Mallentech NOx Sensors

Fleet Technicians Trust MallenTech NOx Sensors for Unmatched Diesel Emissions Control

Unmatched Diesel Emissions

Fleet and transit professionals need reliable, cost-effective replacement parts for emissions control, but negative past experiences with non-OEM NOx Sensor manufacturers may cause hesitation. MallenTech addresses any hesitation with propriety research and superior NOx Sensor products for heavy-duty diesel engines. 

A Brief History of MallenTech

MallenTech is an innovative company founded in 2008 by seasoned automotive veterans Earl Lankheet, Fred Kennard, and Steve Chen. Their combined experience leading teams at Ford, General Motors, and Delphi prepared them for the opportunity to develop emissions control products that set new standards in the aftermarket emissions industry.

These engineers sought to fill the market’s need for high-quality exhaust gas monitoring products. Initially focusing on oxygen sensors, they expanded the product line to include nitrogen oxide (NOx) sensors and serve both domestic and international markets, including China and Thailand.

MallenTech offers a compelling blend of reliability and availability at competitive prices. 

The Challenge: Accurate Measurement and Control of NOx Emissions

Nitrogen oxides (NOx) are notorious for contributing to smog and posing severe health risks. The stakes are exceptionally high for managers of large fleets since non-compliance with emissions standards can result in downtime, hefty fines, and legal penalties. 

NOx Sensors Play a Key Role in Managing Pollutants

NOx sensors are critical components that measure and help control nitrogen oxide emissions in diesel exhaust systems. High-temperature combustion within the engine forms these harmful pollutants.

As shown below, the diesel NOx aftertreatment system relies on Nox sensors to measure the exhaust before and after selective catalytic reduction (SCR). The upstream (inlet) sensor provides control information, and the downstream (outlet) sensor verifies performance.

Figure 1. Placement of NOx Sensors in the Exhaust Stream

Sensor failures are often due to organic build-up, soot, and moisture and must be addressed when maintenance managers determine maintenance schedules.

A common question for maintenance technicians is whether to replace both sensors when one fails. MallenTech experts agree that considering the cost of downtime and maintenance labor, technicians should consider replacing both sensors when one fails.

Understanding the NOx Sensor System Components

Each sensor unit is composed of a probe and a control device, which interfaces with the engine’s management control unit, as shown below: 

Figure 2. Components of the NOx Sensor System

The sensor probe measures oxygen ion levels. Unlike its competitors, who rely on analog sensor signals, Mallentech’s controller digitally amplifies and processes sensor signals to detect lower NOx levels more accurately. Their software logic and communications protocol match the OEM’s, while competitors lack some onboard diagnostics or exhaust condition corrections, which can cause sensor failures.

When excessive levels of NOx are detected, the sensor control unit works with the engine controller to bring down emissions levels. 

Figure 3. Illustration of the Operation of the NOx Sensor

How to Tell if Your NOx Sensors Are Properly Working Before They Become a Serious Issue

Recognizing signs of a malfunctioning exhaust system is crucial. Improper NOx measurement can lead to downtime, higher costs, public health risks, and environmental consequences. 

Regular maintenance combined with dependable products can minimize sensor failures. Frequent sensor failures lead to higher maintenance costs, increased downtime, and reduced fleet efficiency.

The following symptoms or indicators may signal the need for a technician to assess whether a sensor is failing: 

Symptoms of a Failing NOx Sensor in Heavy-Duty Applications

  • Visible exhaust smoke.
  • An intense, acrid smell coming from the exhaust.
  • Decreased or poor fuel economy.
  • Loss of power, engine knocking, or rough idling.
  • Dashboard lights or trouble codes are visible.
  • SCR problems, regeneration issues.
  • Unplanned downtime.

What Are the Consequences of a Failing NOx Sensor?

Recognizing signs of a malfunctioning exhaust system is crucial for maintaining engine health and avoiding these outcomes: 

Effects of a Malfunctioning NOx Sensor 

  • The engine control unit may incorrectly adjust fuel levels and combustion, causing excessive nitric oxide (NO) and nitrogen dioxide (NO2) and loss of power.
  • Incorrect quality of diesel exhaust fluid (DEF) injected into the dosing module, causing damage to the aftertreatment system.
  • Air quality degradation and potential health risks arising from excessive emissions. 
  • Increased fuel usage.
  • Engine wear and tear from incorrect combustion, leading to engine knocking and engine component wear.
  • Non-compliance with emissions standards.

NOx Sensor Maintenance and Replacements

Accurate measurement and control of NOx emissions are necessary to optimize engine performance. Regular maintenance ensures that sensors remain free of contaminants like soot and moisture, which can lead to sensor failure. Timely replacements of faulty sensors prevent non-compliance with emission standards and avoid costly downtime for your fleet.

How MallenTech’s Innovative NOx Sensor Design Results in Building Better Aftermarket Sensors

Unlike competitors who rebrand foreign-made parts, MallenTech NOx sensor components are engineered and tested in its Detroit laboratories, leveraging decades of OEM experience. Continuous software updates and manufacturing process improvements ensure full compatibility of MallenTech NOx sensors with OEM specifications.

Here’s how MallenTech’s NOx sensors stand out from its competitors:

  • Advanced Engineering: MallenTech’s NOx sensors, constructed with a unique combination of multi-layered ceramics and high-strength aluminum, use an electrochemical process to measure gas decomposition accurately. This technology ensures that the sensor functions reliably.

    Another advantage of MallenTech’s sensors is that they utilize a duty cycle voltage process, providing improved accuracy and response time compared to the constant voltage used by most competitors.  
  • Unique Design and Durability: MallenTech’s sensors feature a laminated dual-material design for the sensing element, with ceramics providing longevity and the ability to withstand extreme temperatures and harsh weather conditions. This design makes them ideal for the heavy demands of transit and long-haul applications.

Figure 4. Sensor Probe and Ceramic Sensing Element

  • Rigorous Quality Control: MallenTech’s manufacturing, certified to IATF Standard 16949, guarantees continuous improvement and high-quality sensors, unlike competitors with high return rates.
  • Comprehensive Product Range: MallenTech offers the most extensive aftermarket catalog, covering all major diesel engines and brands.
  • Software Design Compatibility: MallenTech continually updates its sensor software to ensure compatibility with OEM requirements and compliance with EPA standards. 

Other Reasons to Choose MallenTech

Beyond solving the immediate problem of NOx emission control, MallenTech offers several additional benefits that make them the preferred choice for transit authority managers and heavy-duty fleet owners:

  • Exceptional Customer Service: Based in Michigan, MallenTech’s experts quickly address technical questions they receive from customers. Recently, they demonstrated their level of commitment by sending their technical team to a customer over 1,400 miles away to resolve a customer’s issue.
  • Reliable Distributors: By partnering only with reputable distributors like KIRKS, MallenTech keeps them stocked for fast turnaround times.
  • Competitive Pricing: MallenTech’s unique capabilities allow it to produce high-quality sensors at competitive prices, making emission control solutions accessible to a broader range of customers who demand a high-quality alternative to the OEM, with a cost-saving advantage. 
  • Unlimited Mileage Warranty: Unlike competitors who impose mileage limitations, MallenTech offers a one-year warranty with unlimited mileage, providing peace of mind and added value to customers.

Take the High Road: Contact Kirks for Your Emissions Solutions

KIRKS carries MallenTech oxygen and NOx sensors for all diesel engine brands, and most orders are processed and shipped the same day.

Since 1946, KIRKS has been solving the parts problems maintenance professionals face. KIRKS is a proud distributor of MallenTech NOx Sensors, working to drive your fleet towards a cleaner, more efficient future. Our team provides expert guidance on selecting appropriate new or remanufactured Approved Equal replacement parts. Contact KIRKS and talk with a product specialist today, email us directly at sales@kirks.com, or call (313) 933-7030.