General Information

Diesel Exhaust Fluid (DEF) is a liquid that is injected into the exhaust system of engines
equipped with Selective Catalytic Reduction (SCR) systems. SCR reduces emissions of
nitrogen oxides (NOx) in diesel engine exhaust.

Diesel Exhaust Fluid (DEF) is available in many brands, including those brands that
carry the AdBlue or API certification. DEF is also generically referred to as urea.

In engines equipped with SCR emissions reduction system, DEF is injected in controlled
amounts into the engine exhaust stream. At the elevated exhaust temperature, urea in
DEF is converted to ammonia. The ammonia chemically reacts with NOx in diesel
exhaust in the presence of the SCR catalyst. The reaction converts NOx into harmless
nitrogen (N2) gas and water vapor (H2O).

Note: Follow all applicable industry standards and all applicable governmental,

environmental, safety guidelines, practices, regulations, and mandates.

Note: These general recommendations and guidelines concerning maintenance and

care of DEF and DEF storage systems are not intended to be all inclusive. Discuss
proper DEF safety, health, handling, and maintenance practices with your DEF supplier.
Use of these general recommendations and guidelines does not lessen the
responsibility of the engine owner and/or DEF supplier to follow all industry standard
practices for DEF storage and for DEF handling.

DEF Recommendations for SCR Aftertreatment Systems

For use in Cat engines, DEF must meet all the requirements defined by the "ISO 22241-
1" standard.

The caps of DEF tanks are typically blue as recommended by the "ISO 22241-4"
Standard. Fill DEF only in clearly marked DEF tanks that have the blue cap.

Caterpillar recommends the use of DEF available through the Cat parts ordering system
for use in Cat engines equipped with SCR systems. Refer to Table 1 for part number
information:

Table 1
Cat Part Number
Container Size 
(32.5% Urea) 
350-8733  2.5 gal bottle 
350-8734  1000-L tote 
In North America, commercial DEF that is API approved and meets all the requirements
defined in "ISO 22241-1" may be used in Cat engines that are equipped with SCR
systems.

Outside of North America, commercial DEF that meets all requirements defined in "ISO
22241-1" may be used in Cat engines that are equipped with SCR systems.

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

NOTICE
Cat does not warrant the quality or performance of non-
Cat fluids.

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

DEF is a solution of solid urea that is dissolved in deionized water to produce a final
concentration of 32.5% urea. Most SCR systems are designed to operate only on DEF
concentration of 32.5 percent. DEF solution of 32.5% urea has the lowest attainable
freeze point of −11.5° C (11.3° F). DEF concentrations that are higher or lower than
32.5% have higher freeze points. DEF dosing systems and "ISO 22241-1" specifications
are designed for a solution that is approximately 32.5%.

Cat offers refractometers that can be used to measure DEF concentration. Refer to
Table 2 for the part numbers. Follow the instructions provided with the instruments.

Table 2
Cat DEF Refractometers 
360- Digital display, easy to use, and multifunctional
Refractometer Part 0774  (DEF, coolant, battery fluid, and more) 
Numbers  431- Analog, specific to DEF, and requires a multi-step
7087 test procedure 

DEF Guidelines
DEF solution is typically colorless and clear. Changes to color or clarity are indicators of
quality issues. Quality of DEF can degrade when stored and handled inappropriately or
if DEF is not protected from contamination. Details are provided below.

If quality issues are suspected, testing of DEF should focus on urea percentage,
alkalinity as NH3 and biuret content. DEF that does not pass all these tests or that is no
longer clear should not be used.

Note: Caterpillar strongly recommends that customers purchase the pre-mixed DEF

urea solution from a reputable supplier. The DEF must satisfy all the specifications of
quality given in this chapter of this Special Publication. Urea solutions that are not made
of urea and water of the appropriate quality and cleanliness may damage the SCR
system. Poor or questionable quality DEF can lead to additional repair and maintenance
costs to the customer. Cat warranties do not cover failures caused by or related to use
of out of specification urea solutions in Tier 4 Stage IIIB MLIT Step 4 products equipped
with SCR systems.

Materials compatibility
DEF is corrosive. Due to the corrosion caused, DEF must be stored in tanks
constructed of approved materials. Recommended storage materials:

Stainless Steels:

 304 (S30400)
 304L (S30403)
 316 (S31600)
 316L (S31603)

Alloys and metals:

 Chromium Nickel (CrNi)

 Chromium Nickel Molybdenum (CrNiMo)
 Titanium

Non-metallic materials:

 Polyethylene
 Polypropylene
 Polyisobutylene
 Teflon (PFA)
 Polyfluoroethylene (PFE)
 Polyvinylidene fluoride (PVDF)
 Polytetrafluoroethylene (PTFE)
Materials NOT compatible with DEF solutions include aluminum, copper, copper alloys,
magnesium, zinc, nickel coatings, silver, and carbon steel and solders containing any of
the above. Unexpected reactions may occur if DEF solutions come in contact with any
non-compatible material or unknown materials.

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

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

Handling
Follow all local regulations covering transport and handling. DEF transport temperature
is recommended to be −5° C (23° F) to 25° C (77° F). All transfer equipment and
intermediate containers should be used exclusively for DEF. Containers should not be
reused for any other fluids. Ensure that transfer equipment is made from DEF-
compatible materials. Recommended material for hoses and other non-metallic transfer
equipment include:

 Nitrile Rubber (NBR)

 Fluoroelastomer (FKM)
 Ethylene Propylene Diene Monomer(EPDM)

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

Cleanliness
Contaminants can degrade the quality and life of DEF. The recommended DEF
cleanliness target as dispensed into the machine or engine fill tank is ISO 18/16/13.
Refer to the Contamination Control Chapter in this Special Publication.

Filtering DEF is recommended when dispensed into the DEF tank to achieve the
recommended cleanliness targets. DEF filters should be compatible with DEF and
should be used exclusively with DEF. Check with the filter supplier to confirm
compatibility with DEF before using. Mesh type filters using compatible metals, such as
stainless steel, can be used. Paper (cellulose) media and some synthetic filter media
are not recommended because of degradation during use. The filter size must be
appropriate for the DEF pump design, flow rate, expected pressures and required filter
life. Refer to Table 3 below for filtration requirements for Cat engines.

For large machine engines including 3500 series and C175 engine models, filtration of
DEF as it is dispensed from bulk tank is recommended to support the durability
designed into the SCR system. Filters should be located between the bulk DEF tank
and the ground level DEF receiver nozzle.

Note that Cat Diesel Exhaust Fluid Filter group 491-6779, 40 microns efficiency and
Beta value 75 can be used to filter DEF when applicable. Refer to your local Cat dealer
for availability.

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

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

Table 3
DEF Filtration Requirements For Bulk Tanks in Specific Applications 
DEF System  Filter Requirements    Filter location 
(1)

All Cat engines except those

given below in this Table. 
Airless 3500 series and C175 Recommended: ≤ 5 microns (µm), Inlet to DEF Pump
engine models Machine Beta value ≥ 1000 Required: ≤ 10 Electronic Tank
engines (Fast or conventional microns (µm), Beta value ≥ 1000  Unit (PETU) 
fill) 
Airless Marine applications 
Air Assisted, Marine
applications 
≤ 40 microns (µm), Beta value ≥ Inlet to DEF
Air Assisted, Locomotive and
1000  Dosing Cabinet 
Electric Power Generation
applications 
Refer to Caterpillar publication PELJ0133, “Filters, Use of Micron Ratings in the Filter Industry” for
(1)

clarification of Beta values and filter efficiency

Stability
DEF fluid is stable when stored and handled properly. The quality of DEF rapidly
degrades when stored at high temperatures. The ideal storage temperature for DEF is
between −9° C (15.8° F) and 25° C (77° F). DEF that is stored above 35° C (95° F) for
longer than 1 month must be tested before use. Testing should evaluate Urea
Percentage, Alkalinity as NH3 and Biuret content.

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

Table 4
Storage Temperature  Expected DEF Life 
Below 25° C (77° F)  18 months 
25° C (77° F) to 30° C (86°
12 months 
F) 
30° C (86° F) to 35° C (95°
6 months 
F) 
Above 35° C (95° F)  test quality before use 

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

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

General Characteristics of DEF

For detailed information on the requirements and characteristics of DEF, refer "ISO
22241". For a quick reference, typical characteristics of DEF are given in Table 5.

Table 5
Characteristics for Urea Solutions 
Property  Unit  DEF 32.5 percent 
Urea content    32.5 percent   
(1)

Alkalinity as NH3  Percent  0.2 

Density at 20° C (68° F)  g/L  1.087 - 1.093   
(2)

Refractive Index at 25° C (77°

  1.381 - 1.384   
(3)

F) 
Biuret  Percent  0.3 max 
Aldehydes  mg/kg  5 max 
Insoluble Matter  mg/kg  20 max 
Aluminum  mg/kg  0.5 max 
Calcium  mg/kg  0.5 max 
Chromium  mg/kg  0.2 max 
Copper  mg/kg  0.2 max 
Iron  mg/kg  0.5 max 
Magnesium  mg/kg  0.5 max 
Nickel  mg/kg  0.2 max 
Phosphate (PO4)  mg/kg  0.5 max 
Potassium  mg/kg  0.5 max 
Sodium  mg/kg  0.5 max 
Zinc  mg/kg  0.2 max 
Acceptable range is 31.8 - 33.2 percent
(1)
 Target value is 1.090 g/L
(2)

Target value is 1.382

(3)

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