Controls and On

Board Diagnostics

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Controls and On Board Diagnostics

OBD 1 Overview
OBD 1 Specific diagnostics
OBD 1+ Overview
OBD 1+ Specific diagnostics

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Euro 4 OBD
1
Euro 4 OBD 1 Product

Overview
Euro 4 OBD 1 System Overview

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EuroIV Diagnostic Set

Non-OBD Diagnostics which
remain in an OBD product.

New Diagnostics
-System Monitors
-In-Range Diagnostics

Standard Diagnostic Set

-OOR Diagnostics

OBD Diagnostics

Cummins EuroIV OBD Product

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Euro 4 OBD 1 Product Overview

Cummins Euro 4 Products

All Euro 4 engines feature electronic fuel systems.
Euro 4 emissions levels are met on all platforms
using selective catalytic reduction (SCR) NOx
aftertreatment.
This means 4 and 6 liter platforms - all applications.
Cummins has integrated the engine, aftertreatment,
and OBD System into one control module.
Engine Platforms
ISBe4 6 Cylinder
ISBe4 4 Cylinder

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Euro 4 OBD 1 System Overview

Diagnostics
Fuel System
Electrical disconnection of any component that results in an
emissions increase exceeding any of the OBD threshold limits

Engine System
Electrical disconnection of any component that results in an
emissions increase exceeding any of the OBD threshold limits

SCR System
Electrical disconnection of any component that results in an
emissions increase exceeding any of the OBD threshold limits
Bulleted failure modes identified in the regulation specific to a deNOx
system

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Euro 4 OBD 1 System Overview

Fuel System: Electrical Disconnection

Fuel Pressure Sensor
Sensor disconnection FC 451

High Pressure Fuel Pump Injection Metering Valve

Actuator disconnection FC 272

Fuel Injectors 1-6

Injector disconnection FC 322-325, 331, 332

Engine Speed Sensor (Crank)

Sensor disconnection FC 689

Engine Position Sensor (Cam)

Sensor disconnection FC 778

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Euro 4 OBD 1 System Overview

Engine System: Electrical Disconnection

Coolant Temperature Sensor
Sensor disconnection FC 144

Charge Temperature Sensor (Intake Manifold

Temperature)
Sensor disconnection FC 153

Charge Pressure Sensor (Boost Pressure)

Sensor disconnection FC 123

Ambient Air Pressure Sensor

Sensor disconnection FC 222

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Euro 4 OBD 1 System Overview

SCR System
Level Sensor
Dosing Unit

CAN bus
(SAE J1939)

Urea Supply

Air Supply

Electronic Control
Module (ECM)

Temperature Sensor
Tank Heater

Urea Return

Air Solenoid
Urea Tank
Exhaust Gas
Temperature Sensors
Mixing

Exhaust
Gas

SCR
Catalyst
Urea Injector

Exhaust Gas Processor (EGP)

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Euro 4 OBD 1 System Overview

SCR System: Electrical Disconnection
Catalyst Input Temperature Sensor
Sensor disconnection FC 1666

Catalyst Output Temperature Sensor

Sensor disconnection FC 1675

SCR Air Solenoid

Solenoid disconnection FC 1698

Urea Level Sensor

Sensor disconnection FC 1668

Urea Temperature Sensor

Sensor disconnection FC 1678

Urea Tank Heater Relay

Relay disconnected FC 1683

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Euro 4 OBD 1 System Overview

SCR System: Failure Detection

Urea Tank Level Monitor
Urea Tank Heater Monitor
Urea Consumption Monitor (SCR System Monitor)
SCR Dosing Unit
SCR Catalyst Presence

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Euro 4 OBD 1 System Overview

Urea Tank Level Monitor
1671 Detects a low urea tank level
when the urea level sensor reads
below 12%. (Yellow Diagnostic Lamp)
1673 - Detects an empty urea tank
when the urea level sensor reads less
than 6% urea. (Flashing MI)

Watch outs

Level Sensor
Temperature Sensor
Tank Heater

The weema sensor steps need to be

able to read between 18%-12%, 12%6% and 6%-0%

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Euro 4 OBD 1 System Overview

Urea Tank Heater Monitor FC
1712

Detects a disconnected urea tank

heater

Malfunction
Heater unable to heat urea tank
50 minutes with temperature increase
below 2 Deg C, -5 Deg is considered
a frozen tank

Level Sensor
Temperature Sensor
Tank Heater

Watch outs
If no heater fitted and disabled in
Insite the diagnostic will still
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Euro 4 OBD 1 System Overview

Urea Consumption Monitor FC 1699
Detects SCR system failures by comparing
commanded urea injection to actual urea consumed.

Malfunction
Abnormal Adblue usage
If 3.2 letters of Adblue have been commend and the
level sensor dose not indicate this
If the level has changes by 3.2 letters but this has
not be commanded by the ECM
Leaking tanks, Nozzle directed back into the tank,
Dosing pump incorrectly working

Watchouts
Tank correctly setup in Insite
No more than 2 letters over the 100% mark on the
sensor
Liner Adblue volume Vs sensor level
Level sensor step size
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Euro 4 OBD 1 System Overview

SCR Dosing Unit

Missing Dosing Unit FC 1711

Power Disconnect FC 1711
No Communication with ECM FC 1711
Disconnected Air Supply Line FC 1682
Disconnected Urea Supply Line FC 1682
Restricted Air Supply Line FC 1682
Restricted Urea Supply Line FC 1682
Restricted Return Line FC 1682
Restricted Injection Line FC 1682

CAN bus
(SAE J1939)
Dosing Unit
Urea Supply
Air Supply

Urea Return

Watchouts

Heated lines if needed frozen line will cause a 1682 if trying to Air Solenoid
dose
Correct connections for the Line, Urea build up around connection
Drawing air in the supply lines
J1939 Can communication

Injection

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Euro 4 OBD 1 System Overview

SCR Catalyst Presence FC 1664
8 hours cold soak (no engine starts),
Delta temperature between the
temperature sensor needs to be over
25 DegF within the first minute of
engine idle

Malfunction

Catalyst Brick Missing

Catalyst Brink Deteriorated
Exhaust gas by passing the brick
High back pressure after the EGP

Watchouts
Catalyst temperature sensor wrong
away around
Diesel particulate filters increasing
back pressure

Exhaust Gas
Temperature Sensors

Catalyst Brick

Exhaust Gas Processor (EGP) - Production

Exhaust Gas
Temperature Sensors

Missing
Catalyst Brick

Exhaust Gas Processor (EGP) - Limit

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Euro 4 OBD 1 System Overview

Clearing of the MIL

Once the failure has been removed the monitor has
to run and passed 3 consecutive times.
At a minimum this will be 3 x 10 seconds engine runs
Some monitors will have to see specific conditions to
run therefore these will have to be met 3 time before
the MIL can switch off.

At OBD 1 fault code will be able to be cleared

OBD Diagnostic in Insite will be state if the MIL lamp
is being illuminated for the particular fault code

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Real Time Clock

Real time clock is a requirement for the OBD regulations
Time and Date stamps for the fault codes
Diagnostic need to know a real time to determine 8 hours
cold soaks

The ECM has no way of determining time with no power.

The ECM can gain the time from the tachograph of a
datalink message TD (Time Date)
If no tachgraph and no permanent power supply a battery
backup will be needed
Plugs into the harness

Permanent power supply to the ECM

This needs to be setup in Insite

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Euro 4 OBD 1+
Euro 4 OBD 1+ Product Overview
Euro 4 OBD 1+ System Overview

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Euro4 OBD 1+ Product Overview

Product Architecture Similar to Euro4:

Electronic Fuel System

Euro4 Emissions
Integrated Controls
All Engine Platforms:

ISBe 6 Cylinder
ISBe 4 Cylinder
ISLe 6 Cylinder

Level Sensor
Dosing Unit

Temperature Sensor

Urea Supply
Air Supply

Tank Heater

Urea Return

With Catalyst Outlet NOx Sensor

Air Solenoid
Urea Tank
CAN bus
(SAE J1939)

Exhaust Temp Sensors

NOx Sensor

Mixing

ECM

Exhaust
Gas

SCR
Catalyst
Urea Injector

Exhaust Gas Processor (EGP)

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Euro4 OBD 1+ Product Overview

Key Differences From OBD 1 to OBD 1+

Monitoring of tail pipe out NOx with NOx sensor
Fault codes for exceedence of over 5 g/kwh and 7 g/kwh

OBD derate strategy

25% or 40% torque derate depending on vehicle
classification (Settable in Insite within the first 25 miles)
Instant and 50 hour OBD derates depending on severity
for the fault on the emissions

Non-erasable faults code, These will stay in the

ECMs memory for 9600 hours of engine run time

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New fault code in OBD1+

1692 Catalyst NOx sensor internal error

1694 NOx sensor in range error
2771 Aftertreatment NOx sensor
communication error
2772 Aftertreatment NOx exceedence least
server > 5 g/kwh
2773 Aftertreatment NO exceedence most
severe > 7 g/kwh

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OBD 1+ Overview
1692 Catalyst NOx sensor internal error
If an internal error has been hound in the NOx sensor

Malfunction
Sensor will report internal errors through the J1939 Can bus to
the ECM
Internal heater error Internal heater with the sensor malfunction
Low power supply voltage to the sensor below voltage threshed
Sensor internal error Other electrical failure within the sensor

Watchouts
Sensor location possibility of splash back and thermal shock
Maximum temperature of the sensor control unit
Sensor orientation

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OBD 1+ Overview
1694 NOx sensor in range error
Designed to determine if the sensor has drifted or is reading a
constant high or low value

Malfunction
Sensor Reading vs. Estimate if the reading is lower than
expected
Under specific operation conditions:
Engine speed
Reagent dosing
Non-transient fueling

When the engine is in a motoring condition (Zero Fuelling) NOx

reading should be 0 ppm if over the threshold then error will be set

Watchouts

Sensor location out of exhaust gas flow

High back pressure
Exhaust leaks
Over dosing
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OBD1+ Overview
2771 Aftertreatment NOx sensor communication error
To determine if there is a communication error between
the NOx sensor and the engine ECM

Malfunction
Communication between the engine ECM and NOx
sensor has been lost

Watchouts
Poor can bus, connections, connectors, etc
Fuse to the sensor the sensor need a large fuse due to
the internal heater

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OBD1+ Overview
2772 & 2773 Aftertreatment NOx exceedence least server > 5 g/kwh
& 7g/kwh

To determine if the exhaust out NOx levels are grate than the above
thresholds

Malfunction
Sensor Reading vs. Estimate if the reading is lower than expected
Under specific operation conditions:
Engine speed
Reagent dosing
Non-transient fueling

intrusive:
Under normal dosing, measure NOx
Under disabled dosing (for minimal time) measure NOx again
Compare observed efficiency vs. minimum allowed

Watchouts

Exhaust design per the AEB

Doser line connections
Adblue Injector positioning
Adblue???
Doser issues
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Euro4 OBD 1+ System Overview

Clearing of the MIL
If the diagnostic is non erasable the MIL can switch of
once the monitor has run and passed.
If the Diagnostic is erasable the monitor will have to run
and pass 3 consecutive times for the MIL to switch off.
At a minimum this will be 3 x 10 seconds engine runs
Some monitors will have to see specific conditions to run
therefore these will have to be met 3 time before the MIL can
switch off.

The fault will be in the DM1 message (Active Trouble

Codes) until the MIL is off, then in DM2 message
(Previously Active Trouble Codes)

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Euro4 OBD 1+ System Overview

OBD Derate
Activation of instant derate
If a fault becomes active and it is an instant derate then the next time
vehicle speed = 0 then the derate will become active.
Only 2 faults in the Cummins system that cause an Instant derate
Empty urea tank
NOx exceedence most severe

Activation of 50 hour derate

If a fault becomes active and is active for 50 hours of engine run
time the next time the vehicle speed = 0 the derate will engage
Any faults that have a direct link the engine emission will be a 50
hours derate

Deactivation of the derate

Once the failure is corrected the monitor will have to run and pass
once this has happened the derate will ramp out over a period of time
and the MIL will switch off.
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OBD Derate Torque Curve

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