09 Doosan Tier 4i Engine (120425)

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Doosan Tier4-i Engine Sensors & Actuators

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

Slide 2

INDEX 1. Development Background 2. Boring Parts & Lubrication 3. FIE system 4. Breather system 5. Cooling system 6. EGR system 7. Regeneration system 8. Forced Regeneration 9. Sensors & Actuators

Doosan Infracore

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Contents

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

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Tier4i Engine Specification System improvement from Previous Tier 3 Engine Higher Combustion Pressure, Turbo System, Cooling Capacity, After treatment (EGR + DPF) (NOTE: SCR will be added, for Tier4 Final Emission Regulation in the future) item,

Tier 4 Interim

Tier 4 Final

160

←

←

TC or WGT*

WGT* or VGT**

←

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

←

EGR

I-EGR***

20 ~ 25%

←

Combustion pressure (bar) Turbo System Piston

Tier 3

DPF SCR

-

Yes

←

No

Yes

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

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Slide 5

Tier4 Engine Specification Tier4 interim Engine Power

Engine Model Model

Performance Max. Power Kw / rpm 161 /1800 (216 PS / 1800) 216 /1800 (291 PS / 1800) 212 / 1800 (285 PS/ 1800)

Code (Suffix) EHPEA

DL08K

DL08-LDE01 DL08-LDE00

Max. Torque N.m / rpm 970 / 1300 (99 kg.m / 1300) 1274 /1300 (130 kg.m / 1300) 1274 /1300 (130 kg.m / 1300)

Idle RPM (rpm)

Max. RPM (rpm)

800

1900

800

1900

800

1900

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Slide 6

Tier4 Engine Specification Tier4 interim Engine Power Engine Model Model

DL06K

Performance

Code (Suffix) DX255LC-3 (DL06-LDE03) DX225LC-3 (DL06-LDE00) DX180LC-3 (DL06-LDE02) DX140LC-3 (DL06-LDE01)

Max. Power (Kw / rpm) 140 /1900 (188 PS / 1900) 126 / 1800 (169 PS / 1800) 94 /1800 (127 PS / 1950) 87 /1800 (117.8 PS / 1800)

Max. Torque (N.m / rpm) 804 / 1400 (82 kg m / 1400) 755 /1400 (77 kg m / 1400) 529 /1950 (54 kg m / 1400) 502 /1400 (51.2 kg m / 1400)

DX190W-3 (DL06-LDE06) DX170W-3 (DL06-LDE05) DX140W-3 (DL06-LDE04)

131 / 1900 (176 PS / 1900) 114 / 2000 (154 PS / 2000) 103 / 2000 (139 PS / 2000)

755 /1400 (77 kg m / 1400) 647 /1400 (66 kg m / 1400) 588 / 1400 (60 kg m / 1400)

Idle RPM (rpm)

Max. RPM (rpm)

800

2020

800

1920

800

2070

800

1970

800

2020

800

2120

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 mass flow & Temperature Sensor

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Slide 9

Engine System Layout After treatment system overview of DOOSAN TIER4i DPF system  TIER4i Engine  DPF Muffler (DOC + DPF)  MU + IU  Temperature Sensor (3 off)  Differential Pressure Sensor (1 off)

Diesel Fuel Return Fuel Pump Fuel Filter

Diesel Fuel Inlet

Fuel Tank

ECU

Metering Unit (MU) Diesel Engine

Actuators 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 treatment system overview of DOOSAN TIER4i DPF system 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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Engine Sensors (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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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 detected during current operating cycle) Check lamp =On Failure Code stored. Next operating cycle it will take the default value of 40 deg C

Boost Pressure

100kPa < Normal < 340kPa

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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Engine Sensors Coolant / Fuel Temperature Sensor. Harness connector

2 1

No. 1 2 Sensed Parameter Range: High / Low (Units)

Sensor Name

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

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

Default Mode Threshold value

Failure Consequence

(Sensor Operating) Threshold temp = 105° C

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.

Impacts on Emissions

105° C: Max. fuel rate 2% limit

Power derated for engine protection .

110° C: Max. fuel rate 20% limit

105 deg C: Torque 2% limit

Threshold temp = 110° C

115° C: Max. fuel rate 50% limit

Threshold temp = 115° C

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

110 deg C: Torque 20% limit 115 deg C: Torque 50% limit

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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

Sensed Parameter Range: High / Low (Units)

No. 1 2 3

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

Sensor Signal

Failure Detection

Failure Indication

No. 1 2 3

Default Mode Threshold value

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

Pulse signal

By ECM

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

Check lamp =on and Failure Code stored.

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

Starting delay during engine cranking. After cranking, no effect

Impacts on Emissions

Vehicle safety engine protection

Vehicle safety engine protection

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Engine Sensors Crankshaft Speed Sensor (DL08) Harness connector

2 1

No. 1 2

Sensor Name

Crankshaft Speed Sensor

Sensed Parameter Range: High / Low (Units)

Sensor Signal

Failure Detection

Failure Indication

Pulse signal

By ECM

Check lamp =on and Failure Code stored.

650 rpm < normal < 2200 rpm

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

Default Mode Threshold value

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

Impacts on Emissions

Torque limit 10% CAM shaft sensor back up mode

vehicle safety engine protection

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Engine Sensors Rail Pressure Sensor. Harness connector

1

No. 1 2 3

Sensor Name

Sensed Parameter Range: Low / High (Units)

Fuel Pressure (High Pressure)

50MPa < Normal < 180MPa

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

ECU Pin 260 236 211

Failure Detection

Failure Indication

Default Mode Threshold value

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

Impacts on Emissions

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 Flow Sensor. Harness connector

B

A No. A B C D E

Sensor Name

Mass Air Flow (HFM) Sensor

Air Flow Temperature

Sensed Parameter Range: Low / High (Units)

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

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

Failure Consequence

Default Mode Threshold value

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

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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Sensors & Actuators (DL08)

1 2

3

4

1. 2. 3. 4.

EGR Valve (Exhaust Gas Recirculation) Throttle Valve VGT (Variable Geometry Turbo) Oil Pressure & Temperature Sensor

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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

4

Supply Voltage

24V

Operating Voltage

9V ~ 32V

Typical Operating Voltage

13.8V ~ 28V

Max. Operating Temp. Range

140 ℃ ambient (with water cooling, max. 110℃)

Max. Storage Temp. Range

-40 ℃ ambient

CAN communication Baud rate

250k bits/s

Min. Operating Temp. Range

Sensor or Actuator Name

EGR Flow Control

Sensed Parameter Range: Low /High (Units)

0 < Normal < 100%

-50 ℃ ~ 150 ℃

No. 1 2 3 4

ECU Pin Vbat GND 218 217

3

2

1

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

Sensor Actuator control

Failure Detection

Failure Indication

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

Impacts on Emissions

If EGR is deactivated, NOx emissions increase.

* SRA: Smart Remote Actuator

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

Coolant Temp. HFM Air Temp.

Desired Value Calculation

AirCtl_mDesVal Desired air mass set point (mg/hub)

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

AirCtl_rCtlVal

Engine RPM

AirCtl_rGovEGR

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

Engine Stop (IGN On)

Engine Running (Idle 800rpm)

Engine Running (900rpm)

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

Name

Transmission Repetition

ECU  EGR

ComTx_EDC2EGRVLV

10ms

ECU  EGR

ComRx_EGRVlv2EDC

20ms

ComRx_EGRErrSt

100ms

Realized Byte Byte 1,2[1..8] : EGR Actuator Position Request Byte 3[1..8] : EGR Actuator Command State Byte 0 : Actuator state Byte 1,2 : Actuator actual shaft position Byte 3 : Actuator Internal 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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Engine Actuator Throttle Valve Actuator.

Harness connector

6 2 1

Characteristic

Position Angle

Mechanical Stop Min. Electrical 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 +

Sensed Parameter Range: High / Low (Units)

Sensor - Actuator Value: Low (unit)

Sensor / Actuator Value: High (unit)

Failure Detection

Failure Indication

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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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 Max. Storage Temp. Range

-40 ℃ ~ 130 ℃ (140 ℃ for 100 hours)

CAN communication Baud rate

250k bits/s

VGT

VGT Control and Position Sensor

0 < Normal < 100%

No. 1 2 3 4

-40 ℃ ~ 150 ℃

Sensed Parameter Range: Low / High Sensor - Actuator control (Units)

Sensor or Actuator Name

3 4

Supply Voltage

Failure Detection

By itself (Sends message to ECM)

Controls itself (Smart Control)

Failure Indication

Check lamp =on and Failure Code stored.

ECU Pin Vbat GND 218 217

Default Mode threshold value

Failure Consequence

0~100%

N/A

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

Impacts on Emissions 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 (%)

Engine 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

Engine Stop (IGN Off)

Engine Stop (IGN On)

Engine Running (Idle 800rpm)

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 line Byte 5 : Power applied to the motor 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

Sensed Parameter Range: Low / High (Units)

Sensor Value: Low (unit)

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

Check lamp =Blink Failure Code stored.

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

Impacts on Emissions

N/A

N/A

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

Replacement value = 450 kPa

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.

Shut Off Valve Upstream Pressure & Temperature Sensor Dosing Valve 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

No. 1 2

1

Shutoff Valve ECU Pin PIN description 120 Shutoff valve high side 145 Shutoff valve low side

No. 1 2

Dosing Valve ECU Pin PIN description 122 Dosing valve high side 124 Dosing valve low side

Dosing Valve Feature Normal value Coil resistance 15.95Ω

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 Pressure & Temperature Sensor) Harness connector

Upstream P_T

4 3 2 1 No. 1 2 3 4

Sensor Name

HCI Upstream Pressure HCI Upstream Temperature

Sensed Parameter Range: Low / High (Units)

0 kpa < Normal < 1200 kpa

-40° C < Normal < 130° C

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

250 mV

250 mV

4850 mV

4750 mV

Failure Detection

Failure Indication

ECU Pin 133 142 191 130

Default Mode threshold value

PIN description Ground Temperature signal +5 V supply Pressure signal

Failure Consequence

Impacts on Emissions

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.

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 (Downstream Pressure.) Harness connector

No. 1 2 3

Downstream Pressure Sensor

Sensor Name

Downstream Pressure Sensor

Sensed Parameter Range: Low / High (Units)

ECU Pin 167 133 156

Sensor Value: Low (unit)

Sensor Value: High (unit)

Failure Detection

Failure Indication

Default Mode threshold value

250 mV

4750 mV

By ECM

Check lamp =Blink Failure Code stored.

Replacement value = 200 kpa

0 kpa < Normal < 1200 kpa

3

2

1

PIN description +5 V supply Ground Pressure signal

Failure Consequence

Impacts on Emissions

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

Sensed Parameter Range: Low / High (Units)

No. 1 2

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

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

Failure Indication

Default Mode threshold value

No. 1 2

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

Failure Consequence

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 =Blink Failure Code stored.

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

Impacts on Emissions

Torque limit 25% EGR valve = 0 %

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.

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

Threshold temp = 600° 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)

1 2 3

Ground

1 Output Signal

Sensor Name

DPF Differential Pressure

Sensed Parameter Range: Low / High (Units)

No. 1 2 3

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

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

85 mV

4085 mV

ECU Pin 190 143 155

Failure Indication

Default Mode threshold value

Red Stop lamp = On Failure Code stored

Threshold = 20 kPa

By ECM

2

3

PIN description + 5 V supply Ground Diff pressure signal

Failure Consequence

Impacts on Emissions

DPF plugging and cracking can be found by DPF differential pressure sensor. Torque limit 10%

Check lamp = On Replacement value Failure Code stored. = 3 kPa

Monitors DPF soot / ash loading to establish service / maintenance intervals.

Note: A reading of >2 kPa at idle with no load indicates a blocked DPF

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Slide 32

ECU Terminal Diagram

Slide 33

ECU Terminal Diagram

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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

ECU Terminal Diagram

Air Flow Meter Shield

Oil Pressure & Temperature Sensor

Can H0

Boost Pressure & Temperature Sensor

Can L0 Shield Can H1 Can L1

Variable Turbo Geometry (VGT) Actuator 1 / Waste Gate1

Shield

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Slide 36

ECU Terminal Diagram

(Preheat Symbol)

HCI Pressure Sensor Downstream

HCI Pressure & Temperature Sensor Upstream

Throttle Plate Actuator

Throttle Plate Actuator

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

ECU Terminal Diagram

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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Slide 38

ECU Terminal Diagram

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.

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Slide 40

ECU Connector Connector (96-way module)

Vehicle side

Locking Slide

Engine side

73

1

96

24

73

1

Locking lever

96

24

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Slide 41

CAN Network Configuration

CAN 0 High : Pin No. 146

Machine controller (EPOS)

Vehicle side

CAN 0

120 Ω

120 Ω

CAN 0 Low : Pin No. 147

CAN 1 Low : Pin No. 195

Communication with computer

CAN 1

(use only for Dev. Engineer)

CAN 1 High : Pin No. 171

EDC17 ECU

Engine side CAN 2 Low : Pin No. 218

CAN 2

120 Ω

120 Ω

CAN 2 High : Pin No. 217

EGR

VGT

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Slide 42

CAN Massage Information (ECU – EPOS) New ID Sub Title DEC1_V 0x0CFF0117 EBC1 0x18F00100

Period 50ms

100ms

Data Byte

Bit

Byte0 Byte1

Bit0~1

Byte0~2 Bit4~5

Request PGN 0x18EA0017

1000ms

Byte0 Byte1 Byte2 Receive Frame to control fan speed : DL06 Fan Clutch 0x18FF2800 1000ms Byte0 Bit0~1 Bit0~1 Byte1 Byte2 Bit0~1

Name Accelerator pedal position Accelerator pedal position Unused Auxiliary Engine Shutdown Switch

New ID Period Sub Title EEC2 : Electronic Engine Controller 2 0x0CF00300 50ms EEC1 : Electronic Engine Controller 1 0x0CF00400 10ms

PGN number low byte PGN number mid byte PGN number high byte

ET1 : Engine Temperature 1 0x18FEEE00 1000ms

status message to reduce fan speed by 0%

EFL / P1 :Engine Fluid Level/Pressure 1 0x18FEEF00 500ms

status message to reduce fan speed by 30% status message to reduce fan speed by 70%

Byte3

Bit0~1

status message to reduce fan speed by 80%

Byte4

Bit0~1

status message to reduce fan speed by 100%

0x18FEF200

100ms

IC1 : Inlet/Exhaust Conditions 1 0x18FEF600 500ms

Unused Bit2~3

Data Name

Byte0~1 Byte2

Unused Percent Load at current Speed

Byte0~1 Byte2 Byte3~4

Unused Actual Engine - Percent Torque Engine Speed

Byte0 Byte1 Byte2~3

Engine Collant Temperature Fuel Temperature Engine Oil Temperature

Byte0 Byte3 Byte0~1 Byte6

Hydraulic Oil Temperature

Bit

Engine Fuel Delivery Pressure Engine Oil Pressure

LFE : Fuel Economy

AAI : Auxiliary Analog Information : Hyd.Oil Temp 0x18FE8C17 1000ms Byte0 AUXIO1 : Auxiliary Input/Output Status 1 0x18FDCB1 100ms Byte0 7

Byte

Pilot Cutoff Status FD : Fan Drive 0x18FEBD00

1000ms

LFC : Fuel Consumption 0x18FEE900 receiving a PGN request

Fuel Rate Engine Throttle Position

Byte0 Byte1

Boost Pressure

Byte2

Intake Manifold temperature

Byte0 Byte2~3 Byte0~3 Byte4~7

Fan Speed

Total Fuel Consumption

PTC1 1000ms

DM1-Single DM2-Multi Packet and BAM

Diesel Particulate Filter Regeneration

Byte0

Bit 1..3 status Lamp Command

Byte3

Bit 3..4 Status Lamp command

Byte7

Bit 3..5 Lamp Command

DPF Active Regeneration Inhibited Exhaust System High Temperature

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Slide 43

Diagnostic Trouble Shooting Codes DTC List No.

DTC

1

C028

Bus Off error CAN A

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 Vehicle cut off switch

9

C125

Vehicle cutoff switch error

10

C141

Timeout Error of CAN-Receive-From Hydraulic oil temperature

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

P0089

pressure relief valve is out of range : increase, pressure shock

17

P0096

Physical Signal Range high on the air mass flow sensor temperature

18

P0100

Battery voltage error of HFM sensor

19

P0101

Sensitivity drift out of range error for HFM sensor

20

P0102

SRC low error for raw value in HFM sensor

21

P0103

SCB of hardware signal or SRC high error for raw value of HFM sensor

22

P0112

SRC Low for boost temperature

23

P0113

SRC High for boost temperature

24

P0116

Physical out of range check high for coolant temperature

:

:

Description

:

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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 Application 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 engine 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 Lamp 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.

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Slide 47

Example Of Diagnostic Trouble Trouble 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

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Slide 48

- EOD -

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