553
Calibration point for distilled water

1. Follow the instructions included with Tooling (A) to calibrate the waterline of the meter.

2. Clean Tooling (A) and apply two drops of Diesel Exhaust Fluid (DEF) collected from the DEF tank.
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   Illustration 11	g03370573
   Typical reading for DEF in good condition

3. Inspect the DEF in Tooling (A). The DEF quality must measure between 29 and 35 percent. If the DEF does not meet specification, replace the DEF in the tank with new DEF. Refer to Operation and Maintenance Manual for more information. The new DEF must meet ISO 22241 standards.

   Note: Dispose of the DEF removed as per local regulations and mandates.