KC-2165
Service Bulletin Details
Public Details for: KC-2165
Def pump troubleshooting guide - us10+obd13 and newer emissions
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1956 MACK MACK |
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1955 MACK MACK |
6/1/22, 3:55 PM Article DEF Pump Troubleshooting Guide - US10+OBD13 And Newer Emissions Component Overview The Diesel Exhaust Fluid (DEF) Pump's function is to build and regulate the DEF systems pressure that is supplied to the dosing valve. The DEF Pump is a multi-unit component that consists of: Mechanical pump Reverting valve Pressure sensor Main filter Fluid connectors (2 coolant & 3 DEF) Electrical connector The DEF Pump is controlled by the After-Treatment Control Module (ACM). On every key cycle, the sensors and actuators in the DEF dosing system perform a self-check for proper operation. When the truck is turned off, the ACM uses a temperature based delayed reverting/draining strategy to pump the DEF back into the tank. ; Live UI https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD1?pyActivity=%40base… 1/10 6/1/22, 3:55 PM Article The primary failure mode of the DEF Pump is: Leak - externally leaking fluid Internal Failure - which will generate a specific DTC Diagnose and Repair NOTE: a large amount of DEF Pumps returned through warranty have been tested and determined to have No Fault Found. It is extremely important to not replace the DEF Pump unnecessarily but to determine the root cause of the failure. Leaking DEF ; Live UI N t ll l k t th DEF i l t f th https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD1?pyActivity=%40base… 2/10 6/1/22, 3:55 PM Article Not all leaks at the DEF pump require replacement of the pump assembly. It is imperative to determine the location of the leak. 1. Clean the suspected area using a suitable solvent. 2. Run PTT Option 2589-08-03-05 Subtest A to pressurize the system. 3. Inspect the affected area to determine the location of the leak using the table below. Location of Leak Fluid Connectors Filter Assembly Electrical Connector Pump splitting Direction Repair or Replace fitting and/or hose Replace Filter Assembly Replace Filter Assembly Replace Filter Assembly Internal Failure of the Pump All internal pump failures will generate a specific Diagnostic Trouble Code (DTC) Perform a DTC Readout using Premium Tech Tool. Review the tables below to determine which category the Fault Code currently being diagnosed falls under. Proceed according to the directions for the appropriate section. Under Pressure Faults DTC Description P20E8-92 Reductant Pressure Too Low, Incorrect Operation P202D-00 Aftertreatment Reagent Pressure Leakage P20BA-00 Reductant Heater A control Performance Directions: 1. Inspect def tank for frozen fluid, debris, or low level. 2. Disconnect the supple line at the DEF Pump. ; Live UI https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD1?pyActivity=%40base… 3/10 6/1/22, 3:55 PM Article 3. Connect a clear 3/8" (inner diameter) hose to the fitting and place the other end of the hose into the DEF Tank. • Note: This will require removal of DEF Tank Filer Neck Insert (Impact 2589-03-02-42). 4. Run Pressure Build Up Operation in PTT 2589-08-03-05 Selection A. Ensure the DEF Pump is running (audible noise) and allow to run for at least 5 minutes. 5. Evaluate results: • If the system is not able to build pressure: Replace the inlet fitting (which contains a screen, which could be blocked). Re-run evaluate. If the pump is still not able to build pressure, Replace the DEF Pump in accordance with Impact operation 2581-03-02-01 . ; Live UI https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD1?pyActivity=%40base… 4/10 6/1/22, 3:55 PM Article • If the system is able to build pressure: The pump in not the issue. Further diagnosis is needed for the supply side of the system. Inspect the below components and repair as necessary: - DEF Tank Vent - make sure the vent is clean and free of debris. ○ NOTE: Do NOT blow air through the line, as this will likely introduce debris into the DEF Tank. - Lines Blockage from DEF Tank to Pump. ; Live UI - Blocked/damaged Tank Screen or pickup tube. https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD1?pyActivity=%40base… 5/10 6/1/22, 3:55 PM Article Over Pressure Faults - only diagnose active DTCs. Description DTC P208B-00 P10CE-97 Reductant Pump "A" Control Performance/Stuck Off P20A1-07 Aftertreatment Reagent Direction Valve Mechanical Problem Reductant Return No Flow Detected Directions: 1. Inspect def tank for frozen fluid or debris. 2. Replace return line fitting (this fitting contains a return orifice). 3. Run Pressure Build Up Operation in PTT 2589-08-03-05 Selection A. ; Live UI 4 E l t th lt https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD1?pyActivity=%40base… 6/10 6/1/22, 3:55 PM Article 4. Evaluate the results • If the DEF Pump builds pressure and does not shut down for 5 minutes: Clear the faults and release the vehicle. • If the DEF Pump over pressures and stops running (DTC will log again): a. Check return line (from DEF Pump to DEF Tank) for blockage and replace as necessary. b. Re-run the evaluation. If the pump continues to overpressure, replace the pump in accordance with Impact operation 2581-03-02-01. Electrical Faults - only diagnose active or confirmed DTCs DTC P20A0-13 P10AD-13 P204A-13 P208A-13 P208C-00 P20A2-00 P204C-00 P10AF-00 P204B-64 P10AE-00 P208D-00 P20A3-00 Description Reductant Purge Control Valve, Open Circuit Reductant Pump "A" Control Low Side, Open Circuit Reductant Pressure Sensor, Open Circuit Reductant Pump "A" Control, Open Circuit Aftertreatment Reagent Pump Control Short Circuit Low Aftertreatment Reagent Direction Valve Short Circuit Low Aftertreatment Reagent Pressure Sensor Circuit Low Reductant Pump "A" Control Low Side Circuit High Aftertreatment Reagent Pump Orifice Blocked Reductant Pump "A" Control Low Side Circuit Low Aftertreatment Reagent Pump Control Short Circuit High Aftertreatment Reagent Direction Valve Short Circuit High Directions: all of the above codes will cause the DEF Pump to discontinue operation until code is corrected. Inspect electrical circuits using PTT Diagnostics to identify the electrical issue. NOTE: For trucks operating in a dirty or harsh environment and experiencing repeat DEF Pump Failures see Technical Service Bulletin (TSB) Aftertreatment Diesel Exhaust Fluid (DEF) Tank Vent Filter, New Installation. ; Live UI https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD1?pyActivity=%40base… 7/10 6/1/22, 3:55 PM Article Rules for Replacement Warranty will only cover replacement of the DEF Pump if: Leak is identified as unrepairable (leaks at fittings or main filter are repairable), these pumps may require parts returned for analysis. Fault codes in the Yellow sections above is active or confirmed. In addition, if the DEF Pump is being replaced. Maintenance records will be required showing the cleaning of the DEF Tank and Filter Change have been properly maintained and are not the root cause of the failure. Refer to Service At a Glance (SAG) found in the Trucks Dealer Portal under the Information tab - Service - Service literature for replacement and cleaning intervals of the DEF Tank & Filters. Standard Diagnostic Time 1.0 hrs Diagnostic Trouble Codes With DEF/Urea in the Description Direction/Repair: DO NOT REPLACE the DEF Pump for these codes. Diagnostics should be performed using PTT Diagnostics and the comment Live UI in the table below. ; section https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD1?pyActivity=%40base… 8/10 6/1/22, 3:55 PM Article DTC Description Probable Source P2042- Reductant Temperature Temperature - Check wiring 01 Sensor, Electrical Failure harness CBR-2015 P21CA- Reductant Control Module 00 Check ACM Power Supply CBR- Supply Voltage 2040 Review the video link below. DEF PUMP Tags p2042-01 p20a3-00 def pump def tank def filter p204b-64 p10af-00 p204c-00 p20a2-00 p208c-00 p208a-13 p10ce-97 p20a1-07 p20e8-92 p202d-00 p20ba-00 p204a-13 p10ad-13 p20a0-13 p208b-00 unlocking uptime mack p208d-00 p10ae-00 p21ca-00 volvo ; Live UI https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD1?pyActivity=%40base… 9/10 6/1/22, 3:55 PM Related links and attachments KC-2165 2581-03-02-01 KC-2165 2589-03-02-42 Article Feedback Give feedback to help improve the content of this article KC-2165 2589-08-03-05 IMG 1 KC-2165 2589-08-03-05 IMG 2 KC-2165 2589-08-03-05 IMG 3 ; Live UI https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD1?pyActivity=%40bas… 10/10