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1 TO: GRADALL Excavator Service Managers AFFECTED MODEL: Series IV Highway Speed Excavators SUBJECT: T4i Emissions System Resource Website RELEASE DATE: January 18, 2013 BULLETIN NUMBER: The GRADALL Series IV Highway Speed Excavators use engines that are compliant with the U.S. EPA T4i emissions regulations. The emission system requires an understanding of the system operation when using or servicing the machines. Affected Units: All Series IV Highway Speed Excavators Corrective Action: GRADALL has developed a website to provide our dealer network with up to date information on the emissions system as used on the engines in the machines. The website provides training on the emissions system operation, troubleshooting, engine manuals, fault code lists, technical documentation, bulletins, and other information related to the emissions system. The website is available as of January 15th, Updates will occur as new information becomes available or existing material is revised. The website is free to use. The website can be found at: The website requires a password to access. The password is: tier4i. Recommended Action: Provide this Service Information to your service technicians and customer service personnel. This Service Information has been provided for information only. No warranty repairs are authorized or expected to be done as a result of this Service Information. Contacts: Should you have any questions or require further assitance concerning this bulletin, please contact your GRADALL Regional Service Manager or the GRADALL Service Department at

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3 TO: GRADALL Excavator Service Managers AFFECTED MODEL: All Series IV Highway Speed Excavators SUBJECT: Diesel Exhaust Fluid (DEF) RELEASE DATE: December 12, 2012 BULLETIN NUMBER: GRADALL Series IV Highway Speed Excavators use engines that are Tier 4i compliant for emissions. The engine uses Selective Catalyst Reduction (SCR) to achieve the exhaust emissions requirements within the Tier 4i regulations. The Tier 4i engine has a catalyst within the muffler and a Diesel Exhaust Fluid (DEF) tank as part of the system. A dosing unit on the engine injects DEF into the exhaust to activate the catalyst, as required, to reduce emissions. Affected Units: All Series IV Highway Speed Excavators Corrective Action: This Service Information Bulletin provides additional information and details about the Diesel Exhaust Fluid (DEF) product, use, and handling. No changes have been made in the the use of the DEF since the introduction of the SIV machines and no changes are required to the machines. Selective Catalyst Reduction (SCR) is a technology that uses a urea based fluid (DEF) to transform nitrogen oxides (NOx) into less harmful byproducts. The DEF is injected into the exhaust before it reaches the catalytic converter. The reaction of the fluid, exhaust, and catalyst material produces non-toxic nitrogen and water vapor. Diesel Exhaust Fluid (DEF) is composed of 32.5% high purity automotive grade urea and 67.5% demineralized water. Urea is a compound of nitrogen that turns to ammonia when heated. Only automotive grade urea is to be used in the DEF tank. Diesel Exhaust Fluid (DEF) is also referred to as AdBlue, Urea or BlueTec. DEF that is automotive grade should state and display the American Petroleum Institute (API) certification, German Institure of Standardization - DIN70700, International Standards Organization ISO 22241, and Australian AUS 32 specifications. This will insure the DEF that is being used meets the purity requirements of the SCR system on the machine. The 32.5% purity of DEF is critical to the optimum operation of the catalyst and provides the ideal freeze point for the solution. Due to the purity requirements for proper SCR operation, DEF should never be made out of locally available material or be mixed with water or other urea based fluid of unknown purity. Damage to the SCR system may occur and engine operation may be restricted (derated by the SCR system) due to incorrect emissions levels.

4 DEF freezes at 12 F (-11 C). With DEF using the correct 32.5% solution, both the urea and water will begin to freeze at the same point. A heating system is provided within the DEF tank to warm the DEF in cold temperatures. As the DEF solution warms, the urea and water will thaw at the same rate and remain in proper solution. The SCR system software checks DEF tank temperature and does not affect start up and operation of the engine during the warming cycle of the tank. The freezing and warming of the DEF within the tank does not cause the DEF to degrade. No additives should be added to the DEF tank to affect the freezing point, as the purity of the DEF will be affected by the additves and engine operation may be affected due to incorrect emissions being detected by the SCR software. DEF should be stored in a cool, dry place out of direct sunlight. If the DEF is stored at temperatures below 77 F (25 C), it will have a shelf life of 1 year. If stored in temperatures above 95 F (35 C), shelf life is reduced to 6 months. Automotive grade DEF will have a date code on the container. During normal machine operation, higher ambient temperatures (90 F/32 C) will not affect the quality of the DEF as long as the machine is being used and DEF is replenished. DEF should only be stored in approved containers. Never store DEF in any container that has contained any other material. DEF containers should be made out of approved alloy steel, plastic, or plastic coated metal. DEF should never be stored in non-alloy steel, aluminum, copper, copper alloy, or zinc coated steel containers. Per EPA regulations, engine operation will be affected when the DEF level is low. The DEF level gauge will indicate the amount of remaining DEF in the tank. When the level reaches 14% full, a yellow LIM light will illuminate and an alarm is triggered. 30 minutes after the fluid level reaches 10% full, the yellow LIM light will begin to blink and engine torque will begin to derate. It is recommended that machines operating in remote locations carry DEF in approved containers in case of low DEF level during operation. The DEF tank on a GRADALL SIV highway speed excavator is located on the right hand side of the chassis in front of the fuel tank. The DEF tank has a blue cap. The actual inlet of the tank is made to only accommodate a ¾ (19 mm) nozzle. Only automotive quality DEF should be put into the DEF tank. No other fluid, compound, or solid is to be put into the DEF tank. If anything other than automotive quality DEF is introduced into the DEF tank, the machine should not be run until the tank is removed and replaced. If the machine is run with anything other than automotive grade DEF in the tank, the entire SCR system will require replacement due to damage. A contaminated SCR system can not be adequately cleaned and only replacement will provide correct SCR operation.cleaning the DEF tank is not recommended and should not be attempted.

5 Never operate or store the machine with the DEF tank cap removed. With the cap missing, evaporation of the water and crystallization of the 32.5% urea compound will occur, affecting SCR operation and possibly causing engine derate to occur. In addition, contamination will be allowed to enter the tank causing loss of purity of the DEF, affecting the SCR system operation and possibly causing engine derate to occur. Contamination may also damage the SCR components, requiring replacement of the SCR system. A test kit is available from GRADALL to test DEF for purity. Contact GRADALL Parts Department to order DEF Test Kit, P/N If you are required to remove DEF from the DEF tank or SCR system, the DEF must be drained into approved containers that have not had any other type of fluid in the container. If DEF is put into a container that has had any other type of fluid in it, the DEF must be properly disposed of as well as the container. DEF should never be mixed with anti-freeze, fuel, brake fluid, or any type of lubricating oil(s) as damage may occur to components within engines, transmissions, hydraulic systems and brake systems from the DEF contamination. Any of the listed fluids will damage the SCR system if allowed to mix with the DEF within the DEF tank. All tools must be clean before servicing the SCR system. Tools should be washed in warm, soapy water then rinsed with warm water before servicing SCR system components. After servicing SCR system components, the tools must be washed and rinsed again to avoid contaminating any other component(s) with DEF. Care must be taken to avoid spilling DEF on to steel, aluminum and painted surfaces, as the DEF may be corrosive to those and other surfaces. Protect surfaces with plastic sheet before service. If DEF is spilled onto a surface, the surface must be washed with clean water to remove all traces of DEF. Your DEF supplier should supply you with Material Safety Data Sheets (MSDS) when the DEF is purchased. Make sure any personnel working with the machine and DEF is familiar with the location of the DEF MSDS in case of a spill or contact with the DEF. Recommended Action: Provide this Service Information to your service technicians and customer service personnel. This Service Information has been provided for information only. No warranty repairs are authorized or expected to be done as a result of this Service Information. Contacts: Should you have any questions or require further assitance concerning this bulletin, please contact your GRADALL Regional Service Manager or the GRADALL Service Department at

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7 GRADALL Product Support Information Subject: Affected Model: Affected Units: Engine DEF Tank Contamination All SIV Highway Speed Excavators Any machine listed above Series IV highway speed excavators use a Detroit Diesel Tier 4i engine with Selective Catalyst Reduction (SCR) to meet EPA emissions regulations. As part of the SCR system, Diesel Emissions Fluid (DEF) is injected into the catalyst to reduce engine emissions. The DEF is stored in a separate tank from the diesel fuel. The DEF fluid is not to be contaminated with other fluids. Corrective Action: The Diesel Emissions Fluid tank is located on the right hand side of the machine in front of the fuel tank. It has a blue cap and a smaller opening than the fuel tank. Only approved Diesel Emissions Fluid (DEF) is to be put in the DEF tank. Incorrect fluid may cause engine derate due to inadequate emissions reduction at the tail pipe or in some cases may cause catastrophic failure of the DEF pump and dosing unit. Contamination of the DEF fluid requires all components of the DEF system be replaced. Gradall Industries, Inc. 1

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9 TO: GRADALL Excavator Service Managers AFFECTED MODEL: All Series IV Highway Speed Excavators SUBJECT: DEF Injector Unit Filter Replacement Interval REVISION DATE: October 26, 2017 BULLETIN NUMBER: A GRADALL Series IV Highway Speed Excavators use engines that are Tier 4i compliant for emissions. The engine uses Selective Catalyst Reduction (SCR) to achieve the exhaust emissions requirements within Tier 4i regulations. The DEF system uses a frame mounted pump to supply the DEF to the engine during the dosing cycle. To maintain cleanliness of the fluid and components within the DEF system, a filter is part of the pump assembly. The filter requires regular maintenance to maintain optimum performance of the DEF pump. Affected Units: All Series IV Highway Speed Excavators Corrective Action: The filter is available from GRADALL as DEF Injector Unit Filter, P/N The DEF Injector Unit Filter must be changed at every engine oil change (400 hours or once a year, whichever comes first). DEF Supply to Engine DEF Line From Tank DEF Tank Lightly clamp DEF lines in this area when changing filter DEF Pump & Filter Fuel Tank (Not Shown)

10 The DEF Injector Unit Filter should only be changed with the engine off and purge cycle complete (See Service Information for purge cycle details). After the purge cycle is complete, drain the air tanks and turn off the battery disconnect switch before servicing filter. DEF Pump Module DEF Filter Housing DEF Injector Unit Filter (P/N ) Filter Cup To change the DEF Injector Unit Filter: 1. Lightly clamp the DEF lines. (see illustration on previous page for DEF lines) 2. Remove filter cup from DEF pump module and remove DEF Injector Unit Filter. Clean filter cup and DEF filter housing. NOTE! Use soap and clean warm water only to clean the DEF filter cup and DEF filter housing. Thoroughly rinse with clean warm water after washing. Use of any other type of cleaning agent may contaminate the DEF and cause significant damage to the DEF system components! 3. Install new DEF injector unit filter (P/N ) into the filter cup. Lightly lubricate o-rings on filter cup and filter element with silicone grease, such as die-electric grease. NOTE! Do not use any type of petroleum based lubricant on the filter element o-ring or filter cup o-ring. Petroleum based lubricants may contaminate the DEF system and cause significant damage to DEF system components! 4. Install the filter cup back into the DEF pump module. Torque filter cup to 24 ft/lb (32 nm). 5. Remove clamps from lines, start engine and verify no leaks are present in the filter cup area. Recommended Action: Provide this Service Information to your service technicians and customer service personnel. This Service Information has been provided for information only. No warranty repairs are authorized or expected to be done as a result of this Service Information. Contacts: Should you have any questions or require further assistance concerning this bulletin, contact your GRADALL Regional Service Manager or the GRADALL Service Department at

11 TO: GRADALL Excavator Service Managers AFFECTED MODEL: All Series IV Highway Speed Excavators SUBJECT: Emissions System Purge Cycle RELEASE DATE: September 20 th, 2012 BULLETIN NUMBER: GRADALL Series IV Highway Speed Excavators use engines that are Tier 4i compliant for emissions. The engine uses Selective Catalyst Reduction (SCR) to achieve the exhaust emissions requirements within the Tier 4i regulations. The Tier 4i engine has a catalyst within the muffler and a Diesel Exhaust Fluid (DEF) tank as part of the system. A dosing unit on the engine injects DEF into the exhaust to activate the catalyst, as required, to reduce emissions. After engine shutdown, the SCR system purges the DEF from the engine dosing unit and nozzle. An incomplete or lack of purge after shutdown may cause the dosing unit to stop functioning, resulting in an engine derate condition. Once this condition occurs, the engine dealer is required to repair/replace the dosing unit and nozzle and recomission the engine to return to normal operation. This condition is not covered by warranty if caused by incomplete or lack of purge due to incorrect shutdown procedure. Affected Units: All Series IV Highway Speed Excavators Corrective Action: Customers should be instructed in proper shutdown procedures as soon as possible. The proper shutdown procedure involves proper air system pressure at shutdown and a time requirement before using the battery disconnect switch. The SCR purge cycle will occur after machine shutdown any time the the SCR has dosed (injected) DEF into the exhaust system, or every 11 th shutdown if it has not dosed. The purge cycle lasts for 5 full minutes after engine shutdown. During the purge cycle, the SCR system cycles the air valve on and off once a minute to purge all DEF fluid from the dosing unit, nozzle, and lines. If the purge cycle is interupted or not allowed to happen, it is possible for the DEF fluid to to crystallize within the dosing unit and nozzle in the exhaust. 1. Prior to machine shutdown, the operator must be instructed to allow air pressure in both air tanks to be at governor cutoff ( psi bar) before shutting down the engine. During a typical purge cycle, the air pressure in the air system may drop 30 psi (2 bar). If the air system drops below 80 psi (5.5 bar), the SCR system may not fully purge due to low air pressure and place a fault into the engine management system. The incomplete purge may allow crystallization to form within the dosing unit and nozzle resulting in an active fault due to the emissions system not running at the correct level of exhaust emissions and cause an engine derate. 2. When a machine is shutdown, the operator must be instructed not to turn off the battery disconnect switch for a minimum of 5 minutes after shutdown. This will allow the purge cycle to be completed. If the purge cycle is interrupted due to a loss of power from the battery disconnect

12 switch being activated, crystallization may form within the dosing unit and nozzle resulting in an active fault due to the emissions system not running at the correct level of exhaust emissions and cause an engine derate. The instruction plate for the battery disconnect switch provides a warning not to turn off the electrical power for 5 minutes. The warning is shown below: Warning located above battery disconnect switch Incorrect machine shutdown may cause engine derate. When the engine derates, the machine not only can not be operated as an excavator, it also can not be driven on the highway. Repair will be required on site or after the machine is towed to an authorized engine dealer. If the engine derates either due to low air system pressure after machine shutdown, or due to use of the battery disconnect switch after machine shutdown, there is no warranty from the engine supplier or GRADALL for the repairs required to clean the system of crystallazation and recomission the engine to restore full power. Recommended Action: Provide this Service Information to your service technicians and customer service personnel. This Service Information has been provided for information only. No warranty repairs are authorized or expected to be done as a result of this Service Information. Contacts: Should you have any questions or require further assitance concerning this bulletin, please contact your GRADALL Regional Service Manager or the GRADALL Service Department at

13 TO: GRADALL Excavator Service Managers AFFECTED MODEL: All Series IV Highway Speed Excavators SUBJECT: Air System Maintenance RELEASE DATE: September 20 th, 2012 BULLETIN NUMBER: GRADALL Series IV Highway Speed Excavators use engines that are Tier 4i compliant for emissions. The engine uses Selective Catalyst Reduction (SCR) to achieve the exhaust emissions requirements within Tier 4i regulations. The Tier 4i engine has a catalyst within the muffler and a Diesel Exhaust Fluid (DEF) tank as part of the system. A dosing unit on the engine injects DEF into the exhaust to activate the catalyst, as required, to reduce emissions. The dosing unit, DEF pump, and associated valves require a constant supply of clean air from the air system. The air system requirements are more demanding than previous air systems. Maintenance requirements are being adjusted to meet the needs of the SCR system on the engine. Affected Units: All Series IV Highway Speed Excavators Corrective Action: Maintenance procedures for the machine air system are being revised to meet the requirements of the air system and the SCR components on the engine. This service information will list the revised maintenance procedures. Updates to the operator s manual will also be made. The air tanks are to be drained every 10 hours or daily, which ever comes first. The air tanks are both equipped with petcocks to faciliate draining. Some machines may have optional air tank drain valves (installation p/n ) which provide external laynards to drain the air tanks. In either case, observe any fluid or debris that may be ejected from the air tanks. If fluid (water or oil) or debris is ejected, do not run the machine and contact your GRADALL Product Support Manager for further assistance. The air dryer desiccant cartridge has been changed to an oil coalescing type cartridge available under GRADALL p/n (See Service Bulletin for additonal details). Do not use any type of air dryer desiccant cartridge that does not have oil coalescing capability. Use of incorrect cartridges may also cause damage to the SCR components. The air dryer cartridge will still have a 1500 hours or 1 year, whichever comes first, requirement to be replaced. Failure to replace the cartridge at the correct interval may cause air system damage. Recommended Action: Provide this Service Information to your service technicians and customer service personnel. This Service Information has been provided for information only. No warranty repairs are authorized or expected to be done as a result of this Service Information.

14 Contacts: Should you have any questions or require further assitance concerning this bulletin, please contact your GRADALL Regional Service Manager or the GRADALL Service Department at