Application

Engineering
Bulletin
Subject This AEB is for the following applications:
Automotive and Bus Selective
Catalytic Reduction Controls Automotive Industrial Marine
Interface Requirements - Euro 4/5 /
China Stage 4 / Conama P7 G-Drive Genset
Filtration Emissions Solution
Date: January 25, 2012 Refer to AEB 9.01 for Safety Practices, AEB Number 21.104
Guidelines and Procedures
Engine Models included: ISF 2.8 / 3.8 Euro 4/5 / China Stage 4 / Conama P7

Author: Vinicius Cabrera Approver: per Procedure: VPI-GAE-0001 Page 1 of 20

This AEB supersedes AEB 21.104

dated April 15, 2010

This AEB outlines the main SCR system components and the known Cummins Inc. requirements for application
in on-highway truck and bus. This AEB contains information that Cummins Inc. has learned during development
to date. Revisions to this bulletin are anticipated as experience is gained. This bulletin should be used by the
OEM to assist in vehicle design but is not a substitute for validation of individual vehicle applications of the SCR
system.

Overview

The purpose of this document is to provide application guidelines for integrating a Selective Catalytic Reduction
(SCR) system with the Cummins Inc., European Union, China, and Brazil products. These guidelines focus on
SCR control system requirements for proper system operation, engine diagnostic operation, and compliance
with regulations specific to the ISF 2.8 / 3.8 applications.

Additional information related to the mechanical installation of the SCR aftertreatment system may be found in
Cummins Inc., Application Engineering Bulletin 21.103 titled: Automotive and Bus Selective Catalytic Reduction
Installation Requirements.

Cummins Acronyms

SCR = Selective Catalytic Reduction

DCU = Dosing Control Unit
DM = Dosing Module
SM = Supply Module
DPF = Diesel Particulate Filter
NOx ECU = NOx Electrical Control Unit
Engine ECM = Electronic Control Module
Urea = Diesel Exhaust Fluid
EGP = Exhaust Gas Processor

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TABLE OF CONTENTS
1. Installation Requirements................................................................................................................................................. 3
1.1. Dosing Control Unit (DCU) ........................................................................................................................................ 3
1.2. Dosing Module (DM) ................................................................................................................................................. 3
1.3. Supply Module (SM) ................................................................................................................................................. 3
1.4. Urea tank level sensing ............................................................................................................................................. 3
1.5. Urea level gauge ....................................................................................................................................................... 3
1.6. Urea tank temperature sensing ................................................................................................................................ 3
1.7. Urea line heating....................................................................................................................................................... 3
1.8. Ambient Air Temperature Sensor ............................................................................................................................. 4
1.9. Urea Line Heater Relay ............................................................................................................................................. 4
1.10. Urea Tank Coolant Flow Valve .................................................................................................................................. 4
1.11. Dosing System Wiring Harness ................................................................................................................................. 4
1.12. SCR electrical connectors .......................................................................................................................................... 4
1.13. NOx Sensor................................................................................................................................................................ 4
1.14. Reference Documents............................................................................................................................................... 4
2. Introduction ...................................................................................................................................................................... 5
3. Discussion ......................................................................................................................................................................... 6
3.1. General...................................................................................................................................................................... 6
3.2. Dosing System ........................................................................................................................................................... 6
3.3. Dosing System – Purging Cycle ................................................................................................................................. 6
3.4. Urea Line Heater Relay ............................................................................................................................................. 6
3.5. Coolant Flow Valve ................................................................................................................................................... 7
3.6. Urea Tank and Line Heating ...................................................................................................................................... 7
3.7. Urea Tank – Temperature Sensing............................................................................................................................ 7
3.8. Urea Tank – Level Sensing......................................................................................................................................... 8
3.9. Urea Level Sensor Interface Specifications ............................................................................................................... 9
3.10. Dosing System Harness ........................................................................................................................................... 10
3.11. SCR Harness Connectors ......................................................................................................................................... 11
3.12. Temperature Sensors (Thermistors) ....................................................................................................................... 11
3.13. J1939 Datalink ......................................................................................................................................................... 11
3.14. NOx sensor .............................................................................................................................................................. 11
4. EOL – END OF LINE TESTING ........................................................................................................................................... 12
4.1. End‐of‐line Test ....................................................................................................................................................... 12
4.2. Pre EOL Test Conditions: ......................................................................................................................................... 12

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1. Installation Requirements
In order to receive Cummins Inc. approval of the Selective Catalytic Reduction (SCR) system, the installation
must meet the following requirements.

1.1. Dosing Control Unit (DCU)

• The Dosing Control Unit connector must not be connected or disconnected while the unit is actively
powered.
• OEM must meet electrical requirements of DCU as defined within Table 5.
• OEM must procure a wiring harness to connect the Dosing System including the Dosing Control Unit,
Supply Module, Dosing Module, line heaters, coolant valve, battery, key switch, ground, J1939 and tank
sensors.
• DCU must not be exposed to temperatures greater than 85 °C.
• If a battery disconnect is used in the vehicle, then provisions must be made to allow DCU to receive
power during “standby phase,” and purge cycle even when disconnect is deployed.
• DCU must not be grounded to the engine block stud.

1.2. Dosing Module (DM)

• OEM must meet electrical requirements of DM as defined within Table 5.
• Dosing Module and its connectors must not be exposed to temperatures greater than 120 °C.

1.3. Supply Module (SM)

• OEM must meet electrical requirements of SM as defined within Table 5.

• Supply Module must not be exposed to temperatures greater than 80 °C.

1.4. Urea tank level sensing

• Vehicles must be equipped with a urea tank level sensor.
• Tank level sensing must adhere to Table 4 tank level sensing requirements defined within this
document.

1.5. Urea level gauge

• Vehicle (In-cab) must be equipped with urea level gauge and urea lamp to indicate low urea level.
• Urea level gauge and urea lamp must be continuously visible to the operator.
• OEM must document (print) on the urea level gauge and/or urea Tank the values (percentages) for low
urea warnings and inducements that the ECM is programmed/trimmed to for that particular vehicle.

1.6. Urea tank temperature sensing

• Vehicles must be equipped with urea tank temperature sensing capabilities.
• Tank temperature sensing must adhere to Table 2 and 3 tank temperature sensing requirements
defined within this document.

1.7. Urea line heating

• Hydraulic urea lines (Pressure, Suction, and Throttle Lines) must not exceed maximum lengths outlined
in AEB 21.103.
• It is the OEM’s responsibility to ensure that the vehicle is properly equipped to meet the needs and
expectations of territory in which it will operate therefore the OEM must provide suitable Pressure,
Suction, and Backflow Line heating equipment to ensure vehicle acceptance for all seasons.

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• Heated connectors are recommended for the urea lines.

• OEM must meet electrical requirement defined within Table 5.

1.8. Ambient Air Temperature Sensor

• For ISF applications the OEM must provide an ambient air temperature signal to within +/- 10 °C in order
for the SCR heating control to operate. For further information on requirements please see AEB 15.100,
CM2220 Electronic Subsystem Technical Package - OEM Components.

1.9. Urea Line Heater Relay

• Urea Line Heater Relay is required.
• Urea Line Heater Relay must be rated for vehicle battery voltage.
• OEM must meet electrical requirements of urea Line Heater Relay as defined within Table 5.

1.10. Urea Tank Coolant Flow Valve

• OEM must meet electrical requirements of Valve as defined within Table 5.

1.11. Dosing System Wiring Harness

• The OEM must procure a wiring harness to connect the Dosing System including the Dosing Control
Unit, Supply Module, Dosing Module, line heaters, coolant valve, battery, key switch, ground, J1939 and
tank sensors.
• All unpopulated connector cavities must be fitted with a proper sized sealing plug to prevent dirt and
moisture intrusion.

1.12. SCR electrical connectors

• Selective Catalyst Reduction (SCR) connectors must not be subjected to temperatures greater than
125°C.
• All unpopulated connector cavities must be fitted with a proper sized sealing plug to prevent dirt and
moisture intrusion.

1.13. NOx Sensor

• OEM must meet electrical requirements of NOx sensor as defined within Table 5.
• NOx sensor ECU and connectors must not be subjected to temperatures greater than 85 °C.
• NOx sensor wiring must not be subjected to temperatures greater than 200 °C.
• NOx sensor wiring must not be modified.
• NOx sensor must not be grounded to engine block stud.

1.14. Reference Documents

AEB No. Title
10.162 ISF3.8 Mechanical Technical Package
15.92 CM2220 Electronic Subsystem Technical Package - OEM Interfaces
15.100 CM2220 Electronic Subsystem Technical Package - OEM Components
15.103 CM2220 Electronic Subsystem Technical Package - Serial Communications
21.103 Automotive and Bus Selective Catalytic Reduction Installation Requirements
21.100 Automotive IQA Mechanical Checklist

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2. Introduction

A block diagram of the SCR System is provided below (Figure 1):

Red = Cummins Supplied

Others = OEM Supplied
Components & Wiring

Figure 1 – SCR Controls System Block Diagram

The SCR control algorithm is embedded within the engine Electronic Control Module (ECM). The ECM and
DCU receive electrical signals and J1939 datalink messages from sensors and SCR system components.
Signals received by the ECM include: catalyst inlet and outlet temperature, key switch, NOx sensor and DCU.
Signals received by the DCU include: key switch, tank temperature, urea dosing rate requests and tank level.

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3. Discussion

3.1. General
The SCR aftertreatment system determines and commands dosing rates for current engine operating conditions
to reduce tailpipe emissions levels. Diagnostics will prevent the dosing pump from operating when the pump
detects it is too cold for it to operate and when the urea tank temperature indicates that the urea supply is
frozen.

The OEM supplied components are the responsibility of the OEM to implement and install, however Cummins
Inc will work with OEM’s to integrate these components into their vehicle systems – See Figure 1 and table
below for more details:

Table 1 - SCR electrical components responsibility

OEM Supplied Cummins Supplied

Urea tank coolant valve Dosing Control Unit
Tank level sensor Dosing Module
Tank temperature sensor Supply Module
Tank heating SCR electrical connectors, wiring, thermistors
Urea line heating NOx sensor
Dosing System wiring harness NOx sensor ECU
Line Heater Relay
Wiring from Dosing Control Unit to ECM
Wiring from NOx sensor to ECM (SCR outlet)

3.2. Dosing System

The Dosing system is comprised of the Dosing Control Unit, Supply Module, and Dosing Module. The Dosing
Control Unit is the central control for the Dosing System and handles all dosing activity, tank level sensing, and
temperature sensing. The Supply Module, a high accuracy electronic pump works in conjunction with the
dosing module for injecting the required urea quantity into the exhaust after-treatment system.

3.3. Dosing System – Purging Cycle

The Purge Cycle is necessary to protect the Dosing System from expansion of Diesel Exhaust Fluid during hard
freezes which will damage dosing system components (temperatures below -11 °C). The Purge cycle functions
by engaging the reverting valve (located within Dosing Supply Module) which pumps the urea inside the suction
and pressure lines back into the tank.

Purging starts at key-off and is completed in 60 seconds. Power must be available to the DCU for at least 60
seconds after key-off to ensure that purging is completed. During service events battery must not be
disconnected for at least 60 seconds after key-off.

3.4. Urea Line Heater Relay

The Urea Line Heater Relay is controlled by the DCU and must be procured by the OEM. The Urea Heater
Relay enables line heating for all three urea lines (pressure, backflow, and suction lines) and stays on when key
is on. Low side of line heaters are controlled by DCU internally. Selected relay should have coil suppression,
preferably by a diode with the cathode at pin 86.

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3.5. Coolant Flow Valve

The Coolant Flow Valve is also controlled by the DCU and must be procured by the OEM. The coolant flow
valve allows coolant flow to urea tank for urea tank heating. It is recommended that valve sourced
incorporates coil suppression.

3.6. Urea Tank and Line Heating

The freezing point of urea solution is -11 °C. Heated lines and connectors should be used in all application
where it would regularly see temperatures below -5 °C. The DCU is capable of controlling an external relay
for electric line heaters and a valve for a coolant loop tank heater. See the Electrical Specifications Table 5 at
the end of this document for the list of complete electrical requirements.

The urea tank coolant control valve and line heating are managed by two heating strategies: Defrost and
Maintenance Control.

1. Defrost control is enabled at key-on if ambient is below temperature threshold of 0 °C.

2. Maintenance control is enabled once defrost has finished and threshold temperature of 5°C is reached.
*Current draw will be dependent upon heating condition.

3.7. Urea Tank – Temperature Sensing

The temperature sensor is a resistive analog device that provides a temperature representative signal
through an A/D converter to the DCU. The tank temperature is used to monitor temperature within the tank
and control tank heater activation. The sensor is located at the end of the suction tube. The DCU is
designed for a thermistor sensor with the following characteristics:

Table 2 – Urea Tank Temperature Characteristics

Reference temperature: 25 °C
Reference resistance value: 500 Ohm
Reference tolerance: 5 %
B25/85 value: 3194 K
B25/85 value tolerance: 1.0 %

Figure 2 – Thermistor Temperature vs A/D Voltage

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Table 3 – Urea Tank Temperature Sensor Input Table

Temperature in deg C Resistance in Ohms

-55 25417.2
-50 18308.5
-45 13379.0
-40 9909.2
-35 7432.3
-30 5640.9
-25 4329.2
-20 3357.3
-15 2629.5
-11 2177.1
-10 2078.6
-5 1657.6
0 1332.9
5 1080.2
10 881.9
15 725.2
20 600.2
25 500.0
30 419.0
35 353.2
40 299.3
45 255.0
50 218.3
55 187.8
60 162.3
65 140.8
70 122.7
75 107.3
80 94.3
85 83.1
90 73.5
95 65.2
100 58.1

3.8. Urea Tank – Level Sensing

The urea tank level sensor provides a volume representative signal through an A/D converter to the DCU.
The sensor can be an active or passive/resistive device. The tank level sensor is used to monitor low and
empty level warnings. The urea level sensor shall have the following characteristics:

1. The sensor must be able to detect, at a minimum, a tank level change of 10%.
2. The level sensor should indicate 100% when the tank is fully filled.
3. The urea tank supply tube must extend below the level sensor, 0% fluid level indication.
4. Legislation requires vehicles to be equipped with a urea tank level indication. The DCU does not
directly provide a driver for this gauge. It will broadcast tank level information to allow the vehicle
manufacturer to meet this requirement.
5. European legislation requires an indication for both low and empty urea tank level detection. As part of
CES controls a low level warning will be triggered at 12% and empty a 6%.
6. Resistor steps for the level sensor should provide equidistance voltage steps from empty to full.

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Further information on physical tank requirements can be found in AEB 21.103, Automotive and Bus Selective
Catalytic Reduction Installation Requirements.

3.9. Urea Level Sensor Interface Specifications

The urea level sensor shall provide a signal proportional to the percentage of total usable volume of urea
remaining in the tank. The linearization table and out-of-range values are shown in Table 4. A simplified
schematic of the input circuit is shown in Figure 3 for design purposes. Rsense represents a passive
resistance sensor that would typically be a potentiometer or ladder network connected to a float. An active
sensor would inject its signal here with reference to ground and Rsense would not be present. See AEB
21.103 for mechanical requirements.

Table 4 – Urea Fluid Level Sensor Linearization Table

Urea Tank
Level Voltage
% DCV
Out of Range High >4.5
0 4.00
100 0.50
Out of Range Low <0.25

Figure 3 – Urea Tank Level Sensing Simplified Analog Input Circuit

Special considerations for powered sensors-

1. The available power supply is 5 VDC +/- 0.10 volts. Maximum current draw shall not exceed 150 mA.
2. A loss of power or ground to the sensor shall result in an out-of-range value.

Warning Lamps and Audible Alerts

For information specific to in-Cab warning lamp audible alerts, please reference CM2220 Electronic
Subsystem Technical Package - Serial Communications (AEB 15.103). Audible alerts are optional.

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3.10. Dosing System Harness

The OEM must procure a wiring harness to connect the Dosing System including the Dosing Control Unit,
Supply Module, Dosing Module, line heaters, coolant valve, battery, key switch and ground. The harness will
also need to integrate the electrical connections between the engine ECM, the SCR temperature sensors and
the NOx sensor control module.

For any components with wiring approaching from above like connector L in the illustration, make sure to
provide a drip loop to help prevent unnecessary water intrusion.

Figure 4 – Wire Harness Guidelines urea Dosing System

Ensure no connectors are mounted vertically. Horizontal mounting or connecting from below is best.
Use mounting clips to avoid abrasion or impingement of the harness against:
• Sharp surfaces.
• Moving parts.
• Radiant heat sources.
• Avoid routing harness directly beneath fluid fills and serviceable items (oil filters etc.).
• Provide strain relief using mounting clips behind each connection.
• Troubleshooting for electromagnetic noise problems:
• By default twist only circuits shown on schematic. If electromagnetic noise proves to be a problem
on other circuits, twisting them may help.
• Route power and ground inputs to DCU in separate bundles from other wires.
• Also, route circuits for heating (lines and supply module) in their own bundle (separate from sensors).
• Avoid other high current and high intensity lines from other harnesses.

Ensure mating terminals are using the same plating (tin to tin, gold to gold, etc.).

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3.11. SCR Harness Connectors

Please reference AEB 15.102, titled, CM2220 Electronic Subsystem Technical Package for complete SCR
system harness diagram, which details connector and wiring requirements for the SCR system, when using an
analog combination sensor for urea tank temperature and level information.

3.12. Temperature Sensors (Thermistors)

Two thermistors are installed at the inlet and outlet openings of the SCR. These sensors detect temperature
levels of emissions entering and exiting the SCR device. Dosing rate is a function of temperature across the
SCR catalyst.

Additionally both thermistors employ keying, which physically prevents any erroneous or backwards installation
of the sensors to the temperature junction connectors. For improved robustness, the vehicle harness should be
designed to prevent the possibility of reversing these sensor connections. Thermistors are supplied with the
Exhaust Gas Pipe (EGP).

Please refer to AEB 15.92 / 15.100 - CM2220 Electronic Subsystem Technical Package, which details
connector and wiring requirements for the SCR system

3.13. J1939 Datalink

DCU and NOx sensor communication has moved to the Engine / Aftertreatment Communication Network.
For specific wiring requirements please reference AEB 15.92, CM2220 Electronic Subsystem OEM Interfaces.

3.14. NOx sensor

For ISF applications the NOx sensor is located on the outlet of the SCR while the NOx ECU (electronic control
unit) must be mounted in a suitable location that provides adequate protection from heat. Maximum
temperature of the ECU must not exceed 105 °C.

The NOx sensor monitors emissions of Nitrogen Oxides exiting the SCR. The NOx sensor communicates with
the ECM via public, J1939 datalink. This connection occurs at the NOx ECU. The J1939 connectors and wiring
are shown in Figure 5. The maximum lead length allowed between the sensor and ECU is 608 mm for both 12
V and 24 V systems.

All NOx sensor communication has moved to the Engine / Aftertreatment Communication Network. For
specific wiring requirements please reference AEB 15.92, CM2220 Electronic Subsystem OEM Interfaces.

Figure 5 – NOx Sensor Connections

Battery Switched Source

Battery ( – )

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4. EOL – END OF LINE TESTING

4.1. End-of-line Test

The purpose of the SCR End-of-Line (EOL) test is to ensure the SCR components have been correctly
installed in the vehicle. The test covers J1939 communications, sensor connectivity and Diesel Exhaust
Fluid (DEF) doser functionality. This built-in test mode has been implemented in the ECM software and is
initiated at first key switch ON and engine start.

4.2. Pre EOL Test Conditions:

 The quantity of Diesel Exhaust Fluid (DEF) in the vehicle DEF tank must be at least above the
initial DEF low level warning. It is recommended to fill the tank just above the initial DEF low level
warning as DEF degrades over time and vehicle lead time from build to sale must be considered.
 Engine must be installed and ready to run.
 Vehicle Batteries must be installed and connected.
 Entire SCR system must be connected properly including DEF tank, Supply Module, Dosing
Module, Dosing Control Unit, DEF Supply line, DEF Throttle line, DEF Pressure line, Coolant lines
and electrical connections.
 Vehicle is stationary/stopped (0 mph Vehicle speed and 0 rpm Engine speed)

This feature is common disabled and will be only available with a VPC Request (Value Package Change).
This feature is intended to detect a several communication/connection issues still on the OEM production
line - this is a test check between a checking tool and the CES components.

IMPORTANT: This feature only detects after treatment failures and fault codes.

Find below the logical flowchart:

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EOL Flowchart

Not all after treatment FC can be diagnosed on the use of the EOL, due to its time of diagnose or its
nature, e.g. FC 2772 and 2773 do not appear immediately on the occurrence of the NOx exceedance, so
for all FC (Fault Codes) please ask for the Application Engineer the following AEBs:

Engine AEB for Fault Codes

ISF 2.8 & 3.8 15.100
ISL 8.9 15.77

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APPENDIX
Notes:
1. Heated line connectors to be defined by OEM.
2. Tank heating valve connectors to be defined by OEM.
3. Tank level and temperature sensor connector to be confirmed with OEM choice of sensor.

Figure 6 – Electrical Schematic for Dosing System used in SCR system (Passive Level Sensor)

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Notes:
1. Heated line connectors to be defined by OEM.
2. Tank heating valve connectors to be defined by OEM.
3. Tank level and temperature sensor connector to be confirmed with OEM choice of sensor.

Figure 7 – Electrical Schematic for Dosing System used in SCR system (Active Level Sensor)

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Reference Tables

Table 5 - Diesel Exhaust Fluid Dosing System Electrical Specifications

Item / Description Specification

DCU Voltage Range without 12 V: 9-16 V

Performance Degradation (V)
DCU Voltage Range without Damage (V)
Commonality between 12V and
24V Systems
Poke Yoke between 12V and 24V
system if not common
Maximum Continuous Current Draw with
heating – SM, DM (A)
Maximum Continuous Current Draw with
heating – urea lines(A)
Maximum power per meter – Urea lines (W/m)
Maximum Continuous Current Draw with
heating – DCU (A)
*Maximum Continuous Current Draw of DCU
during purging standby phase – DCU (A)
*Maximum Continuous Current Draw of SM
during purging cycle (pump and reverting
valve active) – SM (A)
Minimum Current rating urea Line Heater Relay
Maximum urea Line Heater Relay source
current (continuous) – DCU (A)
Maximum Continuous Current Draw with
heating – DCU, SM, DM, urea lines, and
Coolant Valve (A)
Electrical Interface
load dump protection
EMC
24 V: 16-32 V
12 V: 6.5-24 V
24 V: 15-42 V
Separate Supply Module PN for 12 vs 24
Volt system
Mechanical poke-yoke: different elec.
connectors
DM (12 V and 24 V): 2 A
SM operation (12 V and 24 V): 4 A
SM heating (12 V and 24 V): 10 A
Pressure line (12 V and 24 V): 5A
Suction line (12 V and 24 V): 3.5 A
Backflow line (12 V and 24 V): 3.5 A
Coolant Valve(12 V and 24 V): 2 A
18 - 22 W / m (12 V and 24 V)
DCU (12 V and 24 V): 0.25 A
DCU (12 V and 24 V): 0.25 A
SM (12 V and 24 V): 7 A
12 A (12 V and 24 V)
0.75 A (12 V and 24 V)
29. 75 A
Engine / Aftertreatment Communication
Network
Optional protected vehicle system voltage
platform solution available
(Ubatt<58V)
CISPR level 5

* Active only during purging standby phase and actual purging cycle.

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Table 6 - NOx Sensor Electrical Specifications

Supply voltage
Minimum supply voltage (ECM) 9 V (12 V), 14 V (24 V)
Minimum supply voltage (Sensor Heater) 12 V (12 V)
Standard supply voltage 13.5 V (12 V), 28.5 V (24 V)
Maximum supply voltage (Sensor Heater) 16 V (12 V)

Supply current
Normal Supply Current <1.5 A (12 V), 0.6 A (24 V)
Peak Supply Current (at switch on) 16 A (12 V), 12 A (24 V)
Maximum supply power 20 W (12 V and 24 V)

*The NOx sensor is protected against reverse battery voltage on supply pins 1 and 4

Table 7 – Operating Temperatures

Nox Sensor
Minimum ambient temperature of NOx ECU -40 °C
Maximum ambient temperature of NOx ECU 105 °C
Minimum storage temperature w/o powering -40 °C
Maximum storage temperature w/o powering 120 °C
Maximum exhaust gas temperature (sensor) 800 °C
Minimum sensor connector temperature -40 °C
Maximum sensor connector temperature 100 °C
Minimum wire temperature -40 °C
Maximum wire temperature 200 °C

SCR Thermistors
Minimum wiring harness connector temp. -40 °C
Maximum wiring harness connector temp. 100 °C
Maximum temperature for thermistor junction box 248 °C
Delta Pressure junction box 220 °C

Urea Dosing System

Doser Control Unit 85 °C
Supply Module 80 °C
Dosing Module 120 °C
Urea Line (pressure line) 120 °C
Urea Lines (suction and throttle lines) 50 °C

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Table 8 – Dosing System Connectors

Manufacturer Function Part Number Quantity Required

Dosing Control Unit DCU 462U03600 1
Dosing Control Unit DCU (86- See Bill of Materials within
See Table 9
Kostal way connector) appendix
Dosing Control Unit DCU (53- See Bill of Materials within
See Table 9
way connector) appendix
1 928 404 072 or
Dosing Module (Connector) 1
1 928 403 874
Bosch Kompakt Dosing Module (Terminals) 1 928 498 058 2
Dosing Module (Cable seals) 1 928 300 599 2
Supply Module (12 V) 1-1703639-1 1
Supply Module (24 V) 2-1703639-1 1
Supply Module
1418884-3 10
(Terminals)
Tyco
Supply Module (Cable seal) 964972-1 10

Supply Module (Cavity plug) 963531-1 2

Table 9 - DCU Connector Bill of Materials

Quantity required for each

Kostal Part Number Description
connector
9448691 Receptacle housing 86 way 1
10400661162 Cap (strain relief) for 86 way 1
10400642403 Seal retainer 40 way (black 47-86) code A 1
10400642404 Seal retainer 40 way (white 7-46) code B 1
10400642432 Lock mechanism 80 way 1
9449391 Receptacle housing 53 way 1
10400625522 Cap (strain relief) for 53 way 1
10400642483 Seal retainer 22 way (black 10-31) code A 1
10400642484 Seal retainer 22 way (white 32-53) code B 1
10400642452 Lock mechanism 44 way 1
32124734020000 * Terminal MLK 1.2 Silver 18-20 AWG
23
32124734030000 * Terminal MLK 1.2 silver 16-18 AWG
22124492070050 Terminal SLK 2.8 Silver 14-16 AWG 13
22400643996 Terminal carrier (22 way black 10-31) 1
22400643997 Terminal carrier (22 way white 32-53) 1
22400643998 Terminal carrier (40 way black 47-86) code A 1
22400643999 Terminal carrier (40 way white 7-46) code B 1
10800444523091 Wire Seal Reddish Brown 5.2mm 13
10800472631091 Cavity Plug for 2.8 mm 2

* Only one set of MLK 1.2 terminals is required. Either part number can be used.

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Table 10 - Supplier Contacts for SCR Electrical Components

Business / Company Website Phone(s)

Tyco Electronics (Amp) http://catalog.tycoelectronics.com + 1 800-522-6752

Chief Enterprises http://www.chiefent.com/ + 1 800-831-7294

(US distributor for Bosch)
Kostal http://www.kostal.com + 1 248-471-0871

Cummins Confidencial & Proprietary

 AEB 21.104
Page 20 of 20

CHANGE LOG

Date Author Description Page (s)

January 25, Added Euro 5 and Conama P7. 1
2012 V. Cabrera Added reference to AEB 9.01 in header. 1
Updated Approver number in header. 1
Added Table of Contents. 2
Added EOL Section. 12-13
Appendix update with Active and Passive Level Sensor Electrical 14-15
Diagram.
Removed relay from NOx sensor diagram 10
April 15,
G. Bassi Added Tank temp voltage vs temp graph 6
2010
General update All
Added detail around CES controls for level triggers 7
Blanked out NOx sensor part number 12
13/05/09 G. Bassi Re-named table 8 15
Added quantity to table 8 / 9 15
Added various AEB references
18/03/09 G. Bassi Changed heated line specification to 18 – 22 w/m within table 5. 13

Initial Release
18/03/09 G. Bassi

Cummins Confidencial & Proprietary