Diesel Exhaust Fluid.

JCB Guide
SERVICE
 Diesel Exhaust Fluid JCB Guide
SERVICE

Diesel Exhaust Fluid what it is and what it does

Diesel Exhaust Fluid (DEF) is a highly purified, colourless liquid containing
demineralised water (67.5%) and Urea (32.5%). DEF is specified under ISO 22241
and is marketed under various names such as AdBlue, ARLA 32 or AUS 32.
DEF is used within Selective Catalytic Reduction (SCR) systems on diesel engines
to reduce harmful exhaust gas emissions known as NOx.
How SCR works
NOx Sensor
(upstream)
Dosing Module
Engine exhaust
gas
Mixer

NOx Sensor
(downstream)
Temp. Sensor

SCR Catalyst

Typical JCB Tier 4 Final engine
DEF is injected into the mixer before the SCR catalyst. When the DEF is injected
into the exhaust stream it turns into ammonia and water, this ammonia enters the
catalyst and reacts with the NOx molecules to form nitrogen and water. Naturally
occurring and harmless, they are then released into the atmosphere.
Why DEF and SCR are required
DEF and SCR are required to satisfy the more stringent emissions legislation
coming into force in 2015, namely:
European Union (EU) Stage IV in Europe and
Environmental Protection Agency (EPA) Tier 4 Final in the USA
JCB, are introducing SCR systems in all engines above 55kw (75hp). SCR
requires DEF to ensure machines meet the significantly reduced levels of
exhaust NOx, particulate matter and hydrocarbons required by this legislation.
The chart below details the Tier 4 Final/Stage IV reduced emissions levels
required from off-highway diesel engines.

Tier 3 (75-130kW) Tier 4 Interim (56-130kW) Tier 4 Final (56-130kW)

0.35
0.30
T3 baseline
0.25
PM (g/kWhr)

NOx and particle allowance at Tier 3

0.20
T4f PM reduction 93% T4i PM reduction 80%
0.15 T4i NOx
T4f NOx reduction 90% reduction 15%
0.10
0.05
NOx and particle NOx and particle allowance at Tier 4 Interim
allowance at Tier 4 Final
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5
NOx (g/kWhr)
Emissions legislation for Tier 3, Tier 4 Interim and Tier 4 Final

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DEF has been used for a number of years in higher powered tractors,
off road vehicles, on highway trucks and some large diesel engine cars.
DEF sensible precautions
DEF is not a hazardous substance, however to prevent the possibility
of allergic reaction:
Wear gloves and eye protection when using it
Do not drink
Do not inhale
Avoid all contact with skin and eyes
If irritation occurs, or if you are in any doubt whatsoever, seek medical
attention immediately. Consult the material safety datasheet for complete
medical advice.
Recognising the DEF tank
You can recognise your DEF tank by its blue cap or an AdBlue label
DEF has a totally separate tank of its own
Preventing cross contamination of diesel and DEF
The opening for your DEF tank is narrower than the opening for a diesel
tank, so you should not be able to put diesel in the wrong tank (as the
Typical DEF tank arrangement nozzle does not fit)
The DEF cap on every JCB machine is clearly marked with AdBlue,
DEF and the ISO symbol in white lettering
The diesel cap is also clearly marked in white lettering
There are warning decals next to the DEF filling point
Every JCB DEF cap is lockable with a special key with a blue key fob, which
can be given to a site supervisor or other person of responsibility
There is a special magnet fitted in the DEF filler neck which will allow some
DEF electric dispensing pumps to start if it has the matching ISO feature, as
all forecourt dispensing systems have
DEF is 67.5% de-mineralised water and, if poured into the diesel tank, can
severely damage the fuel injection pump and injectors. Consult your local
JCB dealer for detailed advice on draining and flushing the diesel tank before
DEF tank key
starting the engine

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Preventing contamination of the DEF tank

In order to prevent damage to the SCR system, DEF used must be
compliant to the ISO 22241-1 standard with the correct urea concentration
ISO 22241-1 DEF is available from all JCB dealers
Every machine equipped with a JCB SCR system is fitted with a quality
sensor in the DEF tank to help prevent problems caused by cross
contamination with other fluids
DEF needs to be kept free from dirt and other particle contaminants at all
times to prevent damage to the SCR system. There is a mesh strainer fitted
in the JCB DEF filler neck
DEF needs to be kept free from liquid contaminants such as diesel, oil,
antifreeze, screenwash and other fluids at all times.
Digital DEF concentration
measuring device (Refractometer).
If contamination occurs do not start the engine. Please contact your local
JCB dealer immediately so they can correctly flush the system to avoid an
JCB part number: 333/H5662
expensive repair
A range of special tools and fluid analysis services are available at your local
JCB dealer to check DEF quality via simple hydrocarbon test paper strips, or
a more comprehensive laboratory service. Digital and optical concentration
measuring devices are also available
If any cross contamination is detected the customer will be liable for any
further diagnosis or repairs to the SCR system
What to do if you spill DEF
A small DEF spill can be diluted with water. It is best to mop up the spillage
and avoid flushing it down a drain or waterway
In case of a large spill, try to prevent the spillage from entering drains or
waterways. Contain the spill with sand, earth or your spill kit and dispose
of it properly
The surface on which you spill DEF may become slippery. Make sure
that you clean up the spill as quickly as possible to prevent slips and falls
If a spill occurs on the machine, wash away with water as white crystals will
form and these will eventually become corrosive to paintwork and, in turn,
metal work
DEF should never be spilled onto electrical connectors as it will destroy
terminals quickly. It can also travel easily by capillary action between the
insulation and copper wires in harnesses

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DEF temperature sensitivity

DEF will freeze at -11C (12.2F)
The DEF system on your machine will have the required expansion room
built into its design
All the DEF lines have electrical trace heating. The DEF supply module is also
heated internally. The DEF storage tank on the machine will be heated from
the engine cooling system automatically
DEF can be stored for up to 18 months in a sealed container and must be
kept between -6C (21.2F) and 25C (77.0F) in a shaded area, out of
direct sunlight and UV radiation
Running out of DEF damage implications
The engine or SCR will not be damaged when you run out of DEF.
To protect itself the machine will go into limp home mode. Refill the
DEF tank to restore performance
It is recommended that the DEF tank is not continually run down to the
minimum, as this may drag contamination into the system
The engine will not shut down if you run out of DEF, however it will:
Give the driver a warning when the remaining level reaches 15% full, which if
continually ignored will progressively automatically reduce torque and speed to
tick over, preventing effective working activity
Allow only enough power for limp home mode
Restore power when the DEF tank is refilled
Attempting to operate the machine without DEF is a Federal Offence in the
United States of America, operators may be prosecuted under the Clean Air Act
DEF is required for European Union type approval. Operators attempting to
operate the machine without DEF may be liable for civil and criminal prosecution

JCB Dashboard DEF level symbol (full tank)

STOP

Progressive dash warnings

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Key Dos for machines with DEF

Before engine start up, locate and identify both separate diesel and
DEF tanks, they do NOT share the same tank. Do NOT allow cross
contamination between diesel and DEF
Act on machine warnings that DEF is running low
Ensure that there is sufficient DEF in the machine at all times
Use only high quality DEF to ISO 22241-1 from a reputable source
Keep all DEF, tanks, tank necks, drums and dispensing equipment clean
to prevent contamination
When the engine is switched off, there is a small pump in the DEF system
which purges the line from the supply module to the dosing injector.
DEF supply module and filter Do not remove the battery isolator for 30 seconds so this operation can
be completed and the system shut down correctly
If the machine is to be stored for an extended period, ensure the DEF tank
is completely filled to prevent water evaporation and crystallisation. Consult
your local JCB dealer for system re-commissioning
Crystallised DEF in lines and other components can be removed with the
use of warm water
The use of oils, grease, copper slip and other such products can cause severe
damage to the SCR catalyst. Use only the correct recommended products
The only additional regular service schedule item on a machine fitted with
the JCB SCR system is changing the DEF supply module filter, which needs
to be carried out at 1,000 hours or 500 hours under arduous, dusty working
conditions
Every JCB Tier 4 Final machine fitted with a SCR system should be fitted
only with the correct CJ grade oil available from all JCB dealers. Failure to
do this can result in permanent damage to the SCR catalyst in such a way
that it cannot be recovered. On the Ecomax engine, the colour of the engine
JCB Ecomax engine oil cap oil filler caps has been changed from black to yellow to alert the operator
Key Donts for machines with DEF
Dont allow contamination of your DEF by dirt or fluid as it will damage the
SCR system
Dont mix DEF with your diesel; it is NOT a fuel additive
Dont put DEF in your diesel tank if you do, do not start the engine,
call your JCB dealer immediately
Do not add chemicals to your DEF to prevent freezing
Do not dilute DEF with water or any other fluids or the machine may stop
or be permanently damaged

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Obtaining DEF
JCB supply DEF through its dealers under the AdBlue trade name. We have
a number of pack size solutions, all supplied in industry standard containers to
meet all requirements.
Pack size Part number
10L AdBlue can 4007/1009
18L AdBlue drum (includes built-in dispensing tube) 4007/1008
200L AdBlue barrel 4007/1003
1,000L IBC Direct supply
2,900L tank complete with telemetry Direct supply

Storing DEF
Always use polyethylene, polypropylene, stainless steel or plastic containers
for storing DEF, as DEF can be corrosive to most metals (eg steel, copper,
and aluminium). This applies to any funnels, jugs, pipes, pumps and other
handling equipment
Avoid decanting wherever possible to prevent contamination from dirt or
trace amounts of metals that can occur when metal containers are used
Ensure DEF is stored out of strong direct sunlight
Always ensure any caps on DEF storage containers are screwed tight to
prevent evaporation and crystallisation
DEF and warranty
JCB warranty will not cover damage or failure of SCR systems due to the
use of contaminated DEF

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Dispensing equipment
JCB Service has a range of dispensing equipment to meet all pack sizes and
depot/customer requirements:

18L AdBlue manual pump

990/89707

200L AdBlue manual lever pump

990/89701

IBC AdBlue electric pump

990/89703
Complete with standard nozzle

IBC AdBlue electric pump

990/89702
Complete with magnetic mis filling nozzle

IBC AdBlue gravity feed

connector and nozzle
990/89704

2,900L AdBlue tank

complete with telemetry
Details on request

SERVICE JCB Service, World Parts Centre, Waterloo Park,

Beamhurst, Uttoxeter, ST14 5PA

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