D6CA

(L-Engine)
Engine Management System

Input & Output Diagram

Intake Air Temp. Intake Air Pressure Coolant Temp. Atmospheric Air Pressure. Fuel Temp. Fuel pressure CAM Position Crank Position Vehicle Speed Switches Battery + Diagnosis (Hi-scan) CAN BUS(LAN) Relay control EUI (6)

Engine Control Unit

Tachometer Drive Vehicle Speed Check Engine

Boost pressure & Temp. Sensor

1 2 3 4

1 : Boost air pressure 2 : Power 3 : Boost air Temperature 4 : Ground

350 300

140 120 100 80 60 40 20 0 - 20

air pressure [kPa]

200 150 100 50 0 1.06 1.45 1.83 2.21 2.59 2.97 3.35 3.74 4.12 4.50 4.88
88 182 424 1141 2438 9105

- 40 44642

Output Voltage[ V]

Resistance[ Ohm]

Tem perature[C]

250

Coolant Temperature Sensor

N Th m er TC er ist 400 380 360 340 320 300 280 260 240 220 200 0 47 132 278 469 632 Tem er u e [K p at r ] 778 869 Sensor output[m V]

1 : Ground 2 : Gauge 3 : Sensor

Fuel Pressure Sensor

1200

Fuel pressure [kP a]

1000 800 600 400 200 0 0.2000 1.1010 2.0020 2.9030 3.8040 4.7050

1 3

2 4

1 : Fuel Temperature 2 : Power 3 : Ground 4 : Fuel Pressure

O utput voltage [ V]

Pedal Position Sensor

Voltage 4.5V

0.5 V 0 Potentiometer
6

95 %

Pedal Angle

Cam Angle Sensor

1 2 3

1 : Ground 2 : Sensor 3 : shield

Negative going zero crossing signal Triggers the signal

Raw Signal

Processed Signal No. 6 Cylinder +1 teeth No. 1 Cylinder No. 2 Cylinder

Crank Position Sensor

1 2 3

1 : Ground 2 : Sensor 3 : Shield

Raw Signal

10

11

12

13

14

15

16

17

18

19

20

Alignment of Crank wheel & Cam wheel at TDC position

CPS
11th teeth 6 deg Gap : 1.5 +/-0.5 2nd wheel teeth 69 CA

CAM
1st wheel teeth 15 CAM

34.5

+1 teeth

6th wheel teeth

6 tooth have 60 degrees interval

Crank Sensor Wheel

Cam Sensor Wheel

9

Wave form of the Crank wheel & CAM wheel

Zero crossing of raw cam signal occurs in the Center of the gap in the crank signal Center of the gap

Direction of the engine rotation

Raw signal

Processed signal No. 4 cylinder

Cam signal

+1 flag

No. 1 cylinder

10

11

12

13

14

15

16

17

18

19

20

-6

6 Bolt up angle

Crank signal

TDC

10

MAP Sensor

Input Voltage Voltage Operating Voltage Range Storage Temperature Range Operating Temperature Range Operating Pressure Range 1.924 0.512 Pressure [kPa, mmHg] Current

Vin = 5 V 4.75~ 5.25 V -40 ~ 125 -30 ~ 110 20 ~ 102 10 mA

4.818

20 46.66 [150] [350]

101.32 [760]

Built In ECU

11

Diagnosis Connector

VSPD

CAN_L

4 ABS Check 12

L_LINE

GND

CAN_H

10

11

13 T/M Check

K_LINE

14

15

BATT+

16

K_LINE L_LINE
Engine ECU ASTRONIC T/M ABS/ASR ZF INTARDER

Connector Side
12

Trouble Code
How To Read Trouble Code
1. KEY ON 2. Engine Stop (not fuelled) 3. Press set/inc or res/dec for 3 seconds. 4. If press the set/inc, following trouble code will be shown. 5. If press the res/dec, previous trouble code will be shown.

13

Trouble Code
ON

IG S/W Press for 3 sec

1 1

3 T5

1 T2

3 T5

4 T2

Engine check T1 T4 lamp Press for 3 sec

T6
Next trouble code Previous code trouble

SET/INC S/W

RES/DEC S/W

ex) Trouble Code :1134 and 1234

14

Engine Control
1) Fueling control 2) Injection timing control 3) Pre-heater (Cold start) 4) Starting Fuel control & Idle control 6) Output power control according to fuel pressure 7) High coolant temperature Warning lamp 8) Cylinder balancing Control

15

Vehicle Control
1) Calculate Vehicle Speed 2) Crouse Control 3) PTO Control 4) Vehicle Speed Limiter 6) Auxiliary Brake Control 7) Fuel Control 8) Output Engine Speed/Vehicle Speed Signal 9) Self diagnosis 10) Communication
16

Fueling Control
Cranking Cranking
Maximum Fuel Maximum Fuel Amount Amount
Vehicle Speed

Intake Air Press. & Temp.

Idle Idle
Pedal Angle

Compensatio n

Coolant Temperature Fuel Temp. & Press. Atmospheric Pressure

Engine Speed

Pedal Pedal

Target Fuel Amount

Mini mum

Actual Fuel Amount

PTO PTO

Cruise Cruise
17

Fueling Control
Compensated Maximum MUL Torque Curve Fuel Limit

Smoke fuel limit High idle speed fuel limit

Lowest wins

N
MUX

Fuel Pressure Derate %

Absolute Max. fuel

N MUX Y

Fuel Limit

- Engine Torque Limit - Smoke Reduction - Engine Speed Limit - Engine Max. output Power Limit - Absolute Fuel Amount Limit

Absolute Max. Fuel

Cranking ETF Comp Test Fuel Limit

Comp Test Active

18

Injection Timing Control

Intake Air Temperature Coolant Temperature

Timing Timing at Cranking at Cranking

Advanced Injection Angle K3 K3 Compensation Compensation

Starting Angle of injection

Timing at PTO Timing at PTO

End of Injection Engine Speed Fuel Injection Amount

General Injection General Injection Timing Timing

Fuel Injected Angle

Injection Amount Fuel Temperature

Intake Air Temperature Coolant Temperature

19

Cold Start Control

Preheating & Postheating Cranking without fuel - Compress the air inside the cylinders Engine warm up Restriction of intake and exhaust air flow - Activate Exhaust brake Injection Timing Compensation - Compensate ignition delay due to the low intake air temperature - Cranking injection timing compensation Coolant temperature compensation Boost air temperature compensation - Normal injection timing compensation Coolant temperature compensation Boost air temperature compensation
20

High Idle Speed Fuel Limit

Reduce the fuel injection amount at the high idle speed to protect the engine
Nx = Nnl - Dn = 2230 - 260 = 1970 K1 = (Fz-Fr) / (Nx-Nr) = (203-250) / (1970-1800) = -0.276 K2 = Fz / Dn = 250 / 260 = 0.962 Fr Nr = Rated speed (1800rpm) Fr = Fuel limit at rated speed (250 mg) Fz = Fuel limit at the gain change over speed (203 mg) Nnl = No load max. speed (2230 rpm) Dn = Required drop in speed between Nnl and gain change over speed (260 rpm) Nr Nx Droop speed Dn Nnl Fz Abs. Max. Fuel Max. torque fuel curve K1 K2

21

Preheating & Postheating

Intake air heating at cold start condition
- Reduce the smoke - Fast engine warm-up
START KEY S/W Indicating Lamp Engine RPM Heater ON OFF PREHEATING ON OFF ON OFF Engine speed > limitation

APV POSTHEATING

No Pre/Post Heating

Operating of Pre/Post Heating

22

Preheating & Postheating Time

40000 40 35000 35 30000 30

TIME[ s]

25 25000 20 20000 15 15000 10 10000 5 5000 00

Preheating Time

233 244 245 248 253 258 263 268 0 -40 -29 -28 -25 -20 -15 -10 -5 273 COOLANT TEMPERATURE[ ]

35000 35 30000 30

TIME[ s]

Postheating Time

25000 25

20 20000 15 15000 10 10000 5 5000 00

247 267 270 280 290 300 310 320 330 -26 -6 - 3 7 17 27 37 43 57

COOLANT TEMPERATURE[ ]

23

Cranking without Fuel ( Cold Start )

Compress the air inside cylinders Warm up the engine block Number of non-injection is determined by the engine coolant temperature
Number of non- injection
12 10 8 6 4 2 0 240-28 -26 -24 -22 253 303 318 328 338 245 247 249 251 -20 30 45 55 65

Engine Coolant Temperature [ ]

24

Cold Start Control

Activate the exhaust brake : Warm up the engine Operating Condition :
- Engine coolant temperature -25 - IGN ON or ST position - Engine RPM 50 RPM OFF Condition : - Engine coolant temperature -25 - Engine running condition - Engine RPM 450 RPM

Injection timing compensation

Compensate ignition delay due to the low intake air temperature - Cranking injection timing compensation - Normal injection timing compensation
25

Cranking Fuel
More fuel amount is injected at the initial cranking condition. Initial crank fuel = f(coolant temperature)
160 140

Fuel Amount(mg)

120 100 80 60 40 20 0 230 245 255 -8 280 300 308 318 55 65 -40 -28 -18 265 7 27 35 45 328 338

Coolant Temperature

Fuel injection amount is returned to the normal condition when the engine RPM is over the crank exit speed. Crank exit speed = idle reference speed + APV When the engine RPM cannot get over the crank exit speed within the limited revolution, additional fuel amount is injected.
26

Idle Speed Control

Idle speed control Idle speed is increased in proportion to the load Stabilization the idle speed Idle trim Idle speed can be adjusted by the driver Before the other value is set, default idle speed is memorized Idle speed up At the cold start condition To help engine warm up Air conditioner operating condition (700rpm) To prevent battery discharge when the air conditioner is ON When battery voltage is too low (550rpm) To help battery charging Idle stop When there is no driving operation during setting time, engine is stopped to reduce the useless idle time.
27

Idle Speed Control

Fuel amount

Engine RPM Reference Idle speed 500 RPM

Time
28

Idle Speed Control

Engine RPM

500 RPM

TIME

Keeping the engine idle speed at any load (2RPM) Adjusting fuel injection amount to maintain the stable idle speed
29

Idle Speed Control Cold Start Idling

Idle speed
Cold idle
500 RPM

800 RPM

Normal idle

Coolant temperature -10 0

30

Idle Speed Control Idle Trim

Function - Setting the desired idle RPM by driver ( 500 ~ 800 ) Operating
- Increasing or decreasing the idle RPM when driver push the set/inc or res/dec

Condition
- Engine stop - Idle switch ON and PTO OFF - Service brake operating
+ 25 RPM

800 RPM

INC DEC
- 25 RPM

500 RPM
31

Cylinder Disablement
Function
3 Cylinders disablement at the high RPM with low load

Condition
Engine speed > APV Fuel value < APV No injectors errors Pilot injection is not active 3 Cylinders are selected and fuel injection amount will be double ( Injection timing is same)

CDS_MASK_APV= 42 => 0010 | 1010 Cylinder number CDS_MASK_APV 0 6 0 5 1 4 0 3 1 2 1 0 1 1 : enable 0 0 : disable

32

Fuel Pressure Derate Protection

If the fuel pressure is lower than normal value at any engine RPM, derating the desired fuel injection amount and warning to the driver. This function is to protect the engine
Fuel Pressure

Condition A
Level 1 Threshold APV
APV1

APV2

Required Fuel Required fuel pressure Pressure for Speed for speed

Level 2 Threshold APV

Getting lower than level 2 pressure

Lamp On Derate Level 2 Derate Level 1 No Derate

Lamp Flashing

Time
33

Fuel Pressure Derate Protection

Fuel Pressure

Condition B
Level 1 Threshold APV Level 2 Threshold APV
APV1

Required fuel pressure Required Fuel for speed for Speed Pressure

APV3 Lamp On Derate Level 2 Derate Level 1 No Derate APV4 Lamp Flashing

Time

34

Engine Overheat Warning

- Warning lamp comes on when the coolant temperature is higher than limit
Coolant Temperature Warning Lamp ON Warning Lamp OFF

103
Hysteresis Zone

98

Time
35

Cruise Control
Function Controlling the vehicle speed as a constant speed Operating condition
Cruise control switch is ON Safety switch input is NOT active - Brake and clutch pedal are NOT depressed - Brake check has been successfully completed

Releasing condition
Cruise control switch is OFF - Brake or clutch pedal is depressed Vehicle speed is below the lowest allowed vehicle speed

If the vehicle speed is higher than setting speed and the difference is too big, ECU operates 3rd Brake (Exhaust brake, Jake brake) Cruise control speed setting
- Cruise switch - Accelerator pedal - SET/INC or RES/DEC switch

Cruise control speed range : 15 ~ 80 km/hr

36

Door Switch
Function
When the door is open, ECU doesnt accept the accelerator position signal and keeps the idle RPM.
Engine RPM

EUI

ECU ECU

Door SW

Accelerator Position
37

PTO (Power Take Off)

Function
Setting engine RPM to operate additional device at any load condition

Operating Condition
Cruise/PTO Switch is ON PTO Control Switch is ON Engine speed > APV ( 20 km/h)

Operation
In the PTO mode, PTO governor adjust engine rpm to the PTO initial engine RPM and then PTO operation lamp comes on

OFF
When the Cruise/PTO switch is OFF, engine RPM return to the idling RPM
38

PTO Control
PTO Mode
PTO can be operated at the driver seat side or vehicle outside(Remote Mode)

Accelerator Pedal Function

When the accelerator pedal is depressed, PTO engine RPM is increased. And when the pedal is released, engine RPM return to the setting PTO engine RPM

Clutch / Brake Pedal Function

When the clutch or brake pedal is depressed, PTO engine RPM is decreased to the initial PTO engine RPM. And when the pedal is released, engine RPM return to the setting PTO engine RPM.

PTO time-out
If there is no operation during APV time, ECU stops engine
39

Auto Cruise Control / PTO Control

CRUISE/PTO ENABLE SW SET / INC RES / DEC BRAKE SW CLUTCH SW

AUTO CRUISE CONTROL

Vehicle Speed > 40 km/h Engine Speed > Cruise speed

VEHICLE SPEED

UCE

ENGINE SPEED

EUI
POWER TAKE OFF CONTROL
Vehicle Speed < 10 km/h Engine Speed > Idle speed

REMOTE PTO ENABLE SW INCREMENT DECREMENT

OUTSIDE CAB

40

Schematic Diagram

BASE1 HIGH SIDE

E43 H1

Engine Side

EUI 3
INJECTOR1 LOW SIDE INJECTOR2 LOW SIDE INJECTOR3 LOW SIDE BASE2 HIGH SIDE

EUI 2
E29 E45 E30 L1 L2 L3 H2 E46

EUI 1

EUI 6
INJECTOR4 LOW SIDE INJECTOR5 LOW SIDE INJECTOR6 LOW SIDE CAM SIGNAL RETURN CAM SIGNAL

ENG CONNECTOR

CAM

CRANK

EUI 5
SCREEN CRANK SIGNAL RETURN CRANK SIGNAL SCREEN 5V SUPPLY BOOST PRES SENSOR BOOST TEMP SENSOR RETURN 5V SUPPLY BOOST PRES SENSOR BOOST PRES SENSOR RETURN COOL TEMP SENSOR

EUI 4

ECU
L4 L5 L6 S1 E32 E31 E33 E25 E11 E22 E39 E38 E37 E10 E7 E24 S2 V2 A4 A11

BOOST PRES & TEMP FUEL PRES & TEMP

1999. 1. 25

E4 E8 E21 COOLANT TEMP

42

A6 A14

A12
RETURN

E6 E19

BATTERY

MAIN RELAY

SWITCHED BATTERY(IG)

ECU GND

BATTERY GND
15A

B12 B13 B14 B26 B27 B42 B30

5A 5A
PARKING SWITCH

BAT+ BAT+

B7
F/BRAKE

F=5A

B17 PEDAL ASS'Y

STOP LAMP

SENSOR POWER PEDAL SENSOR PEDAL SENSOR GND IVS1 IVS2 T/M PTO ON/OFF SAFETY SWITCH REMOTE PTO ENABLE SW

F/BRAKE SWITCH

B34
CLUTCH(W/O TM PTO)-N/CLOSE

B35 B5
PTO RLY CLUTCH SW (W/TM PTO)-N/OPEN

IDLE SWITCH

B8 B15 B20 B16 B31

T/M PTO CONTROL SWITCH

WARN'G

PTO LAMP PTO M/VALVE

R/PEDAL SENSOR R/PEDAL RETURN

B25 B24
JAKE#2

EXHAUST/JAKE#1

OFF
ABS ACTIVE

DBR RLY

R/PTO INCREASE R/PTO DECREASE

B33 B3 B4

JAKE#3

B32 B6

E C

B18 B21 B22 B9

CC/ENG PTO ENABLE

SET/INC

RES/DEC

B28
TACHO METER EXHAUST BRAKE

A/C COMPRESSURE (OPT-BUS ONLT)

B19 B43 B46 B47

ENGINE BRK LO/HI

NEUTRAL SWITCH

OVER HEAT LAMP

B48 B44 B49 B51

ENGINE BRK MED/HI

ENGINE BRK LAMP AIR HEATER CRUISE/PTO LAMP

Vehicle Side Vehicle Side

CHECK ENG

#3,4 #1,2 #5,6

ENGINE

B45

B50

AIR HEAT SUB_RELAY

ABS/ASR ABS/ASR <1m

ASTRONIC ASTRONIC CAN_H CAN_L CAN_SHIELD

B52 B53 B54

120

AIR HEAT RELAY

B1 B36
KWP2000_K

VEHICLE SPEED OUTPUT DIAGNOSTIC CONNECTOR D3 B38

KWP2000_L TWIST(SHIELD)

Astronic Astronic Intarder Intarder B39

VDO T/GRAPH

VEHICLE SPEED SENSOR (HALL EFFECT TYPE)

43

MAIN RELAY

BATTERY

ECU GND

BATTERY GND B26 B27 B42 B30

5A 5A
F=5A

BAT+
15A

SWITCHED BATTERY(IG)

B12 B13 B14 BAT+

PARKING SWITCH

B7
F/BRAKE
PEDAL ASS'Y

B17
STOP LAMP

SENSOR POWER PEDAL SENSOR P/ SENSOR GND IVS1 IVS2

IDLE SWITCH

F/BRAKE SWITCH

B34
CLUTCH

B35 B8 B15 B20 B5

OFF

B33
JAKE#2

EXHAUST/JAKE#1 DBR RLY ABS ACTIVE CC/ENG PTO ENABLE

B3 B4 B18 B21

JAKE#3

SET/INC

E C U
EXHAUST BRAKE

B22

RES/DEC

B9 B19 B43 B46 B47

A/C COMPRESSURE (OPT-BUS ONLT) NEUTRAL SWITCH

OVER HEAT LAMP

ENGINE BRK LO/HI #3,4

B48 B44
ENGINE

ENGINE BRK LAMP

B49 B51

AIR HEATER CRUISE/PTO LAMP ENGINE BRK MED/HI

Vehicle Side Vehicle Side

CHECK ENG

#1,2

#5,6

B45

B50

AIR HEAT SUB_RELAY

ABS/ASR ABS/ASR <1m

120

CAN_H CAN_L CAN_SHIELD

B52 B53 B54 B1 B36 DIAGNOSTIC CONNECTOR

KWP2000_K

AIR HEAT RELAY

VEHICLE SPEED OUTPUT

D3

B38 B39
KWP2000_L VDO T/GRAPH

Astronic Astronic Intarder Intarder

44

TWIST(SHIELD)

VEHICLE SPEED SENSOR (HALL EFFECT TYPE)

MAIN RELAY

BATTERY

SWITCHED BATTERY(IG)

ECU GND
BATTERY GND

15A

B12 B13 B14 B42 B30

5A 5A
F=5A PARKING SWITCH

B26 BAT+ BAT+ B27

B7 B17
PEDAL ASS'Y
STOP LAMP

F/BRAKE

SENSOR POWER

B34
CLUTCH

F/BRAKE SWITCH

PEDAL SENSOR

B35 B5
T/M PTO ON/OFF

P/ SENSOR GND IVS1 IDLE SWITCH SAFETY SWITCH IVS2

B8 B15 B20 B16

PTO M/VALVE

PTO RLY CLUTCH SW (W/TM PTO)-N/OPEN

WARN'G PTO LAMP

REMOTE PTO ENABLE SW

B31

R/PEDAL SENSOR

OFF

B25 B24 B32 B6

JAKE#2 JAKE#3

EXHAUST/JAKE#1

R/PEDAL RETURN

DBR RLY ABS ACTIVE

R/PTO INCREASE R/PTO DECREASE

B33 B3 B4 B18 B21 B22

CC/ENG PTO ENABLE

SET/INC

RES/DEC

B28

B9 B19

ENGINE BRK LO/HI

B48 B44 B49 B51

ENGINE BRK MED/HI

ENG BRK LAMP AIR HEATER CRUISE/PTO LAMP

Vehicle Side Vehicle Side

#3,4

ABS/ASR ABS/ASR <1m

120

DIAGNOSTIC CONNECTOR

TACHO METER

NEUTRAL SWITCH

EXHAUST BRAKE

B43

B46 B47

CHECK ENG

OVER HEAT LAMP

#1,2

#5,6

TWIST(SHIELD)

ENGINE

B45

B50

AIR HEAT SUB_RELAY

ASTRONIC ASTRONIC CAN_H CAN_L CAN_SHIELD

AIR HEAT RELAY

B52 B53 B54 B1 B36

KWP2000_K

VEHICLE SPEED OUTPUT

B38 B39
KWP2000_L VEHICLE SPEED SENSOR (HALL EFFECT TYPE)

D3

Astronic Astronic Intarder Intarder VDO T/GRAPH

45