EURO4 Engine

Cummins I.E.M System

Cummins IEM
Integrated Emissions Management Single Control Module
CM850

Incorporating

Engine plus after treatment

Controls and On Board Diagnostics

Communication via J1939 Datalink

Management of Emissions
After treatment Management
Fleet Data Management
Options for achieving EURO4

SCR- Selective Catalytic

Reduction

EGR-Exhaust Gas
Recirculation
 What is OBD?

OBD (On Board Diagnostics) are fault codes designed to

detect failures that impact engine emission levels, or impact
Cummins ability to detect errors that impact engine
emission levels.
OBD MIL lamps Various OEMs
What is Urea ?

NOxCare (Urea) is a high-purity 32.5 % (by

weight) aqueous urea solution
 Adblue

32.5% urea solution.

Non-toxicnon-contaminated
non-explosivenon-flammable.
Crystallizing when it lacks of
water.
Freezing at point of -11C.
Adblue consumption is 5% of
fuels.
SCR principle
SCR catalyst
Urea Injector

Gas Flow

Urea solution is injected into hot exhaust pipe,then urea

decomposes into ammonia and carbon dioxide(>160 C):
(NH2) 2CO+H2O = 2NH3 + CO2
SCR is a chemical reaction of Nox and ammonia at catalystic
converter:
4NH3 + 4NO + O2 = 4N2 + 6H2O
4NH3 +2NO2 + O2 = 3N2 + 6H2O
 SCR

Vehicle Air
Supply

?
 System Principle and
Operation.
The SCR system converts the Nitrogen Oxides produced by
the engine (exhaust) into Nitrogen and Water.

Liquid urea is injected upstream of a catalyst in the exhaust

system using a very accurate dosing pump. The amount of
urea injected by the pump is controlled by the engine ECM.

Under normal operation the Dosing pump has three control

Phases:-

Priming
Dosing
Purging
 System Priming

Every time the Engine is RUNNING the dosing pump

will go into the PRIMING phase. Urea solution is
circulated through the pump and back to the tank
purging air from the system. If the PRIMING phase is
successful you will hear the Doser Motor operate at
100% for 30 seconds, an air solenoid will operate at
the end of this phase.

If the PRIMING phase is not successful first time, the

air solenoid will de-energize and the motor will run at
100% for another 30 seconds. This sequence can be
repeated up to 20 times before ERROR 1682 SCR
Pump State Control Doser Error is displayed.
System Priming.
System Dosing Air Only ,Engine Running

At the end of the PRIMING phase the Air Solenoid Valve opens and
the pump motor stops. The pump is now ready to DOSE. The
DOSING phase is controlled by the engine ECM depending on the
NOx produced by the engine and the exhaust temperature.

The pump will not start dosing Urea unless both exhaust
temperature sensors reach 200 degrees, however air will be
continuously dosed through the Dosing Pump, Injector Supply line &
Injector while the engine is running to prevent the nozzle from
becoming blocked.

In the DOSING phase air regulated to 4 bar continuously passes

and through the air solenoid to the injector. The air has two
functions.

Acts as a transport media for the urea.

Prevents the injection nozzle from becoming blocked.
System Dosing Air Only ,Engine Running
Conditions for Dosing
Urea

200 degrees C @ both Exhaust Inlet and Outlet

No SCR System Relating Fault code OBD
Urea Tank Level above 12%
Air pressure above 4 bar, and urea pressure 3
bar
Above -5 degrees C
Cummins Nox Algorithm
System Dosing
 System Purging.
When the Key Switch is turned to the OFF position the
system enters the PURGING phase. Compressed air flows
through the injector and the pump.

The air removes any urea droplets from the system that
could otherwise block the pump valves or the injection
nozzle. The phase lasts for 30 seconds then the system
switches off.
Purging is performed with every key off cycle.

If a SCR system Fault becomes active, then the SCR

system will switch off, but first purge the system of UREA.
System Purging.
System Purging.
Mobile Selective Catalytic
Reduction
System function lamps

Urea storage tank

Usage around Urea Pump

5% of Fuel

Compressed
Dosing Unit Air supply

N2 + H 2 O Nox Sensor
2007 Urea
Temperature Sensors Injection

Decomposition Turbo
Tailpipe Exhaust
SCR Brick Area

Too much Ammonia = Ammonia Slip

 MSCR System Components -
Nozzle
Connector to Doser

Insulation Material

Spray Nozzles x 4
 SCR System Layout

Urea dissociates into ammonia and carbon dioxide when sprayed into the hot exhaust gases
Urea Dosing Unit

The Dosing unit is

fundamentally an
intelligent pump, dosing
urea to the nozzle for
injection, controlled via the
Engines ECM.

The pump is Black

Box and not a
serviceable item!!.
Dosing Pump Connections

1. Urea in from urea tank

2
2. Air supply in

4 3
3. Urea out to Injector
4. Urea out to tank
1
Doser Unit

4 3

1
Pin No 1
Air supply Pin No 37 Pin Number Description

regulator 15 Can bus shield

16 Battery +
@ 4bar 22 Can data link
23 Ground
28 Can data link +
34 Key switch enable
35 Air solenoid enable ( 12Volts DC from ECM)
36 Air solenoid return
 Thermistors
There are two Thermistors on the EGC
One inlet thermistor and one outlet thermistor.
They are monitoring the Catalyst temperature.
Component Location

EGC bosses &

Thermistors
Exhaust Temp Thermistors
Urea Injection Nozzle

The Urea Injection Nozzle has 4 x

0.55m holes at the tip which
atomises the urea and air, This
injects directly into the exhaust
gases and onto the EGP.
The injector is made from 304
Stainless Steel with a ceramic core.
Care should be taken when handling
the nozzle. Do not drop it as the
ceramic coating can be damaged.
 Urea
Nozzle

Ceramic Insulation
Caution do not drop

4 Angled spray holes

Spray hole diameter 0.55mm +\- 0.05mm

Injector Nozzle Check
During checks of the Urea Injector Nozzle, you should expect to
see the spray pattern in 4 distinct jets as show below
Catalyst (EGC)

The Catalyst is typically twice the size of the current exhaust muffler.
The Catalyst comprises of two sections
1) Sound deadening
2) The SCR brick
Cataly
st
FULL Catalyst - no precious metal - good NH3 absorption - good Nox conversion

Flat Fibreglass Paper

with pleats

Rolled into various sizes/shapes

Reduces Particle Matter PM by around 30% (soluble fraction)
Typical Right hand Mount with soft mountings on the
EGP

No Joint Fully Welded

Soft Mounts
Radial
Nozzle Outlet
Exhaust Brake
Air/Oil Filter Separator

Extruded Head

Working Pressure = 10 bar

Spin On Canister
CLT Sensor & Urea Tank Heater

Urea supply to Doser Heater (water) in

Urea return from Doser Heater ( water) out

Float
Temperature Thermister 4 Pin electrical connector
Urea Tank Level & Temperature
Sensors

Level (Magnetic
Float)
&
Temperature
(Thermistor)
Sensor

Notes:
Level sensor has 14 resistance steps operated by
reed switches it is important to reference first and
last resistor for calibration. Maximum distance per
step is 21mm
MAX Urea Level

Float
Level

MIN Urea Level

Gap ~ 5mm
In Cab Gauge for Urea level
(OEM)
Urea In Tank Filter

Free before assembly

Compressed after assembly

 OEM Component Location
Component layout will vary depending on specific OEM

Layout with the

dosing unit on the
outside of the
chassis rail.
 Switches and
indicators
Asking switch of idling speed
Engine fault lamp
Water in fuel lamp SCR fault lamp

Preheating lampAdjusting switch of idling speed

Diagnostic switch OBD lamp
Potential Issues

Problem: Diesel added to the urea Tank.

Diesel attacks EPDM rubber seals used in the pump head and
check valves.
Prolonged exposure to diesel can cause the EPDM seals to fail
causing urea to leak from the pump head.
 Throttle-activated
diagnostic
The throttle-activated diagnostic switch feature is intended to eliminate the need for a dash-mounted
diagnostic switch, which is used to activate the fault code flash-out on the lamps.

The fault code flash-out will be activated through a simple sequence of throttle movements.

When this feature is enabled, the engine is in stop state and the key-switch is turned on.

Every successive cycle of the throttle will lead to the next fault code to be flashed on the lamps, in the same
manner as if the increment switch were depressed.

To activate this feature, the engine must be stopped and the key-switch turned to the ON position. Then
depress the accelerator pedal completely three times the feature should then be enabled.

Transitioning to the next fault code will happen automatically after the first fault code is flashed out twice or
if the throttle pedal is cycled.

NOTE: There is an optional, error sensitive mode for this feature, If any of the throttle-related errors occur,
this feature will turn on the diagnostic switch automatically when the engine is stopped and the keyswitch is
on.During this mode, only the increment switch can be used to flash out the next fault code.

Engine Protection System

The ISB CM850 engines are equipped with an engine protection system. The system monitors critical
engine temperatures and pressures and will log diagnostic faults when an over or under normal condition
occurs. If an out-of-range condition exists and engine derate action is to be initiated, the operator will be
alerted by an in-cab Warning lamp, the stop lamp will blink or flash when out of range conditions continue
to worsen, the engine protection system will not shut the engine down unless the feature has been
enabled.
Questions?