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
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
Slide 3
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
Doosan Infracore
Slide 4
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
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
Doosan Infracore
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
Doosan Infracore
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
Doosan Infracore
Slide 8

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
Doosan Infracore
Slide 9

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
Doosan Infracore
Slide 10

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
Doosan Infracore
Slide 11
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
Doosan Infracore
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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
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

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.
Doosan Infracore
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Slide 13
Engine Sensors
Coolant / Fuel Temperature Sensor.
Harness connector
2
1
No.
1
2
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

105 C: Max. fuel rate 2% limit
Power derated for engine

protection .
105 deg C: Torque 2% 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

Doosan Infracore
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Slide 14
Engine Sensors
Camshaft Speed Sensor (DL08,DL06) Crankshaft Speed Sensor (DL06)
Harness connector
Crankshaft Speed Sensor (DL06)

No.
ECU Pin
PIN description
1
266
CRS POS
2
265
CRS NEG
3
269
Shield
Sensor Name

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
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
Vehicle safety
engine protection
Vehicle safety
engine protection
Doosan Infracore
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Slide 15
Engine Sensors
Harness connector
2
1
No.
1
2
Sensor Name
Crankshaft
Speed Sensor

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

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
Torque limit 10%

CAM shaft sensor back
up mode
vehicle safety
engine protection
Doosan Infracore
14
Slide 16
Engine Sensors
Rail Pressure Sensor.
Harness connector
No.
1
2
3
Sensor Name

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

Replacement value is
varied according to CP
pump metering unit.
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.
Doosan Infracore
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Slide 17
Engine Sensors
Air Mass Flow Sensor.
Harness connector
A
No.
A
B
C
D
E
Sensor Name
Mass Air Flow

(HFM) Sensor
Air Flow Temperature

Low / High (Units)

Low (unit)
High (unit)
Failure
Detection
Failure
Indication
100kg/hr < Normal < 1000kg/hr
70 us
7000 us
By ECM
Check lamp =Blink

Cold < 20 C
20 C <= Normal <= 30 C
Hot > 30 C
400mV
4900mV
By ECM
Check lamp =on

ECU Pin
230
238
230
284
254
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)
Doosan Infracore
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Slide 18
Sensors & Actuators (DL08)
1
2
1.
2.
3.
4.
EGR Valve (Exhaust Gas Recirculation)

Throttle Valve
VGT (Variable Geometry Turbo)
Oil Pressure & Temperature Sensor
Doosan Infracore
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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
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
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

0 ~ 100%
N/A
If EGR is deactivated, NOx

emissions increase.
* SRA: Smart Remote Actuator
Doosan Infracore
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Slide 20
Engine Actuator
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.
Doosan Infracore
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Slide 21
Engine Actuator
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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Slide 22
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)
901% (4.5V)
88.5% (4.425V)
18.51%(0.926V)
14.253.5% (0.713V)
No.
1
2
3
5
6
ECU Pin
234
229
240
215
205
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

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.
Smart Remote Actuator
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
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

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
Oil Pressure
400kPa < Normal < 600kPa
202.8 mV
4924.2 mV
By ECM
Check lamp =Blink

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.
Replacement value
= 450 kPa
N/A
Doosan Infracore
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Slide 26
Metering Unit & Exhaust System Sensors (DL08)
5
6
7
8
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
Doosan Infracore
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Slide 27
Metering Unit
Metering Unit (Shut Off Vale & Dosing Valve)
Harness connector
Dosing Valve
No.
1
2
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
15.95
Shutoff Valve
Feature
Normal value
Coil resistance
3.3
Shut Off Valve
Cooling adapter
Doosan Infracore
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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

Low / High (Units)
0 kpa < Normal < 1200 kpa
-40 C < Normal < 130 C

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
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
Exhaust Gas temperature

control for DPF regeneration.
Doosan Infracore
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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

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

Replacement value
= 200 kpa
0 kpa < Normal < 1200 kpa
PIN description
+5 V supply
Ground
Pressure signal
Failure Consequence
Active Regeneration is Exhaust Gas temperature

prevented
control for DPF
Torque limit 25%
regeneration.
Doosan Infracore
28
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

Low / High (Units)
No.
1
2
T5 DPF upstream
ECU Pin
PIN description
117
Temperature signal
118
Ground

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

Check lamp =on

By ECM
By ECM
Check lamp =Blink

Check lamp =Blink
Replacement value
= 200 C
Threshold temp
= 700 C
Replacement value
= 200 C
Replacement value
= 200 C
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 200C.

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
29
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

Low / High (Units)
No.
1
2
3

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
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%
Check lamp = On
Replacement value
= 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
Doosan Infracore
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Doosan Infracore
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Slide 32
Slide 33
Doosan Infracore
32
Doosan Infracore
33
Slide 34

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 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
Doosan Infracore
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Slide 36
(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)
Doosan Infracore
35
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
36
Doosan Infracore
37
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
38
Slide 40
ECU Connector
Connector (96-way module)
Vehicle side
Locking Slide
Engine side
73
96
24
73
Locking lever
96
24
Doosan Infracore
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Slide 41
CAN Network Configuration
CAN 0 High : Pin No. 146
Machine
controller
(EPOS)
Vehicle side
CAN 0
120
120
CAN 0 Low : Pin No. 147
Communication
with computer
CAN 1
(use only for Dev. Engineer)
EDC17
ECU
Engine side
CAN 2
120
120
EGR
VGT
Doosan Infracore
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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

Byte3
Bit0~1
Byte4
Bit0~1
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
Doosan Infracore
41
Slide 43
Diagnostic Trouble Shooting Codes

DTC List
No.
DTC
C028
Bus Off error CAN A
C046
Bus Off error CAN C
C10A
EGR valve actuator communication loss error
C10C
Timeout error of CAN receive from VGT
C121
Timeout error of CAN receive from TCU
C122
Timeout Error of CAN-Receive-From DEC1V
C123
Accel pedal CAN max error
C124
Timeout error of CAN receive from Vehicle cut off switch
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
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
Application
Software
[deg C]
< Transfer curve >

SRC MAX
<The sensor raw signal voltage is above the threshold.>
SRC MIN
<The sensor raw signal voltage is below the threshold.>
Physical range MAX

<The sensed sensor signal is greater than the threshold.>
Physical range MIN

<The sensed sensor signal is less than the threshold.>
Doosan Infracore
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Slide 45
Engine Torque Derating

Torque Derating
Doosan Infracore
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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.
Doosan Infracore
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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
Doosan Infracore
Slide 48
- EOD -
Doosan Infracore
46

09 Doosan TIER 4I Engine (120425)

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09 Doosan TIER 4I Engine (120425)

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Slide 1

Doosan Tier4-i Engine

Tier4i Engine Specification

Tier4i Engine Specification

Tier4 Engine Specification

Tier4 Engine Specification

Engine System Layout

Air Mass Sensor with Temperature (HFM)

Coolant / Fuel Temperature Sensor

Rail Pressure Sensor

Boost Pressure and Temperature Sensor

Fuel Metering Unit (High Pressure Pump)

Metering Unit (DPM)

Oil Pressure / Temperature Sensor

CAM / Crank Speed Sensor

Fan Speed Sensor/ Drive

VGT (Variable Geometry Turbocharger)

Throttle Valve Actuator

EGR (Exhaust Gas Recirculation)

DPF Differental Pressure Sensor

Exhaust Gas Temperature Sensor (Before DOC)

Exhaust Gas Temperature Sensor (Before DPF)

Exhaust Gas Temperature Sensor (After DPF)

Engine System Layout

T4,T5,T6 Temperature Sensors

Air mass flow &

Engine System Layout

Diesel Fuel Return

Engine System Layout

Engine Sensors (DL08)

Boost Pressure & Temperature Sensor

Sensor Value: Failure

Sensed Parameter Range:

Replacement value = Frozen value

100kPa < Normal < 340kPa

Check lamp = Blink

Replacement value = 220 kPa

VGT actuator is controlled

Sensor Value: Sensor Value: Failure

-30 C <= Normal <= 40 C

Check lamp =Blink

Check lamp =On

105 C: Max. fuel rate 2% limit

Power derated for engine

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%

Torque limit 10%

Power derated for engine

110 deg C: Torque 20% limit

Crankshaft Speed Sensor (DL06)

Sensed Parameter Range:

Camshaft Speed Sensor (DL06)

Camshaft Sensor (DL08)

650 rpm < normal < 2200

Check lamp =on

If the camshaft rotation counter

Torque limit 10%