Audio Only

SCR Systems Introduction

Scene Number: 0040 1000
Audio
All numbers and specifications listed in this program are used for illustration purposes only.
Current information can be found in the Service Manuals located on QuickServe Online.
Scene Number: 0040 1010
Audio
Upon completion of this course the learner will be capable of:
Describing the reasons for SCR after treatment requirement.
Demonstrating knowledge of the basic chemical reaction.
Identifying and describing typical SCR system features or components.
Describing the function of SCR system components.
Demonstrating knowledge of the electronic control system.
Scene Number: 0040 1020
Audio
Selective Catalytic Reduction, or SCR, is a term used to describe a method of exhaust after
treatment systems.
Selective The process is focused on treating a specific chemical or compound found in the
engines exhaust.
Catalytic The after treatment requires an exhaust catalyst element that is heated by the
engines exhaust gases. With the systems discussed in this course, a urea solution or AdBlue is
required for the desired chemical reaction to take place.
Reduction The after treatment process acts to reduce emissions of the selected chemical or
compound to legislated emission levels.
Scene Number: 0040 1030
Audio
Examples of types of service literature that may be available from Cummins for support of an
engine equipped with SCR systems such as the ISBe4 engines are:
The ISBe4 4.5L and 6.7L (Common Rail Fuel System) Operation and Maintenance Manual.
ISBe4, ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual.
ISBe4 CM850 Electronic Control System Troubleshooting and Repair Manual.
ISBe4 with CM850 Electronic Control Module Wiring Diagram.
The majority of this service information is available electronically on QuickServe Online and
Intercept. All of these examples are available in hard copy.
For more information contact your local Cummins Distributor.
Scene Number: 0040 1040
Audio
Selective Catalytic Reduction is the method of exhaust after treatment chosen by Cummins to
meet the on-highway vehicular emissions targets for specific markets.
 Scene Number: 0040 1050
Audio
The SCR system is made up of many components including:
The Tank,
Dosing Control Unit,
ECM,
Urea Filter,
Inline Air Filter,
Urea Solution Level/Temperature Sensor,
Exhaust Gas Temperature Sensors,
Exhaust Catalyst Element and
Urea Injection Nozzle.
Scene Number: 0040 1060
Audio
The tank is the container that stores the urea prior to injection into the exhaust system.
Scene Number: 0040 1065
Audio
The typical urea solution tank will include an in-tank filter.
Scene Number: 0040 1070
Audio
The dosing control unit pumps and precisely meters the volume of urea injected into the
exhaust stream.
Scene Number: 0040 1080
Audio
On SCR equipped engines the ECM, or Engine Control Module, takes on the additional
functions of controlling the Dosing control Unit, monitoring the urea solution level, temperature,
and the exhaust gas temperature sensors.
Scene Number: 0040 1100
Audio
The inline air filter is required to prevent damage or contamination of the SCR systems air
components.
Scene Number: 0040 1110
Audio
The air solenoid is controlled by the dosing control unit. Regulated compressed air, supplied
by vehicle air system, is used to transport the urea dosage into the exhaust stream.
Scene Number: 0040 1120
Audio
The Urea Solution Level/Temperature Sensor is a combination sensor. The level function of
this sensor may drive a low or very low tank level warning lamp, or be used for system
diagnostics. The temperature functions of this sensor allow the ECM to monitor the urea solution
temperature and to energize the urea pump and other OEM installed SCR system heaters as
required.
 Scene Number: 0040 1140
Audio
Two exhaust gas temperature sensors are found with a typical SCR system. The first sensor
measures the temperature of exhaust gases at the inlet to the exhaust catalyst element, and the
second sensor measures exhaust gas temperature after the exhaust catalyst element.
Scene Number: 0040 1150
Audio
The exhaust catalyst element is often referred to as a brick. The element is constructed of
fiberglass paper and it may be rolled into various sizes and shapes depending on the application.
Scene Number: 0040 1160
Audio
The urea injection nozzle is fabricated from stainless steel with ceramic insulation and four
angle drilled spray holes.
Scene Number: 0040 1170
Audio
Now let's take a look at the basic chemical reaction: Nitrogen oxides, Nitrogen Monoxide and
Nitrogen Dioxide, are gaseous byproducts of combustion.
In the typical SCR system Ammonia, in the form of urea, and a catalyst element are used to
reduce the Nitrogen oxide emissions.

Scene Number: 0040 1180

Audio
The urea solution is injected into the exhaust gas stream after the turbocharger, but before the
exhaust catalyst element.
Scene Number: 0040 1190
Audio
Heat from the exhaust gases cause the urea solution to hydrolyze, or convert into ammonia
molecules. Urea is used because it is much safer to handle and is more chemically stable, than
ammonia.
Scene Number: 0040 1200
Audio
The ammonia molecules attach to the specially coated and textured surface of the exhaust
catalyst element. The exhaust catalyst element is heated by the exhaust gasses
Scene Number: 0040 1210
Audio
The ammonia molecules that have attached to the exhaust catalyst element react chemically
when exposed to the Nitrogen oxide molecules. The Ammonia molecules and Nitrogen oxide
molecules effectively neutralize and Nitrogen and Water vapor are produced.
Scene Number: 0040 1220
Audio
On a typical SCR system the urea solution is transported by compressed air into the exhaust
system.
 Scene Number: 0040 1230
Audio
Air is continuously injected into the exhaust except during the automatic priming sequence
during key on. The health of the compressed air system should always be considered when
troubleshooting the SCR system.
Scene Number: 0040 1240
Audio
Air is continuously injected following key off during an automatic purge cycle that lasts 30
seconds. The automatic purge cycle is controlled by the ECM.
During the purge cycle the movement of air from the reservoir to the nozzle may be noticed. A
single click of the air solenoid relay may also be noticed at the end of the automatic purge
cycle.
(Audio Supplement to speech sounds of the air purging and relay click placed appropriately
within speech.)
Scene Number: 0040 1250
Audio
The SCR system requires that an inline air filter be installed between the OEM air supply and
the SCR systems air supply solenoid to prevent damage or contamination of the SCR system air
injection or control components. This filter is a serviceable item and needs to be changed with oil
and fuel filters according to the maintenance schedule.
Scene Number: 0040 1260
Audio
The dosing control unit is typically designed to have minimal contact with the urea solution to
limit potential damage from corrosion. The dosing control unit can be damaged by low
temperatures. In the case of sensed temperatures below 5C the pump head will be warmed by an
internal heating element before the automatic priming sequence begins. This unit is not
serviceable and should not be taken apart.
Scene Number: 0040 1270
Audio
The dosing control units are designed to operate on both 12 and 24 VDC systems.
Scene Number: 0040 1280
Audio
The dosing control unit contains multiple connectors and sealed sections. To prevent damage to
the seals and connector pins the dosing control unit should never be steam cleaned or washed
with high pressure water.
Scene Number: 0040 1290
Audio
The tank capacity, volume, shape, and location can vary by OEM and engine rating. The tank
must have provision for a solution level and temperature sensor.
Scene Number: 0040 1300
Audio
The urea solution tank and the supply lines to the dosing control unit may require a heater for
operation in colder climates. Urea solutions will typically begin to freeze around -11C.
 Scene Number: 0040 1310
Audio
The solution tank will also contain a filter. The filter may be constructed of a mesh material
and last the lifetime of the system. The filter will be attached to the suction line within the urea
solution tank.
Scene Number: 0040 1320
Audio
The exhaust catalyst element may vary in size, shape, and location by OEM and engine rating.
In addition to the reduction of Nitrogen oxides produced by the engine the catalyst element also
works to reduce particulate emissions from the engine. The catalyst has a functional operating
range of 200C to 550C. The particulate reduction process with typical SCR systems is constant
and the catalysts typically will not require maintenance.

Scene Number: 0040 1330

Audio
It is important to remember when troubleshooting an ISBe4 engine or the SCR system that
each OEM may choose a different lamp strategy. Consult the OEM service literature for lamp
operation information.
Scene Number: 0040 1350
Audio
The vehicle may be equipped with other separate malfunction indicator and maintenance lamps
provided by the OEM. These lamps may also flash out SAE standard faults that indicate failure
or other conditions within the SCR system. The Insite electronic service tool can be used to
access these fault codes.
Scene Number: 0040 1360
Audio
The dosing control unit communicates with the ECM and OEM systems via the SAE J1939
datalink. The datalink is shielded within the engine wiring harness from the SCR connector on
the harness to the ECM.
Scene Number: 0040 1370
Audio
The ECM uses the level sensor to alert the operator of a low level of urea solution and to
roughly calculate the ratio of urea solution to fuel used.

Scene Number: 0040 1375

Audio
You are about to leave the Virtual Classroom and take the assessment.
Select "Next" to continue to the assessment. Select "Back" to return to the Virtual Classroom or
click on the Program Guide icon to view the program guide.
Note: If you are in Review Mode selecting "Next" will either return you to the Main Menu if
you have completed all of the modules in your Play List, or it will take you to the next module in
your Play List.
 Scene Number: 0040 1380
Audio
Which of these is not true about urea?
Scene Number: 0040 1390
Audio
What component pumps and precisely meters the volume of urea injected into the exhaust
stream?
Scene Number: 0040 1400
Audio
Which component is required to prevent damage or contamination of the SCR systems air
components?
Scene Number: 0040 1410
Audio
The exhaust catalyst element is often referred to as what?
Scene Number: 0040 1420
Audio
How many exhaust gas temperature sensors are found with a typical SCR system?
Scene Number: 0040 1430
Audio
Selective Catalytic Reduction converts Nitrogen Oxide molecules into?
Scene Number: 0040 1440
Audio
At what temperature will urea solutions typically begin to freeze?
Scene Number: 0040 1450
Audio
Which of these is not true about the automatic purge cycle?