3500 C175 C280 AftertreatmentCEM T4 Marine A and I

2013 Caterpillar 1 10Dec2013
All rights reserved.

Marine Application of Aftertreatment
3500, C175, C280
Cat Clean Emissions Module (CEM)
Application & nstallation !uide


"a#le of Contents

$e%ision &ummar' ((((((((((((()))))))) 121
"a#le of Contents ((((((((((((((())) 2

1) ntroduction ((((((((((((((((( 5
*urpose ((((((((((((((((((((())()) 5
$e+uirements & A,reements ((((((((((())(( -
.ocument /a'out (((((((((((((((((())) 7
"ier 0 Emissions &trate,' "a#le (()))(((())((()))))) 7
&afet' (((((((((((((((((((((((() 7
*ressure Air and 1ater(((((((((((((((() 8
2i,3 *ressure 1as3 ((((((((((((((((( 8
1eldin, ((((((((((((((((((()(((( 4
*aintin, ((((((((((((((()))((((((() 4
Cleanliness(((((((((((((((((((((( 4
$eplacement *arts (((((((((((((((((() 4
"ier 0 or M5 6 Emissions $e+uirements())))))())))))))))))))) 4
"erminolo,' ((((((((((((((((((((() 11

2) Cat CEM 5%er%ie7 (((((((((((()))( 13
Cat CEM &'stems )((((((((((((((((())) 13
"ec3nolo,' Component .escriptions ((((((((()) 13

3) &C$ Clean Emissions Modules ((((((())) 15
ntroduction and *urpose (((((((((((((()))) 15
&'stem 2ard7are 5%er%ie7 ((((((((((((()))) 15
CEM Application !uide (((((((((((((())))))))) 1-
Cat CEM Mandator' nterface Connections )(((((()) 17
Air &'stem(((((((((((((((((((((()) 17
A8& 9 .E: &'stem (((((((((((((((((()) 14
A8& 9 .E: &pecifications ))))))((())((((((()) 14
.osin, &trate,ies ((())))))())((((((((()))) 21
.osin, Ca#inet ((((((((()))))))((((())))) 22
A8& 9 .E: .eli%er' &'stem (((((((())((((())) 24
A8& 9 .E: 2andlin, ))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))) 24
Material &election for "an; and *ipin, ((((()))))))())))) 24
A8& 9 .E: /ines (((((((((((((((())))))))() 30
A8& 9 .E: &tora,e "an; ((((((((((((())))))))) 31
Electrical((((((((((((((((())((((()) 38
E<3aust &'stem(((((((((((((()))(((()))) 00

E<3aust Connections (((((((((((()))))))) 00
&ound Attenuation ((()(((((((((((() 0-
nstallation ((((((((())(((((((((((() 0-
nstallation .imensions and !eneral =ie7s ()))))))))))) 08
Mountin, & /iftin, ((((((((((((((())) 04
nitial &tart up(((((((((((((((((()))))))))) -0
&er%ice & Maintenance (((((((((((((((() -0

0) E<3aust &'stem (((())))))))))))((((((())) 70
ntroduction(((((((((((((((((((()( 70
E<3aust &'stem 5%er%ie7 (((((((((((((()) 70
Mandator' $e+uirements (((((((((((((()))) 70
:le<pipe .esi,n (((((((((((((((((())( 71
5EM &upplied E<3aust *ipe $e+uirements(((((())))) 72
*ipe Material ((((((((((((((((((()))))))) 72
E<3aust >ac;pressure ((((((((((((()))))))()) 72
E<3aust "emperature /oss (((((((((((())))))))) 70
?oint /oadin, & &upports ((((((((((((()))))))) 75
1ater n,ress *re%ention ((((((((((((() )))))))) 78
E<3aust &'stem =erification ((((((((((())))))))))) 80
&ound *ressure /e%el ((((((((((((((((( 82

5) Mountin, Considerations(((((((((())))) 83
ntroduction(((((((((((((((((((((( 83
Mountin,((((((((((((((((((((((() 83
CEM =i#ration Accepta#ilit' 5%er%ie7 ((((((((()) 8-
nstallation(((((((((((((((((((((()) 84
/iftin, /in;s ((((((((((((((((((())(( 84

-) "3ermal Mana,ement ))))))))))))))))))))))))))))))))))))))))))))) 41
ntroduction ))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))) 41
"3ermal *rotection ))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))) 41
"3ermal 1rappin, )))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))) 41

7) Appendices((((((((((((((((())) 43
Appendi< A@ Cat CEM 2arness nstallation !uide )(((( 43
Appendi< >@ nitial &tartup *rocedures ((((((((() 105
Appendi< C@ >ello7s6Mount .isplacement Calculator )))))))))))) 104
Appendi< .@ A8& 9 .E: 2andlin, )))))))))))))))))))))))))))))))))))))))))))) 117
Appendi< E@ Critical nstallation C3ec; list ))))))))))))))))))))))))))) 120


1) ntroduction

*urpose

This document is intended as a reerence and guide or the correct installation o
the Caterpillar Clean !missions "odule #Cat C!"$ or Caterpillar !ngines. The
primar% purpose is to assist engineers and designers speciali&ing in engine
installations. The !ngine !lectrical Applications and 'nstallation (uide) !ngine
Application and 'nstallation (uide) and !ngine Data *heets complement this
+oo,let.

A5"E@ The information in this document is subject to change as engine exhaust
aftertreatments are revised, improved and required for emission reduction
standards.

The !-haust *%stem and Cat C!" are an integral part o Caterpillar.s !/A Tier
4) '"0 ''' and !uro *tage '''1 engine solution. Caterpillar !ngines are designed
and +uilt to provide superior value2 ho3ever) achieving the end user.s value
e-pectations depends greatl% on the perormance o the complete installation to
assure proper unction over the design lie o the installation. This proper detail
3ill allo3 the engine to produce its pu+lished rated po3er) uel consumption and
conorm to emissions regulations.

Caterpillar e-ercises all reasona+le eort to assure engine and Cat C!" perorm
properl%. 4o3ever) it is the responsi+ilit% o the 0!" 5 installer to properl% install
the engine and Cat C!". Caterpillar assumes no responsi+ilit% or deiciencies in
the installation. 't is the responsi+ilit% o the 0!" 5 installer to meet all o
Caterpillar.s re6uirements) as provided in this Application and 'nstallation (uide.
Caterpillar does not guarantee or approve the validit% or correctness o an%
installation. Caterpillar7s sole o+ligation 3ith respect to an% product is as set orth
in the applica+le Caterpillar 3arrant% statement.

't is the installer.s responsi+ilit% to consider and avoid possi+l% ha&ardous
conditions) 3hich could develop rom the s%stems involved in the speciic engine
installation. The suggestions provided in this guide regarding avoidance o
ha&ardous conditions appl% to all applications and are necessaril% o a general
nature since onl% the installer is amiliar 3ith details o the installation. The
suggestions provided in this guide should +e considered general e-amples onl%
and are in no 3a% intended to cover ever% possi+le ha&ard in ever% installation.

The inormation in this document is the propert% o Caterpillar 'nc. and 5 or its
su+sidiaries. 8ithout 3ritten permission) an% cop%ing) transmission to others)
and an% use e-cept that or 3hich it is loaned is prohi+ited.

Contact the appropriate application support group or the latest inormation on
Cat C!" guidelines and re6uirements.

CAT) CAT!:/';;A:) their respective logos and <Caterpillar =ello3>) as 3ell
as corporate and product identit% used herein) are trademar,s o Caterpillar
and ma% not +e used 3ithout permission.

This document serves as Caterpillar.s instructions re6uired +% ?.*. !/A
regulations #40 C.@.:. /art 109A$ to acilitate the selection and application o the
correct Cat C!" module +% the 0!" or <installer> +ased upon engine selection.

$e+uirements and A,reements

1. !ach 0!" shall enter into a delegated inal assem+l% agreement 3ith
Caterpillar) 'nc. as re6uired +% 40 C.@.:. B 109A.291. This pu+lication
ulills Caterpillar.s o+ligation under 40 C.@.:. B 109A.291 #c$#2$ to provide
installation instructions to ensure the engine 3ill +e in certiied
coniguration.

2. 0!" is re6uired to ollo3 Caterpillar.s Applications and 'nstallation
re6uirements or proper Cat C!" integration 3ith the Caterpillar engine.

An' de%iation from t3ese instructions resultin, in improper installation or
connection of Cat CEM ma' #e considered an emissions6related defect
re+uirin, t3e 5EM or installer to report to 8)&) E*A pursuant to 00 C):)$) B
10-8)2-1 (3)) 5EM installations are su#Cect to audit #' Caterpillar pursuant
to 00 C):)$) B 10-8)2-1 (d)(3), as furt3er set fort3 in t3e dele,ated final
assem#l' a,reement)

Aote@ Ao aftertreatment component s3all #e placed #et7een t3e en,ine out
e<3aust and t3e CEM inlet e<cept for t3at 73ic3 t3is document 3as
specified)

Aote@ f t3e a%aila#le Cat CEM option does not meet t3e
application9installation re+uirements, t3e 5EM nstaller must contact 3is or
3er respecti%e Caterpillar sales mana,er) An' de%iation from t3ese
instructions resultin, in t3e installation of Cat CEM not included as part of
t3e applica#le certified en,ine confi,uration 7ill #e considered a mis6#uild
and must #e reported immediatel' to Caterpillar)

Cat CEM dentification

Caterpillar 3ill provide AutoCdetection to ensure the proper Cat C!" is itted to
the proper engine. The engine 3ill identi% the C!" and allo3 proper operation o
the engine and atertreatment s%stem. @ailure to detect proper C!" 3ill result in
100D derated engine perormance.

The Caterpillar Clean !missions "odule 3ill +e stamped 3ith a Caterpillar part
num+er or identiication and part service re6uirements. Eo 0!" part num+ers
or supplier part num+ers 3ill +e stamped on the device.

2013 Caterpillar F 10Dec2013
.ocument /a'out

This document provides application inormation) speciications and installation
procedures to install Cat C!" or selected Caterpillar engines that meet ?* Tier
4 and '"0 ''' emissions regulations. To determine 3hich module is availa+le or
%our engine application please revie3 the ollo3ing Caterpillar Clean !missions
*trateg% Ta+le or the emissions technolog% provided or the selected engine
/latorm#s$. Ater reading and understanding the Cat C!" technolog% overvie3
proceed to that Cat C!" Components section or detailed design and installation
inormation. The Appendi- contains additional detailed design and installation
inormation and is reerenced throughout the document.

This document provides the re6uired inormation or Cat C!" mounting including
electrical) plum+ing) and e-haust connections.

Aote@ "3ere are critical specifications re+uired for proper performance and
compliance 7it3 8)&) E*A, M5 and European Commission re,ulations)
:ailure to meet t3ese re+uirements 7ill constitute a Dmis6#uildE and prompt
notification to Caterpillar is re+uired) nstallation Audits are re+uired for
eac3 ne7 application #uild)

"ier 0 Emissions &trate,' "a#le

Caterpillar Clean Emission &trate,'
*o7er

En,ine
*latform
Aftertreatment
"ec3nolo,'
Applications
F7502*
(5-0G1)

C100
3500
C175

A8& 9 .E:
&C$
"arine 5 /etro 0shore
2019
C280

#2000,8C3F00 ,8 onl%$
2019
#G3F00 ,8 onl%$
201F

"a#le 1)1 H Caterpillar Clean Emissions &trate,' "a#le

&afet'

"ost accidents that involve product operation) maintenance) and repair are
caused +% ailure to o+serve +asic saet% rules or precautions. An accident can
oten +e avoided +% recogni&ing potentiall% ha&ardous situations +eore an
accident occurs. An 0!" 'nstaller must +e alert to potential ha&ards. An 0!"

2013 Caterpillar A 10Dec2013
'nstaller should also have the necessar% training) s,ills) and tools in order to
perorm these unctions properl%.

The inormation in this pu+lication 3as +ased upon current inormation at the
time o pu+lication. Chec, or the most current inormation +eore %ou start an%
Ho+. Caterpillar dealers 3ill have the most current inormation.

Warning: mproper operation, maintenance, or repair of t3is
product ma' #e dan,erous) mproper operation, maintenance, or
repair of t3is product ma' result in inCur' or deat3) .o not operate or
perform an' maintenance or repair on t3is product until 'ou 3a%e
read and understood t3e operation, maintenance, and repair
information. >urn and fire 3aIards are possi#le) :ailure to properl'
connect t3e After6treatment, or properl' route t3e e<3aust ,ases
a7a' from t3e module ma' result in personal inCur' or death)

Notice: :ailure to properl' connect t3e after6treatment 7ill result in
poor en,ine performance, en,ine and after6treatment s'stem
dama,e)

Caterpillar cannot anticipate ever% possi+le circumstance that might involve a
potential ha&ard. The 3arnings in this pu+lication and on the product are not all
inclusive. ' a tool) a procedure) a 3or, method) or an operating techni6ue that is
not speciicall% recommended +% Caterpillar is used) %ou must +e certain that it is
sae or %ou and or other people. =ou must also +e certain that the product 3ill
not +e damaged. =ou must also +e certain that the product 3ill not +e made
unsae +% the procedures that are used.

Pressurized Air and Water

/ressuri&ed air and5or 3ater can cause de+ris and5or hot 3ater to +e
+lo3n out. This could result in personal inHur%. Al3a%s 3ear a protective ace
shield) protective clothing) and protective shoes 3hen cleaning components. The
ma-imum air pressure or cleaning purposes must +e reduced to 205 ,/a #30
psi$ 3hen the air no&&le is deadheaded and used 3ith eective chip guarding #i
applica+le$ and personal protective e6uipment. The ma-imum 3ater pressure or
cleaning purposes must +e +elo3 2F5 ,/a #40 psi$.

High Pressure Wash

Aotice@ 4ighCpressure 3ash s%stems) including high pressure spra% 3ashers
and 3ater cannons) are no3 in re6uent use +% maintenance people. Connector
seals 3ill ail 3hen hit directl% 3ith high pressure spra%. "an% connection
s%stems have adapters availa+le that can +e attached to the +ac, o the
connector to protect the 3ire seals rom direct high pressure 3ash. 13ere direct
e<posure to 3i,3 pressure 7as3 s'stems cannot #e a%oided t3en
protecti%e s3ields 7ill need to #e desi,ned and installed) @or the +eneit o
service) connectors should +e placed in accessi+le locations.

2013 Caterpillar I 10Dec2013

Welding

1A$AA! Aotice J 1eldin, on Cat CEM frame9c3assis is pro3i#ited)

Painting

/ainting o Caterpillar C!" is A5" recommended and strongl% discouraged.
*ome components s,in temperatures on the C!" can get to as high as 525
degrees Celsius during operation and 3ill cause charring or +urning o the paint.

Cleanliness

Air lines) @uel lines) coolant lines and oil lines that connect to the C!" or engine
should meet Caterpillar cleanliness speciication contained in AJ' (uide
;!18001I.

Replacement Parts

8hen replacement parts are re6uired or this product) Caterpillar recommends
using Caterpillar replacement parts or parts 3ith e6uivalent speciications
including) +ut not limited to) ph%sical dimensions) t%pe) strength) and material.

"ier 0, M5 6 Emissions $e+uirements

This 'nstallation (uide is intended or use or engines that must compl% 3ith Tier
4 or '"0 ''' emission re6uirements. /roper luids must +e used to meet these
re6uirements. :eer to the speciic 0peration and "aintenance "anual #0""$
or the Caterpillar engine model +eing installed or the proper uel) lu+ricants) and
coolants that are to +e used. The proper uels) lu+ricants and coolants must +e
used to ena+le the engine to produce its pu+lished rated po3er) uel
consumption and conorm to emissions regulations.

K/A Diesel uel is not compati+le 3ith Caterpillar Tier 4 and '"0 ''' Cat C!".
?.*. !/A Tier 4 regulations re6uire the use o commercial ?;*D that conorms
3ith the A*T" DIF5 speciication o 15 ppm ma- sulur uel per ?* !/A Tier 4
re6uirements. '"0 ''' re6uires that the uel sulur levels are +elo3 1)000ppm.
?sing an% uel 3hich is not e6uivalent to A*T" DIF5 or !E5I0 ma% damage
engine and Atertreatment s%stems. 'n this case) consult Caterpillar or %our
Caterpillar dealer or urther direction. 1iodiesel is compati+le 3ith the Cat C!"
up to 120 +ut can have an aect on some C!" components #:eer to *!1?
9251 L Caterpillar @luids :ecommendations$. The ollo3ing ta+le summari&es
the engine operating luids re6uirements or engines e6uipped 3ith the Cat C!"

En,ine 5peratin, :luids
@uel Tolerance L *ulur #ppm$
Tier 4
15 or less
'"0 '''
1)000
0il Tolerance #ash content$ CK4 or +etter
@uel Tolerance L +iouels #A*T" 9F51C0F5 1100$ 120 or less
Ta+le 1.2 C Tier 4 !ngine 0perating @luids ;imits

A5"CE@

0ils that have more than 1D total sulated ash should not +e used in
Atertreatment device e6uipped engines.

'n order to achieve e-pected ash service intervals) perormance) and lie)
Atertreatment device e6uipped diesel engines re6uire the use o Cat D!0C?;*
or oils meeting the Cat !C@C3 speciication and the A/' CKC4 oil categor%. 0ils
that meet the Cat !C@C2 speciication and that have a ma-imum sulated ash
level o 1D are also accepta+le or use in most atertreatment e6uipped engines.
?se o oils 3ith more than 1D total sulated ash in atertreatment device
e6uipped engines 3ill cause the need or more re6uent ash service intervals)
and5or cause loss o perormance. :eer to %our engine speciic 0peration and
"aintenance "anual) and reer to %our atertreatment device documentation or
additional guidance.

1arnin,@ 8se of 5il $ene7al &'stem (5$&) is strictl' for#idden) An' 5$&
t3at e<tends t3e oil life t3rou,3 t3e com#ustion process and topin, off t3e
oil reser%oir 7it3 ne7 oil 7ill dama,e t3e aftertreatment de%ice) :ailures
t3at result from t3e use of an' oil are not Caterpillar factor' defects)
"3erefore, t3e cost of repair 7ould A5" #e co%ered #' t3e Caterpillar
7arrant' for materials and9or t3e 7arrant' for 7or;mans3ip)

EoteM The ?.*. @orest *ervice operates a national la+orator% that provides spar,
arrester 6ualiication testing pursuant to ?.*. @orest *ervice *tandard 5100C1c)
<*par, Arresters or 'nternal Com+ustion !ngines)> 3hich is currentl% +eing
revised so as to e-tend its assessment +e%ond particle capture measurement.

The CAT C!" 3ith D/@ is +eing validated per *A!K350) <*par, Arrester Test
/rocedure or "edium *i&e !ngines)> 3hich 3ill not result in a ormal
6ualiication +% ?.*. @orest *ervice) +ut 3ill document spar, arresting particle
capture capa+ilities)

All other CAT C!".s are pass through atertreatment devices and can not +e
validated to *A!K350. ' spar, arresting is needed or these applications a
dedicated device meeting *A!K350 3ill need to +e installed ater the C!".

$ecorder

!/A recogni&es that it is unsae and unaccepta+le to signiicantl% derate or shut
do3n a marine engine or an atertreatment ailure. *o in the !/A regulations 40
C@: 1042 does not re6uire engine derates or shutdo3ns. To ans3er this issue
in the engine control panels a recorder o certain aults 3ill +e recorded and
stored. ' this ault codes are logged on the recorder than the customer has 30
da% to inorm the !/A on 3hat cause the recorder to recorder the one o those
critical codes.

Caterpillar 3ill provide an A5E2 recorder !C" 3hich 3ill record the re6uired
codes in in nonCvolatile memor%. 't then 3ill +e the end user responsi+le to
respond to !/A i a code is record on the A5E2. The codes that 3ill +e recorder
are in A?*5D!@ 6ualit% is +elo3 the spec) i vessel ever ran out o A?*5D!@ and
i the s%stem 3as ever turned o.

Caterpillar 3ill alarm and record in standard engine !C" memor% all other
incidents relating to engine and atertreatment operation. Active codes 3ill +e
displa%ed) and recordings o the irst and last incident date and time and the
num+er o occurrences 3ill +e recorded in standard engine !C" memor%.

"erminolo,'

"3e terminolo,' used t3rou,3out t3is document 7ill #e as follo7s@

AM5K Ammonia 0-idation Catal%st
A* American /etroleum 'nstitute
A$. Au-iliar% :egeneration Device
A&"M American *ociet% or Testing and "aterials
A" Atertreatment
A"AAC Air to Air Ater Cooler
A8& A6ueous ?rea *olution
A8&32 A6ueous ?rea *olution per '*0 *tandard 22241
A1! American 8ire (auge
>*= 1ac, /ressure Nalve
CAA Controller Area Eet3or,
Cat CEM Caterpillar Clean !missions "odule
Cat EC: Cat !ngine Cran,case @luid
Cat $& Caterpillar :egeneration *%stem
CC1 Counter Cloc,3ise
C.*: Catal%&ed Diesel /articulate @ilter
CE*$8 Caterpillar !lectric /riming and :egeneration ?nit

C:. Computational @luid D%namics
C):)$. Code o @ederal :egulations
C! Center o (ravit%
C&. Compliance and 'nnovative *trategies Division
C5 Car+on "ono-ide
C1 Cloc,3ise
.E: Diesel !-haust @luid #also reerred to as A?*32$
.elta * Dierential /ressure
.5C Diesel 0-idation Catal%st
.*: Diesel /articulate @ilter
.* Delta /ressure 'ndicator
ECM !lectronic Control "odule
E2&& !nvironment o 4ealth J *aet%
E*A !nvironmental /rotection Agenc%
:EA @inite !lemental Anal%sis
:MEA @ailure "odes J !ects Anal%sis
!A. (round
2C 4%dro Car+on
. 'Dentiication or 'nside Diameter #Dimensional :eerence$
EC 'nternational !lectroCtechnical Commission
&5 'nternational 0rgani&ation or *tandardi&ation
?C Koint 'ndustr% Council
MA: "ass Air @lo3
M&.& "aterial *aet% Data *heet
A5< Eitrous 0-ides L E0 and E0
2

5EM 0riginal !6uipment "anuacturer
5MM 0perations J "aintenance "anual
5$& 0il :ene3al *%stem
*M /articulate "atter
*9A /art Eum+er
*&, /ounds per *6uare 'nch gauge
*&*& /roduct *ot3are /rogramming *%stem
&AE *ociet% o Automotive !ngineers
&CAC *eparate Circuit Ater Cooler
&C$ *elective Catal%tic :eduction
&5: *olua+le 0rganic @raction
&"5$ *traight Thread 0C:ing
&9A *erial Eum+er
">. To 1e Determined
8/&. ?ltra ;o3 *ulur Diesel


2) Cat CEM 5%er%ie7

Caterpillar Clean Emissions Module (Cat CEM) &'stems

The Cat C!" consists o the ,e% components necessar% to support an engine
arrangement or emissions compliance. Caterpillar Tier 4) '"0 ''' and !uro '''1
engine s%stems use a variet% o technologies or the reduction o particulate
matter and E0- emissions. *election o the optimal module com+ination is
+ased upon engine rating and application. !ach o the emission reduction
technolog% com+inations is listed in the Cat C!" *trateg% ta+le in section a+ove
and descri+ed in this document.
"ec3nolo,' Component .escriptions
&C$ (&electi%e Catal'tic $eduction) &'stem
*C: is one o a com+ination o several components. *C: units 3ill re6uire the
use o urea or D!@ #Diesel !-haust @luid also reerred to as A?*32$ along 3ith
lo3Cthrough hone%com+ su+strate catal%sts.

A?* 5 D!@ luid is inHected into the e-haust stream +eore entering the *C:.
8hen inHected into the e-haust stream) the A?* 5 D!@ is atomi&ed into ine
droplets and then sent through a mi-er. The mi-er disrupts the e-haust lo3 and
allo3s the A?* 5 D!@ to +e 3ell distri+uted throughout the e-haust gas. The
3ater evaporates due to the high temperature o the e-haust and releases the
E4
3
that 3as chemicall% +ound up in the A?* 5 D!@. The E4
3
is then ree to
react 3ith the E0- and the o-%gen present in the e-haust stream. This reaction
occurs on the *C: catal%st. The E4
3
and E0- are converted into harmless gas
particles o nitrogen and 3ater.


!ngine
"i-ing
Tu+e *C: !-haust 0ut
Control
?nit
D!@ *uppl%
/ump
/rimar%
D!@ @ilter
Air *uppl%
/rimar%
Air @ilter
Tur+ochargers
1ello3s
'nHector
.osin, Ca#inet
/ress
:eg

&C$ CEM &'stem .ia,ram

1or;in, *rinciple

C5(A2
2
)
2
L 2
2
5 M 2A2
3
L C5
2
A5 L A5
2
L 2A2
3
M 2A
2
L 32
2
5


3) &C$ Clean Emissions Modules

ntroduction and *urpose

Caterpillar.s *C: emissions approach com+ines emission reduction technologies
to compl% 3ith Tier 4 emissions re6uirements. *elective Catal%st :eduction
#*C:$ catal%st technolog% is used to reduce E0- emissions and particulate
matter #/"$) car+on mono-ide #C0$) h%drocar+ons #4C$ and solu+le organic
raction #*0@$.

Caterpillar.s *C: is pac,aged in a module that contains the components
necessar% to support the speciic engine coniguration or emissions compliance.
0!" installation 3ill re6uire connections +et3een 0!" module) engine) A?* 5
D!@ tan, and air source. These connections 3ill include engine e-haust piping)
electrical harness) air) and A?* 5 D!@ lines.

&'stem 2ard7are 5%er%ie7

CEM
E<3aust
&C$ Catal'st
.osin,
Ca#inet
79 .E:
*ump
CEM
.E:
"an;
Air
&uppl'
En,ine
T
T
Mi<er & &C$
nCector

:i,) 0)1 H &'stem >loc; .ia,ram


CEM Application !uide

The ollo3ing ta+le provides applica+le C!" or a given application and engine
platorm. There 3ill +e several C!" illustrations or these applications +elo3 in
the ollo3ing su+sections o this *C: C!" Technolog% section.

CEM Application !uide
!ngine /latorm C!" /rei- Application
N35009C175 !C@
"arine 5 /etro #? @lo3 J O @lo3 C!"
Designs$

C28068

!CP
"arine 5 /etro 0shore #2000,8C3F00
,8 onl%$
C280612 !C4
#G3F00 ,8 onl%$
Q The C!" /rei- indicates the 19 +ric, version o C!" or these engine platorms.
Currentl% the prei- designation or the 12 J 20 +ric, version o C!"s are not availa+le

!ach C!" has a *erial Eum+er that is compati+le to a particular engine platorm
and is shipped as a set. This *5E must +e veriied at installation or compati+ilit%
to the engine. The serial num+er prei- 3ill identi% the C!" or correct
application. The prei- on the C!" serial num+er la+el is indicated on the
e-ample +elo3.

E<ample@
MODULE AR
PN
SN
CONV- GP CTLTC
PN
345-6789- 00
ABC123456Z
876- 5432- 00

:eer to <Appendi< >@ nitial &tartup *rocedures> or location o serial num+er
on C!" and dosing ca+inet) documentation and irst it detection.

2013 Caterpillar 1F 10Dec2013

Cat CEM Mandator' nterface Connections@

.oc /oc Connection *oint .escription :ittin, "'pe
@ig. 4.9 J
Ta+le 4.9
Dosing Ca+inet to C!" A?* 5 D!@ ;ine rom
dosing ca+inet to C!"
E0. 9 @emale *T0:
#straight thread 0Cring$
@ig. 4.9 J
Ta+le 4.9
Dosing Ca+inet to C!" Air line rom Dosing
Ca+inet to C!"
Eo. A @emale *T0:
@ig. 4.9 J
Ta+le 4.9
Dosing Ca+inet to C!" !lectronic harness rom
Dosing Ca+inet to C!"
Ruantit% 1
24 /in Connectors
@ig. 4.9 J
Ta+le 4.9
Dosing Ca+inet to !ngine
!C"
!lectronic harness rom
Dosing Ca+inet to
!ngine !C"
Ruantit% 1
24 /in Connectors
@ig. 4.9 J
Ta+le 4.9
Dosing Ca+inet to "ain A?* 5
D!@ Tan,
!lectronic harness rom
Dosing Ca+inet to "ain
A?* 5 D!@ Tan,
Ruantit% 1
24 /in Connectors
@ig. 4.9 J
Ta+le 4.9
Air *ource to Dosing Ca+inet Air line into dosing
ca+inet rom air source
35A> "ale E/T
@ig. 4.9 J
Ta+le 4.9
Customer A?* 5 D!@ tan, to
Dosing Ca+inet
A?* 5 D!@ line into
dosing ca+inet +uer
tan, rom main tan,
152> "ale E/T
@ig. 4.9 J
Ta+le 4.9
Dosing Ca+inet Drain A?* 5 D!@ +uer tan,
manual drain
E0. 9 @emale *T0:
#straight thread 0Cring$
@ig. 4.9 J
Ta+le 4.9
Dosing Ca+inet Nent A?* 5 D!@ +uer tan,
vent J overlo3
S> 4ose 1ead *A!
A*5131
@ig. 4.9a C!" to Dosing Ca+inet Air line rom C!" to
dosing ca+inet
K'C @lare) *A! K514
T U19
@ig. 4.9a C!" to Dosing Ca+inet A?* 5 D!@ line rom
C!" to dosing ca+inet
K'C @lare) *A! K514
I519U1A
@ig. 4.14 C!" to Dosing Ca+inet !lectronic harness rom
C!" to Dosing Ca+inet
24 /in Connector
@ig. 4.A 120N AC source to Dosing
Ca+inet
!lectrical harness rom
Dosing ca+inet to 120N
AC source
1us 1ar #'nside Dosing
Ca+inet$
@ig. 4.19 C!" to Tur+o !-haust pipe into C!"
rom engine
1 C 1A> 1olted @lange
@ig. 4.19 C!" to Atmosphere !-haust pipe rom C!"
to atmosphere
1 C 1A> 1olted @lange
"a#le 0)1 6 nterface Connections

Air &'stem

Compressed Air is usedM

To assist in the atomi&ing o the li6uid A?* 5 D!@ as it is inHected into the
e-haust stream
To shield the li6uid A?* 5 D!@ in the inHector rom the e-haust heat until
inHection) so that no cr%stalli&ation occurs 3hich could plug the inHector
no&&le
To purge the A?* 5 D!@ line during shutdo3n in order to prevent
cr%stalli&ation

"'picall', compressed air 7ill carr' some oil from t3e compressor and
some sediment from t3e pipin,) "3is de#ris can collect in t3e noIIle and
clo, t3e unit) 8se a coalescin, filter9separator t3at is 40 percent effecti%e
t3at is rated for 10-4 ;*a, (155 psi,) and 804)5 liter9min (30 C:M))

2013 Caterpillar 1A 10Dec2013
$eference Air :ilter $e+uirements in t3e su# section DAir :ilter
$ecommendationsE for details) An air dr'er is recommended to ;eep
relati%e air 3umidit' #elo7 10O)

The air suppl% delivered to the dosing ca+inet must meet the speciications in
Ta+le 4.2 3hen engine is running and an% nonCparasitic load.

Air &uppl'
Air 6ualit% '*0 A5F3.1 Class 4
0il Content #mg5m
3
$ #"a-.$ 25 #mg5m
3
$
/article *i&e #"a-$ #micron$ 40 micron
/article Densit% #"a-$ #mg5m
3
$ 10 #mg5m
3
$
:elative Air 4umidit% V10D
Air deliver% #compressor capa+ilit%$M
Air Temperature C40 to 50 C
Air @lo3 Capacit% 10 C@"
Air Consumption Continuous 3hen s%stem is dosing
Air /ressure F0 to 155 /*'g
Air /ressure at !ngine *tartup F0 /*'g at start up
0:
F0 /*'g 3ithin 3 minutes maintaining V30D
load or C!" outlet temp V250C
/urge Air /ress5Nol at *hutdo3n GF0 /*'g 510 *C@" or 30 sec
*elected ilter should meet the ilter perormance test per '*0 12500.3
"a#le 0)2 H Air suppl' deli%er' re+uirements at .osin, Ca#inet nlet

EoteM An optional air compressor s%stem is availa+le rom Caterpillar that is
designed speciicall% or use 3ith the Caterpillar C!" #*C:$. /lease reer to the
air compressor AJ' guidelines or re6uirements.

Air &uppl' /ine $e+uirements@

The air line that is used or delivering air rom the dosing ca+inet to the inHector is
to +e si&ed and routed such that the pressure loss across the line is no greater
than 1.0 /*' at the ma-imum lo3 capacit%.

EoteM :outing o this air line must progress continuousl' 3ithout air loc,s or line
+ends that 3ould allo3 condensation to orm and ree&e preventing air suppl% to
Dosing Ca+inet air valve.

&econdar' Air :ilter
The A?* 5 D!@ dosing ca+inet re6uires customer to provide compressed air to
the dosing ca+inet 3hich meet '*0 A5F3.1 Class 5 re6uirements speciied in
Ta+le 4.2 a+ove.

A ca+inet contains a secondar% air screen ilter at the dosing ca+inet air inlet.

Air inlet port on the screen ilter is "ale 35A> E/T. 't is recommended to have a
dr%er installed on the compressed air s%stem to maintain the V10D relative air

2013 Caterpillar 1I 10Dec2013
humidit%. *ee Air J A?* 5 D!@ @ilter 'nstallation igure +elo3 or interace
connection location on dosing ca+inet.

*ee maintenance schedule or service interval o air ilter. *ee service manual or
service procedure.

A8& 9 .E: &'stem
A8& 9 .E: &pecifications

@or *C: applications the re6uired A?* 5 D!@ solution to +e used is *C: (rade
A?*32) or A6ueous ?rea *olution o 32.5D or 40D concentration 3ith 6ualit%
properties per '*0 22241C1. A solution 32.5D concentration provides the lo3est
possi+le ree&ing point) C11WC #12
o
@$ 3hile 40D concentration ree&ing point is at
0WC #32W@$. The solution is homogeneous) allo3ing partial or total ree&ing and
tha3ing 3ithout changing the concentration. The solution is +asic) 3ith a p4 o
a+out I.0) and is slightl% corrosive. :eerence '*0 22241C3 standard or
X4andling) Transportation) and *torage o A?*32 #A?* 5 D!@$X.

@ertili&er or technical grade urea ma% contain elements that 3ill clog the inHector
no&&le. 't should not +e used to suppl% the dosing ca+inet.

The A?* 5 D!@ suppl% to the dosing ca+inet inlet should +e iltered. The iltration
re6uirement is 40 microns to protect valves inside the dosing ca+inet. Caterpillar
oers a A?* 5 D!@ ilter part num+er 3F0C9215.

Customer needs to 3a%e onsite A8& 9 .E: filters 7it3 filtration capa#ilit' of
00P (microns) usin, differential pressure ,au,es across t3e filters for
ser%ice)

Ca+inets 3ill include a A?* 5 D!@ ilter screen assem+led and mounted on the
ront o the ca+inet using all stainless steel ittings.

A?* 5 D!@ inlet port on the screen ilter is "ale 152> E/T. ' the s%stem 3ill +e
shut do3n in ree&ing conditions or put into storage) the screen ilter and suppl%
line should +e drained. Customer is responsi+le or protecting the suppl% line
rom ree&ing and damage rom oreign o+Hects #stainless steel suppl% line is
recommended$.

*ee maintenance schedule or service interval o A?* 5 D!@ screen ilter. The
ilter is reusa+le and can +e cleaned using an ultrasonic +ath. :eer to igure
+elo3 or interace and installation on dosing ca+inet.

Air J A?* 5 D!@ *trainer ;ocationsM

@ig. 4.2 L Dosing Ca+inet Air J A?* 5 D!@ 'nterace Connections

'*0 22241C3 has comprehensive list o A?* 5 D!@ compati+le materials
including 300 and 400 series stainless steel) !th%lene /rop%lene Diene "onomer
#!/D"$) /ol%eth%lene) /ol%prop%lene) and etc.

An% 0Crings must +e !/D". :eerence <"aterial *election or Tan, and /iping>
ound later in this section or details regarding tan, material) si&e) piping) ittings)
etc.

CA8"5A@ >ase material and t3eir allo's of copper, Iinc, aluminum and
ma,nesium are not compati#le) Also solderin, material containin, sil%er
and nic;el coatin,s are considered not compati#le 7it3 A8& 9 .E:) Car#on
steels, Iinc coated car#on steels, and mild iron are not to #e used 7it3 A8&
9 .E: .o not store A8& 9 .E: in a tan; or use suppl' lines or fittin,s t3at
are made of t3e a#o%e materials)

The 40D urea solution 3ill have the advantage o smaller storage tan,s) 3hile
maintaining the ree&ing point o 3ater. Caterpillar recommends A?* 32.5D
solution per '*0 22241C1. A?* 5 D!@ must +e ,ept +elo3 50 WC #122 W@$ to ,eep
it rom decomposing too 6uic,l% and a+ove L 11
o
C #12 W@$ to prevent it rom
ree&ing during cold operation. According to Caterpillar speciication 1!4413)
storage near 25WC provides a shel lie o appro-imatel% 1A months 3hile storage
around 35WC reduces storage lie to appro-imatel% si- months. 0ther storage and
handling methods have to +e ollo3ed.

The +est operating temperature or the urea solution is L 5
o
C to Y 50
o
C #23
o
@ to
122
o
@$. ' am+ient temperature goes +elo3 C11
o
C) A?* 5 D!@ inside tan, and
lines outside dosing ca+inet need tha3ing +eore starting A?* 5 D!@ dosing.

The tha3ing time re6uirement is deined in the !/A *C: guideline #C'*DC0IC04$.
The dosing ca+inet has a ree&e prevention strateg%.
.osin, &trate,ies@
The dosing ca+inet re6uires a A?* 5 D!@ suppl% o 5C10 psig 3ith a ma- o 10
psig at the dosing ca+inet A?* 5 D!@ suppl% inlet. There is no A?* 5 D!@ return
line +ac, to the remote tan, rom the tan, located inside the dosing ca+inet. A
vent in the dosing ca+inet release purged air J A?* 5 D!@ vapor during purge
event. The vent line connected 3ith the dosing ca+inet should +e +elo3 the A?*
5 D!@ inHector mounting location at the C!". The e-it location should meet
0*4A saet% re6uirements. /lease contact local !4J* organi&ation or related
concern.

:i,) 0)3 H .osin, s'stem sc3ematic
.osin, &'stem 5perations

As sho3n in @ig. 4.3 air pressure must +e present at the input to the dosing
ca+inet +eore dosing can +egin. This air pressure is regulated to 94 psig. Y5C 4
psig. at *olenoid Nalve Z1. 8hen dosing conditions are met the Atertreatment

!C" energi&es *olenoid Nalve Z1 3hich loo,s or the re6uired psig using /1
sensor. ' pressure is present *olenoid Nalve Z2 is energi&ed to close and allo3s
A?* 5 D!@ to +e supplied to the A?* 5 D!@ 'nHector via the A?* 5 D!@ Dosing
/ump. The A?* 5 D!@ Dosing /ump pulses A?* 5 D!@ rom the Dosing tan, to
A?* 5 D!@ inHector controlled +% the Atertreatment !C". The /1 pressure signal
is ed to the Atertreatment !C" that in turn inhi+its dosing 3ithout the re6uired
psig pressure rom the /1 sensor signal. /urging is accomplished +% energi&ing
*olenoid Nalve Z1 and deCenergi&ing *olenoid Nalve Z2 providing compressed
air +ac, through A?* 5 D!@ 'nHector via *olenoid Nalve Z2 to Dosing Tan, 3hen
dosing is not re6uired.

The A?* 5 D!@ ill is controlled +% Atertreatment !C" to the +uer tan, or the
ca+inet sho3n in @ig. 4.3 8hen the +uer tan, A?* 5 D!@ level is lo3ered and
the A?* 5 D!@ ;evel *ensor detects a lo3 level condition the Atertreatment
!C" energi&es *olenoid Nalve Z3 3hich ills the Dosing Tan, to maintain
ade6uate suppl% o A?* 5 D!@ to the inHector. The ma-imum A?* 5 D!@
pressure allo3ed at the input to *olenoid Nalve Z3 is 10 psig. The allo3a+le
range o A?* 5 D!@ pressure and lo3 rate is 5 to 10 psig and 1.25.to 2.5 gallons
per minute respectivel%. A?* 5 D!@ pressure rom the A?* 5 D!@ *uppl% Tan, is
t%picall% 5 to A psig. A 10 psig ma-imum pressure relie valve is recommended in
series 3ith A?* 5 D!@ *uppl% Tan,.

.osin, Ca#inet

Eormal unctions5operations o a dosing ca+inet includeM
"onitor and dose A?* 5 D!@
"onitor and regulate compressed air
4ouse !lectronic Control "odule #!C"$
/rovide customer connections

The Atertreatment !C" in the dosing ca+inet 3ill communicate 3ith the engine
over K1I3I data lin, via the electronic connector on the ca+inet interace
illustrated +elo3. Dosing ca+inet is shipped ull% cali+rated to 3or, 3ithin
speciied operating conditions. ' the operating conditions change +e%ond the
speciication) additional care needs to +e ta,en to address these issues.
8henever a critical component is replaced) recali+ration might +e re6uired. The
dosing pump comes 3ith a tamper evident stic,er. ' this stic,er is damaged due
to normal 3ear and tear) please contact the local Caterpillar dealer or
replacement. ' this stic,er is tampered 3ith this implies !/A violation.


:i,) 0)5 H .osin, Control Ca#inet

.osin, ca#inet connection points@

Dosing ca+inet communicates 3ith e-ternal components via its connection
points. These connections could +e electrical) air and A?* 5 D!@. @or
descriptions a+out the connections and their meaning see Ta+le 4.3.

1
10
I
A
F
9
5 4 3 2

:i,) 0)- H Connection to .osin, Ca#inet

Connection
*oint N
.escription :ittin, "'pe
1 *ervice tool connector
2
!lectrical harness rom Dosing Ca+inet to
!ngine !C"
24 /in Connector
3
!lectrical harness rom Dosing ca+inet to main
A?* 5 D!@ tan, #level sensor5transer
pump[[[$
24 /in Connector
4 !lectrical harness rom C!" to Dosing ca+inet. 24 /in Connector

5 A?* 5 D!@ Nent /ort #see Eote +elo3$ S> 4ose 1ead *A! A*5131
9
!lectrical harness rom Dosing ca+inet to 120N
AC source
(rommet or 3iring J 3 Terminal 1loc,s

F A?* 5 D!@ line rom Dosing Ca+inet to C!" Eo. 9 *T0: #*traight Thread 0C:ing$
A
A?* 5 D!@ inlet line to strainer on Dosing
Ca+inet.
152> E/T
I Air line rom Dosing Ca+inet to C!" Eo. 9 *T0: #*traight Thread 0C:ing$
10 Air line into Dosing ca+inet 35A> E/T
"a#le 0)3 H .osin, Ca#inet Connection *oints

Aote@ "3e A8&9.E: =ent port of item 5 a#o%e must 3a%e a A8&9.E: =ent
/ine installed to route #uffer tan; fumes to meet local95&2A ,uidelines for
Ammonia fumes and t3e follo7in, routin, re+uirements@
1) =ent /ine e<it must #e #elo7 A8& 9 .E: inCector
2) =ent line must #e routed #ac; to stora,e tan; or a local95&2A
appro%ed 7aste container in t3e unli;el' e%ent of #uffer tan; o%erfill
3) =ent line must #e routed continuousl' a7a' from %ent port 7it3out
an' ;in;s or loops t3at 7ould allo7 A8& 9 .E: poolin, in line

.osin, Ca#inet to A8& 9 .E: nCector

Air /ine
Connection from
.osin, Ca#inet
?C :lare, &AE
?510
Q K1-
.E: /ine
Connection from
.osin, Ca#inet
?C :lare, &AE
?510
491-K18
D!@ 'nHector Connections

@ig. 4.9a L A?* 5 D!@ 'nHector Connections

.osin, ca#inet s'm#ols@
.E:
.E:
.E:
.E:
.E:
.E:
CA8"5A@ 110=AC -02I electric
po7er present)
110=
-02I
3
0
4
6
5
7
5
4

AC *o7er Connection

During the installation o the dosing ca+inet) e-ternal po3er suppl% #AC po3er
onl%$ has to +e routed inside the ca+inet via appropriate opening. The
termination o these po3er lines are inside the ca+inet at the Hunction +loc, as
sho3n +elo3.
Customer
Connections@
!round
Common
(Aeutral)
*o7er
(2ot)

@ig. 4.A L !-ample AC /o3er Connection to Dosing Ca+inet


A8& 9 .E: &uppl' to t3e .osin, Ca#inet

Desired ill rate is a+out 1.5 gallon per min at 5C10 psig A?*5D!@ suppl%
pressure at the dosing ca+inet ill port. @or e-ample a 10 eet height dierence
generates 4.Fpsi A?* 5 D!@ pressure. @ill rate and overall lo3 restriction in
valves) lines) and ilters upstream to the dosing ca+inet need to +e accounted or
3hen designing the A?* 5 D!@ suppl%.

A?* 5 D!@ suppl% to the dosing ca+inet must +e supplied +% a transer pump.
The transer pump must +e si&ed to provide 5C10 psig 3ith ma- o 10 psig A?* 5
A?* 5 D!@ pressure at the dosing ca+inet ill port +ased on the lo3 rate and
total lo3 restriction in the line rom the remote tan, to the ca+inet.

Dosing ca+inet provides a 24NDC #ma- ampM 300 mA$ signal via atertreatment
!C" connector to control a rela% used to control the po3er suppl% to the transer
pump as sho3n in @ig. 9.10. Atertreatment sot3are 3ill energi&e the rela% at ill
and turn it o 3hen the ill is done. This rela% is not provided 3ith the dosing
ca+inet. To use this eature) the customer needs to 3ire the rela%. 'n addition)
the customer also need connect a 3ire rom the pin K1C31 o the atertreatment
!C" connector inside the dosing ca+inet to the pin 14 o the connector or
Ca+inet to !ngine) i.e. item 1 sho3n in @ig. 4.9. The 3iring diagram or the
optional installer provided transer pump e-ample is sho3n +elo3.

:i,) 0)10 H "ransfer *ump 1irin, .ia,ram 7it3 ECM and $ela'


1ei,3t and .imensions@

3516 Dosing Cainet C!"# Dosing Cainet
$ength %mm& '(# 1#1#
Width %mm& 5## 553
Height %mm& 5"5 63(
Weight )ithout A*+ , D-. %/g& '5 '5

1oth the 3519 J C2A0 Dosing Ca+inet have identical interace connections.
4o3ever the C2A0 application has a larger ootprint and space claim. The igure
+elo3 sho3s these dimensions and dierences.
5
8
5

m
m
6
3
4

m
m

@ig. 4.11 L 3519 J C2A0 Dosing Ca+inet *pace Claim J *5E ;ocation

/iftin, and Mountin,@

The preerred method o liting the dosing ca+inet is to use t3o straps through the
openings in the +ase rame as sho3n in @ig. 4.12.

The ca+inet can +e mounted +% the use o +olts. The ca+inet rame rails have 4
" 10 +olts holes that are to +e used to mount the ca+inet to the vessels
mounting structure.

Mountin,
>rac;ets
2ole siIed
for M10
>olt K0
/iftin, &lots

:i,) 0)12 H Mountin, .osin, Ca#inet

:eer to &ection 5 L "ounting Considerations or additional mounting guidelines.

Clearance@

Dosing ca+inet is re6uired to have clearances around the outside o the +o- per
@ig. 4.13. ' one o the sides 3ith 2 t o clearance is not accessi+le then it is
re6uired to have 4 t o clearance on the side that is accessi+le and is not
necessar% to maintain the 2 t o clearance on the inaccessi+le side.
2 t.
2 t.
0.5 t.
1.5 t.

:i,) 0)13 H .osin, Ca#inet Mountin, Clearance $e+uirements

5rientation@

The dosing ca+inet has to +e mounted per @ig. 4.12 in the vertical position. The
ca+inet needs to +e mounted 3ith the top o the ca+inet parallel 3ith the hori&on.
The dosing ca+inet should not +e tilted +% more than 1A deg rom the vertical
position.

/ocation@

"ounting location o the Dosing ca+inet must +e 3ithin 10 meters #30t$ o the
C!" inHector and the top o the Dosing ca+inet must +e at or +elo3 the +ottom o
the C!" "ounting pads. The ma-imum pressure drop in the A?* 5 D!@ ;ine
+et3een the Dosing Ca+inet and C!" inHector no&&le is 2I psi or 200 ,/a.

En%ironment@

The dosing ca+inet needs to +e located so that it 3ill not +e su+Hected to am+ient
temperatures higher than 55 C or lo3er than C40 C. The components 3ithin the
dosing ca+inet are designed to operate in temperatures per the a+ove
speciications.

A8& 9 .E: .eli%er' &'stem

Caterpillar.s *elective Catal%st :eduction #*C:$ s%stem is contained in a module
and utili&es A?* 5 D!@ to reduce engineCout E0-. A?* 5 D!@ is a solid at room
temperature) +ut is t%picall% placed into a deCioni&ed 3ater solution to acilitate
high resolution metering 3hich is necessar% or the D!@5*C: s%stem to operate
at high eiciencies 3ithout inducing ammonia slip. Also note that D!@
#C0#E4
2
$
2
$ itsel is simpl% a sae <transporter> o ammonia #E4
3
$ 3hich is 3hat
ultimatel% drives this *C: process. This is descri+ed in the glo+al e6uations
+elo3.
C0#E4
2
$
2
Y 4
2
0 \ 2E4
3
Y C0
2
E0 Y E0
2
Y 2E4
3
\ 2E
2
Y 34
2
0

An onsite) or in the case o a "arine Nessel) an on +oard A?* 5 D!@ storage
must +e provided +% the installer and the piping to deliver the A?* 5 D!@ 3ater
solution to the pump on the module 3hich 3ill inHect the A?* 5 D!@ into the
engine e-haust stream 3here the A?* 5 D!@ then decomposes into E43 and
reacts 3ith E0- primaril% in the presence o the *C: catal%st.
A8& 9 .E: 2andlin,
:eer to Appendi- DM <A?* 5 D!@ 4andling> or appropriate handling methods.

Material &election for "an; and *ipin,

"aterial compati+ilities must +e considered in the A?* 5 D!@ storage and
deliver% s%stem due to the caustic corrosive nature o the li6uid.


4ighl% allo%ed austenitic CrCEi and CrCEiC"o *teels or *tainless *teel
#304) 304;) 319;) 40I) 43I$ materials are recommended or use 3ith
A?*32 #urea 3ater solution$.

Titanium is recommended or use 3ith A?* 5 D!@ 3ater solution

"etals J /lastics coated 3ith nic,el are not recommended +ecause nic,el
coating inner diameters o components and dura+ilit% #resistance to
la,ing$ o nic,el coating are not consistent.

/ol%eth%lene) /ol%prop%lene) /ol%iso+ut%lene) /erluoroal,o-%l al,ane
#/@A$) /ol%luroeth%lene #/@!$) /ol%vin%lideneluoride #/ND@$)
/ol%tetraluroeth%lene #/T@!$ are all recommended materials

*eal54ose "aterials L !/D" #1!0F121$ and E1: #1!0F41$ are
suggested materials or use 3ith A?*32.

Aluminum and its allo%s are not recommended or use as tan, material or
D!@ tan,s. 0nl% certain grades o anodi&ed aluminum are accepta+le +ut
due to varia+ilit% o anodi&ing 6ualit%) it is not recommended as tan,
material either.

EonCerrous metals and allo%s #copper) copper allo%s) &inc) lead$ are
strongl% not recommended
A8& 9 .E: /ines
Connections
T%pical ittings have mild steel as the +ase material) 3hich 3ill not +e compati+le
3ith A?* 5 D!@. All connection points and ittings or the A?* 5 D!@ lines are
re6uired to +e stainless steel or A?* 5 D!@ compati+le material.
/ine &pecifications
Dosing Ca+inet to C!" A?* 5 D!@ line
nside .iameter H !reater t3an 5)5mm and /ess t3an 7)5mm
;ength L ;ess than 9.1 meter #20 t.$ in length
0il resistant
Connections per Ta+le 4.1

A?* 5 D!@ ;ines rom storage tan, to +uer tan,

A minimum of 5 *& 3ead pressure on A8& 9 .E: in line and a
ma<imum of 10 *& is re+uired at all times durin, operation to
assure t3at t3e #uffer tan; can #e filled 73en it runs lo7)
A8& 9 .E: line must #e capa#le of deli%erin, A8& 9 .E: in
atmosp3eric conditions do7n to 600C 7it3out A8& 9 .E:
freeIin, and impedin, fillin, of #uffer tan; 73en re+uired)

A?* 5 D!@ ;ines 'nstallation J :outing

A?* 5 D!@ lines are to +e installed ollo3ing instructions +ased on D'E 20099
part 4. (eneral routing and clipping rules should include ,eeping these lines rom
coming in contact 3ith sharp edges that 3ould atigue and ail the line rom
vi+ration or s%stem operating movements. 0ther considerations should include
continuous routing 3ithout ,in,s) e-treme +ends and loops that 3ould restrict
A?* 5 D!@ lo3 throughout the operating temperature e-tremes.

' there is more than one engine5/!T?5C!" installed on a vessel) than a shut o
valve must +e installed +eore the dosing ca+inet5/!T? in the A?*5D!@ line
rom the transer pump. The valve 3ill allo3 that one /!T? to +e turned o or
service) 3hile other engines and /!T? are still running. The valve can also +e
used to i a lea, 3ould occur in one o the /!T? to compete its repair.
"3ermal Control

A?* 5 D!@ storage and deliver% s%stems must +e designed to accommodate
ree&ing as 3ell as perorm E0- reduction unctionalit% at am+ient temperatures
+elo3 the ree&ing point o the luid.

A8& 9 .E: &tora,e "an;

The 0!" or installer must provide a A?* 5 D!@ main storage tan, and deliver%
s%stem.

The 0!" or 'nstaller must provide a means to sample A?* 5 D!@ in the tan, to
determine A?* 5 D!@ Rualit%.

A?* 5 D!@ storage tan,s must +e designed to the industr% +est practices or luid
storage tan,s) +ut also 3ith consideration or A?* 5 D!@ %ou need to 3atch or
am+ient conditions or +oth high and lo3 temperatures. ' the tan, 3ould have a
chance o ree&ing) then the tan, needs to +e designed 3ith an eective heat
e-changer that is capa+le o tha3ing the tan,. ?nli,e other common operating
luids) such as diesel uel and coolant) A?* 5 D!@ ree&es at a temperature
3ithin the operating limits o the engine.

A?*5D!@ in the tan, ree&es rom the outside to the center. The densit% o ro&en
A?*5D!@ is lo3er than the densit% o the li6uid A?*5D!@. This means that the

ro&en A?*5D!@ loats on the li6uid A?*5D!@. To ensure that the complete tan,
o A?*5D!@ is tha3ed) at least part o the heating source has to +e located at
the +ottom o the tan,. The A?*5D!@ pic,Cup location has to +e ver% close to the
heating source and dra3 rom the +ottom o the tan, as 3ell. As the A?*5D!@ is
consumed) the A?*5D!@ level in the tan, reduces and the cold A?*5D!@
approaches the heater.

To acilitate the tha3ing process) the tan, should have a simple rectangular or
trape&oidal shape 3herein the +ase o the tan, is slightl% larger than the top o
the tan,2 a <p%ramid> design #no plateaus$ is recommended or +est tha3ing
perormance. *hapes that do not assure the gradual reduction in the level o
A?*5D!@ have to +e avoided. Tan, shapes var% rom application to application
+ased on design and space limitations. 'rregularit% in these shapes is accepta+le
as long as the air poc,ets and5or stuc, chun,s o ro&en A?*5D!@ inside the
ridges or an% other contours o the tan, can +e avoided. 't is also preera+le to
have the 3idth o the tan, e6ual or smaller than the height o the tan,. *hort and
long tan,s are not avora+le or A?*5D!@ ree&e protection.

0an/ 1olume

Tan, volume should +e si&ed +ased on re6uired reill re6uenc%) A?* 5 D!@
ree&e e-pansion) and the volume o internal tan, components. The A?* 5 D!@
tan, si&e is dependant upon A?* 5 D!@ 6ualit% over duration o use and deliver%
inrastructure. The A?* 5 D!@ tan,s must +e si&ed never to run out. Tan, si&es
3ill depend on vessel designed operating proile and its normal ueling stops.
A?* 5 D!@ tan,s must +e si&ed such that suicient A?* 5 D!@ is al3a%s
availa+le to ade6uatel% operate the *C: s%stem. The amount o A?* 5 D!@
usage can +e reasona+l% estimated as a direct raction o the engine uel +urn)
on an average the amount o A?* 5 D!@ consumed +% the engines 3ill +e
around 10D or the 3500 engines and up3ards o 15D or C2A0 engines.
!-ample or 3500 engine is 1 gallon o A?* 5 D!@ or ever% 10 gallons o uel
usage. *uch) a calculation must +e +ased on the amount o uel that ma% +e
+urned +% the engine5engines +et3een A?* 5 D!@ ill up opportunities. This
value should +e +ased on an operational ,no3ledge o the vessels e-pected
service) and the engines proHected uel usage. The A?* 5 D!@ tan, should then
+e si&ed to accommodate the re6uisite raction o A?* 5 D!@ as outlined in the
ta+le +elo3. As an e-ample) i an anal%sis o the operating proile o a 3500
si&ed engine sho3s that it could +urn 1)000 gallons o uel +et3een A?* 5 D!@
ill opportunities) then the A?* 5 D!@ tan, 3ould need to +e si&ed to hold at least
100 gallons o 32.5D A?* 5 D!@ over and a+ove an% space ta,en up +% an%
tan, inserts) such as level s3itches.X 8hen igure out the uel usage and A?* 5
D!@ usage the operation proile must +e used to determine +oth uel tan, si&e
and A?* 5 D!@ tan, si&e.


The urea #A?* 5 D!@$ tan, placement into a "arine Nessel must +e designed
into a place 3here the urea 3ill not +e allo3ed to ree&e. Caterpillar.s normal tan,
ree&e protection s%stem volume o 2D or ree&e e-pansion volume 3ill not +e
re6uired. Caterpillar o road capacit% saet% margin is 5D o the total tan,
volume. The urea tan,s si&e on "arine Nessels 3ill +e designed +ased on
operating load proile o the vessels 3ith a saet% actor o <never to run out>. @uel
and urea tan, volume 3ill +e +ase on operating proile and normal vessel ueling
stop.
'nstances 3here insuicient A?* 5 D!@ is availa+le 3ill +e recorded in
nonvolatile memor% +% the engine) and the end user must report these instances
to the !/A.

0an/ Connections

The A?*5D!@ line suction or pic,Cup connection should +e placed at the
+ottom o the tan,) and as close to the heat e-changer as possi+le i installed.
This location has the greatest potential or the irst availa+le li6uid A?* 5 D!@
during tha3ing. Ade6uate protection o the pic,up tip is recommended to
,eep untha3ed A?* 5 D!@ rom +loc,ing port. 0n the return side) melted
A?* 5 D!@ returning rom the pump has the potential to help tha3 the
remaining ro&en A?* 5 D!@. To ta,e advantage o this potential) the return
port on the tan, should +e at the top o the tan,.
"an; mountin, location in Marine =essels

The ideal location o the A?*5D!@ tan, is as close as possi+le to the center o
gravit% o the Nessel. This 3ould result in the least sloshing possi+le. /ro-imit%
to heat sources should also +e considered in tan, placement) as prolonged
e-posure to elevated temperatures causes thermal degradation o A?* 5 D!@ in
the tan,. The tan, should +e located in the Nessel 3here the tan, temperatures
3ill not ree&e and not e-ceed the high temperature re6uirements or proper
storage. The proper storage temperature range or A?*5D!@ is +et3een 15W@
and FFW@ #CIWC and 25WC$ that is stored a+ove the I5W@ #35WC$ or longer than
one month must +e tested to ma,e sure 6ualit% is not degrading and A?*5D!@
meets re6uired spec. Tan, must +e location on Nessel to meet the temperatures
re6uirements to avoid degradation o A?*5D!@. ' location o the tan, 3ithin a
Nessel can.t meet the temperature re6uirements or A?*5D!@ than a 3a% to cool
or heat the luid must +e installed in the main A?*5D!@ tan,. ?se o thermal
insulation is another 3a% o ,eeping the tan, temperatures 3ithin the proper
temperature re6uirements or storage.

Although highCdensit% pol%eth%lene is a poor conductor o heat) additional
insulation 3ill help to protect A?*5D!@ rom thermal degradation.

"an; Materials

EonCcross lin,ed pol%eth%lene #/!$ is the material o choice or A?*5D!@ tan,s.
't provides a 3ide temperature range o operation) has good strength properties)
allo3s or le-i+ilit% in <shaping>) lo3 in 3eight) and has +een used other
A?*5D!@ applications.

2n30an/ .iltration

'nCtan, iltration is re6uired to protect the A?*5D!@ deliver% s%stem.

An inlet strainer is re6uired to prevent large de+ris rom entering the tan,. The
strainer should +e made o stainless steel 3ith 30Cmesh5500 micron iltration.
# :e. Cat /E 10AC3F30$.

An <'ce+erg Catcher> must +e located at the end o the A?*5D!@ pic,up line in
the tan, to ,eep ro&en chun,s o A?*5D!@ out o the deliver% s%stem. This 3ill
act as secondar% iltration into the A?*5D!@ deliver% s%stem) +ut 3ill not provide
enough iltration to meet the re6uirements or the A?*5D!@ deliver% s%stems.
@unctional speciication or the ice+erg catcher is consistent 3ith !uro 4 #!*C
20A4$. Technical re6uirements o the ilter are or A?*5D!@ lo3 capacit% or the
deliver% s%stem #area o the mesh$ and the iltration re6uirements #si&e o the
mesh C 100 um$.
"an; &ensors

A?*5D!@ tan, designs must provide or appropriate interaces 3ith tan, sensors.
The ultrasonic A?*5D!@ level sensor needs to +e installed perpendicular to the
luid #3hen level$ 3ith a minimum o a 2> space +et3een the sensor and the luid.
This re6uirement drives the placement o the sensor to the top o the tan,.
Additionall% the A?*5D!@ level sensor should +e placed as close to the center o
the A?*5D!@ tan, as possi+le and have line o sight to the +ottom o the
A?*5D!@ tan,. The sensor is salt and A?*32 corrosion resistant) 3ith an
operating temperature range o L40WC to A5WC.

A*+ , D-. 0emperature +ensor

The A?*5D!@ temperature sensor pro+e unctionall% needs to +e located ver%
close to the A?*5D!@ suction line in order to determine i there is li6uid A?* 5
D!@ availa+le or the s%stem.

Temperature sensor re6uirements +ased on the reerence sensor includeM
operating temperature range L40C and 150C #pro+e end$) L40C and 120C
#connector end$) vi+ration limitsM 30(rmsU3sigma or 0.03D o operational
lietime) and it is salt J A?* 5 D!@ corrosion resistant.
' an electrostatic painting process is used) then proper grounding must +e in
place during the paint process.

A*+ , D-. $e4el +ensor

A lo3 level urea tan, sensor must +e placed in the main urea tan,. The sensor
3ill send a signal to the dosing ca+inet !C" 3hen the A?*5D!@ level in the tan,
drops to 13.5D let in the tan,. The dosing ca+inet 3ill 3arn the vessel operator
3hen the A?*5D!@ main tan, reaches the sensor. Eo aults are recorded unless
the tan, runs empt% o A?*5D!@. The sensor inside the dosing ca+inet 3ill
record 3hen the s%stem is completel% out o A?*5D!@. The lo3 level sensor in
the main A?*5D!@ tan, 3ill onl% suppl% a 3arning to the operator that his
A?*5D!@ tan, is running lo3. The lo3 level sensor input into the dosing ca+inet
!C" is a s3itch input to (ED. These t3o points are re6uired to compl% 3ith !/A
1042 rules.

't is recommended that along 3ith the level sensor a 3arning light is provided to
indicate 3hen A?*5D!@ level is lo3. The 3arning light should +e set at a level
that 3ill provide ade6uate time to ac6uire 6ualit% A?*5D!@ and reill the tan,.

"an; 2eatin,

4eating o the A?*5D!@ tan, or tha3ing can +e carried out in various 3a%s.
4eat can come rom an electric heater) or a heat e-changer using one o the
various 3or,ing luids on a "arine Nessel) including coolant) engine oil) h%draulic
oil) and e-haust. 0ut o these sources) a heat e-changer using coolant is the
optimal solution. !lectricit% is also accepta+le or perormance) +ut the
amperage re6uirement is ver% high. Although other luids ma% have e6ual or
higher temperatures) coolant.s high speciic heat ena+les it to outperorm the
others. "ass lo3 rate also pla%s a maHor role in determining the heating
potential o a luid.

8hile a heat e-changer using coolant has man% advantages) it also has one
maHor perormance disadvantage compared to an electric heater. 8hile an
electric heater can +egin tha3ing A?*5D!@ almost immediatel% ater startup)
engine coolant 3arms up more slo3l%.

2eat E<c3an,er .esi,n

1ased on the highest rate o consumption) the heat e-changer #a stainless steel
coolant line$ can +e si&ed to provide tha3ing. The si&ing is accomplished +%
utili&ing the ollo3ing e6uationM
mC
p) solid D!@
dT
solid D!@
Y m4 Y mC
p)li6uid
dT
li6uid D!@
] ?A #T
coolant
CT
D!@
$
3hereM

m ] 2 - D!@ consumption) ,g5s

C
p) solid D!@
] speciic heat o ro&en D!@ solution) ,K5,gCP

C
p) li6uid D!@
] speciic heat o li6uid D!@ solution) ,K5,gCP

dT
solid D!@
] C11C C 'nitial temperature o D!@) C


4 ] ;atent heat o usion o A?* 5 D!@ solution) ,K5,g

dT
li6uid D!@
] @inal) re6uired temperature o D!@ C C11C) C
? ] 0verall heat transer coeicient) ,85m
2
CP

A ] 4eat transer area) m
2

T
coolant
] A!CD Coolant temperature) C

T
D!@
] :e6uired temperature o A?* 5 D!@) C

The overall heat transer coeicient) ? can +e o+tained rom the ollo3ing e6uationM
ice ice ss ss
ss
coolant coolant
A h A K
l
A h UA
1 1 1
+ + =

8hereM
h
coolant
] Convective heat transer coeicient o the coolant inside the coolant line)
3hich can +e o+tained rom the e6uation
Eu ] hD5P
A
coolant
] *urace area o the coolant) m
2

l
ss
] thic,ness o the stainless steel tu+e) m

P
ss
]Thermal conductivit% o stainless steel) ,85mCP

A
ss
] "ean surace area o the stainless steel tu+e) m
2

h
ice
] Convective heat transer coeicient o the ro&en A?* 5 D!@ solution
surrounding the tu+e) ,85m
2
CP

A
ice
] *urace area o the 0D o the tu+e) m
2

The heat transer area) A) can +e calculated rom the a+ove e6uation. This area
can +e translated into an e6uivalent length and diameter o the coolant line.

2nsulation Re5uirements

Although nonCmetallic A?*5D!@ tan,s are a ver% poor conductor o heat)
depending on the pro-imit% o the A?*5D!@ tan, to a heat source) additional
thermal insulation ma% +e re6uired. @or metallic tan,s) thermal insulation is
re6uired to help improve the A?*5D!@ tha3ing process in addition to heat
protection. A?* 32 ree&es at L11WC and starts to degrade at elevated
temperatures a+ove 50 WC.

The main storage tan, location in a Nessel needs to +e ta,en into consideration
or +oth high and lo3 temperature re6uirements o urea. ' the tan, is located in a
high temperature area o the vessel then insulate the tan, or design in some t%pe
o cooling design to ,eep the urea +elo3 the ma-imum temperature limits. '
"arine Nessel 3ill +e spending time in cold operating areas then the urea tan,s
needs to +e ,eep rom ree&ing. This can +e accomplished +% insulating the tan,
or +% adding heater to the tan, to ,eep the temperatures rom ree&ing.


-nerg6 +ource

!nerg% :e6uirements

@or A?*5D!@ tha3ing) the recommended melt rate or ro&en A?*5D!@ is t3ice
the ma-imum consumption rate. This gives a +ra,eCspeciic melting rate o 34
g5,8Chr and 21 g5,8Chr or ratings 1F5CF50 hp and greater than F50 hp)
respectivel%. These num+ers should +e used 3hen si&ing a heat e-changer or
electric heater.

4eat !-changer Design

/ic,up5:eturn ;ocation

@lo3 rate5Tha3 rate min.


Electrical
>loc; .ia,ram

:i,) 0)10 H .osin, Ca#inet >loc; .ia,ram H 351-C2.9C175

Electrical Connections

2nterconnect Harness Connectors
Dosing Ca+inet *ide
All Applications

Dosing Ca+inet /TCC9F4 to !ngine via Kunction 1o-
23 8a% 'nterconnect 4arness ConnectorM 433C030A #"atingM 3AAC9913$
TermM /ins
Connector
/in !C" /in @unction 8ire 'D
8ire *i&e
#A8($
A Cat Data ;in, #C$ I45C1: 1A
1 Cat Data ;in, #Y$ I44C0: 1A
C K1I3I C (lo+al CAE A #C$ PII0C(E 1A
D K1I3I C (lo+al CAE A #Y$ PI00C=; 1A
! CCCCCCCC C C
@ CCCCCCCC C C
( K1I3I C ;ocal CAE 1 #C$ :IF9C(E 1A
4 K1I3I C ;ocal CAE 1 #Y$ :IF0C=; 1A
K A?* 5 D!@ ;ine 4eater :ela% 4' *3 1att Y /A30C/? 1A
P A?* 5 D!@ ;ine 4eater :ela% ;o *3 1att C ;A3AC0: 1A
; A?* 5 D!@ Transer /ump *3 =F1IC1? 1A
" !C" K1 L 1atter% Y 101C:D 14
E !C" K1 L 1atter% C A250C1P 14
0 CCCCCCCC C C
/ !C" K1 L 1atter% Y 101C:D 14
R CCCCCCCC C C
: !C" K1 L 1atter% C A250C1P 14
* A?* 5 D!@ ;ine 4eater :ela% 4' C54FC1 103C=; 1A
T A?* 5 D!@ ;ine 4eater :ela% ;o C54AC1 22IC1P 14
? A?* 5 D!@ "aniold 4eater :ela% C549C1 103C=; 14
N A?* 5 D!@ "aniold 4eater :eturn 22IC1P 14
8 Pe%s3itch 105C1: 1A
U CCCCCCCC C C


Dosing Ca+inet /TCC9IA to Tan, %ia ?unction >o<
14 8a% 'nterconnect 4arness ConnectorM 425C453F #"atingM 433C0310$
TermM *oc,ets
Connector
8ire *i&e
#A8($
A A?* 5 D!@ ;evel *ensor 4A5FC/P 1A
1 A?* 5 D!@ Tan, Temperature PA11C1; 1A
C Analog *ensor :eturn =I4FC1: 1A
D A?* 5 D!@ Tan, 4eater :ela% *uppl% PA3IC1? 1A
! A?* 5 D!@ Tan, 4eater :ela% :eturn TFI1C1: 1A
@ A?* 5 D!@ ;ine 4eater :ela% 4' *3 1att Y /A30C/? 1A
( A?* 5 D!@ ;ine 4eater :ela% ;o *3 1att C ;A3AC0: 1A
4 A?* 5 D!@ Transer /ump *3 =F1IC1? 1A
K Tan, 4igh *3 410C84 1A
P Tan, ;o3 *3 A4AFC/? 1A
; A?* 5 D!@ Transer /ump :ela% 1att Y 101C:D 1A
" CCCCCCCCCCCCCC C C
E CCCCCCCCCCCCCC C C
/ CCCCCCCCCCCCCC C C

Dosing Ca+inet /TCC9II to C!" %ia ?unction >o<
23 8a% 'nterconnect 4arness ConnectorM 433C030I #"atingM 425C4540$
TermM /ins
Connector
8ire *i&e
#A8($
A A@T" Z1 'D "odule PAI5C1? 1A
1 CCCCCCCCCCCC C C
C Y5N Analog *ensor *uppl% IIFC0: 1A
D CCCCCCCCCCCC C C
! CCCCCCCCCCCC C C
@ Analog *ensor :eturn TII3C1: C
( CCCCCCCCCCCC C C
4 K1I3I C ;ocal CAE 1 #C$ :IF9C(E 1A
K K1I3I C ;ocal CAE 1 #Y$ :IF0C=; 1A
P D0C 1 Delta /ressure /I3AC84 1A
; A@T" 1 *C: 'nlet (as Temp KAI0C1? 1A
" *C: 1 0utlet (as Temp KAI1C(E 1A
E 'nlet 1 E0- *ensor ;I20C1: 1A
/ 0utlet 1 E0- *ensor ;I21C=; 1A
: 0utlet 2 E0- *ensor ;I22C1? 1A
* E0- *ensor :eturn KA0FC1P 1A
T A?* 5 D!@ ;ine 4eater :ela% 4' *3 1att Y /A30C/? 1A
? A?* 5 D!@ ;ine 4eater :ela% ;o *3 1att C ;A3AC0: 1A
N CCCCCCCCCCCC C C
8 CCCCCCCCCCCC C C
U CCCCCCCCCCCC C C


C!" *ide

C!" 'nlet 1o- /ACCI10 to Dosing Ca+inet via Kunction 1o-
1A 8a% 'nterconnect 4arness ConnectorM 331C35IA #"atingM 331C35I2$
TermM *oc,ets
Connector
8ire *i&e
#A8($
1 CCCCCCCCCCCCCC C C
2 K1I3I C ;ocal CAE 1 #C$ :IF9C(E 19
3 K1I3I C ;ocal CAE 1 #Y$ :IF0C=; 19
4 (nd L 'nta,e E0- *ensor KA0FC1P 19
5 N* L 'nlet Temp *ensor IIFC0: 19
F CCCCCCCCCCCCCC C C
A CCCCCCCCCCCCCC C C
I *ignal L C!" 'nlet A1* /ressure *ensor /I3AC84 19
10 N* L 'nlet E0- *ensor ;I20C1: 19
11 N* L C!" 'nlet A1* /ressure *ensor IIFC0: 19
12 (nd L 'nlet Temp *ensor TII3C1: 19
13 (nd L C!" 'nlet A1* /ressure *ensor TII3C1: 19
14 *ignal L 'nlet Temp *ensor KAI0C1? 19
1F CCCCCCCCCCCCCC C C
1A CCCCCCCCCCCCCC C C

C!" 0utlet 1o- /@CCI10 to Dosing Ca+inet via Kunction 1o-
1I 8a% 'nterconnect 4arness ConnectorM 1IFCF35I #"atingM 1IFCF291$
TermM *oc,ets
Connector
8ire *i&e
#A8($
1 *ignal C 0utlet Temp *ensor KAI1C(E 19
2 Y5N C A@T"T 'D "odule IIFC0: 19
3 0utput *ignal C A@T" 'D "odule PAI5C1? 19
4 (nd L A@T"T 'D "odule TII3C1: 19
5 K1I3I L ;ocal CAE 1 #Y$ :IF0C=; 19
9 K1I3I L ;ocal CAE 1 #C$ :IF9C(E 19
F N* L 0utlet E0- *ensor ;I21C=; 19
A CCCCCCCCCCCCCC C C
I (nd L 0utlet E0- *ensor KA0FC1P 19
11 K1I3I L ;ocal CAE 1 #C$ :IF9C(E 19
13 K1I3I L ;ocal CAE 1 #Y$ :IF0C=; 19
15 (nd L 0utlet Temp *ensor TII3C1: 19
1F N* L 0utlet Temp *ensor IIFC0: 19
1A CCCCCCCCCCCCCC C C
1I CCCCCCCCCCCCCC C C


1!#1 Po)er Connection

The dosing pump re6uires 120N AC po3er to operate. The connection or the
po3er is made inside the dosing ca+inet on a +us +ar 3ith the ca+le routing
through a 3iring grommet on the dosing ca+inet. The hot and neutral 3ire coming
into the ca+inet 3ill hoo, to the terminal strip connectors. Then the ground 3ire
needs to +e hoo,ed up to the grounding stud. This 3ill allo3 the dosing ca+inet
to meet the grounding re6uirements. :eer to 3iring e-ample in @ig. 4.A.

:i,) 0)15 H 120= AC Connection .ia,ram


Electrical /oads

&C$ Component Electrical /oad
#Assume Cold Am+ient Temps$
Component *o7er
AC .C
AC ma<
amp
AC ma<
amp
.C ma<
amp
.C A%e
amp
.C ma<
amp
.C A%e
amp
En,ine
$unnin,
En,ine
&topped
En,ine
$unnin,
En,ine
$unnin,
En,ine
&topped
En,ine
&topped
Dosing pump AC 0.F 0.0
1uer Tan, 4eater AC 2.I 2.I
"aniold heater DC A.3 4.2 A.3 4.2
12N po3er
conditioner
DC 1.0 0.2 1.0 0.2
;ine heater
#dosing5tan, 2.9 m$
DC 15.0 5.0 15.0 5.0
!C" J connected
items TotalM
DC 11.4 3.F 4.2 2.0
1. !C" DC 0 0.3 0.3 0.3 0.3
2. E0-
*ensors
DC 0 F.0 1.0 0.0 0.0
3. Air suppl%
ena+le
solenoid
DC 0 2.0 0.5 2.0 0.0
4. :eagent
return
solenoid
DC 0 0.2 0.1 0.0 0.0
5. /ump ill
solenoid
DC 0 0.2 0.1 0.2 0.0
9. /ump
motor
4eater
DC 0 1.F 1.F 1.F 1.F
F. A?* 5 D!@
Transer
/ump :ela%
#0ptional L
Customer
*upplied$
DC C C 0.3 0.1 0.3 0.1
"otal Component
Current (Amps)
3.9 2.I 39.0 13.2 2A.A 11.5
E0T!M /o3er consumption 35*C: Atertreatment s%stem. This does not include air compressor
and air dr%er.
"a#le 0)5 H Electrical /oads

Electrical Component temperature limits

There are components on the C!" that are re6uired to sta% under speciied
temperature limits. The sensor +o- on the C!" contains the critical electrical
components such as the E0- sensors and temperature sensors. The pressure
sensors ma% or ma% not +e located in the sensor +o-. 't is necessar% that the
components in Ta+le 4.9 do not e-ceed the listed speciications during operation
o the engine s%stem.


Component "emperature /imits
Component
"emp /imit
(C)
Temperature *ensor 120
E0- *ensor Control 1o- A5
Delta /ressure *ensor 125

"a#le 0)- H Electrical Component "emperature /imits

@ig. 4.19 C 3519C4D 'nlet50utlet *pool !lectrical Component ;ocations

The a+ove igure sho3s the electrical component locations or the inlet and outlet
e-haust spools that attach to the C!" +oth ? and O lo3 conigurations.


@igure 4.19a L 0utlet *pool 0rientation

The installation o the outlet spool re6uires the *ensor 1o- to +e on top in
hori&ontal installations 3ith ade6uate clearance to allo3 service o the E0-
sensor. C!"s mounted verticall% #on its end$ the spool must +e oriented to allo3
eas% access to E0- *ensor or service. :eer to the "ounting J ;iting
installation su+section +elo3 or 4ori&ontal and Nertical installation e-amples.

E<3aust &'stem
E<3aust Connections

1oth the inlet and outlet e-haust connections to the C!" utili&e a +olted lange
connection. A gas,et and standard +olt tor6ues are re6uired to maintain a lea,
tight seal. An% connections or the e-haust that are +et3een the tur+o out and
C!" inlet are re6uired to +e lea, tight and utili&e industr% standard e-haust
connection components.

@or urther !-haust *%stem :e6uirements reerence <*ection 4 L !-haust
*%stem.>

Exhaust Inlet
DEF Injector
Inlet Sensor Box
Outlet Sensor Box
Exhaust Outlet
Exhaust Inlet
DEF Injector
Inlet Sensor Box
Outlet Sensor Box
Exhaust Outlet

"op front %ie7 of DRE &t'le &C$ CEM for 351-C2.

"op front %ie7 of D8E &t'le &C$ CEM for 351-C2.


:i,) 0)1- H 351- CEM E<3aust nlet & 5utlet :lan,e .imensions
&ound Attenuation

*ee T"' or sound attenuation data.

nstallation
C!" installation considerations should +e +ased on application) location)
environment and servicea+ilit%. *ervicea+ilit% includes +ut not limited to repair
and maintenance o C!" *%stem components. This ma% include dosing ca+inet)
sensors) catal%st and dosing inHectors. The inlet spool on the C!" that houses
the A?* 5 D!@ inHector is le-i+le through orientation or +etter servicea+ilit%.
Careul attention to details such as this 3ill enhance service and maintenance o
Caterpillar atertreatment s%stems.

Inlet Spool Orientation Flexibility
Option to Enhance Service Access

AoteM Clearance or servicing the A?* 5 D!@ 'nHector must +e maintained +%
providing 20 inches #50A mm$ clearance or inHector access and removal. *pool
orientation option a+ove ma% assist %ou 3hen designing or C!" installation.
-nclosure 0emperature $imits
Nentilating air should enter near the +ottom o the enclosure and then lo3
up3ard around the engine and5or Cat C!" module +eore e-iting a+ove the
engine.

:oom51uilding ventilation should +e designed to +ring the coolest air to the Cat
C!" module. ' the engines and modules are placed in a +uilding that has a
pitched roo then ventilating air should lo3 out at the pea, or near the top o the
ga+le ends. The source o the air must +e lo3 in the room and rise across the
engine and Cat C!" and other e6uipment.

@or personnel comort) maintain air velocit% at 1.5 m5sec #5 t5sec$ in areas o
heat sources or areas that e-ceed 3AWC #100W@$. /otential dead air spaces
should +e chec,ed or temperature rise during engine operation. Chec, all
electrical and mechanical e6uipment in the dead air space or an% detrimental
eects caused +% e-cessive temperatures. :e6uire corrections i necessar%.
!ngine room pressure should not +ecome e-cessivel% negative. This 3ould
indicate a shortage o ventilating air or e-cessive ventilating ans i e6uipped.


nstallation .imensions and !eneral =ie7s@

$efer to "M data for 7ei,3ts of CEM)

Center of !ra%it' /ocation@ 351- R flo7 1- #ric; desi,n CEM

1826 mm
670 mm
!
5 mm
!
1875 mm
"25 mm
2776 mm
3663 mm
1660 mm

"ass o the O lo3 is 13II ,g. The catal%sts are arranged in an A -2 stac,
design.

Center of !ra%it' /ocation@ 8 flo7 1- #ric; desi,n CEM

!
6 mm
1875 mm
683 mm
!
2776 mm
1581 mm
1660 mm
"25 mm

"ass o the ? lo3 is 13I0 ,g. The catal%sts are arranged in an A -2 stac,
design.


Mountin, & /iftin,

@or re6uirements :eerence *ection 5 L "ounting Considerations.

'n addition to the a+ove re6uirements) please note the gCload re6uirements or
the ollo3ing C!" amiliesM

1) 3500 and C175@ 8 and R flo7 desi,n CEM
a) :ore9Aft H up to 2 !Ss
#) =ertical H up to 2 !Ss
c) &ide to &ide H up to 2 !Ss
2) C280 CEM desi,n@
a) :ore9Aft H up to 2 !Ss
#) =ertical H up to 2 !Ss
c) &ide to &ide H up to 2 !Ss

1arnin,@ &tandin, on top of t3e CEM and usin, t3e top of t3e CEM as 7or;
platform is strictl' pro3i#ited)
Marine Aftertreatment Mountin, 6 "3ermal E<pansion
#hermal Ex$ans%on &
15 mm
#hermal Ex$ans%on &
7 mm 'to (e
a(sor(e) (* (ello+s,
#hermal Ex$ans%on &
8 mm
#hermal Ex$ans%on &
4mm
#hermal Ex$ans%on &
15 mm
#hermal Ex$ans%on &
7 mm 'to (e
#hermal Ex$ans%on &
8 mm
#hermal Ex$ans%on &
15 mm
#hermal Ex$ans%on &
7 mm 'to (e
#hermal Ex$ans%on &
8 mm
#hermal Ex$ans%on &
4mm

"3ermal nsulation
'nsulation is re6uired or Atertreatment inlet and outlet. :eer to *ection 9M
Thermal "anagement or insulation details.

nsulation must #e
used 7it3 proper
spool orientation)

3500 and C175@ 8 and R :lo7 CEM Mountin,

Cat C!" provisions or mounting are a 4 +olt pattern per pad. There are a
num+er o pad locations depending on 3hich 3a% the C!" is mounted in the
Nessel. "ounting re6uires the use o at least our mounting pads 3hen mounting
in the vessel. 1olt re6uirements are "20 grade 10.I 1olts.


There are t3o t%pes o C!" 3hich are +ased on the e-haust lo3 direction. 0ne
t%pe is ?Clo3 and another one is OClo3. 'n ?Clo3 coniguration) +oth the inlet
and outlet o e-haust gas are on same side o the C!".
8hereas) in case o OClo3 coniguration) the inlet and outlet o e-haust gas are
on opposite sides o the C!".

The mounting components should +e a+le to meet the ollo3ing re6uirementsM
1$ "ount should +e a+le to support the 3eight o the C!"
2$ 't should +e a+le to 3ithstand the high temperature o e-haust gases
3$ 't should +e a+le to limit the stresses on +ello3s rom displacement and
thermal gro3th) 3hich necessitates the i-ed mount on the inlet side.
4$ There should +e le-i+le mount on the outlet side to ta,e care o d%namic
conditions and allo3 thermal e-pansion o C!"

;C+rac,et needed or mounting and add to the stiness
/ipe length has no inluence i the 3eight change is less than 5D.

There are mainl% three t%pes o mountsM cushion mount) ca+le mount and
sta+ili&er. Cushion mount alls under the i-ed mount categor%) 3hereas) ca+le
mount and sta+ili&er all under the le-i+le mount categor%.

The pros and cons associated 3ith the sta+ili&er and cushion5ca+le mount
options are as ollo3sM
1$ *ta+ili&er option is more prevalent than the cushion and ca+le mount
options.
2$ *ta+ili&er is around 20D cheaper than cushion and ca+le mount.
3$ Eoise and vi+ration is more 3ith sta+ili&er option.

'n order to isolate the vi+ration rom the mounts) the mount stiness
re6uirements are as ollo3sM
1$ The mounting +rac,et should +e at least 10 times stier than the mounts
#i-ed and le-i+le$.
2$ @oundation should +e 10 times stier than the mounts #i-ed J le-i+le$.

0ther3ise) no vi+ration isolation rom the mounts.

8 :lo7 &'stem /e%el &c3ematic
As sho3n in the schematic +elo3) or ?Clo3) the e-haust gas inlet and outlet are
on the same side o the C!". The C!" is supported 3ith i-ed mount on the
inlet J outlet side to ,eep this side o the C!" rigid limiting the stresses on the
+ello3s on upstream side o C!". 4o3ever) the other side o the C!" is
supported on le-i+le mount to ta,e care o d%namic conditions and allo3 thermal
e-pansion o the C!".

Inlet S$ool
Outlet S$ool
-ount%n. /s
atal*st !$
o0er !$
on0erter /s

System Level Schematic U Flow
Engine Bellows
AT System
Muffler/
Tailpipe
Fie! Mount Flei"le Mount
Movement

AT ] Atertreatment

O @lo3 *%stem ;evel *chematic
As sho3n in the schematic) or OClo3) the e-haust gas inlet and outlet are on the
opposite side o the C!". The C!" is supported 3ith i-ed mount on the inlet
side to limit stresses on +ello3s and le-i+le mount on the outlet side o the C!"
to allo3 le-i+ilit% and thermal e-pansion o C!".

on0erter /s
Inlet Sensor Box
Outlet Sensor Box
Insulat%on
Outlet S$ool
o0er !$
Inlet S$ool
-ount%n. /s
on0erter /s
Inlet Sensor Box
Outlet Sensor Box
Insulat%on
Outlet S$ool
o0er !$
Inlet S$ool
on0erter /s
Inlet Sensor Box
Outlet Sensor Box
Insulat%on
Outlet S$ool
on0erter /s
Inlet Sensor Box
Outlet Sensor Box
Insulat%on
Outlet S$ool
o0er !$
Inlet S$ool
-ount%n. /s

System Level Schematic # Flow
Engine Bellows
AT System
Muffler/
Tailpipe
$nlet %&igh Temp 'utlet%Low Temp
Fie! Mount
Flei"le Mount
Movement

Mountin, &upport

There are three t%pes o C!" support mountsM

:i<ed &upport@ !-haust !6uipment Categor%
C ** Cushion "ount #semiCcustom$ L compression mount
AT ] Atertreatment


:le<i#le &upport@ *hoc, "ounting Categor%
C ** Ca+le "ount L Compression mount

:le<i#le &upport (3an,in,)@ !-h. !6uipment Categor%
C @le-i+le *uspension L Tension mount

The i-ed support) 3hich is compression mount) alls under the e-haust
e6uipment categor%. The le-i+le support) 3hich is also compression mount) is
categori&ed as shoc, mount. 4o3ever) the hanging option) 3hich is tension
mount) is categori&ed as e-haust e6uipment.

8 :lo7 Mountin, Confi,uration
2oriIontal Mountin, #"ounted on @loor$
The +asic ?Clo3 C!" mounting coniguration is the hori&ontal mounting as
sho3n +elo3. The t3o mounting eet on inlet and outlet sides are i-ed and that
on the opposite side are allo3ed to move using le-i+le mounting.

#hermal Ex$ans%on
F%xe) -ount
F%xe) -ount
Flex -ount
Inlet 1Ox sensor at 2
o2cloc3 $os%t%on
Outlet 1Ox sensor at
12 o2cloc3 $os%t%on
Door remo0al 4or
S5 com$onents
86:lo7 Aftertreatment Mountin, 6 2oriIontal
:actor' *osition
2 @le- "ounts

*NC ] *ervice

Door remo0al 4or
S5 com$onents
From 4actor* chan.es
Inlet 6 Outlet S$ools rotate)
-ount%n. 4eet relocate)
Inlet sensor (ox
on to$
Su$$orte) 4rom (ottom Outlet 1Ox sensor &
12 O2cloc3 $os%t%on
Intlet 1Ox sensor &
2 O2cloc3 $os%t%on
Door remo0al 4or
S5 com$onents
From 4actor* chan.es
Inlet 6 Outlet S$ools rotate)
-ount%n. 4eet relocate)
Inlet sensor (ox
on to$
Su$$orte) 4rom (ottom Outlet 1Ox sensor &
12 O2cloc3 $os%t%on
Intlet 1Ox sensor &
2 O2cloc3 $os%t%on

2oriIontal Mountin, #4anging$
The ?Clo3 C!" can also +e mounted hori&ontall% 3ith t3o i-ed support on the
inlet and outlet sides 3hereas other side is allo3ed to move using t3o sta+ili&ers
on top.

2 sta(%l%7ers on rear
2 4%xe) mounts on
4ront
2 sta(%l%7ers on rear
2 4%xe) mounts on
4ront

'n another coniguration) the atertreatment can +e mounted hori&ontall% 3ith our
sta+ili&ers on top allo3ing le-i+ilit% to C!" 3hile one i-ed support on +ottom
ront prevents e-cessive movement o the C!".

4 sta(%l%7ers on
to$
1 4%xe) mount
on (ottom
4 sta(%l%7ers on
to$
1 4%xe) mount
on (ottom

=ertical Mountin, (=ert :lo7)
The ?Clo3 atertreatment can +e mounted on rear end 3ith i-ed mount on
e-haust end and le- mount on rear end. This is a vertical e-haust lo3.

&ide =ertical Mountin, #"ounted on @loor$

The ?Clo3 atertreatment can +e mounted on side vertical 3ith t3o i-ed on
+ottom ront and t3o le-i+le on the +ottom rear. The height o the C!" can +e
supported using t3o le-i+le mounts on rear top o the C!".
Fixed Mount Thermal
Expansion
Thermal
Expansion
Door removal for SV
components
Inlet Spool
Outlet Spool
Fixed Mount Thermal
Expansion
Thermal
Expansion
Door removal for SV
components
Inlet Spool
Outlet Spool
!"Flo# Aftertreatment Mountin$ % Side Vertical
Supported on bottom
From Factory han$es
Spool rotated
&Ox sensor moved

R :lo7 Mountin, Confi,uration
O @lo3 mounting has similar mounting re6uirements as ?C@lo3 mounting +ut the
e-haust lo3 is rom end to end instead o in and out at the same end. This
dierence should drive more consideration or e-haust interace and use o
+ello3s to align engine e-haust to C!". :eer to ?Clo3 i-ed and le-ed
mounting. The vertical mounting 3ill re6uire additional capa+ilities or +ello3s
movement.


/iftin,

@our liting lin,s are to +e +olted to the C!" assem+l% and lited as illustrated
+elo3. *preader +ar might not +e re6uired i liting straps are used and straps are
,ept a3a% rom all sensors and 3iring harness on the inlet spool and C!".

C280 CEM nstallation

!uidelines for /iftin, and nstallationM
?se all liting lugs 3hen liting the C!" #Clean !mission "odule or
:eactor$ into place.
?se all mounting eet 3hen securing the C!" housing into its operating
position.
"a,e sure all ports2 openings and connections are clear rom o+struction.
/iftin, nstructions@

1. The C!" should +e delivered l%ing on its side in the hori&ontal position2
the liting e%es must +e used to remove rom the +ed o the shipping or
deliver% truc,.
2. ?se 2 or more sets o liting e%es to rotate the reactor into the upright
position 3hile ,eeping the +ottom secured +ut ree to rotate. A saet%
chain can +e used on each o the +ottom opposing eet to prevent the unit
rom slipping. .o not lift t3e CEM off of t3e ,round 7it3 onl' 2 liftin,
e'es)
3. :otate it into the upright position irst and onl% ater it is lat on the ground)
secure all o the liting e%es to remove o o ground.
a. 1arnin,@ :ailure to follo7 t3ese instructions could result in
accidents, potential inCur' and e+uipment dama,e)
Aote@ The eet are not to +e used or liting.
Aote@ ?nit is shipped 3ithout the modules +loc, catal%sts installed2 these +loc,s
3ill need to +e installed ater the unit is in its permanent location.

"ounting the C!" C 1olting 'nstructions

1olting the C!" to the pedestal using the mounting eet provided) include F5A in.
slotted holes running parallel to the short a-is o the unit. The customer installed
mounting platorm that the unit rests on should have preCa+ricated F5A in. slotted
holes running parallel to the long a-is o the unit. 8hen the mounting eet are set
on the mounting rame the slots 3ill orm a cross. This allo3s the unit to thermall%
e-pand side3a%s and long 3a%s. @lat 3ashers should +e used on +oth the
+ottom and top 3hen tightening do3n the unit. A tor6ue collar or spacer installed
+et3een the t3o lat plains #+olt holes$ ena+les the unit to move thermall% +ac,
and orth or let and right discouraging structural impact on the housing o the
*C: reactor. 1oth top and +ottom must +e secured. *ecure the top once the
+ottom has +een +olted in place.

Aote@ :ailure to install t3e tor+ue collar could cause metal fati,ue in t3e
&C$ 3ousin, and crac;ed 7elds 73ere e<3aust ,as lea;a,e is eminent)

!-ample o 1olting "ethod

EoteM ?nit must +e +olted to the mount utili&ing the 1olts) 3ashers) tor6ue collars
and nuts sho3n in the diagram. Tor6ue collars must +e used. 1olt Tor6ue is set at
200 ^ 40 ECm #11AC1FF l+ t$. This 3ill ensure proper reedom or thermal e-pansion
and contraction.

nitial &tartup

*ee Appendi< >@ 'nitial *tartup /rocedures

&er%ice and Maintenance

Catal'st stora,e
Caterpillar re6uires that i the catal%st are not installed in the C!" right a3a%)
then the catal%st need to +e stored indoors out o the 3eather. The shipping
pallets that the C2A0 catal%st arrive on are not totall% sealed and are not totall%
impervious to rain 3ater.

3500 and C175 &C$ Access@
*C: catal%st cover access needs to +e considered 3hen designing the
installation o the C!". The a+ilit% to remove the service cover and the
*C: catal%st is re6uired. The minimum catal%st removal length is 450mm
3hich includes the handle and the catal%st. The handle is used or pulling
the catal%st out o the C!" and the a+ilit% to carr% the catal%st. The
minimum length sho3n +elo3 is onl% needed on the service side cover
side o the C!". The service cover is the onl% access point into the C!"
+esides the inlet and out ports. :eer to the Assem+le and Dissem+le
guide or complete instructions on to remove the catal%st rom the C!".


The igure a+ove sho3s the inlet) outlet and the service cover or the
catal%st. The igure +elo3 sho3s the re6uired removal distant to pull the
catal%st out o the C!".

atalyst Serviceability
1 meter 8emo0al
D%stance
Door
Door Flan.e
'( mm '( mm

To service the catal%st the service cover needs to +e removed) and then
each catal%st can +e removed 3ith the service tool +% removing the
retention +olts and pulling the catal%st out. 8hen replace the catal%st all
ne3 retention hard3are 3ill +e re6uired to install the ne3 catal%st.


mportant Aote@ Aon6Caterpillar supplied &C$ s'stem components (E<)
A8& 9 .E: :ilter, Air .r'er 9 :ilter, etc) t3at are an inte,ral part of t3e &C$
s'stem must meet t3e "ier 0 interim E*A re+uirements for maintenance
ser%ice inter%als) "3e ;e' criteria for meetin, t3e re,ulation is t3at an'
re,ularl' sc3eduled adCustment, replacement, cleanin, or repair of
components must #e at a minimum of 0500 en,ine 3ours) Component life
must meet 10,000 en,ine 3ours for 3500 and C175 en,ines and 20,000
en,ine 3ours for C280 en,ines)

C280 &C$ Access@
&pecial nstructions
Access 2atc3 $emo%al

:eactor hatches can 3eigh up to 250 l+s. #113 ,g$. To avoid inHur% use a hoist
3hen liting components 3eighing 50 l+s #23 ,g$ or more. The hatch handles
must +e used to attach the liting hoo,s. The liting hoo,s must +e e6uipped 3ith
a spring latch2 ensure that the liting hoo,s are positioned correctl%. !nsure that
the hoist) chains or slings and liting hoo,s are in good 3or,ing condition and can
3ithstand the hatch 3eight.
*ee @ig +elo3.

:einstallation o the hatchM
1$ Align the hatch) gas,et and lange to the holes. These parts need to la% lat
against one another 3ith their holes lined up so the +olts can go straight in.
Appl% anti sei&e compound to all the threads to avoid thread galling.
2$ The +olts 3ith 3ashers should then +e placed through the holes) secured
using 3ashers and loc,nuts. The +olts must +e handCtightened to the point
3here the hatch) gas,et and lange are held together. The +olts ma% need to
+e gentl% tapped through the holes +eore the parts are completel% lined up.
*ee @ig +elo3M

:i, 2) @asteners used in the 4atch.
1$ 4e- 4ead 1olt

2$ 8asher L4ard
3$ ;oc, Eut
4$ 4atch
5$ (as,et
9$ @lange

3) The +olts should +e tightened to a tor6ue o 4F Am (35 l#6ft))

:i, 3) 4atch 'nstallation.
@lange
(as,et
4atch
The recommended tor6ue se6uence is as ollo3sM start in the center o the hatch
then 3or, to3ard the outside. At the end do a second round to veri% the tor6ue
in all the +olts. *ee @ig 4.

@ig 4

C28068 & 12

&C$ >loc; nstallation
!rid nstallation
The C2A0 *elective Catal%st :eactor 4ousing has +een speciall% designed to utili&e
the 3hole cavit% o the C!"5reactor 3ithout having to 3restle 3ith or stuing ceramic
i+er insulation in and around the *C: +loc,s. This ne3 design ma,es the
installation o the canned +loc,s much easier to handle and secure in place 3ith little
or no tools.

The +ottom most part o the
reactor has a diuser pan) this
pan 3hich allo3s the e-haust
to lo3 through 3hile ,eeping
the +ac, pressure o the
e-haust lo3.

This pan can +e stood on to
install the irst grid la%er.

nstallin, t3e ,rid

@or the +ottom most la%er) +ring 1 grid hal in rotated as sho3n to it in the door.
The channel support on the ceiling can +e used to hoist the grid into place. To
ma,e installation easier) the 6uarter inch <T> pinned anchors on the sides can +e
removed and reCpinned ater the grids are in place.

EoteM The vertical 6uarter inch +eam 3ith the 3 holes in it is located on the
inner most triangular support on the grid. 'n the corresponding images it is
sho3n located on the outside) 3hich 3ill +e the case in the production +uilds.


;o3er the grid hal into place +% ,eeping it rotated as sho3n. 0nce the grid edge
is resting on the +ottom grid support ledge) push the grid edge into this corner
and allo3 the grid to rotate until the other lat surace hits the other side o the
ledge. *tart rom the +ac, 3or,ing %our 3a% out to3ards the hatch opening.

8ith one grid in place) repeat the procedure to +ring in a second grid hal that
has the corresponding num+er posted on its triangular +eam section. :otate the
grid so that the slotted connections align. ?se the clevis pins to Hoin the t3o
sections together. :emove an% tape that remains on the grid halves.
A ru++er mallet can +e used to adHust the grids into place.


0nce the grids are in place) the T shaped anchors are pinned into place. !nsure
that the lan%ards remain looped through the T anchors.
/in all T anchors on all sides.

0nce the grid is on the irst ledge) 3ith t3o pins secured +eneath the grids and
the T anchors installed) insert the irst 4 +ric,s in each corner.


'nstall the 3 +ric,s on each side +et3een the corners ne-t. 0nce all +ric,s are
installed around the perimeter) install the center +ric,s

'nstall the T +eams in one direction perpendicular to the vertical 6uarter inch
holed connectors. The T +eams are held in place +% a ? shaped channel that is
pinned to these 6uarter inch holed +ars.


0nce all o the T +eams are placed +et3een the catal%st modules) install the ?
shaped +ars across the top o the T +eams on each side.
'nsert the clevis pin into each slot on each side.


/erorm these steps or each o the 4 la%ers on the reactor.

2013 Caterpillar F0 10Dec2013

0)0 E<3aust &'stem

ntroduction
The engine !-haust *%stem discussed in this section consists o the interace o
the tur+o e-haust gases to the Cat C!". This includes Cat 1ello3s Assem+l% or
le-pipe assem+l%) Cat C!" or atertreatment and muler or e-haust pipe.

Cat C!" e-haust gas inlet receives the engine e-haust gas through le- +ello3s
Hoints allo3ing or misalignment that ma% occur rom the man% installation
arrangements o the Cat C!". Caterpillar recommends the com+ination o
+ello3s) +all and slip Hoints. /articular attention must +e ta,en to ensure proper
design and placement o the Cat C!" to maintain alignment 3ith the engine
e-haust and sta% 3ithin the vi+ration and industr% standard lea, tight connection
re6uirements.

The engine and atertreatment should +e considered as a s%stem. The mounts
or the engine limit pitch and roll and thereore reduce the re6uirement on the
+ello3s assem+l%. :eer to !ngine AJ' guide or inormation on !ngine "ounts.

E<3aust &'stem 5%er%ie7

E
n
,
i
n
e

:i,) 7)1 H E<3aust &'stem E<ample

Mandator' $e+uirements@
@le-pipe Design
0!" *upplied !-haust /ipe :e6uirements
/ipe *i&e
/ipe "aterial
1ac,pressure Apportionment
!-haust (as Temperature ;oss Through !-haust /ipe
8ater 'ngress /revention
!-haust gas sampling port


:le<pipe .esi,n
!ach application re6uires understanding o the installation re6uirements or
proper location o the Cat C!" relative to the engine e-haust. The actual
le-pipe #+ello3s$ 3ill account or movement during engine operation. The
ollo3ing application parameters should +e considered +eore selection o le-i+le
Hoint that accommodates the application needsM
Tolerance *tac,C?p #static$
8orst Case !ngine 0peration5Dut% C%cle
Ni+rator%C 4igh c%cle lo3 displacement
Thermal (ro3th
*hoc, ;oadingC ;o3 c%cle high displacement
Temperature
/ressure

:lan,e6pipe .esi,n $e+uirements (=ee En,ines H 3500, C100,
C175)@
The Nee !ngine design re6uirements are included in the ollo3ing sections
3here appropriate 3hen interacing 3ith a langeCpipe connection.

EoteM Additional general guidelines or !-haust *%stems AJ' is availa+le
in "edia Eum+er ;!184IF0 <!-haust *%stems>.
En,ine E<3aust :lan,e /oadin,
Careul consideration must +e given to the load e-ternal piping ma% induce on
the e-haust lange. To minimi&e the load carried +% the lange) do3nstream
e-haust piping should +e sel supporting. The thermal gro3th o hori&ontal piping
connected to the lange e-haust must also +e accounted or in the design.

"a-imum allo3a+le vertical load and +ending moment limits are provided or
each engine model. Consult the Technical "ar,eting 'normation #T"'$ or the
appropriate inormation.

:le<i#le ?oints

@le-i+le Hoints are needed to isolate engine movement) vi+rations) and "arine
Nessel rame delection. 1ello3s ta,e up d%namic a-ial and lateral movement.
1all Hoints compensate or radial misalignment. *lip Hoints compensate or a-ial
misalignment. Additionall% the% are needed to oset assem+l% tolerances and
thermal e-pansion and contraction o the main e-haust. (reat care should +e
ta,en to ensure that these actors are accounted or in the design and
development o the le-i+le sections o these s%stems.

@rom its cold state) 304; *tainless *teel 3ill e-pand 0.3mm #.011Iin$ per 305mm
#1t$ per 50W C #122W@$ temperature rise. ' not accounted or) the thermal gro3th

can e-ert undue stress on the engine and Cat C!" connections) as 3ell as the
pipe supports. *ee the Allo3a+le Koint ;oading section or speciic re6uirements

The Cat C!" e-haust outlet piping 3ith additional components such as e-haust
temperature cooling devices) e-haust stac,s and long lengths o unsupported
pipe should +e designed and revie3ed per Caterpillar) 0!" and installer
agreement. All installation re6uirements per this AJ' guide must +e complied 3ith
per agreement outlined in the introduction o this document.

't is important that the le-i+le sections continue to meet the pressure drop and
lea,age specs throughout the lie o the installation in order to ensure compliance
3ith emissions regulations. A ro+ust le-i+le Hoint 3ill accommodate all the
various movements o these routings through the man% thermal) vi+ration and
loading c%cles e-perienced +% the application.

/roper assem+l% o the lange is necessar% to orm a strong seal that provides a
lea, tight Hoint.

5EM &upplied E<3aust *ipe $e+uirements

1) *ipe Material
Material
The material selection is an important part o ensuring that the s%stem 3ill
continue to perorm over the lie o the "arine Nessel. Traditional steel and
alumini&ed steel) have lo3er thermal sta+ilit% and corrosion resistances than
higherCgrade stainless materials. 300 series stainless steel material is
re6uired to +e used or 0!" supplier e-haust piping +et3een the tur+o out
and C!" inlet. C!" and tur+o connections are ductile iron and have similar
thermal e-pansion coeicients as the 304**T.

:e6uiredM 0!" /ipe "aterialM 304 ;o3 car+on *tainless *teel
#*A!30304;$

2) E<3aust >ac;pressure
E<3aust &'stem Apportionment
Commercial En,ines
' apportioned e-haust +ac,pressure is higher than speciied in ta+le +elo3 it can
result in poor engine perormance. :eer to T"' or ma-imum +ac,pressure
re6uirement.

En,ine

*o7er $atin, Apportioned Ma< *ress .rop
2* G1 G*A
C1F553500
G120F GI00
9.F
C2A0 2.5
"a#le 7)5 H Commercial &'stem >ac;pressure "a#le


:i,) 7)13 H E<3aust &'stem E<ample for Cat Aftertreatment

E<ample of Apportioned *ressure .rop Calculation@ #:eerence
igure and ta+le a+ove$

0!"5'nstaller #,/a$ ] Total 1ac,pressure #,/a$ L Cat C!" #,/a$
0!"5'nstaller #,/a$ ] 1A.F L 12 ] 9.F

8hereM
Total 1ac,pressure ] 1A.F ,/a
Cat C!" ] 12 ,/a

Calculatin, E<3aust $estrictions

!stimation o the 0!" piping +ac,pressure can +e done 3ith this ormulaM

/ ] /ressure drop #+ac,pressure$ measured in inches o 3ater.
; ] Total e6uivalent length o pipe in eet.
R ] !-haust gas lo3 in cu+ic eet per minute at rated conditions
D ] 'nside diameter o pipe in inches.
T ] !-haust temperature in W@.

Eom /ipe Dia. #in.$ Actual 'D #in.$Q D_5 #in.
5
$
5 4.AF 2F40
9 5.AF 9IF0
A F.AF 301I2
10 I.AF I39F1
14 13.AF 51332A
21 20.AF 3I5I31I

"a#le 7)- H *ipe .iameter .
5
Calculations
* T
0)22/
e+
U
2
(0-0 L ").
5

Q1ased on a tu+e 3idth o 1.95mm. Calculation 3ill var% i thic,ness is dierent)
such as 1.Amm.

To determine values o straight pipe e6uivalent length or smooth el+o3s useM

*tandard I0W el+o3 ] 33 - pipe diameter
;ong s3eep I0W el+o3 ] 20 - pipe diameter
*tandard 45W el+o3 ] 15 - pipe diameter

To determine values o straight pipe e6uivalent length or le-i+le tu+ing useM
; ] ; - 2

mportant considerations

*harp +ends in the e-haust s%stem 3ill signiicantl% increase e-haust
+ac,pressure. The piping si&e decision assumes a minimum num+er o
short radius +ends. ' a num+er o sharp +ends are re6uired) it ma% +e
necessar% to increase the e-haust pipe diameter. *ince restriction varies
inversel% 3ith the ith po3er o the pipe diameter) a small increase in pipe
si&e can cause an apprecia+le reduction in e-haust pressure.

't is essential that the s%stem does not impose more than the allo3a+le
ma-imum +ac,pressure. The ma-imum +ac,pressure must not e-ceed
the limit 3hile certi%ing each engine model or conormit% to e-haust
smo,e and e-haust gas emissions under @ederal) Caliornia) and other
agenc% regulations. To avoid this pro+lem) e-haust s%stem +ac,pressure
should +e calculated +eore inali&ing the design. Testing should +e done
to validate design is compliant 3ith AJ' re6uirements.

!-haust piping is a critical component in the Cat C!" operation re6uired
to meet emission standards. Care should +e e-ercised in coniguring and
designing the e-haust piping to meet pac,aging and e-haust component
load and operational limits.

0!" pipe diameter has a signiicant impact on the pressure drop through
the s%stem. The engine and Cat C!" connections have +een conigured
or the recommended pipe diameter in order to meet the pressure drop
re6uirements.

3) E<3aust "emperature /oss
E<3aust "emperature
ntroduction
The Caterpillar C!" relies on a minimum average temperature during operation
to provide the necessar% emissions reduction. Control o the temperature loss
through the e-haust pipe rom tur+o out to C!" inlet is re6uired to maintain this
average temperature. There are t3o methods that can +e used to determine i
this temperature loss is accepta+le.

"eeting "a-imum e-haust length re6uirements
"eeting the e-haust temperature loss re6uirements

Ma<imum e<3aust len,t3
0ne method to meet the temperature loss re6uirement is to not e-ceed the
speciied ma-imum e-haust lengths. Ta+le +elo3 provides the ma-imum
allo3a+le 0!" e-haust pipe length to maintain an accepta+le temperature loss.

En,ine
*latform
Application Ma< /en,t3
(Meter)
Ma< /en,t3
(nc3es)
3512 Commercial 1.52 m 90 in
3519 Commercial 1.52 m 90 in
C1F5 Commercial 3.99 m 144 in
"a#le 7)7 6 Ma<imum allo7a#le e<3aust len,t3N

*ome commercial installations ma% re6uire an e-haust pipe that is longer than
the ma-imum. ' the ma-imum e-haust pipe length re6uirement cannot +e met
then the installation must meet e-haust temperature loss re6uirements. /roviding
insulation o the e-haust pipe in most cases 3ill maintain the necessar% e-haust
temperature loss re6uirements.

NMa<imum len,t3s in ta#le a#o%e are pro%ided for installations in 73ic3 t3e
e<3aust pipes are not in t3e direct pat3 of an' fan air flo7) f an' portion of
t3e e<3aust pipe is in t3e direct pat3 of fan air flo7 t3e e<3aust
temperature loss re+uirements must #e met)

E<3aust temperature loss re+uirement
The second method to meet e-haust temperature loss through the e-haust pipe
re6uirements is to meet temperature loss re6uirements in ta+le +elo3.

En,ine
*latform
&C$
10O $ated /oad
Ma< Allo7a#le "emp .rop
(C)
Allo7a#le En,ine $*M ran,e durin, test
3500
10
:ated *peed C1F5
C2A0 15
"a#le 7)8 H Allo7a#le temperature loss from tur#o to CEM

0) ?oint /oadin, & &upports
/oadin,
@lange load limit) C!" connection lange load limit or either end o the e-haust
pipe connection has a ma-imum allo3a+le load limit. This load is a unction o
the material and geometr% o the lange e-haust outlet and the C!" e-haust
inlet.

The le-i+le Hoint should t%picall% +e positioned to minimi&e cantilever t%pe loads
to the tur+o e-haust outlet connection and C!" inlet and outlet.

The ollo3ing ta+le provides guidelines or D%namic loading o the connection
interace at the engine tur+o e-haust and Cat C!" inlet and outlet. All reerence
to tur+o outlet load must +e veriied 3ith T"' load re6uirements or the engine o
%our application.

E<3aust Component
Connection

?oint "'pe
&iIe
Ma<imum Allo7a#le
.'namic load
C!" 'nlet50utlet #3512$ Cat /attern @lange 2UA> 000 A6m9100 A6m
C!" 'nlet50utlet #3519$ Cat /attern @lange 2U10512< 000 A6m9100 A6m
C!" 'nlet50utlet #C1F5C19$ AE*'5D'E
2U19>
1U20>
100 A6m9-0 A6m
"a#le 7)4 6 E<3aust ?oint /oadin, "a#le !uidelines
.eterminin, Allo7a#le ?oint /oadin,
Koint loading is complicated +% several actors that all 3ithin 0!" design
control. Application installation design should +e designed to protect the Cat
C!" devices rom d%namic loading in addition to the resonance concerns that
3ould cause s%stem overload.
!-haust pipe *upports
o *upport ;ocations
o T%pe o e-haust support
/ipe Considerations rom closest support to Cat C!" connection points
o 8eight
o ;ength
o Center o (ravit% #C($
;ocation o @le- Koint

The allo3a+le Hoint load should +e evaluated using d%namic load. The d%namic
load is the com+ination o actors including 3eight) length o pipe) center o
gravit% and ma-imum acceleration rate. "a-imum acceleration rate is t%picall%
the ma-imum anticipated (Cload. As a reerence point) 5 ( is oten used in cases
3here the ma-imum d%namic load is not 3ell ,no3n.

C!" or Tur+o lange loading 3ill +e calculated one o t3o 3a%s depending upon
ho3 the e-haust pipe is supported.
Met3od V1@ &imple Cantile%er /oadin,@
' the pipe is simpl% connected to theM
'nlet or 0utlet #C!" or Tur+o connection$
To the le- Hoint

8ithout an% other support points) then this method can +e used to determine the
!stimated loadingM
M T ma/
8hereM
" ] D%namic load in Ee3tonC"eter #poundCoot$) ECm #l+Ct$

2013 Caterpillar FF 10Dec2013
m ] "ass o the pipe supported +% the Hoint in ,ilogram #pound$) ,g #l+$
a ] Acceleration) ma-imum amplitude o the C( location o the supported
pipe in meters5second s6uared #eet5second s6uared$) m5s2 #t5s2$
; ] Distance rom the C( o the supported pipe to the Cat C!" Hoint in
meter #eet$) m #t$
Met3od V2@ &upported E<3aust *ipes@
' the pipe is connected to theM
C!" 'nlet or Tur+o 0utlet connection
@le- Hoint
And is supported in some 3a% o o the engine or C!" or it.s mounting
structure

This alternative method must +e used to evaluate the lange loading.

*ome orm o rigid support is recommended on +oth sides o the le-i+le Hoint to
prevent Hoint ailure at the C!" or engine.

' supporting +et3een the +ello3s and engine the support structure should
+e mounted on the engine.
' supporting +et3een +ello3s and atertreatment s%stem the support
structure should +e mounted rom the atertreatment s%stem.
This 3ill insure the +ello3s unctionalit% and not induce undue stress in the
le-pipe s%stem components.

't is critical that e-haust pipe support +e done in such a 3a% that thermal gro3th
o the e-haust pipe does not result in loading either the tur+o e-haust outlet or
the C!" inlet. This ma% mean that the pipe +e supported or t%pical static 3eight
and (Cloading 3hile also allo3ed to move such that the e-haust pipe thermal
gro3th is ta,en up +% the le- Hoint rather than e-erting a orce on the tur+o
e-haust outlet or the C!" inlet.

Allo3a+le loads must not +e e-ceeded 3hen designing the le-pipe interace
connections.

A triCa-ial mounting support is recommended 3ithin I15 mm #3 t$ o the Cat
connections. A triCa-ial support provides support to the UCA-is) =CA-is) and OC
A-is planes.

"3e fle<i#le Coints t3at isolate t3e CEM from t3e en,ine %i#rations s3ould
#e positioned to pre%ent cantile%er arm t'pe loads to t3e CEM connections)
Cantile%er arm t'pe loads due to pipe 7ei,3t can easil' create
%i#ration9resonance t3at can o%erload t3e connection on t3e CEM causin,
a Coint failure)

Met3od 3
The orce method is another 3a% to determine i %ou are e-ceeding the limits on
the tur+o and C!" inlets and outlets.

2013 Caterpillar FA 10Dec2013

:eer to the !-haust Koint ;oading Ta+le a+ove or the ma-imum allo3a+le
d%namic load or each speciic Hoint connection.

5) 1ater n,ress *re%ention
Moisture /imits
ntroduction
The presence o 3ater in the C!" can cause ailures such as crac,ing o
catal%st rom ree&e5tha3 c%cles) crac,ing o catal%st +% 3ater causing thermal
gradients across the catal%st. !-haust s%stem outlets must +e provided 3ith an
appropriate means o preventing sno3) rain3ater or sea spra% rom entering the
C!" through the e-haust piping. This can +e accomplished +% several methods)
+ut must +e given careul consideration. The selected method can impose
signiicant restrictions that must +e ta,en into account 3hen calculating s%stem
+ac,pressure.

@or engine applications 3ith GF50 4/5590 P8 ratings the ma-imum 3ater
ingress is 1 ;iter at ma-imum 5 degree angle.

0ne simple method) used primaril% 3ith hori&ontal e-haust pipes) is to angle cut
the end o the e-haust pipe 3ith the point at the top.

A common method used 3ith vertical e-haust pipes is to angle the pipe at 45 or
I0W rom vertical using an appropriate el+o3) then angle cutting the pipe end as
previousl% descri+ed.

Another eature that ma% +e used in conHunction 3ith either o the a+ove methods
is :ain5*pra% *lots as sho3n in igure +elo3.

2013 Caterpillar FI 10Dec2013

:i,) 7)15 H $ain9&pra' .rain &lots

*lots are cut into the e-haust pipe to allo3 rain5spra% to drain harmlessl%. The
edges o each slot are deormed as sho3n in the previous graphic. The engine
side o the slot is +ent in3ard and the do3nstream side o the slot is +ent
out3ard. Eo more than a 90W arc o the pipe circumerence should +e slotted in
this 3a%.

@or applications 3here none o the a+ove methods are possi+le) it ma% +e
necessar% to it some orm o rain cap to the end o the vertical pipe section. This
method can provide a positive means o 3ater ingress prevention) +ut not 3ithout
imposing a signiicant +ac,pressure restriction.

-) &amplin, port

'n accordance 3ith "!/C 103.4I re6uirements #ON-BOARD NOx
VER!CATON PROCEDURE " DRECT MEASUREMENT AND MONTORNG
MET#OD$ the e-haust s%stem must provide a sample port located do3nstream
o the last e-haust treatment s%stem to measure gaseous emissions. /lease
reer to regulations on t%pe and correct location or the sampling port. A cop% o
the re6uirement is stated +elo3.

5)4)3 &amplin, for ,aseous emissions
5.I.3.1 The sampling pro+es or the gaseous emissions shall +e itted at least
0.5m or 3 times the diameter o the e-haust pipe C 3hichever is the larger C
upstream o the e-it o the e-haust gas s%stem) as ar as practica+le) +ut
suicientl% close to the engine so as to ensure an e-haust gas temperature o at
least 343 P #F0#C$ at the pro+e.

5.I.3.2 'n the case o a multiCc%linder engine 3ith a +ranched e-haust maniold)
the inlet o the pro+e shall +e located suicientl% ar do3nstream so as to ensure
that the sample is representative o the average e-haust emission rom all
c%linders. 'n multiCc%linder engines having distinct groups o maniolds) such as in
a XNeeX engine coniguration) it is permissi+le to ac6uire a sample rom each
group individuall% and calculate an average e-haust emission. 0ther methods
3hich have +een sho3n to correlate 3ith the a+ove methods ma% +e used. @or
e-haust emission calculation) the total e-haust mass lo3 must +e used.

2013 Caterpillar A0 10Dec2013
5.I.3.3 ' the composition o the e-haust gas is inluenced +% an% e-haust aterC
treatment s%stem) the e-haust sample must +e ta,en do3nstream o this device.

7) E<3aust &'stem =erification

=erification ntroduction
The e-haust s%stem must +e designed to +e lea, tight and compl% 3ith the
minimum !/A useul lie re6uirements. During the useul lie) the piping cannot
contri+ute to plugging) a+rasion) e-haust gas lea,age) or other damage to Cat
C!".

To ensure proper operation o the engine 5 Cat C!" pac,age during the lie o
the "arine Nessel) care must +e ta,en to ensure these s%stems are constructed
o proper materials 3ith relia+le Hoints) le-i+le sections) and mountings. !-haust
piping must provide or movement and thermal e-pansion to ensure undue
stresses are not imposed on Cat C!" components or engine connections.

!eneral $e+uirements &ummar'

Attention should +e given to e-haust gas lo3 restriction 3ith the ollo3ing
recommendationsM

The e-haust +ac,pressure must not e-ceed the limits given or each
engine amil% and Cat C!" installation. :eerence T"' *%stem Data or
!ngine *ales "anual or Commercial applications and !ngine Technical
*peciications.

The e-haust piping must allo3 or movement and thermal e-pansion so
that undue stresses are not imposed on the tur+ocharger structure or
e-haust maniold.

Eever allo3 the tur+ocharger to support more than allo3a+le loads.
:eerence T"' *%stem Data or !ngine *ales "anual or Commercial
applications and !ngine Technical *peciications.

Allo3a+le Distance rom Tur+ocharger to Cat C!" is restricted +% the
ma-imum +ac,pressure and ma-imum length or engine application.

To determine values o straight pipe e6uivalent length or smooth el+o3s useM

*tandard I0W el+o3 ] 33 - pipe diameter
;ong s3eep I0W el+o3 ] 20 - pipe diameter
*tandard 45W el+o3 ] 15 - pipe diameter

>ac;pressure =erification

!-cessive pressure drop #+ac,pressure$ in the e-haust 3ill adversel% aect the
perormance o the engine and the Cat C!" s%stem. 't is re6uired that the

s%stems meet these criteria or optimal perormance. !-cessive pressure drops
can %ield higher than e-pected e-haust temperatures) lo3er uel econom%)
reduced altitude capa+ilit%) and less than rated po3er. The ma-imum pressure
drop or these s%stems is sho3n in the +ac,pressure Ta+le F.5 L Commercial
*%stem 1ac,pressure Ta+le.

Measurin, >ac;pressure@

!-haust +ac,pressure is measured as the engine is operating under ull rated
load and speed conditions #4igh 'dle or Eaturall% Aspirated engines$. !ither a
3ater manometer or a gauge measuring inches o 3ater ma% +e used. :eer to
@ig. F.19 or @ig. F.1F.

:i,) 7)1-H Manometer used to Measure E<3aust >ac;pressure

:i,) 7)17 H E<3aust >ac;pressure &ensor $ecommended /ocation

*ressure .rop Measurement (testin, procedure)

!-haust s%stem pressure drop is measured 3hile the engine is operating at rated
speed and ull load conditions #reer to the !ngine Data *heet or rated :/" and

load conditions$. !ither a 3ater manometer or a pressure gauge can +e used. '
not e6uipped) install t3o pressure taps on a straight length o e-haust pipe. The
irst tap should +e located as close as possi+le to the +eginning o the pipe
section) +ut at least 12 in. do3nstream o a +end. The second tap should +e
located Hust +eore the end o the pipe section. ' an uninterrupted straight length
o at least 1A in. is not availa+le #12 in. preceding and 9 in. ollo3ing the tap$)
locate the pro+e as close as possi+le to the neutral a-is o the e-haust gas lo3.
@or e-ample) a measurement ta,en on the outside o a I0W +end at the pipe
surace 3ill +e higher than a similar measurement ta,en on the inside o the pipe
+end. A 15A E/T hal coupling can +e 3elded or +ra&ed to the e-haust pipe to
create a pressure tap. Ater the coupling is attached) drill a 3Cmm #15A in$
diameter hole through the e-haust pipe 3all. ' possi+le) remove +urrs on the
inside o the pipe so the gas lo3 is not distur+ed. The gauge or gauge hose can
then +e attached to the hal coupling.

This procedure can +e repeated or each pipe section. #:eerence *!1D9F2I
or additional inormation.$

'normation that can +e used or C@D anal%sis o the e-haust piping s%stems is
contained in the engine data sheet or the engine rating that the e-haust is +eing
designed. The data sheet 3ill contain inormation re6uired or C@D such as
e-haust lo3 and e-haust stac, temperatures.
&ound *ressure /e%el

:eerence T"F0A0 or procedure in T"' L Deinitions5/erormance De o ho3 to
o+tain data.

A muler ma% +e added i sound attenuation is re6uired in addition to the
atertreatment. The muler or resonator must meet the +ac,pressure
re6uirements descri+ed in e-haust +ac,pressure su+ section a+ove and must +e
installed ater the Cat C!".

The Cat C!" noise attenuation data can +e ound in T"' or the C!" selected.


5) Mountin, Considerations

ntroduction
This section is comprised o t3o parts) "ounting :e6uirements and "ounting
(uidelines. The irst part descri+es metrics that a mounting s%stem must meet
or the C!" installation to +e successul. The second part gives some tips
a+out ho3 to approach the design and validation o a mounting s%stem that
should ma,e it easier #though not guaranteed$ to meet the re6uirements in the
irst part. !ver% installation is uni6ue) so individual customers ma% have to adapt
the methods descri+ed here to +etter it an individual application.

The C!" has +een designed and validated to provide accepta+le dura+ilit% in a
3ide variet% o applications 3ith load re6uencies less than 90 4& 3ithout the use
o isolation mounts. 4o3ever) certain applications ma% still re6uire the use o
isolation mounts or one o the ollo3ing reasonsM
The C!" hard mounted to a particular structure 3ould +e e-posed to
vi+rations greater than 904&.
The mounts supporting the C!" move independentl% o each other and
3ould cause damage to the C!" or mounting supports.
The noise generated +% a hard mounted C!" 3ould +e o+Hectiona+le
*ome le-i+ilit% in the attachments ma% ma,e assem+l% easier and5or
reduce assem+l% stress.
The volume is lo3 enough 3here it ma% +e preera+le to add component
cost in order to reduce validation cost.

Aotice@ En,ine mountin, of aftertreatment is not recommended)

Mountin,
Mountin, $e+uirements
The C!" ma% +e attached 3ith or 3ithout the use o ru++er isolation mounts.
:egardless o the st%le o design or the method used to validate it) an%
successul C!" attachments must meet the ollo3ing criteriaM
C!" vi+ration #during operation) shipping) etc$ must not e-ceed re6uired
limits or C!" component dura+ilit% or load input re6uencies o less than
90 4&. A maHorit% o applications 3ill operate 3ith re6uencies less than 90
4&.
' load re6uenc% input is greater than 90 4&) the C!" must use tuned
isolation mounts to reduce loads at greater input re6uenc% than 90 4& or
3or, 3ith a Caterpillar AJ' engineer to design5select a C!" suited or the
particular application.
An% +rac,ets) +olted Hoints) mounts) 3elds or other structural elements
supporting the C!" must +e a+le to 3ithstand all mechanical loads seen
during operation #including thermal gro3th$ or shipping. !ach o these
elements ma% have dierent load limits) and the limits ma% depend on the
direction o loading or num+er o load c%cles e-pected during the products

lietime. :or non6Cat applications t3e CEM !6/oadin, limits 3a%e
#een e%aluated up to L96 5!Ss)
An% structural elements must provide accepta+le strength and dura+ilit%
over the entire temperature range e-pected to +e e-perienced in the
application.
"otion o the C!" during operation must not e-ceed 3hat can +e
accommodated +% the le-i+le connections attached to the C!" and the
clearances +et3een the C!" and surrounding o+Hects.
Caterpillar stron,l' recommends ;eepin, t3e mountin, contact points
7it3in t3e perimeter of t3e cradle mountin, feet) f t3e mountin, structure
e<tends #e'ond t3e cradle mountin, feet perimeter, care must #e ta;en to
ensure t3at t3e structure does not interfere 7it3 ot3er components on t3e
CEM t3at ma' e<tend #elo7 t3e cradle mountin, feet plane)

Mountin, !uidelines
There are a num+er o #sometimes conlicting$ goals and criteria to ,eep in mind
3hen designing a C!" mounting s%stem. 't.s important to chec, several criteria
or an% given mounting s%stem. The speciic criteria to chec, depend on 3hether
or not sot mounts are used in the design.

2ard mounted
A hard mounted design should +e evaluated 3ith a stressC6ualit% @!A model.
The model should have at a minimum all structural components meshed +et3een
the C!" cradle and 3hatever is acting as <ground.> An e-perienced anal%st
should +e involved to ensure that all the important sources o stiness) mass)
and loads are +eing accounted or in each application. At least the ollo3ing
anal%ses should +e runM
"odal anal%sisM Chec, natural re6uencies and compare 3ith the iring
re6uencies o the engine over the operating engine speeds and other
sources o strong vi+ration #or e-ample) i the primar% load on the engine
is a pump) compare to the pumping re6uenc%$. ' one o the s%stem
natural re6uencies is close to a re6uenc% o e-citation) a harmul
resonance condition could occur.
*tatic gCloadingM The model should +e run 3ith a num+er o load cases to
simulate +oth lo3Cc%cle and highCc%cle #atigue$ shoc, events. The
speciic loads to appl% 3ill depend on the application. /redicted stresses
should +e compared to material limits #endurance limit or high c%cle) %ield
strength or lo3 c%cle$. ;oads through +olted Hoints should +e compared
to Hoint capacit%. :or non6Cat applications t3e CEM !6/oadin, limits
3a%e #een e%aluated up to L96 5!Ss)
4ard mounting is recommended i the load input re6uenc% is less than 90
4&. A maHorit% o applications 3ill operate 3ith re6uencies o less than 90
4&. *ome e-amples o e-ceptions to this could +e :oc, :ipper) :oc,
Drilling and certain trac, t%pe tractor applications. n t3ese applications,
properl' tuned isolation mounts s3ould #e used to reduce all
%i#ration inputs into t3e CEM to less t3an -0 2I)

*ome applications ma% need additional anal%ses run or additional criteria
chec,ed. Consult 3ith %our Caterpillar AJ' !ngineer i %ou re6uire
assistance.

&oft mounted
*ot mounted s%stems must meet the same re6uirements as hard mounted
s%stems) so the same techni6ues descri+ed a+ove can +e helpul. 'n practice)
some additional screening tools can +e useul to evaluate sot mounted s%stems
more eicientl% using a lo3er level o detail than a ull @!A model. 0ne such tool
is a rigid +od% anal%sis. This t%pe o anal%sis assumes that ever%thing is rigid
e-cept the mounts) and Hust uses si- degrees o reedom to descri+e the motion
o the C!". Also) the mounts are assumed to +e the onl% connection +et3een
the C!" and ground #i.e. the pipes) hoses) and 3ire harnesses are assumed to
contri+ute negligi+le stiness$. This tool is oten used at the earl% stages o
mounting s%stem design in order to 6uic,l% evaluate several possi+le mounting
conigurations +eore moving on to more thorough anal%sis such as @!A. This
anal%sis can +e run +% individual customers on their o3n commercial or inChouse
sot3are.

The anal%ses run 3ith a rigid +od% code are identical to those descri+ed a+ove
or @!A. The onl% dierences are that the rigid +od% anal%sis can +e +uilt) run)
interpreted) altered) and rerun much aster than @!A) and that some additional
model outputs need to +e chec,ed. 'n particular) the static gCloading results
should +e chec,ed in the ollo3ing 3a%sM
/ea, loads through mounts should +e compared 3ith limits associated
3ith the +olted Hoints.
4igh c%cle mount delections should +e compared to the delection #strain$
limits or the mounts +eing used.
"otion across the e-haust +ello3s should +e compared to their limits.
"otion o other critical parts o the C!" #e-tremities near tight clearances)
or e-ample$ should also +e chec,ed.
0nce a design has +een ound 3hich meets all the criteria that a rigid +od%
model chec, can) the ne-t step is to move on to a @!A model to chec, the same
things #plus stresses o metallic structures$ 3ith more precision.

?sing anal%sis results to guide design changes
' a particular design did not pass all the criteria ater running rigid +od% or @!A
anal%sis. The results o the ailed design can help determine 3hat changes are
necessar% to improve the design. *ome e-amples o corrective actions are listed
+elo3.

' component stresses are too highM Tr% using a material 3ith higher
stress limits) strengthening the section) or changing the relative stiness o
dierent mem+ers in order to adHust ho3 the loads are distri+uted.
' mount strain is too highM Consider using a stier mount) using a larger
mount) or changing relative stiness or mount pattern in order to change
the distri+ution o loads.

' motion is too high at +ello3sM Consider using a stier mount) spreading
out the mount pattern) putting the plane through the mounts closer to the
C!" center o gravit%) or putting the +ello3s closer to the C!" center o
gravit%.
CEM =i#ration Accepta#ilit' 5%er%ie7
C!" vi+ration capa+ilit% is diicult to assess. 8hen vi+ration isolation mounts
are used and properl% speciied) it is understood that C!" vi+ration 3ill li,el% +e
accepta+le. 'n some cases) e-tensive vi+ration measurements ma% +e re6uired.
!ach o the scenarios discussed in this section 3ill designate the need or
vi+ration measurements.

E<3aust :le<pipe and CEM =i#ration .esi,n Considerations@
!ach 'nstallation ma% have an esta+lished choice or engine mounting.
Considering Tier 3 engine installations) either hard or vi+ration isolation mounts
have +een used or the engine. This choice should +e used as a starting point in
the design process. This design process ma% +e iterative in order to satis% +oth
e-haust le- pipe and C!" vi+ration considerations.

&cenario CEM
Mountin,
En,ine
Mountin,
*referred
&cenarioW
1 4ard 4ard Eo
2
Ni+ration
'solation
4ard =es
3 4ard
Ni+ration
'solation
=esQ
4
Ni+ration
'solation
Ni+ration
'solation
EoQ
Q *ee notes 3ith regard to scenario Z3 J Z4 in the detail +elo3.

&cenario V1@ CEM 2ard Mounted, En,ine 2ard Mounted
This is a not preerred scenario. Although this scenario oten provides the +est
case in terms o le- pipe capa+ilit%) it is not preerred +ecause the C!" is
e-posed directl% to engine vi+ration. 'n some cases this scenario ma% +e used
ho3ever e-tensive vi+ration testing 3ill +e re6uired. This scenario should +e not
used i at all possi+le.

&cenario V2@ CEM solation Mounted, En,ine 2ard Mounted
This is a preerred scenario. 8hen the C!" is attached to the master structure
using vi+ration isolation mounts) it is preera+le to hard mount the engine to the
master structure. This scenario allo3s the C!" to +e isolated rom engine and
"arine Nessel vi+ration sources. A "arine Nessel vi+ration source ma% originate
rom rotating e6uipment associated 3ith trenching) drilling) chipping J grinding)
road +uilding e6uipment etc. Cat t%picall% preers to suppl% these isolation
mounts as part o the engine pac,age. @le- pipe relative movement due to
isolation mounting is minimi&ed since isolation mounts are onl% used or the
C!".

2013 Caterpillar AF 10Dec2013

&cenario V3@ CEM 2ard Mounted, En,ine solation Mounted
This can +e a preerred scenario. 8hen the engine is attached to the master
structure using vi+ration isolation mounts) it is preera+le to hard mount the C!"
to the master structure. This is t%picall% preerred or installations that do not
have "arine Nessel vi+ration sources #see *cenario Z2 or e-amples o "arine
Nessel vi+ration sources$. ' this scenario is to +e used 3ith "arine Nessel
vi+ration sources) then e-tensive vi+ration testing ma% +e necessar%.

'n this scenario) onl% 1 o the 2 components is isolation mounted. @le- pipe
relative movement due to isolation mounting is minimi&ed since isolation mounts
are onl% used or the engine.
&cenario V0@ CEM solation Mounted, En,ine solation Mounted
This is not a preerred scenario. 8hen the engine and C!" are +oth attached to
the master structure using vi+ration isolation mounts C!" vi+ration 3ill tend to
+e accepta+le. 4o3ever) e-haust le- pipe relative movement capa+ilit% ma% +e
diicult or impossi+le to satis%. 'n this scenario) relative movement 3ill originate
at +oth the engine and C!". The relative movement at the e-haust le- pipe 3ill
+e e6ual to the movement allo3ed +% the isolation mounts at the engine and
C!" and their component.s relative position to the e-haust le- pipe. ' the
engine and C!" are not in close pro-imit% then achieving le- pipe capa+ilit%
re6uirements in this scenario ma% +e impossi+le.

This scenario ma% +e re6uired or installations thatM
:e6uire the engine to use vi+ration isolation mounts
4ave "arine Nessel vi+ration sources present #see *cenario Z2 or
e-amples o "arine Nessel vi+ration sources$.
&cenario V160 &ummaries@
Eo3 that each scenario has +een discussed) the chart rom a+ove as +een
updated 3ith C!" vi+ration) !-haust pipe Capa+ilit% and Ni+ration measurement
re6uirements.

&cenario CEM
Mountin,
En,ine
Mountin,
*referred
&cenarioW
*referred
for CEM
%i#rationW
*referred
for e<3aust
fle< pipe
capa#ilit'W
=i#ration
Measurin,
$e+SedW
1 4ard 4ard Eo Eo =es =es
2
Ni+ration
'solation
4ard =es =es =es Eo
3 4ard
Ni+ration
'solation
=esQ EoQ =es
'n some
casesQ
4
Ni+ration
'solation
Ni+ration
'solation
EoQ =es EoQ Eo
Q *ee notes 3ith regard to scenario Z3 J Z4 in the detail +elo3.

2013 Caterpillar AA 10Dec2013

>ello7s6Mount .isplacement Calculator@
The 1ello3sC"ount Displacement calculator should +e used to determine i the
installation satisies the re6uired le- pipe capa+ilit%. This calculator must +e
used 3ith the C!" "ounts Decision Tree to determine C!" vi+ration
accepta+ilit%. The le- pipe calculator is availa+le in !ngipedia C Tool 1o- L AJ'
(uides.

2013 Caterpillar AI 10Dec2013
The installer designed engine and C!" installed s%stem must satis% 2 criteria to
ensure accepta+le le- pipe dura+ilit%.
1. :adial Capa+ilit%
2. A-ial Capa+ilit%

The le- pipe calculator re6uires several inputs includingM
!ngine
'nstalled mass o the engine and all loads cantilevered o the
l%3heel housing
'nstalled center o gravit% or the engine and all loads cantilevered
o the l%3heel housing
Eum+er o !ngine mounts
(C;oad
!ngine "ount positions
!ngine mount stiness
C!"
"ass
Center o gravit%
Eum+er o C!" mounts
(C;oad
C!" "ount positions
C!" mount stiness

The calculator uses this inormation to determine radial and a-ial movement at
the le- pipe. 1ased on this movement the calculator 3ill designate the radial
and a-ial le- pipe capa+ilit% as accepta+le or unaccepta+le. All installations
must ac3ie%e fle< pipe radial and a<ial accepta#ilit')

nstallation

2andlin, and s3ippin,

The Cat C!" unit 3ill +e pac,ed in order to protect the assem+l% during shipping
and deliver%. *hipping covers 3ill +e installed on all lange connections. These
"?*T +e removed +eore the unit is placed into service.

/iftin, /in;s

;iting ;in,s are availa+le to acilitate handling o Cat C!" units. :eer to
appropriate *ervice "anual and 0"" or liting details.

mportant@ ;iting lin,s are rated to support the 3eight o the Clean !missions
"odule unit 5A/XY $emo%e an' liftin, lin;s after installation is completedY

1arnin,@ Care must #e used 73en liftin, t3e CEM) /iftin, at ad%erse an,les
to t3e liftin, #rac;et ma' cause dama,e to t3e CEM and potential inCur' to
t3e 3andler) Al7a's lift in line 7it3 t3e #rac;et) &preader #ars are
mandator' for liftin, t3e CEM 73en inline liftin, cannot #e ac3ie%ed 7it3
c3ains9strap)

2013 Caterpillar I0 10Dec2013

Mountin, *ads

The *C: units 3ill have 9 "ounting /ads using "19U2 3eld nuts or the 3519
and 4 mounting pads using *A! T C 10 U 3 in. clearance holes.

The Cat C!" assem+l% should +e mounted in a location that provides air
circulation around the can and %et protects it rom possi+le de+ris or oreign
o+Hect damage. 0nl% a protective heat shield located a3a% rom the Cat C!"
allo3ing airlo3 around it is accepta+le. ?nless approved +% CAT) protective heat
shields should not +e used as the% can cause locali&ed heating.

Aote@ "3e Cat CEM s3ould #e mounted in a location t3at allo7s access and
remo%al for ser%ice re+uirements) A minimum of 200 mm is re+uired
#et7een t3e en,ine %al%e co%ers and Cat CEM 73en mounted a#o%e t3e
en,ine for en,ine ser%ice) &ee t3e Caterpillar 5peration and Maintenance
Manual (5MM) for actual ser%ice re+uirements and procedures)

Eotice L 8elding mounting +rac,ets to the Cat C!" is not permitted2 this could
lead to ailure o the unit and emissions nonCcompliance.

All mounting +rac,ets must +e properl% adHusted so that the inlet and outlet o the
Cat C!" line up properl% 3ith the e-isting inlet and outlet pipes o the installation
application. Designated clamping &ones 3ill +e provided 3ith Cat C!" models to
avoid damaging the ilter 3ithin the can. :eer to D&ection 5 6 E<3aust &'stemE
or @le-pipe 1ello3s Coupling :e6uirements.


-) "3ermal Mana,ement

ntroduction
The main e-haust piping routes e-haust gas rom the engine to the Cat C!".
Eormal operating temperatures can reach up to 525WC at pea, tor6ue or C140
through C2A0 engine amilies including 3500 series. Thereore) thermal insulation
on the surace o the main e-haust piping ma% +e re6uired. /roper precaution
should +e ta,en to ensure that the Cat C!" is not mounted in close pro-imit% to
components that ma% +e damaged +% heat.

'n addition) "arine Class *ocieties have a 220 C s,in temperature re6uirement)
per *0;A* regulations Chapter ''C2) :egulation 4) /aragraph 2.2.9.1.

"3ermal *rotection
The main e-haust piping routes e-haust gas rom the engine to the Cat C!".
Eormal operating temperatures can reach up to 525ZC at pea, tor6ue. Thereore)
thermal protection rom the surace o the main e-haust piping ma% +e re6uired.
/roper precaution should +e ta,en to ensure that the atertreatment device is not
mounted in close pro-imit% to components that ma% +e damaged +% heat.

EoteM The atertreatment s,in temperature and the gas temperature are diicult
to measure and5or simulate and are dependent upon man% actors including the
ollo3ingM the nature o the engine5atertreatment ailure) the design and
pac,aging o the atertreatment) the engine speed5load conditions) the condition
o the atertreatment) and the am+ient conditions. Thereore) the potential
temperatures are provided as a guideline or sae design o the installation even
under conditions o une-pected engine and5or atertreatment ailure2 and proper
precaution should +e ta,en to insure that the atertreatment device is properl%
shielded and not mounted in close pro-imit% to surrounding components that ma%
+e damaged +% heat.

'n general surace temperature 3ill increase 3ith emissivit% assuming all else
+eing e6ual. (eometr% also pla%s a role. The :u++er 4ose has lo3er surace
temperature than the E%lon *trip +ecause o its si&e and shape and surace
orientation to the heat source relative to the C!".

Narious t%pes o insulation and shielding are readil% availa+le and can +e applied
according to the re6uirements o the speciic application. 'nsure that the chosen
thermal management device is ade6uate or the application under all conditions.
*pecial consideration must +e given to conduction) as 3ell as radiation eects
due to each option.
"3ermal 1rappin,
Caterpillar stron,l' recommends 7rappin, t3e en,ine e<3aust
aftertreatment) Applications must loo; into alternati%e means of reducin,
radiated 3eat effects from t3e aftertreatment de%ice suc3 as increased air

flo7 around t3e aftertreatment and9or 3eat s3ields to protect 3eat sensiti%e
de%ices)

There are components and areas on the Cat C!" that re6uire protection rom
high temperatures. @ollo3 the component temperature limit re6uirements ound
in this AJ' document to ensure ade6uate thermal protection is adhered to.

' the C!" !-haust Tu+es need to +e 3rapped in an applicationM

"aintain the temp limits o electronics as listed in the AJ' guide)
Component Temperature ;imits

Clearance must +e maintained +oth inside and outside o sot 3rap to
avoid points 3here 3ear a+rasion can ta,e place

8raps must have openings to allo3 sensor pro+es to pass through and
openings must +e suicient to prevent sensor contact 3ith 3raps. Do not
place 3raps over 3ires or sensor leads.


7) Appendices@
Appendi< A@ Cat CEM 2arness nstallation !uide
>ac; to "5C
1irin, 2arness Components

Deutsch DT Jumper Harness Connectors C!,C"#

The DT connector is the lo3Ccost preerred choice or inline applications. The
connector is availa+le in 2) 3) 4) 9) A) and 12 terminal conigurations. 't is also
intended or *A! K1I3I application use. The 3ire si&e range the connector 3ill
accept is 0.A mm
2
#1A A8($) 1.0 mm
2
#19 A8($) and 2.0 mm
2
#14 A8($. The
plug assem+l% 3ith interace seal accepts soc,et terminals and the receptacle
assem+l% accepts pin terminals. *ealing plugs are to +e used in unused 3ire
cavities.

The DT connector has a 3edge that loc,s the pins and the soc,ets in place. The
3edge can +e removed and replaced 3ithout cutting the 3ires. The 3edge
removal tool #p5n 14FC9459$ can +e used to aid in the removal o the 3edges.
8hen the receptacle is inserted into the plug) a clic, should +e heard as the t3o
halves loc, together. The connector should not +e a+le to +e pulled apart.

The ollo3ing ta+le contains the Caterpillar part num+ers or DT inline connector
plug and receptacle ,its or all availa+le num+er o pin positions. The ,it is
comprised o the plug or receptacle and the respective loc,ing 3edge.

&tandard ." Connectors
*ositions
Cat *art Aum#er
*lu, Git $eceptacle Git
2 155C22F0 102CAA02
3 155C2290 102CAA03
4 155C22F1 1IFCF595
9 155C22F4 102CAA05
A 155C2295 102CAA09
12 155C2255 102CAA01

Contact the local Deutsch sales contact or more inormation on these
connectors.

Deutsch A$C Jumper Harness Connectors C%,C&#


The connector is availa+le in 24) 40) and F0 terminal conigurations. 't can +e
used or inline or +ul,head mountings. The connector is re6uentl% used in
electronic +o- applications. The 3ire si&e range the connector 3ill accept is 0.A
mm
2
#1A A8($) 1.0 mm
2
#19 A8($) and 2.0 mm
2
#14 A8($. The plug assem+l%
3ith interace seal accepts soc,et terminals and the receptacle #header$
assem+l% accepts pin terminals. *ealing plugs are to +e used in unused 3ire
cavities.

The Caterpillar 0!"5'nstaller harness uses the A!C14C40/A!C!01I terminal
coniguration. 0!"5'nstaller interace 3ith this harness is the 40Cposition plug
connector #Caterpillar part num+er 324C929F$. This connector is la+eled as /KC
C1 and /KCC2 on Kumper 4arness. The A!C connectors are ,e%ed to align
correctl% 3hen the t3o parts are mated together. An Allen head scre3 holds the
t3o connectors in place. !nsure that the Allen head scre3 is tightened to a
tor6ue o 9 Y5C 1.0 E`m #4.4 Y5C 0.F l+Ct.$.

Connector Terminal Contacts

There are t3o t%pes o terminal contacts availa+le or production useM machined)
and stamped and ormed. "achined terminal contact) also reerred to as a solid
contact) is used or lo3 volume harness production and or ield repair. *tamped
and ormed contact is used or high volume harness production and is the lo3est
cost terminal contact option.

Terminal contacts are availa+le 3ith nic,el or gold plating. (old plating should +e
used or applications o 5 volts or less and5or less than 100 milliamps. T%picall%
these lo3 level circuits re6uire lo3 resistance at the pin5soc,et connection and
gold plating is the +est lo3Ccost choice. Eic,elCplated contacts can +e used in
po3erCt%pe circuits or circuits 3here lo3 resistance at the pin5soc,et connection
is not a concern.

(oldCplated contacts can +e used in all circuit applications regardless o the
voltage and current re6uirements. (old plating provides some marginal
improvement in vi+ration versus nic,el plating. Caterpillar re6uires that onl%
(oldCplated soc,ets are used in the !C? connector #K1$.

Aote@ Deutsch nic/el3plated stamped and 7ormed terminals are not
recommended 7or use ecause o7 e8cessi4e 4oltage drop e8perience in
laorator6 tests9

'ire T(pe and )auge *i+e
8ire *election

8ire must +e o a t%pe suita+le or the application. 8ire must +e selected so that
the rated ma-imum conductor temperature is not e-ceeded or an% com+ination
o electrical loading) am+ient temperature) and heating eects o +undles)

protective +raid) conduit) and other enclosures. T%pical actors to +e considered
in the selection are voltage) current) am+ient temperature) mechanical strength)
connector sealing range) a+rasion) le-ure) and e-treme environments such as
areas or locations suscepti+le to signiicant luid concentrations.
1ire &iIe
The minimum conductor si&e used on Caterpillar products is 0.A mm
2
#1A A8($.
*maller conductors are suscepti+le to +rea,age and atigue ailures. *A! K1914)
3iring distri+ution s%stems or construction) agricultural) and oCroad 3or,
machines re6uire 3ire si&es no smaller than 0.A mm
2
#1A A8($.

Kumper harness 3ire si&e re6uirements per connection are deined in the Cat
C!" and !ngine Kumper 4arness Deinition ta+les +elo3.

1ire nsulation
A5"E@ 0hermoplastic Pol64in6l Chloride %P1C& insulation shall not e used
in )ire harness designs ecause o7 its lo) operating temperature range %3
(# to "5: C&; and melt and 7lammailit6 characteristics9

Cross ;in,ed /ol%eth%lene #U;/!$ is the primar% 3ire insulation t%pe used in
chassis) ca+) and engine compartment locations. 't has a temperature rating o C
50 to 120W C. The voltage rating or Caterpillar 1!0A15 3ire and *A! K112A)
T%pe (U; is 50 volts. The circuit voltage shall +e considered 3hen ma,ing 3ire
selections. This 3ire insulation is also availa+le 3ith 50) 150) 300) or 900Cvolt
ratings.

0utside diameter insulation range is 2.29 to 3.33 mm #0.0AI to 0.131 in.$. The
ta+le +elo3 provides insulation diameter range or each gauge and 3ire t%pe.

*? Connector 1ire nsulation and !au,e &iIe
1ire "'pe 1ire !au,e nsulation .iameter
(U;
14 0.114 L 0.125
19 0.0IA L 0.112
1A 0.0AI L 0.0IA

Connector +eal Plug

All unused cavities or soc,ets and pins must +e illed 3ith seal plugs in order to
ensure that the connector is sealed. T3o options are availa+le or plugging
unused connector cavities. !ither the Deutsch 11401F #Caterpillar part num+er
ATCAF3F$ or /!' (enesis 225C00I3C000 #Caterpillar part num+er I(C39I5$
sealing plugs can +e used.
Metric E+ui%alents for A1! 1ire Aum#ers
A1! 20 14 18 1- 10 12 0
.iameter (mm
2
) 0)5 0)-5 0)8 1 2 3 14


*lu, nsertion in 8nused Connector Ca%it'

The seal plugs are installed rom the 3ire insertion side o the plug or receptacle.
Correct installation o either o these cavit% plugs is critical to maintain connector
sealing integrit%. @igure a+ove illustrates the correct insertion o the plug. The
seal plug cap is designed to rest against the seal) not inserted in the hole in the
seal.

2013 Caterpillar IF 10Dec2013

2arness $outin,

8iring shall +e routed to ensure relia+ilit% and to oer protection rom the
ollo3ingM
1. Chaing5ru++ing5vi+rating against other parts.
2. ?se as handholds or as support or personal e6uipment.
3. Damage +% personnel moving 3ithin the "arine Nessel.
4. Damage +% impact) or thro3n or alling de+ris.
5. Damage +% +atter% acid umes) engine and h%draulic oil) uel) and
coolant.
9. A+rasion or damage 3hen e-posed to roc,s) ice) mud) etc.
F. Nandalism damage #to the ma-imum e-tent practica+le$.
A. Damage +% moving parts.
I. 4arsh environment such as nitrite mines) high temperatures) or areas
suscepti+le to signiicant luid or ume concentration.

8ire harnesses shall not +e located in close pro-imit% to oil and uel luid ill
areas or +elo3 uel and oil ilter locations. ' these locations cannot +e avoided)
additional protective covers and shields must +e provided to
protect the harness.

4arnesses shall +e located a minimum o 50 mm rom high heat sources #e.g.
e-haust maniolds) tur+ochargers) h%draulic components) etc.$ to avoid insulation
and5or connector deterioration.

2arness Maintenance Considerations
The maintaina+ilit% o the 3iring s%stem shall +e an important consideration in the
selection) design) and installation o harnesses) ca+le assem+lies) and other
3iring s%stem components. All 3iring components shall +e accessi+le)
repaira+le) and replacea+le #i.e. connector terminals$.

4ighCpressure 3ash s%stems are no3 in re6uent use +% maintenance people.
8hen locating electrical connectors) place them in accessi+le locations 3hile
using other ph%sical elements or protection and prevention o direct e-posure to
3ash s%stems #e.g. +rac,ets) housings) sheet metal structure) etc.$. 8here direct
e-posure to high pressure 3ash s%stems cannot +e avoided) protective shields
3ill need to +e designed and installed.

2arness Appearance

The primar% purpose or the 3iring s%stem is to provide electrical and
electronic component unction. There is) ho3ever) another important
and intangi+le value to consider 3hen designing the 3iring s%stem.

2013 Caterpillar IA 10Dec2013
The appearance o the 3ire harness and its routing path should
relect an orderl%) 3ellCthoughtCout design plan. A poorl% e-ecuted
plan can have a negative impact on 0!"5'nstaller perceptions o the
entire product. ?se the product.s hori&ontal and vertical lines or
routing paths. Design preormed +ends into large harnesses to
acilitate product assem+l% and improve appearance. ?se other
product elements to shield or hide the harness rom vie3. 1enchmar,
ne3 automotive product applications or ideas.

2arness >ends
:outing o the harness should insure connector seals are not stressed +ecause
the harness curvature is too close to the connector. This applies to routing o
0!"5'nstaller lines on or near the engine harness as 3ell as the !C?
0!"5'nstaller connector #K15/1$.

The minimum +end radius or a +raided 3ire harness as measured rom the
inside o the +end shall +e our times the outer diameter o the harness. Tighter
+ends are possi+le i the +end is preormed during harness manuacture. The
+end radius si&e and location must +e speciied on the 3ire harness dra3ing.
1ends in Hac,eted ca+les shall +e +ased on manuacturer recommendations. A
+end must not adversel% aect the operating characteristics o the ca+le. @or
le-i+le coa-ial ca+les) the +end radius must not +e less than si- times the
outside diameter. @or semiCrigid coa-ial ca+le) the +end radius must not +e less
than ten times the outside diameter o the ca+le.

The minimum +end radius or le-i+le conduit must +e si- times the outer
diameter o the conduit. Conduit +ends shall not cause internal chaing o the
3iring.

2arness >ends near Connectors
Avoid 3ire harness +ends 3ithin 25 mm #1.0 in.$ o the connector. 8hen a
harness +end is too close to the connector) the connector seal is stretched a3a%
rom the 3ire) providing an opening or moisture entr%. The 3ire should e-it
perpendicular to the connector +eore curving as necessar% or routing. :eer to
illustration in @igure +elo3.

2013 Caterpillar II 10Dec2013

E<ample of 1ire 2arness $outin, at t3e *?6C1,C2 Connectors

8ire harness +ends near a connector must +e no less than t3ice the 3ire
harness diameter. *pecial consideration shall +e given to connectors 3ith large
3ire counts. *tresses placed upon the retention s%stem o the connector can
cause contact retention ailures and 3ire pullCout. 'n order to avoid this pro+lem
consider the ollo3ing optionsM
1. /reCorm the harness to the re6uired +end. The harness assem+l%
dra3ing shall detail the harness +end re6uirements #e.g. location and
radius$. The harness +raid protection should +e applied up to the tangent
point o the +end urthest rom the connector. Connector orientation to the
+end ma% +e necessar% and should +e speciied on the harness print.
2. ' harness +raiding is used) increase the un+raided harness length to 150
mm. This 3ill allo3 the 3ires to an out 3hen the harness is +ent) greatl%
reducing the orces placed on the connector contact retention s%stem. The
connector should also +e oriented properl% 3ith respect to the harness so
that upon installation to the product the harness 3ill not need to +e t3isted
to align the connector.

.rip /oop
8hen a harness is routed do3n3ard to a connector) terminal +loc,) panel) or
Hunction +o-) a trap or drip loop shall +e provided in the harness. This eature 3ill
prevent luids or condensate rom running into the a+ove devices.

&ealin, &plices and $in, "erminals
Caterpillar re6uires all ring terminals and splices connected to the engine !C?
+e sealed using :a%chem !*2000 adhesive lined heat shrin, tu+ing or
e6uivalent. :eer to Ta+le +elo3 or heat shrin, tu+ing si&ing inormation.


2eat &3rin; "u#in, $eference "a#le

1ire Connection !uidelines
The ollo3ing re6uirements ensure the correct installation o solid contacts into
connector terminalsM
Do not solder the contact #soc,et or pin$ to the 3ire.
Eever crimp more than one 3ire into a contact. Connector contacts are
designed to accept onl% one 3ire o a speciied gauge or gauge range) do
E0T insert multiple 3ires o a smaller gauge.
All contacts should +e crimped on the 3ires. ?se the Crimp Tool #Caterpillar
part num+er 1?C5A04$ or 12 to 1A A8( 3ire.
/erorm the pull test on each 3ire. The pull test is used to veri% that the 3ire
is properl% crimped in the contact and the contact is properl% inserted in the
connector terminal. !ach contact and connector terminal should easil%
3ithstand 45 E #10 l+$ o pull such that the 3ire remains in the connector
+od%.

&AE ?1434911 J .ata >us 1irin,

?1434 .ata >us 2arness .esi,n

The data +us connector that Caterpillar uses is a modiied DT connector) special
3edge) ca+le) and e-tended soc,et. The harness assem+l% re6uirements are
uni6ue to t%pical Caterpillar 3ire harnesses. Caterpillar recommends 2 conductor
shielded ca+le rom :a%chem Corp #:a%chem part num+er 201ID030IC05Cat
part num+er 153C2F0F$ or all K1I3I data lin, 3iring. This is t3isted pair 3iring. '
the Caterpillar recommended ca+le is not used) the ca+le must meet K1I3I
speciications or conductors. @or additional inormation
regarding the electrical s%stem design see the *A! pu+lication K1I3I511
/h%sical ;a%er.> The minimum +end radius or the data +us ca+le is 40 mm.


'n order that the data +us 3ill unction as intended the ollo3ing re6uirements
must +e identiied on the customer 3ire harness print.

1. :emove F5 mm o the outer Hac,et o data lin, shielded ca+le. #:eerence
Cat part num+er 153C2F0F$

2. :emove the oil shield rom the e-posed 3ires to 3ithin 3 mm o the ca+le
Hac,et end.

3. Crimp goldCplated soc,et terminals to the 3ires and the e-tended soc,et
terminal to the drain 3ire.

4. *lide heat shrin, tu+e over the ca+le end. #:eerence Cat part num+er
125CFAF9$

5. 'nstall the terminals into the appropriate connector cavit% positions.

9. 'nstall the 3edge into the connector.

F. Appl% the heat shrin, tu+e over the +ac, o the connector +od% and the
Hac,et o the ca+le.

The a+ove components and assem+l% procedures must +e used to ensure the
ca+le to connector Hoint 3ill +e sealed. @ailure to conorm to these re6uirements
3ill result in ca+le contamination and result in loss o shield perormance. *ee
@igure 9.


Connectin, Modules to t3e CAA .ata /in;

The *A! K1I3I data lin, is used to communicate engine inormation to an *A!
K1I3I compati+le displa% or other desired *A! K1I3I compati+le modules. :eer
to *!E:IF94 <'nstallation (uide or 'ndustrial !lectronic !ngine Displa%s> or
more inormation on connecting K1I3I displa%s to Caterpillar industrial engines.
The illustration in @igure F sho3s t3o K1I3I modules properl% connected to the
K1I3I data +us. The ,e% components to note are as ollo3sM

The total length o the data lin, +et3een terminal resistors must not
e-ceed 40 m #130 t$.

;ength o each +ranch) or stu+ length) must not e-ceed 1 m #3.3 t$.
:eerence ca+le assem+l% #Cat part num+er 195C0200$ that is .15 m long
3ith Deutsch DT 3 pin plug on one end and K1I3I signal and shield 3ires
3ith appropriate crimped soc,et on the other end or insertion into K1I3I
module connector.

All splices and end nodes can +e implemented using a connector tee.
#:eerence Deutsch DT receptacle assem+l% a Cat part num+er 133C
0IF0$.
T3o terminal resistors must +e installed. 0ne resistor is re6uired at each
end o the data lin, in order to ensure proper operation. These t3o
terminal resistors are critical or the proper operation o the net3or,.

#:eerence Deutsch DT plug 3ith integrated termination resistor a Cat part
num+er 1F4C3019$.


#1$ T3o terminal resistors are re6uired. 0ptional Customer
4arness provides the resistor at the !C" i installed
#2$ "a-imum stu+ length ] 1 m #3.3 t$
#3$ @a+ricate 153C2F0F ca+le to length

A5"E@ ,f the requirements for J%-!- data lin. connections are met, an( number of
displa( modules or service tool connectors ma( be connected to the J%-!- data lin..
A5"E@ /ne terminal resistor for the J%-!- data lin. is included in the optional customer
harness. ,f the optional customer harness is not present, t0o terminal resistors must be
installed. An( J%-!- data lin. must have a terminal resistor at each end of the data lin..
A5"E@ A terminal resistor is required at the terminal ends of the data lin. cable. A
terminal resistor is not required at each node on the data lin..

'ntentionall% 1lan,


Appendi< >@ nitial &tartup *rocedure

En,ine and Aftertreatment Compati#ilit' C3ec;

Ater completing installation o the atertreatment hard3are) a hard3are
compati+ilit% chec, is re6uired. There are three criteria or meeting
atertreatment compati+ilit% chec,.
1. Automatic compati+ilit% chec, at ,e% on
2. Neri%ing that the C!" and Dosing ca+inet serial num+ers match
3. Documentation o C!" and !ngine serial num+er

Automatic compati#ilit' c3ec; at ;e' on

All C!".s contain a chip that 3ill chec, or proper compati+ilit% 3ith the engine.
At irst start up the engine !C" 3ill read the C!" chip and 3rite the serial Z
inormation to the engine !C". The engine !C" 3ill then determine i a
compati+le C!" and dosing ca+inet has +een installed 3ith the engine.
' the C!" and5or dosing ca+inet are not compati+le 3ith the engine) the
engine 3ill derate and trigger an active ault. A compati+le C!" and5or
dosing ca+inet or the engine 3ill need to +e installed to resolve this issue.
' the C!" and dosing ca+inet is compati+le the engine 3ill not derate and
there 3ill +e no ault code. Eo urther action or the automatic
compati+ilit% chec, is re6uired.

The engine 3ill continue the compati+ilit% chec, o the C!" or the irst 25 hours
o operation o the installation. ' or an% reason the engine !C" is replaced or
atertreatment is replaced 3ithin the irst 25 hours o operation the engine !C"
3ill re3rite the C!" serialZ rom the C!" chip. The 25 hour cloc, or
compati+ilit% chec, 3ill also restart ater initial compati+ilit% chec, o the ne3
hard3are.

=erif'in, t3at t3e CEM and dosin, ca#inet serial num#ers matc3

C!" and dosing ca+inet are shipped as a matched set rom Caterpillar. 't is
re6uired that the installer use a C!" and dosing ca+inet 3ith matching serial
num+ers or an% installation. Neri% that the serial num+ers are identical or +oth
the C!" and dosing ca+inet.


/ocation of CEM &erial Aum#er@

/ocation of .osin, Ca#inet serial num#er@

.ocumentation of CEM and En,ine &erial Aum#er

Documentation o engine serial num+er and C!" serial num+er is a re6uirement
or all installations

The inal installer o the engine and C!" 3ill +e re6uired to document the engine
and C!" serial num+er and provide that inormation to Caterpillar. The Dealer
3ill ollo3 the standard reporting re6uirements through the 8e+ /ortal Tier 4
Commercial !ngine Application. This site re6uires an 'nstallation Audit and

*erial Eum+er pairing entr% on either an individual engine s%stem +asis or part o
a mass upload perormed +% the Dealer.

En,ine and Aftertreatment Assem#l' documentation

Documentation o the engine and C!" serial num+er is to +e done to +e
reported +ac, to Caterpillar to meet the !/A re6uirements. The engine and
atertreatment serial num+ers are to +e re6uired 3ithin the D@A.

'ntentionall% 1lan,


Appendi< C@ >ello7s6Mount .isplacement Calculator
*rocess

*urpose@
This procedure is provided to assist in determining the 1ello3C"ount capa+ilit% o
the T4 atertreatment application installation and the need or hard or sot mount
C!". This process should +e used in concert 3ith the 1ello3sC"ount Calculator)
Cat C!" AJ' (uide in section 5 L !-haust *%stem5'nstallation Design J
Assem+l% 'nstructions and *ection 5 L "ounting Considerations5C!" Ni+ration
Accepta+ilit% 0vervie3. This tool provides guidance or calculation o +ello3sC
mount displacement +oth a-iall% and radiall% using distance measurements and
engine J C!" mount inormation rom a t%pical application installation design.
/rocess procedure ollo3sM

*rocess@
Calculate +ello3s relative movement a-iall% J radiall% using distance
measurements and engine J C!" mount inormation.
" 'ndependentl% moving engine
" 'ndependentl% moving C!"
" 4o3 does the +ello3s move to compensate[


&preads3eet *re%ie7
The spreadsheet consists o data input rom engine and C!" application and
installation parameters to determine +ello3sCmount capa+ilit%.

En,ine setup #t%pical$M
Top Nie3
" A)1)C)D] !ngine
mounts
" ()4)')K] C!" mounts
" :] C!" 'nlet
" T] Tur+o
" "] 1ello3s 'nlet
" E] 1ello3s 0utlet
" A] Oero /oint #All
points measured
relative to A$

2
C .
A >
En,ine "op
?
!
<=
<>
M
A
CEM "op
$
"
(A!)<
E<ample
Measurements
>ello7s6
End of
con%olution
alon, a<is
( AM)<

:ront =ie7
` @ront Nie3
En,ine :ront
<?
<>
CEM :ront
! 2
A >
M
A
"
$
AT Mount
&upported
&tructure

/eft =ie7
En,ine /eft
!
<=
<?
A
CEM /eft
$
C A
End of tu#e
alon, a<is
"
M

&preads3eet &tep6#'6&tep *re%ie7

E<cel &3eet .irections

1. Choose tu+e routing nominal diameter #4> or 5>$

2. 'nput !ngine and C!" mass
" This is the mass supported +% %our mounts i the% e-ist

3. 'nput !ngine and C!" mount 6uantit%

4. 'nput !ngine and C!" e-pected (Cloads i ,no3n #5g other3ise$


5. 1ased on inputs a+ove the spreadsheet 3ill output a load in Ee3ton

9. ?se mount load to displacement chart to determine a-ial and lateral
displacement at the output load.
NN"3is c3art 7ill
differ #' mount)
$adial A<ial

F. 'nput A-ial and :adial #;ateral$ displacements into spreadsheet or engine
and C!" respectivel%.

A. Ta,e measurements o all points relative to point A #@ront let engine
mount$
NN A%oid enterin, Ieros 3ere) E%en if 3ard mounted
enter 3ard mountin, locations)

4)
4)
10)

I. !nter C( #center o gravit% distances$ a+ove mount locations or engine
and C!".
10. !nter average s,in temperature o e-haust line +et3een tur+o and
atertreatment 3hen gas temperatures are at their highest.

*preadsheet 3ill output estimated movement +ello3s must a+sor+
" "a- a-ial and radial displacement
" 'ncludes d%namic and thermal displacement
" 3 potential outputs

" (] ' all inputs are correct) design should +e accepta+le

" =] Contact %our AJ' integration engineer

" :] Design is not accepta+le and 3ill need some t3ea,ing as
sho3n on the ne-t slide

5ptions for redesi,n@
0ptions i +ello3s capa+ilit% is less than calculated displacements[
" 'ncrease mount stiness #Ee3 "ount$
" 'ncrease Z o mounts
" Decrease distance +et3een tur+o outlet and C!" inlet

$ecommendations9!uidelines@
' %ou don.t ,no3 %our (C;oads C recommendation is to use 5(.s to
evaluate 3orst case.
' C!" or engine is hard mounted) mount delection values should e6ual 0


Appendi< .@ A8& 9 .E: 2andlin,

:eer to Caterpillar @luid document /!;K1190C01 or additional inormation on
D!@ luids.

2aIards dentification
A?* 5 D!@ #A?*32 C a6ueous urea solution) 32 or 40D$ is a colorless li6uid 3ith
a slight ammonia #pungent$ odor.

Aote@ Consult t3e Material &afet' .ata &3eet (M&.&) pro%ided #' 'our
A8&32 supplier) "*D* e-ample isM
"*D* Eum+er 2049 #:evised 0cto+er 4) 2009$ or ?rea ;i6uor supplied
+% Terra 'ndustries 'nc.

Warning: A8& 9 .E: is a sta#le material, #ut 3i,3l' reacti%e 7it3 stron,
o<idiIers) A%oid contact 7it3 all o<idiIers) A8& 9 .E: reacts %iolentl' 7it3
sodium 3'poc3lorite (suc3 as Cloro<
"M
) or calcium 3'poc3lorite to form
t3e nitro,en tric3loride, 73ic3 spontaneousl' e<plodes or rapidl'
decomposes creatin, to<ic fumes, 73ic3 ma' cause personal inCur' or
deat3)

8hen heated) A?*5D!@ releases ammonia. 8hen heated to decomposition)
such as in a ire) it emits to-ic umes o nitrogen o-ides #E0
U
$) ammonia) and
c%anuric acid. ?se 3ater to control ires involving A?*5D!@ li6uid i 3ater is
compati+le 3ith +urning material. Eote that +oth A?*5D!@ li6uid and solid
A?*5D!@ are nonClamma+le.

'n storage) a ver% small amount o the A?*5D!@ in the li6uid state 3ill h%drol%&e
orming gaseous ammonia and car+on dio-ide. The ammonia) 3hich is solu+le
in the li6uid) 3ill cause the corrosiveness o A?*5D!@ solution to increase as it
ages due to its increasing concentration. That is) the higher ammonia
concentration ma,es it more caustic. Eote that high storage temperatures
increase the rate o this decomposition.


*ince A?*5D!@ li6uid is caustic) deliver% and
storage re6uires materials that are not
suscepti+le to corrosion.

$ecommended Materials@
*tainlessCsteel
o 300 seriesM 0P
o 400 seriesM *lo3 corrosion
o Corrosion rate increases 3ith
temperatures G 90 WC
/lastics

Materials to A%oid@
1nallo(ed steel
Aluminum
2rass
)alvani+ed steel
Copper

E'e contact ma% cause mild e%e irritation) including stinging) 3atering) and
redness. 8ear saet% glasses. *aet% shield ma% +e needed in some conditions.

&;in contact ma% cause mild s,in irritation including redness and +urning. Eo
harmul eects rom s,in a+sorption have +een reported. ?se ru++er gloves to
prevent s,in contact #All ru++er t%pes 0P$.

=apor n3alation ma% cause irritation leading to cough or diicult% in +reathing.

Aote@ Contact ha&ards are rom the caustic p4 #F.5 L 10$ actor o solution. A?*
5 D!@ in solution slo3l% decomposes into ammonia causing the caustic reaction.
<Aged> A?* 5 D!@ solution is more caustic #high p4$ than <resh>.

/ea;s and9or &pills
There is visi+le evidence should a lea, occurM
A?* 5 D!@ stalactites J stalagmites
" @ormed rom slo3 lea,s and
evaporation o 3ater
" :ate o 3ater evaporation
determines si&e o cr%stal ormation
Eeed to veri% that Hoints are tight
" *top lea,s 3hen irst noticed
*olid A?* 5 D!@ 3ill continue
to accumulate
A?* 5 D!@ solution is
corrosive to steel and other
metals
*olid A?* 5 D!@ is 3ater solu+le
" @utb ma% +e slo3 to get into solution
Clean up spills and lea,s before components can corrode
" "inor spillsM ?se paper to3els or a+sor+ent mat
*olid A?* 5 D!@ is highl% 3ater solu+le

" 4ot 3ater 3ill reCdissolve solid A?* 5 D!@ aster
" *mall amount o soap or detergent in hot 3ater ma% enhance clean up
" /lent% o hot 3ater is ,e% to removing dr% A?* 5 D!@
A?* 5 D!@ solution contains small amount o ammonia
" *,in irritant
" 8ear gloves



$e%ision &ummar'

Due to several changes re6uired :evision 1 3ill +e considered the irst release
3ith no :evision *ummar% listed. :evision *ummar% 3ill +egin at Drat :ev 2
release.

"aterials and speciications are su+Hect to change 3ithout notice.
CAT) CAT!:/';;A:) their respective logos) <Caterpillar =ello3> and the
/08!: !D(! trade dress) as 3ell as corporate and product identit% used
herein) are trademar,s o Caterpillar and ma% not +e used 3ithout permission.

3500 C175 C280 AftertreatmentCEM T4 Marine A and I

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2013 Caterpillar 1 10Dec2013

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