SFN-20250828A KUS DEF TANK Maintenance Instructions

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TICO Document #: SFN-20250828A

Description of Procedure: KUS DEF TANK Maintenance Instructions

Instructions:

  1. Park vehicle on a flat surface, apply parking brake and chock wheels. Perform the lock-out tag-out procedure.

Functions of Urea Tank Assembly

NO.

DESCRIPTION

MAIN FUNCTION

1

Air Vent

Balancing air pressure inside and outside the tank to ensure no urea refilling failures, to ensure the work of the urea tank.

2

Sensor

Urea suction for supply to the system in a certain amount to keep it running in accordance with the indication of SCR system, continuous detection of urea solutions volume and temperature in the tank.

3

Tank cap

Sealing urea filling port

4

Magnetic filler port

Cooperate with filling gun to realize automatic filling and gun jumping

5

Filter

Filtering urea impurities

6

Tank body

Urea storage

7

Drain port

Clear up urea residuals inside the tank, avoid the impurities cumulated at the bottom of the tank, mainly used in tank cleaning process.

 

Comments of DEF Refilling Operations

  • DEF FLUID

    DEF tank can only be refilled with DEF solution according to the ISO-22241 standard.

  • DEF NOZZLE USE

    Filling neck of DEF tank has a magnetic induction device. When the DEF nozzle is placed into the filling neck, the magnet system will allow DEF to be dispensed. When the tank has reached its rated volume, the nozzle will shut off automatically to avoid excessive filling.

  • MANUAL FUNNEL FILLING

    The DEF tank can also be filled manually. Put the funnel on filling neck, then pour the DEF into the tank through the funnel. When using this method be extra careful with the amount of DEF being dispensed into the tank to avoid overfilling, as there is no automatic shut off valve when the tank is full.

Maintenance frequency of Urea Tank Assembly

NO.

Parts

Frequency

Maintenance Requirement

Effect

1

Tank body

Once a year or every 2000hrs

Clean the impurities and foreign objects in the tank

  1. Impurities adhere to the probe, affect the function and causing the SCR system to throw faults, affect driving.

  2. Stuck float, impacting level.

2

Filter of filler neck

Once a year or every 2000hrs

Disassemble and clean

  1. Affect urea filling.

  2. Impurities entering the tank.

3

Air vent

Half a year or 1000hrs

  1. In harsh environments, after every 500hrs, use a rag to remove any foreign matter from the surface in vent.

  2. If the urea tank is starting to “collapse” due to suction, check the position of blockage. If the tube is clogged, remove any foreign matter. If the waterproof breathable membrane is clogged, replace the air vent.

Tank is collapsed

4

Filter of sensor tube

N/A

If clogged, remove the filter and clean out foreign matter

Can not suck urea properly.

5

Filter of coolant tube

1-First maintenance half a year or 1000hrs.

2-After that, every 3500hrs.

Remove foreign matter from the filter

Sensor heating and thawing function fail.

Empty and clean the tank body

  1. Disconnect the connector, hold the tank and loosen the screws of the bracket.

  2. Use a tool to disassemble the sensor from the tank and place it in a clean area.

  3. Remove the drain plug screw from the tank and put it in a clean area.

  4. Drain the residual urea from the draining hole until the tank is empty.

  5. Clean the tank with clean water from sensor assembly port.

  6. Drain the water, dry the tank with air gun / or let it air dry, to remove all water from the tank.

1)

2)

3)

4)

Remarks:

Should keep tank without water after cleaning, otherwise it will affect the urea concentration.

Disassemble and clean the filter of filler neck

  1. Remove the tank cap.

  2. Loosen the two buckles of the magnetic filler port with a screwdriver and the buckles pop up.

  3. Take out the magnetic filler port and put it at the clean area.

  4. Insert the rubber stick into the filler neck and pull the filter out.

  5. Clean and brush the filter with water. Dry the filler after cleaning.

1)

2)

3)

4)

5)

Remarks:

  1. Do not damage the components during disassembly.

  2. Don’t damage the filter.

Disassemble and clean the air vent

  1. Remove the air vent from the tank by hand.

  2. Open the cover with a screwdriver and put it in a clean area and expose the waterproof breathable membrane.

  3. Clean the membrane with water and dry it after cleaning.

1)

2)

3)

Remarks:

  1. Do not damage the components during disassembly.

  2. Do not damage the membrane. If damaged, you will need to replace with a new air vent.

Disassemble and clean the filter of coolant tube

  1. Use a screwdriver to disassemble the cooling water tube.

  2. Pinch the filters clasp by hand, meanwhile, pull the filter out in a vertical direction.

  3. Check the filter and wash it by water, blow to drying the filter.

  4. Assemble filter, pinch filters clasp hand. Fix hose clamp firmly.

1)

2)

3)

4)

Remarks:

  1. Don’t damage the filter otherwise you will need to replace with a new one.

Failure mode and service of Urea Tank Assembly

NO.

Failure mode

Cause

Actions

Remarks

1

Difficult filling

Block at the filter of the filler neck

Clean the filter of filler neck

In dusty climates, increase the cleaning frequency appropriately

2

Air vent failure during filling

Block at the air vent

Replace the air vent

Check the tube

In dusty climates, increase the cleaning frequency appropriately

3

Severe expand of the tank in cold weather

Excessive filling

After thawing, extract a portion of the solution

Follow the refilling principle, do not refill too much

4

Poor ventilation of coolant tube

Filter is clogged

Clean or replace the filter

Impurities in cooling water, increase the cleaning frequency appropriately

5

Sensor level remains constant

Float is stuck

Remove sensor, check the float, remove the impurities

Should fill standard urea, keep clean