62688496-sistema-inyeccion-hyunday.pdf

D6CA (L-Engine) Engine Management System

Input & Output Diagram Intake Air Temp.

EUI (6)

Intake Air Pressure Coolant Temp. Atmospheric Air Pressure. Fuel Temp. Fuel pressure CAM Position Crank Position

Relay control

Engine Control Unit

Tachometer Drive Vehicle Speed Check Engine

Vehicle Speed Switches Battery +

Diagnosis (Hi-scan) CAN BUS(LAN)

2

Boost pressure & Temp. Sensor 1

2

3

4

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

140

350

120 100

250

80

200

60

150

40 20

100

Temperature[C]

air pressure [kPa]

300

0

50

- 20

0 1.06 1.45 1.83 2.21 2.59 2.97 3.35 3.74 4.12 4.50 4.88

Output Voltage[ V]

88

182

424

1141

2438

9105

- 40 44642

Resistance[ Ohm]

3

Coolant Temperature Sensor

Sensor output[mV]

NTC Thermister 400 380 360 340 320 300 280 260 240 220 200

1

2

3

1 : Ground 2 : Gauge 3 : Sensor 0

47

132 278 469 632 Temperature [K]

778

869

4

Fuel Pressure Sensor

Fuel pressure [kP a]

1200 1000 800

1 3

600 400 200

2 4

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

0 0.2000

1.1010

2.0020

2.9030

3.8040

4.7050

O utput voltage [ V]

5

Pedal Position Sensor

Voltage 4.5V

0.5 V 95 %

0

Pedal Angle

Potentiometer 6

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

7

Crank Position Sensor 1

2

3

1 : Ground 2 : Sensor 3 : Shield

Raw Signal

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

1

8

Alignment of Crank wheel & Cam wheel at TDC position CPS

CAM

11th teeth 6 deg

Gap : 1.5 +/-0.5 2nd wheel teeth

1st wheel teeth

15˚ CAM

34.5 ˚

+1 teeth

69 ˚ CA

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

1

2

3

4

5

6

7

8

9

10

11

12

13

14

-6

Crank signal

No. 1 cylinder

+1 flag

Cam signal

TDC

15

16

17

18

19

20

1

6 Bolt up angle

10

MAP Sensor

Input Voltage Voltage

4.818

Vin = 5 V

Operating Voltage Range

4.75~ 5.25 V

Storage Temperature Range

-40 ~ 125 ℃

Operating Temperature Range

-30 ~ 110 ℃

Operating Pressure Range Current

1.924

20 ~ 102 10 mA

0.512

20 46.66 [150] [350]

101.32 [760]

Pressure [kPa, mmHg]

Built – In ECU

11

Diagnosis Connector

VSPD

GND

1

9

CAN_L

CAN_H

2

3

4 ABS Check

5

10

11

12

13 T/M Check

L_LINE

K_LINE

6

7

14

15

8

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

1 1

Press for 3 sec

Engine check T1 T4 lamp Press for 3 sec

3

4

T5

1

2

3

4

1

0

T2

3 T5

4

2 T2

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 Maximum MaximumFuel Fuel Amount Amount

Cranking Cranking

Vehicle Speed

Intake Air Press. & Temp.

Compensatio n

Idle Idle

Coolant Temperature Fuel Temp. & Press.

Pedal Angle 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

Fuel Pressure Derate %

Lowest wins

Absolute Max. fuel

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

N MUX

Y

N MUX

Fuel Limit

Y Absolute Max. Fuel

Cranking

Comp Test Active

ETF Comp Test Fuel Limit

18

Injection Timing Control Intake Air Temperature Coolant Temperature

Timing Timing atatCranking Cranking

Σ K3 K3 Compensation Compensation

Advanced Injection Angle

Timing TimingatatPTO PTO

Starting Angle of injection

End of Injection Engine Speed Fuel Injection Amount

General GeneralInjection Injection Timing Timing

Fuel Injected Angle

Σ 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 Max. torque fuel curve

Nx = Nnl - Dn = 2230 - 260 = 1970 K1 = (Fz-Fr) / (Nx-Nr) = (203-250) / (1970-1800) = -0.276

Abs. Max. Fuel

K2 = Fz / Dn = 250 / 260 = 0.962

K1 K2

Fr Nr = Rated speed (1800rpm)

Fz

Fr = Fuel limit at rated speed (250 mg) Dn

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

Nnl

Droop speed

21

Preheating & Postheating • Intake air heating at cold start condition - Reduce the smoke - Fast engine warm-up START KEY S/W Indicating Lamp

ON OFF ON OFF Engine speed > limitation

Engine RPM Heater

ON

APV

OFF

PREHEATING

No Pre/Post Heating

POSTHEATING

Operating of Pre/Post Heating 22

Preheating & Postheating Time 40000 40 35000 35

Preheating Time

25 25000 20 20000 15 15000 10 10000 55000 00

0

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

35000 35 30000 30

Postheating Time

25000 25

TIME[ s]

TIME[ s]

30000 30

20 20000 15 15000 10 10000 55000 00

0

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

COOLANT TEMPERATURE[ ℃]

23

Cranking without Fuel ( Cold Start ) ● Compress the air inside cylinders → Warm up the engine block

Number of non- injection

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

Fuel Amount(mg)

140 120 100 80 60 40 20 0 230 -28 245-18 255 265 300 35 308 45 318 328 -40 -8 7280 27 55 338 65

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

K

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

Idle Speed Control – Cold Start Idling

800 RPM

Cold idle 500 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

APV2

Level 1 Threshold APV

APV1

Required Fuelfuel pressure Required Pressure for Speed for speed

Getting lower than level 2 pressure

Level 2 Threshold APV

Lamp On

Lamp Flashing

Derate Level 2 Derate Level 1 No Derate

Time 33

Fuel Pressure Derate Protection Fuel Pressure

Required fuel pressure Required Fuel for speed Pressure for Speed

Condition B Level 1 Threshold APV

APV1

Level 2 Threshold APV APV3 Lamp Flashing

Lamp On Derate Level 2 Derate Level 1

APV4

No Derate

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

- Brake and clutch pedal are NOT depressed

– Safety switch input is NOT active

- 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 doesn’t accept the accelerator position signal and keeps the idle RPM. Engine RPM

EUI

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

AUTO CRUISE CONTROL

SET / INC

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

RES / DEC BRAKE SW

ENGINE SPEED VEHICLE SPEED

REMOTE PTO ENABLE SW INCREMENT DECREMENT

UCE

CLUTCH SW

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

OUTSIDE CAB

40

Schematic Diagram

EUI 2 EUI 5

EUI 3 EUI 6 BOOST PRES & TEMP

E24 RETURN

FUEL PRES & TEMP

COOL TEMP SENSOR RETURN

COOLANT TEMP

RETURN

BOOST PRES SENSOR

BOOST PRES SENSOR

E6 E19

E8 E21

E4

E7 BOOST TEMP SENSOR

5V SUPPLY

E10 BOOST PRES SENSOR

E32 E31 E33 E25 E11 E22 E39 E38

E46

E29 E45 E30

E43

E37

ENG CONNECTOR

5V SUPPLY

SCREEN

CRANK SIGNAL RETURN CRANK SIGNAL

SCREEN

CAM SIGNAL

CAM SIGNAL RETURN

INJECTOR6 LOW SIDE

INJECTOR5 LOW SIDE

INJECTOR4 LOW SIDE

EUI 4

CRANK

BASE2 HIGH SIDE

INJECTOR3 LOW SIDE

INJECTOR2 LOW SIDE

INJECTOR1 LOW SIDE

EUI 1

CAM

BASE1 HIGH SIDE

A12

A14

A6

A11

A4

V2

S2

S1

L5 L6

L4

H2

L1 L2 L3

H1

Engine Side

ECU

1999. 1. 25

42

TWIST(SHIELD)

CAN_L

CAN_H

120Ω

KWP2000_L

KWP2000_K

CAN_SHIELD

ASTRONIC ASTRONIC

B39

B38

B52 B53 B54

B45

B44

B43

U

C

E

B36

B1

B50

B51

B49

B48

B47

B46

B19

B9

B22

B21

B18

B33 B3 B4

T/M PTO CONTROL SWITCH

PTO M/VALVE DBR RLY

VDO T/GRAPH

D3

VEHICLE SPEED OUTPUT

AIR HEAT RELAY

VEHICLE SPEED SENSOR (HALL EFFECT TYPE)

AIR HEAT SUB_RELAY

CRUISE/PTO LAMP

AIR HEATER

ENGINE BRK LAMP

OVER HEAT LAMP

CHECK ENG

ABS ACTIVE

OFF

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

RES/DEC

SET/INC

CC/ENG PTO ENABLE

JAKE#3

JAKE#2

EXHAUST/JAKE#1

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

PTO LAMP

WARN'G

T/M PTO ON/OFF

F=5A

Astronic Astronic Intarder Intarder

5A

DIAGNOSTIC CONNECTOR

<1m

#5,6

ENGINE

ABS/ASR ABS/ASR

#1,2

ENGINE BRK MED/HI

ENGINE BRK LO/HI

EXHAUST BRAKE

B28

B32 B6

B24

B25

B31

B5

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

Vehicle Vehicle Side Side

#3,4

TACHO METER

R/PTO DECREASE

R/PTO INCREASE

R/PEDAL RETURN

R/PEDAL SENSOR

REMOTE PTO ENABLE SW

B16

B8 B15 B20

B35

B34

F/BRAKE

BAT+ BAT+

STOP LAMP

SAFETY SWITCH

IVS1 IVS2

PEDAL SENSOR GND

PEDAL SENSOR

SENSOR POWER

B17

B30

B42

B26 B27

5A

PEDAL ASS'Y

B7

B12 B13 B14

MAIN RELAY

IDLE SWITCH

ECU GND PARKING SWITCH

BATTERY GND

SWITCHED BATTERY(IG)

BATTERY 15A

F/BRAKE SWITCH

43

ECU GND <1m 120Ω

ENGINE

KWP2000_L

KWP2000_K

CAN_SHIELD

CAN_L

CAN_H

ENGINE BRK MED/HI

B39

B38

B52 B53 B54

B45

U

C

E

B36

B1

B50

B51

B49

B48

B47

B46

B19

B9

B22

B21

B18

ENGINE BRK LAMP

AIR HEAT RELAY

VDO T/GRAPH

D3

DBR RLY

VEHICLE SPEED OUTPUT

VEHICLE SPEED SENSOR (HALL EFFECT TYPE)

AIR HEAT SUB_RELAY

CRUISE/PTO LAMP

AIR HEATER

ABS ACTIVE

OFF

A/C COMPRESSURE (OPT-BUS ONLT)

OVER HEAT LAMP

CHECK ENG

NEUTRAL SWITCH

RES/DEC

SET/INC

CC/ENG PTO ENABLE

JAKE#3

JAKE#2

EXHAUST/JAKE#1

Astronic Astronic Intarder Intarder

5A

TWIST(SHIELD)

DIAGNOSTIC CONNECTOR

ABS/ASR ABS/ASR

#5,6

PEDAL ASS'Y

#1,2

#3,4

IDLE SWITCH

B3 B4

B33

B5

CLUTCH

F/BRAKE

BAT+

BAT+

Vehicle Vehicle Side Side B44

B43

B35 B8 B15 B20

B34

B17

B30

B42

B27

B26

STOP LAMP

ENGINE BRK LO/HI

EXHAUST BRAKE

IVS2

IVS1

P/ SENSOR GND

PEDAL SENSOR

SENSOR POWER

B7

B12 B13 B14 F=5A

MAIN RELAY

PARKING SWITCH

BATTERY GND

SWITCHED BATTERY(IG)

BATTERY

15A

F/BRAKE SWITCH

5A

44

IDLE SWITCH

ECU GND TACHO METER

120Ω

TWIST(SHIELD)

KWP2000_L

KWP2000_K

B39

B38

B52 B53 B54

B45

B36

B1

B50

B51

B49

B48

B47

B46

B19

B9

SET/INC

VEHICLE SPEED OUTPUT

AIR HEAT RELAY

VEHICLE SPEED SENSOR (HALL EFFECT TYPE)

AIR HEAT SUB_RELAY

CRUISE/PTO LAMP

AIR HEATER

ENG BRK LAMP

OVER HEAT LAMP

CHECK ENG

NEUTRAL SWITCH

RES/DEC

D3

VDO T/GRAPH

ABS ACTIVE

DBR RLY

Astronic Astronic Intarder Intarder

5A

DIAGNOSTIC CONNECTOR

CAN_SHIELD

CAN_L

CAN_H

ASTRONIC ASTRONIC

ENGINE <1m

#5,6

B44

B43

B28

B22

B21

B18

CC/ENG PTO ENABLE

JAKE#3

JAKE#2

Vehicle Vehicle Side Side ENGINE BRK MED/HI

ENGINE BRK LO/HI

EXHAUST BRAKE

R/PTO DECREASE

B32 B6

EXHAUST/JAKE#1

OFF

R/PTO INCREASE

B33 B3 B4

B5

PTO M/VALVE

B24

B25

B31

B16

B8 B15 B20

CLUTCH

WARN'G PTO LAMP

T/M PTO ON/OFF

R/PEDAL RETURN

R/PEDAL SENSOR

REMOTE PTO ENABLE SW

SAFETY SWITCH

IVS2

P/ SENSOR GND IVS1

B35

B34

F/BRAKE

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

ABS/ASR ABS/ASR

#1,2

SENSOR POWER PEDAL SENSOR

B17

B30

B42

B26 BAT+ BAT+ B27

STOP LAMP

#3,4

PEDAL ASS'Y

B7

B12 B13 B14 F=5A

MAIN RELAY

PARKING SWITCH

BATTERY GND

SWITCHED BATTERY(IG)

BATTERY

15A

F/BRAKE SWITCH

5A

45