Cat Clean Emissions Module A&i LEBE0005-01

APPLICATION AND INSTALLATION GUIDE
CAT® CLEAN EMISSIONS MODULE

(CAT CEM)
Emission-Related Installation Instructions
Failing to follow these instructions when installing a certified engine in
a piece of non-road equipment violates federal law (40 CFR 1068.105(b)),
subject to fines or other penalties as described in the Clean Air Act.
Use of this Guide
This guide contains the latest available information for Tier 4 EP products as
a combined document. This A & I guide outlines best practices for applying
different technologies according to specific engine families. Please use this
information as guidance for prospective project development. This guide is
subject to change and will be updated with the most current information just prior
to open order board for each product family.
Use this guide as a technical resource for installation considerations, but do not
use it for construction purposes until the final update released at time of open
order board.
Product drawings and TMI information will be available at time of open order
board.
Contact the ASC through the inquiry system if you have any questions prior to
the product release.
Table of Contents
1. Interim Supplement........................................................................................... 1
Technologies ..................................................................................................... 2
Cat® NOx Reduction System.......................................................................... 2
Cat Clean Emissions Module (Cat CEM) Systems ........................................ 2
DOC (Diesel Oxidation Catalyst) ................................................................... 2
DPF (Diesel Particulate Filter) ....................................................................... 1
CDPF (Catalyzed Diesel Particulate Filter) .................................................... 1
Regeneration of Particulate Filters................................................................. 1
SCR (Selective Catalytic Reduction) System................................................. 2
Installation Requirements.................................................................................. 4
200 ekW Genset Powered by C7.1 ACERT Engine ...................................... 4
Other Installation Requirements .................................................................... 8
500 ekW Genset Powered by the C15 ACERT Engine ................................. 8
Other Installation Requirements .................................................................. 10
800 ekW Genset Powered by the C27 ACERT™ Engine............................ 10
Other Installation Requirements .................................................................. 12
Genset Powered by the 3516CHD and C175 Engines ................................ 12
Safety .............................................................................................................. 15
Pressure Air and Water ................................................................................... 16
High Pressure Wash.................................................................................... 16
Welding ........................................................................................................... 16
Painting ........................................................................................................... 16
Cleanliness...................................................................................................... 17
Replacement Parts.......................................................................................... 17
Tier 4 – Emissions Requirements.................................................................... 17
2. Cat CEM Overview ......................................................................................... 19
Cat Clean Emissions Module (Cat CEM) Systems.......................................... 19
Technology Component Descriptions.............................................................. 19
DOC (Diesel Oxidation Catalyst) ................................................................. 19
SCR (Selective Catalytic Reduction) ........................................................... 20
3. Clean Emissions Modules............................................................................... 21
Introduction and Purpose ................................................................................ 21
System Hardware Overview ............................................................................ 21
CEM Application Guide ................................................................................... 22
Cat CEM Mandatory Interface Connections: ................................................... 23
Air System ....................................................................................................... 24
Air Line Requirements ................................................................................. 24
Secondary Air Filter ..................................................................................... 25
Secondary DEF Filter Requirement ............................................................. 25
DEF System .................................................................................................... 26
DEF Specifications ...................................................................................... 26
Dosing Strategies ........................................................................................ 27
Dosing Cabinet................................................................................................ 29
Dosing Cabinet Connection Points .............................................................. 30
Dosing Cabinet Symbols Pictograms........................................................... 32
AC Power Connection ................................................................................. 33
DEF Supply to the Dosing Cabinet with a Buffer Tank ................................ 33
Storage or Non-operational Condition ......................................................... 34
Weight and Dimensions ............................................................................... 34
Lifting and Mounting .................................................................................... 35
Clearance .................................................................................................... 36
Orientation ................................................................................................... 36
Environment................................................................................................. 36
Location ....................................................................................................... 36
Electrical.......................................................................................................... 37
Block Diagram ............................................................................................. 37
Electrical Connections ................................................................................. 38
Electrical Loads ........................................................................................... 42
Electrical Component temperature limits ..................................................... 43
Exhaust System .............................................................................................. 44
Exhaust Connections................................................................................... 44
Mounting ......................................................................................................... 47
DEF Handling .................................................................................................. 47
Hazards Identification .................................................................................. 47
Leaks and/or Spills ...................................................................................... 49
Material Selection for Tank and Piping............................................................ 50
DEF Storage Tank........................................................................................... 51
Tank Volume................................................................................................ 52
Tank Connections........................................................................................ 52
DEF Pickup/Return ...................................................................................... 53
Coolant Connection ..................................................................................... 53
Integrated Sender Unit................................................................................. 53
Tank Fill Interface ........................................................................................ 54
Fast Fill Applications.................................................................................... 54
Tank Fill Cap................................................................................................ 54
Tank Vent .................................................................................................... 55
Tank Mounting ............................................................................................. 55
Tank Materials ............................................................................................. 55
In-Tank Filtration.......................................................................................... 55
Level Sensors .............................................................................................. 55
Tank Heating ............................................................................................... 56
Coolant Diverter Valve Strategy................................................................... 56
Heat Exchanger Design............................................................................... 57
Insulation Requirements .............................................................................. 58
Energy Source ............................................................................................. 58
General Installation Information....................................................................... 58
Enclosure Temperature Limits ..................................................................... 58
Installation Dimensions and General Views................................................. 59
Service and Maintenance................................................................................ 62
4. Exhaust System .............................................................................................. 63
Introduction ..................................................................................................... 63
Mandatory Requirements ................................................................................ 63
Flex-Pipe Design ............................................................................................. 63
Flex-pipe Design Requirements................................................................... 64
Turbocharger Loading ................................................................................. 64
CEM Exhaust Joint Loading Guidelines .......................................................... 65
Maximum Exhaust Length ........................................................................... 66
Regeneration of the SCR Aftertreatment......................................................... 68
Air Filter Inlet Temperature .......................................................................... 68
Inlet Manifold Temperature .......................................................................... 68
Exhaust Restriction...................................................................................... 69
Altitude......................................................................................................... 69
Temperature drop from engine to CEM inlet................................................ 69
Total Column “F”.......................................................................................... 69
Cut outs ....................................................................................................... 70
5. Mounting Considerations ................................................................................ 71
Mounting Guidelines........................................................................................ 71
Mounting ......................................................................................................... 72
Mounting Considerations ............................................................................. 72
Installation ....................................................................................................... 72
Handling and shipping ................................................................................. 72
Mounting Pads............................................................................................. 72
6. Thermal Management..................................................................................... 73
Introduction ..................................................................................................... 73
Enclosure Temperature Limits......................................................................... 73
Thermal Protection .......................................................................................... 74
7. Appendices ..................................................................................................... 75
Appendix A: See Special Instruction (REHS7129) for Assembling
and Installing a Selective Catalytic Reduction (SCR) Module
for Certain 3516CHD Generator Sets.............................................................. 75
Terms and Definitions
Acronyms
A&I Applications and Installation
AMOx (Ammonia Oxidation Catalyst)
ATAAC Air To Air After Cooler
bkW Brake (mechanical) kilowatt
Cat CEM Cat Clean Emissions Module
Cat NRS Cat NOx Reduction System
Cat RS Cat Regeneration System
CDPF Catalysed Diesel Particulate Filter
CO Carbon Monoxide
DEF Diesel Exhaust Fluid (also referred to as AUS 32)
DFA Delegated Final Assembly
DOC Diesel Oxidation Catalyst
DPF Diesel Particulate Filter
DPI Delta Pressure Indicator
ekW Electrical kilowatt
eMW Electrical megawatt
EPA Environmental Protection Agency
g/kW-h Grams per kilowatt-hour
HC Hydro Carbons
kPa Kilo Pascal (SI Unit of Pressure)
NOx Oxides of Nitrogen
OCV Open Crankcase Ventilation
PM Particulate Matter
ppm Parts-Per-Million (unit of concentration)
RPM Revolutions Per Minute
SCR Selective Catalytic Reduction
SOF Soluble Organic Fraction
Cat® Clean Emission Module (Cat CEM) Application and Installation Guide
1. Interim Supplement
This document is intended as a reference and guide for the correct installation of Cat
Tier 4 gensets. This guide provides information on safe installation and helps ensure the
genset complies with EPA emissions regulations. Additional information is available in
other Caterpillar A & I guides located in Power Net.
Note: The information in this document is subject to change
Caterpillar has developed a number of different technologies to meet Tier 4 Interim
regulations as they apply to electric power products. These technologies, which include after-
treatment devices, are described later in this document. Not all Cat EP engines require after-
treatment devices in order to comply with Tier 4 limits but, where this technology is required,
it is packaged into a module referred to as a Cat CEM (Cat Clean Emissions Module).
The Cat CEM is an integral part of the Cat EPA Tier 4 engine solutions. Cat engines are
designed and built to provide superior value; however, achieving the end user’s value
expectations depends greatly on the performance of the complete installation to assure
proper function over the design life of the installation. Wherever possible, Caterpillar has
packaged the CEM as an integral part of the genset to ensure consistency of installation
standards and system performance. However, for gensets rated >1eMW this is not a
practical proposition and the genset, CEM and associated sub-systems must be assembled
at the customer site by the installer under a process called Delegated Final Assembly (DFA).
This document provides an overview of the Cat Tier 4 Interim technologies and their
applicability to each of the Tier 4 Interim gensets. For each Tier 4 Interim genset,
specific installation requirements are listed. These requirements must be satisfied by
the genset installer and failure to do so is a violation of federal law (40 CFR
1068.105(b)). For larger gensets >1eMW, instructions are also provided for the
assembly of the complete engine / CEM system into its certified configuration.
Instructions on initial startup procedures for these larger gensets are also included.
All Cat Tier 4 Interim gensets must be audited following installation, to ensure
compliance with EPA exhaust emissions regulations. The auditable parameters vary
depending on the model of genset and the technologies incorporated.
Caterpillar exercises all reasonable effort to assure engine and Cat CEM perform
properly, however, it is the responsibility of the genset installer to follow the Caterpillar
instructions and to properly install the genset and Cat CEM. Caterpillar assumes no
responsibility for deficiencies in the installation. It is the responsibility of the genset
installer to meet all of the Caterpillar requirements, as provided in this Application and
Installation Supplement. Caterpillar does not guarantee or approve the validity or
correctness of any installation. Caterpillar’s sole obligation with respect to any product
is as set forth in the applicable Caterpillar warranty statement.
It is the installer’s responsibility to consider and avoid possibly hazardous conditions,
which could develop from the systems involved in the specific engine installation. The
information in this document is the property of Caterpillar Inc. and/or its subsidiaries.
Without written permission, any copying, transmission to others, and any use except
that for which it is loaned is prohibited. Contact the appropriate application support
group for the latest information on Cat CEM guidelines and requirements.
©2012 Caterpillar
Page 1 All rights reserved.
Application and Installation Guide Cat Clean Emission Module (Cat CEM)
CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power Edge”
trade dress as well as corporate and product identity used herein, are trademarks of
Caterpillar and may not be used without permission.
This document serves as the Caterpillar instructions required by U.S. EPA regulations
(40 C.F.R. Part 1068) to facilitate the selection and application of the correct Cat CEM
module by the OEM or “installer” based upon engine selection.
Technologies
Tier 4 regulated exhaust emissions limits for electric power applications vary considerably
depending on engine power. In order to offer its customers solutions that are properly
optimized in terms of performance, size and cost, Caterpillar has developed a number of
technology solutions to address these limits. The technologies consist of in-cylinder, on-
engine & after-treatment strategies which are utilized either in isolation, or in combination,
to address the particular requirements of each of the EPA regulated power bands.
Each of the emissions reduction technologies is described below & their application to the
various engines/gensets is outlined in the table at the end of the section.
Cat NOx Reduction System
An electronically controlled air management system lowers the engine’s combustion
temperature by combining a small amount of non-combustible gas with the combustion
air, resulting in decreased NOx output.
Cat Clean Emissions Module (Cat CEM) Systems
The Cat CEM consists of the key components necessary to support an engine
arrangement for emissions compliance. Cat Tier 4 engine systems use a variety of
technologies for the reduction of particulate matter and NOx emissions depending on
engine rating and application.
DOC (Diesel Oxidation Catalyst)
This is a flow through honeycomb substrate with a catalytic coating containing precious
metal applied to the surface. Catalytic coatings typically contain precious metals. As
exhaust gas from the engine passes over the catalyst a chemical reaction takes place
oxidizing carbon monoxide (CO), hydrocarbons (HC) and soluble organic fraction (SOF)
of particulate matter. SOF consists of the partially burned fuel and engine lube oil
suspended in the engine exhaust gas. In some applications, a DOC is used by itself.
Applications requiring a DPF or SCR (see below) will use a DOC upstream to condition
the exhaust gases.
2012 Caterpillar
All rights reserved. Page 2
Cat Clean Emission Module (Cat CEM) Application and Installation Guide
DPF (Diesel Particulate Filter)

These filters have a cellular structure with individual channels open and plugged at
opposite ends. Exhaust gases enter the open end, flow through the pores of the cell
walls, and exit the filter through the adjacent channel. Soot particles that are too large
to flow through the pores collect on the channel walls.
CDPF (Catalyzed Diesel Particulate Filter)

This is a DPF as above with a catalytic coating made up of precious metals coating the
cellular structure to enhance the regeneration process.
Regeneration of Particulate Filters

Passive Regeneration
Passive regeneration occurs when the rate of soot oxidation in the particulate filter
meets or exceeds the rate of soot generated by the engine thus preventing excessive
soot accumulation levels from occurring. A catalytic coating can be used to promote
oxidation by increasing the speed of the chemical reaction. The DOC converts NOx
(Oxides of Nitrogen) to NO2 Nitrogen Dioxide. The DPF is placed after the DOC in the
system. As the oxidized NO2 passes through the DPF, it combines with the collected
carbon (C) (soot) to form CO2 (Carbon Dioxide), which leaves the exhaust system as a
clear gas. Passive Regeneration is continually cleaning the diesel particulate filter when
engine-operating conditions maintain sufficient exhaust temperatures.
©2012 Caterpillar
Cat RS (Cat Regeneration System) - Active Regeneration
The exhaust gas temperatures are periodically elevated by combustion of injected fuel
and air to promote oxidation and burn trapped soot. Cat RS is used in conjunction with
a DOC and a DPF to provide an Active Regeneration System.
SCR (Selective Catalytic Reduction) System
SCR is one of a combination of several components that include a DOC, an SCR, an
AMOx, and a DEF (Diesel Exhaust Fluid also referred to as AUS32) injector. The DOC,
SCR, and AMOx are all flow-through honeycomb substrates with a unique catalyst
coating. In some applications, the AMOx is not required.
In an SCR system, the main function of the DOC is to optimize the ratio of NO2 to NO
before it enters the SCR. This optimized ratio then allows the best type of reaction to
occur on the SCR that reduces the NOx into harmless gases. For the SCR to reduce
NOx, it requires the aid of the ammonia (NH3) that is found in DEF. This fluid is injected
into the exhaust stream before entering the SCR. When injected into the exhaust
stream, the DEF is atomized into fine droplets and then sent through a mixer. The mixer
disrupts the exhaust flow and allows the DEF to be well distributed throughout the
exhaust gas. The water evaporates due to the high temperature of the exhaust and
releases the NH3 that was chemically bound up in the DEF. The NH3 is then free to
react with the NOx and the oxygen present in the exhaust stream. This reaction occurs
on the SCR catalyst. The NH3 and NOx are converted into harmless gas particles of
nitrogen and water.
AMOx (Ammonia Oxidation Catalyst)
NH3 is a regulated gas and has a distinct, noticeable, and foul odor even in very small
quantities. Some SCR systems are not able to consume all of the NH3 in the SCR.
These systems require the addition of an AMOx to oxidize and convert the remaining
NH3 into harmless gases. Similar to the DOC and SCR, the AMOx is a flow-through
honeycomb substrate with a unique catalyst coating.
2012 Caterpillar
Mixing
Bellows DOC Tube SCR AMOx Exhaust Out
Turbochargers
Injector
Dosing Cabinet
Control Unit
Engine
Buffer Tank
Primary Air
Filter Primary DEF Filter
Installer
Air Supply Pump DEF Supply Supplied
DOC+SCR+AMOx System Diagram

Working Principle
CO(NH2)2 + H2O → 2NH3 + CO2
NO + NO2 + 2NH3 → 2N2 + 3H2O
Application of Technologies
The table below details the application of each of the Tier 4 Interim technologies to the
Cat genset lineup:
Regulated NOx PM Genset
Engine Engine CEM
Power Limit Limit Rating
Model Technology Technology
Band (g/kW-h) (g/kW-h) (ekW)
C7.1 200 DOC & DPF
>130 bkW
2.0 0.02 Cat RS Active
<560 C13 350 Cat Regeneration
NRS
>560 bkW C15 500
3.5 0.10 None
<900 C27 800
1500
2000 DOC + SCR +
>900 bkW 0.67 0.10 3516CHD 2250 In-Cylinder AMOx
2500
C175 3000
©2012 Caterpillar
Installation Requirements
This section deals with unique installation requirements for each of the Cat Tier 4
Interim gensets.
200 ekW Genset Powered by C7.1 ACERT Engine
The Cat 200 ekW genset, (standby rating at 1800 rpm / 60 Hz) utilizes the Cat NRS
system plus a Cat CEM containing a DOC, a DPF and the Cat RS. The Cat RS is added
to provide active controlled regeneration of the DPF to maximize uptime of the engine
system and provide max operating hours between ash service maintenance times. The
Cat RS can elevate the temperature of the exhaust gas from the engine significantly to
assure oxidation and burning of any accumulated soot before the gas is expelled to the
atmosphere.
Schematic of C7.1 Engine and After-treatment System
Cat NOx Reduction System System Layout
2012 Caterpillar
Cat NOx Reduction System System Layout – On Engine
Cat CEM Typical Configuration
The NRS & CEM technologies are fully packaged within the genset enclosure at the
factory and require few special installation procedures. However, to ensure full
compliance with EPA regulations, installers & operators must ensure that they comply
with the following requirements:
Mandatory Installation Requirements
Labels
• The genset installer must ensure that the engine emission control information label
remains readily visible to the average person after all installation of the genset is
complete.
If installation renders the engine’s emission control information label hard to read
during the normal engine maintenance, a duplicate label must be placed on the
equipment, as described in 40 CFR 1068.105.
The use of a duplicate emission label must meet the regulatory requirements set out
in 40 CFR 1068.105(c). Contact your local Caterpillar representative to order a
duplicate label.
• The genset installer must ensure a separate label with the statement ‘Ultra Low
Sulfur Fuel Only’ is permanently attached to the equipment near the fuel inlet in
accordance with regulatory requirements 1039.135. Labels are available from
©2012 Caterpillar
Caterpillar via the Industrial Price List by selecting the feature codes LBULSD1
or LBULSD2 (EPA or EU label).
• All oil fill locations must be labeled designating only Cat DEO-ULS™, API CJ-4
or ACEA E9 oils are acceptable. Cat label 350-0684 is recommended.
Factory provided oil fill locations will be properly labeled from the factory.
• If any of the engine labels are damaged or over-sprayed after shipment of the
genset it, is the responsibility of the installer to replace these labels and fit them
in accordance with the Caterpillar instructions.
Air Inlet
• The addition of heavy duty air cleaners, or pre-cleaners is permitted however,
the maximum allowable induction depression limits much be observed.
• The maximum allowable induction depression, when the air filter is clean, is 3.7 kPa
(consult Technical Marketing Information for the latest values).
• The maximum allowable induction depression, when the air filter is dirty, is 6.2 kPa
• The must be tested in accordance with the test procedure in Testing and Adjusting
procedures located in SIS Web.
Fuel
• Only Ultra-Low Sulfur Diesel (ULSD) may be used in Cat Tier 4 Interim gensets.
ULSD means diesel fuel containing <15 ppm of Sulfur.
• Biofuels which conform to ASTM 6751-075 B100 may be used in concentrations of
20% or less (B20). Refer to SEBU 6250 – Cat Machine Fluids Recommendations.
Engine Lubricating Oil
• Only Cat DEO-ULS, or oils that meet the Caterpillar ECF-3 specification and the
API CJ-4 or ACEA E9 category should be used in Cat Tier 4 Interim gensets.
• Use of an Oil Renewal System (ORS) is strictly forbidden. Any ORS that extends
the oil life through the combustion process and toping off the oil reservoir with new
oil will damage the after-treatment device
Exhaust and After-treatment System
• Under no circumstances is it acceptable to modify, tamper with or customize the
CEM assembly, or flex pipe components, as supplied by Caterpillar.
• It is not permitted for the CEM canister restraining clamps (to the mounting frame)
to be loosened to reorient the canister.
• Welding components onto the CEM is prohibited.
• Bolting of any components to the CEM is prohibited.
• The aftertreatment is not qualified as a spark arrestor. If this is an application
requirement then it is recommended to work directly with the applicable bodies
2012 Caterpillar
(i.e., U.S. Department of Agriculture, Forest Service) to ensure all the necessary
requirements are met.
• The CEM must only be lifted by its integral lifting links.
• The CEM integral lifting links are not designed to lift the engine, generator,
baseframe or any additional weight.
• If additional silencing or after-treatment devices are attached to the genset exhaust
outlet. The exhaust system backpressure as measured per Testing and Adjusting
procedures located in SIS web, this data must be within the range designated in
Technical Marketing Information (TMI); this value is for an end of life, fully soot
loaded DPF.
• Any extensions to the exhaust system / exhaust outlet must be designed to prevent
water and dirt ingress.
In-Use Testing Provision
• Provision must be made at the time of genset installation for the in-use sampling of
the genset exhaust.
• The standard method of sampling is by the addition of a 20-centimeter sample pipe to
the outlet of the exhaust. The Cat factory-fit exhaust exhaust outlet is protected by a rain
flap, secured by a band-clamp. When sampling the genset exhaust, the clamp should
be loosened & the flap assembly removed so that the necessary 20-centimeter sample
pipe can be attached to the exhaust outlet. The flap assembly should be replaced &
securely fastened once testing is complete. Installers should ensure that there is
adequate clearance around the installation to perform these activities.
• If a non Caterpillar supplied exhaust system is used, or the standard system is
extended, the installer must ensure that in-use exhaust sampling is still possible
using the method described above.
• If a modification to the genset exhaust outlet renders the described sampling method
impossible, it is the installers responsibility to show how an exhaust sample may be
taken in a way that prevents diluting the exhaust sample with ambient air, or
increasing the exhaust back pressure beyond the limits specified in the Caterpillar
Technical Marketing Information (TMI).
Crankcase Ventilation System
• The open crankcase ventilation (OCV) filter is used to separate oil vapor from
crankcase fumes. The fumes disposal tube connected to the outlet port may be
extended if necessary; however it must not have any sags or low spots in it. Low
spots will allow condensation to other liquids to gather and create a blockage in the
fumes disposal’s vent to atmosphere. Due diligence must be carried out to ensure
that the disposal tube never accumulates water and freezes solid.
• Except for extension of the fumes disposal tube, under no circumstances may any
Caterpillar supplied OCV components be modified.
©2012 Caterpillar
Other Installation Requirements

Mounting
500 ekW Genset Powered by the C15 ACERT Engine
system. This technology is fully packaged within the genset at the factory and requires
few special installation procedures. However, to ensure full compliance with EPA
regulations, installers & operators must ensure that they comply with the following
requirements:
Labels
complete.
The use of a duplicate emission label must meet the regulatory requirements set
out in 40 CFR 1068.105(c). Contact your local Caterpillar representative to order a
duplicate label.
• All oil fill locations must be labeled designating only Cat DEO-ULS, API CJ-4 or
ACEA E9 oils are acceptable. Cat label 350-0684 is recommended. Factory
provided oil fill locations will be properly labeled from the factory.
genset it, is the responsibility of the installer to replace these labels and fit them in
accordance with the Caterpillar instructions.
Air Inlet
• The addition of heavy duty air cleaners, or pre-cleaners is permitted however, the
maximum allowable induction depression limits much be observed.
2012 Caterpillar
Fuel
• Only Cat DEO-ULS, or oils that meet the Caterpillar ECF-3 specification and the API
CJ-4 or ACEA E9 category should be used in Cat Tier 4 Interim gensets.
• Use of an Oil Renewal System (ORS) is strictly forbidden. Any ORS that extends the
oil life through the combustion process and toping off the oil reservoir with new oil
will affect the engine’s exhaust emissions such that it may not achieve the Tier 4
Interim regulated limits.
Exhaust System
• Any extensions to the Cat exhaust system / exhaust outlet must be designed to
prevent water and dirt ingress.
• A minimum exhaust restriction of 2.5 kPa restriction must be maintained for the
emissions control system to perform correctly. Failure to apply proper restriction may
result in power derate.
the genset exhaust.
©2012 Caterpillar
Crankcase Ventilation Systems

Exhaust System
• Installers must ensure that the exhaust system is installed & supported such that no
weight from exhaust system components is transferred to the turbocharger.
Mounting
800 ekW Genset Powered by the C27 ACERT Engine
system. This technology is fully packaged within the genset at the factory and requires few
special installation procedures. However, to ensure full compliance with EPA regulations,
installers & operators must ensure that they comply with the following requirements:
Labels
complete.
duplicate label.
2012 Caterpillar
in accordance with the Caterpillar instructions.
Air Inlet
Fuel
Exhaust System
loaded DPF.
• A minimum exhaust restriction of 2.5 kPa restriction must be maintained for the
emissions control system to perform correctly. Failure to apply proper restriction may
result in power derate.
the genset exhaust.
©2012 Caterpillar

Exhaust System
• Installers must ensure that the exhaust system is installed & supported such that
no weight from exhaust system components is transferred to the turbochargers.
Mounting
• All C27 Tier4 Interim generator sets must be isolated from solid surface mounting of
the base by utilizing linear vibration isolators (spring). Caterpillar offers the options of
1.5G IBC isolators and 95% efficient spring isolators. Failure to properly isolate the
generator set may result in premature loss of structural integrity.
Genset Powered by the 3516CHD and C175 Engines
These engines utilize the Cat SCR system. This technology is fully packaged within the
genset at the factory and requires few special installation procedures. CEM Substrate
life is directly impacted by CEM inlet temperature. The minimum inlet temperature is
200C and the maximum inlet temperature is 550C. Maximum temperatures should not
be sustained for extended periods of time. The optimal inlet operating temperature
range is 400C-450C to sustain maximum CEM life. CEM inlet temperatures are directly
impacted by Air Cleaner Inlet Temp, Air Cleaner Restriction, Radiator Air Inlet Temp,
2012 Caterpillar
ATAAC Restriction, Humidity, Altitude, Exhaust Backpressure, Exhaust Shielding, and

Load. A system evaluation should be performed during the design layout phase of each
project to ensure maximum CEM life is obtained. To ensure full compliance with EPA
regulations, installers & operators must ensure that they comply with the following
requirements:
Emissions Related Installation Instructions
Failing to follow these instructions when installing a certified engine in a piece of non-
road equipment violates federal law (40 CFR 1068.105(b)), subject to fines or other
penalties as described in the Clean Air Act.
Labels
complete.
duplicate label.
Caterpillar via the Industrial Price List by selecting the feature codes LBULSD1 or
LBULSD2 (EPA or EU label).
in accordance with Caterpillar’s instructions.
Air Inlet
©2012 Caterpillar
Fuel
Exhaust System
• If additional silencing or aftertreatment devices are attached to the genset exhaust
loaded DPF.
the genset exhaust.
• The standard method of sampling is by the addition of a 20-centimeter sample
pipe to the outlet of the exhaust. The Cat factory-fit exhaust exhaust outlet is
protected by a rain flap, secured by a band-clamp. When sampling the genset
exhaust, the clamp should be loosened & the flap assembly removed so that the
necessary 20-centimeter sample pipe can be attached to the exhaust outlet. The
flap assembly should be replaced & securely fastened once testing is complete.
Installers should ensure that there is adequate clearance around the installation
to perform these activities.
2012 Caterpillar

• The crankcase ventilation (CCV) filter is used to separate oil vapor from crankcase
fumes. The fumes disposal tube connected to the outlet port may be extended if
necessary; however it must not have any sags or low spots in it. Low spots will allow
condensation to other liquids to gather and create a blockage in the fumes disposal’s
vent to atmosphere. Due diligence must be carried out to ensure that the disposal
tube never accumulates water and freezes solid.
Caterpillar supplied CCV components be modified.
Exhaust System
• Installers must ensure that the exhaust system is installed & supported such that no
weight from exhaust system components is transferred to the turbochargers.
Mounting
• All 3516CHD Tier4 Interim generator sets must be isolated from solid surface
mounting of the base by utilizing linear vibration isolators (spring). Caterpillar offers
the options of 1.5G IBC isolators and 95% efficient spring isolators. Failure to
properly isolate the generator set may result in premature loss of structural integrity.
Installation Audit
Please refer to the Caterpillar A & I Guide LEBW4986 for application & installation
guidance that is not specific to Tier 4 Interim gensets.
Safety
Most accidents that involve product operation, maintenance, and repair are caused by
failure to observe basic safety rules or precautions. An accident can often be avoided by
recognizing potentially hazardous situations before an accident occurs. An OEM
Installer must be alert to potential hazards. An OEM Installer should also have the
necessary training, skills, and tools in order to perform these functions properly.
The information in this publication was based upon current information at the time of
publication. Check for the most current information before you start any job. Cat dealers
will have the most current information.
Improper operation, maintenance, or repair of this product may result in injury or death.
Do not operate or perform any maintenance or repair on this product until you have read
and understood the operation, maintenance, and repair information.
©2012 Caterpillar
Improper operation, maintenance, or repair of this product may result in

injury or death. Do not operate or perform any maintenance or repair on
this product until you have read and understood the operation,
maintenance, and repair information. Burn and fire hazards are possible.
Failure to properly connect the after-treatment / regeneration device, manage
the regeneration gas temperature, or properly route the exhaust gases away
from the module may result in personal injury or death.
Notice: Failure to properly connect the after-treatment / regeneration device or

manage the regeneration gas temperature may result in poor engine performance,
engine and after-treatment system damage or vehicle / chassis damage.
Caterpillar cannot anticipate every possible circumstance that might involve a potential
hazard. The warnings in this publication and on the product are not all inclusive. If a tool,
a procedure, a work method, or an operating technique that is not specifically
recommended by Caterpillar is used, you must be certain that it is safe for you and for
other people. You must also be certain that the product will not be damaged. You must
also be certain that the product will not be made unsafe by the procedures that are used.
Pressure Air and Water

Pressurized air and/or water can cause debris and/or hot water to be blown out. This
could result in personal injury. Always wear a protective face shield, protective clothing,
and protective shoes when cleaning components. The maximum air pressure for
cleaning purposes must be reduced to 205 kPa (30 PSI) when the air nozzle is
deadheaded and used with effective chip guarding (if applicable) and personal
protective equipment. The maximum water pressure for cleaning purposes must be
below 275 kPa (40 PSI).
High Pressure Wash
Notice: High-pressure wash systems, including high pressure spray washers and water
cannons, are now in frequent use by maintenance people. Connector seals will fail when
hit directly with high pressure spray. Many connection systems have adapters available
that can be attached to the back of the connector to protect the wire seals from direct high
pressure wash. Where direct exposure to high pressure wash systems cannot be
avoided then protective shields will need to be designed and installed. For the
benefit of service, connectors should be placed in accessible locations.
Welding
WARNING Notice — Welding on Cat CEM frame/chassis is prohibited.
Painting
Painting of Cat CEM is NOT recommended and strongly discouraged. Some
components skin temperatures on the CEM can get to as high as 650 ºC during
operation and will cause charring or burning of the paint.
2012 Caterpillar
Cleanliness
Air lines, Fuel lines, coolant lines and oil lines that connect to the CEM or engine should
meet Caterpillar cleanliness specification 1E2500.
Replacement Parts
When replacement parts are required for this product, Caterpillar recommends using
Cat replacement parts or parts with equivalent specifications including, but not limited
to, physical dimensions, type, strength, and material.
Tier 4 – Emissions Requirements

This Installation Guide is intended for use for machines/engines that must comply with Tier
4 or emissions requirements. Proper fluids must be used to meet these requirements. Refer
to the specific Operation and Maintenance Manual (OMM) for the Cat engine model being
installed for the proper fuel, lubricants, and coolants that are to be used. The proper fuels,
lubricants and coolants must be used to enable the engine to produce its published rated
power, fuel consumption and conform to emissions regulations.
JP8 Diesel fuel is not compatible with Cat Tier 4 and Cat CEM. U.S. EPA Tier 4
regulations require the use of commercial ULSD that conforms with the ASTM D975
specification of 15 ppm max sulfur fuel per US EPA Tier 4 requirement. Euro Stage IIIB
requires the use of the EN590 fuel specification of 10 ppm max sulfur content. Using
any fuel which is not equivalent to ASTM D975 or EN590 may damage engine and
after-treatment systems. In this case, consult Caterpillar or your Cat dealer for further
direction. Biodiesel is compatible with the Cat CEM up to B20 but can have an affect on
some CEM components (Refer to SEBU 6250 – Cat Machine Fluids
Recommendations). The following table summarizes the engine operating fluids
requirements for engines equipped with the Cat CEM.
Engine Operating Fluids
Fuel Tolerance – Sulfur (ppm) 15 or less
Oil Tolerance (ash content) CJ4 or better
Fuel Tolerance – biofuels (ASTM 6751-075 B100) B20 or less
Table 1.1: Tier 4 Engine Operating Fluids Limits
Notice: Oils that have more than 1% total sulfated ash should not be used in
aftertreatment device equipped engines.
©2012 Caterpillar
In order to achieve expected ash service intervals, performance, and life, after-treatment
device equipped diesel engines require the use of Cat DEO-ULS or oils meeting the
Caterpillar ECF-3 specification and the API CJ-4 oil category. Oils that meet the Cat ECF-2
specification and that have a maximum sulfated ash level of 1% are also acceptable for use
in most after-treatment equipped engines. Use of oils with more than 1% total sulfated ash
in after-treatment device equipped engines will cause the need for more frequent ash
service intervals, and/or cause loss of performance. Refer to your engine specific Operation
and Maintenance Manual, and refer to your after-treatment device documentation for
additional guidance.
Notice: Use of Oil Renewal System (ORS) is strictly forbidden. Any ORS that
extends the oil life through the combustion process and toping off the oil
reservoir with new oil will damage the after-treatment device. Failures that result
from the use of incorrect oils are not Caterpillar factory defects. Therefore, the
cost of repair would NOT be covered by the Caterpillar warranty for materials
and/or the warranty for workmanship.
Note: The U.S. Forest Service operates a national laboratory that provides spark
arrestor qualification testing pursuant to U.S. Forest Service Standard 5100-1c, “Spark
Arrestors for Internal Combustion Engines,” which is currently being revised so as to
extend its assessment beyond particle capture measurement. The Cat CEM with DPF
is being validated per SAEJ350, “Spark Arrestor Test Procedure for Medium Size
Engines,” which will not result in a formal qualification by U.S. Forest Service, but will
document spark arresting particle capture capabilities.
All other Cat CEM’s without DPF are pass through after-treatment devices and can not be
validated to SAEJ350. If spark arresting is needed for these applications a dedicated device
meeting SAEJ350 will need to be installed after the CEM.
2012 Caterpillar
2. Cat CEM Overview
Cat Clean Emissions Module (Cat CEM) Systems

The Cat CEM consists of the key components necessary to support an engine
arrangement for emissions compliance. Cat Tier 4 and Euro IIIB engine systems use
a variety of technologies for the reduction of particulate matter and NOx emissions.
Selection of the optimal module combination is based upon engine rating and
application. Each of the emission reduction technology combinations is listed in the
following table and described in this document.
Technology Component Descriptions

DOC (Diesel Oxidation Catalyst)
This is a flow through honeycomb substrate with a catalytic coating containing precious
metal applied to the surface. The DOC unit assembly has a round cross-section to
eliminate non-uniform thermal gradients. As exhaust gas from the engine passes over
the catalyst a chemical reaction takes place oxidizing carbon monoxide (CO),
hydrocarbons (HC) and soluble organic fraction (SOF) that is unburned fuel and engine
lube oil suspended in the engine exhaust gases.
Ca t a l y s t
Exhaust Exhaust
In out
©2012 Caterpillar
Soot Collects Cells

Along the Fill Up Filter Substrate
Inlet Walls
Clean
Particulate Exhaust
Matter Out
or Soot
(CO2, H2O)
SCR (Selective Catalytic Reduction)

This is a flow through honeycomb substrate with a catalytic coating containing a precious
metal that is applied to the substrate surface. A chemical change takes place as exhaust
gas passes over the catalyst. This reduces NOx (NO and NO2) to nitrogen (N2). In a lean
gas stream, it is necessary to add ammonia to the system to enable this reaction. To
reduce the hazards associated with transporting liquid ammonia, a solution of de-ionized
water and DEF is used. When this DEF and water solution (AUS32) is injected into the
exhaust stream, the water evaporates, leaving fine droplets of DEF. The DEF
decomposes in the exhaust heat to form ammonia and carbon dioxide. In the presence of
the SCR catalysts, NOx and ammonia react to form nitrogen and water vapor.
The SCR unit consists of an inlet section, center section, and an outlet section, and
contains one or more catalyst substrates. These sections are welded together to minimize
package size. The SCR unit must be used in conjunction with a DEF delivery system and
mixing pipe to support the reduction of NOx emissions in the exhaust stream.
Ca t a l y s t
Exhaust Exhaust
In out
Working Principle
CO(NH2)2 + H2O ⇒ 2NH3 + CO2
NO + NO2 + 2NH3 ⇒ 2N2 + 3H2O
2012 Caterpillar
3. Clean Emissions Modules
Introduction and Purpose

The Caterpillar emissions approach combines three emission reduction technologies to
meet Tier 4 interim emissions requirements. Selective Catalyst Reduction technology is
used to reduce NOx emissions, Diesel Oxidation Catalyst is used to reduce particulate
matter (PM), carbon monoxide (CO), hydrocarbons (HC) and soluble organic fraction
(SOF), and Ammonia Oxidation Catalyst is used to control ammonia slip.
The Cat DOC + SCR +AMOx is packaged in a module that contains the components
necessary to support the specific engine configuration for emission compliance. CEM
installation will require connections between CEM module, engine DEF tank and air source.
These connections will include engine exhaust, electrical harness, air and DEF lines.
System Hardware Overview
DEF Engine
Dosing Cabinet
Tank
DEF Pump
T C
T
CEM Exhaust SCR Assy.
Muffler DEF Mixing DOC

ASCR Pipe And Nozzle
Catalyst
Schematic 3.1: System Block Diagram
©2012 Caterpillar
CEM Application Guide

The following table provides applicable CEM family for a given application and engine
platform. There will be several CEM illustrations for these applications below in the
following subsections of this DOC + SCR + AMOx CEM Technology section.
CEM Application Guide

Engine Platform Required CEM Application
3516CHD Family C
Electric Power
C175-16 Family D
The CEM family can be determined by looking at the CEM serial number. The CEM
serial number structure is LLLNNNNNNL where “L” is for a letter and “N” is for a
number. The fist letter of the serial number is the CEM family which correlates to above
chart. The second and third letter refers to the Exhaust Module Arrangement. The
following numbers 4-9 refer to a unique serial code specific to ordered level. No
repeated of duplicated numbers allowed. The last letter is “H”.
Example:
CPM000001H – This serial number is for a Family C CEM. The Dosing Cabinet and the
CEM serial number must match.
Cabinet Label CEM Label
Ordered Level - 362-5225-01 Ordered Level - 362-5225-01
Control Gp - DEF 360-1777-00 Conv Gp-CTLTC 362-5224-00
Serial # CPM000001H Serial # CPM000001H
2012 Caterpillar
Cat CEM Mandatory Interface Connections:

Connection Point Description Fitting Type Application
DEF Line from dosing cabinet to N0. 6 Female STOR
Dosing Cabinet to CEM ALL
CEM (straight thread O-ring)
Air line from Dosing Cabinet to
Dosing Cabinet to CEM No. 8 Female STOR ALL
CEM
Electronic harness from Dosing Quantity 1
Dosing Cabinet to CEM ALL
Cabinet to CEM 24 Pin Connectors
Dosing Cabinet to Electronic harness from Dosing Quantity 1
ALL
Engine ECM Cabinet to Engine ECM 24 Pin Connectors
Dosing Cabinet to Main Electronic harness from Dosing Quantity 1
Electric Power
DEF Tank Cabinet to Main DEF Tank 24 Pin Connectors
Dosing Cabinet to Air Air line into dosing cabinet from air
1/2" Male NPT ALL
Source source
Dosing Cabinet to DEF DEF line into dosing cabinet from Dosing cabinet without
No. 6 SAE J2044
Tank DEF tank buffer tank
Dosing Cabinet to DEF DEF line from dosing cabinet to Dosing cabinet without
No. 6 SAE J2044
Tank DEF tank buffer tank
Dosing Cabinet to DEF DEF line into dosing cabinet buffer Dosing cabinet with
3/8" Male NPT
Tank tank from main tank buffer tank
1/2" Hose Bead SAE Dosing cabinet with
Dosing Cabinet Drain DEF buffer tank manual drain
AS5131 buffer tank
1/2" Hose Bead SAE Dosing cabinet with
Dosing Cabinet Vent DEF buffer tank vent & overflow
AS5131 buffer tank
Air line from CEM to dosing
CEM to Dosing Cabinet 3/4-16 Male JIC All
cabinet
DEF line from CEM to dosing
CEM to Dosing Cabinet 9/16-18 Male JIC All
cabinet
Electronic harness from CEM to
CEM to Dosing Cabinet 16 Pin Connector Electric Power
Dosing Cabinet
Dosing Cabinet to 120V Electrical harness from Dosing
Bus Bar ALL
AC source cabinet to 120V AC source
2 - 10" Cat Bolted Flange
Exhaust pipe into CEM from (3516CHD)
CEM to Turbo Electric Power
engine 2 - 16" Bolted ANSI
Flange (C175-16)
2 - 12" Outlet Cat Bolted
Exhaust pipe from CEM to Flange (3516CHD)
CEM to Atmosphere Electric Power
atmosphere 1 - 20" Outlet ANSI Flange
(C175-16)
Table 3.1: Interface Connections
©2012 Caterpillar
Air System
Compressed Air is used:
• To assist in the atomizing of the liquid DEF as it is injected into the exhaust stream
• To shield the liquid DEF in the injector from the exhaust heat until injection, so
that no crystallization occurs which could plug the injector nozzle
• To purge the DEF line during shutdown in order to prevent crystallization
Typically, compressed air will carry some oil from the compressor and some
sediment from the piping. This debris can collect in the nozzle and clog the unit.
Use a coalescing filter/separator that is 90 percent effective that is rated for
1069 kPag (155 PSIG) and 849.5 liter/min (30 CFM). Reference Air Filter
Requirements in the sub section “Air Filter Recommendations” for details.
An air dryer is recommended to keep relative air humidity below 10%.
The air supply delivered to the dosing cabinet must meet the specifications in Table 3.2.
Air Supply
Air quality ISO 8573.1 Class 5
Oil Content (mg/m3) (Max.) 25 (mg/m3)
Particle Size (Max) (micron) 40 micron
Particle Density (Max) (mg/m3) 10 (mg/m3)
Relative Air Humidity <10%
Air delivery (compressor capability):
Air Temperature -40 to 50 ºC
Air Flow Capacity 9 SCFM
Air Consumption Continuous when system is dosing
Air Pressure 105 to 155 PSIG
Air Pressure at Engine Startup 80 PSIG at startup
OR
80 PSIG within 3 minutes maintaining
<30% load or CEM outlet temp <250 ºC
Purge Air Press/Vol at Shutdown 80 PSIG / 10 SCFM for 30 sec
Selected filter should meet the filter performance test per ISO 12500.3
Table 3.2: Air supply delivery requirements at Dosing Cabinet Inlet
Note: An optional air compressor system is available from Caterpillar that is designed
specifically for use with the Cat SCR CEM.
Air Line Requirements
The air line that is used for delivering air from the dosing cabinet to the injector is to be
sized and routed such that the pressure loss across the line is no greater than 1.0 PSI
at the maximum flow capacity.
2012 Caterpillar
Secondary Air Filter

The DEF dosing cabinet requires customer to provide compressed air to the dosing
cabinet which meet ISO 8573.1 Class 5 requirements specified in Table 3.2 above.
Cabinets with an integrated DEF buffer tank (open Genset) contain a secondary air
screen filter at the dosing cabinet air inlet.
Air inlet port on the screen filter is Male 1/2" NPT. It is recommended to have a drier
installed on the compressed air system to maintain the <10% relative air humidity. See Air
& DEF Filter Installation figure below for interface connection location on dosing cabinet.
See maintenance schedule for service interval of air filter. See service manual for
service procedure.
Secondary DEF Filter Requirement
The DEF dosing cabinet requires customer to provide DEF to the dosing cabinet which
meets ISO22241-1 quality requirements with a maximum particle size of 40µ (microns).
Customer needs to have onsite DEF filters with filtration capability of 40µ
(microns) using differential pressure gauges across the filters for service.
Cabinets with an integrated DEF buffer tank (open Genset) will include a DEF filter screen
assembled and mounted on the front of the cabinet using all stainless steel fittings.
DEF inlet port on the screen filter is Male 3/8" NPT. If the system will be shut down in
freezing conditions or put into storage, the screen filter and supply line should be
drained. Customer is responsible for protecting the supply line from freezing and
damage from foreign objects (stainless steel supply line is recommended).
See maintenance schedule for service interval of DEF screen filter. The filter is reusable
and can be cleaned using an ultrasonic bath. Refer to figure below for interface and
installation on dosing cabinet.
©2012 Caterpillar
Air & DEF Filter Installation

on Dosing Cabinet
Air DEF
Screen Screen
Filter Filter
1/2” Male 3/8” Male

NPT NPT
Interface Interface
Required Required
Figure 3.1
DEF System
DEF Specifications
For SCR applications the required DEF solution to be used is SCR Grade AUS32, or
Aqueous Urea Solution of 32.5% concentration with quality properties per ISO 22241-1.
A solution of this concentration provides the lowest possible freezing point, -11 °C (12 °F).
The solution is homogeneous, allowing partial or total freezing and thawing without
changing the concentration. The solution is basic, with a pH of about 9.0, and is slightly
corrosive. Reference ISO 22241-3 standard for “Handling, Transportation, and Storage of
AUS32 (DEF)”.
Fertilizer or technical grade urea may contain elements that will clog the injector nozzle.
It should not be used to supply the dosing cabinet.
The DEF supply to the dosing cabinet inlet should be filtered. The filtration requirement
is 40 microns to protect valves inside the dosing cabinet.
ISO 22241-3 has comprehensive list of DEF compatible materials such as stainless
steel including 300 and 400 series stainless steel Ethylene Propylene Diene Monomer
(EPDM), Polyethylene, Polypropylene, and etc.
Any O-rings must be EPDM. Reference “Material Selection for Tank and Piping” found
later in this section for details regarding tank material, size, piping, fittings, etc.
2012 Caterpillar
CAUTION: Base material and their alloys of copper, zinc, aluminum and
magnesium are not compatible. Also soldering material containing silver and
nickel coatings are considered not compatible with DEF. Carbon steels, zinc
coated carbon steels, and mild iron are not to be used with DEF Do not store DEF
in a tank or use supply lines or fittings that are made of the above materials.
DEF must be kept below 50 °C (122 °F) to keep it from decomposing too quickly and
above -11 °C (12 °F) to prevent it from freezing during cold operation. According to
Caterpillar specification 1E4413, storage near 25 °C provides a shelf life of
approximately 18 months while storage around 35 °C reduces storage life to
approximately six months. Other storage and handling methods have to be followed.
The best operating temperature for the urea solution is – 5 °C to + 50 °C (23 °F to
122 °F). If ambient temperature goes below -11 °C, DEF inside tank and lines outside
dosing cabinet need thawing before starting DEF dosing. The thawing time requirement
is defined in the EPA SCR guideline (CISD-09-04). The dosing cabinet has a freeze
prevention strategy.
Dosing Strategies
There are two types of dosing cabinets to serve variance in DEF supply to the cabinet:
• with a buffer tank as shown in Figure 3.2
• without a buffer tank as shown in Appendix A
The dosing cabinet with a buffer tank requires a DEF supply of 2-3 PSIG with a max of
5 PSIG at the dosing cabinet DEF supply inlet. There is no DEF return line back to the
remote tank. A vent in the dosing cabinet release purged air & DEF vapor during purge
event. The vent line connected with the dosing cabinet should be below the DEF
injector mounting location at the CEM. The exit location should meet OSHA safety
requirements. Please contact local EH&S organization for related concern.
Reference “Material Selection for Tank and Piping” found later in this section for details
regarding lines and fittings.
©2012 Caterpillar
Dosing Cabinet
Air Press DEF Press Schematic
P2
P1
Dosing Valve Static States:
Injector Press Sol
Reg Vlv Sol Sol Vlv #1 Close
#1 Vlv Sol Vlv #2 Open
#2 Air
Op Sol Vlv #3 Close
Vlv Air Op. Vlv #1 Open
#1
Air Op. Vlv #2 Close
Sol
Vlv #3
Pump
Relief Valve Air Op
2 to 3 Vlv #2
psig, Level Sensor
Max 5
psig
Vent
Remote Tank
Buffer Tank
Sediment Strainer
Figure 3.2: Dosing system schematic with a buffer tank
Dosing System Operations

As shown in Figure 3.2 and 3.3, air pressure must be present at the input to the dosing
cabinet before dosing can begin. This air pressure is regulated to 64 PSIG at Solenoid
Valve #1 and a three way Solenoid Valve #3. Note the Valve Static States in the
diagram above. When dosing conditions are met the ECM energizes Solenoid Valve #1
and looks for the required 60 PSIG using P1 sensor. If pressure is present Air Operated
Valve #1 closes and allows DEF to be supplied to the DEF Injector via the DEF Dosing
Pump. The DEF Dosing Pump pulses DEF from the Dosing tank to DEF injector
controlled by the ECM. Compressed air after the pressure regulator is supplied to the
DEF injector and sensed by P1. This pressure signal is fed to the ECM that in turn
inhibits dosing without the required 60 PSIG pressure from the P1 sensor signal.
Purging System Operations
Purging is accomplished by energizing Solenoid Valve #1 and Solenoid Valve #2
providing compressed air back through DEF Injector via Solenoid Valve #1 and Air
Operated Valve #1 to Dosing Tank when dosing is not required.
DEF Filling System Operations
The DEF fill is controlled by ECM to the buffer tank for the cabinet shown in Figure 3.2.
When the buffer tank DEF level is lowered and the DEF Level Sensor detects a low
level condition the ECM energizes three way Solenoid Valve #3 to actuate the Air
Operated Valve #2 which fills the Dosing Tank to maintain adequate supply of DEF to
the injector. The maximum DEF pressure allowed at the input to Air Operated Valve #2
2012 Caterpillar
is 5 PSIG. DEF pressure from the DEF Supply Tank is typically 2 to 3 PSIG. A 5 PSIG
maximum pressure relief valve is recommended in series with DEF Supply Tank.
Dosing Cabinet
Normal functions/operations of a dosing cabinet include:
Monitor and dose DEF
Monitor and regulate compressed air
House Electronic Control Module (ECM)
Provide customer connections
Buffer tank
ECM can be communicated with via the engine J1939 connector via the electronic
connector on the cabinet interface. Dosing cabinet is shipped fully calibrated to work
within specified operating conditions. If the operating conditions change beyond the
specification, additional care needs to be taken to address these issues. The dosing
pump comes with a tamper evident sticker. If this sticker is damaged due to normal
wear and tear, please contact the local dealer for replacement. If this sticker is
tampered with this implies EPA violation.
Figure 3.3: Dosing Control Cabinet

©2012 Caterpillar
Dosing Cabinet Connection Points

Dosing cabinet communicates with external components via its connection points.
These connections could be electrical, electronic, air and DEF. For descriptions about
the connections and their meaning see Table 3.3 for the dosing cabinet with a buffer
tank and Appendix A for the dosing cabinet without a buffer tank
Figure 3.4: Connection to Dosing Cabinet with a Buffer Tank-Open Gen Set
2012 Caterpillar
Connection
Description Fitting Type
Point *
Electrical harness from Dosing
1 24 Pin Connector
Cabinet to Engine ECM
Electrical harness from Dosing 24 Pin Connector, for the
2
Cabinet to remote Tank (Optional) cabinet without a buffer tank
Electrical harness from CEM to
3 24 Pin Connector
Dosing Cabinet
Electrical harness from Dosing Grommet for wiring &
4
cabinet to 120V AC source 3 Terminal Blocks
5 DEF Vent Port (see Note below) 1/2" Hose Bead SAE AS5131
6 DEF Line from dosing cabinet to CEM No. 6 J2044
No. 8 STOR
7 Air line from Dosing Cabinet to CEM
(Straight Thread O-Ring)
Air line into strainer at dosing cabinet
8 1/2" NPT
from air source
DEF line into strainer at dosing
9 3/8" NPT
cabinet buffer tank from main tank
10 DEF Drain 1/2" Hose Bead SAE AS5131
Table 3.3: Dosing Cabinet with Buffer Tank Connection Points
Note: The DEF vent port of item 5 above must have a DEF vent line installed to route
buffer tank fumes to meet local/OSHA guidelines for Ammonia fumes and the following
routing requirements:
1. Vent lline exit must be below DEF injector
2. Vent line must be routed back to storage tank or a local/OSHA approved waste
container in the unlikely event of buffer tank overfill.
3. Vent line must be routed continuously away from vent port without any inks or
loops that will allow DEF pooling in line.
©2012 Caterpillar
Dosing Cabinet Symbols Pictograms
DEF DEF
DEF DEF
DEF DEF
CAUTION110VAC
349-5759
110V CAUTION: : 110VAC60Hz
50/60Hz Electric
electric
60Hz Powerpresent.
power Present.
Ground (Earth)
2012 Caterpillar
AC Power Connection
During the installation of the dosing cabinet, external power supply (AC power only) has
to be routed inside the cabinet via appropriate opening. The termination of these power
lines are inside the cabinet to the junction block as shown below.
Customer Power
Connections: (Hot)
Ground
Common
(Neutral)
Figure 3.5: Example AC Power Connection to Dosing Cabinet
DEF Supply to the Dosing Cabinet with a Buffer Tank

Desired fill rate is about 1.5 gallon per min at 2.5 PSIG DEF supply pressure at the
dosing cabinet fill port. For the reference, 10 feet height difference generates 4.7 PSI
DEF pressure. Fill rate and overall flow restriction in valves, lines, and filters upstream
to the dosing cabinet need to be accounted while designing the DEF supply.
DEF supply to the buffer tank can be accomplished in two ways:
Transfer pump
Gravity feed
The transfer pump must be sized to provide 2-3 PSIG with max of 5 PSIG DEF pressure
at the dosing cabinet DEF fill port based on the flow rate and total flow restriction in the
line from the remote tank to the cabinet.
Dosing cabinet provides a 24VDC (max amp: 300 mA) signal via after-treatment ECM
connector to control a relay used to control the power supply to the transfer pump.
Aftertreatment software will energize the relay at fill and turn it off when the fill is done.
This relay is not provided with the dosing cabinet. To use this feature, the customer
needs to wire the relay. In addition, the customer also need connect a wire from the pin
J1-31 of the after-treatment ECM connector inside the dosing cabinet to the pin 14 of
the connector for Cabinet to Engine.
©2012 Caterpillar
Storage or Non-operational Condition

Ambient temperature Ambient temperature
> -10 ºC < -10 ºC
No additional No additional
Dosing system power - ON
operation required operation required
Drain Buffer tank
No additional
Dosing system power - OFF before switching
operation required
off the power
Caution: Buffer tank does not have thaw capability. The buffer tank must be drained if
temperatures are <10C and cabinet power is off. If DEF is allowed to freeze in the buffer
tank the SCR system will not operate properly. The engine will be shutdown or allowed
to operate only at idle until the DEF is completely thawed in the buffer tank. If DEF is
frozen severe damage may occur to the dosing cabinet.
Weight and Dimensions
Dosing cabinet with a buffer tank
Application EP Open Genset
Length (mm) 790
Width (mm) 364
Height (mm) 1033
Weight without DEF (kg) 120
Weight with DEF (kg) 210
2012 Caterpillar
Lifting and Mounting

The preferred method of lifting the dosing cabinet could be the use of two straps wrap
around through the openings in the base frame as shown in Figure 3.9. The cabinet can
be mounted by the use of bolts or welding. Weld mount is accomplished by either solid
or skip welding the outside of the dosing cabinet frame or bolted with M8 bolts to a
mounting structure.
Lifting
Provision
M8
Bolt
Weld along
both edges
Figure 3.6: Mounting Location Dosing Cabinet
Reference 5: Mounting Considerations for additional mounting requirements.
©2012 Caterpillar
Clearance
Dosing cabinet is required to have clearances around the outside of the box per
Figure 3.8. If one of the sides with 2 ft of clearance is not accessible then it is required
to have 4 ft of clearance on the side that is accessible and is not necessary to maintain
the 2 ft of clearance on the inaccessible side.
2 ft.
0.5 ft.
1.5 ft.
2 ft.
Figure 3.7: Dosing Cabinet Mounting Clearance Requirements
Orientation
The dosing cabinet has to be mounted per Figure 3.7 in the vertical position (dosing
cabinet housing above the tank). The cabinet needs to be mounted with the top of the
cabinet parallel with the horizon. The dosing cabinet should not be tilted by more than
18º from the vertical position.
Environment
The dosing cabinet needs to be located so that it will not be subjected to ambient
temperatures higher than 50 ºC or lower than -40 ºC. The components within the dosing
cabinet are designed to operate in temperatures per the above specifications.
Location
Mounting location of the Dosing cabinet must be within 20 feet of the CEM injector and the
top of the Dosing cabinet must be at or below the bottom of the CEM Mounting pads.
2012 Caterpillar
Electrical
Block Diagram
Figure 3.8: Dosing Cabinet Block Diagram – EP 3516CHD/C175
©2012 Caterpillar
Electrical Connections
Interconnect Harness Connectors
Dosing Cabinet Side
All Applications
Connector for Cabinet to Cat CEM Wiring Part Number: 9X-7143
24 Way Interconnect Harness Connector: 9X-7144
SCR
Connector Pin ECM Pin Function Wire ID
ECM Pin
1 Analog Sensor Supply J2-72 997-OR Output
2 Analog Sensor Return J2-17 T993-BR Output
3, 4 Spares
5 Local CAN - J2-11 R976-GN Input/Output
6 Local CAN + J2-12 R970-YL Input/Output
7 Local CAN Shield J2-23 A234-BK Input/Output
8 DOC #1 Delta Pressure J2-57 P938-WH Input
9 DOC #2 Delta Pressure J2-28 P339-BU Input (PR)
10 After-treatment 1 DOC Outlet Gas Temp J2-40 J890-BU Input
11 After-treatment 1 SCR Outlet Gas Temp J2-16 J891-GN Input
12 After-treatment 2 DOC Outlet Gas Temp J2-41 P844-PK Input (PR)
13 After-treatment 2 SCR Outlet Gas Temp J2-15 P845-PU Input (PR)
14 Intake NOx Sensor Power J2-8 L920-BR Output
15 Outlet 1 NOx Sensor Power J2-5 L921-YL Output
16 Outlet 2 NOx Sensor Power J1-20 L922-BU Output (PR)
17 Dout Return J2-79 J807-BK Output
18 P830-PU
19 L838-OR
20 K895-BU
21 I49-PU
22 J842-BK
23 - 24 Spares
2012 Caterpillar
Connector for Cabinet to Engine Part Number: 9X-7145

Interconnect Harness Connector: 9X-7146
SCR
Connector Pin ECM Pin Function Wire ID
ECM Pin
1 SCR Diagnostic Active J1-30 H779-GN Output
2 Cat Data Link - J1-9 945-BR Input/Output
3 Cat Data Link + J1-8 944-OR Input/Output
4 Global CAN - J1-34 K990-GN Input/Output
5 Global CAN + J1-50 K900-YL Input/Output
6 Global CAN Shield J1-42 234-BK Input/Output
7 Intake Manifold Air Temp J2-91 G853-OR Input (PR)
8 Analog Sensor Reference J2-30 Y947-BR Output (PR)
9 Local Can - J2-11 R976-BU Input/Output
10 Local Can + J2-12 R970-YL Input/Output
11 Local Can Shield J2-23 A234-BK Input/Output
12 Heated Line Supply – Sw’d A-C5-4 P830-PU Output
13 Heated Line Return – Sw’d A-C17-4 L838-OR Output
14 - 15 Spares
16 + Battery J1-48 101-RD Input
17 - Battery J1-61 A-250-BK Input
24 Keyswitch J1-70 105-BR Input
©2012 Caterpillar
CEM Side
Electric Power
Connector for CEM to Cabinet Part Number: 6D-8177
Interconnect Harness Connector: 6D-8151
Dosing
Connector Pin ECM Pin Function
Cabinet Pin
A Analog Sensor Supply 1
B Analog Sensor Return 2
C Local CAN - 5
D Local CAN + 6
E Local CAN Shield 7
F DOC #1 Delta Pressure 8
G After-treatment 1 DOC Outlet Gas Temp 10
H After-treatment 1 SCR Outlet Gas Temp 11
I Intake NOx Sensor Power 14
J Outlet 1 NOx Sensor Power 15
K Dout Return 17
L-P Spares
2012 Caterpillar
120V Power Connection

The dosing pump requires 120V AC power to operate. The connection for the power
is made inside the dosing cabinet on a bus bar with the cable routing through a wiring
grommet on the dosing cabinet. Refer to wiring example in Figure 3.5.
Figure 3.9: 120V AC Connection Diagram
©2012 Caterpillar
Electrical Loads
SCR Component Electrical Load
(Assume Cold Ambient Temps)
AC DC
AC Max AC Max DC Max DC Ave DC Max DC Ave
Component Power Amp Amp Amp Amp Amp Amp
Engine Engine Engine Engine Engine Engine
Running Stopped Running Running Stopped Stopped
Dosing AC 0.7 0.0
Pump
Buffer Tank AC 2.9 2.9
Heater
Manifold DC 8.3 4.2 8.3 4.2
Heater
12V Power DC 1.0 0.2 1.0 0.2
Conditioner
Line Heater DC 15.0 5.0 15.0 5.0
(dosing/tank
2.6 m)
ECM & DC 11.4 3.7 4.2 2.0
Connected
Items Total:
1. ECM DC 0 0.3 0.3 0.3 0.3
2. NOx DC 0 7.0 1.0 0.0 0.0
Sensors
3. Air DC 0 2.0 0.5 2.0 0.0
Supply
Enable
Solenoid
4. Reagent DC 0 0.2 0.1 0.0 0.0
Return
Solenoid
5. Pump DC 0 0.2 0.1 0.2 0.0
Fill
Solenoid
6. Pump DC 0 1.7 1.7 1.7 1.7
Motor
Heater
Total 3.6 2.9 35.7 13.1 28.5 11.4
Component
Current
(Amps)
Note: Power consumption w/ SCR Aftertreatment system. This does not include air
compressor, air dryer, DEF transfer pump
Table 3.4: Electrical Loads
2012 Caterpillar
Electrical Component temperature limits

There are components on the CEM that are required to stay under specified
temperature limits. The sensor box on the CEM contains the critical electrical
components such as the NOx sensors and temperature sensors. The pressure sensors
may or may not be located in the sensor box. It is necessary that the components in
Table 3.5 do not exceed the listed specifications during operation of the engine system.
Component Temperature Limits
Temp Limit
Component
(ºC)
Temperature Sensor 120
NOx Sensor Control Box 85
Delta Pressure Sensor 125
Table 3.5: Electrical Component Temperature Limits
CAUTION:
NOx sensor control box near both exhaust outlets must be protected from proximity
temperatures >85 °C
Outlet NOx
Sensor
NOx Sensor Probes
Control Box –
Max Temp 85C
Inlet Pressure
Delta Pressure
Sensor – Max
Temp 125C
Outlet Inlet NOx

Sensor NOx Sensor
Pressure
Probe Control Box – Max
Temp 85C
3516CHD Electrical Component Locations
©2012 Caterpillar
Outlet NOx Sensor

Probes
Outlet NOx Sensor

Control Box – Max
85C
Inlet NOx
Sensor Probe
Delta Pressure
Sensor – Max 125C
Inlet NOx Sensor

Control Box – Max 85C
Outlet Temp
Inlet Temp Sensor
Sensor
C175 Electrical Component Locations
Exhaust System
Exhaust Connections
Both the inlet and outlet exhaust connections to the CEM utilize a bolted flange
connections. A gasket and standard bolt torques are required to maintain a leak tight
seal. Any connections for the exhaust that are between the turbo out and CEM inlet are
required to be leak tight and utilize industry standard exhaust connection components.
For further Exhaust System Requirements reference “Section 4 – Exhaust System.”
Electric Power Exhaust Connection

There are two exhaust inlet flanges and two exhaust outlet flanges on the CEM. See
Figure 3.10 for mounting flange details.
2012 Caterpillar
Top front view of Electric Power SCR CEM for 3516CHD
Exhaust Outlet
Doc Cover
Exhaust Inlets
SCR Cover
Top front view of Electric Power SCR CEM for C175
©2012 Caterpillar
Figure 3.10: Electric Power Exhaust Flanges
Bottom view Electric Power SCR CEM for 3516CHD
2012 Caterpillar
Electrical Aftertreatment
Connection ID
Air DEF
Connection Connection
from Dosing from Dosing
Cabinet Cabinet
Bottom view Electric Power SCR CEM for C175
Mounting
For requirements Reference Section 5 – Mounting Considerations.
All CEM’s are to be mounted so that the top of the CEM is parallel with the
horizon. Mounting at angles in any plane is not permitted.
Electric Power/Mounting
Cat CEM provisions for mounting are 6 Mounting Pads with a 4 bolt pattern per pad.
Bolt requirements are M16 grade 10.9 Bolts.
DEF Handling
Hazards Identification
AUS32 (aqueous urea solution, 32%) is a colorless liquid with a slight ammonia
(pungent) odor.
Note: Consult the Material Safety Data Sheet (MSDS) provided by your AUS32
supplier. MSDS example is:
• MSDS Number 2046 (Revised October 4, 2006) for DEF Liquor supplied by
Terra Industries Inc.
Warning: DEF is a stable material, but highly reactive with strong oxidizers. Avoid contact
with all oxidizers. DEF reacts violently with sodium hypochlorite (such as Clorox) or
calcium hypochlorite to form the nitrogen trichloride, which spontaneously explodes or
rapidly decomposes creating toxic fumes, which may cause personal injury or death.
©2012 Caterpillar
When heated, DEF releases ammonia. When heated to decomposition, such as in a

fire, it emits toxic fumes of nitrogen oxides (NOx), ammonia, and cyanuric acid. Use
water to control fires involving DEF liquor if water is compatible with burning material.
Note that both DEF liquor and solid DEF are non-flammable.
In storage, a very small amount of the DEF in the liquor will hydrolyze forming gaseous
ammonia and carbon dioxide. The ammonia, which is soluble in the liquor, will cause
the corrosiveness of DEF solution to increase as it ages due to its increasing
concentration. That is, the higher ammonia concentration makes it more caustic. Note
that high storage temperatures increase the rate of this decomposition.
Since DEF liquor is caustic, delivery and storage requires materials that are not
susceptible to corrosion.
Recommended Materials:
• Stainless-steel
– 300 series: OK
– 400 series: Slow corrosion
¾ Corrosion rate increases
with temperatures
> 60 °C
• Plastics
Materials to Avoid:
– Unalloyed steel
– Aluminum
– Brass
– Galvanized steel
– Copper
2012 Caterpillar
Eye contact may cause mild eye irritation, including stinging, watering, and redness.
Wear safety glasses. Safety shield may be needed in some conditions.
Skin contact may cause mild skin irritation including redness and burning. No harmful
effects from skin absorption have been reported. Use rubber gloves to prevent skin
contact (All rubber types OK)
Vapor Inhalation may cause irritation leading to cough or difficulty in breathing.
Note: Contact hazards are from the caustic pH (7.5 – 10) factor of solution. DEF in
solution slowly decomposes into ammonia causing the caustic reaction. “Aged” DEF
solution is more caustic (high pH) than “fresh”.
Leaks and/or Spills
Should a leak occur there is evidence to observe:
• DEF stalactites & stalagmites
– Formed from slow leaks and evaporation of water
– Rate of water evaporation determines size of crystal formation
• Need to verify that joints are tight
– Stop leaks when first noticed
¾ Solid DEF will continue to accumulate
¾ DEF solution is corrosive to steel and other metals
• Solid DEF is water soluble
– But… may be slow to get into solution
• Clean up spills and leaks before components can corrode

– Minor spills: Use paper towels or absorbent mat
©2012 Caterpillar
• Solid DEF is highly water soluble

– Hot water will re-dissolve solid DEF faster
– Small amount of soap or detergent in hot water may enhance clean up
– Plenty of hot water is key to removing dry DEF
• DEF solution contains small amount of ammonia
– Skin irritant
– Wear gloves
Material Selection for Tank and Piping

Material compatibilities must be considered in the DEF storage and delivery system due
to the caustic corrosive nature of AUS 32.
• Highly alloyed austenitic Cr-Ni and Cr-Ni-Mo Steels or Stainless Steel (304,
304L, 316L, 409, 439) materials are recommended for use with AUS32 (DEF
water solution).
• Aluminum and its alloys are not recommended for use as tank material for DEF
tanks. Only certain grades of anodized aluminum are acceptable but due to
variability of anodizing quality, it is not recommended as tank material either.
• Titanium is recommended for use with DEF water solution
Non-ferrous metals and alloys (copper, copper alloys, zinc, lead) are strongly not
recommended.
• Metals & Plastics coated with nickel are not recommended because nickel
coating inner diameters of components and durability (resistance to flaking) of
nickel coating are not consistent.
• Polyethylene, Polypropylene, Polyisobutylene, Perfluoroalkoxyl alkane (PFA),
Polyfluroethylene (PFE), Polyvinylidenefluoride (PVDF), Polytetrafluroethylene
(PTFE) are all recommended materials
• Seal/Hose Materials – EPDM (1E0712B) and NBR (1E0741) are suggested
materials for use with AUS32.
2012 Caterpillar
DEF Storage Tank

The OEM or installer must provide a DEF storage tank and delivery system.
DEF storage tanks must be designed to the industry best practices for fluid storage
tanks, but also with consideration for DEF freezing and effective thawing with a heat
exchanger. Unlike other common operating fluids such as diesel fuel and coolant, AUS
32 freezes at a temperature within the operating limits of the engine.
DEF in the tank freezes from the outside to the center. The density of frozen DEF is
lower than the density of the liquid DEF. This means that the frozen DEF floats on the
liquid DEF. To ensure that the complete tank of DEF is thawed, at least part of the
heating source has to be located at the bottom of the tank. The DEF pick-up location
has to be very close to the heating source and draw from the bottom of the tank as well.
As the DEF is consumed, the DEF level in the tank reduces and the cold DEF
approaches the heater.
To facilitate the thawing process, the tank should have a simple rectangular or
trapezoidal shape wherein the base of the tank is slightly larger than the top of the tank;
a “pyramid” design (no plateaus) is recommended for best thawing performance.
Shapes that do not assure the gradual reduction in the level of DEF have to be avoided.
Tank shapes vary from application to application based on design and space limitations.
Irregularity in these shapes is acceptable as long as the air pockets and/or stuck chunks
of frozen DEF inside the ridges or any other contours of the tank can be avoided. It is
also preferable to have the width of the tank equal or smaller than the height of the tank.
Short and long tanks are not favorable for DEF freeze protection.
The table below is from ISO standard 22241 and provides DEF shelf life as a function of
temperature.
Shelf life as a function of temperature

Constant ambient storage temperature Minimum shelf life
°C months
≤ 10 36
≤ 25a 18
≤ 30 12
≤ 35 6
> 35 —b
Note: The main factors taken into account to define the shelf life in this table are the
ambient storage temperature and the initial alkalinity of AUS 32. The difference in
evaporation between vented and non-vented storage containers is an additional factor.
a
To prevent decomposition of AUS 32, prolonged transportation or storage above 25 °C
should be avoided.
b
Significant loss of shelf life: check every batch before use.
©2012 Caterpillar
Tank Volume
Tank volume should be sized based on required refill frequency, DEF freeze expansion,
and the volume of internal tank components. The DEF tank size is dependant upon DEF
quality over duration of use and delivery infrastructure. It is required that the DEF tank
size meets a fill ratio of at least 1 fuel tank refill to 1 DEF tank refill (1:1 fuel to DEF).
Accounting for DEF freeze expansion of 9%, Freeze Protection System Volume of 2%
and a 5% capacity safety margin, tank sizes should be a minimum of 7.5% of diesel
capacity (where capacity is fuel tank volume) for 175 to 750 hp and 4.87% of diesel
capacity for greater than 750 hp. See Tank Sizing table.
The DEF tank volume sizing calculation is described below and is based on 95% NOx
conversion efficiencies and a 2:1 ratio tank size.
• UCR = DEF consumption rate (worst case, in-use): 175 hp to 750 hp = 6.44%, >
750 hp = 4.18%
• FR = Fill ratio of fuel tank to DEF tank = 2
• CSM = Capacity Safety Margin = 5%
• UXR = DEF expansion rate when it freezes (9%)
• FPSV = Freeze protection system volume (assumed 2% of DEF tank volume)
• DEF tank Volume = Fuel tank Volume * UCR * (1+UXR+FPSV) * FR * CSM
Example for 175 hp to 750 hp Engine with 100 gallon fuel tank:
UV = FV * UCR * (1+UXR+FPSV) * 2 * CSM
UV = 100 * 0.0644 * (1+0.09+0.02) * 2 * 1.05
UV = 15.01 gallons
Tank Sizing Parameters

Power Range (HP) 175 to 750 > 751
Fuel Refill per AUS32 Refill 2 2
Capacity Safety Margin (CSM) 1.05 1.05
AUS32 Consumption Rate 6.44% 4.18 %
Freeze Expansion Rate 9% 9%
FPSV 2% 2%
Total Volume 15.01 % 9.74 %
Table 3.6: Tank Sizing Parameters
Tank Connections
The DEF suction or pick-up connection should be placed at the bottom of the tank, and
as close to the heat exchanger as possible. This location has the greatest potential for
2012 Caterpillar
the first available liquid DEF during thawing. On the return side, melted DEF returning
from the pump has the potential to help thaw the remaining frozen DEF. To take
advantage of this potential, the return port on the tank should be at the top of the tank.
DEF Pickup/Return
Tank Side
Line side
The DEF connections should follow the “de facto” standard set forth by Euro 4 and
Euro 5 DEF delivery systems. This standard is the SAE J2044 “quick connect fitting” on
the line side and a standard ORFS connection on the tank side. Typically in Europe,
these connections on both the tank side and line side are of varying diameter (5/16 in
and 3/8 in typically on the line side) to ensure a “poke-yoke” assembly process. Above
is a picture of this fitting.
Coolant Connection
Coolant connections to the DEF tank for coolant lines should follow any applicable
standards. In general this team did not investigate this connection interface, but would
suggest using quick connect fittings in this situation as well.
Integrated Sender Unit
An integrated sender unit is highly recommended. The sensor should provide the
following functions:
• DEF pick up and return
• coolant supply and return
• heat exchanger
• Temperature
• level sensor
©2012 Caterpillar
Tank Fill Interface

Splash Fill:
The fill neck of the DEF tank should be designed with consideration for fill nozzle
geometry, fill flow rate, and common cap engagement. The fill neck must meet ISO
standard 22241-4. ISO standard requires the angle of the fill neck to be 50° to 90°
above horizontal. The fill neck should be design with a minimum flow restriction to
ensure DEF filling does not take longer than fuel filling. The target fill flow rate is
20 GPM with no splash back. Below is a picture of this fill neck interface, which is
“poke yoke” from a diesel fill nozzle by its smaller diameter.
Fast Fill Applications

For applications with optional fast fill system, accommodations should be made for
higher fill rate and quick-connect interface. Fast fill system requirements depend on the
relative volume of the DEF tank to fuel tank, location of the DEF tank (remote fill) and
relative position of the DEF tank to the service center of the machine application. The
fast fill system will fill at flow rates minimum 20 GPM and maximum 30 GPM which will
guarantee that a fast fill system will fill the DEF tank as fast as or faster than the fuel
tank. The quick-connect interface will be designed such that it cannot be installed or
connected to any other fluid connector. Apart from operating media (AUS 32) Fast Fill
system should withstand splash exposure to diesel fuel, motor oil, engine coolant, and
hydraulic fluid. The fast fill system and quick disconnects must meet the cleanliness
requirements of Caterpillar specification 1E2860.
Tank Fill Cap
The cap and adaptor interface must be designed such that the DEF cap cannot be
installed in the any other fluid adaptor and the fluid cap from another source cannot be
installed in DEF adaptor. The cap is to be a typical Lift & Turn Lock style. Apart from the
operating media (AUS 32), the cap should withstand splash exposure to diesel fuel,
motor oil, engine coolant, and hydraulic fluid. The cap should also be UV resistant. The
cap and adaptor must meet the cleanliness requirements of Caterpillar specification
1E2860. (The cap shall be colored blue and the symbol and marking is done according
to ISO 22241-1 and ISO 2573).
The symbol for AUS 32, according to ISO standards 22241-1 and 2575 is shown below.
2012 Caterpillar
Tank Vent
DEF tanks must include both positive pressure and vacuum venting for flow into and out
of the tank. A vacuum vent with 10-micron nominal filter is to be incorporated in the cap
assembly.
Positive Pressure Venting – is needed for two reasons:
• Eliminate the build up of pressure in the tank as gasses/fluids expand as
temperature increases
• Allow for air to escape during the filling of the tank with DEF.
Vacuum Pressure Venting is provided by the DEF cap (and is part of the functional
specification ES-2072) and typically requires a 10u nominal filter.
Tank Mounting
Proximity to heat sources should also be considered in tank placement, as prolonged
exposure to elevated temperatures causes thermal degradation of DEF in the tank. The
tank should not be located in compartments containing exhaust components to reduce
heat exposure. If this is not possible, sufficient thermal insulation must be added to the
tank to keep the DEF below the maximum temperature limit. Although high-density
polyethylene is a poor conductor of heat, additional insulation will help to protect DEF
from thermal degradation.
Tank Materials
Non-cross linked polyethylene (PE) is the material of choice for DEF tanks. It provides a
wide temperature range of operation, has good strength properties, allows for flexibility
in “shaping”, low in weight, and has been used other DEF applications.
In-Tank Filtration
In-tank filtration is required to protect the DEF delivery system.
An inlet strainer is required to prevent large debris from entering the tank. The strainer
should be made of stainless steel with 30-mesh/500 micron filtration (Ref. Cat part
number 108-3730).
An “Iceberg Catcher” must be located at the end of the DEF pickup line in the tank to
keep frozen chunks of DEF out of the delivery system. This will act as secondary filtration
into the DEF delivery system, but will not provide enough filtration to meet the
requirements for the DEF delivery systems. Functional specification for the iceberg
catcher is consistent with Euro 4 (ES-2084). Technical requirements of the filter are for
DEF flow capacity for the delivery system (area of the mesh) and the filtration
requirements (size of the mesh - 100 um).
Level Sensors
A visible level sensor in the storage tank is required. It is recommended that along with
the level sensor a warning light is provided to indicate when DEF level is low. The
warning level sensor should be set at a level that will provide adequate time to have
DEF available and refill the tank.
©2012 Caterpillar
Tank Heating
Heating of the DEF tank for thawing can be carried out in various ways. Heat can come
from an electric heater, or a heat exchanger using one of the various working fluids on a
machine, including coolant, engine oil, hydraulic oil, and exhaust. Out of these sources,
a heat exchanger using coolant is the optimal solution. Electricity is also acceptable for
performance, but the amperage requirement is very high. Although other fluids may have
equal or higher temperatures, coolant’s high specific heat enables it to outperform the
others. Mass flow rate also plays a major role in determining the heating potential of a fluid.
While a heat exchanger using coolant has many advantages, it also has one major
performance disadvantage compared to an electric heater. While an electric heater can
begin thawing DEF almost immediately after startup, engine coolant warms up more
slowly.
Coolant Diverter Valve Strategy
Cold Weather
In cold weather heating of the DEF must be accomplished as fast as possible. Two
temperature sensors are required to operate the coolant diverter valve:
• Ambient temperature
• DEF temperature sensor located inside the tank.
For ambient temperatures below -11 °C, the coolant diverter valve should be open and
continue to remain open until the DEF temperature inside the tank is >-11 °C. It is
recommended that the temperature sensor be placed at a distance from the heating
source. This will ensure that the heat is dissipated and the frozen DEF is melted all
throughout the tank. Once the entire DEF tank is melted, the coolant flow can be
stopped. In the event of re-freezing inside the tank during the operation, temperature
sensor in the tank should trigger the opening of the coolant diverter valve again to
resume the melting process.
Under “rated engine” conditions engine coolant temperature can reach up to 104 °C.
Studies of the thermal degradation of DEF indicate that DEF loses its concentration at
temperatures greater than 60 °C. However, this degradation is very slow and the impact
won’t be observed until 5-6 days of continued exposure to the higher temperatures. The
DEF temperature right next to the coolant line will also be as high as 104 °C. But the
DEF pick-up location is very close to the heating source (coolant line) and this will
ensure the consumption of the high temperature DEF quickly. Even if it isn’t consumed
immediately, the machine applications’ duty cycle is of the order of 12-20 hrs in a day.
In this short span of time, the thermal degradation of DEF is negligible.
Hot weather
The ambient sensor will indicate that the temperature is greater than -11 °C and the
DEF temperature sensor will indicate that the DEF in tank is completely thawed. These
two sensors will shut-off the coolant diverter valve and no coolant is allowed to flow
through the DEF tank. Otherwise the risk is aiding/increase the rate of DEF thermal
aging.
2012 Caterpillar
Heat Exchanger Design

Based on the highest rate of consumption, the heat exchanger (a stainless steel coolant
line) can be sized to provide thawing. The sizing is accomplished by utilizing the
following equation:
mCp, solid DEFdTsolid DEF + mH + mCp,liquiddTliquid DEF = UA (Tcoolant-TDEF)
Where:
m = 2 x DEF consumption, kg/s
Cp, solid DEF = specific heat of frozen DEF solution, kJ/kg-K
Cp, liquid DEF = specific heat of liquid DEF solution, kJ/kg-K
dTsolid DEF = -11C - Initial temperature of DEF, C
H = Latent heat of fusion of DEF solution, kJ/kg
dTliquid DEF = Final, required temperature of DEF - -11C, C
U = Overall heat transfer coefficient, kW/m2-K
A = Heat transfer area, m2
Tcoolant = AECD Coolant temperature, C
TDEF = Required temperature of DEF, C
The overall heat transfer coefficient, U can be obtained from the following equation:
1 1 l 1
= + ss +
UA hcoolant Acoolant K ss Ass hice Aice
Where:
hcoolant = Convective heat transfer coefficient of the coolant inside the coolant line, which can
be obtained from the equation
Nu = hD/K
Acoolant = Surface area of the coolant, m2
lss = thickness of the stainless steel tube, m
Kss =Thermal conductivity of stainless steel, kW/m-K
Ass = Mean surface area of the stainless steel tube, m2
hice = Convective heat transfer coefficient of the frozen DEF solution surrounding the tube,
kW/m2-K
Aice = Surface area of the OD of the tube, m2
The heat transfer area, A, can be calculated from the above equation. This area can be
translated into an equivalent length and diameter of the coolant line.
©2012 Caterpillar
Insulation Requirements
Although non-metallic DEF tanks are a very poor conductor of heat, depending on the
proximity of the DEF tank to a heat source, additional thermal insulation may be
required. For metallic tanks, thermal insulation is required to help improve the DEF
thawing process in addition to heat protection. AUS 32 freezes at -11 °C and starts to
degrade at elevated temperatures above 50 °C.
Energy Source
Energy Requirements
For DEF thawing, the recommended melt rate for frozen DEF is twice the maximum
consumption rate. This gives a brake-specific melting rate of 34 g/kW-hr and 21 g/kW-hr
for ratings 175-750 hp and greater than 750 hp, respectively. These numbers should be
used when sizing a heat exchanger or electric heater.
• Heat Exchanger Design
• Pickup/Return Location
• Flow rate/Thaw rate min.
General Installation Information

Enclosure Temperature Limits
Ventilating air should enter near the bottom of the enclosure and then flow upward
around the engine and/or Cat CEM module before exiting above the engine.
Building ventilation should be designed to bring the coolest air to the Cat CEM module.
If the engines and modules are placed in a building that has a pitched roof then
ventilating air should flow out at the peak or near the top of the gable ends. The source
of the air must be low in the room and rise across the engine and Cat CEM and other
equipment.
Maintain air velocity at 1.5 m/sec (5 ft/sec) in areas of heat sources or areas that exceed
38 °C (100 °F). Potential dead air spaces should be checked for temperature rise during
engine operation. Check all electrical and mechanical equipment in the dead air space for
any detrimental effects caused by excessive temperatures. Require corrections if
necessary. Engine room pressure should not become excessively negative. This would
indicate a shortage of ventilating air or excessive ventilating fans if equipped.
2012 Caterpillar
Installation Dimensions and General Views

Electric Power
Overall dimensions of the Electric Power CEM is 912 mm high x 2258 mm wide x
3385 mm long
Side View
DOC
Cover SCR
Cover
Front View
Top View
Bottom View
©2012 Caterpillar
Lifting Eyes
Four lifting eyes are to be bolted to the CEM assembly, one on each corner. Use of
spreader bars is mandatory for lifting this CEM to prevent damage to the CEM
structure. Refer to Electric Power rear view on next page for example of spreader
bar usage.
Notice: Standing on top of the CEM and using the top of the CEM as work platform is
strictly prohibited
2012 Caterpillar
Electric Power
Rear of view of CEM
Lifting Links
Electric Power Mounting

Cat CEM provisions for mounting are 6 mounting pads with a 4 bolt pattern per pad.
Bolt requirements are M16 grade 10.9 Bolts. (See Section 5 Mounting Considerations)
©2012 Caterpillar
Service and Maintenance

Access to the DOC covers and SCR covers need to be considered when
designing the installation of the CEM. The ability to remove the DOC cover and
remove the DOC may be necessary in the life of the CEM. In addition it may be
necessary to access the SCR catalyst through the SCR cover.
DOC
Cover SCR
Cover
Reference the Operation and Maintenance Manual for detailed maintenance

requirements.
Non Caterpillar supplied SCR system components (Exhaust, Air Compressor, Air Dryer,
Electrical harnesses, DEF lines, DEF storage tank etc.) that are an integral part of the
SCR system must meet the Tier 4 interim EPA requirements for maintenance service
intervals. The key criteria for meeting the regulation is that any regularly scheduled
replacement/servicing of components must be at a minimum of 4500 engine hours.
Component life must meet 8000 engine hours.
2012 Caterpillar
4. Exhaust System
Introduction
The engine Exhaust System discussed in this section consists of the interface of the
turbo exhaust gases to the Cat CEM. This includes Cat CEM or after-treatment and
muffler or exhaust pipe.
Cat CEM exhaust gas inlet receives the engine exhaust gas through flex coupling joints
allowing for misalignment that may occur from the many installation arrangements of the
Cat CEM. Caterpillar recommends the combination of bellows, ball and slip joints.
Particular attention must be taken to ensure proper design and placement of the Cat
CEM to maintain alignment with the engine exhaust and stay within the vibration and
industry standard leak tight connection.
The engine and after-treatment should be considered as a system. The mounts for the
engine limit pitch and roll and therefore reduce the requirement on the bellows assembly.
Refer to A&I guide LEBW4974 for information on Engine Mounts.
Mandatory Requirements
• Flex-pipe Design
• Dealer Supplied Exhaust Pipe Requirements
¾ Pipe Size
¾ Pipe Material
¾ Backpressure Apportionment
¾ Exhaust Gas Temperature Loss Through Exhaust Pipe
¾ Water Ingress Prevention
Flex-Pipe Design
Each application requires understanding of the installation requirements for proper
location of the Cat CEM relative to the engine exhaust. The actual flex-pipe (bellows)
will account for movement during engine operation. The following application
parameters should be considered before selection of flexible joint that accommodates
the application needs:
• Tolerance Stack up - static
• Worst Case Engine Operation/Duty Cycle
• Vibratory- High cycle low displacement
• Thermal Growth
• Shock Loading- Low cycle high displacement
• Temperature
• Pressure
©2012 Caterpillar
Exhaust system components must meet the Tier 4 interim EPA requirements for
maintenance service intervals. The key criteria for meeting the regulation is that any
regularly scheduled adjustment, cleaning, replacement, or repair of components must be at
a minimum interval of 4500 engine hours. Component life must meet 8000 engine hours.
Flex-pipe Design Requirements
• BELLOWS ARE ONE TIME ONLY USE PARTS
• Bellows must always be assembled with 1 mm misalignment
• Engine and after-treatment mounts (if required) must be designed
to restrict movement at the turbo to within spec as stated in TMI
• The Flex-pipe kit must not be modified from as received
• The Flex-pipe kit must not be used as a physical step
• Any insulation must not make contact with the bellows
• Do Not Remove Alignment Cover (Bellows Constraint) Prior
To Installing Bellows
• Alignment Cover (Bellows CONSTRAINT) Must Be Removed Prior
To Running Engine
Turbocharger Loading
Careful consideration must be given to the load external piping may induce on the
turbocharger. To minimize the load carried by the turbocharger diffuser, the bellows
should be placed as close as possible to the turbocharger outlet and downstream
exhaust piping should be self supporting. The thermal growth of horizontal piping
connected to the turbocharger exhaust must also be accounted for in the design.
Maximum allowable vertical load and bending moment limits are provided for each
engine model. Consult the Technical Marketing Information (TMI) for the appropriate
information.
Important Considerations
• Sharp bends in the exhaust system will significantly increase exhaust
backpressure. The piping size decision assumes a minimum number of short
radius bends. If a number of sharp bends are required, it may be necessary to
increase the exhaust pipe diameter. Since restriction varies inversely with the
fifth power of the pipe diameter, a small increase in pipe size can cause an
appreciable reduction in exhaust pressure.
• It is essential that the system does not impose more than the allowable maximum
backpressure as stated in TMI. The maximum backpressure must not exceed the
limit while certifying each engine model for conformity to exhaust smoke and
exhaust gas emissions under Federal, California, and other agency regulations.
To avoid this problem, exhaust system backpressure should be calculated before
finalizing the design. Also, backpressure differential side to side before and after
CEM must be less than 0.5 kPa. Testing should be done to validate design is
compliant with A&I requirements.
2012 Caterpillar
• Exhaust piping is a critical component in the Cat CEM operation required to meet
emission standards. Care should be exercised in configuring and designing the
exhaust piping to meet packaging and exhaust component load and operational
limits.
• Exhaust pipe diameter has a significant impact on the pressure drop through the
system. The engine and Cat CEM connections have been configured for the
recommended pipe diameter in order to meet the pressure drop requirements.
CEM Exhaust Joint Loading Guidelines

The following table provides guidelines for Dynamic loading of the connection interface
at the engine turbo exhaust and Cat CEM inlet and outlet. All reference to turbo outlet
load must be verified with TMI load requirements for the engine of your application
Exhaust
Maximum Allowable
Component Joint Type Size
Dynamic Load
Connection
Bellows will always be
attached at Turbo/BPV end
and must be braced post
bellows to eliminate dynamic
loading from exhaust pipe
installation.
8 N.m
4 kg Static
Bearing
Weight
Moment
CEM Inlet/Outlet Cat Pattern
2 x 10 in 400 N.m/100 N.m
(3516CHD) Flange
CEM Inlet/Outlet
ANSI/DIN 2 x 10 in 100 N.m/60 N.m
(C175-16)
Table 4.1
Exhaust Temperature Loss

The Cat CEM relies on a minimum average temperature during operation to provide the
necessary emissions reduction. Control of the temperature loss through the exhaust
pipe from turbo out to CEM inlet is required to maintain this average temperature. There
are two methods that can be used to determine if this temperature loss is acceptable.
• Meeting Maximum exhaust length requirements
• Meeting the exhaust temperature loss requirements
©2012 Caterpillar
Maximum Exhaust Length

One method to meet the temperature loss requirement is to not exceed the specified
maximum exhaust lengths. Table below provides the maximum allowable exhaust pipe
length to maintain an acceptable temperature loss.
Engine Max Length Max Length
Application
Platform (Meter) (Inches)
C9-C32 Commercial 1.52 m 60 in
Commercial
C9-C32 3.66 m 144 in
w/ Insulation
3516CHD Commercial 1.52 m 60 in
C175 Commercial 3.66 m 144 in
Table 4.2: Maximum allowable exhaust length*
Some commercial installations may require an exhaust pipe that is longer than the
maximum. If the maximum exhaust pipe length requirement cannot be met then the
installation must meet exhaust temperature loss requirements. Providing insulation of
the exhaust pipe in most cases will maintain the necessary exhaust temperature loss
requirements.
*Maximum lengths in Table 4.2 are provided for installations in which the exhaust
pipes are not in the direct path of any fan air flow. If any portion of the exhaust
pipe is in the direct path of fan air flow the exhaust temperature loss
requirements must be met.
Exhaust Temperature Loss Requirement
The second method to meet exhaust temperature loss through the exhaust pipe
requirements is to meet temperature loss requirements in the next table per the
following procedure.
Test procedure for measuring temperature loss through turbo to CEM piping
1) The test can be performed in ambient temperatures between 4.5 °C (40 °F)
and 43 °C (110 °F)
2) Set up temperature measurements at the turbo out and CEM:
1) Turbo out exhaust temperature – Install a beaded thermocouple in the
exhaust stream no more than 6 inches downstream from the end of
connection point at the turbo.
2) CEM inlet exhaust temperature – One of two suggested ways to measure
temperature:
i. Install a thermocouple in the exhaust stream no more than 6 inches
upstream of the CEM inlet.
ii. Use Cat Electronic Technician (ET) to read DOC inlet temperature
or SCR inlet temperature value.
2012 Caterpillar
3) Test Engine Load Requirements:

3) Systems with DOC + SCR run the engine at 10% rated load for test.
4) Any air flow that the exhaust piping will be subjected to during normal operation
of the engine will need to be simulated for the test. For example, if the exhaust is
in the air flow of a cooling fan the fan will need to be run at maximum operating
speed during the temperature drop test.
5) The engine speed must be within range provided for the given engine platform
and test load condition per table below.
6) For engines with NRS the engine application parameters must also be met.
7) Measure the exhaust temperature at turbo out and the exhaust temperature at
CEM in.
8) The temperature differential which equals Turbo out exhaust temperature minus
CEM inlet exhaust temperature cannot exceed the value provided in table below
for the given engine platform and loading the test was performed at.
9) It is also necessary to verify at test conditions that the CEM inlet exhaust
temperature is not less than 250 °C at test conditions.
10) If the temperature drop is greater than allowable, insulate the exhaust pipe as
needed until the specification can be met.
DOC Only, DOC+DPF and DOC+CDPF DOC+SCR+AMOx
100% Rated Load 50% Rated Load 10% Rated Load
Engine Max Allowable Max Allowable Max Allowable
Platform Allowable Engine Allowable Engine Allowable Engine
Temp RPM range Temp RPM range Temp Drop RPM range
Drop (°C) during test Drop (°C) during test (°C) during test
Peak Peak
Torque to Torque to
C32 50 25 TBD TBD
Rated Rated
Speed Speed
3516CHD N/A N/A N/A N/A 10 Rated
C175 N/A N/A N/A N/A 40 Speed
Table 4.3: Allowable temperature loss from turbo to CEM
©2012 Caterpillar
Regeneration of the SCR Aftertreatment

To maintain optimal performance of the SCR aftertreatment, the generator set should
be loaded periodically to elevate the SCR inlet temperature. This allows for regeneration
of the catalyst. In order to fully regenerate the catalyst, the CEM inlet temperature must
be maintained above 450 °C for 30 minutes or above 425 °C for 90 minutes.
For most applications, regeneration will occur naturally as the generator set is exercised
during normal operation. However, if normal operation of a generator set does not
elevate the SCR inlet temperature to the levels mentioned above, a service procedure
may be required to fully regenerate the catalyst.
The engine control system will continuously monitor the SCR inlet temperature and alert
if regeneration is required. The monitor will reset if the generator set is operated to
achieve the SCR inlet temperature and time requirements mentioned above. The SCR
inlet temperature sensor can be monitored on the EMCP.
In most applications that meet the definition of “standby power”, regeneration will not be
required often—perhaps once every 4 or more years. In applications operating within
the “prime power” definition, an annual regeneration is recommended. Regeneration will
be easiest to achieve during periods of warmest ambient and highest load. Ideally,
regeneration will be achieved during normal operation, eliminating the need for a
service procedure. As an example, applying 75% load at 25 C ambient conditions for 90
minutes is typically sufficient for full regeneration.
If the installation operates more than 2000 hours per year below 0 °C ambient
temperature or 750 hours below -15 °C ambient temperature, regeneration may need to
occur more than once per year. For those applications, an air inlet heater is
recommended from the factory to extend the time between regenerations. Extending the
time between regenerations allows for more flexible planning of regeneration events.
For example, one could delay the need for regeneration from winter to summer months
when warmer ambient temperatures are prevalent.
The following worksheet will allow the operator/dealer to calculate the exhaust
temperature at the SCR inlet to predict the ability to regenerate. When the worksheet
calculation is completed using the site altitude, ambient temperature, exhaust
restriction, and inlet manifold temperature for the engine, the result will be an “expected
SCR inlet temperature”. If it is determined that regeneration is not possible, consult the
factory for assistance and have the site parameters available.
Air Filter Inlet Temperature
1) Record, in column B, temperature at engine’s compressor inlet when operating
at rated.
2) Subtract column C from column B and record the answer in column D.
3) Multiply 1.8 times column D and record the answer in column F.
Inlet Manifold Temperature
1) Record, in column B, the engine’s inlet manifold temperature when operating
at rated.
2012 Caterpillar
2) Record, in column C, the engine’s TMI inlet manifold temperature.

Exhaust Restriction
1) Record, in column B, engine’s exhaust restriction when operating at rated.
Altitude
1) Record in column B, altitude of installation.
2) Subtract column C from column B and divide by 100, then record the answer
in column D.
Temperature drop from engine to CEM inlet
1) Record in column D, temperature drop (as a positive number) from engine to
CEM inlet as measured during commissioning.
2) Multiply -1.0 times column D and record the answer in column F.
Total Column “F”
1) Degrees Celsius that ambient site operating conditions affect the SCR inlet
temperature.
2) Add “Total Column F” to engine’s TMI “ENGINE OUTLET TEMP” and the answer
is the expected SCR inlet temperature of the engine at rated, when operating at
these ambient site conditions.
(B) (C) (D) (E) (F)
(A)
Site Data TMI Standard B-C Sensitivity Factor DXE
Air filter inlet temperature (°C) 25 1.8
Inlet manifold temp (°C) TMI 1.0
Exhaust restriction (kPa) 0 4.0
Altitude (meters) 0 3.6
Temperature drop from engine to CEM inlet measured during
-1.0
commissioning (°C)*
Total Column “F”
* Temperature drop in column (D) should be a positive number. Max allowed temperature drop from
engine to CEM inlet is 10 °C for 3500 powered generator sets and 40 °C for C175 powered generator
sets. Refer to CEM A&I guidelines for more details.
Table 4.4: Exhaust Temp Calculator
©2012 Caterpillar
Cut outs
If operating above the described temperature occurs with frequent regularity of a site’s
normal operation or within a year, planned regeneration will not be required unless there
are extended periods of time at low ambients and loads.
At least 30% of the rated power should be available on site to prevent slobber.
First, refer to the TMI performance data to determine the engine-out exhaust
temperature at the appropriate site generator load. Second, adjust the engine-out
exhaust temperature to account for other site specific conditions shown in the table
below. To accomplish this, take the engine-out exhaust temperature and subtract the
temperature drop between the engine and CEM as measured during commissioning.
This final temperature will indicate the ability to regenerate to the above criteria.
The monitoring system for the aftertreatment unit will alert the operator if the
regeneration needs to occur by lighting the main fault light on the annunciator panel and
displaying the diagnostic code on the EMCP panel. Once the operator has been alerted,
he will regenerate the system. The above calculation will again allow the operator to
determine the conditions in which a regeneration is possible. If a regeneration is not
possible, consult the factory for assistance and have the above parameters available.
2012 Caterpillar
5. Mounting Considerations
The CEM has been designed and validated to provide acceptable durability in a wide
variety of applications with load frequencies less than 60 Hz without the use of isolation
mounts. However, certain applications may still require the use of isolation mounts for
one of the following reasons:
• The CEM hard mounted to a particular structure would be exposed to vibrations
greater than 60 Hz.
• The mounts supporting the CEM move independently of each other and would
cause damage to the CEM or mounting supports.
• The noise generated by a hard mounted CEM would be objectionable
• Some flexibility in the attachments may make assembly easier and/or reduce
assembly stress.
• The volume is low enough where it may be preferable to add component cost in
order to reduce validation cost.
• Any brackets, bolted joints, mounts, welds or other structural elements
supporting the CEM must be able to withstand all mechanical loads seen during
operation (including thermal growth) or shipping. Each of these elements may
have different load limits, and the limits may depend on the direction of loading or
number of load cycles expected during the products lifetime.
• Any structural elements must provide acceptable strength and durability over the
entire temperature range expected to be experienced in the application.
• Motion of the CEM during operation must not exceed what can be
accommodated by the flexible connections attached to the CEM and the
clearances between the CEM and surrounding objects.
Mounting Guidelines
There are a number of (sometimes conflicting) goals and criteria to keep in mind when
designing a CEM mounting system. It’s important to check several criteria for any given
mounting system. The specific criteria to check depend on whether or not soft mounts
are used in the design.
©2012 Caterpillar
Mounting
Mounting Considerations
In addition to the above requirements, please note the g-load requirements for the
following CEM families:
1. Family C Low Cycle:
a. Fore/Aft – +/-4 G’s
b. Vertical – 1 +/- 5 G’s
c. Side to Side - +/- 3 G’s
2. Family D Low Cycle:
a. Fore/Aft – +/-2 G’s
b. Vertical – 1 +/- 4 G’s
c. Side to Side - +/- 2 G’s
3. Family C & D High Cycle:
a. Fore/Aft – +/- 1 G’s
b. Vertical – 1 +/- 2.5 G’s
c. Side to Side - +/- 1.5 G’s
All CEM’s are to be mounted so that the top of the CEM is parallel with the horizon
within +/- 5 degrees.
Installation
Handling and shipping
The Cat CEM unit will be packed in order to protect the assembly during shipping and
delivery. Shipping plugs will be installed on all flange connections. These MUST be
removed before the unit is placed into service.
Mounting Pads
The Cat CEM assembly should be mounted in a location that provides air circulation
around the can and yet protects it from possible debris or foreign object damage. Only
a protective heat shield located away from the Cat CEM allowing airflow around it is
acceptable. Unless approved by Caterpillar, protective heat shields should not be used
as they can cause localized heating.
Note: The Cat CEM should be mounted in a location that allows access and
removal for service requirements. See the Caterpillar Operation and Maintenance
Manual (OMM) for actual service requirements and procedures.
Notice: Welding mounting brackets to the Cat CEM is not permitted; this could lead to
failure of the unit and emissions non-compliance.
All mounting brackets must be properly adjusted so that the inlet and outlet of the Cat
CEM line up properly with the existing inlet and outlet pipes of the installation application.
2012 Caterpillar
6. Thermal Management
Introduction
The main exhaust piping routes exhaust gas from the engine to the Cat CEM. Normal
operating temperatures can reach up to 550 °C at peak torque for C4.4 through C175
engine families. Therefore, thermal protection on the surface of the main exhaust piping
may be required. Proper precaution should be taken to ensure that the Cat CEM is not
mounted in close proximity to components that may be damaged by heat.
SKIN TEMPERATURE CONSIDERATION
Enclosure Temperature Limits

Proper thermal analysis or field testing should be taken to ensure enclosure
temps don’t exceed max temp requirements for Cat CEM. Below is an example of
how exhaust flow in the form of a venture can help circulate air around the CEM.
Sensors
Figure 6.1: Tier4 Interim Venture Exhaust Flow Example for C6.6
Ventilating air should enter near the bottom of the enclosure and then flow upward
around the engine and/or Cat CEM module before exiting above the engine. Building
ventilation should be designed to bring the coolest air to the Cat CEM module. If the
engines and modules are placed in a building that has a pitched roof then ventilating air
should flow out at the peak or near the top of the gable ends. The source of the air must
be low in the room and rise across the engine and Cat CEM and other equipment. The
example below shows correct ventilation flow.
©2012 Caterpillar
Ventilation
Exhaust
Engine
Fresh Air
Figure 6.2: Enclosure Ventilation Example
Thermal Protection
The main exhaust piping routes exhaust gas from the engine to the Cat CEM. Normal
operating temperatures can reach up to 550 °C at peak torque. Therefore, thermal
protection on the surface of the main exhaust piping may be required. Proper precaution
should be taken to ensure that the after-treatment device is not mounted in close
proximity to components that may be damaged by heat. The main exhaust piping may
need to be insulated such that CEM sensors and / or wiring may be protected.
2012 Caterpillar
7. Appendices
Appendix A: See Special Instruction (REHS7129) for Assembling and

Installing a Selective Catalytic Reduction (SCR) Module for Certain
3516CHD Generator Sets
©2012 Caterpillar
CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,”
the “Power Edge” trade dress as well as corporate and product identity used
herein, are trademarks of Caterpillar and may not be used without permission.
LEBE0005-01 ©2012 Caterpillar Printed in U.S.A.

All rights reserved.

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APPLICATION AND INSTALLATION GUIDE

CAT® CLEAN EMISSIONS MODULE

DPF (Diesel Particulate Filter)

CDPF (Catalyzed Diesel Particulate Filter)

Regeneration of Particulate Filters

Cat RS (Cat Regeneration System) - Active Regeneration

DOC+SCR+AMOx System Diagram

Cat NOx Reduction System System Layout

Cat NOx Reduction System System Layout – On Engine

Cat CEM Typical Configuration

Other Installation Requirements

Crankcase Ventilation Systems

• The standard method of sampling is by the addition of a 20-centimeter sample pipe to

ATAAC Restriction, Humidity, Altitude, Exhaust Backpressure, Exhaust Shielding, and

Crankcase Ventilation Systems

Improper operation, maintenance, or repair of this product may result in

Notice: Failure to properly connect the after-treatment / regeneration device or

Pressure Air and Water

Tier 4 – Emissions Requirements

2. Cat CEM Overview

Cat Clean Emissions Module (Cat CEM) Systems

Technology Component Descriptions

Soot Collects Cells

SCR (Selective Catalytic Reduction)

3. Clean Emissions Modules

Introduction and Purpose

System Hardware Overview

Muffler DEF Mixing DOC

Schematic 3.1: System Block Diagram

CEM Application Guide

CEM Application Guide

Cat CEM Mandatory Interface Connections:

Table 3.1: Interface Connections

Secondary Air Filter

Air & DEF Filter Installation

1/2” Male 3/8” Male

Figure 3.2: Dosing system schematic with a buffer tank

Dosing System Operations

Figure 3.3: Dosing Control Cabinet

Dosing Cabinet Connection Points

Dosing Cabinet Symbols Pictograms

Figure 3.5: Example AC Power Connection to Dosing Cabinet

DEF Supply to the Dosing Cabinet with a Buffer Tank

Storage or Non-operational Condition

Lifting and Mounting

Figure 3.6: Mounting Location Dosing Cabinet

Reference 5: Mounting Considerations for additional mounting requirements.

Figure 3.7: Dosing Cabinet Mounting Clearance Requirements

Figure 3.8: Dosing Cabinet Block Diagram – EP 3516CHD/C175

Connector for Cabinet to Engine Part Number: 9X-7145

120V Power Connection

Figure 3.9: 120V AC Connection Diagram

Electrical Component temperature limits

Outlet Inlet NOx

3516CHD Electrical Component Locations

Outlet NOx Sensor

Outlet NOx Sensor

Inlet NOx Sensor

C175 Electrical Component Locations

Electric Power Exhaust Connection

Top front view of Electric Power SCR CEM for 3516CHD

Top front view of Electric Power SCR CEM for C175

Figure 3.10: Electric Power Exhaust Flanges