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 1
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 2

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 3 Tier 4 Interim Tier 4 Final
Combustion pressure
160
(bar)
Turbo System TC or WGT* WGT* or VGT**
Al-Gallery
Piston 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%
DPF Yes
SCR - 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 3
Slide 5

Tier4 Engine Specification

Tier4 interim Engine Power

Engine Model Performance

Code Max. Power Max. Torque Idle RPM Max. RPM
Model
(Suffix) Kw / rpm N.m / rpm (rpm) (rpm)
161 /1800 970 / 1300
EHPEA 800 1900
(216 PS / 1800) (99 kg.m / 1300)
216 /1800 1274 /1300
DL08K DL08-LDE01 800 1900
(291 PS / 1800) (130 kg.m / 1300)
212 / 1800 1274 /1300
DL08-LDE00 800 1900
(285 PS/ 1800) (130 kg.m / 1300)

Doosan Infracore 4

Slide 6

Tier4 Engine Specification

Tier4 interim Engine Power

Engine Model Performance

Code Max. Power Max. Torque Idle RPM Max. RPM
Model
(Suffix) (Kw / rpm) (N.m / rpm) (rpm) (rpm)
DX255LC-3 140 /1900 804 / 1400
800 2020
(DL06-LDE03) (188 PS / 1900) (82 kg m / 1400)
DX225LC-3 126 / 1800 755 /1400
800 1920
(DL06-LDE00) (169 PS / 1800) (77 kg m / 1400)
DX180LC-3 94 /1800 529 /1950
800 2070
(DL06-LDE02) (127 PS / 1950) (54 kg m / 1400)
DX140LC-3 87 /1800 502 /1400
800 1970
DL06K (DL06-LDE01) (117.8 PS / 1800) (51.2 kg m / 1400)

DX190W-3 131 / 1900 755 /1400

800 2020
(DL06-LDE06) (176 PS / 1900) (77 kg m / 1400)
DX170W-3 114 / 2000 647 /1400
800 2120
(DL06-LDE05) (154 PS / 2000) (66 kg m / 1400)
DX140W-3 103 / 2000 588 / 1400
800 2120
(DL06-LDE04) (139 PS / 2000) (60 kg m / 1400)

Doosan Infracore 5
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 6

Slide 8

Engine System Layout

Sensor & Actuator positioning concept

Boost Pressure & Throttle Valve

Temperature Sensor

CAM / CRS
Sensor

Oil Pressure &

Temperature
Coolant Sensor
Temperature
Sensor

EGR Valve
Injection
Unit
Turbo
Charger

T4,T5,T6 Temperature Sensors Air mass flow &

& Differential Pressure Sensor Temperature Sensor

Doosan Infracore 7
Slide 9

Engine System Layout

After treatment system overview of DOOSAN TIER4i DPF system
Diesel Fuel Return TIER4i Engine
Fuel Pump
DPF Muffler (DOC + DPF)
MU + IU
Diesel Fuel Fuel Filter Temperature Sensor (3 off)
Inlet Differential Pressure Sensor (1 off)

Fuel Tank

ECU

Metering
Unit (MU)

Diesel Engine Actuators

Engine CAN
Injection Diagnostic CAN
Unit (IU) Temp Differential Pressure
Temp
Sensor Sensor Temp
Sensor
Sensor
Engine
Exhaust Gas

Glossary:
DOC DPF
DOC : Diesel Oxidation Catalyst
DPF : Diesel Particulate Filter
MU : Metering Unit
IU : Injection Unit
ECU : Engine Control Unit Doosan Infracore 8

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

Doosan Infracore 9
Slide 11

Engine Sensors (DL08)

1
7

3
6
4
5
2

1. Boost Pressure & Temperature Sensor

2. Coolant Temperature Sensor
3. Crankshaft Speed Sensor
4. Rail Pressure Sensor
5. CP Pump Metering Unit
6. Camshaft Speed Sensor
7. Fuel Temperature Sensor

Doosan Infracore 10

Slide 12

Engine Sensors

Boost Pressure & Temperature Sensor.

Harness connector

4
3
2
1

No. ECU Pin PIN description

1 290 Ground
2 237 Boost temperature signal
3 207 + 5 V supply
4 286 Boost pressure signal

Sensed Parameter Range: Sensor Value: Sensor Value: Failure Failure Default Mode Failure
Sensor Name Impacts on Emissions
Low / High (Units) Low (unit) High (unit) Detection Indication Threshold value Consequence

Replacement value = Frozen value

(Last valid value: just before error was
Cold < 20 C
Boost Check lamp =On detected during current operating cycle)
20 C <= Normal <= 50 C 215.2 mV 4921.8 mV By ECM N/A N/A
Temperature Failure Code stored.
Hot > 50 C
Next operating cycle it will take the
default value of 40 deg C

Boost Check lamp = Blink * Torque limit VGT actuator is controlled

100kPa < Normal < 340kPa 202.8 mV 4873 mV By ECM Replacement value = 220 kPa
Pressure Failure Code stored. 10% by boost air pressure.

Doosan Infracore 11
Slide 13

Engine Sensors

Coolant / Fuel Temperature Sensor.

Harness connector

2
1

Coolant temperature Fuel temperature

No. ECU Pin PIN description No. ECU Pin PIN description
1 239 Coolant Temperature Signal 1 212 Fuel Temperature Signal
2 259 Ground 2 259 Ground
Sensed Parameter Range: Sensor Value: Sensor Value: Failure Failure Default Mode Failure
Sensor Name Impacts on Emissions
High / Low (Units) Low (unit) High (unit) Detection Indication Threshold value Consequence
(Sensor Operating) 105 C: Max. fuel rate 2% limit
Power derated for engine
protection .
Threshold temp = 105 C 110 C: Max. fuel rate 20% limit
105 deg C: Torque 2% limit
Threshold temp = 110 C 115 C: Max. fuel rate 50% limit
Cold < 60 C Check lamp =Blink Threshold temp = 115 C 107 C : Engine check lamp On
110 deg C: Torque 20% limit
Coolant
60 C <= Normal <= 100 C 188.2 mV 4929 mV By ECM and Failure Code
Temperature stored. 115 deg C: Torque 50% limit
Hot > 100 C 107 C : Engine check lamp On EGR Valve 0%, VGT 0%

(Sensor Failure)
Replacement value Torque limit 10% Power derated for engine
engine is running = 85 C EGR valve 0% / VGT 0% protection only.
engine is not running = - 25 C

Fuel Check lamp =On

-30 C <= Normal <= 40 C 188.2 mV 4929 mV By ECM Replacement value = 48 C N/A N/A
Temperature Failure Code stored.

Doosan Infracore 12

Slide 14

Engine Sensors

Camshaft Speed Sensor (DL08,DL06) Crankshaft Speed Sensor (DL06)

Harness connector

3
2
1

Crankshaft Speed Sensor (DL06) Camshaft Speed Sensor (DL06) Camshaft Sensor (DL08)
No. ECU Pin PIN description No. ECU Pin PIN description No. ECU Pin PIN description
1 266 CRS POS 1 268 CAS POS 1 267 CAS NEG
2 265 CRS NEG 2 267 CAS NEG 2 268 CAS POS
3 269 Shield 3 269 Shield 3 269 Shield

Sensed Parameter Range: Failure Failure Default Mode Failure

Sensor Name Sensor Signal Impacts on Emissions
High / Low (Units) Detection Indication Threshold value Consequence

If the camshaft rotation counter

Check lamp =on
Crankshaft 650 rpm < normal < 2200 crosses the threshold "threshold Torque limit 10% Vehicle safety
Pulse signal By ECM and Failure Code
Speed Sensor rpm =4"and if the camshaft signal is tested CAM shaft sensor back engine protection
stored.
and plausible the error is set up mode

Check lamp =on In between of several crankshaft Starting delay during

CAM Vehicle safety
20 Hz < Normal < 95 Hz Pulse signal By ECM and Failure Code revolutions there is not any camshaft engine cranking.
Position Sensor engine protection
stored. edge present. (Threshold = 4) After cranking, no effect

Doosan Infracore 13
Slide 15

Engine Sensors

Crankshaft Speed Sensor (DL08)

Harness connector

2
1

Crankshaft Speed Sensor (DL08)

No. ECU Pin PIN description
1 266 CRS POS
2 265 CRS NEG

Sensed Parameter Range: Failure Failure Default Mode Failure

Sensor Name Sensor Signal Impacts on Emissions
High / Low (Units) Detection Indication Threshold value Consequence

If the camshaft rotation counter

Check lamp =on
Crankshaft 650 rpm < normal < 2200 crosses the threshold "threshold Torque limit 10% vehicle safety
Pulse signal By ECM and Failure Code
Speed Sensor rpm =4"and if the camshaft signal is tested CAM shaft sensor back engine protection
stored.
and plausible the error is set up mode

Doosan Infracore 14

Slide 16

Engine Sensors

Rail Pressure Sensor.

Harness connector

3
2
1

No. ECU Pin PIN description

1 260 Ground
2 236 Rail pressure signal
3 211 + 5 V supply

Sensed Parameter Range: Sensor Value: Sensor Value: Failure Failure Default Mode Failure
Sensor Name Impacts on Emissions
Low / High (Units) Low (unit) High (unit) Detection Indication Threshold value Consequence

Torque limit 50%

Replacement value is
Fuel Pressure Check lamp = Blink varied according to CP Changes with speed /
50MPa < Normal < 180MPa 268 mV 4868 mV By ECM
(High Pressure) Failure Code stored. pump metering unit. load conditions.
Rail pressure for
opened PRV

Doosan Infracore 15
Slide 17

Engine Sensors

Air Mass Flow Sensor.

Harness connector

E
D
C
B
A

No. ECU Pin PIN description

A 230 Ground
B 238 Air temperature signal
C 230 Ground
D 284 + 12 V
E 254 Frequency output

Sensed Parameter Range: Sensor Value: Sensor Value: Failure Failure Default Mode Failure
Sensor Name
Low / High (Units) Low (unit) High (unit) Detection Indication Threshold value Consequence

Replacement value = Model value by Boost

Torque limit 10%
Mass Air Flow Check lamp =Blink pressure and Boost temperature
100kg/hr < Normal < 1000kg/hr 70 us 7000 us By ECM EGR valve = 0 %
(HFM) Sensor Failure Code stored. When Boost sensor is failed, engine
VGT = 0%
chooses mapping value by engine rpm.
Replacement value = Frozen value (Last
valid value: just before error was detected)
Cold < 20 C
Check lamp =on at detect operating cycle EGR Valve = 0%
Air Flow Temperature 20 C <= Normal <= 30 C 400mV 4900mV By ECM
Failure Code stored. VGT = 0%
Hot > 30 C
Next operating cycle will take default value
( 30 C)

Doosan Infracore 16

Slide 18

Sensors & Actuators (DL08)

1. EGR Valve (Exhaust Gas Recirculation)

2. Throttle Valve
3. VGT (Variable Geometry Turbo)
4. Oil Pressure & Temperature Sensor

Doosan Infracore 17
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)
1
2
Smart Remote Actuator 3
4
Supply Voltage 24V
Operating Voltage 9V ~ 32V
Typical Operating Voltage 13.8V ~ 28V
EGR Valve
Max. Operating Temp. Range 140 ambient (with water cooling, max. 110)
No. ECU Pin PIN description
Min. Operating Temp. Range -40 ambient 1 Vbat +24 Volt supply
Max. Storage Temp. Range -50 ~ 150 2 GND Ground
3 218 CAN 2 Low
CAN communication Baud rate 250k bits/s 4 217 CAN 2 High

Sensed Parameter
Sensor or Sensor - Default Mode / Failure
Range: Low /High Failure Detection Failure Indication Impacts on Emissions
Actuator Name Actuator control threshold value Consequence
(Units)

By itself
Controls itself Engine Check lamp =On If EGR is deactivated, NOx
EGR Flow Control 0 < Normal < 100% (Sends message 0 ~ 100% N/A
(Smart Control) Failure Code stored. emissions increase.
to ECM)

* SRA: Smart Remote Actuator

Doosan Infracore 18

Slide 20

Engine Actuator

Smart Actuator. (EGR)

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

EGR Valve Inter-cooler Turbocharger

Fresh Air

EGR DPF
Cooler

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 19
Slide 21

Engine Actuator

Smart Actuator. (EGR)

Current Air Mass
(AFS_mAirPercyl)

Coolant Temp. Desired Value

AirCtl_mDesVal
Calculation
HFM Air Temp. Desired air mass set point (mg/hub)
PI- Controller
Monitoring
Adjusting the Measured air AirCtl_rGovEGR and Shut-off EGRVlv_r
mass to match the desired
set point air mass Working ranges
AirCtl_rCtlVal Sys. error Mon
Engine RPM Air Ctl _Gov Closed-Loop Transient detection
EGR open-loop control value (%)
Control
Injection Quantity

Engine Stop (IGN On) Engine Running (Idle 800rpm) Engine Running (900rpm)
EGR 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 Realized Byte

Byte 1,2[1..8] : EGR Actuator Position Request

ECU EGR ComTx_EDC2EGRVLV 10ms
Byte 3[1..8] : EGR Actuator Command State
Byte 0 : Actuator state
Byte 1,2 : Actuator actual shaft position
Byte 3 : Actuator Internal temperature
ComRx_EGRVlv2EDC 20ms
ECU EGR Byte 4 : Actuator fault code
Byte 5,6 : Actuator target shaft position
Byte 7 : Actuator Motor Effort
ComRx_EGRErrSt 100ms Byte 0 ~ Byte 7 : Actuator Fault Code

Doosan Infracore 20

Slide 22

Engine Actuator

Throttle Valve Actuator.

Harness connector

6
2 5
3
1

Sensor Output(%Vdd) No. ECU Pin PIN description

Characteristic Position Angle
(Based On 5V Voltage Supply) 1 234 5 Volt supply
Mechanical Stop 0 901% (4.5V) 2 229 DC motor -
Min. Electrical closed position 1.8 88.5% (4.425V) 3 240 Ground
Max. Electrical open position 84 18.51%(0.926V) 5 215 Feedback sensor signal
DC-Motor unpowered 89 14.253.5% (0.713V) 6 205 DC motor +

Sensed Parameter
Sensor - Actuator Sensor / Actuator Default Mode / threshold
Actuator Name Range: Failure Detection Failure Indication Failure Consequence
Value: Low (unit) Value: High (unit) value
High / Low (Units)

0 < Normal < 100

NOTE:
When throttle value
Throttle Feed (Activated only when Check lamp =On Torque limit 25%
400mV 4800mV By ECM feedback failed
back sensor DOC upstream Failure Code stored. EGR valve = 0%
Default value = 0%
temperature is < 230 C,
else 0% full open.)

OC = Oxydation Catalyst

Doosan Infracore 21
Slide 23

Engine Actuator

Smart Remote Actuator. (VGT Only On DL08 Engines)

- The SRA controls its position by use of an internal closed-loop system. Harness connector
- CAN Communication is used to input / output information to the SRA.
- If the VGT does not receive a valid CAN signal for 1sec. Default position 15%.
- Once the VGT receives a valid CAN signal for 4 sec. resumes normal operation.

1
Smart Remote Actuator 2 3
Supply Voltage 24V 4

Reduced Function 18V ~ 22V and 32V ~ 36V

Full Function 22V ~ 32V VGT
No. ECU Pin PIN description
Max. Operating Temp. Range -40 ~ 130 (140 for 100 hours) 1 Vbat +24 Volt supply
Max. Storage Temp. Range -40 ~ 150 2 GND Ground
3 218 CAN 2 Low
CAN communication Baud rate 250k bits/s 4 217 CAN 2 High

Sensed Parameter
Sensor or Default Mode
Range: Low / High Sensor - Actuator control Failure Detection Failure Indication Failure Consequence Impacts on Emissions
Actuator Name threshold value
(Units)

VGT pressure controls boost and

EGR pressures so that
By itself Check lamp =on
VGT Control and Controls itself N/A proportionality is maintained and
0 < Normal < 100% (Sends message and Failure Code 0~100%
Position Sensor (Smart Control) EGR can be driven into the intake air
to ECM) stored.
supply. Also manages power control
via the Speed/Load (Boost) tables

* SRA: Smart Remote Actuator

Doosan Infracore 22

Slide 24

Engine Actuator

Smart Actuator. (VGT Only DL08)

Boost pressure sensor value

PCR_pDesVal
boost-pressure set point (hPa)
PID- Controller Monitoring
PCR_rGov and Shut-off TrbCh_r
Minimize the deviation between
pressure set point and boost
pressure sensor Working ranges
PCR_rCtlVal Sys. error Mon
Engine RPM Transient detection
VGT open-loop control value (%) PCR _Gov Closed-Loop Control

Injection Quantity

Engine Stop (IGN Off) Engine Stop (IGN On) Engine Running (Idle 800rpm)
VGT 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 Realized Byte

Byte 0,1 : Position demand for actuator in terms of duty cycle

ECU VGT ComTx_EDC2VGTB 10ms 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
ECU VGT ComRx_VGTB2EDC 30ms
Byte 5 : Power applied to the motor
Byte 6 : Fault and warning messages
Byte 7[1] : Actuator learn status

Doosan Infracore 23
Slide 25

Engine Sensors

Oil Pressure & Temperature Sensor.

Harness connector

4
3
2
1

No. ECU Pin PIN description

1 206 Ground
2 213 Oil temperature signal
3 231 + 5 V supply
4 235 Oil pressure signal

Sensed Parameter Range: Sensor Value: Sensor Value: Failure Failure Default Mode Failure
Sensor Name Impacts on Emissions
Low / High (Units) Low (unit) High (unit) Detection Indication Threshold value Consequence
Replacement value
Oil Temperature -30 C <= Normal <= 115 C 232.2 mV 4924.4 mV By ECM Failure Code stored. N/A N/A
= Coolant temperature
MIN Threshold pressure
800 rpm : 220 kPa
900 rpm : 240 kPa
1000 rpm : 260 kPa Torque limit 50%
1200 rpm : 280 kPa Only for Engine
Check lamp =Blink 1600 rpm : 300 kPa
Oil Pressure 400kPa < Normal < 600kPa 202.8 mV 4924.2 mV By ECM protection
Failure Code stored. 3200 rpm : 320 k=hPa Check lamp only.

Replacement value
N/A
= 450 kPa

Doosan Infracore 24

Slide 26

Metering Unit & Exhaust System Sensors (DL08)

5
6

7
8

2 3

1 4

1. Shut Off Valve

2. Upstream Pressure & Temperature Sensor
3. Dosing Valve
4. Downstream Pressure Sensor
5. DOC Upstream Temperature Sensor
6. DPF Upstream Temperature Sensor
7. DPF Downstream Temperature Sensor
8. DPF Differential Pressure Sensor

Doosan Infracore 25
Slide 27

Metering Unit

Metering Unit (Shut Off Vale & Dosing Valve)

Harness connector

Dosing Valve

2 2
1 1

Shutoff Valve Dosing Valve

No. ECU Pin PIN description No. ECU Pin PIN description
1 120 Shutoff valve high side 1 122 Dosing valve high side
2 145 Shutoff valve low side 2 124 Dosing valve low side

Shutoff Valve Dosing Valve

Feature Normal value Feature Normal value
Coil resistance 3.3 Coil resistance 15.95
Shut Off Valve

Cooling adapter

Doosan Infracore 26

Slide 28

Metering Unit

Metering Unit (Upstream Pressure & Temperature Sensor)

Harness connector
Upstream P_T

4
3
2
1

No. ECU Pin PIN description

1 133 Ground
2 142 Temperature signal
3 191 +5 V supply
4 130 Pressure signal

Sensed Parameter Range: Sensor Value: Sensor Value: Failure Default Mode
Sensor Name Failure Indication Failure Consequence Impacts on Emissions
Low / High (Units) Low (unit) High (unit) Detection threshold value

HCI Upstream Check lamp = Blink Replacement value Inhibit the HC dosing Exhaust Gas temperature
0 kpa < Normal < 1200 kpa 250 mV 4850 mV By ECM
Pressure Failure Code stored = 300 kpa Torque limit 25% control for DPF regeneration.

HCI Upstream Check lamp = On Replacement value Exhaust Gas temperature

-40 C < Normal < 130 C 250 mV 4750 mV By ECM Inhibit the HC dosing
Temperature Failure Code stored = 48 C control for DPF regeneration.

Doosan Infracore 27
Slide 29

Metering Unit

Metering Unit (Downstream Pressure.)

Harness connector

3
2
1

No. ECU Pin PIN description

1 167 +5 V supply
2 133 Ground
Downstream 3 156 Pressure signal
Pressure Sensor

Sensed Parameter Range: Sensor Value: Sensor Value: Failure Default Mode
Sensor Name Failure Indication Failure Consequence Impacts on Emissions
Low / High (Units) Low (unit) High (unit) Detection threshold value

Downstream Active Regeneration is Exhaust Gas temperature

Check lamp =Blink Replacement value
Pressure 0 kpa < Normal < 1200 kpa 250 mV 4750 mV By ECM prevented control for DPF
Failure Code stored. = 200 kpa
Sensor Torque limit 25% regeneration.

Doosan Infracore 28

Slide 30

Exhaust System Sensors

Exhaust Gas Temperature Sensors

Harness connector

2
1

T4 DOC upstream T5 DPF upstream T6 DPF downstream

No. ECU Pin PIN description No. ECU Pin PIN description No. ECU Pin PIN description
1 116 Temperature signal 1 117 Temperature signal 1 140 Temperature signal
2 118 Ground 2 118 Ground 2 143 Ground

Sensed Parameter Range: Sensor Value: Sensor Value: Failure Default Mode
Sensor Name Failure Indication Failure Consequence Impacts on Emissions
Low / High (Units) Low (unit) High (unit) Detection threshold value

Threshold temp HC dosing module can start

= 600 C dosing by upstream DOC
Exhaust Gas
temperature sensor.
Temperature Sensor Check lamp =Blink Torque limit 25%
-40 C <= Normal <= 500 C 200 mV 3000 mV By ECM Regeneration is not allowed at
(T4 Upstream of Failure Code stored. Replacement value EGR valve = 0 %
idle but may be allowed at light
DOC) = 200 C load conditions where upstream
temperature is above 200C.
Check lamp =on Threshold temp Inhibit the HC dosing
Exhaust Gas
Failure Code stored. = 700 C system HC dosing module is controlled
Temperature Sensor -40 C <= Normal <= 500 C 200 mV 4900 mV
By ECM Replacement value Torque limit 25% by temperature sensor between
(T5 Between 200 C <= DPF RGN <= 800 C Check lamp =Blink
= 200 C EGR valve = 0 % DOC and DPF
DOC and DPF) Failure Code stored.
Inhibit HC dosing
Exhaust Gas
Temperature Sensor -40 C <= Normal <= 500 C Check lamp =Blink Replacement value
500 mV 1800 mV By ECM N/A N/A
(T6 Downstream of 200 C <= DPF RGN <= 800 C Failure Code stored. = 200 C
DPF)

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)

Ground

1 2 3
3
2
1

Output Signal
No. ECU Pin PIN description
1 190 + 5 V supply
2 143 Ground
3 155 Diff pressure signal

Sensed Parameter Range: Sensor Value: Sensor Value: Failure Default Mode Failure
Sensor Name Failure Indication Impacts on Emissions
Low / High (Units) Low (unit) High (unit) Detection threshold value Consequence

Red Stop lamp =

Threshold DPF plugging and
On
= 20 kPa cracking can be found
Failure Code stored
by DPF differential
pressure sensor.
DPF 0 kPa <= Normal or RGN <= 9 kPa
85 mV 4085 mV By ECM Torque limit 10%
Differential Pressure DPF Cleaning at >12 kPa
Check lamp = On Replacement value Monitors DPF soot / ash
Failure Code stored. = 3 kPa loading to establish
service / maintenance
intervals.

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

Doosan Infracore 30

Slide 32

ECU Terminal Diagram

Doosan Infracore 31
Slide 33

ECU Terminal Diagram

Doosan Infracore 32

Slide 34

ECU Terminal Diagram

Engine ECU

Engine Vehicle
Connector Connector
Injector
Solenoids

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

Doosan Infracore 33
Slide 35

ECU Terminal Diagram

Air Flow
Meter
Shield

Oil Pressure &

Temperature
Sensor

Can H0
Boost
Pressure & Can L0
Temperature Shield
Sensor
Can H1
Can L1
Variable Turbo
Geometry Shield
(VGT)
Actuator 1 /
Waste Gate1

Doosan Infracore 34

Slide 36

ECU Terminal Diagram

(Preheat Symbol)

HCI Pressure
Sensor
Downstream

HCI Pressure
&
Throttle Plate
Temperature
Actuator
Sensor
Upstream
Throttle Plate
Actuator HCI Metering
Valve
Engine Brake Actuator 1 HCI Shut-Off
Internal Engine Valve
Decompression Valve

Turbine Wheel DPF

Speed Sensor A Differential
Pressure
Sensor

Controller Area DPF Exhaust

Network 2 Shield Temperature
Sensor (T6)
DPF Exhaust
Temperature
EGR Differential Sensor (T5)
Pressure Sensor
DPF Exhaust
Temperature
Sensor (T4)

Doosan Infracore 35
Slide 37

ECU Terminal Diagram

Camshaft Speed Sensor

Output Signal
Crankshaft Speed Sensor Inhibit
Output Signal Regenerate
DPF
Fuel
Regeneration
Temperature
Switch
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

Slide 38

ECU Terminal Diagram

Doosan Infracore 37
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 Engine side

73 1 73 1
Locking Slide Locking lever

96 24 96 24

Doosan Infracore 39
Slide 41

CAN Network Configuration

Machine
CAN 0 High : Pin No. 146
Vehicle side controller
(EPOS)
120 CAN 0 120

CAN 0 Low : Pin No. 147

CAN 1 Low : Pin No. 195

Communication
CAN 1 with computer
(use only for Dev. Engineer)
CAN 1 High : Pin No. 171
EDC17
ECU

Engine side
CAN 2 Low : Pin No. 218

120 CAN 2 120

CAN 2 High : Pin No. 217

EGR VGT

Doosan Infracore 40

Slide 42

CAN Massage Information (ECU EPOS)

New ID Data New ID Data
Period Period
Sub Title Byte Bit Name Sub Title Byte Bit Name
DEC1_V EEC2 : Electronic Engine Controller 2
0x0CFF0117 50ms Byte0 Accelerator pedal position 0x0CF00300 50ms Byte0~1 Unused
Byte1 Bit0~1 Accelerator pedal position Byte2 Percent Load at current Speed
EBC1 EEC1 : Electronic Engine Controller 1
0x18F00100 100ms Byte0~2 Unused 0x0CF00400 10ms Byte0~1 Unused
Bit4~5 Auxiliary Engine Shutdown Switch Byte2 Actual Engine - Percent Torque
Request PGN Byte3~4 Engine Speed
0x18EA0017 1000ms Byte0 PGN number low byte ET1 : Engine Temperature 1
Byte1 PGN number mid byte 0x18FEEE00 1000ms Byte0 Engine Collant Temperature
Byte2 PGN number high byte Byte1 Fuel Temperature
Receive Frame to control fan speed : DL06 Fan Clutch Byte2~3 Engine Oil Temperature
0x18FF2800 1000ms Byte0 Bit0~1 status message to reduce fan speed by 0% EFL / P1 :Engine Fluid Level/Pressure 1
Byte1 Bit0~1 status message to reduce fan speed by 30% 0x18FEEF00 500ms Byte0 Engine Fuel Delivery Pressure
Byte2 Bit0~1 status message to reduce fan speed by 70% Byte3 Engine Oil Pressure
Byte3 Bit0~1 status message to reduce fan speed by 80% LFE : Fuel Economy
Byte4 Bit0~1 status message to reduce fan speed by 100% 0x18FEF200 100ms Byte0~1 Fuel Rate
AAI : Auxiliary Analog Information : Hyd.Oil Temp Byte6 Engine Throttle Position
0x18FE8C17 1000ms Byte0 Hydraulic Oil Temperature IC1 : Inlet/Exhaust Conditions 1
AUXIO1 : Auxiliary Input/Output Status 1 0x18FEF600 500ms Byte0
0x18FDCB1
100ms Byte0 Unused Byte1 Boost Pressure
7
Bit2~3 Pilot Cutoff Status Byte2 Intake Manifold temperature
FD : Fan Drive
0x18FEBD00 1000ms Byte0
Byte2~3 Fan Speed
LFC : Fuel Consumption
0x18FEE900 receiving a PGN request Byte0~3
Byte4~7 Total Fuel Consumption
PTC1
Diesel Particulate Filter Regeneration
1000ms Byte0 Bit 1..3 status Lamp Command
DPF Active Regeneration Inhibited
Byte3 Bit 3..4 Status Lamp command
Exhaust System High Temperature
Byte7 Bit 3..5 Lamp Command
DM1-Single
DM2-Multi Packet and BAM

Doosan Infracore 41
Slide 43

Diagnostic Trouble Shooting Codes

DTC List

No. DTC Description

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
: : :

Doosan Infracore 42

Slide 44

Basic Concept Of Signal Sensing

Raw Raw Sensed

value
Signal value
[mV]
value
[deg C]
Physical [deg C] Signal used in
ADC Range Range Application
Software

Check Check
< Transfer curve >

SRC MAX Physical range MAX

<The sensor raw signal voltage is above the threshold.> <The sensed sensor signal is greater than the threshold.>

SRC MIN Physical range MIN

<The sensor raw signal voltage is below the threshold.> <The sensed sensor signal is less than the threshold.>

Doosan Infracore 43
Slide 45

Engine Torque Derating

Torque Derating

Doosan Infracore 44

Slide 46

Engine Fault Lamp

Error Code Class & Lamp Information

Failure Display Action Display

OK 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 45
Slide 47

Example Of Diagnostic Trouble

Trouble Shooting
DTC Description
C122 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 46

Slide 48

- EOD -

Doosan Infracore