D6CA

(L-Engine)

Engine Management System

Input & Output Diagram

Intake Air Temp. EUI (6)

Intake Air Pressure
Coolant Temp.
Atmospheric Relay control
Air Pressure.
Engine
Fuel Temp.
Control Tachometer Drive
Fuel pressure
Vehicle Speed
CAM Position Unit
Crank Position Check Engine

Vehicle Speed
Diagnosis (Hi-scan)
Switches
CAN BUS(LAN)
Battery +

2
Boost pressure & Temp. Sensor

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

140
350
120
300
100
250

Temperature[C]
air pressure [kPa]

80
200 60

150 40
20
100
0
50
- 20
0 - 40
1.06 1.45 1.83 2.21 2.59 2.97 3.35 3.74 4.12 4.50 4.88 88 182 424 1141 2438 9105 44642
Output Voltage[ V] Resistance[ Ohm]

3
Coolant Temperature Sensor

NTC Thermister

400
1 2 3
Sensor output[mV]

380
360
340
320
300 1 : Ground
280
260 2 : Gauge
240 3 : Sensor
220
200
0 47 132 278 469 632 778 869
Temperature [K]
4
Fuel Pressure Sensor

1200

1000
Fuel pressure [kP a]

800 1 : Fuel Temperature

600
1 2 2 : Power
400 3 4 3 : Ground
4 : Fuel Pressure
200

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

0 95 % 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 1st wheel 15˚ CAM

teeth

2nd wheel
teeth
34.5 ˚
69 ˚ CA +1 teeth

6th wheel
teeth

6 tooth have 60 degrees interval

Crank Sensor Wheel Cam Sensor Wheel

9
Wave form of the Crank wheel & CAM wheel
Zero crossing of raw cam signal occurs in the
Center of the gap in the crank signal

Center of the gap

Direction of the engine rotation

Raw signal

Processed signal

No. 4 cylinder +1 flag No. 1 cylinder

Cam signal

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1

-6 6
Crank signal TDC
Bolt up angle

10
MAP Sensor

Input Voltage Vin = 5 V

Operating Voltage Range 4.75~ 5.25 V
Voltage
Storage Temperature Range -40 ~ 125 ℃
Operating Temperature Range -30 ~ 110 ℃
4.818

Operating Pressure Range 20 ~ 102

Current 10 mA
1.924
0.512

20 46.66 101.32 Pressure

[150] [350] [760] [kPa, mmHg] Built – In ECU

11
Diagnosis Connector

1 2 3 4 5 6 7 8
VSPD CAN_L ABS Check L_LINE

9 10 11 12 13 14 15 16
GND CAN_H T/M Check K_LINE BATT+

K_LINE
L_LINE

Engine ASTRONIC ZF
ECU ABS/ASR
T/M 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 3 4 1 2 3 4 1 0 3 4 2

Press for 3 sec

T5 T2 T5 T2

Engine check T1 T4 T6
lamp
Next trouble code
Press for 3 sec
Previous trouble
code

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
Idle
Idle Coolant Temperature
n
Fuel Temp. & Press.

Pedal Angle
Atmospheric Pressure

Engine Pedal
Pedal
Speed Target Mini Actual Fuel
Fuel Amount
Amount
mum

PTO
PTO

Cruise
Cruise

17
Fueling Control

Compensated
Maximum MUL
Torque Curve
Fuel Limit Smoke fuel limit Lowest
High idle speed wins N
fuel limit MUX N
Fuel Pressure MUX Fuel Limit
Absolute Max. fuel Y
Derate %
Y

- Engine Torque Limit Absolute Max.

Fuel
- Smoke Reduction Cranking Comp Test
- Engine Speed Limit Active
- Engine Max. output Power Limit
- Absolute Fuel Amount Limit ETF Comp
Test Fuel
Limit

18
Injection Timing Control
Intake Air Temperature
Coolant Temperature

Timing
Timing Σ
atatCranking
Cranking K3
K3 Starting Angle
Compensation
Compensation of injection
Advanced
Injection Angle
Timing
TimingatatPTO
PTO

End of Injection
Engine
Speed
Fuel Injected
General
GeneralInjection
Injection Angle
Fuel
Timing
Timing Σ
Injection
Amount Fuel
Injection Temperature
Amount
Intake Air
Temperature
Coolant Temperature

19
Cold Start Control
• Preheating & Postheating
• Cranking without fuel
- Compress the air inside the cylinders → Engine warm up
• Restriction of intake and exhaust air flow
- Activate Exhaust brake
• Injection Timing Compensation
- Compensate ignition delay due to the low intake air temperature
- Cranking injection timing compensation
Coolant temperature compensation
Boost air temperature compensation
- Normal injection timing compensation
Coolant temperature compensation
Boost air temperature compensation

20
High Idle Speed Fuel Limit

Reduce the fuel injection amount at the high idle speed

to protect the engine

Nx = Nnl - Dn = 2230 - 260 = 1970 Max. torque fuel curve

K1 = (Fz-Fr) / (Nx-Nr) = (203-250) / (1970-1800) = -0.276
K1
K2 = Fz / Dn = 250 / 260 = 0.962 Abs. Max. Fuel

Fr K2

Nr = Rated speed (1800rpm) Fz

Fr = Fuel limit at rated speed (250 mg)
Fz = Fuel limit at the gain change over speed (203 mg) Dn
Nnl = No load max. speed (2230 rpm) Nx
Nr Nnl
Dn = Required drop in speed between Nnl and gain change over speed
(260 rpm) Droop speed

21
Preheating & Postheating
• Intake air heating at cold start condition
- Reduce the smoke
- Fast engine warm-up
START
ON
KEY S/W

OFF
Indicating ON
Lamp
OFF
Engine speed > limitation
Engine
RPM

Heater ON APV

OFF PREHEATING POSTHEATING

No Pre/Post Heating Operating of

Pre/Post Heating
22
Preheating & Postheating Time

40
40000
35
35000
30
30000
25
25000
Preheating Time
TIME[ s]

20
20000
15
15000
10
10000
55000
00
0 -40
233 -29
244 -28
245 -25
248 -20
253 -15
258 -10
263 -5 0
268 273

COOLANT TEMPERATURE[ ℃]
35
35000
30
30000

Postheating Time 25
25000
TIME[ s]

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 is determined by the engine
coolant temperature

12
Number of non- injection

10

0
240-28
245 -26
247 -24
249 -22 -20 303
251 253 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
140
120
Fuel Amount(mg)

100
80
60
40
20
0
-40
230 -28
245-18 -8 7280 27
255 265 300 35
308 45 55 338
318 328 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 500 RPM

Idle speed

Time
28
Idle Speed Control

Engine RPM

500 RPM

TIME

Keeping the engine idle speed at any load (±2RPM)

Adjusting fuel injection amount to maintain the stable idle speed

29
Idle Speed Control – Cold Start Idling

speed
Idle
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
800 RPM
+ 25 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 6 5 4 3 2 1
CDS_MASK_APV 0 0 1 0 1 0 1 0
1 : enable 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 Required
Required Fuelfuel pressure
Pressure for Speed
Level 1 for speed
APV1
Threshold
APV
Level 2 Getting lower than
Threshold
APV level 2 pressure

Lamp On Lamp Flashing

Derate Level 2

Derate Level 1

No Derate

Time

33
Fuel Pressure Derate Protection

Fuel Pressure Required fuel pressure

Condition B Required Fuel
for speed
Pressure for Speed
Level 1 APV1
Threshold
APV
Level 2
Threshold
APV

APV3

Lamp
Lamp On Flashing

Derate Level 2

APV4
Derate Level 1

No Derate

Time

34
Engine Overheat Warning

- Warning lamp comes on when the coolant temperature is higher

than limit

Coolant
Temperature
Warning Lamp 103℃
ON
Hysteresis Zone
Warning Lamp 98℃
OFF

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 - SET/INC or RES/DEC switch
- Accelerator pedal
• 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

Door SW ECU

Accelerator
Position

37
PTO (Power Take Off)
• Function
– Setting engine RPM to operate additional device at any load
condition
• Operating Condition
– Cruise/PTO Switch is ON
– PTO Control Switch is ON
– Engine speed > APV ( 20 km/h)
• Operation
– In the PTO mode, PTO governor adjust engine rpm to the PTO
initial engine RPM and then PTO operation lamp comes on
• OFF
– When the Cruise/PTO switch is OFF, engine RPM return to the
idling RPM

38
PTO Control
• PTO Mode
– PTO can be operated at the driver seat side or vehicle
outside(Remote Mode)
• Accelerator Pedal Function
– When the accelerator pedal is depressed, PTO engine RPM is
increased. And when the pedal is released, engine RPM return
to the setting PTO engine RPM
• Clutch / Brake Pedal Function
– When the clutch or brake pedal is depressed, PTO engine
RPM is decreased to the initial PTO engine RPM. And when
the pedal is released, engine RPM return to the setting PTO
engine RPM.
• PTO time-out
– If there is no operation during APV time, ECU stops engine
39
Auto Cruise Control / PTO Control

CRUISE/PTO ENABLE SW

SET / INC
AUTO CRUISE CONTROL
RES / DEC Vehicle Speed > 40 km/h
Engine Speed > Cruise speed
BRAKE SW

CLUTCH SW

ENGINE SPEED
EUI

UCE
VEHICLE SPEED

POWER TAKE OFF

REMOTE PTO ENABLE SW
CONTROL
INCREMENT

DECREMENT Vehicle Speed < 10 km/h

Engine Speed > Idle speed

OUTSIDE CAB

40
Schematic Diagram
 BASE1 HIGH SIDE E43 H1

EUI 3
EUI 2
EUI 1
INJECTOR1 LOW SIDE E29 L1
INJECTOR2 LOW SIDE E45 L2
INJECTOR3 LOW SIDE E30 L3
Engine Side

BASE2 HIGH SIDE E46 H2

EUI 6
EUI 5
EUI 4
INJECTOR4 LOW SIDE E32 L4
INJECTOR5 LOW SIDE E31
ECU

L5
INJECTOR6 LOW SIDE E33 L6
CAM SIGNAL RETURN E25
CAM SIGNAL E11 S1
CAM SCREEN E22
ENG CONNECTOR

CRANK SIGNAL RETURN E39

CRANK SIGNAL E38 S2
CRANK SCREEN

5V SUPPLY E37 V2
BOOST PRES SENSOR E10 A4
BOOST TEMP SENSOR E7 A11
& TEMP

RETURN E24
BOOST PRES

5V SUPPLY

BOOST PRES SENSOR

E4 A6
BOOST PRES SENSOR
E8 A14
& TEMP

RETURN E21
1999. 1. 25
FUEL PRES

COOL TEMP SENSOR

COOLANT TEMP E6 A12
RETURN E19
42
 MAIN
BATTERY

RELAY

ECU GND
BATTERY GND BAT+
B12 B26 15A
SWITCHED

BAT+
BATTERY(IG)

B13 B27
B14
B42
PARKING SWITCH B30
F=5A

5A
5A
B7 F/BRAKE
B17
PEDAL ASS'Y
SENSOR POWER STOP
B34 LAMP
SWITCH

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

F/BRAKE

B35
PEDAL SENSOR GND
IVS1 B8 B5
IVS2 B15 T/M PTO
PTO RLY
IDLE SWITCH B20 ON/OFF

SAFETY SWITCH CLUTCH SW

(W/TM PTO)-N/OPEN
B16 WARN'G
REMOTE PTO
T/M PTO
ENABLE SW
CONTROL
B31 SWITCH PTO LAMP
R/PEDAL PTO M/VALVE
SENSOR
EXHAUST/JAKE#1 OFF DBR
B25
R/PEDAL RETURN B33 RLY
B24 JAKE#2
B3
JAKE#3
B4 ABS ACTIVE
R/PTO INCREASE CC/ENG PTO
B32 ENABLE
B6 B18
R/PTO DECREASE E SET/INC
B21
RES/DEC
B22
C
Vehicle

A/C COMPRESSURE
B9 (OPT-BUS ONLT)
B28 U
NEUTRAL SWITCH
B19
TACHO METER
EXHAUST BRAKE CHECK ENG
B46
Vehicle Side

B43
Side

OVER HEAT LAMP

B47
ENGINE BRK LAMP
ENGINE BRK LO/HI B48
AIR HEATER
B44 B49
CRUISE/PTO LAMP
#3,4 B51
ENGINE
#1,2 #5,6 BRK MED/HI AIR HEAT
B45 SUB_RELAY
B50
ENGINE

ABS/ASR
ABS/ASR ASTRONIC
ASTRONIC

<1m
CAN_H AIR HEAT
B52
CAN_L RELAY
B53
CAN_SHIELD
120Ω

B54
VEHICLE
B1 SPEED OUTPUT

DIAGNOSTIC D3
B36 Astronic
Astronic
CONNECTOR KWP2000_K
B38 Intarder
Intarder
B39
KWP2000_L VDO T/GRAPH
TWIST(SHIELD)
VEHICLE SPEED SENSOR
(HALL EFFECT TYPE)
43
 BATTERY GND

MAIN
RELAY

ECU GND
BAT+ BATTERY
B12
15A
B26
SWITCHED

B13 BAT+
BATTERY(IG)

B27
B14
B42
PARKING SWITCH F=5A
B30

5A
B7
5A
F/BRAKE
B17

ASS'Y
PEDAL
SENSOR POWER

STOP
LAMP
B34 CLUTCH
PEDAL SENSOR
B35
SWITCH
F/BRAKE

P/ SENSOR GND
IVS1 B8 B5
IVS2
B15
B20

IDLE
SWITCH
OFF
EXHAUST/JAKE#1
B33 DBR RLY
JAKE#2
B3
JAKE#3
B4 ABS ACTIVE
CC/ENG PTO
ENABLE
B18
SET/INC
B21
RES/DEC
B22
E
Vehicle

A/C COMPRESSURE
B9 (OPT-BUS ONLT)
C
NEUTRAL
SWITCH
B19
U
EXHAUST BRAKE CHECK ENG
B43 B46
Vehicle Side
Side

OVER HEAT LAMP

B47
ENGINE BRK LAMP
ENGINE BRK B48
LO/HI AIR HEATER
B44 B49
CRUISE/PTO LAMP
#3,4 B51
ENGINE

ENGINE
#1,2 #5,6 BRK MED/HI AIR HEAT
B45 SUB_RELAY
B50

ABS/ASR
ABS/ASR

<1m CAN_H
B52 AIR HEAT
CAN_L
B53 RELAY
120Ω

CAN_SHIELD
B54
VEHICLE
B1 SPEED
OUTPUT

DIAGNOSTIC B36 D3
KWP2000_K Astronic
Astronic
CONNECTOR B38 Intarder
Intarder
B39
KWP2000_L VDO T/GRAPH
TWIST(SHIELD) VEHICLE SPEED SENSOR
44

(HALL EFFECT TYPE)

 MAIN
BATTERY GND

RELAY

ECU GND
BATTERY
B12 B26 BAT+
SWITCHED

BAT+ 15A
BATTERY(IG)

B13 B27
B14
B42

PARKING SWITCH B30 F=5A

5A
B7
5A
F/BRAKE
B17
PEDAL ASS'Y
SENSOR POWER
STOP
LAMP
B34 CLUTCH
PEDAL SENSOR
B35
SWITCH
F/BRAKE

P/ SENSOR GND
B8 B5
IVS1
B15
IVS2
IDLE SWITCH B20
PTO
RLY

ON/OFF
T/M PTO
SAFETY SWITCH
B16
WARN'G
REMOTE PTO
CLUTCH SW

ENABLE SW
B31

PTO
PTO LAMP

M/VALVE
(W/TM PTO)-N/OPEN

R/PEDAL
SENSOR
EXHAUST/JAKE#1
OFF

B25
R/PEDAL RETURN B33 DBR RLY
B24 JAKE#2
B3
JAKE#3
B4 ABS ACTIVE
R/PTO INCREASE B32 CC/ENG
PTO ENABLE
B6 B18
R/PTO DECREASE
SET/INC
B21
RES/DEC
B22
Vehicle

B9
B28
NEUTRAL SWITCH
B19

TACHO METER
EXHAUST BRAKE CHECK ENG
B43 B46
OVER HEAT LAMP
Vehicle Side

B47
Side

ENG BRK LAMP

ENGINE B48
BRK LO/HI
AIR HEATER
B44 B49
CRUISE/PTO LAMP
#3,4 B51
ENGINE
#1,2 #5,6 BRK MED/HI AIR HEAT
B45 SUB_RELAY
B50
ENGINE

ABS/ASR
ABS/ASR ASTRONIC
ASTRONIC

<1m
CAN_H
B52
CAN_L
RELAY

120Ω

B53
AIR HEAT

CAN_SHIELD
B54
B1
SPEED
OUTPUT
VEHICLE

DIAGNOSTIC B36 D3
KWP2000_K Astronic
Astronic
CONNECTOR B38 Intarder
Intarder
B39
KWP2000_L VDO T/GRAPH
TWIST(SHIELD) VEHICLE SPEED SENSOR
(HALL EFFECT TYPE)
45