SISTEMA INYECCION HYUNDAY

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D6CA(L-Engine)Engine Management System

Input & Output DiagramIntake Air Temp. Intake Air Pressure Coolant Temp. Atmospheric Air Pressure. Fuel Temp. Fuel pressure CAM Position Crank Position Vehicle Speed Switches Battery + Diagnosis (Hi-scan) CAN BUS(LAN) Relay control EUI (6)

Engine Control UnitTachometer Drive Vehicle Speed Check Engine

2

Boost pressure & Temp. Sensor1 2 3 4

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

350 300

140 120 100 80 60 40 20 0 - 20

air pressure [kPa]

200 150 100 50 0 1.06 1.45 1.83 2.21 2.59 2.97 3.35 3.74 4.12 4.50 4.8888 182 424 1141 2438 9105

- 40 44642

Output Voltage[ V]

Resistance[ Ohm]

Tem perature[C]

250

3

Coolant Temperature Sensor

N Th m er TC er ist 400 380 360 340 320 300 280 260 240 220 200 0 47 132 278 469 632 Tem er u e [K p at r ] 778 869 Sensor output[m V]

1

2

3

1 : Ground 2 : Gauge 3 : Sensor

4

Fuel Pressure Sensor

1200

Fuel pressure [kP a]

1000 800 600 400 200 0 0.2000 1.1010 2.0020 2.9030 3.8040 4.7050

1 3

2 4

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

O utput voltage [ V]

5

Pedal Position Sensor

Voltage 4.5V

0.5 V 0 Potentiometer6

95 %

Pedal Angle

Cam Angle Sensor1 2 3

1 : Ground 2 : Sensor 3 : shieldNegative 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 Sensor1 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 positionCPS11th teeth 6 deg Gap : 1.5 +/-0.5 2nd wheel teeth 69 CA

CAM1st wheel teeth 15 CAM

34.5

+1 teeth

6th wheel teeth

6 tooth have 60 degrees interval

Crank Sensor Wheel

Cam Sensor Wheel9

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

Direction of the engine rotationRaw signal

Processed signal No. 4 cylinder

Cam signal

+1 flag

No. 1 cylinder

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

1

-6

6 Bolt up angle

Crank signal

TDC

10

MAP Sensor

Input Voltage Voltage Operating Voltage Range Storage Temperature Range Operating Temperature Range Operating Pressure Range 1.924 0.512 Pressure [kPa, mmHg] Current

Vin = 5 V 4.75~ 5.25 V -40 ~ 125 -30 ~ 110 20 ~ 102 10 mA

4.818

20 46.66 [150] [350]

101.32 [760]

Built In ECU

11

Diagnosis Connector

VSPD

1

CAN_L

2

3

4 ABS Check 12

5

L_LINE

6

7

8

GND

9

CAN_H

10

11

13 T/M Check

K_LINE

14

15

BATT+

16

K_LINE L_LINEEngine ECU ASTRONIC T/M ABS/ASR ZF INTARDER

Connector Side12

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 CodeON

IG S/W Press for 3 sec

1 1

3 T5

4

1 T2

2

3

4

1

0

3 T5

4 T2

2

Engine check T1 T4 lamp Press for 3 sec

T6Next trouble code Previous code trouble

SET/INC S/W

RES/DEC S/W

ex) Trouble Code :1134 and 123414

Engine Control1) 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 Control1) 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) Communication16

Fueling ControlCranking CrankingMaximum Fuel Maximum Fuel Amount AmountVehicle Speed

Intake Air Press. & Temp.

Idle IdlePedal Angle

Compensatio n

Coolant Temperature Fuel Temp. & Press. Atmospheric Pressure

Engine Speed

Pedal Pedal

Target Fuel Amount

Mini mum

Actual Fuel Amount

PTO PTO

Cruise Cruise17

Fueling ControlCompensated Maximum MUL Torque Curve Fuel Limit

Smoke fuel limit High idle speed fuel limit

Lowest wins

NMUX

Fuel Pressure Derate %

Absolute Max. fuel

Y

N MUX Y

Fuel Limit

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

Absolute Max. Fuel

Cranking ETF Comp Test Fuel Limit

Comp Test Active

18

Injection Timing ControlIntake Air Temperature Coolant Temperature

Timing Timing at Cranking at Cranking

Advanced Injection Angle K3 K3 Compensation CompensationStarting Angle of injection

Timing at PTO Timing at PTO

End of Injection Engine Speed Fuel Injection Amount

General Injection General Injection Timing Timing

Fuel Injected Angle

Injection Amount Fuel Temperature

Intake Air Temperature Coolant Temperature19

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 compensation20

High Idle Speed Fuel LimitReduce the fuel injection amount at the high idle speed to protect the engineNx = Nnl - Dn = 2230 - 260 = 1970 K1 = (Fz-Fr) / (Nx-Nr) = (203-250) / (1970-1800) = -0.276 K2 = Fz / Dn = 250 / 260 = 0.962 Fr 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 Droop speed Dn Nnl Fz Abs. Max. Fuel Max. torque fuel curve K1 K2

21

Preheating & Postheating Intake air heating at cold start condition- Reduce the smoke - Fast engine warm-upSTART KEY S/W Indicating Lamp Engine RPM Heater ON OFF PREHEATING ON OFF ON OFF Engine speed > limitation

APV POSTHEATING

No Pre/Post Heating

Operating of Pre/Post Heating22

Preheating & Postheating Time40000 40 35000 35 30000 30

TIME[ s]

25 25000 20 20000 15 15000 10 10000 5 5000 00

Preheating Time

0

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

35000 35 30000 30

TIME[ s]

Postheating Time

25000 25

20 20000 15 15000 10 10000 5 5000 00

0

247 267 270 280 290 300 310 320 330 -26 -6 - 3 7 17 27 37 43 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 temperatureNumber of non- injection12 10 8 6 4 2 0 240-28 -26 -24 -22 253 303 318 328 338 245 247 249 251 -20 30 45 55 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 compensationCompensate ignition delay due to the low intake air temperature - Cranking injection timing compensation - Normal injection timing compensation25

Cranking FuelMore fuel amount is injected at the initial cranking condition. Initial crank fuel = f(coolant temperature)160 140

Fuel Amount(mg)

120 100 80 60 40 20 0 230 245 255 -8 280 300 308 318 55 65 -40 -28 -18 265 7 27 35 45 328 338

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 Wh