03:14-02

Issue 4 en-GB

SCR

Selective Catalytic Reduction

Troubleshooting

Scania CV AB 2011, Sweden
Contents

Contents
Introduction ................................................................................. 4
High reductant pressure ........................................... 5
Low reductant pressure ............................................ 6
Air and reductant circuits ........................................ 8

Reductant pressure ............................................................................... 10

R-a ......................................................................... 10
R-b ......................................................................... 10
R-c ......................................................................... 11
R-d ......................................................................... 12

Air pressure/dosing ............................................................................... 13

L-a Start-up check ................................................. 13
L-b Air pressure ..................................................... 13
L-c1 Blockage ....................................................... 14
L-c2 Blockage continued from L-c1 ..................... 15
L-d Return flow ..................................................... 15
L-e Leakage ........................................................... 16

Checks ............................................................................... 17
K1-Checking the reductant pump .......................... 17
K2-Checking ventilation of the reductant tank ..... 17
K3-Checking the reductant hose ........................... 18
K4-Checking the reductant filter ........................... 19
K5-Checking reductant tank 1 ............................... 20
K6-Checking reductant tank 2 ............................... 21
K7-Checking the urea crystals on the level
sensor in the reductant tank ................................... 21
K8-Checking the silencer and injection nozzle ..... 22
K9-Checking for leaks ........................................... 23

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 Contents

Actions ................................................................................24
A1-Cleaning the reductant tank and level
sensor .....................................................................24
A2-Sealing leaks ....................................................25
A3-Renewing the main unit ...................................25
A4-Cleaning the injection nozzle ...........................26
A5-Burning away crystals in the injection
nozzle .....................................................................26
A6-Cleaning the reductant doser ...........................27

Tools ................................................................................29
Test equipment for SCR system ............................29
Hose A ...................................................................29
Adapter B ...............................................................29
Hose C ....................................................................30
Hose D ...................................................................30
Hose E ....................................................................31
Hose F ....................................................................31
Hose G ...................................................................32
Resistor H ...............................................................32
Hose V1 .................................................................33
Hose V2 .................................................................33
Cooling system tester .............................................34
Pressurisation tool ..................................................34
Oil detection test strip ............................................35

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Introduction

Introduction

A problem with the SCR system may be

attributable to a number of different
components. Troubleshooting diagrams show
how the system can be checked systematically.

Read the troubleshooting diagrams from left to 3

right as illustrated.
2
1
2
3

149 163

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 Introduction

High reductant pressure

A problem with lowering the reductant pressure (reductant pressure too high) may be attributable to:
1 The ventilating valve for return to reductant tank (internally in the main unit).
2 Hose and connections between the main unit and the level sensor in the reductant tank.
3 Return pipe in the reductant tank level sensor.
4 Bleeding the reductant tank.

2
1

308 259

Fault codes for high reductant pressure:

4157 / 42255: The pressure in the SCR system is implausible in comparison with the atmospheric
pressure.
4160 / 41251: The pressure was above the permitted level during system start-up.

Recommended troubleshooting diagram: R-a

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Introduction

Low reductant pressure

A problem with building up the reductant pressure (reductant pressure too low) may be attributable to
(in order of flow):
1 Reductant filter in the reductant tank level sensor
2 The level sensor in the reductant tank
3 Hose and connections between the level sensor in the reductant tank and the main unit.
4 Reductant filter (prefilter) in the connection for reductant
5 Diaphragm pump, ventilating valve and pressure sensor (internally in the main unit)
6 Reductant filter (main filter)
7 Hose and connections between the main unit and the reductant doser
8 Reductant doser

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 Introduction

Fault codes for low reductant pressure:

4143 / 41267: The pressure has not increased enough after the reductant pump started at full capacity.
4157 / 42255: The pressure in the SCR system is implausible in comparison with the atmospheric
pressure.

Recommended troubleshooting diagram: R-a

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Introduction

Air and reductant circuits

A problem with the SCR system compressed air circuit and dosing circuit may be attributable to a
number of different components. The most commonly occurring causes are shown below:
1 Air pressure into the main unit too low.
2 Leakage in the air hoses between the main unit and the reductant doser.
3 Blockage in the air hoses between the main unit and the reductant doser.
4 Blockage in the reductant doser compressed air circuit.
5 Reductant doser blocked in the open or closed position.
6 Blockage in the dosing line between the reductant doser and injection nozzle.
7 Blockage in the injection nozzle.
8 Blocked return hose to the reductant tank.
9 Blocked silencer; see Check K8.

1
8
5

2 4

3 7
309 759

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 Introduction

Fault codes for air pressure and dosing in the SCR system
4116 / 43592: The air pressure in the SCR system is too high.
4098 / 42258: Internal fault in the main unit.
8247 / 41235: The air pressure in the SCR system has been outside the permitted range.
8394 / 42264: The air pressure in the SCR system is too low.

Recommended troubleshooting diagram (start): L-a

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Reductant pressure

Reductant pressure

R-a

Go to R-c
The pump can build up pressure
R-a Carry out check K1
The pump cannot build up pressure or the main
unit cannot bring down the pressure
Connect hose A to the main unit connection for reductant
(outlet). Pump using the hand pump and check the pressure in
SDP3. Check if it is possible to build up pressure in the
connection for reductant (return) by detaching the reductant
hose and flushing water through it. Also check that the
ventilating valve is open at the same time.
Go to R-b

R-b

Continue to troubleshooting
diagram R-c if this has not been
done. Otherwise proceed to
R-d.
No visible contamination
R-b Carry out check
K4 and K5
Contaminated
Is the contamination oil-based?
Save a sample of the contamination
as necessary. Carry out A3 and A1.
Devalidate and check fault codes.
Yes
No, it seems to be
reductant or dirt.
Rectify the fault using A1, renew
the main filter in the main unit and
then flush out the main unit by
running water into the filter
housing. Devalidate and check fault
codes.

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 Reductant pressure

R-c

Rectify the fault. Devalidate and check fault

codes.
Blocked
Carry out check K2
No leaks Not blocked
Carry out check Continue to troubleshooting diagram R-b if this
K3 has not been done; otherwise continue to R-d.
Traces of Leakage. Rectify the
crystals fault as described in A2
and check with K3.
Devalidate and check
fault codes.
R-c Carry Rectify the fault via A1. Devalidate and check
out check fault codes.
K7.
No traces Blocked
of crystals
Carry out check Rectify the fault as described in A2
K2 and check with K3. Devalidate and
check fault codes.
Not blocked Leakage
Carry out check
K3
No leaks
Continue to troubleshooting
diagram R-b if this has not been
done; otherwise continue to R-d.

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Reductant pressure

R-d

Save a sample of the contamination

as necessary; carry out A3 and A1.
Devalidate and check fault codes.
Yes
Is the contamination oil-based?
Contamination found No, it seems to be
reductant or dirt.
R-d Carry out check K6 Rectify the fault using A1, renew the
main filter in the main unit and then
flush out the main unit by running
water into the filter housing.
Devalidate and check fault codes.
See section 03-25.
No contamination
Carry out A3. Devalidate and
check fault codes.

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 Air pressure/dosing

Air pressure/dosing
L-a Start-up check

The fault has probably been rectified by driving the vehicle; the
crystal formation on the nozzle has been burned away. Check
inactive fault codes.
No problem detected
L-a Run system checks 1
and 2 with SDP3
Problem detected
Check fault messages and select troubleshooting diagram: L-b,
L-c1, L-d or L-e.

L-b Air pressure

Start the vehicle or connect an external compressed air

source to build up air pressure in the system. Then
continue from L-a
No
L-b Does the vehicle Return to troubleshooting
have sufficient air diagram L-a and restart
pressure troubleshooting
Yes No problem detected
Check the compressed air lines to
the main unit and between the
main unit and the reductant doser
Problem detected
Rectify the problem; verify with
L-a

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Air pressure/dosing

L-c1 Blockage

Continue troubleshooting according to the

fault message
Yes
Is another fault message
generated from the devalidation
test?
The pressure drops No. The fault has probably been rectified by
below 4.2 bar the devalidation test. Verify with L-a
L-c1 Carry out action
A5
The pressure does not No. Continue to troubleshooting diagram
drop below 4.2 bar L-c2
Remove the nozzle from the
connection pipe. Run system
tests 1 and 2 again. Is a blockage
still indicated?
Yes
Carry out action A6, Flushing the reductant
doser. Verify with system test L-a. If the
fault remains, renew the reductant doser and
verify with L-a

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 Air pressure/dosing

L-c2 Blockage continued from L-c1

Rectify the problem using the injection nozzle

with A4 and renew end plate. Verify with L-a
Problem detected
L-c2 Run check K8
of the end plate and
nozzle
No problem detected
Carry out action A6, Flushing the
reductant doser. Verify with L-a
Continuing problem
Renew the injection nozzle;
verify with L-a

L-d Return flow

Rectify the problem. Verify with L-a

Problem detected
L-d Check for any visible damage
on the return hose between the main
unit and tank
No problem detected
Continue with troubleshooting diagram R-b to
determine whether oil has damaged the return valve
in the main unit

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Air pressure/dosing

L-e Leakage

Refit and verify with L-a

Leakage has been
rectified
Carry out action A6, Flushing.
Check whether water is running
out from somewhere other than
the dosing pipe
No problem detected Leakage
L-e Check that all connections Renew the reductant doser, hose
are sealed using check K9 or hose connection where the
leakage occurred
Problem detected
Rectify the fault and verify with
L-a

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Checks
K1-Checking the
reductant pump
1 Start system check 3 in SDP3.
2 If there is reductant pressure, start the test
by releasing the reductant pressure.
3 Check that the pump can build up reductant
pressure (2.8 bar).
Note: If the system check cannot release the
reductant pressure, the pressure can be released
by opening reductant doser V117 and then
carrying out system check 3.
03:14-02
Scania CV AB 2011, Sweden
Checks
K2- Checking ventilation
of the reductant tank
On a vehicle with filler cap without gasket to
reductant tank:
Remove the filler cap and check whether it is
blocked; clean if necessary. The tank should be
ventilated via the threads of the filler cap.
On a vehicle with a gasket in the filler cap to
the reductant tank:
Ensure there is no blockage or other problem
with the ventilation hose. This can be done, for
example, by unscrewing the filler cap and then
blowing into the hose whilst covering the filler
opening with your hand. If the tank ventilation
works then air should flow out of the filler
opening.
17
Checks

K3- Checking the

reductant hose
1 Clean and dry around the reductant level
sensor, especially by the connection for the
reductant hose (suction hose) see
illustration.
2 Use hose V1 from test equipment 99 628
together with tool 99 557.
3 Connect hose V1 to a compressed air
supply. Make sure that the shut-off valve
of the tool is open and turn the regulator
lever down to 0.

4 Pinch the hose between the pressurisation

tool and the cover. Increase the pressure
carefully to a maximum of 0.5 bar
overpressure with the regulator lever.
5 Replace the filler cap with hose V1.
6 Pressurise the tank to a maximum of
0.5 bar overpressure using the tool and
compressed air. Wait for approx. 2-3 min.

308 261
Note: If the vehicle has a bleed hose (as shown
in the illustration), the bleed hose must be
clamped together to build up the pressure in the
tank.

Note: The tank will expand when pressurised,

which is why it is important not to apply more
pressure than prescribed. Otherwise the tank
might rupture.

Note: There will be leakage from the level

sensor attachment during pressurisation.
However, there must not be any leakage from
the reductant hoses. Even very small leaks can
be detrimental!

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 Checks

K4- Checking the

reductant filter

Note: Also check the prefilter in the main unit.

1 Unscrew the main filter from the main unit.

The filter contains a small amount of liquid
which is drained when opening. Be
prepared to take a sample. At least 100 ml
is required in order to make a full analysis.
2 Make sure the filter is yellow and does not
show signs of blockage.

309 762
3 If required, use oil detection test strip
588 876 to determine whether an oil-based
substance has contaminated the system.
Insert the oil detection test strip between
the filter discs and rub it.
4 Make sure that the gasket in the bottom of
the filter is not "swollen" nor asymmetrical
instead of round and in good condition.
This indicates oil-based contamination.
5 Look at the surface of the gasket to see
whether it is oily or greasy. It should be
free from contamination. An odour, for
example, can disclose whether there are
traces of fuel on the gasket. Compare with
clean reductant from a can.

Note: Newer filter elements do not have a

gasket in the bottom.
308 263

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Checks

K5- Checking reductant

tank 1
1 Unscrew the magnetic lock fitted to the
filler opening.
2 Smell the tank.
3 Using a torch, check whether there is any
sludge formation in the bottom of the tank.
4 Check whether it is possible to see the
white plastic plug in the bottom of the tank.
Is it visible or covered by contamination?
(Look in the direction of the arrow through
the filler opening.)
5 If required, use oil detection test strip
588 876 to determine whether an oil-based
substance has contaminated the system.

308 264
Attach the oil detection test strip to a rod.
Insert the rod with oil detection test strip
into the tank so that the oil detection test
strip is on the surface of the liquid in the
tank. Dip one half of the oil detection test
strip into the liquid so that you have the
other half as a reference.
Check the colour on the oil detection test
strip to determine the type of
contamination, if any.

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 Checks

K6- Checking reductant

tank 2
1 Remove the level sensor from the reductant
tank.
2 Check the prefilter in the level sensor.
3 Check whether there is any contamination
in the tank by looking into the tank using a
torch. Take a sample if necessary.
4 Check for leaks from the suction hose on the
reductant pick-up unit using check K3.

K7- Checking the urea

crystals on the level
sensor in the reductant
tank
Check whether there are traces of urea crystals
on the suction hose attachment on the level
sensor.

308 261

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Checks

K8- Checking the silencer

and injection nozzle
1 Turn the nozzle; it should move without
problem. If it sticks, there is crystallisation
around the nozzle.
2 Remove the nozzle, flush water through the
intake to the nozzle and check the spread of
water when it comes out. Water should spurt
from all the small holes at the nozzle outlet.
See also action A4.
3 Look with an endoscope, handheld torch or
similar through the nozzle hole. It is
important to look right down into the
silencer as illustrated. Also use a steel wire
to feel around and determine whether there
crystallisation on the inside of the silencer.

309 760
Note: If problems with blockage in the injection
nozzle or crystallisation of the silencer is
persistent, consider changing the alignment of
the injection nozzle.

309 761

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 Checks

K9- Checking for leaks

IMPORTANT! For vehicles incapable of

carrying out system test 1, control unit EEC3
must be updated with the latest software version.

1 Start system test 1 using SDP3 to build up

the air pressure in the system.
2 Use leak detection spray or soapy water to
check for leakage; search in the following

310 028
order:
The air hose between the main unit and
reductant doser, search especially for heat
damage close to the silencer, see A in the
illustration.
Connection of the doser pipe between the A
reductant doser and injection nozzle.
Connection of the air hose between the main
unit and reductant doser.
Connections after the reductant doser where
the air and reductant are mixed.

309 982

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Actions

Actions

A1- Cleaning the

reductant tank and level
sensor
1 Clean the tank:

308 265

Use high pressure cleaning equipment with

an angled nozzle. Insert the nozzle into all
holes and turn the nozzle so that all
recesses are flushed clean. Use hot water
and detergent for the best results.
Flush the tank clean of any residual
detergent.
Stand the tank with the filler hole facing
downwards to empty the tank; the last
drops can be dried off with a clean cloth.
Feel the inside of the tank and check that
the surface feels clean and free from oil.
2 Clean the level sensor:
Cover the electrical connection.
Flush with hot water so that oil and other
dirt is removed.

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 Actions

3 Clean the prefilter in the level sensor using

detergent. The filter should be transparent
and white when it is clean.
4 Top up the tank with new reductant.

Note: Reductant tank cleaning should not be

carried out with any oil-based substance or
fuel.

A2- Sealing leaks

Fit an extra hose clamp on the reductant hose if
there is any leakage by the level sensor. Renew
the reductant hose if the main unit is leaking.

IMPORTANT! Make sure the hose clamp on

the reductant hose by the level sensor is
positioned correctly and that it is not too tight
so that the hose is deformed.

A3- Renewing the main

unit
Follow the instructions in section 03-25 Main
unit for checks, repairs or renewal of the main
unit if applicable.

Note:

If there is contamination containing diesel:

renew the reductant pump, ventilating
valve and gaskets.
If there is no reductant pressure: renew the
ventilating valve and pump.
If the main unit does not work even though
there is reductant pressure and cleaning has
been carried out: renew the main unit.

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Actions

A4- Cleaning the injection

nozzle
Use hose F from test equipment 99 628 or run a
dosage test using air pressure and reductant.

1 Remove the injection nozzle.

2 Flush water through the intake to the
nozzle and check the spread of water when
it comes out. Water should spurt from all
the small holes at the nozzle outlet. If there
is still a blockage, try placing the nozzle in
a container of warm water for a few hours.
3 If the crystals in the injection nozzle cannot
be removed using the above methods, a last

141 477
measure can be to heat the nozzle using a
welding torch and then blow compressed
air back through it.

A5- Burning away crystals

in the injection nozzle
1 Start the devalidation test with SDP3 to try
and burn away the crystal formation on the
nozzle.
2 When the devalidation test checks the
injection nozzle, look at the air pressure
after the restrictor and follow
troubleshooting diagram L-c1.
310 058

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 Actions

A6- Cleaning the reductant

doser 1

Check the electrical function of the reductant doser

by activating the reductant doser at 50%. A
clicking noise should be heard.

1 Detach the reductant hose at the connection (1)

on the main unit; see illustration. Connect
hose D from test equipment 99 628 to
connection (1) and pressurise to 1 bar with tool 3

321 988
587 048. Check that the pressure drops when 2
the reductant doser is activated in SDP3.
2 Remove the hose and tool and connect the
removed reductant hose.
3 Detach the injection nozzle from the silencer.
Fit hose E from test equipment 99 628 between
the pipe for the reductant from the reductant
doser and the injection nozzle.
4 Detach the air hose between the main unit and
the reductant doser at the main unit connection
(2) and remove the O-ring on the air hose
connection; see illustration.
5 Connect hose V2 from test equipment 99 628
on the air hose to the reductant doser; see
illustration.
6 Also connect hose V2 to a water outlet using a
water connection.

321 491

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Actions

7 Flush hot water through the reductant doser

so that water sprays out through all of the
nozzle holes. Flush for 5 minutes with
water flow (~400 ml/min). The goal is to
remove crystals at the marked areas; see
lower illustration.
8 Remove adapter B from hose V2 and allow
the water to drain out from the hose. Use
compressed air and blow through the hose
using tool 99 557.

321 444
9 Refit the removed O-ring on the air hose
connection and connect the air hose to the
main unit connection (2). Run system test 1
three times to blow all the water away.
10 Refit the injection nozzle in the silencer.

Note: Ensure the water pressure remains within

2-5 bar overpressure. This is achieved when the
water flow is ~400 ml/min and there is no
blockage in the nozzle.

309 986

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 Tools

Tools

Test equipment for SCR system

The test equipment is used for cleaning and troubleshooting the reductant system,
SCR1. The equipment consists of a number of hoses, an adapter to connect a water
hose to a hose, a silencer with a valve to empty the air from the pneumatic system
before starting any repair work. There is also a resistor to start up the reductant
system during a dosage test with air and urea. When the hoses have been used, they
must be flushed with hot water to avoid crystallisation.

Hose A
Used to clean the main unit internally. Can also be used for cleaning with
compressed air together with tool 99 557 or for flushing clean with water together
with adapter B.
321439

Adapter B
Used to connect the workshop water hose to the hoses in the hose kit. If necessary,
manufacture an adapter to fit the workshop local connection.
320 839

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Tools

Hose C
Used to carry out a leak test of the main unit together with tool
587 048. Always clean 587 048 using alcohol if it has had any
contact with diesel.

321 440

Hose D
Used for flushing clean the main unit together with adapter B and
cleaning the hose from the ventilating valve with compressed air. In
addition it is used to check the reductant doser together with
587 048. The hose can also be used to clean the reductant hoses for
return and intake into the main unit using compressed air. If the
hoses are open there should be bubbles in the reductant tank.
321 441

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 Tools

Hose E
Used for carrying out a dosage test of the reductant.

321 442

Hose F
Used together with adapter B to clean the nozzle and
check the spread of water that comes out.
321 443

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Tools

Hose G
Used to empty the pneumatic system of air before
commencing any work on compressed air components.
To be connected to the workshop compressed air.

321 445

Resistor H
Used to replace temperature sensor T113 to force the
reductant system to start in order to carry out a dosage
test.
321 381

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 Tools

Hose V1
Used to pressurise the reductant tank together with
99 557 to test pipes and hoses for leaks. Never
pressurise the reductant tank more than 0.5 bar to avoid
any risk of the tank cracking.

321 380

Hose V2
Used to clean the SCR system air and reductant
circuits. Used together with Adapter B when flushing
clean. Remove the air pipe seal when connecting to the
main unit. To be connected between the main unit and
the reductant doser.
321 446

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Tools

Cooling system tester 587 048.

Used to pressurise the SCR system together with hose
kit 99 628. Clean all tools and hoses after use. The
tools must not get in contact with diesel before use. If
this happens, clean using alcohol before use.

320 838
Pressurisation tool 99 557
Used to pressurise the SCR system together with hose
kit 99 628. Clean all tools and hoses after use. The
tools must not get in contact with diesel before use. If
this happens, clean using alcohol before use.
309 991

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 Tools

Oil detection test strip 588 876

Used to check if there is any oil contamination of the
main unit reductant filter.

301 659

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