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Perkins 1200F Series
Models MT, MU, MV and MW
DEF SYSTEM SUPPLEMENT
1204F-E44TA
1204F-E44TTA
Developed to meet EEC off-road mobile machinery Stage IV and U.S. EPA off-road Tier 4 Final
legislation
Publication No.TPD1832 – Production Issue 3. May 2015
Four cylinder diesel engines
for agricultural, industrial,
construction applications
1200
Tier 4F 1204F
Series
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Table of Contents
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Summary of Contents for Perkins 1200F Series
- Page 1 1200 Tier 4F 1204F Series 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 Publication No.TPD1832 –...
- Page 2 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.
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Page 3: Table Of Contents
1204F - DEF System Supplement 1.0 INTRODUCTION ........................... 5 1.1 S ......................5 AFETY EQUIREMENTS 1.2 T ..........................6 ERMINOLOGY 2.0 MANDATORY INSTALLATION REQUIREMENTS ..............7 2.1 G ......................7 ENERAL EQUIREMENTS 2.2 C ..........................7 LEANLINESS 2.3 P ....................... 7 ROHIBITED ATERIALS 2.4 DEF... - Page 4 1204F - DEF System Supplement 5.4.4 Bulk Fuel and DEF Tanks ....................37 5.5 DEF C ................38 OMPONENT OUNTING AND ISOLATION 5.5.1 PEU/DCU Mounting Requirements ................. 38 5.5.2 DEF Component Relative Positioning ................39 5.6 DEF T ..................39 ERVICE ONSIDERATIONS 5.6.1 DEF Tank Filling ......................
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Page 5: Introduction
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. -
Page 6: Terminology
1204F - DEF System Supplement 1.2 Terminology • Selective Catalytic Reduction • CDPF Catalysed Diesel Particulate Filter • Diesel Exhaust Fluid • PETU Pump Electronic Tank Unit • Pump Electronic Unit • Dosing Control Unit • ULSD Ultra Low Sulphur Diesel •... -
Page 7: Mandatory Installation Requirements
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 •... -
Page 8: Def Tank
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). -
Page 9: Def Tank Mounting
• 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 •... -
Page 10: 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 •... -
Page 11: Def Component Relative Positions
1204F - DEF System Supplement • There must be a minimum of 150mm clearance above the filter cap to provide sufficient space to service the filter. Access for a 22mm hex socket is required to replace the filter cap (to 14Nm +/- 2Nm) •... -
Page 12: Peu To Def Injector
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 •... -
Page 13: Def Coolant Valve
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. -
Page 14: Def Tank Coolant Supply Lines
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 •... -
Page 15: Def Lines
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: •... -
Page 16: Scr System Fundamentals
(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 -... -
Page 17: Regulations
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. -
Page 18: Scr System
1204F - DEF System Supplement 4.0 SCR System 4.1 AT/ SCR System Schematic DCU and PUMP with heated DEF feed and return lines DOC* *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. - Page 19 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 •...
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Page 20: Components
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. -
Page 21: Def Filler Cap
OEM designed tank (both in same engine option). Fig 4.3 below shows the different elements that go to make up the Perkins DEF tank header The correct fitment of the coolant lines to the DEF tank header is critical to ensure the venting of air and thawing efficiency. -
Page 22: Coolant Lines And Valve
4.2.3.2 Level Sensor This level sensor has been carefully designed and validated to work with Perkins supplied DEF tanks. It measures the DEF level to ensure proper inducement occurs and that all applicable regulations are met. -
Page 23: Def Pump
1204F - DEF System Supplement 4.2.5 DEF Pump The DCU is supplied as part of the DEF pump assembly and transfers DEF from tank to DEF injector and back to tank. Figure 4.5 below shows the different constituent parts within the PEU. Fig 4.5 –... -
Page 24: Def Lines
Correct operation of these lines is required to ensure adherence to emissions requirements. These parts should, therefore, be selected from the Perkins product offering. Figure 4.6 – Heated DEF Lines A&I manual Publication TPD 1832 – Production issue 3. -
Page 25: Def Injector
1204F - DEF System Supplement 4.2.7 DEF injector The DEF injector is a critical emission critical component. It is supplied pre-fitted into the mixer as an integral part of the aftertreatment system. The injector is supplied with DEF, controlled by the DCU, through the heated DEF lines, which are fitted by the OEM. -
Page 26: Operational Parameters
1204F - DEF System Supplement 4.3 Operational Parameters 4.3.1 DEF Component temperature Requirements COMPONENT MAX TEMP °C -40 to 70°C Continuous Operational DCU/PEU – Ambient temperature around all -40 to 75°C max 120 minutes intermittent sides (worst case)* -40 to 85°C Storage DEF Injector –... -
Page 27: Def Component Vibration Requirements
1204F - DEF System Supplement 4.3.2 DEF Component Vibration Requirements Vibration needs to be taken into consideration for all DEF system components. DEF components must be mounted on a structure that will provide sufficient rigidity to support the mass of the components and avoid system resonances during the machine operating cycle including the worst case cycle and shock loading. -
Page 28: Scr System Design Considerations
1204F - DEF System Supplement 5.0 SCR system Design Considerations 5.1 DEF Line and Coolant schematic Fig 5.1 below shows the system cooling and DEF line schematic; detailing each individual line and its relevant option code designation thus enabling a cross reference to be made to the ESM in order to select the most appropriate line length option. -
Page 29: Coolant Connections
1204F - DEF System Supplement 5.2.1 Coolant Connections Coolant must be supplied from the engine to the DEF tank header in order to heat the DEF in cold conditions. The coolant is supplied via the coolant valve which is controlled via the DCU. Coolant is taken from the coolant outlet on the engine to the coolant valve, then to the tank header, returning directly back to the engine at the water pump inlet. - Page 30 1204F - DEF System Supplement 5.2.1.1 General Coolant Line recommendations • The coolant hoses should be standard coolant hose material. • The hoses must be as short and direct as possible with minimal bends to reduce restriction. • The hoses must not contain any dips or sags which may encourage air entrapment. •...
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Page 31: Def Connection Detail
(3/8”) (5/16”) header inlet NOTE: PERKINS LINES ARE SUPPLIED PRE-FITTED WITH APPROPRIATE SAEJ2044 CONNECTORS, SEE FIG 5.2 Refer to section 2.11 for maximum total line length of the system Table 5.3- DEF Line Connections A&I manual Publication TPD 1832 – Production issue 3. - Page 32 1204F - DEF System Supplement DEF supply - DEF suction line from the tank header to the PEU I - DEF Tank Header J - PEU Outlet/suction DEF Inlet Fig 5.3 DEF supply - PEU to injector K - PEU L - DEF Injector DEF inlet DEF Outlet/pressure...
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Page 33: Materials
Any component coming into direct contact with DEF should be constructed of stainless steel. Aluminium is not suitable for use without special coatings and is not recommended. Refer to ‘Appendix A – Chemical Compatibility table’ to see Perkins supplied components compatibility/resistance to common chemicals/fluids. An X indicates resistance. -
Page 34: Def Tanks
5.4.4. Detail on the volume apportionments of the DEF tank are shown in the Fig 5.6 below. Further detail on the actual tank volumes of Perkins DEF tanks is shown in Table 5.4 below. Fig 5.6 DEF tank Appoprtionment A&I manual Publication TPD 1832 –... -
Page 35: Def Tank Mounting And Installation
5.4.3 DEF Tank Straps • The Perkins supplied DEF tanks feature grooves to help locate the tank straps. The groove tolerances are shown in table 5.6 below. The Mandatory requirements are detailed in section 2 and must be adhered to. - Page 36 1204F - DEF System Supplement • All DEF tanks held down by straps must have their base fully supported by a structural platform. Full support is defined as a continuous material that is at least as large as the tank's base dimensions.
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Page 37: Bulk Fuel And Def Tanks
1204F - DEF System Supplement 5.4.4 Bulk Fuel and DEF Tanks Where a bulk fuel tank supply is used a remote DEF tank will be required in addition to the on board machine DEF tank ref 5.4.1 In order to maintain DEF quality and emissions compliance, the DEF level in the tank MUST cycle from the low DEF warning level to the maximum DEF fill level. -
Page 38: Def Component Mounting And Isolation
1204F - DEF System Supplement 5.5 DEF Component Mounting and isolation 5.5.1 PEU/DCU Mounting Requirements The Mandatory requirements in section 2.7 must be adhered to. Fig 5.8 below shows the mounting holes that must be used. Fig 5.8 – PEU mounting A&I manual Publication TPD 1832 –... -
Page 39: Def Component Relative Positioning
• Prevent overfill All adapters supplied by Perkins include a magnetic toggle. The customer’s fill nozzle may or may not have the magnetic safety switch. The nozzle switch only prevents DEF from being dispensed into a non-DEF tank. The neck size prevents a standard diesel or gasoline fill nozzle from being inserted into the tank and a resulting miss fill. -
Page 40: Remote Fill
1204F - DEF System Supplement 5.6.3 Remote Fill Remote fill is defined as a system where the ISO 22241-4 adapter is not fastened directly to the tank. If a remote fill is required then the requirements detailed in IGB 99.05.1 must be adhered to. 5.6.4 DEF Tank Draining A drain port is included in the DEF tank design and must be located in an accessible location that is easily available to service. -
Page 41: Record Of Amendment
1204F - DEF System Supplement 6.0 Record of Amendment 6.1 Changes from Issue 1 to Issue 2 New Mandatory added on cycling of DEF in Tank 5.4.1 Amended to refer to section 5.4.4 for bulk tanks Table 5.4 updated 5.4.4 New section added on Bulk Fuel and DEF Tanks New section added on DEF Tank Service considerations Added Recommended Factory Fill and Storage requirements...
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