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D6CA(L-Engine)
Engine Management System
2
Intake Air Temp.
Intake Air Pressure
CAM Position
Crank Position
Coolant Temp.Atmospheric Air Pressure.
Fuel Temp.
Fuel pressure
Switches
Battery +
EUI (6)
Relay control
Tachometer Drive
Vehicle Speed
Diagnosis (Hi-scan)
CAN BUS(LAN)
Check Engine
Vehicle Speed
Engine
Control
Unit
Input & Output Diagram
3
1 : Boost air pressure2 : Power3 : Boost air Temperature4 : Ground
1 2 3 4
0
50
100
150
200
250
300
350
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]
air p
ress
ure
[kPa
]Boost pressure & Temp. Sensor
- 40
- 20
0
20
40
60
80
100
120
140
4464291052438114142418288
Resistance[Ohm]
Tem
pera
ture
[C]
4
1 2 3
1 : Ground2 : Gauge 3 : Sensor
NTC Thermister
200220240260280300320340360380400
0 47 132 278 469 632 778 869
Temperature [K]
Senso
r outp
ut[
mV]
Coolant Temperature Sensor
5
1 : Fuel Temperature2 : Power 3 : Ground 4 : Fuel Pressure
1 2
3 4
0
200
400
600
800
1000
1200
0.2000 1.1010 2.0020 2.9030 3.8040 4.7050
Output voltage [V]
Fuel
pre
ssur
e [k
Pa]
Fuel Pressure Sensor
6
Pedal Angle
Voltage
0.5 V
4.5V
95 %0
Potentiometer
Pedal Position Sensor
7
1 2 3
1 : Ground2 : Sensor 3 : shield
Negative going zero crossing signalTriggers the signal
Raw Signal
+1 teeth
Processed Signal
No. 1 Cylinder No. 2 CylinderNo. 6 Cylinder
Cam Angle Sensor
8
1 2 3
1 : Ground2 : Sensor 3 : Shield
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 2019 1
Crank Position Sensor
Raw Signal
9
15˚ CAM
+1 teeth
1st wheelteeth
6th wheelteeth
2nd wheelteeth
34.5 ˚69 ˚ CA
6 deg
6 tooth have 60 degrees interval
CPS CAM11th teeth
Gap : 1.5 +/-0.5
Crank Sensor Wheel Cam Sensor Wheel
Alignment of Crank wheel & Cam wheel at TDC position
10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 2019 1
Raw signal
Processed signal
TDCBolt up angle
Direction of the engine rotation
No. 4 cylinder No. 1 cylinder
-6 6
Center of the gap
Cam signal
Crank signal
+1 flag
Zero crossing of raw cam signal occurs in theCenter of the gap in the crank signal
Wave form of the Crank wheel & CAM wheel
11
101.32 [760]
20[150]
46.66[350]
4.818
1.924
0.512
Voltage
Pressure[kPa, mmHg]
MAP Sensor
Built – In ECU
Input Voltage Vin = 5 V
Operating Voltage Range 4.75~ 5.25 V
Storage Temperature Range -40 ~ 125
Operating Temperature Range
-30 ~ 110
Operating Pressure Range 20 ~ 102
Current 10 mA
12
K_LINEL_LINE
※ Connector Side
ASTRONICT/M
EngineECU ABS/ASR
ZFINTARDER
1 2 3 4 5 6 7 8VSPD CAN_L ABS Check L_LINE
9 10 11 12 13 14 15 16GND CAN_H T/M Check K_LINE BATT+
Diagnosis Connector
13
• 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.
Trouble Code
14
ex) Trouble Code :1134 and 1234
IG S/W
ON
Press for 3 sec
Engine check lamp
Press for 3 sec
SET/INC S/W
RES/DEC S/W
Previous trouble code
Next trouble code
1
T5
T6T4T1
T2 T5 T2
1 3 4 1 2 3 4 1 0 3 4 2
Trouble Code
15
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
Engine Control
16
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
Vehicle Control
17
CrankingCranking
IdleIdle
PedalPedal
Pedal Angle
Engine Speed
PTOPTO
CruiseCruise
Maximum Fuel AmountMaximum Fuel Amount
Compensation
MinimumTarget Fuel
Amount
Coolant Temperature
Vehicle Speed
Intake Air Press. & Temp.
Fuel Temp. & Press.
Atmospheric Pressure
Actual Fuel Amount
Fueling Control
18
CompensatedMaximumTorque Curve
Fuel Limit Smoke fuel limit
Absolute Max. fuel
High idle speed fuel limit
Lowestwins N
Y
MUX
Fuel LimitN
MUX
Y
Comp TestActive
Cranking
ETF CompTest Fuel
Limit
Fuel PressureDerate %
MUL
Absolute Max.Fuel
- Engine Torque Limit - Smoke Reduction- Engine Speed Limit- Engine Max. output Power Limit- Absolute Fuel Amount Limit
- Engine Torque Limit - Smoke Reduction- Engine Speed Limit- Engine Max. output Power Limit- Absolute Fuel Amount Limit
Fueling Control
19
Timing at Cranking
Timing at Cranking
Timing at PTOTiming at PTO
General Injection Timing
General Injection Timing
Engine Speed
Fuel Injection Amount
Coolant Temperature
Intake Air Temperature
Σ
Coolant Temperature
Intake Air Temperature
Σ
Advanced
Injection Angle
Starting Angle of injection
K3 Compensation
K3 Compensation
Fuel Injected Angle
End of Injection
Injection Amount
Fuel Temperature
Injection Timing Control
20
• 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
Cold Start Control
21
High Idle Speed Fuel Limit
Nx = Nnl - Dn = 2230 - 260 = 1970
K1 = (Fz-Fr) / (Nx-Nr) = (203-250) / (1970-1800) = -0.276
K2 = Fz / Dn = 250 / 260 = 0.962
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 Nnl
K1
K2
Fz
Fr
Abs. Max. Fuel
Dn
Max. torque fuel curve
Droop speed
Reduce the fuel injection amount at the high idle speed
to protect the engine
22
• Intake air heating at cold start condition - Reduce the smoke - Fast engine warm-up
No Pre/Post Heating Operating ofPre/Post Heating
OFF
START
IndicatingLamp
ON
OFF
Heater
Engine RPM
KEY S/W
ON
OFF
ON
Engine speed > limitation
APV
PREHEATING POSTHEATING
Preheating & Postheating
23
0
5000
10000
15000
20000
25000
30000
35000
40000
0 233 244 245 248 253 258 263 268 273
COOLANT TEMPERATURE[]
TIM
E[s]
0
5000
10000
15000
20000
25000
30000
35000
0 247 267 270 280 290 300 310 320 330
COOLANT TEMPERATURE[]
TIM
E[s
]
Preheating Time
Postheating Time
-40 -29 -28 -25 -20 -15 -10 -5 0
40 35 30 25 20 15 10 5 0
35 30 25 20 15 10 5
0 -26 -6 - 3 7 17 27 37 43 57
Preheating & Postheating Time
24
Compress the air inside cylinders → Warm up the engine block
Number of non-injection is determined by the engine coolant temperature
0
2
4
6
8
10
12
240 245 247 249 251 253 303 318 328 338
Engine Coolant Temperature []
Num
ber of no
n-in
ject
ion
-28 -26 -24 -22 -20 30 45 55 65
Cranking without Fuel ( Cold Start )
25
• ※ 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
Cold Start Control
26
0
20
40
60
80
100
120
140
160
230 245 255 265 280 300 308 318 328 338
Coolant Temperature
Fuel
Am
ount
(mg)
-40 -28 -18 -8 7 27 35 45 55 65
Cranking Fuel
More fuel amount is injected at the initial cranking condition.
Initial crank fuel = f(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.
27
• 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 st
opped to reduce the useless idle time.
Idle Speed Control
28
Engine RPM
K
ReferenceIdle speed
Time
500 RPM
Fuel amount
Idle Speed Control
29
Engine RPM
TIME
500 RPM
Idle Speed Control
Keeping the engine idle speed at any load (±2RPM)
Adjusting fuel injection amount to maintain the stable idle speed
30
Normal idle
Cold idle
Coolant temperature
-10 0
800 RPM
500 RPM
Idle Speed Control – Cold Start Idling
Idle
sp
eed
31
500 RPM
INC
DEC
+ 25 RPM
- 25 RPM
800 RPM
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
Idle Speed Control – Idle Trim
32
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_APV123456
0 1 1 10 0 0 0
1 : enable 0 : disable
33
–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
Condition ALevel 1
ThresholdAPV
Required FuelPressure for Speed
Fuel Pressure
APV1
Time
Level 2Threshold
APV
APV2
Derate Level 2
Derate Level 1
No Derate
Lamp On Lamp Flashing
Getting lower than level 2 pressure
Fuel Pressure Derate Protection
Required fuel pressure
for speed
34
Condition B
Fuel Pressure Derate Protection
Level 1Threshold
APV
Required FuelPressure for Speed
Fuel Pressure
APV1
Time
Level 2Threshold
APV
APV3
Derate Level 2
Derate Level 1
No Derate
Lamp On
LampFlashing
APV4
Required fuel pressure
for speed
35
Engine Overheat Warning
Warning Lamp ON
Warning Lamp OFF
Hysteresis Zone
Coolant Temperature
Time
103
98
- Warning lamp comes on when the coolant temperature is higher
than limit
36
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 to
o big, ECU operates 3rd Brake (Exhaust brake, Jake brake)
• Cruise control speed setting
- Cruise switch - SET/INC or RES/DEC switch
- Accelerator pedal
• Cruise control speed range : 15 ~ 80 km/hr
37
Door Switch
EC
UE
CU
EUI
Door SW
Accelerator
Position
Engine RPM
Function
When the door is open, ECU doesn’t accept the accelerator position signal and keeps the idle RPM.
38
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
39
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
40
CRUISE/PTO ENABLE SW
SET / INC
RES / DEC
BRAKE SW
CLUTCH SW
ENGINE SPEED
VEHICLE SPEED
REMOTE PTO ENABLE SW
INCREMENT
DECREMENT
EC
U
EUI
OUTSIDE CAB
AUTO CRUISE CONTROL
Vehicle Speed > 40 km/h Engine Speed > Cruise speed
POWER TAKE OFF CONTROL
Vehicle Speed < 10 km/h Engine Speed > Idle speed
Auto Cruise Control / PTO Control
Schematic Diagram
42
ECU
EUI 1
EUI 3
EUI 4
EUI 5
EUI 61999. 1. 25
ENG CONNECTOR
E43
E29
E45
E30
E46
E32 E31 E33
E25
E11
E39
E38
E37
E10
E7
E24
E4
E8
E21
E6
E19
E22
H1
L1
L2
L3
H2
L4 L5
L6
S1
S2
V2
A4
A11
A6
A14
A12
BA
SE
1 H
IGH
SID
E
INJE
CT
OR
1 L
OW
SID
E
INJE
CT
OR
2 L
OW
SID
E
INJE
CT
OR
3 L
OW
SID
E
BA
SE
2 H
IGH
SID
E
INJE
CT
OR
4 L
OW
SID
E
INJE
CT
OR
5 L
OW
SID
E
INJE
CT
OR
6 L
OW
SID
E
CA
M S
IGN
AL
RE
TU
RN
CA
M S
IGN
AL
CR
AN
K S
IGN
AL
RE
TU
RN
5V S
UP
PL
Y
BO
OS
T P
RE
S S
EN
SO
R
BO
OS
T T
EM
P S
EN
SO
R
RE
TU
RN
5V S
UP
PL
Y
BO
OS
T P
RE
S S
EN
SO
R
BO
OS
T P
RE
S S
EN
SO
R
CO
OL
TE
MP
SE
NS
OR
RE
TU
RN
SC
RE
EN
RE
TU
RN
SC
RE
EN
CR
AN
K S
IGN
AL
CO
OL
AN
T T
EM
P
FUEL PRES& TEMP
BOOST PRES& TEMP
CR
AN
K
CA
MEUI 2
Engine Side
43
Vehicle SideVehicle Side
B
AT
TE
RY
GN
D
PA
RK
ING
SW
ITC
H
BA
T+
BA
T+
MAIN RELAY
F=
5A
F/BRAKE SWITCH
E C U
B26
B27
SWITCHEDBATTERY(IG)
B42
B30
B17
STOP LAMP
F/B
RA
KE
PT
O L
AM
P
PT
O R
LY
PT
O M
/VA
LV
E
WA
RN
'G
B5
T/M
PT
O
ON
/OF
F
CL
UT
CH
(W/O
TM
PT
O)-
N/C
LO
SE
OF
FE
XH
AU
ST
/JA
KE
#1
JAK
E#2
JAK
E#3
B33
B3
B4
B21
B22
B18
CC
/EN
G P
TO
E
NA
BL
E
SE
T/I
NC
RE
S/D
EC
B7
B12
B13
B14
A/C
CO
MP
RE
SS
UR
E(O
PT
-BU
S O
NL
T)
B9
CH
EC
K E
NG
B46
B49
AIR
HE
AT
ER
B48
EN
GIN
E B
RK
LA
MP
B51
CR
UIS
E/P
TO
LA
MP
B47
OV
ER
HE
AT
LA
MP
B19
NE
UT
RA
L S
WIT
CH A
IR H
EA
TR
EL
AY
B50
IVS
2ID
LE
SW
ITC
H
PE
DA
L A
SS'
Y
IVS
1
PE
DA
L S
EN
SO
R G
ND
PE
DA
L S
EN
SO
R
SE
NS
OR
PO
WE
RB
34
B35
B8
B15
B20
B43
EX
HA
US
T B
RA
KE
B45
B44
EN
GIN
E B
RK
LO
/HI
EN
GIN
E
BR
K M
ED
/HI
TA
CH
O M
ET
ER
B28
TW
IST
(SH
IEL
D)
VE
HIC
LE
SP
EE
D O
UT
PU
TB
1
AIR
HE
AT
SU
B_R
EL
AY
DB
R
RL
Y
AB
S A
CT
IVE
#3,4
#5,6
#1,2
ENGINE
VE
HIC
LE
SP
EE
D S
EN
SOR
(HA
LL
EF
FE
CT
TY
PE
)
B36
VD
O T
/GR
AP
H
Ast
ron
icIn
tard
erA
stro
nic
Inta
rder
D3
DIA
GN
OS
TIC
C
ON
NE
CT
OR
B52
B53
B38
B39
B54
CA
N_H
CA
N_L
CA
N_S
HIE
LD
KW
P20
00_K
KW
P20
00_L
AB
S/A
SR
AB
S/A
SR
AS
TR
ON
ICA
ST
RO
NIC
<1m
R/P
TO
IN
CR
EA
SE
R/P
ED
AL
RE
TU
RN
R/P
ED
AL
S
EN
SO
R
B25
B24
B32
B6
R/P
TO
DE
CR
EA
SE
SA
FE
TY
SW
ITC
H
B31
RE
MO
TE
PT
O
EN
AB
LE
SW
B16
CL
UT
CH
SW
(W/T
M P
TO
)-N
/OP
EN
T/M
PT
OC
ON
TR
OL
SWIT
CH
15A
5A
5A
120Ω
BATTERY
ECU GND
44
B
AT
TE
RY
GN
D
PA
RK
ING
SW
ITC
H
BA
T+
BA
T+
MAIN RELAY F
=5A
F/BRAKE SWITCH
E C U
B26
B27
SWITCHEDBATTERY(IG)
B42
B30
B17
STOPLAMP
F/B
RA
KE
B5
CL
UT
CH
OF
FE
XH
AU
ST
/JA
KE
#1
JAK
E#2
JAK
E#3
B33
B3
B4
B21
B22
B18
CC
/EN
G P
TO
E
NA
BL
E
SE
T/I
NC
RE
S/D
EC
B7
B12
B13
B14
A/C
CO
MP
RE
SS
UR
E(O
PT
-BU
S O
NL
T)
B9
CH
EC
K E
NG
B46
B49
AIR
HE
AT
ER
B48
EN
GIN
E B
RK
LA
MP
B51
CR
UIS
E/P
TO
LA
MP
B47
OV
ER
HE
AT
LA
MP
B19
NE
UT
RA
L
SW
ITC
H
AIR
HE
AT
RE
LA
Y
B50
IVS
2
IDLE SWITCH
PEDAL ASS'Y
IVS
1
P/ S
EN
SO
R G
ND
PE
DA
L S
EN
SO
R
SE
NS
OR
PO
WE
R
B34
B35
B8
B15
B20
B43
EX
HA
US
T B
RA
KE
B45
B44
EN
GIN
E B
RK
L
O/H
I
EN
GIN
E
BR
K M
ED
/HI
TW
IST
(SH
IEL
D)
VE
HIC
LE
SP
EE
D
OU
TP
UT
B1
AIR
HE
AT
SU
B_R
EL
AY
DB
R R
LY
AB
S A
CT
IVE
#3,4
#5,6
#1,2
ENGINE
VE
HIC
LE
SP
EE
D S
EN
SOR
(HA
LL
EF
FE
CT
TY
PE
)
B36
VD
O T
/GR
AP
H
Ast
ron
icIn
tard
erA
stro
nic
Inta
rder
D3
DIA
GN
OS
TIC
C
ON
NE
CT
OR
B52
B53
B38
B39
B54
CA
N_H
CA
N_L
CA
N_S
HIE
LD
KW
P20
00_K
KW
P20
00_L
AB
S/A
SR
AB
S/A
SR
<1m
BATTERY
15A
5A
5A
120ΩECU GND
Vehicle SideVehicle Side
45
B
AT
TE
RY
GN
D
PA
RK
ING
SW
ITC
H
SWITCHEDBATTERY(IG)
PTO LAMP
PTOM/VALVE
WARN'G
T/M PTO ON/OFF
OFF
EX
HA
US
T/J
AK
E#1
JAK
E#2
JAK
E#3
CC
/EN
GP
TO
EN
AB
LE
SE
T/I
NC
RE
S/D
EC
CH
EC
K E
NG
AIR
HE
AT
ER
EN
G B
RK
LA
MP
CR
UIS
E/P
TO
LA
MP
OV
ER
HE
AT
LA
MP
NE
UT
RA
L S
WIT
CH
AIR HEATRELAY
IVS
2ID
LE
SW
ITC
H
PE
DA
L A
SS
'Y
IVS
1
P/ S
EN
SO
R G
ND
PE
DA
L S
EN
SO
R
SE
NS
OR
PO
WE
R
EX
HA
US
T B
RA
KE
EN
GIN
E
BR
K L
O/H
I
EN
GIN
EB
RK
ME
D/H
I
TACHO METER
TW
IST
(SH
IEL
D)
VEHICLESPEED
OUTPUT
AIR
HE
AT
SU
B_R
EL
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STOPLAMP
F/B
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15A
5A
5A
B26
B27
B42
B30
B17
B5
B33
B3
B4
B21
B22
B18
B7
B12
B13
B14
B9
B46
B49
B48
B51
B47
B19
B50
B34
B35
B8
B15
B20
B43
B45
B44
B28
B1
B36
B52
B53
B38
B39
B54
B25
B24
B32
B6
B31
B16
ENGINE
AB
S/A
SR
AB
S/A
SR
120ΩECU GND
Vehicle SideVehicle Side
