Solution K68360438

Wednesday, March 11, 2020 3:20:15 PM CET

** SOLUTION **
Title To Be Published Description and Function - Premium Tech Tool (PTT) Operation 2589-
08-03-18 Exhaust Aftertreatment System Analysis

Mack Models
Mack Model LR , TE - TerraPro , AN - Anthem , GR - Granite , PI - Pinnacle

Volvo Models
Volvo Model VN , VNL , VNR , VNX , VAH , VHD

Emission Standard
Emission Standard US17+OBD18

Engine family
Engine family 11L Engine , 13L Engine , MP7 , MP8

** SOLUTION **
Cause Purpose: To have a series of routines in Premium Tech Tool (PTT) to effectively
evaluate and diagnose the NOx sensors, Urea (DEF) dosing system, and SCR efficiency.
The routine is also captured in a .csv file and can be downloaded from Product History
Viewer for later review if necessary. This document includes the list of Diagnostic
Trouble Codes (DTC) that, when following Guided Diagnostics (GD), will list this
operation as a step. This document will outline key details that the technician should be
aware of when performing the operation. Currently this operation is only available for 11
and 13 liter engines with:

• US17+OBD18 Emissions
• A Variable Geometry Turbo (VGT)
• Engine Control Module (EMS) Main Software (MSW) Part Number 23766686
and newer.

For these vehicle configurations, the NOx Conversion Test (operation 2549-08-03-03) is
replaced by this operation (2589-08-03-18 EATS Analysis). The NOx Conversion Test
will remain available for all other variants except US17 emissions turbo compound
engine configurations.

Soluti Current operations in Premium Tech Tool typically allow for activation of actuators with the engine off/key
on on or without control over other variables, and trying to record on-the-road data typically introduces too many
variables to make an effective diagnosis. The Exhaust Aftertreatment System Analysis attempts to resolve
many of these issues by testing engine and emissions components as a system with the engine running under
more controlled operating conditions and without the requirement of removing engine components. The
current operation consists of 4 subtests:

1. Aftertreatment Hydrocarbon Injection (AHI) System

 • Verifies that the AHI system is properly working to warm the exhaust system at various levels of fuel
dosing. Aids in clearing the SCR buffer.

2. NOx Sensors

• Checks NOx sensor readings during varying engine operating conditions.

3. Diesel Exhaust Fluid (DEF) Dosing System

• Verifies proper DEF flow, dosing valve operation, and pump function.

4. SCR efficiency

• Provides an objective evaluation of SCR efficiency under controlled, repeatable conditions.

Prior to these tests, there is a warm-up step to ensure proper exhaust/ aftertreatment temperatures and that the
NOx sensors are warmed up/enabled:

These routines can be run separately or in combination. By default, all of the subtests are enabled. Typical
time to run all 4 subtests is 25-45 minutes. The test time is dependent on many factors: engine/coolant
temperature and ambient temperature, for example.
Diagnostic Trouble Codes

The Guided Diagnostic (GD) trees for the DTCs below will be updated to reflect this operation.

Diagnosti
c Trouble Description Behavior
Code

SCR NOx Catalyst Efficiency Below Threshold All subtests should be

P20EE-00
Bank 1 performed

All subtests should be

P103C-00 SCR NOx Catalyst Efficiency Inducement
performed

All subtests should be

Catalyst 2 Efficiency Below Threshold Bank 1 performed
P0422-00
(DPF NMHC conversion efficiency) (only when DTC is
confirmed)
 All subtests should be
NOx Sensor Performance Signal Stuck High
P225E-00 performed
Bank 1 Sensor 2 (NOx outlet)
(only when DTC is
confirmed)

Only the NOx sensors

NOx Sensor Circuit Range/Performance Bank 1
P2201-64 subtest should be
Sensor 1 / Signal Plausibility Failure (NOx inlet)
performed

Only the NOx sensors

NOx Sensor Performance Signal Stuck High
P225C-00 subtest should be
Bank 1 Sensor 1 (NOx inlet)
performed

Only the NOx sensors

NOx Sensor Circuit Range/Performance Bank 1
P229F-64 subtest should be
Sensor 2 / Signal Plausibility Failure (NOx outlet)
performed

General Testing Conditions

The primary thresholds / enable and exit conditions are listed below:

Parameter Value Behavior

Between 11 °F and
Ambient Air Temperature 104 °F (12 °C an 40 °
C)

DPF Soot Level Less than 69%

DEF Tank Level Greater than 10%

Vehicle will run in Heating EATS

Greater than 140 °F
Coolant Temperature phase until minimum temperature is
(60 °C)
reached.

Diesel Oxidation Catalyst

Greater than 734 °F
(DOC) Outlet
(390 °C)
Temperature (T2)

SCR Average Greater than 680 °F Minimum temp must be maintained

Temperature (Calculated (360 °C) for at least 2 for minimum time period for test to
Value) minutes. begin.

• When coolant and SCR average temp requirements are satisfied, and if NOx sensors have not come online,
the routine allows 4 minutes for NOx Inlet and 5 minutes for NOx outlet to come online before it will abort
test for NOx sensor quality (bad).
• Additionally, if the NOx sensors are the last to come online, there is a 60 second delay before it will enter
the NOx sensor evaluation.
• If the conditions are not met within 1800 seconds (30 minutes) the test will abort.

• EGR position is commanded to zero (full closed) for warmup and currently every phase of the operation.
NOTE: Test abort due to NOx Inlet or Outlet sensor quality bad is an unlikely scenario, however if
this exception occurs, it is advisable to re-run test 1 more time.

Tests and Operations

Heating EATS Phase (Warmup)

Heating EATS Phase Operation Details

The purpose of the warmup phase is to stabilize engine and exhaust temperatures, bring the NOx sensors
online, and clear the SCR buffer. During the Heating EATS phase (sometimes referred to as “warmup”) the
engine enters a state similar to regeneration and will vary engine speed between 1200 and 1250 rpm and
control the VGT position to reach the target range for engine exhaust temperature (measured by the T1
temperature sensor). This phase will occur during all of the selected sub tests. AHI dosing will occur whether
or not the AHI subtest is selected in order to meet target DOC outlet temperature (measured by the T2
temperature sensor) and SCR average temperatures and bring the NOx sensors online faster.

Operation failure during Heating EATS phase:

The screenshot below shows the current recommended actions for the scenario when criteria are met for the
Heating EATS phase, except NOx outlet sensor came online just after the timeout period.

The first recommended action in this scenario, specifically if the unit did not have NOx sensor DTCs, is
to rerun the test.

AHI Subtest

The AHI subtest has the advantage of adding more heat to the system and aids in clearing the SCR buffer
faster. When the AHI system subtest is selected, AHI dosing is added at 3 fixed dosing rates for 2 minutes at
each step. When the AHI subtest is selected and the Engine exhaust temperature (T1) reaches 527 °F (275 °C),
AHI dosing will begin.

Subtest conditions:

Condition Value

Engine Exhaust Temperature (T1) Minimum of 527 °F (275 °C)

AHI Subtest Failure

The following conditions will allow the AHI subtest to complete, but will show a “test failed” status for the
results:

DOC Outlet Temperature (T2) Threshold Time Limit

T2 fails to reach 464 °F (240 °C) First 2 minutes of dosing

T2 fails to reach 626 °F (330 °C) Second 2 minutes of dosing

T2 fails to reach 734 °F (390 °C) Third 2 minutes of dosing

The conditions below will cause the AHI Subtest to abort or fail:

Parameter Condition Effect

Test aborts due

Engine, DOC, or DPF Outlet Temperature exceeds 914 °F (490 °
to over-
Temperature (T1, T2, OR T3) C)
temperature

Engine Exhaust Temperature Temperature falls below 527 °F Test result will
(T1) (275 °C) after AHI dosing begins show failed

If the AHI subtest fails as shown in the screenshot below, the first recommended action is to uncheck the
AHI system test and restart the test. This failure can result if the DOC Outlet Temperature (T2) does not reach
the specified minimum temperature for each of the subtest's 3 steps.
The “Not tested” response shown under the AHI Response section in the screenshot below is the result of
unchecking the AHI subtest.
NOx Sensor Subtest

The primary purpose for the NOx high and low phase evaluation is to verify the plausibility of the sensors at
two points in the measurement range where the readings should be within the manufacturers specified
accuracy with the SCR buffer cleared, the readings should be within the “allowable difference” tolerance and
the NOx level is not expected to exceed the Max/Min limits.

After conditions are satisfied for the warmup state, the routine enters the NOx sensor high and low evaluation
phases. This phase replaces the current NOx Conversion test.

IMPORTANT NOTE: In the rare case that there are enough crystals in the urea (DEF) injection pipe to
sublimate during the warmup, the Outlet NOx Value will read significantly lower than the Inlet NOx Value
during the last part of the Heating EATS phase, typically when the DPF outlet temperature (T3) is above
approximately 626 °F (330 °C). as T3 drops—which should occur during NOx sensor high and low
evaluations—NOx outlet may rise as less sublimation occurs. This could cause the routine to abort
immediately after the Heating EATS phase, or cause the NOx sensor evaluation to fail if this is suspected, a
crystal sublimation should remedy the problem.

Subtest conditions:
High Evaluation

Value
Condition
11 Liter Engine 13 Liter Engine

Engine Speed 1050 RPM 1100 RPM

VGT (Turbo) Position 10% 7%

Injection Timing 5° BTDC 5° BTDC

Fan Speed Max Max

The routine will stabilize for 40 seconds and then average the NOx sensor readings for 20 seconds before
entering NOx low evaluation.

NOx sensor low evaluation:

Value
Condition
11 Liter Engine 13 Liter Engine

Engine Speed 1050 RPM 1100 RPM

VGT (Turbo) Position 25% 25%

Injection Timing 0° (TDC) 0° (TDC)

Fan Speed Max Max

The routine will stabilize for 40 seconds and then average the NOx sensor reading for 20 seconds.

Limits (For test to complete successfully)

Phase Maximum Difference between Inlet and Outlet NOx Values

High 100 ppm

Low 50 ppm

Operations Screens - NOx Sensor High Level Evaluation

Urea (DEF) Dosing System Subtest

The primary purpose for the urea dosing system check is to verify urea flow prior to evaluation of the SCR
efficiency. While this test can be performed separately, and has the advantage over the flow test in that there is
no dis assembly for some cases it may be good practice to also perform the standard dosing valve test,
especially in any case when SCR replacement is considered. This would allow for visual inspection of the urea
injection pipe for excessive crystal buildup. In any cases where excessive crystal buildup is observed , it may
be advisable to perform a sulfur regeneration or crystal sublimation and then re run the operation.

After conditions are satisfied for the NOx Sensor Subtest, the routine enters the DEF dosing system check.

Subtest Conditions

Condition Value (11L & 13L Engines)

Engine Speed 1000 RPM

VGT (Turbo) Position ~10%

 Injection Timing 20° BTDC

The DEF Dosing Routine lasts approximately 30 seconds. The DEF pump duty cycle is first evaluated during
a “no dosing” state at 131 psi (900 kPa) pressure. The ACM will then command .8 g/sec (0.028 oz/sec) urea
flow. The urea dosing valve duty cycle will last approximately 10 seconds, and the change in pump duty cycle
to maintain pressure is evaluated.

Limits (For test to complete successfully)

Parameter Allowable change (.8 g/s flow, 10 second average)

DEF Pump Duty Cycle Between 8% and 12%

This range allowance, while appearing narrow is actually quite wide. Based on test data, typical pump duty
cycle change is about 9-10%

Cooldown Mode (Intermediate Phase)

The primary purpose for the cooling phase is to bring exhaust and SCR temperatures lower in order to
expedite the stabilization step prior to efficiency evaluations. The target SCR temperature for the stabilization
and SCR efficiency low evaluation steps is relatively low at 518.9 °F (270.5 °C) when compared to the
temperature targets reached during the warmup phase. The SCR temperature reacts significantly slower than
the other exhaust temperatures, and is usually elevated well above the target for SCR evaluation from the
previous steps.

Both the NOx flow and Exhaust Mass Flow are recorded in the data (csv) file and displayed in the results of
the test. These are not displayed during the test for initial releases of the EATS Health Check due to current
Tech Tool limitations.

After conditions are satisfied for the Urea Dosing System check, the routine enters the Cooling step.

Phase Conditions

Condition Value (11L & 13L Engines)

Engine Speed 1600 RPM

VGT (Turbo) Position Variable

Injection Timing Variable

This step will last approximately 30 seconds.

Limits (For phase to complete successfully)

Parameter Condition

SCR Outlet Temperature Temperature decreasing toward 518.9 °F (270.5 °C)

Stabilize Low SCR Temperature (Intermediate Phase)

The purpose of the stabilization step is to stabilize the SCR temperature, exhaust mass flow and NOx flow to
begin the SCR efficiency evaluation.

After the cooling step, the routine enters the Stabilize low SCR temp step.

Phase Conditions

Condition Value (11L & 13L Engines)

Engine Speed 1550 RPM

VGT (Turbo) Position 18% (At start of phase)

Injection Timing 20° BTDC (At start, then retarding)

Intake Throttle Valve (ITV) Position Closes from 87% to 20%

After approximately 5 seconds, injection timing will retard from 20 BTDC to control NOx flow at 0.40 ± 0.01
g/s (.052 to .054 lb/min)

After approximately 1 minute, the routine will evaluate the exhaust temperature and exhaust mass flow routine
will adjust the VGT to raise or lower the exhaust temperature between 518 and 536 °F (270 and 280 °C) and
engine speed may be increased or decreased in 30 RPM increments as required to maintain exhaust mass flow
between 0.21 and 0.26 kg/s (27.783 to 34.398 lb/min)

After the target exhaust mass flow and engine temperatures are reached, the routine will wait until the
SCR average temperature falls within the range of 509-527 °F (265-275 °C) for 30 seconds to begin the SCR
efficiency low step.

Additional condition for exiting stabilize low is the difference between NOx inlet and outlet doesn’t exceed
150 ppm (this is to ensure any SCR buffer accumulated during the UDS check is clear)

Limits (For phase to complete successfully)

Parameter Condition

Engine Speed Variation Maximum of 150 RPM for the duration of the phase

VGT (Turbo) Position

Maximum of 10% from the start position
Change

Target Temperature Range 509-527 °F (265-275 °C) for minimum of 30 seconds

Maximum difference of 150 ppm between inlet and outlet

NOx Values
sensors
Operation failure during Stabilize Low SCR Temperature phase:

The routine will timeout if target temperatures and exhaust flow are not met within 1800 seconds.

Operations Screens - Stabilize Low SCR Temperature Phase

NOx Conversion Efficiency Low Temperature Evaluation Subtest

The purpose for SCR efficiency evaluation is to evaluate SCR performance, and in most cases, assist in
determination of whether the SCR is failed or still serviceable. The temperature and mass flow set points
allow for evaluation under “less than ideal” conditions for the SCR (relatively low temperature and typical
mass flow). There are cases in which the duty cycle of the vehicle allows for very optimum conditions during
the On board diagnostic, (heavy loads and high average exhaust temperatures) and there may be only
minimum instances of r elated fault codes, since this test evaluates at “less optimum” conditions the results of
the test may indicate failure without setting related DTCs.

After the stabilize low SCR temperature conditions are satisfied, the routine enters the NOx conversion
efficiency low temperature evaluation :
Conditions

Condition Value

SCR Temperature Range 509-527 °F (265-275 °C)

Exhaust Mass Flow Range 27.8-34.4 lb/min (12.6-15.6 kg/min)

NOx Flow Range 0.052-0.054 lb/min (0.0236-0.0245 kg/min)

When conditions are met, urea (DEF) dosing will begin at a rate of 0.8 g/sec (0.028 oz/sec)

Limits (For phase to complete successfully)

SCR Efficiency Value Time Limit Behavior

Greater than or equal to Within first 5

Subtest will pass
85% minutes

Within first 5 DEF dosing continues for 5 more

Between 65% and 85%
minutes minutes

Does not reach 77% After 10 minutes Subtest will fail (See note below)

NOx Conversion Efficiency Low Temperature Evaluation Subtest Failure

In some cases where the efficiency is borderline (within 3-4% of the limit) consider the items below:

• There is possibility of aged SCRs that will finish the evaluation step a few percent below the failure limit
after 10 minutes of evaluation. These instances should be handled on a case-by-case basis. For this reason, the
test will be uploaded as a .csv file in case additional review is needed. It may be possible that SCR evaluation
is borderline or slightly below the limit, but replacement may not be necessary. These cases will most often
include vehicles that do not show frequent SCR related faults, and may operate in extreme enough conditions
to allow average exhaust temperatures greater than 660 °F (350 °C).

• In all cases where the SCR shows efficiency at or below the passing limit, the following checks should al
ways be done prior to SCR replacement:

• Check the DEF quality with refractometer and test strips, and perform visual inspection of the tank for
any contaminants
• Inspect SCR inlet for excessive crystal buildup, also inspect the SCR inlet for any indications of
contaminants e.g. oil in exhaust from component failure upstream

Post Test Results - Screenshots And Recommendations

NOx sensor evaluation results

The screen shows both High and Low phases with the difference and average value.
DEF Dosing system and SCR Evaluation Phases

In the screenshot below, step 2 conversion efficiency is not shown because the “fast pass” limit is 85% (shown
at 93% in step 1).
Step 2 conversion efficiency failed to reach the expected efficiency limits in both steps of the SCR evaluation
in the screenshot below. The next test update will allow for a “fast fail” if SCR efficiency does not reach 65%
in the first 5 minutes of evaluation.
The screen below shows the rare scenario when one or both sensors fail to reach a minimum value and also
exceeds the allowable difference between the sensors.
Internal comments (BO) The attached pdf document is intended to assist the technician that is unfamiliar with this
operation or has questions that may not be answered while performing the operation

Solution visibility Dealer distribution

Function(s)/component(s) affected
Function affected SCR , DEF Dosing , DOC , DPF , Fuel Dosing

Function Group
Function Group 254 catalytic converter; exhaust emission control equipment , 258 emissions after-
treatment

Customer effect
Main customer effect diagnostics/methodology , fault code/display

Fault Codes And Error Codes

OBDII Diagnostic Trouble P0422 , P0422-00 , P103C , P103C-00 , P20EE , P20EE-00 , P2201 , P2201-64 , P2
Codes (P, U, B Format) 25C , P225C-00 , P225E , P225E-00 , P229F , P229F-64
 Administration
Author UT9246H

Dealer ID UT9246H

Last modified by A241298

Creation date 06-01-2020 15:01

Date of last update 11-03-2020 14:03

Status To be published

UNCONTROLLED COPY. Printed document is for temporary use only and should not be retained.