D4DD Engine EURO 3

Copyright by Hyundai Motor Company. All rights reserved

 Overview D4DD Engine

▶ Development Order

D4AL D4DA D4DD

EURO I/II EURO I/II EURO III

- Injection pump - Injection pump - Common rail

- 3,900cc - 3,900cc - 3,900cc
- 120/3,000(ps/rpm) - 140/2,900(ps/rpm) - 140/2,800(ps/rpm)
- 30/1,800(kgm/rpm) - 38/1,800(kgm/rpm) - 40/1,600(kgm/rpm)
 Overview D4DD Engine

▶ Denso Common rail System Overview

Injection timing and amount
Injectors

④
③ HP Line
LP Line (vehicle)
Common Rail
① ~ ⑥ Fuel flow

RPS

⑤
②
Pressure Limit Valve
Supply pump

⑥
Return line

Actuator Sensor
Feed line
①
Fuel temp. sensor
Fuel-filter
Fuel pressure control (scv)
Tank
ECU
 Overview D4DD Engine

▶ Specifications
Items W-engine (Euro III)
Model Mighty
Displacement ( ㏄ ) 3,907
Engine type Serial 4-cylinder 4stroke common rail
General Compression ratio 17.5:1
Maximum power (ps/rpm) 140/ 2,800
Maximum torque (kg·m/rpm) 38 / 1,600
Compression pressure (kg/cm²) 26 (at 200rpm, Limit 20)
Valve No / CAM type 4 / OHC
Fuel injection system Common rail
Turbo type WGT
Firing order 1→3→4→2
Idle speed(rpm) 700±25
Engine oil capacity (ℓ) (Oil pan/ total quantity) 8/9 API CI-4(10W-30) or more
 Fuel system D4DD Engine

▶ Fuel Injection System

Injection timing and amount
Injectors

④
③ HP Line
LP Line (vehicle)
Common Rail
① ~ ⑥ Fuel flow

RPS

⑤
②
Pressure Limit Valve
Supply pump

⑥
Return line

Actuator Sensor
Feed line
①
Fuel temp. sensor
Fuel-filter
Fuel pressure control (scv)
Tank
ECU
 Fuel system D4DD Engine

▶ Supply Pump
Injectors

Common rail

SCV

Feed pump
3 bar

Regulating valve (3bar)

Fuel filter : 5 ㎛

Primary Pump Hi
Low
 Fuel system D4DD Engine

▶ Fuel supply pump remove and reinstall

Make sure the mark is

aligned.
 Fuel system D4DD Engine

▶ SCV (Supply Control Valve)

SCV On SCV Off

SCV
Fuel In

Fuel Out
Needle valve
 Fuel system D4DD Engine

▶ Common Rail

Rail Pressure Sensor

Flow Damper

Pressure Limit Valve

• Opening Pressure : 2219 Mpa

• Closing Pressure : 5010 MPa
 Fuel system D4DD Engine

▶ Flow Damper
Engine
Engine stop
stop

Common Rail   To injector

Piston Ball Spring

Damping
Damping
Orifice

Common Rail   To injector

Piston Ball Spring

Fuel
Fuel Leak
Leak
SEAT

Common Rail   To injector

 Fuel system D4DD Engine

▶ Injector

Solenoid

Operating Operating Operating

Valve Current Current Current

Outlet Orifice Common

Rail
Inlet Orifice

Pressure Control Pressure Control Pressure Control

Chamber Chamber Chamber
Command Piston

Injection Injection Injection

Nozzle
Amount Amount Amount

Before Injection Injection After Injection

 Fuel system D4DD Engine

▶ Injector – QR Compensation
 Fuel system D4DD Engine

▶ Fuel filter

Supply pump Fuel tank

Fuel-filter (30 ㎛ )
- Heater
- Themo switch
. ON : 7℃±4 ℃
. OFF : 24℃±4 ℃
 Closed Crankcase Ventilation D4DD Engine

▶ CCV(Closed Crankcase Ventilation)

Blow by gas

Oil
 Engine Management System D4DD Engine

▶ Input and output

Accelerator pedal sensor

CKPS, CMPS

MAP, Intake air temp. sensor

Rail pressure sensor

Injector
Fuel temp. sensor (Quantity/Timing)

Water coolant temp. sensor

Denso
DensoECU
ECU Fuel pressure control (SCV)
Idle up/down switch EURO
EUROIllIll

Exhaust brake ECM control

Neutral switch
Glow plug relay
Brake & Clutch switch
CAN
ETACS-vehicle speed K/L-Line
 Engine Management System D4DD Engine

▶ CKP (Crankshaft Position sensor)

Checking items Descriptions

Resistance (Ω) 125±20 (20℃)
Air gap 1.50±0.5mm
Crank sensor active OFF (At IG ON)
Crank sensor active ON (At idle)
 Engine Management System D4DD Engine

▶ CMP (Camshaft Position sensor)

Checking items Descriptions

Air gap 1.50±0.5mm
CAM sensor active OFF (At IG ON)
CAM sensor active ON (At idle)
 Engine Management System D4DD Engine

▶ Boost Air Pressure & Temp. Sensor

1 2 3 4

1 : Intake air pressure signal

2 : Sensor power source
3 : Intake air temp signal
4 : Sensor ground
 Engine Management System D4DD Engine

▶ Rail pressure sensor

Output(V)

Fuel pressure
 Engine Management System D4DD Engine

▶ Fuel Temperature Sensor

 Engine Management System D4DD Engine

▶ Coolant Temperature Sensor

 Engine Management System D4DD Engine

▶ Accelerator pedal position sensor

 Engine Control Module D4DD Engine

▶ When ECM is Replaced

1. Injector Data Input(QR CODE)

2. Engine PTO Setting
3. ECM Data Calibration Input
4. ECM Upgrade-ECU Calibration data
 Engine Control Module D4DD Engine

▶ Injector Data Input(QR CODE)

 Engine Control Module D4DD Engine

▶ Engine PTO Setting

 Engine Control Module D4DD Engine

▶ ECM Data Calibration Input

Engine Control Module D4DD Engine
 Engine Control Module D4DD Engine

▶ ECM Upgrade
 Engine Control Module D4DD Engine

▶ PTO Governor Option Settings and Wiring for W & K Engine

2005.09.28.
Representa Operate
PTO PTOPTO
control PTO maxi-
PTO PTO
PTO de-
TYPE mum rpm fault rpm Applied
TY PE 대표차종
tive Model PTO 적용차종
페달pedal
작동 mode
제어모드 최대 RPM 기본 RPM Model

C P/PACK DISABLE REMOTE(SW) 1100 750 P/PACK,R/PACK

2800(compact)
2800 (소형) /
F FIRE DISABLE BOTH(SW) 2500 (mid-sized) 750 FIRE
/2500 (중형)

WRECKER,CRANE
H WRECKER ENABLE REMOTE(PEDAL) 2200 750
SAFETY LODDER

J LADDER ENABLE REMOTE(PEDAL) 1200 750 LADDER

FGC,T/LORRY
L FGC DISABLE BOTH(SW) 1000 750
,C/PACK

M W/WAGON DISABLE CAB(SW) 1800 750 W/WAGON

*.
*. Parameters
상기에 표기하지 that are
않은 not indicated above
PARAMETER는 are the값과
DEFAULT same as the default values.
동일함
 Engine Control Module D4DD Engine

▶ W & K Engine PTO Governor Diagram

Mighty Middle Size

Mighty
Middle Size

OEM; Factory installed

For reconfiguration;
to be purchased separately

IDLE UP/DOWN used

at the same time.
Factory installed

Turned on
when IN CAB ENG PTO SW
is activated.