09 Doosan TIER 4I Engine (120425)

Slide 1

Doosan Tier4-i Engine Sensors & Actuators

Date : 2012-04-25 EMEA Heavy line Training Team

Slide 2

INDEX

Doosan Infracore

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Slide 3

Contents

• Tier4i Engine Specification • Engi Engine ne system layout layout • Engi Engine ne sensors sensors • Engi Engine ne actuators actuators • ECU Terminal Terminal Diagram Diagram • ECU conne connectors ctors • CAN network configuration • CAN Msg. Msg. Information Information • Diagnostic Trouble Code • Basic concept concept of signal signal sensing • Engine Torque Derating • Engi Engine ne Fault Fault Lamp • Example of diagnostic trouble

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Slide 4

Tier4ii Engine Specification Tier4 System improvement fro m Previous Tier 3 Engine Engine Higher Combustion Pressure, Turbo System, Cooling Capacity, After treatment (EGR + DPF) (NOTE: (NOTE: SCR SCR will be added, for Tier4 Final Final Emission Regulation in the future) i t em ,

Ti er 3

Ti er 4 In t er i m

T i e r 4 Fi n a l

Combustion pressure (bar)

160

←

←

Turbo System

T C o r W G T*

W GT* or VGT**

←

Piston

Al-Gallery

Al-Gallery Material strength increased

←

Cyl.Block

Cast Iron

←

←

Cyl.Head

Cast Iron

←

←

Con-rod

Steel

Strength increased

←

Crankshaft

Steel

Strength increased

←

Cooling System

-

Capacity increment

←

EG R

I-EGR***

20 ~ 25 %

←

Yes

←

No

Yes

DPF SCR

-

* WGT : Waste Gate Turbocharger Turbocharger (Variable (Variable waste waste gate on DL06 Tier 4i) ** VGT : Variable Geometry Turbo Charger (DL08 Tier 4i) *** I-EGR : Internal Exhaust Gas Recirculation Recirculation Doosan Infracore

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Slide 5

Tier4 Engine Specification Tier4 interim Engine Power

Engine Model Model

DL08K

Performance

Code (Suffix)

Max. Power Kw / rpm

Max. Torque N.m / rpm

Idle RPM (rpm)

Max. RPM (rpm)

EHPEA

161 /1800 (216 PS / 1800)

970 / 1300 (99 kg.m / 1300)

800

1900

DL08-LDE01

216 /1800 (291 PS / 1800)

1274 /1300 (130 kg.m / 1300)

800

1900

DL08-LDE00

212 / 1800 (285 PS/ 1800)

1274 /1300 (130 kg.m / 1300)

800

1900

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Slide 6

Tier4 Engine Specification Tier4 interim Engine Power Engine Model Model

DL06K

Performance

Code (Suffix)

Max. Power (Kw / rpm)

Max. Torque (N.m / rpm)

Idle RPM (rpm)

Max. RPM (rpm)

DX255LC-3 (DL06-LDE03)

140 /1900 (188 PS / 1900)

804 / 1400 (82 kg m / 1400)

800

2020


126 / 1800 (169 PS / 1800)

755 /1400 (77 kg m / 1400)

800

1920


94 /1800 (127 PS / 1950)

529 /1950 (54 kg m / 1400)

800

2070


87 /1800 (117.8 PS / 1800)

502 /1400 (51.2 kg m / 1400)

800

1970

DX190W-3 (DL06-LDE06)

131 / 1900 (176 PS / 1900)

755 /1400 (77 kg m / 1400)

800

2020

DX170W-3 (DL06-LDE05)

114 / 2000 (154 PS / 2000)

647 /1400 (66 kg m / 1400)

800

2120

DX140W-3 (DL06-LDE04)

103 / 2000 (139 PS / 2000)

588 / 1400 (60 kg m / 1400)

800

2120

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Slide 7

Engine System Layout Tier4 interim Sensor Supplier information Component

Supplier

Air Mass Sensor with Temperature (HFM)

Delphi

Coolant / Fuel Temperature Sensor

Bosch

Rail Pressure Sensor

Bosch

Boost Pressure and Temperature Sensor

Bosch

Fuel Metering Unit (High Pressure Pump)

Bosch

Metering Unit (DPM)

Bosch

Oil Pressure / Temperature Sensor

Bosch

CAM / Crank Speed Sensor

Continental

Fan Speed Sensor/ Drive

BorgWarne

VGT (Variable Geometry Turbocharger)

BorgWarne

Throttle Valve Actuator

Seohan

EGR (Exhaust Gas Recirculation)

SONCEBOZ

DPF Differental Pressure Sensor

Sensata

Exhaust Gas Temperature Sensor (Before DOC)

NITE

Exhaust Gas Temperature Sensor (Before DPF)

NITE

Exhaust Gas Temperature Sensor (After DPF)

NITE

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Slide 8

Engine System Layout Sensor & Actuator positioning concept Boost Pressure & Temperature Sensor

Throttle Valve

CAM / CRS Sensor Oil Pressure & Temperature Sensor

Coolant Temperature Sensor

EGR Valve Injection Unit

T4,T5,T6 Temperature Sensors & Differential Pressure Sensor

Turbo Charger

Air m ass f low & Temperature Sensor

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Slide 9

Engine System Layout After tr eatm ent syst em ov erv iew o f DOOSAN TIER4i DPF syst em Diesel Fuel Return Fuel Pump

Fuel Filter

Diesel Fuel Inlet



TIER4i Engine



DPF Muffler (DOC + DPF)



MU + IU



Temperature Sensor (3 off)



Differential Pressure Sensor (1 off)

Fuel Tank

ECU

Metering Unit (MU) Diesel Engine

Actuat ors Engine CAN

Injection Unit (IU)

Diagnostic CAN

Temp Sensor

Differential Pressure Sensor

Temp Sensor

Temp Sensor

Engine Exhaust Gas

Glossary: DOC : Diesel Oxidation Catalyst DPF : Diesel Particulate Filter MU : Metering Unit IU : Injection Unit ECU : Engine Control Unit

DOC

DPF

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Slide 10

Engine System Layout After tr eatm ent syst em ov erv iew o f DOOSAN TIER4i DPF syst em The MU consists of a housing containing: • One Shutoff Valve (SV) • Two Pressure Sensors (PS) • One Dosing Valve (DV)

Cooling adapter

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Slide 11

Engine Sensor s (DL08)

1 7

3 6 4 5 2

1. 2. 3. 4. 5. 6. 7.

Boost Pressure & Temperature Sensor Coolant Temperature Sensor Crankshaft Speed Sensor Rail Pressure Sensor CP Pump Metering Unit Camshaft Speed Sensor Fuel Temperature Sensor

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Slide 12

Engine Sensors Boost Pressure & Temperature Sensor. Harness connector

4 3 2 1 No. 1 2 3 4

Sensor Value: Low (unit)

Sensor Value: Failure High (unit) Detection

Failure Indication

ECU Pin 290 237 207 286

Sensor Name

Sensed Parameter Range: Low / High (Units)

Default Mode Threshold value

Boost Temperature

Cold < 20 °C 20 C <= Normal <= 50 °C Hot > 50 °C

215.2 mV

4921.8 mV

By ECM

Replacement value = Frozen value (Last valid value: just before error was Check lamp =On detected during current operating cycle) Failure Code stored. Next operating cycle it will take the default value of 40 deg C

Boost Pressure

100kPa < Normal < 340kP a

202.8 mV

4873 mV

By ECM

Check lamp = Blink Failure Code stored.

Replacement value = 220 kPa

PIN description Ground Boost temperature signal + 5 V supply Boost pressure signal

Failure Consequence

Impacts on Emissions

N/A

N/A

* Torque limit 10%

VGT actuator is controlled by boost air pressure.

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Slide 13

Engine Sensors Coolant / Fuel Temperature Sensor. Harness connector

2 1

No. 1 2 Sensor Name

Sensed Parameter Range: High / Low (Units)

Coolant temperature ECU Pin PIN description 239 Coolant Temperature Signal 259 Ground

Sensor Value: Sensor Value: Failure Low (unit) High (unit) Detection

Failure Indication

Fuel temperature ECU Pin PIN description 212 Fuel Temperature Signal 259 Ground

No. 1 2


Failure Consequence

(Sensor Operating)

Cold < 60° C 60° C <= Normal <= 100 ° C Hot > 100° C

Coolant Temperature

Fuel Temperature

-30° C <= Normal <= 40 ° C

188.2 mV

188.2 mV

4929 mV

By ECM

4929 mV

By ECM

Check lamp =Blink and Failure Code stored.

Check lamp =On Failure Code stored.


105° C: Max. fuel rate 2% limit

Threshold temp = 105° C




Power derated for engine protection . 105 deg C: Torque 2% limit 110 deg C: Torque 20% limit


107° C : Engine check lamp On

107° C : Engine check lamp On

EGR Valve 0%, VGT 0%

(Sensor Failure) Replacement value engine is running = 85° C engine is not running = - 25° C

Torque limit 10% EGR valve 0% / VGT 0%

Power derated for engine protection only.

Replacement value = 48 ° C

N/A

N/A

115 deg C: Torque 50% limit

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Slide 14

Engine Sensors Camshaft Speed Sensor (DL08,DL06) Crankshaft Speed Sensor (DL06) Harness connector

1

Crankshaft Speed Sensor (DL06) No. ECU Pin PIN description 1 266 CRS POS 2 265 CRS NEG 3 269 Shield

Sensor Name


No. 1 2 3

Camshaft Speed Sensor (DL06) ECU Pin PIN description 268 CAS POS 267 CAS NEG 269 Shield

Sensor Signal

Failure Detection

Failure Indication

No. 1 2 3


2

3

Camshaft Sensor (DL08) ECU Pin PIN description 267 CAS NEG 268 CAS POS 269 Shield

Failure Consequence

Crankshaft Speed Sensor

650 rpm < normal < 2200 rpm

P ul se sig nal

B y E CM

Check lamp =on and Failure Code stored.

If the camshaft rotation counter crosses the threshold "threshold =4"and if the camshaft signal is tested and plausible the error is set

Torque limit 10% CAM shaft sensor back up mode

CAM Position Sensor

20 Hz < Normal < 95 Hz

Pulse signal

By ECM


In between of several crankshaft revolutions there is not any camshaft edge present. (Threshold = 4)

Starting delay during engine cranking. After cranking, no effect


Vehicle safety engine protection

Vehicle safety engine protection

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Slide 15

Engine Sensors Crankshaft Speed Sensor (DL08) Harness connector

2 1

No. 1 2

Sensor Name

Crankshaft Speed Sensor


Sensor Signal

Failure Detection

Failure Indication

P ul se sig nal

B y E CM


650 rpm < normal < 2200 rpm

Crankshaft Speed Sensor (DL08) ECU Pin PIN description 266 CRS POS 265 CRS NEG


Failure Consequence

If the camshaft rotation counter crosses the threshold "threshold =4"and if the camshaft signal is tested and plausible the error is set


Torque limit 10% CAM shaft sensor back up mode

vehicle safety engine protection

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Slide 16

Engine Sensors Rail Pressure Sensor. Harness connector

1

No. 1 2 3

Sensor Name


Fuel Pressure (High Pressure)

50MPa < Normal < 180MPa

Sensor Value: Sensor Value: Low (unit) High (unit)

ECU Pin 260 236 211

Failure Detection

Failure Indication


By ECM

Check lamp = Blink Failure Code stored.

Replacement value is varied according to CP pump metering unit.

2

3

PIN description Ground Rail pressure signal + 5 V supply

Failure Consequence


Torque limit 50% 268 mV

4868 mV

Rail pressure for opened PRV

Changes with speed / load conditions.

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Slide 17

Engine Sensors Air Mass Fl ow Senso r. Harness connector

B

A No. A B C D E

Sensor Name

Mass Air Flow (HFM) Sensor

Air Flow Temperature



Failure Detection

Failure Indication

100kg/hr < Normal < 1000kg/hr

70 us

7000 us

By ECM

Check lamp =Blink Failure Code stored.

Cold < 20° C 20° C <= Normal <= 30 ° C Hot > 30° C

400mV

4900mV

By ECM

Check lamp =on Failure Code stored.

ECU Pin 230 238 230 284 254

C

D

E

PIN description Ground Air temperature signal Ground + 12 V Frequency output


Replacement value = Model value by Boost pressure and Boost temperature When Boost sensor is failed, engine chooses mapping value by engine rpm. Replacement value = Frozen value (Last valid value: just before error was detected) at detect operating cycle

Failure Consequence

Torque limit 10% EGR valve = 0 % VGT = 0%

EGR Valve = 0% VGT = 0%

Next operating cycle will take default value ( 30 ° C)

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Slide 18

Sensors & Actuators (DL08)

1 2

3

4

1. 2. 3. 4.

EGR Valve (Exhaust Gas Recirculation) T h ro t tl e Va lv e VGT (Variable Geometry Turbo) Oil Pressure & Temperature Sensor

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Slide 19

Engine Actuator Smart Actuator. (EGR) Harness connector

- The *SRA controls the position using an internal closed-loop system. - CAN Communication is used to input / output information to the SRA. - If the EGR does not receive a valid CAN signal.  It goes to its Default position of 0%. (Fully Closed, no EGR)

Smart Remote Actuator

Supply Voltage

9V ~ 32V

Typical Operating Voltage

13.8V ~ 28V

M ax . O pe rat in g T em p. R an ge

1 40

℃

Mi n. Oper at ing Tem p. Range

- 40

℃

ambient

Max. Storage Temp. Range

-50

℃

~ 150 ℃

CAN communication Baud rate

250k bits/s

EGR Flow Control

2

1

24V

Operating Voltage

Sensor or Actuator Name

4

3

Sensed Parameter Range: Low /High (Units)

0 < Normal < 100%

ambient (with water cooling, max. 110 ℃)

No. 1 2 3 4

ECU Pin Vbat GND 218 217

EGR Valve PIN description +24 Volt supply Ground CAN 2 Low CAN 2 High

Sensor Actuator contr ol

Fai lu re D et ec ti on

F ai lu re I nd ic at io n

Default Mode / threshold value

Failure Consequence

Controls itself (Smart Control)

By itself (Sends message to ECM)

Engine Check lamp =On Failure Code stored.

0 ~ 100%

N/A


If EGR is deactivated, NOx emissions increase.

* SRA: Smart Remote Actuator

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Slide 20

Engine Actuator Smart Actuator. (EGR) To minimize formation of NOx, recirculation of some of the exhaust gas into combustion chamber along with the fresh air is used (lowers oxide concentration and decreases combustion temperature)

EGR Valve

Inter-cooler

Turbocharger

Fresh Air

EGR Cooler

DPF

Exhaust Gas

Cooled EGR (Exhaust Gas Recirculation) – Uses a water cooled heat exchanger (EGR Cooler) to cool down the exhaust gas being used for recirculation, to minimize its volume.

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Slide 21

Engine Actuator Smart Actuator. (EGR) Current Air Mass (AFS_mAirPercyl)

Coolant Temp.

Desired Value Calculation

HFM Air Temp.

Air Ctl_m DesVal Desired air mass set point (mg/hub)

PI-Controller Adjusting the Measured air mass to match the desired set point air mass

Air Ctl_rCt lVal

Engin e RPM

Air Ctl_rGo vEGR

EGRVlv_r

Working ranges Sys. error Mon Transient detection

Air Ctl _Gov Closed-Loop Control

EGR open-loop control value (%)

Monitoring and Shut-off

Injection Quantity

EGR

E ng in e St op (I GN O n)

E ng in e R un ni ng (I dl e 8 00 rp m )

E ng in e Ru nn in g ( 90 0r pm )

EGR Valve Closed (0%)

0%

20% ~ 23 %

The function processes and transmits the message every 10ms cycle time of the CAN interface according to SAE J1939, with update rate of 10ms. The first two bytes of CAN Frame is used to transmit EGR valve position value Tx / Rx ECU  EGR

ECU  EGR

Name

Transmission Repetition

ComTx_EDC2EGRVLV

10ms

ComRx_EGRVlv2EDC

20ms

ComRx_EGRErrSt

100ms

Realized Byte Byte 1,2[1..8] : EGR Actuator Position Request Byte 3[1..8] : EGR Actuator Comm and State Byte 0 : Actuator state Byte 1,2 : Actuator actual shaft position Byte 3 : Actuator In ternal temperature Byte 4 : Actuator fault code Byte 5,6 : Actuator target shaft position Byte 7 : Actuator Motor Effort Byte 0 ~ Byte 7 : Actuator Fault Code Doosan Infracore

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Slide 22

Engine Actuator Throttle Valve Actuator.

Harness connector

6 2 1

Characteristic

Position Angle

Mechanical Stop Min. E lectrical closed position Max. Electrical open position DC-Motor unpowered

Actuator Name

Throttle Feed back sensor

0° 1.8° 84° 89 °

Sensor Output(%Vdd) (Based On 5V Voltage Supply) 90±1% (4.5V) 88.5% (4.425V) 18.51%(0.926V) 14.25±3.5% (0.713V)

No. 1 2 3 5 6

ECU Pin 234 229 240 215 205

3

5

PIN description 5 Volt supply DC motor Ground Feedback sensor signal DC motor +


Sensor - Actuator Value: Low (unit)

Sensor / Actuator Value: High (unit)

F ai l ur e De t ec t i on

F ai l u re In d i ca ti o n

Default Mode / threshold value

Failure Consequence

0 < Normal < 100 NOTE: (Activated only when DOC upstream temperature is < 230 ° C, else 0% full open.)

400mV

4800mV

By ECM

Check lamp =On Failure Code stored.

When throttle value feedback failed Default value = 0%

Torque limit 25% EGR valve = 0%

OC = Oxydation Catalyst Doosan Infracore

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Slide 23

Engine Actuator Smart Remote Actuator. (VGT Only On DL08 Engines) - The SRA controls its position by use of an internal closed-loop system.

Harness connector

- CAN Communication is used to input / output information to the SRA. - If the VGT does not receive a valid CAN signal for 1sec.  Default position 15%. - Once the VGT receives a valid CAN signal for 4 sec.  resumes normal operation.

1

Smart Remote Actuator

2

24V

Reduced Function

18V ~ 22V and 32V ~ 36V

Full Function

22V ~ 32V

Max. Operating Temp. Range

-40

℃

~ 130

℃

Max. Storage Temp. Range

-40

℃

~ 150

℃

CAN communication Baud rate

250k bits/s

VGT

VGT Control and Position Sensor

0 < Normal < 100%

No. 1 2 3 4

(140 ℃ for 100 hours)

Sensed Parameter Range: Low / High S en s o r - A c t u at o r c o n tr o l (Units)

Sensor or Actuator Name

3 4

Supply Voltage

Controls itself (Smart Control)

F ai l u re D et ec t i on

F ai l ur e I n di c at i on

By itself (Sends message to ECM)


ECU Pin Vbat GND 218 217

Default Mode threshold value

PIN description +24 Volt supply Ground CAN 2 Low CAN 2 High

F ai lu r e C on s eq u en c e

0~100%

N/A

I mp ac ts o n E mi s si on s

VGT pressure controls boost and EGR pressures so that proportionality is maintained and EGR can be driven into the intake air supply. Also manages power control via the Speed/Load (Boost) tables

* SRA: Smart Remote Actuator Doosan Infracore

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Slide 24

Engine Actuator Smart Actuator. (VGT Only DL08) Boost pressure sensor value

PCR_pDesVal boost-pressure set point (hPa) PID- Controller PCR_rGov

PCR_rCtlVal VGT open-loop control value (%)

Engin e RPM

Minimize the deviation between pressure set point and boost pressure sensor

Monitoring and Shut-off

TrbCh_r

Working ranges Sys. error Mon Transient detection

PCR _Gov Closed-Loop Control

Injection Quantity

VGT

E ng in e St op ( IG N O ff )

E ng in e St op ( IG N O n)

En gi ne Ru nn in g (I dl e 8 00 rp m )

0%

34%

34% ~ 43%

The message TrbCh_rPosVGT gives the demanded position of VGT actuator which is the output duty cycle to power stage .The duty cycle is updated into position demand message Com_rPosEDC2VGTB. Com_rPosEDC2VGTB takes a value 0 for 0% open and 1000 for 100% open. Tx / Rx

Name

Transmission Repetition

ECU  VGT

ComTx_EDC2VGTB

10ms

ECU  VGT

ComRx_VGTB2EDC

30ms

Realized Byte Byte 0,1 : Position demand for actuator in terms of duty cycle Byte 2[0] : Switch status for motor Byte 2[1] : Switch status for learn permission Byte 0,1 : Actual shaft position of actuator Byte 2 : Internal temperature of the actuator Byte 3,4 : Span percent of end of li ne Byte 5 : Power applied to the moto r Byte 6 : Fault and warning messages Byte 7[1] : Actuator learn status Doosan Infracore

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Slide 25

Engine Sensors Oil Pressure & Temperature Sensor. Harness connector

4 3 2 1 No. 1 2 3 4

Sensor Name



Sensor Value: High (unit)

Failure Detection

Failure Indication

Oil Temperature

-30° C <= Normal <= 115 ° C

232.2 mV

4924.4 mV

By ECM

Failure Code stored.

Oil Pressure

400kPa < Normal < 600kPa

202.8 mV

4924.2 mV

By ECM


ECU Pin 206 213 231 235

Default Mode Threshold value Replacement value = Coolant temperature MIN Threshold pressure 800 rpm : 220 kPa 900 rpm : 240 kPa 1000 rpm : 260 kPa 1200 rpm : 280 kPa 1600 rpm : 300 kPa 3200 rpm : 320 k=hPa

PIN description Ground Oil temperature signal + 5 V supply Oil pressure signal

Failure Consequence


N/A

N/A

Torque limit 50% Only for Engine protection Check lamp only.


N/A

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Slide 26

Metering Unit & Exhaust System Sensors (DL08)

5 6 7 8

2

3

1

4

1. 2. 3. 4. 5. 6. 7. 8.

S h ut Of f Va l ve Upstream Pressure & Temperature Sensor D os i ng V al v e Downstream Pressure Sensor DOC Upstream Temperature Sensor DPF Upstream Temperature Sensor DPF Downstream Temperature Sensor DPF Differential Pressure Sensor

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Slide 27

Metering Unit Metering Unit (Shut Off Vale & Dosing Valve) Harness connector Dosing Valve

2

2

1

1

Shutoff Valve

Dosing Valve

No.

ECU Pin

PIN description

No.

ECU Pin

PIN description

1

120

Shutoff valve high side

1

122

Dosing valve high side

2

145

Shutoff valve low side

2

124

Dosing valve low side

Dosing Valve Feature Normal value Coil resistance 15.95 Ω

Shutoff Valve Feature Normal value Coil resistance 3.3Ω Shut Off Valve

Cooling adapter

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Slide 28

Metering Unit Metering Unit (Upstream Pressur e & Temperature Sensor) Harness connector Upstream

4 3 2 1 No. 1 2 3 4

Sensor Name

HCI Upstream Pressure HCI Upstream Temperature


0 kpa < Normal < 1200 kpa

-40° C < Normal < 130° C


Failure Detection

Failure Indication

ECU Pin 133 142 191 130


PIN description Ground Temperature signal +5 V supply Pressure signal

F ai l ur e C o ns eq u en c e

I mp a ct s o n E mi s s io n s

250 mV

4850 mV

By ECM

Check lamp = Blink Replacement value Failure Code stored = 300 kpa

Inhibit the HC dosing Torque limit 25%

Exhaust Gas temperature control for DPF regeneration.

250 mV

4750 mV

By ECM

Check lamp = On Replacement value Failure Code stored = 48° C

Inhibit the HC dosing

Exhaust Gas temperature control for DPF regeneration.

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Slide 29

Metering Unit Metering Unit (Downstr eam Pressure.) Harness connector

No. 1 2 3

Downstream Pressure Sensor

Sensor Name

Downstream Pressure Sensor


ECU Pin 167 133 156


Sensor Value: High (unit)

Failure Detection

Failure Indication


250 mV

4750 mV

By ECM


Replacement value = 200 kpa

0 kpa < Normal < 1200 kpa

3

2

1

PIN description +5 V supply Ground Pressure signal

Failure Consequence


Active Regeneration is Exhaust Gas temperature prevented control for DPF Torque limit 25% regeneration.

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Slide 30

Exhaust System Sensors Exhaust Gas Temperature Sensors Harness connector

2 1

No. 1 2

T4 DOC upstream ECU Pin PIN description 116 Temperature signal 118 Ground

Sensor Name


No. 1 2

T5 DPF upstream ECU Pin PIN description 117 Temperature signal 118 Ground


Failure Indication


No. 1 2

T6 DPF downstream ECU Pin PIN description 140 Temperature signal 143 Ground

F ai l ur e C on s eq u en c e

Torque limit 25% EGR valve = 0 %

Inhibit the HC dosing system Torque limit 25% EGR valve = 0 % Inhibit HC dosing

HC dosing module is controlled by temperature sensor between DOC and DPF


Exhaust Gas Temperature Sensor (T4 Upstream of DOC)

-40° C <= Normal <= 500 ° C

Exhaust Gas Temperature Sensor (T5 Between DOC and DPF)

-40° C <= Normal <= 500 ° C 200° C <= DPF RGN <= 800 ° C

Exhaust Gas Temperature Sensor (T6 Downstream of DPF)

-40° C <= Normal <= 500 ° C 200° C <= DPF RGN <= 800 ° C

200 mV

200 mV

500 mV

3000 mV

4900 mV

1800 mV

By ECM


Check lamp =on Failure Code stored. By ECM

By ECM

Check lamp =Blink Failure Code stored. Check lamp =Blink Failure Code stored.

Replacement value = 200° C Threshold temp = 700° C Replacement value = 200° C

Replacement value = 200° C

I mp a ct s o n E mi s s io n s HC dosing module can start dosing by upstream DOC temperature sensor. Regeneration is not allowed at idle but may be allowed at light load conditions where upstream temperature is above 200°C.

N/A

N/A

Note: HC means Hydro Carbon (ie. Diesel Fuel) Doosan Infracore

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Slide 31

Exhaust System Sensors DPF Differential Pressure Sensor. Harness connector Supply Voltage (Vcc)

Ground

1 2 3

1 Output Signal

Sensor Name

DPF Differential Pressure


0 kPa <= Normal or RGN <= 9 kPa DPF Cleaning at >12 kPa

No. 1 2 3


85 mV

4085 mV

ECU Pin 190 143 155

Failure Indication


Red Stop lamp = On Failure Code stored

Threshold = 20 kPa

Check lamp = On Failure Code stored.


By ECM

2

3

PIN description + 5 V supply Ground Diff pressure signal

Failure Consequence


DPF plugging and cracking can be found by DPF differential pressure sensor. Torque limit 10% Monitors DPF soot / ash loading to establish service / maintenance intervals.

Note: A reading o f >2 kPa at idle with no load indic ates a blocked DPF

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Slide 32

ECU Terminal Diagram

Slide 33


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Slide 34

ECU Terminal Diagram Engine ECU

Injector Solenoids

Engine Connector

Vehicle Connector

Injector 1, Bank 1

Injector 2, Bank 1

Injector 3, Bank 1

Injector 1, Bank 2

Injector 2, Bank 2

Injector 3, Bank 2

Fuel Metering Unit (ZME) Rail Pressure Control Valve (DRV)

Rail Pressure Sensor

Slide 35


Air Flo w Meter Shield

Oil Pressure & Temperature Sensor

Can H0

Boost Pressure & Temperature Sensor

Can L0 Shield Can H1 Can L1

Variable Turbo Geometry (VGT) Act uator 1 / Waste Gate1

Shield

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Slide 36


(Preheat Symbol)

HCI Pressure Sensor Downstream

HCI Pressure & Temperature Sensor Upstream

Throttle Plate Actu ator

Throttle Plate Actu ator

HCI Metering Valve

Engine Brake Actuator 1 Internal Engine Decompression Valve

HCI Shut-Off Valve DPF Differential Pressure Sensor

Turbine Wheel Speed Sensor A

Controller Area Network 2

EGR Differential Pressure Sensor

Shield

DPF Exhaust Temperature Sensor (T6) DPF Exhaust Temperature Sensor (T5) DPF Exhaust Temperature Sensor (T4)

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Slide 37


Camshaft Speed Sensor Output Signal Crankshaft Speed Sensor Output Signal

Inhibit Regenerate

DPF Regeneration Switch

Fuel Temperature Sensor Coolant Temperature Sensor

Crankshaft Speed Sensor Shield

Engine Emergency Stop Switch Camshaft Speed Sensor

Shield

Fuse “14” of Fuse Box “1” Pre Heat Relay Terminal “ C” Pre Heat Relay Terminal “ D” Starter Switch Terminal “R2” Fuse “11” of Fuse Box “1”

Note: Fuse “11” of Fuse Box “ 1” is Key Controlled Fuse “14” of Fuse Box “1” is Constant 24vSupply Doosan Infracore

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Doosan Infracore

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Slide 38


Slide 39

Engine Harness Layout

* ECU mounted on machine Note: With the ECU not mounted on the engine, it is no longer cooled by fuel.

Doosan Infracore

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Slide 40

ECU Connecto r Connector (96-way mod ule)

Vehicle side

Locking Slide

Engine side

73

1

96

24

73

1

Locking lever

96

24

Doosan Infracore

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Slide 41

CAN Network Configuration Machine controller (EPOS)

Vehicle side

CAN 0 High : Pin No. 146

CAN 0

120 Ω

120 Ω

CAN 0 Low : Pin No. 147


Communication with computer

CAN 1

EDC17 ECU

(use only for Dev. Engineer)


Engine side


CAN 2

120 Ω

120 Ω


EGR

VGT

Doosan Infracore

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Slide 42

CAN Massage Informati on (ECU – EPOS)

0x0CFF0117

0x18F00100

50ms

100ms

Byte0 Byte1

Accelerator pedal position Accelerator pedal position

0x0CF00300

50ms

Bit0~1

Byte0~1 Byte2

Unused Percent Load at current Speed

Unused Auxiliary Engine Shutdown Switch

0x0CF00400

10ms

Bit4~5

Byte0~1 Byte2

Unused Actual Engine - Percent Torque

0x18FEEE00

1000ms

Byte0~2

Byte3~4 0x18EA0017

0x18FF2800

1000ms

1000ms

Byte0 Byte1

PGN number low byte PGN number mid byte

Byte2

PGN number high byte

Byte0

Bit0~1

status message to reduce fan speed by 0%

By te1

Bit0~1


By te2

Bit0~1


By te3

Bit0~1


By te4

Bit0~1


Engine Speed

Byte0

Engine Collant Temperature

Byte1 By te 2~3 0x18FEEF00

0x18FEF200

500ms

100ms

Fuel Temperature Eng ine Oi l Te mpe rat ur e

Byte0

Engine Fuel Delivery Pressure

Byte3

Engine Oil Pressure

Byte0~1

Fuel Rate

By te6

Engine Throttle Position

0x18FE8C17

1000ms

Byte0

Hydraulic Oil Temperature

0x18FDCB1 7

100ms

Byte0

Unused

Byte1

Boost Pressure

Pilot Cutoff Status

Byte2

Intake Manifold temperature

0x18FEF600

Bit2~3

0x18FEBD00

500ms

1000ms

0x18FEE900 receiv ing a PGN request

1000ms

Byte0

Byte0 Byte2~3

Fan Speed

Byte0~3 By te 4~7

To tal F uel Co ns ump ti on Diesel Particulate Filter Regeneration

By te 0

B it 1 .. 3 status Lamp Command

By te 3

B it 3 .. 4 Status Lamp command

By te 7

B it 3 .. 5

DPF Active Regeneration Inhibited Exhaust System High Temperature Lamp Command

Doosan Infracore

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Slide 43

Diagnostic Trouble Shooting Codes DTC List No.

DTC

1

C028

Bus Off error CAN A

Description

2

C046

Bus Off error CAN C

3

C10A

EGR valve actuator communication loss error

4

C10C

Timeout error of CAN receive from VGT

5

C121

Timeout error of CAN receive from TCU

6

C122

Timeout Error of CAN-Receive-From DEC1V

7

C123

Accel pedal CAN max error

8

C124

Timeout error of CAN receive from Vehicl e cut off s witc h

9

C125

Vehicle cutoff switch error

10

C1 41

T imeou t E rr or of CA N- Rec ei ve- Fr om H yd raul ic oil t emp er at ur e

11

C40B

EGR valve actuator error

12

C40D

VGT actuator error

13

D100

Engine shut off request from EPOS

14

P0087

Monitoring for minimum rail pressure

15

P0088

Monitoring f or maximum rail pressure

16

P 0089

pr es sur e r eli ef val ve is out of rang e : in cr eas e, pr es su re shoc k

17

P 0096

P hys ic al Si gnal Rang e hi gh on the air mas s f low sens or temp er at ur e

18

P0100

Battery voltage error of HFM sensor

19

P0101

Sens itivit y drift out of range error for HFM s ens or

20

P0102

SRC low error for raw value in HFM sensor

21

P 0103

S CB of har dw ar e s ign al or SRC h igh er ror for raw val ue of HFM sens or

22

P0112

SRC Low for boost temperature

23

P0113

SRC High for boost temperature

24

P 0116

P hys ic al out of r ang e c hec k hi gh f or c ool ant temp er at ur e

:

:

:

Doosan Infracore

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Slide 44

Basic Concept Of Signal Sensing

Raw value

ADC

Signal Range Check

Raw value

Sensed value

[mV]

[deg C]

Physical Range Check

Signal used in Appli cati on Software

[deg C]

< Transfer curve > SRC MAX

SRC MIN

Physical range MAX

Physical range MIN

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Slide 45

Engine Torque Derating Torque Derating

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Slide 46

Engine Fault Lamp Error Code Class & Lamp Information

Failure OK

Display Action

Display

No Lamp

Level 1

SVS Lamp “On”

Level 2

SVS Lamp “Blinking”

Level 3

MIL “On”

Fault Lamp On: It is necessary to take a service when the engi ne has a system error. Service Lamp On : Sensor/ Actuator electronic error or mechanical system error Service Lamp Blinking : Sensor/ Actuator electronic error or mechanical system error with Engine Torque Derating Maintenance Indicator L amp On : DPF related error with DPF protection (ex. Soot max error, DPF differential pressure error) Engine stop and take a service immediately when the error is occurred.

Doosan Infracore

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Slide 47

Example Of Diagnostic Trouble Troub le Shooting DTC C122

Description Timeout Error of CAN-Receive-Frame DEC1V

Model: DX340LC-3 Symptom - SVS Lamp Blinking (only active error) - 1200 RPM shift down and fixed

Check Result -Only history error was stored in EEPROM - Check the msg. missing using the measuring tool

Doosan Infracore

Slide 48

- EOD -

Doosan Infracore

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09 Doosan TIER 4I Engine (120425)

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