Procedure to Install and Operate Diesel Exhaust Fluid Transfer Pump on Certain Cat® Engines {108H, 108J, 108K} Caterpillar

Procedure to Install and Operate Diesel Exhaust Fluid Transfer Pump on Certain Cat® Engines {108H, 108J, 108K}

Usage:

Engine: 3512E (S/N: MR21-UP; SY21-UP; MD31-UP; MR31-UP; SY31-UP; MR41-UP; SY41-UP; SY51-UP; SY61-UP; MR71-UP; SY71-UP; MR81-UP; SY81-UP; SY91-UP); 3516C (S/N: TKG1-UP; TKJ1-UP; TKK1-UP); 3516E (S/N: SW21-UP; SW31-UP; SW41-UP; MD51-UP; SW51-UP; SW61-UP; MR91-UP; MRC1-UP; SWD1-UP; SWK1-UP; MRN1-UP; MRY1-UP); C175-16 (S/N: P6N1-UP; P6P1-UP); C280-08 (S/N: J4R1-UP); C280-16 (S/N: 3N31-UP; A4F1-UP; R4M1-UP; S4M1-UP)
Marine Engine: C280-12 (S/N: RA41-UP; RH71-UP); C32 MARINE (S/N: MX41-UP; PWT1-UP); C32 MARINE GS (S/N: MG41-UP)
Retrofit Aftertreatment: SCR (S/N: EF51-UP; EH61-UP; EH71-UP; EH81-UP; EH91-UP)

Introduction

This Special Instruction provides procedure to install and operate 447-7150 Diesel Exhaust Fluid Transfer Control pump used on certain Cat engines.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. The installer must be alert to potential hazards and have the necessary training, skills, and tools needed to perform these functions properly. Wear safety equipment, such as eye protection and foot protection, and other protection as is appropriate to the work site.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe. Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Personal injury or death can result from high voltage.
Moisture could create paths of electrical conductivity.

Make sure the unit is off line (disconnected from utility and/or other generators), locked out and tagged "Do Not Operate".

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

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When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.

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Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.

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Personal injury can result from improper handling of chemicals.
Make sure you use all the necessary protective equipment required to do the job.
Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used.

Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

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Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

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Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.

Diesel Exhaust Fluid (DEF) General Characteristics and Handling

This section describes the general characteristics, use, and specifications of Diesel Exhaust Fluid (DEF) used in Caterpillar engine emissions control systems. DEF is the intended fluid for which the DEF Transfer Pump is to be used.

DEF with a 32.5% urea solution has a freezing point of −11° C (12° F). The freezing temperature of DEF with a 40% urea solution is 0° C (32° F).

For more information, refer to Special Publication, SEBU6251, "Cat Commercial Diesel Engine system Fluids Recommendations".

Diesel Exhaust Fluid (DEF) Recommendations

For use in Cat engine systems, DEF concentration must be 32.5 percent or 40 percent, meeting all requirements defined by "ISO 22241-1" or "ISO 18611".

Caterpillar recommends the use of DEF available through the Cat parts ordering system for use in Cat engine systems equipped with a Select Catalytic Reduction (SCR) system. Refer to Table 1 for part number information:

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Table 1
Cat Part Number	Container Size
350-8733	2.5 gal bottle
350-8734	1000-L totes

In North America, commercial DEF that is API approved and meets all the requirements defined in "ISO 22241-1" or "ISO 18611" may be used in Cat engine systems that are equipped with SCR systems. Be sure to read the Owners manual for your specific equipment, not all Caterpillar SCR systems are compatible with 40% DEF.

Outside of North America, commercial DEF that meets all requirements defined in "ISO 22241-1" or "ISO 18611" may be used in Cat engine systems that are equipped with SCR systems. Be sure to read the Owners manual for your specific equipment, not all Caterpillar SCR systems are compatible with 40% DEF.

The supplier should provide documentation to prove that the DEF is compliant with the requirements of "ISO 22241-1" or "ISO 18611".

To obtain locations of DEF suppliers, call (888)-598-8186 or (309)-494-7532.

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NOTICE

Caterpillar does not warrant the quality or performance of non Cat fluids and greases.

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NOTICE

Do not use agriculture grade urea solutions. Do not use any fluids that do not meet "ISO 22241-1" or "ISO 18611" requirements in SCR emissions reduction systems. Use of these fluids can result in numerous problems including damage to SCR equipment and a reduction in NO_x conversion efficiency.

DEF is a solution of solid urea that is dissolved in demineralized water to produce a final concentration of 32.5 percent urea. DEF concentration of 32.5 percent or 40 percent is optimal for use in SCR systems.

Caterpillar offers two refractometers, Cat part number 360-0774 and 431-7087 that can be used to measure DEF in percent concentration. Follow the instructions provided with the instrument. Appropriate commercial portable refractometers can be used to determine urea concentration. Follow the instructions from the manufacturer.

DEF Guidelines

Quality of DEF can degrade when stored and handled inappropriately or if DEF is not protected from contamination. Details are provided below.

If quality issues are suspected or a DEF quality fault is active, testing of DEF should focus on urea concentration, alkalinity as NH₃ and biuret content. Do not use DEF that does not pass all these tests.

Note: Caterpillar recommends that customers purchase the pre-mixed DEF urea solution from a reputable supplier. The DEF must satisfy all the specifications of quality. Refer to Special Publication, SEBU6251, "Exhaust Aftertreatment Fluids Specifications". Urea solutions that are not made of urea and water of the appropriate quality and cleanliness may damage the SCR system. Poor or questionable quality DEF can lead to more repair and maintenance costs to the customer. Cat warranties do not cover failures caused by or related to use of out of specification urea solutions in products equipped with SCR systems.

Materials Compatibility

DEF is corrosive. Due to its corrosive nature, DEF must be stored in tanks constructed of approved materials. Recommended storage materials:

Stainless Steels:

304 (S30400)
304L (S30403)
316 (S31600)
316L (S31603)
409 (S40900)
439 (S43035)

Alloys and metals:

Chromium Nickel (CrNi)
Chromium Nickel Molybdenum (CrNiMo)
Titanium

Non-metallic materials:

Polyethylene
Polypropylene
Polyisobutylene
Teflon (PFA)
Polyfluoroethylene (PFE)
Polyvinylidene fluoride (PVDF)
Polytetrafluoroethylene (PTFE)

Materials NOT compatible with DEF solutions include Aluminum, Magnesium, Zinc, Nickel coatings, Silver, and Carbon steel and Solder containing any of the above. Unexpected reactions may occur if DEF solutions come in contact with any non-compatible material or unknown materials.

Bulk Storage

Follow all local regulations covering bulk storage tanks. Follow proper tank construction guidelines. Tank volume typically should be 110% of planned capacity. Appropriately vent indoor tanks. Plan for control of overflow of the tank. Heat tanks that dispense DEF in cold climates.

Bulk tank breathers should be fitted with filtration to keep airborne debris from entering the tank. Do not use desiccant breathers because water will be absorbed, which potentially can alter DEF concentration.

Handling

Follow all local regulations covering transport and handling. DEF transport temperature is recommended to be −5° C (23° F) for 32.5 percent. All transfer equipment and intermediate containers should be used exclusively for DEF. Do not reuse containers for any other fluids. Ensure that transfer equipment is made from DEF compatible materials. Recommended material for hoses and other non-metallic transfer equipment includes:

Nitrile Rubber (NBR)
Fluoroelastomer (FKM)
Ethylene Propylene Diene Monomer (EPDM)

The condition of hoses and other non-metallics that are used with DEF should be monitored for signs of degradation. DEF leaks are easily recognizable by white crystals that accumulate at the site of the leak. Solid urea can be corrosive to galvanized or unalloyed steel, aluminum, copper, and brass. Leaks should be repaired immediately to avoid damage to surrounding hardware.

Cleanliness

Note: Refer to SEBU6251 Cat Commercial Diesel Engine Fluids Recommendations "Contamination Control" Section for detailed DEF cleanliness recommendations.

Contaminants can degrade the life of DEF related components. Care must be taken when refilling or performing service on the DEF system to minimize the introduction of contaminants. Initial operation should include a thorough system flushing with clean distilled water.

Primary DEF filtration is required. Filters must be compatible with DEF and should be used exclusively with DEF. Check with the filter supplier to confirm compatibility with DEF before using any filter.

Care should be taken when dispensing DEF. Spills should be cleaned immediately. Machine or engine system surfaces should be wiped clean and rinsed with clean fresh water. Caution should be used when dispensing DEF near an engine system that has recently been running.

Note: Spilling DEF onto hot components may cause the release of ammonia vapors. Do not breathe ammonia vapors. Do not clean up any spills with bleach.

Stability

DEF fluid is stable when stored and handled properly. The quality of DEF rapidly degrades when stored at high temperatures. The ideal storage temperature for DEF is between −9° C (15.8° F) for 32.5 percent. DEF that is stored above 35° C (95° F) for longer than 1 month must be tested before use. Testing should evaluate Urea Percentage, Alkalinity as NH₃ and biuret content.

The length of storage of DEF is listed in the following table:

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Table 2
Storage Temperature	Expected DEF Life
Below 25° C (77° F)	18 months
25° C (77° F) to 30° C (86° F)	12 months
30° C (86° F) to 35° C (95° F)	6 months
Above 35° C (95° F)	test quality before use

Refer to "ISO 22241" or "ISO 18611" document series for more information about DEF quality control.

Note: Dispose of all fluids according to applicable regulations and mandates.

General Characteristics of DEF

For detailed information on the requirements and other characteristics of DEF, refer to Operation and Maintenance Manual, SEBU6251, "Cat Commercial Diesel Engine system Fluids Recommendations", "Exhaust Aftertreatment Fluids Specifications".

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Table 3
Characteristics for Urea Solutions
Property	Unit	DEF 32.5 percent	DEF 40 percent
Urea content		32.5 percent ⁽¹⁾	40 percent ⁽²⁾
Alkalinity as NH₃	Percent	0.2	0.2
Density at 20° C (68° F)	g/L	1.087 - 1.093 ⁽³⁾	1.108 - 1.114 ⁽⁴⁾
Refractive Index at 25° C (77° F)		1.381 - 1.384 ⁽⁵⁾	1.394-1.397 ⁽⁶⁾
Biuret	Percent	0.3 max
Aldehydes	mg/kg	5 max
Insoluble Matter	mg/kg	20 max
Aluminum	mg/kg	0.5 max
Calcium	mg/kg	0.5 max
Chromium	mg/kg	0.2 max
Copper	mg/kg	0.2 max
Iron	mg/kg	0.5 max
Magnesium	mg/kg	0.5 max
Nickel	mg/kg	0.2 max
Phosphate (PO₄)	mg/kg	0.5 max
Potassium	mg/kg	0.5 max
Sodium	mg/kg	0.5 max
Zinc	mg/kg	0.2 max

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⁽¹⁾	Acceptable range is 31.8 - 33.2 percent
⁽²⁾	Acceptable range is 39 - 41 percent
⁽³⁾	Target value is 1.090 g/L
⁽⁴⁾	Target value is 1.112
⁽⁵⁾	Target value is 1.382
⁽⁶⁾	Target value is 1.3956

General Hazard Information

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Illustration 1	g06261818

Attach a "Do Not Operate" warning tag to the start switch or controls before the engine system is serviced or repaired. These warning tags (Special Instruction, SEHS7332) are available from your Cat dealer. Attach the warning tags to the engine system and to each operator control station. When appropriate, disconnect the starting controls.

Cautiously remove the following parts. To help prevent spraying or splashing of pressurized fluids, hold a rag over the part that is being removed.

Filler caps
Pressure taps
Drain plugs

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Illustration 2	g00702020

Wear a hard hat, protective glasses, and other protective equipment, as required.
Wear protective devices for ears to help prevent damage to hearing.
Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine system.
Ensure that all protective guards and all covers are secured in place on the engine system.
Never put maintenance fluids into glass containers. Glass containers can break.
Use all cleaning solutions with care.
Report all necessary repairs.

Unless other instructions are provided, perform the maintenance under the following conditions:

When the DEF Transfer Pump is stopped. Ensure that the system cannot be started. Ensure that engine systems supplied with DEF from the DEF Transfer Pump cannot be started.
The protective locks or the controls are in the appropriate position.

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Personal injury or death can result from high voltage.
Moisture could create paths of electrical conductivity.

Make sure the unit is off line (disconnected from utility and/or other generators), locked out and tagged "Do Not Operate".

Ensure that the engine system being supplied DEF also has power disconnected.
When starting a new DEF Transfer Pump, make provisions to stop the Pump system if a malfunction occurs. Refer to the emergency stop procedure located within this manual.
Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment.

Pressurized Air and Water

Pressurized air and/or water can cause debris and/or hot water to be blown out which could result in personal injury.

The maximum air pressure for cleaning purposes must be reduced to 205 kPa (30 psi) when the air nozzle is deadheaded and used with effective chip guarding (if applicable) and personal protective equipment. The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).

When pressurized air and/or pressurized clean fresh water is used for cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective face shield. Always wear eye protection for cleaning the cooling system.

Avoid direct spraying of water on electrical connectors, connections, and components. When using air for cleaning, allow the machine to cool to reduce the possibility of fine debris igniting when redeposited on hot surfaces.

Containing Fluid Spillage

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Cat Dealer Service Tool Catalog" or refer to Special Publication, PECJ0003, "Cat Shop Supplies and Tools Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

Lines, Tubes, and Hoses

Do not bend or strike high-pressure lines. Do not install lines, tubes, or hoses that are damaged.

Repair any fuel lines, oil lines, tubes, or hoses that are loose or damaged. Leaks can cause fires.

Inspect all lines, tubes, and hoses carefully. Do not use bare hands to check for leaks. Always use a board or cardboard for checking engine components for leaks. Tighten all connections to the recommended torque.

Check for the following conditions:

End fittings that are damaged or leaking
Outer covering that is chafed or cut
Wire that is exposed in reinforced hose
Outer covering that is ballooning locally
Flexible part of the hose that is kinked or crushed
Armoring that is embedded in the outer covering

Ensure that all clamps, guards, and heat shields are installed correctly. Correct installation of these components will help to prevent these effects: vibration, rubbing against other parts and excessive heat during operation.

Reference: The applicable material safety data sheets can be found at the following web site by searching using part number or the name:

https://emsds.ecorp.cat.com/catmsdssearch.cfm
msdsSearch.controller.
UserIdentificationDisplayServlet

Dispose of Waste Properly

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Illustration 3	g00706404

Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of according to local regulations.

Always use leakproof containers when you drain fluids. Do not pour waste onto the ground, down a drain, or into any source of water.

Disconnect the DEF Transfer Pump from the power supply and secure it against being switched back on.
DEF Transfer Pump cooled down to the ambient temperature and disconnected from the pipe system.
DEF Transfer Pump drained completely.
DEF Transfer Pump at a location suitable for dismantling.
1. Dismantle the DEF Transfer Pump and it's individual parts.
2. Clean any remaining DEF residue or lubricating oil from the individual parts.
3. Remove lubrication oil from the pump. Be sure to follow applicable local and national laws regarding the disposal of used lubrication oil.
4. Ensure that any other material subject to specific disposal requirements are separated and properly disposed.
5. Recycle iron or steel parts.

Fire Prevention and Explosion Prevention

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Illustration 4	g00704000

Use of personal protection equipment (PPE) may be needed.

All fuels, most lubricants, and some coolant mixtures are flammable.

Always perform a Walk-Around Inspection, which may help you identify a fire hazard. Do not operate a product when a fire hazard exists. Contact your Cat dealer for service.

Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire. Fire may cause personal injury and property damage.

Do not expose the DEF Transfer Pump to any flames.

Do not weld on lines or tanks that contain flammable fluids. Do not perform flame cutting process of the lines or tanks that contain flammable fluid. Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or flame cutting.

Wiring must be kept in good condition. Properly route and attach all electrical wires. Check all electrical wires daily. Repair any wires that are loose or frayed before you operate the engine system. Clean all electrical connections and tighten all electrical connections.

Eliminate all wiring that is unattached or unnecessary. Do not use any wires or cables that are smaller than the recommended gauge. Do not bypass any fuses and/or circuit breakers.

Arcing or sparking could cause a fire. Secure connections, recommended wiring, and properly maintained battery cables will help to prevent arcing or sparking.

Fire Extinguisher

Make sure that a fire extinguisher is available. Be familiar with the operation of the fire extinguisher. Inspect the fire extinguisher and service the fire extinguisher regularly. Obey the recommendations on the instruction plate.

Technical Information

Before Operation

The following should be completed prior to start up if the DEF Transfer Pump has been out of service for extended periods of time or maintenance or repair has occurred.

Check Power Supply.
Check and clear debris from motor.
Check and clear debris from the inlet of the ventilation circuits.
Check Fluid Connections.
Check and clean the pipe system.
Inspect for Leaks - Clean and repair any leaks immediately.
Ensure adequate supply of DEF.
Ensure that all controls are in the proper position for the desired mode of operation.
Ensure that the equipment being supplied DEF is also ready for operation.

Cleaning the Pipe System

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NOTICE

Debris in the pipe system impairs the service life of the pump. If the pipe system is flushed using the pump during the initial commissioning, an extra commissioning filter has to be installed temporarily upstream of the pump on the system side.

If required, commissioning filter installed (mesh width 0.02 mm).

Clean the complete pipe system before commissioning to protect the pump.

Ensure that the pump is supplied clean DEF meeting "ISO 22241-1" or "ISO 18611". Flush the system thoroughly prior to final assembly with either DEF or clean fresh water. Do not flush debris back into the bulk tank. If the fluid must be returned to the bulk tank, utilization of a temporary filter is recommended.

Protecting the pump station against impermissible overpressure

Prior to commissioning, ensure that the supplied pressure relief valve is in place, adjusted correctly and system valves are open to allow return flow to the bulk tank. Customer supplied valves that block pressure relief flow are not recommended as they may interfere with the pressure relief function.

Note: Refer to: "Integrated Pressure Relief Valve - Pressure Adjustment Procedure"

Prior to commissioning, ensure that pressure relief valves are in place, set correctly if adjustable, and system valves are open to allow return flow to the bulk tank.

Note: Refer to "Integrated Pressure Relieve Valve - Pressure Adjustment Procedure"

DEF Transfer Pump Operation

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Illustration 5	g06262100
(1) Pump Pressure Relieve Valve 500 kPa (72.5 psi) (2) OEM Pressure Regulator Setting 34.5- 69 kPa (5- 10 psi) (3) OEM Pressure Relief Setting 69 kPa (10 psi)

Note: Pressure Regulator and Pressure Relief Valve (PRV) are customer supplied components.

Note: This system is intended to be used with both Caterpillar air assisted and airless dosing systems. The pressure input requirements and fill request signals are identical for both air assisted and airless systems.

Pressure regulators should be installed before each Dosing Cabinet to ensure that the pressure at each Dosing Cabinet is between 34.5 kPa (5 psi) and 69 kPa (10 psi).
Pressure relief valve on the DEF Transfer Pump should be set at its maximum value 500 kPa (72.5 psi). This will ensure that all available flow from the pump is directed to the Dosing Cabinets.
Pressure relief valves should be placed between each pressure regulator and corresponding Dosing Cabinet. These pressure relief valves should be set to 69 kPa (10 psi). They will help purge any trapped pressure in the line between the pressure regulators and Dosing Cabinets back to the bulk tank.

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Illustration 6	g06262102
(1) Pump Pressure Relieve Valve 500 kPa (72.5 psi) (2) OEM Pressure Regulator Setting 34.5- 69 kPa (5- 10 psi) (3) OEM Pressure Relief Setting 69 kPa (10 psi)

Dosing Cabinet Sends Fill Command to DEF Transfer Pump:

DEF Transfer Pump turns on and Dosing Cabinet solenoid refill valve opens.
DEF Transfer Pump supplies 500 kPa (72.5 psi) of DEF, which is reduced by a pressure regulator at each Dosing Cabinet to 34.5 kPa (5 psi) - 69 kPa (10 psi).

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Illustration 7	g06262103
(1) Pump Pressure Relieve Valve 500 kPa (72.5 psi) (2) OEM Pressure Regulator Setting 34.5-69 kPa (5-10 psi) (3) OEM Pressure Relief Setting 69 kPa (10 psi)

Dosing Cabinet Tank Level Reaches"Full":

Dosing Cabinet solenoid refill valve closes.
DEF Transfer Pump continues running until the transfer time relay (configurable) expires.
DEF pressure dead-heads against the pressure regulators at each dosing cabinet.
Any pressure generated in the line above 500 kPa (72.5 psi) will be relieved through the DEF Transfer Pump pressure relief valve back to the bulk tank.

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Illustration 8	g06262105
(1) Pump Pressure Relieve Valve 500 kPa (72.5 psi) (2) OEM Pressure Regulator Setting 34.5-69 kPa (5-10 psi) (3) OEM Pressure Relief Setting 69 kPa (10 psi)

DEF Transfer Pump Time Relay Expires:

The DEF Transfer Pump is equipped with an automatic time delay which will allow fluid to continue to flow via the pressure relief system to the bulk tank after the dosing cabinet request to fill has terminated. This is in place to prevent unnecessary wear on the DEF Transfer Pump due to excessive starts and stops.

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Illustration 9	g06273856
(1) Dial for selecting operating time (2) Display window for selected time setting range (3) Device designation label (4) Dial for selecting time setting range (5) LED to indicate relay switched (6) LED to indicate time relay energized

Ensure that system is de-energized. Changes to the timer setting will only be effective when timer is de-energized.
Ensure that the time setting range is set to "100 minutes". The setting range will be visible in the window.
Select the shut off delay time by adjusting the "Operating Time Dial". The factory default setting is 15 seconds. For systems with multiple SCR dosing cabinets, it is recommended to adjust this setting to minimize cycling of the DEF transfer pump as various need to fill signals are received.
Re-energize the system.
To confirm the setting, ensure the pump is in automatic mode, then trigger a fill signal from a dosing cabinet. Once a fill signal is received, monitor the time before the DEF Transfer Pump automatically shuts down. The time measured should match the relay setting. The pump status can be monitored by observing the LED indicators.

Cleaning the Pump System

Note: Debris in the pipe system impairs the service life of the pump. If the pipe system is flushing using the pump during the initial commissioning, an extra commissioning filter has to be installed temporarily upstream of the pump on the system side. For further detail on DEF cleanliness, Refer to "Diesel Exhaust Fluid (DEF) Recommendations"

Requirement:

If required, commissioning filter installed (mesh width 0.02 mm).

Clean the complete pipe system before commissioning to protect the pump.

Ensure that the pump is supplied clean DEF meeting "ISO 22241-1" or "ISO 18611". Flush the system thoroughly prior to final assembly with either DEF or clean fresh water. Do not flush debris into the bulk tank. If the fluid must be returned to the bulk tank, utilization of a temporary filter is recommended.

Filling and Venting the DEF Transfer Pump

It is recommended that suction lines and pumps be filled with pumped liquid before commissioning.

Note: Be prepared with a fluid collection container suitable for use with DEF.

Connect the DEF Transfer Pump to a fluid source with not more 5ft (1.5m) suction lift required.

Note: It is recommended to prime the DEF Transfer Pump, but not required if the lift is below the 5 ft. (1.5m) limit.

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Illustration 10	g06272971
(1) Vent Screw and O-rings

Remove and store vent screws and O-rings (1).

Vent the pump station at the highest points.

Let the pumped liquid flow in the pump station until it exits at the venting points on the pump head.

During the filling process, turn the system on and off for just a few seconds until fluid is coming from the venting ports is air-free.

To vent close the opened valves and install vent screws and O-rings (1).

Manually Priming the Pump

When the system has airlock and pump fails to prime.
1. Turn off power.
2. Remove pressure gauge or plug from tee fitting at pump outlet (Refer to illustration drawing at the front of this section).
  Note: Fluid may come out of this port when the plug is removed. Provide an adequate catch basin for fluid spillage, if required. Fluid will come out of this port when the pump is started. It is recommended that you attach adequate plumbing from this port so fluid will not be sprayed or lost. Use high-pressure-rated hose and fittings from this port. Take all safety precautions to assure safe handling of the fluid being pumped.
3. Turn the system on briefly for 10 - 15 seconds until fluid coming from this port is air-free.
4. Turn off power.
5. Remove plumbing that was temporarily installed, and reinstall pressure or plug.

Operation

The DEF Transfer Pump is designed to work in conjunction with both Caterpillar Air Assisted and Airless DEF dosing systems. Its primary function is to draw DEF from the main bulk tank and supply it to one or several SCR Caterpillar dosing control systems. The DEF Transfer Pump has two modes, manual and automatic. Manual mode is only used for testing and troubleshooting. When in automatic mode, the DEF Transfer Pump receives a fill command from the engine system dosing control requesting DEF be supplied. When the DEF Transfer Pump receives a fill signal, it triggers the pump to run until the fill signal terminates. The pump will then continue to run for a brief period before shutting off and waiting for the next fill signal. Also included with the DEF Transfer Pump is a primary DEF strainer and a secondary bypass screen that may be used to continue operation while servicing the primary.

Proper Use

The DEF Transfer Pump is designed solely for transporting DEF (Diesel Exhaust Fluid).
The DEF Transfer Pump may only be used within the operating limits specified on the rating plate and in the published technical data. In the case of operating data that does not agree with the specifications on the rating plate, contact your Cat dealer for assistance.
The DEF Transfer Pump may only be mounted and operated in accordance with the specifications in these mounting and operating instructions and the associated documents.

Misuse

The product is not suitable for pumping liquids outside the operating limits.
Any bypassing or deactivation of safety equipment during operation is prohibited.

General Information

Model View Illustrations

Function Description

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Illustration 11	g06260100
Structure not shown in the graphic (1) Shut-Off Valve Outlet (2) Suction-Side Pressure Gauge (3) DEF Outlet to Dosing Cabinet(s) (4) Switch and Control Cabinet (5) Feet (6) Shut-Off Valve (7) Primary DEF Strainer (8) Shut-Off Valve (9) Motor (10) Drip Pan Drain (11) DEF Inlet (12) Pump (13) Return to DEF Bulk Tank (14) Adjustable Pressure Relief Valve (15) Secondary Strainer (16) Pressure Switch (17) Pressure-Side Pressure Gauge (18) Non-Return Valve Outlet

Functional Principle

The DEF Transfer Pump consists of two filter lines that are fitted with a secondary strainer (15) or primary DEF strainer (7) that protect the pump (12) against damage from fluid born debris. The DEF is always only pumped through one line, while the second one is in stand-by mode. Each line can be individually opened and closed with a shut-off valve (8) upstream or shut-off valve (6) downstream of the secondary strainer or filter.

The adjustable pressure relief valve (14) or the non-return valve outlet (18*) prevents the undesired return flow of the DEF into the pump.

The operating pressure can be monitored with the installed suction-side and pressure-side pressure gauge (17) and the suction-side pressure gauge (2). The pressure switch (16) allows reaction to unwanted values. The overflow valve installed on the pressure side keeps the operating pressure to a constant 5 bar (72.52 psi). When there is excess pressure, the overflow valve opens and returns the DEF back to the tank via the return to DEF bulk tank (13).

The pump station has a switch and control cabinet (4). All the drives and electrical measuring instruments are already wired and connected.

Two DEF Transfer Pumps can be stacked and bolted to each other above the feet (5).

The drip pan collects leaks from the DEF Transfer Pump. The drip pan can be emptied through the drain (10).

On-Board Replacement Parts

Caterpillarrecommends that a supply of DEF Transfer Pump replacement parts be stored on board. This is to allow repair offshore or at remote ports.

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Table 4
Quantity	Item
2 pc	Primary Strainer
1 pc	Secondary Strainer
6 pc	ANSI Flange Gaskets
1 pc	Pump
1 pc	Motor
1 pc	Ball Valve
1 pc	Vacuum Switch
2 L (2 qt)	Lubricating Oil

Specifications

Operating Data

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Table 5
Parameter	Operating Data Value (English Standard)	Operating Data Value (Metric)
Max. operating pressure	72.5 psi	499.8 kPa
Total pressure	72.5 psi	499.8 kPa
Max Ambient	131° F	55.0° C
Viscosity	0.002 in²/sec	1.4 cSt
Density	8.3 lb/gal	.45 kg/L
Delivery rate	1.56 gpm	5.9 L/min
Dry Suction Self Priming Lift Capacity	4.92 ft	1.5 m
Net Positive Suction Head	13 ft	3.96 m
Primary Mesh Filter*	0.0039 in	0.10 mm
Secondary Mesh Filter*	0.0098 in	0.25 mm
Pump Oil Capacity	1.0 Quart	.95 L
Operating Temperature Range	23° F to 131° F	−5° C to 55° C
Lubricating Oil Capacity	2 Quarts	2 Litres
Lubricating Oil Type	Polyalkaline Glycol Hydraulic Oil Compatible with EPDM⁽¹⁾	-

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⁽¹⁾	See Maintenance section for specific example oil.

Note: *Integrated Strainers are intended to protect the DEF Transfer Pump. They do not replace the need to have a DEF filter in place to protect the Dosing cabinet.

Dimensions

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Table 6
Parameter	Unit	Value
Dimensions (Length x Width x Height)	[in]	44.8 x 27.6 x 24.1
Dimensions (Length x Width x Height)	[mm]	1138 x 701 x 612

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Table 7
Function	Flange
Feed line	ANSI 1/2" 150 lbs
Outlet	ANSI 1/2" 150 lbs
Return line	ANSI 1/2" 150 lbs

Weight

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Table 8
Parameter	Unit	Value
Weight	[lbs]	264
Weight	[kg]	120

Sound Pressure Level

The DEF Transfer Pump is a mechanical device and does produce mechanical sound while operating. The following data is provided as general guidance for consideration during the installation design process. It is not a guarantee.

Guide values at 3'4" distance, 1450 rpm, 1999.48 kPa (290 psi), 21 cSt.

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Table 9
Parameter	Unit	Value
Sound pressure level	[db(A)]	< 75

Motor Data

Motor Speed

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Table 10
Hertz	RPM	Motor Voltage (3 Phase)	Starting Motor Current (Amps)	Rated Motor Current (Amps)	Rated Motor Power (KW)
50	934	400	4.5	1.93	0.75
60	1121	480	4.5	1.74	0.75

Dimensional Drawing

Note: Contact your Caterpillar Dealer for further installation drawing detail. Electronic 2D and 3D drawing versions can be found in the Engine Drawing Design Center (EDDC) and Technical Marketing Information (TMI).

Note: Refer to 547-7734 installation drawing.

Product Identification Information

The DEF Transfer Pump was sold by Caterpillar as optional equipment for either a complete engine system or an aftertreatment SCR system. For questions regarding supporting service literature or applicable warranty, consult with your Caterpillar dealer. If known, the serial number of the engine system or aftertreatment system associated with the sale of your transfer pump should be retained for future reference.

Rating Plate

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Illustration 12	g06259715
Rating plate (1) Part No. (2) Serial Number (3) Date

Operating Section

Product Lifting

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NOTICE

Requirement: Mounting site prepared Crane operator and fitter (2 persons) DEF Transfer Pump free of packaging material

Lifting the DEF Transfer Pump

Note: Rough handling, shock loads, and improper lifting procedures can damage internal components or frame and mounting structure. To lift the DEF Transfer Pump, use the lifting eyes that are on each corner of the frame. Chains of equal length and/ or a spreader bar should be used. Damage to the unit may occur if not properly lifted. Ensure that each lifting eye is secured prior to attempting to lift the unit.

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Illustration 13	g06259721
(1) Lifting eyes

The DEF Transfer Pump is only be lifted by the designated lifting eyes (1).

Do not attempt to lift the DEF Transfer Pump using straps around the frame. Do not move the DEF Transfer Pump with a fork lift after the unit has been removed from the original shipping pallet.

Note: It is permissible to stack and mount two DEF Transfer Pumps once installed in their permanent location, only lift one unit at a time.

Product Storage

Transporting the DEF Transfer Pump

The DEF Transfer Pump is packed with anti-corrosion paper and water tight film. It is supplied in a wooden crate. To maintain the corrosion protection, the corrosion protection materials need to remain intact until just before installation of the DEF Transfer Pump.

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Illustration 14	g06262098

The DEF Transfer Pump is shipped in protective packaging from the factory, it is recommended that the unit remain in it's shipping packaging until ready to be installed. Dispose of packaging material in accordance with the local applicable regulations.

Consult the Lifting section of this manual for details on proper lifting of the DEF Transfer Pump.

Storing the DEF Transfer Pump

If the DEF Transfer Pump was used, the system must be decommissioned before storing (See Decommissioning instructions within this manual).
Note: Cleanliness is critical to the function of DEF systems, taking care to ensure that fluid openings are sealed to prevent contamination. Failure to maintain cleanliness may result in poor system performance or component damage.
Place anti-corrosion paper inside of the wooden crate.
Place DEF Transfer Pump into wooden crate.
Place extra film inside the wooden crate.
Ensure that the anti-corrosion paper and film are not damaged.
Store DEF Transfer Pump in a cool dry place and protect against prolonged exposure to sunlight and sea spray.

Storage Conditions

The following conditions must be fulfilled for the storage of the pump station:

Roofed, closed, dry, and dust-free room.

Atmosphere free of corrosive contaminants (salt air).

No prolonged direct exposure to sunlight.

No mechanical impacts.

No magnetic fields.

Aftertreatment System and DEF Transfer Pump Storage Once Installed

Note: For more information on product storage see Special Instruction, SEHS9031.

Normal periods of inactivity will not require special attention to the SCR system. The SCR is designed to begin and end operation with the output of the power system the SCR is assembled to. Extended periods of inactivity or product storage will require preventative maintenance preparations up to, and including:

Purging the emission reduction system.
Shutting off the system prior to storage.
Purging the DEF Transfer Pump.
Flushing the system with clean fresh water to reduce the likelihood of DEF crystals from forming during storage.
Cover or plug all inlet and outlet fittings.
Cover any exposed electrical connection fittings.
Replace the DEF Transfer Pump lubrication oil prior extended storage.

Diesel Exhaust Fluid (DEF) Circulation System

Disconnect electrical service to the DEF supply circulation system if applicable.
Close all ball or gate valves within the circulation loop.
Shut off all ball valves to the closing cabinets.
Close off ball or gates valves coming from the DEF(Urea) holding tank.

Dosing Cabinets

The dosing cabinet will purge out any remaining liquids in the DEF lines.
Review guidelines regarding the long-term storage of DEF.

Product Installation

DEF Transfer Pump Installation

Note: Typical System

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Illustration 15	g06266508
(1) SCR Reactor Housing (Standard scope of supply) (2) DEF Storage Tank (Yard supply) (3) DEF Transfer Pump (Optional) (4) Pressure Regulator and Relief Valve (Customer supplied) (5) Dosing Cabinet (Standard scope of supply) (6) Engine (7) Connecting Pipe (Yard supply) (8) Mixing Tube (Standard scope of supply)

Protecting the DEF Transfer Pump against Impermissible Fluid Overpressure

In the case of DEF Transfer Pumps that do not have a safety valve installed by the manufacturer, the operator-owner is responsible for installing a safety valve in accordance with "EN ISO 4126-1" on the system side to protect against impermissible excess pressure.

Prior to commissioning, ensure that pressure relief valves are in place, set correctly if adjustable, and system valves are open to allow return flow to the bulk tank.

Note: Refer to "Integrated Pressure Relieve Valve - Pressure Adjustment Procedure"

Removing the DEF Transfer Pump

DEF Transfer Pump and pumped liquid cooled down to ambient temperature.

Ensure that the DEF Transfer Pump is de-energized and secured against being switched back on.
Ensure that the DEF Transfer Pump is depressurized.
Disconnect the DEF Transfer Pump from the pipe system and drain. Collect any liquids that are emitted.
Dismantle the DEF Transfer Pump on site or transport to a suitable site. Observe the information on transportation when doing so.

Connection

Decommissioning:

Follow appropriate site lock out safety procedures.
De-energize and disconnect electrical connections.
Ensure that the fluid system has been brought to a de-energized state by relieving all lines of system pressure.
Close all fluid connection valves. Ensure that materials are available to seal any open fluid connections to prevent system contamination.
Be sure that the unit and fluids are cooled down to safe temperatures.
Disconnect piping connections. Be prepared for excess DEF spillage.
Clear passages of excess DEF by flushing with warm water and then blowing dry with compressed air.
Remove pump manifold plugs during the process of blowing out fluid with compressed air.
Seal all fluid connections.
It's recommended to change the oil in the pump hydraulic end before storage for an extended period. This will remove any accumulated condensation and sediment from the oil reservoir. Drain and refill the hydraulic end with the appropriate lubricating oil.

Note: See Maintenance section for details on proper oil.

Disassemble mounting hardware - ensure that the pump is secure and cannot shift or fall as mounting is disassembled.
Follow lifting recommendations in this document.
Follow storage guidance provided in this document.

Connecting the DEF Transfer Pump to the Pipe System

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Illustration 16	g06272572
Connecting the pipe system.

Attach protective covers in front of the connecting flanges before welding work.
Avoid mechanical tensions in the pipe system when carrying out connecting.
Place the piping in position and support the weight of the piping. Do not use the DEF Transfer Pump as a support for connected piping.
Install compensating elements if temperature-related material expansion is possible.
Ensure that the linear and angular position of piping allows for the flanged joints to be connected with out residual assembly stress.
Note: If the screws tighten easily, this is a sure sign that the installation is stress-free.
Tighten the connecting screws crosswise with torque.
Lay the suction line hermetically sealed with a slight ascending slope.

Connecting the DEF Transfer Pump to the Power Supply

Connect the electrical components of the pump station in accordance with the corresponding operating instructions.

Note: For customer electrical connection details, refer to Diagram UENR8335.

Grounding the DEF Transfer Pump

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Illustration 17	g06262303
(1) Grounding location (M12 x 50)

Ground the DEF Transfer Pump carefully via the connection (M12 x 50) (1) at the base frame.
When connecting the DEF Transfer Pump to the complete system, continue electrical grounding of equipment.
Note: Ensure that the DEF Transfer Pump is grounded in alignment with applicable grounding requirements for your installation.

Machine Operation

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Illustration 18	g06287677
(A) Electrical junction box (B) DEF Inlet from bulk DEF tank (C) DEF Return to bulk DEF tank (D) Pressurized DEF flow to primary DEF strainer

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Illustration 19	g06294404
DETAIL A (1) Control module (2) X200 terminal strip for customer power (3) X6 terminal strip for customer power (4) X2 terminal strip for customer power (5) X1 terminal strip for customer power (6) 6K1 pump motor contactor (7) Circuit breaker (8) Circuit breaker (9) Adjuster shut off delay timer (10) 7K1 & 2 pulse input and liquid level

Commissioning

Commissioning the DEF Transfer Pump

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Illustration 20	g06272497
(1) Pump Pressure Relieve Valve 500 kPa (72.5 psi) (2) OEM Pressure Regulator Setting 34.5-69 kPa (5-10 psi) (3) OEM Pressure Relief Setting 69 kPa (10 psi)

Ensure that a customer supplied pressure relief valve is installed which limits inlet pressure to the dosing cabinet. The valve must be capable of relieving full pump flow. Be sure to check the relevant Application and Installation Guide for the correct dosing cabinet inlet pressure range.

All connecting fluid lines must be thoroughly flushed with clean fresh water or DEF prior to final connections and start-up.

It can be helpful to prime the system. Clean fresh water may be used as a DEF substitute for initial priming and set up of the DEF Transfer Pump. Clean fresh water should not be used as a substitute for DEF during SCR operation.

Ensure that all piping is complete and secure.

Ensure all materials being used are compatible with DEF.

DEF Transfer Pump strainer should be configured to allow flow through only the primary strainer.

Check supply power. Refer to table 10 for voltage requirements.

Check customer supplied circuit breaker current capability is aligned with the current draw of the DEF Transfer Pump Skid. Refer to Table 10.

Ensure that power is on by performing a lamp test on the DEF Transfer Pump control panel.

Review the integrated pressure relief spill valve.

Initiate DEF Transfer Pump operation by turning the operation switch to position 2 (Local Control).

Green light on control panel will indicate DEF Transfer Pump operation.

Check outlet pressure using outlet pressure gauge. Follow integrated pressure relief spill valve procedure to set pressure to 70 psig.

Checking the Operating Pressure

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Illustration 21	g06261210
Pressure gauge shut-off valves closed/open - principle diagram.

Open the pressure gauge shut-off valve.
Read the operating pressure and close the pressure gauge shut-off valve.

Monitoring Filters and/or Strainers

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NOTICE

Filters and strainers installed on system side protect the DEF Transfer Pump against soiling. The degree of contamination of the filter and the strainer can be monitored by a suction-side pressure gauge or a differential pressure indicator.

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Illustration 22	g06264026
Primary Strainer and Secondary Strainers are open. (1) Primary Strainer (Inlet/Outlet Valve) (2) Secondary Strainer (Inlet/Outlet Valve)

During normal sustained operation the valves must be configured to allow flow only through the primary strainer flow circuit. The secondary strainer screen is only intended to be used during the servicing of the primary strainer.

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Illustration 23	g06262307
(1) Primary Strainer Valve (Inlet/Outlet Valve)

When the primary strainer (1) is in open position, the fluid passes only through the primary strainer.

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Illustration 24	g06262306
(2) Secondary Strainer (Inlet/Outlet Valve)

When the secondary strainer (2) are in open position, the fluid passes only through the secondary strainer unit of the DEF Transfer Pump.

After commissioning, monitor the degree of soiling of the filter and/or strainer by a suction-side pressure gauge or a differential pressure indicator.
Keep a record of the pressure drop across the strainers upon initial start up. This data can then be used to help establish a strainer change interval specific to your application. Plan to change the strainer more frequently after start up due to construction debris not removed during flushing.
Note: Refer to the Maintenance Section of this manual for the Filter and Strainer removal and installation procedures.
Check the suction-side pressure every shift during ongoing operation.

Switching Off the DEF Transfer Pump

Switch off the motors.
Close the pressure-side and suction-side shut-off devices.

Shut Down Procedure During Freezing Temperatures

Follow appropriate site lock out Safety Procedures.

Turn DEF Transfer Pump Control to "Off".
De-energize electrical connections via any customer supplied circuit breakers.
Ensure that the fluid system has been brought to a de-energized state by relieving all lines of system pressure.
Close all fluid connection valves. Ensure that materials are available to seal any open fluid connections to prevent system contaminations.
Disconnect piping connections. Be prepared for excess DEF spillage.
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Illustration 25 g06272971

(1) Vent Screw and O-rings

Note: Remove vent screw and O-rings (1) during the process of blowing out fluid with compressed air.
Clear passages of excess DEF by flushing with warm clean fresh water and then blowing dry with compressed air.
Seal all fluid connections. This may be accomplished by reconnecting the DEF Transfer Pump to the DEF circulations system. Ensure that fluid is not allowed to reenter the DEF Transfer Pump.
Note: Change the oil in the Pump Hydraulic End before storage for and extended period. This will remove any accumulated condensation and sediment from the oil reservoir. Drain and refill the Hydraulic End with appropriate lubricating oil.
Note: See Maintenance section for details on proper oil.

Functions of DEF Transfer Pump Control Panel

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Illustration 26	g06262434
DEF Transfer Pump control panel emergency stopping - principle diagram.

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Table 11
Signal Lamp
6H1*	Feed pump running
6H2*	Malfunction feed pump
6H3*	Malfunction high suction pressure (vacuum)
6H4*	Malfunction low liquid level in bulk tank
Switch
5S1*	Select switch:	1 = Automatic control 2 = Off 3 = Manual control
Push button
5S2*	Reset malfunction
5S3*	Lamp test

Note: * Refer to Wiring Diagram, UENR8335.

Control Procedures

Pump operation mode is controlled via selector switch 5S1.

Switch setting: "Automatic control"

An external impulse signal starts the DEF Transfer Pump for a preset period (defined by time delay relay installed inside control panel). After the preset time period expires the DEF Transfer Pump is shut-off. If during the operation another impulse signal occurs the time delay relay will be reset and run-time of the DEF Transfer Pump starts from beginning (run-time extension).

Switch setting: "Manual control"

The DEF Transfer Pump is started. Alarm conditions such as high suction pressure (vacuum) and low liquid level in bulk tank are ignored (manual override). Alarm monitoring is not active while in "Manual Control" mode.

Switch setting: "Off"

DEF Transfer Pump is switched off.

Alarm Conditions

During operation of the DEF Transfer Pump the following alarms can occur.

Pump malfunction

- Alarm indication of pump malfunction (motor protection triggered).

Suction pressure alarm

- Too high vacuum pressure on suction side (input signal = "1"equals alarm situation).

- During automatic control pump will be shut off.

Low tank level alarm

- Tank level is too low.

- During automatic control pump will be shut off.

The above mentioned alarm conditions will be directly displayed via indicator lights on the outside front of the control panel. A potential-free "summary alarm"signal for any alarm condition is provided on the terminal block (high-signal = alarm). The indicator lights are active during automatic control.

Alarms are acknowledged and cleared via the alarm reset push button.

Operating Condition Indication

A green light indicates pump running.

Operating Instructions

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Illustration 27	g06261525
Spill valve, adjustment of the blow-off pressure. (1) Decrease blow-off pressure (2) Increase blow-off pressure

The adjustment of the blow-off pressure takes place by turning the adjustment screw. Before turning the adjustment screw the counter nut must be detached.

Ensure that the return to bulk tank isolation valve is open.
Close the outlet, this will force all pump flow through the integrated pressure relief valve.
The desired pressure setting is 500 kPa (72.5 psi).

Increase of the blow-off pressure:

Turn the adjustment screw clockwise until the desired blow-off pressure is reached.

Decrease of the blow-off pressure

Turn the adjustment screw counterclockwise until the desired blow-off pressure is reached.

After the adjustments of the integrated pressure relief valve, retighten the jam nut again. It is recommended to periodically recheck this pressure setting.

Note: If a lower pressure setting is desired, this is acceptable, however it is recommended that the setting not be below half the nominal maximum setting. Therefore the effective pressure setting range is: 248 kPa (35.97 psi) to 496 kPa (71.94 psi).

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Illustration 28	g06278625
(1) Outlet Isolation Valve (A) Pump

Re-open DEF Transfer Pump Outlet Isolation Valve (1).

Maintenance

Prior to performing any maintenance, ensure that you have read and understand all Safety Warnings.

Ball Valves

Before beginning maintenance, ensure that all ball valves move freely and seal appropriately. Adjust or replace as needed.

Maintenance Section

Maintenance Interval Schedule

Daily

Check the oil level and the condition of the oil. The oil level should be 3/4 in. (20 mm) from the top of the fill port.

Contact your local Cat dealer for replacement lubricating oil, or use a Polyalkaline Glycol hydraulic oil that has been proven to be compatible with EPDM ("Example: Mobil Glygol 68").

Oil capacity is 2 quart (2 Liter).

Periodically

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Illustration 29	g06279467
DETAIL - A (2) Drain plug

Change the oil after the first 100 hours of operation, then change according to the guidelines below. When changing, remove the drain plug (2). Allow all oil and contaminant to drain out.

Hours Between Oil Changes @ Various Process Fluid Temperatures

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Table 12
		<90°F	<139°F	<180°F
Pressure	RPM	(32°C)	(60°C)	(82°C)
Metallic Pump Head
<800 psi (55 bar)	<1200	8,000	5,000	3,000

Note: Minimum oil viscosity for proper hydraulic end lubrication is 16-20 cSt (80-100 SSU).

General Maintenance Information

Required Maintenance

The service life depends on the observance of the operating conditions of the pump station and the requirements from the operating instructions of the components.

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Table 13
Component	Required Maintenance	Cycle
DEF Transfer Pump	Visual inspection Acoustic inspection	Daily
Filter/Strainer	Visual inspection If required, clean or replace	Daily Monitor pressure

Maintaining the Pump Station

Servicing

Servicing the Pump - Fluid End Service

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Illustration 30	g06263531
Hydraulic end service for pump housing details (A) Piston Assembly (1) Screw (2) O-ring (3) Diaphragm (4) Socket-Head Capscrews (5) Head Gasket (6) Washer (7) Bolt (8) Valve Assembly (9) Dampening Washer (10) Valve Seat (11) O-ring (12) Tetra Seal (13) Valve Poppet (14) Valve Spring (15) Spring Retainer

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Table 14
Bolt Torque Specifications
Ref. No.	Assembly Torque
4	Hand tight
7	15 ft-lbs/20 Nm

This section explains how to disassemble and inspect all easily serviceable parts of the pump.

Removal and Inspection of Manifold and Valve Plate

Remove all eight bolts (7) and washers (6) around the manifold.
Remove the manifold.
Inspect the manifold for warping or wear around the inlet and outlet ports. If wear is excessive, replace the manifold.
1. To check if the manifold is warped, remove the head gasket (5) and place a straightedge across. A warped manifold should be replaced.
Remove the two socket-head capscrews (4).
Inspect the valve plate in the same manner as the manifold.

Removal and Inspection of Valves

The three inlet and three outlet valve assemblies are identical (but face in opposite directions). Inspect each valve as follows:

Remove valve assembly (8) from valve plate.
Inspect the spring retainer (15), and replace if worn.
Inspect the valve spring (14). If the valve spring is shorter than a new spring, replace (do not stretch the old spring).
Inspect the valve poppet (13). If worn excessively, replace.
Remove the valve seat (12). A seat puller is included in the Wanner Tool Kit. Inspect the valve seat for wear, and replace if necessary. Install a new O-ring (11).
Inspect the dampening washer (9), replace if worn.

Installation of Valves

Clean the valve ports and shoulders with emery cloth, and lubricates with lubricating gel or petroleum.
Install the O-ring (11) on the valve seat (10).
Inlet (3 lower valves in the illustration below).Insert the spring retainer (15) into the valve plate, then insert the spring, valve, tetra seal, valve seat with O-ring, and dampening washer (14) ( 13) ( 12) ( 10) ( 9). A flat O-ring [tetra seal] (11) goes between the plastic spring retainer and seat.
Outlet (3 upper valves in the illustration). Install procedure as inlet valves.

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Illustration 31	g06261855
Installing inlet and outlet valves

Removal and Inspection of Diaphragms

Lift a diaphragm (3) by one edge, and turn the pump shaft until the diaphragm moves up to"top dead center."This will expose machined cross holes in the plunger shaft behind the diaphragm.
Note: If the pump has a hollow shaft, use the shaft rotator from the Wanner Tool Kit to turn the shaft.
Remove the three flat-head screws (1) and O-rings (2) from the edge access holes in the diaphragm plate. Insert a 3/32” hex wrench (A03-163-2200) into one of the holes in the diaphragm plate. Turn and pull the diaphragm (3) until the front cross hole in the valve plunger spool lines up and allows the hex wrench to pass through. (Do not remove the hex wrench until the new diaphragm is installed.
Unscrew the diaphragm. Use a 5/16 in. (8 mm) open-end wrench, and turn counterclockwise.
Inspect the diaphragm (3) carefully. A ruptured diaphragm generally indicates a pumping system problem, and replacing only the diaphragm will not solve the larger problem. Inspect the diaphragm for the following:
- Small puncture.Caused by a sharp foreign object in the fluid, or by an ice particle.
- Diaphragm pulled awayfrom the sides. Caused by fluid being frozen in the pump, or by over pressurization of the pump.
- Diaphragm becoming stiffand losing flexibility. Caused by pumping a fluid that is incompatible with the diaphragm material.
- Diaphragm edge chewed awayUsually caused by over pressurizing the system.

Installation of Diaphragms

Clean away any spilled oil. Apply Loctite No. 242 Threadlocker to the screw of the new diaphragm (or the old one, as appropriate).
Install the diaphragm (3) and tighten to 10 in-lbs (110 N-cm).
Repeat the above inspection procedure (and replacement, if necessary) with the other two diaphragms.
Remove hex wrench (A03-163-2200).

Flush Contaminant from Hydraulic End

(Only if a diaphragm has ruptured)

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Illustration 32	g06280057
(16) Drain plug

With the valve plate and manifold still removed (see above), remove the oil drain plug (16) and allow all oil and contaminant to drain out.
Fill the reservoir with fresh oil, manually turn the pump shaft to circulate the oil, and drain once again.
Refill the reservoir. If the oil appears milky, there is still contaminant in the reservoir. Repeat the flushing procedure until the oil appears clean.

Reinstall Valve Plate and Manifold

Reinstall the valve plate to the diaphragm plate with bolts (4), with the valve assemblies installed as outlined above.
Reinstall the head gasket (5) on the rear side of the manifold. Use petroleum jelly or lubricating gel to hold in place.
Reinstall the manifold onto the valve plate.
Insert all bolts (7), with washers (6), around the edge of the manifold, and alternately tighten opposite bolts until all are bolts are secure. Torque to 15 ft-lbs (20 N-m).
Recheck all bolts for tightness.

With the pump in horizontal position, fill the reservoir with the appropriate lubricating oil for the application.

Note: See Maintenance section for details on proper oil.

All air in the oil within the hydraulic cell (behind the diaphragms) must be forced out by turning the shaft (and thus pumping the piston). A shaft rotator is included in the Wanner Tool Kit.

Turn or jog the shaft until a bubble-free flow of oil comes out of each access hole in the diaphragm plate (11). Watch the oil level in the reservoir; when gets too low during priming, air will be drawn into the pistons (inside the hydraulic end). This will cause the pump to run rough, and you will have to start over again with priming the hydraulic cells.

Reinstall the flat-head screw (4) and O-ring (6) for each access holes are primed.

Disassemble Motor from Pump

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Illustration 33	g06263915
Hydraulic end service (1) Nut (2) Washer (3) Stud (4) Valve Cylinder (5) Shaft Key

Disassemble Motor from Pump

Remove the four nuts (1) and washers (2) from the motor side of the offset stud (3).
Install two M10 x .5 x 40 mm or longer bolts into the threaded holes in the rear flange of the pump housing (4).
Alternately turn the bolts clockwise until the pump and motor separate.

Reassemble Motor to Pump

Thoroughly clean the motor shaft and the hollow pump shaft. Remove the tape from the key (5) and keyway.
Apply a liberal amount of Loctite Nickel Anti-Seize No. 77164 to the pump shaft.
Install the shaft key (5) into the keyway.
Slide the motor shaft into the hollow pump shaft.
Reinstall the four washers (2) and nuts (1).

Primary Strainer Removal and Installation

Primary Strainer Removal

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Illustration 34	g06272994
(1) Primary Strainer (2) Drain Plug (3) Nut (4) Strainer Cover (5) Compression Ring (6) Seal (7) Strainer Housing (8) Strainer Screens

Place a suitable drain pan underneath the primary strainer (1) to capture DEF fluid.
Remove and store the drain plug (2) from the bottom of the strainer cover (4). Allow DEF fluid to drain.
Inspect drain plug (1) and any seals, replace if damaged.
Install drain plug (2) into the bottom of the strainer cover (4).
Remove and store eight nuts (3) and the compression flange (5) located around the bottom of the strainer cover (4).
Remove and store the strainer cover (4) of the primary strainer (1).
Remove and inspect seal (6), replace if damaged.
Remove and discard the primary strainer screens (8) from the screen housing (7).

Primary Strainer Installation

Install new primary strainer screens (8) into the screen housing (7).
Install screen housing (7) into the primary strainer (1).
Install the seal (6) onto the bottom of the strainer cover (4).
Install the strainer cover (4), compression flange (5), and eight nuts (3).
Open primary valve, operate DEF Transfer Pump and check for leaks around the bottom of the primary strainer (1).
Remove drain pan and dispose of DEF fluid.

Secondary Strainer Removal and Installation

Secondary Strainer Removal

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Illustration 35	g06272975
(1) Secondary Strainer (2) Strainer Element (3) Seal (4) Strainer Cover (5) Bolt

Place a suitable drain pan underneath the secondary strainer (1) to capture DEF fluid.
Remove and store the bolts (5).
Remove and store strainer cover (4).
Remove and inspect seal (3), replace if damaged.
Remove and discard strainer element (2).

Secondary Strainer Installation

Install new secondary strainer element (2) into the secondary strainer (1).
Install the seal (3) onto the bottom of the strainer cover (4).
Install the strainer cover (4) with bolts (5).
Open secondary valve, operate DEF Transfer Pump and check for leaks around the bottom of the secondary strainer (1).
Remove drain pan and dispose of DEF fluid.

Product Description

Extended Warranties and Service Contracts

A wide variety of protection plans are available for Cat Engines. Consult your Caterpillardealer for detailed information on the specific programs and coverages that are available.

DEF Transfer Pump is an optional attachment to an engine system. Refer to the warranty information for your engine or consult your Caterpillar dealer.

Customer Assistance

USA and Canada

When a problem arises concerning the operation or the service of a Marine engine, the problem will normally be managed by the dealer in your area.

Your satisfaction is a primary concern to Caterpillar and to Caterpillar dealers. If you have a problem that has not been handled to your complete satisfaction, follow these steps:

Discuss your problem with a manager from the dealership.
If your problem cannot be resolved at the dealer level, use the phone number that is listed below to talk with a Field Service Coordinator:
877-228-9900

The normal hours are from 7:00 AM to 6:00 PM Monday through Friday Central Standard Time.
If your needs have not been met still, submit the matter in an e-mail to following e-mail addresses:
https://marine.cat.com/contact-us
www.marine.cat.com

Keep in mind: probably, your problem will ultimately be solved at the dealership, using the dealership facilities, equipment, and personnel. Therefore, follow the steps in sequence when a problem is experienced.

Outside of the USA and of Canada

If a problem arises outside the USA and outside Canada, and if the problem cannot be resolved at the dealer level, consult the appropriate Caterpillar office.

Latin America, Mexico, Carribean
Caterpillar Americas Co.
701 Waterford Way, Suite 200
Miami, FL 33126-4670
USA
Phone: 305-476-6800
Fax: 305-476-6801

Europe, Africa, and Middle East
Caterpillar Overseas S.A.
76 Route de Frontenex
P.O. Box 6000
CH-1211 Geneva 6
Switzerland
Phone: 22-849-4444
Fax: 22-849-4544

Far East
Caterpillar Asia Pte. Ltd.
7 Tractor Road
Jurong, Singapore 627968
Republic of Singapore
Phone: 65-662-8333
Fax: 65-662-8302

China
Caterpillar China Ltd.
37/F., The Lee Gardens
33 Hysan Avenue
Causeway Bay
G.P.O. Box 3069
Hong Kong
Phone: 852-2848-0333
Fax: 852-2848-0440

Japan
Shin Caterpillar Mitsubishi Ltd.
SBS Tower
10-1, Yoga 4-Chome
Setagaya-Ku, Tokyo 158-8530
Japan
Phone: 81-3-5717-1150
Fax: 81-3-5717-1177

Japan
Caterpillar Power Systems, Inc.
SBS Tower (14th floor)
4-10-1, Yoga
Setagaya-Ku, Tokyo 158-0097
Phone: 81-3-5797-4300
Fax: 81-3-5797-4359

Ordering Replacement Parts

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When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material.

Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

Quality Caterpillar replacement parts are available from Caterpillar dealers throughout the world. Caterpillar dealer parts inventories are up-to-date. The parts stocks include all the parts that are normally needed to protect your Caterpillar engine investment.

When you order parts, specify the following information:

Part number
Part name
Quantity

If there is a question concerning the part number, kindly provide your dealer with a complete description of the needed item.

When a Caterpillar engine requires maintenance and/or repair, provide the dealer with all the information that is stamped on the Information Plate. This information is described in this Operation and Maintenance Manual (Product Information Section).

Discuss the problem with the dealer. Inform the dealer about the conditions of the problem and the nature of the problem, when the problem occurs that will help the dealer in troubleshooting the problem and solving the problem faster.