NHTSA ID Number: 10128904
Manufacturer Communication Number: SM1604
TSB/Document Date: 2018-02-21
Summary
New Diesel Exhaust Fluid (DEF) Tank Assemblies (Gen 5 Tri-Function Sensor): Dealer Memo to provide service related information for buses equipped with new Diesel Exhaust Fluid (DEF) tank assemblies. Blue Bird buses equipped with new (DEF) tank assemblies have a Gen 5 Tri-Function Sensor. The Gen 5 Tri-Function Sensor provides the level, concentration, and temperature of the (DEF) Diesel Exhaust Fluid in the reservoir and returns a defined CAN message for these values. The sensor and controller communicates on a ?Private? J1939 data link with the Cummins
ECM.
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Page 17 of 60
TB – 3019 Rev A
Buttress Thread / Bolt-on Adapters with Fill Port Strainer assembly
The DEF fill port strainer (140 micron gradient) is responsible for minimizing the amount
of debris entering in to the DEF tank during DEF fill / refill events. In the event of DEF
back splash during tank fill / refill (when the strainer meets the maximum limit of its dirt
holding capacity), Shaw Development has designed the fill strainer to be replaceable.
Fill port with strainer option is not available for 5 gallon portrait tank configuration. Also,
fill port with strainer option is not available for 10 gallon cube tank with buttress thread
fill neck design. For instructions on replacing the fill port strainer, refer to Section 3.4
Buttress Threaded Adapter with Strainer
Bolt-On Adapter with Strainer
DEF Inlet Adapter with Strainer
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
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Page 18 of 60
TB – 3019 Rev A
Remote Fill Design
The remote fill design consists of 3 main components: (1) spill pan, (2) outer
hose, & (3) inner hose. The images below identify each of these components.
Image of DEF Tank Assembly w/ Remote
Fill Adapter Design
Interior of DEF Tank Assembly w/ Remote
Fill Adapter Design
2
1
3
The 1” (2.54 cm) inner hose is installed inside the 2” (5.08 cm) outer hose
and directs the flow of DEF during refilling. As shown in the image above, the
inner hose extends into the tank interior. This extension is critical in preventing
the fluid from overfilling the tank during refilling. Any alterations to this extension
are prohibited. The 2” outer hose provides a vent path for the tank assembly
during refilling and normal vehicle operation. The spill pan assembly is the refill
inlet of the remote fill assembly. The outlet of the spill pan adapter is designed
with surfaces for the inner and outer hoses to clamp on to. The spill pan is also
capable of rotating +/- 20° for flexibility during installation (refer to image below
for visual aid). This enables the remote fill design to adapt to a variety of
configurations.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
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Page 19 of 60
TB – 3019 Rev A
Below image shows clamping of the hoses (Both inner and outer) to the outlet of
the spill pan adapter.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
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Page 20 of 60
TB – 3019 Rev A
Bolt on adapter design for remote fill:
See the images below for the Bolt on style remote fill option. This does not include a
spill pan.
Note: The remote fill port must be properly supported to prevent damage to the DEF
tank.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
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Page 21 of 60
TB – 3019 Rev A
DEF Tank Designs
The standard DEF tanks are available in Small, Medium, and Large sizes. Each tank
size comes in Landscape and Portrait orientations. Small, Medium, and Large tanks
roughly hold 5 gallons (18.9 L), 10 gallons (37.9 L), and 15 gallons (56.8 L) of DEF
respectively. There is also a 10 gallon (37.9 L) Cube and a 25 gallon (94.6 L) tank
designs available. Refer to the chart below for reference. The tank fill neck comes in
hose barb, buttress thread and bolt on designs.
Tank ID
DR501
DR502
DR503 DR504 DR505
DR506
DR507 DR525
Tank
Description
5
Gallon
LS
5
Gallon
PT
10 Gal.
LS
15 Gal
PT
10 Gal
Cube
10 Gal
PT
15 Gal
LS
25 Gal
Tank Designs
Landscape [LS]
Portrait [PT]
Cube
25 Gal
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
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Page 22 of 60
TB – 3019 Rev A
DEF Tank Fill neck Designs:
DEF tank designs are available in hose barb, buttress thread and bolt on fill neck styles
respectively. 25 gallon DEF tank is only available in Bolt on fill neck design.
Hose Barb
Buttress Thread
Bolt On
1.2.4 DEF DRAIN PLUG
The DEF drain plug enables users to drain the tank. Some reasons for
draining the tank include DEF contamination, interior cleaning of the tank, and
overfill. The DEF drain plug is a replaceable item. For directions on replacing the
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
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Page 23 of 60
TB – 3019 Rev A
DEF drain plug or draining the DEF tank assembly via the drain plug, please
refer to Section 2.3.
It is highly recommended that DEF drained from the tank be discarded and not
reused to prevent contamination.
It is highly recommended not to add any new features to the drain port or use
non-Shaw components other than the Shaw Drain Plug.
Image of DEF Drain Plug location
2.0
MAINTENANCE
2.1
CLEANING
Scheduled cleaning of the DEF tank assembly is allowable in preventing
DEF contamination and prolonging the life of the DEF tank assembly. The
following section provides important information on cleaning the DEF tank
assembly. Ensure that these steps are performed correctly in order to avoid
contamination and performance related issues.
2.1.1 CLEANING THE EXTERIOR OF THE TANK ASSEMBLY
1. Verify the area around the refill inlet is clean enough to remove the DEF cap
without debris falling into the inlet of the adapter. If so, remove the cap and
inspect the underside for cleanliness.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
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Page 24 of 60
TB – 3019 Rev A
a. If the underside of the cap appears dirty, refer to Section 2.1.3 for
cleaning. Once cleaned, replace the cap firmly on the DEF adapter.
b. If the underside of the cap does not appear dirty, continue to step
2.
2. Verify the DEF cap is securely fastened to the adapter. Inspect the rest of the
tank assembly for any noticeable leak paths where water can penetrate.
a. If leak paths are found, contact your Shaw DEF tank provider and
inform them of the defect.
b. If no defects are found continue to step #3.
3. Begin rinsing the tank assembly using water (and soap if needed). With the
exception of the cap/adapter interface, the tank assembly can withstand
pressures up to 2000 psi. Do not apply direct pressure to the Cap/Adapter
interface. Ensure all debris (i.e. dirt, fuel, oil, hydraulic fluid, etc.) is
completely rinsed off and pay close attention to areas near the MFHU and
the top side of the cap adapter assembly.
2.1.2 CLEANING THE INTERIOR OF THE TANK ASSEMBLY
The interior of the tank assembly may need to be cleaned in the instance of
tank contamination. Tank contamination is the intrusion of liquid and particles
that do not make up 32.5% concentrated DEF. If left untreated, contamination
can cause clogs along the DEF hose lines and/or damage components of the
SCR system. The following instructions describe the proper steps for cleaning
the interior of the Shaw DEF tank assembly.
1. Drain the tank. For instruction on removing and installing the DEF drain plug
refer to Section 2.3. Properly discard the contaminated DEF.
DO NOT attempt to filter or otherwise reuse the contaminated DEF.
2. Once the tank has been completely drained, remove the Multifunction Head
Unit from the tank. Refer to Section 3.5A for instructions on removing the
MFHU.
3. Once the MFHU is removed, inspect the debris saturation of the DEF suction
filter to determine if the filter needs to be replaced.
a. If the filter is damaged or dirty, replace the filter. Refer to Section 3.6
for instructions for replacing the DEF suction filter.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
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Page 25 of 60
TB – 3019 Rev A
b. If the filter does not appear to have any discrepancies, continue to
step 4.
4. Begin to rinse out the interior of the DEF tank using an ordinary hose or
pressure washer. Attempt to rinse all the debris out through the drain port of
the tank. Detergent may be used to clean off the tank. Ensure that all the
areas where debris can potentially enter the tank is cleaned off, to include:
bore seal, DEF cap, interior and exterior of the adapter assembly, and the
drain port.
a. If the DEF cap needs to be cleaned, refer to Section 2.1.3 for
instruction on cleaning the DEF cap.
5. Rinse off the MFHU from top to bottom with low pressure, ensuring that all
the debris has been removed.
6. Reinstall the MFHU per Section 3.5B.
7. Reinstall the drain plug per Section 2.3 to fill the tank and verify no leakage
occurs.
2.1.3 CLEANING THE DEF CAP
Periodic maintenance may be required as crystallized DEF can build up on
the seal surface and under side of the DEF cap. If left untreated, contaminants
may accumulate. This accumulation may compromise the main seal of the cap
and eventually infiltrate the tank interior. As mentioned in Section 2.1, tank
contamination can impact the overall performance of the entire vehicle SCR
system. Cleaning the cap will help in preventing DEF contamination. The
following procedure provides instructions for cleaning the DEF cap.
1. Wipe off the cap and adapter to prevent any debris from entering through the
inlet.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
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Page 26 of 60
TB – 3019 Rev A
2. Grip the cap and turn counter clockwise unit the cap stops turning.
3. Pull the cap off of the adapter (If the cap has a lanyard, it will still be attached
to the DEF tank).
Lanyard Only Caps: Take the lanyard attached to the Lanyard Tab of the cap
and slide it over the tab so that the cap can be removed. See two photographs
below.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
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Page 27 of 60
TB – 3019 Rev A
Lanyard Tab
Lanyard
4. Place the cap in a pan of water filled such that the level of the water is half
way between the bottom of the blue base and the surface where the words
“DEF ONLY” resides. Allow the cap to soak for approximately five (5)
minutes. See the photograph below.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
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Page 28 of 60
TB – 3019 Rev A
Ensure the cap does not become completely immersed in water as this may
affect the venting capabilities of the cap.
5. Shake cap so that any remaining water within the cap assembly is drained.
6. If any DEF crystals or dirt remain on the seal, wipe the seal with a damp
cloth.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 29 of 60
TB – 3019 Rev A
7. Wipe down the tank adapter with a damp cloth. Replace the cap onto the
adapter.
8. Turn the cleaned cap clockwise until it stops.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
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Page 30 of 60
TB – 3019 Rev A
Lanyard Only Caps: To re-attach the lanyard, take the small opening of the
lanyard and slide it over the Lanyard Tab of the cap so that it fits into the groove.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 31 of 60
TB – 3019 Rev A
2.2
FILLING THE DEF TANK
When filling the DEF tank assembly, ensure the filling process or
procedure is in compliance with following cautionary notes provided below. If
further clarification for handling, storing, and transporting DEF is required, please
refer to ISO-22241. It is critical that vehicle operators safely and properly execute
refilling practice while adhering to these notes to avoid potential performance
related issues of the Shaw DEF system and SCR system.
NOTE: The Tri-Function Sensor is expected to report a default value (slow
response times) particularly with respect to the DEF Concentration reading
during the initial filling of DEF tank. This is typically due to air bubbles sticking to
the surfaces of the DEF concentration measurement window.
DO NOT put DEF in the fuel tank, or any fluid other than DEF in the DEF tank.
This will cause engine damage and/or damage to the SCR unit.
Use only API (American Petroleum Institute) or DIN certified Diesel Exhaust Fluid
(per ISO-22241). Improper fluids or contaminated DEF may lead to high Nitrogen
Oxide emissions and damage the SCR system including the DEF assembly. If
the DEF tank is considered contaminated refer to Section 2.1.2. Contaminated
SCR systems should be serviced at an authorized dealer.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 32 of 60
TB – 3019 Rev A
DO NOT use DEF beyond its expiration date or if it has been stored in conditions
over 86°F (30°C) for extended periods of time. This temperature exposure will
cause degradation to the DEF.
DO NOT attempt to top off the tank. Overfilling the tank can inhibit the tank’s
overall performance and potentially damage the assembly due to expansion of
the fluid.
Ensure the cap and adapter are clean prior to cap removal and filling; this helps
prevent tank contamination. Clean off any DEF that may have spilled onto the
tank to maintain cleanliness of the tank assembly.
2.2.1 STATION OR BULK FILLING VIA PUMP AND NOZZLE
Nozzle filling is the preferred method of refilling the DEF tank assembly.
All approved DEF fill stations should utilize magnetic actuating DEF nozzles
designed per ISO-22241. Shaw Development has designed the Shaw DEF
adapters in accordance with ISO-22241 to compliment the functionality of DEF
nozzles. Furthermore, Shaw DEF adapters are designed to prevent overfilling
when using the magnetic actuating DEF nozzle. The procedure below describes
how to fill the DEF tank with an ISO-22241 approved magnetic actuating DEF
nozzle.
Nozzle filling the DEF tank Assembly:
1. Prior to removing the DEF cap, inspect the outside surface of the cap and
surrounding areas for any signs of debris that may fall into the tank when the
cap is removed.
a. If debris has accumulated on the DEF tank assembly, clean it off before
removing the cap. Refer to section 2.1.1 for instructions on cleaning the
DEF tank assembly.
b. If no debris is found, continue to step 2.
2. Inspect the cleanliness of the underside of the DEF cap.
a. If the cap appears dirty, try to clean it off. Refer to Section 2.1.3 for
instruction on cleaning the DEF cap. Once cleaned, replace the cap firmly
on the DEF adapter.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 33 of 60
TB – 3019 Rev A
b. If the cap does not appear dirty, refer to step 3
3. Set the cap aside unless the cap is attached to a lanyard. If the cap is not
attached to a lanyard, ensure that it is placed in a location where it is not
vulnerable to debris exposure.
4. Insert the nozzle securely into the inlet adapter.
5. Depress the nozzle handle, enabling DEF flow into the tank assembly.
6. Continue DEF flow until the nozzle automatically shuts off.
DO NOT repeatedly depress the nozzle handle after the nozzle’s initial automatic
shut-off as this might cause the DEF tank to overfill.
7. Remove the nozzle and replace the cap onto the adapter.
2.2.2 BOTTLE FILLING
Bottle filling is the least preferred method for refilling the DEF tank. Bottle
filling is considered a high risk refilling method for a variety of reason. Some of
these reasons include:
Increased potential for overfilling the tank assembly.
Increased potential for physical contact with the fluid.
Increased potential for spillage.
It is highly recommended to fill the DEF tank assembly using an authorized
ISO-22241 approved DEF nozzle. The following procedure will provide
instructions for bottle filling the DEF tank assembly.
NOTE: Bottle filling should only be conducted with DEF containers that have been
approved by and have been stored in accordance with ISO-22241-3.
Additionally, ensure the container(s) are not contaminated with insoluble
particles in the fluid (i.e. insects or dirt), or have been knowingly stored
continuously at temperatures greater than 30°C (86° F) for more than 18
months.
Bottle filling the DEF tank assembly requires the use of Personal Protective
Equipment to include but not limited to goggles and gloves.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 34 of 60
TB – 3019 Rev A
Bottle Filling the DEF tank assembly:
1. Take the cap off of the Diesel Exhaust Fluid bottle. Twist the spout onto the
opening until it becomes locked into place (if applicable).
2. Prior to removing the DEF cap, inspect the outside surface of the cap and
adapter for any signs of debris that may fall into the tank when the cap is
removed.
a. If debris has accumulated on the DEF tank assembly, clean it off before
removing the cap. Refer to section 2.1.1 for instructions on cleaning the
DEF tank assembly.
b. If no debris is found, continue to step 3.
3. Insert the outlet end of the spout into the inlet of the adapter until the end of
the spout is seated completely in the fill port.
4. If attempting to top off the tank, fill the tank slowly while frequently checking
for the DEF fluid line to rise to the bottom of the adapter inlet. When checking
the fluid line in the tank, bring the DEF bottle to level and lower the bottle to
where the remaining DEF in the spout returns to the container. Then remove
the spout from the adapter inlet by hand and look for the fluid line inside the
tank adapter inlet. If the fluid line is not at the desired level, replace the spout
and continue refilling.
NOTE: DEF will not completely fill the spout of the bottle while flowing; air will also be
trapped inside.
5. When the tank has been filled with DEF fluid, place the DEF cap back onto
the tank.
6. Uninstall the spout from the container and place the cap back on the bottle.
7. If the container still has DEF inside, store it for later use, otherwise, dispose
of the container and nozzle in the correct manner.
8. Clean any spilled DEF immediately with fresh water to prevent corrosion to
the system or vehicle components.
2.3
DRAINING THE DEF TANK ASSEMBLY
The DEF tank assembly is capable of quick draining via the removal of the
DEF drain plug. The following procedure describes how to safely remove the
DEF drain plug from a filled DEF tank assembly.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 35 of 60
TB – 3019 Rev A
Refer to vehicles service manual for safety regulations and recommendations
when servicing the vehicle.
Draining of the DEF tank needs to be conducted in a well-ventilated area, as the
ammonia vapors may cause irritation.
NOTE: It is highly recommended that the volume of DEF drained from the DEF tank be
properly discarded to avoid potential contamination of the DEF tank assembly.
Refer to your Standard operating Procedure or ISO-22241 for proper disposal
of DEF. Do not dispose of DEF down a drain as this may cause clogging If the
DEF is expected to be reused or stored for later use, the fluid should be
contained and stored in compliance with ISO-22241. Failure to comply may
result in degradation of the DEF.
DEF drain procedure via removal of the DEF drain plug:
1. Make sure the vehicle is off.
2. Position an auxiliary reservoir directly beneath the drain plug outlet.
Ensure that the opening of the auxiliary reservoir is wide enough for the
DEF to flow into with spillage, and the reservoir is large enough to carry
the volume of DEF in the DEF tank without spillage.
3. Remove the DEF cap and set aside on a clean surface.
4. Using the ¼” Allen Wrench, unscrew the drain plug from the DEF tank by
turning in the counterclockwise direction. Place drain plug in a location
that is free from debris.
5. Allow tank to drain to desired level.
NOTICE OF CONFIDENTIAL INFORMATION AND PROPRIETARY RIGHTS
THIS DOCUMENT MAY NOT BE DISCLOSED TO OTHERS EXCEPT BY EXPRESS WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. THIS DOCUMENT
CONTAINS CONFIDENTIAL COMMERCIAL AND TECHNICAL DATA, CONCEPTS AND OTHER INFORMATION, ALL OF WHICH ARE PROPRIETARY AND OF
ECONOMIC VALUE TO SHAW DEVELOPMENT, LLC. THIS DOCUMENT MAY NOT BE USED FOR MANUFACTURE OR PROCESSING USES ABSENT EXPRESS
WRITTEN PERMISSION OF SHAW DEVELOPMENT, LLC. ANY USE OTHER THAN CONFIDENTIAL EVALUATION IS STRICTLY PROHIBITED WITHOUT THE PRIOR
WRITTEN CONSENT OF SHAW DEVELOPMENT, LLC. © 2015 Shaw Development, LLC. All rights reserved.
Page 36 of 60
TB – 3019 Rev A
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TSB/Document ID: SM1604
Replacement Service Bulletin Number:
MFR Communication Date: 2016-07-05
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Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, DIESEL
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