DA Series - Training

Electrical appendix

Rev. April / 2012

Doosan Infracore Norway
Aftermarket
 LCD instrumentation unit
Warning Lights Display 1. Engine failure warning
2. Low engine oil pressure warning
3. Low coolant level warning
21 20 19 18 17 4. Air filter warning indicator
1 2 3 4 5 5. Transmission failure warning
6 7 8 9 10 11 12 13 14 15 16
6. Parking brake activated indicator
7. Brake failure warning
8. Hydraulic system failure warning
9. Emergency steering warning
10. General failure
11. Lubrication system warning
12. Battery charge warning
13. Body down indicator
14. Direction light indicator
15. High beam indicator
16. Main light indicator
17. Rear working lights
18. Working lights and extra high beam
19. Rotating beacon light
22 20. Lamp fault
23 21. Seat belt warning
22. Transmission Lock-up indicator
24 23. Automatic/Manual Transmission status
25 24. Retarder brake indicator
25. Engine brake indicator
26. Rear camera view button/Main
27. Menu button
26 27 28 29 34 28. Differential locks indicators
29. Retarder oil temperature
30 33 30. Transmission oil temperature
31. Engine coolant temperature
31 32 32. Body weigth indicator
33. Urea (AdBlue) level
DA Series Training - April / 2012 34. Fuel level Doosan Infracore Norway
Display
Functions and parameters

(Icon number 7 on the display list – Page 2)

Brake/brake charge system
• ACC1, ACC2 and ACC3 alarm limits: 135/120bar (alarm = 120 and reset at 135)
• Max charge time: 3min
• Low pressure warning -> alarm trig: Vehicle moving and/or in gear

Red Alarm – loud alarm Amber Warning – short beep

Sensor error on ACC3 (common/park) Low Pressure warning on ACC3 (*2)
Low Pressure on ACC3 (*1) Low Pressure warning on ACC1 (*2)
Sensor error on ACC1 (front) Low Pressure warning on ACC2 (*2)
Low Pressure on ACC1 (*1)
Sensor error on ACC2 (rear)
Low Pressure on ACC2 (*1)
CHARGE solenoid short circuit (NOT IMPLEMENTED YET)
CHARGE solenoid open circuit (NOT IMPLEMENTED YET)
Charge pressure not reached on ACC3

DA Series Training - April / 2012 Doosan Infracore Norway

Display
Functions and parameters

(Icon number 7 on the display list – Page 2)

WDB Cooling (only on DA40)
• Front hubs temperature warning: 93/100°C (warning= 100°C and reset at 93)
• Front hubs temperature alarm: 110/120°C
• Rear tandem temperature warning: 76/80°C
• Rear tandem temperature alarm: 86/90°C
• Oil level alarm filter time: 3 sec

Red Alarm – loud alarm Amber Warning – short beep

No CAN signal from rear frame High temperature warning on FRONT HUBS
Front WDB oil level too low High temperature warning on TANDEM LEFT
Sensor error on FRONT HUBS High temperature warning on TANDEM RIGHT
Too high temperature on FRONT HUBS
Sensor error on TANDEM LEFT
Too high temperature on TANDEM LEFT
Sensor error on TANDEM RIGHT
Too high temperature on TANDEM RIGHT

DA Series Training - April / 2012 Doosan Infracore Norway

Display
Functions and parameters

(Icon number 9 on the display list – Page 2)

Emergency Steering system
• Reads output shaft speed from transmission.
• Alarm trigger: 2.2/2.5bar + >200rpm for 3 seconds

Red Alarm – loud alarm Amber Warning – short beep

Sensor error on EMST Sensor error Transmission output shaft

Pressure too low while vehicle moving

DA Series Training - April / 2012 Doosan Infracore Norway

 Display
Functions and parameters

(Icon number 6 on the play list – Page 2) (Icon number 6 on the play list – Page 2)
Park brake Clogged air filter
• Engage automatically if ignition is switched off. • Lamp state is controlled from pressure switch on pipe
• If switch is in released position when turning on between filter and turbo.
ignition, the driver will need to flip the switch on-off • Normal voltage = 24-28V
to release park brake. • Alarm voltage < 4V
• Lamp will turn on/off: 10/50bar
• If pressure sensor (PB OUT) fails, the lamp will reflect
switch position. (Icon number 11 on the play list – Page 2)
Lubrication system
• PREMINARY!!
(Icon number 2 on the play list – Page 2) • If CanBus connection is lost nothing happens.
Low engine oil pressure • If Groeneveld reports "Lubrication reservoir level" then
• Lamp state is controlled from Scania CanBus message. lamp will be amber.
• If Groeneveld reports "Pump disabled" then lamp will be
red.
• Vehicle speed limited to 7km/h if lamp is amber or red.
(Icon number 3 on the play list – Page 2)
Low coolant level
• Lamp state is controlled from float switch in (Icon number 12 on the play list – Page 2)
expansion tank. Charge lamp
• Normal voltage = 12-14V • Lamp state is controlled from Scania canbus
• Alarm voltage < 4V message. Scania ECU is monitoring the alternator.

DA Series Training - April / 2012 Doosan Infracore Norway

 Display
Functions and parameters

Body tip system (Icon number 13 on the play list – Page 2)

Green float: Body down (proxy switch contact) and A Amber lock: Body down (proxy switch contact), and A
pressure( body lift) < 7.5bar and engine running. pressure( body lift) > 11.5bar and engine running.
The float solenoid valve is open to tank in this state. Body down (proxy switch contact) and engine
stopped.

Amber body up: Body up (proxy switch open). Red: WB2 communication is missing.

• Then the body is lifted (proxy switch open) then vehicle speed is limited to 10km/h. If the WB2 CanBus communication or the sensor is failing
the vehicle speed is also limited to 10km/h.
• An over center safety function is implemented. This function monitors the A( up) and B(down) pressures and limits the tip up speed. The
function will start limiting the real lift pressure is < 15bar.
• Tipping down with load will limit the down speed of the body. This function will start limit at 70bar on A pressure. Full limit is at 150bar.
• If pressure sensor A or B is faulty/missing the tip speed will be limited both up and down.
• Accumulator charge is activated during tip up at full speed (550/600mA).
• For a soft landing of the body the float is activated during tip down when the proxy switch is closing.
• The button on the joystick is used to active engine control during tipping.
• The Transmission and gear selector must be in neutral state to activate this function.
• The engine speed range is as follows:
Tip up: 450mA=720rpm 620mA=1800rpm
Tip down: 450mA=720rpm 620mA=1300rpm

It is possible to override both the over center and the soft down function by holding the override button on the panel while using the joystick.
DA Series Training - April / 2012 Doosan Infracore Norway
 Display
Functions and parameters

Load weighing (Icon number 32 on the display list – Page 2)

When the body is lifted the tip up drive is limited to 400mA during the measurement phase.
The measure time will last for minimum 0.6sec after the highest pressure is detected.

Typical total measuring time is <1sec.

The pressure is calculated from both A and B pressures (tilt up and down).

The load is registered and counted in the VCU2 if the weighing value is >= 3.0t.
The next registration is not possible before the vehicle has traveled > 50m or after a timeout of 3 minutes.

Amber/red symbol indicates overload with the following values:

DA30 = 28t
DA40 = 40t

DA Series Training - April / 2012 Doosan Infracore Norway

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Functions and parameters
Differential locks (Icon number 28 on the display list – Page 2)

The center differential lock is controlled via the CanBus to the ZF TCU.
The rear diff-lock (DA30 only) is controlled by the VCU2 using a solenoid valve in the hydraulic system.

The center and rear differential lock buttons on the panel are requests for diff-lock.
The differential lock are engaged only if conditions are in valid ranges.
If differential lock is released automatically due to protection the panel buttons
(requests) will also be forced off.

The criteria for engaging the center differential lock is:

Vehicle speed <18km/h
Transmission input torque < 1000Nm

The center differential lock will automatically disengage if vehicle speed >20km/h.
The criteria for engaging the rear differential lock (DA30 only) is:
Vehicle speed <8km/h
Transmission input torque must be in range -500Nm to +1000Nm
Center differential lock must also be engaged.

The rear differential lock will automatically disengage if vehicle speed >12km/h or if center differential lock is released.
The front differential is a limited slip locking type.
On the DA40 the rear differential is a limited slip locking type.
DA Series Training - April / 2012 Doosan Infracore Norway
 Display
Functions and parameters Cooling Fan Control
The VCU2 is controlling the cooling fan using various temperature parameters. The hydraulic part consists of two solenoids. One proportional for speed control, and
one valve for stopping the fan.
o Fan speed is defined as follows:
• 0% = fan stopped
• 1% = fan at minimum speed (approx. 270rpm). Solenoid drive = 800mA
• 100% = fan at maximum speed (approx. 1450rpm). Solenoid drive = 180mA
The temperatures parameters are as follows:

o Engine coolant temperature (measured on engine via canbus): o Transmission sump temperature (measured on transmission via canbus):
• >5°C = 0% • >5°C = 0%
• 5-82°C = 1% • 5-85°C = 1%
• 83-94°C = 1-100% • 86-100°C = 1-100%
• >94°C = 100% • >100°C = 100%

o Retarder temperature (measured on transmission via canbus): o Front WDB oil temperature (DA40 only, measured via VCU2):
• >10°C = 0% • >10°C = 0%
• 10-94°C = 1% • 10-74°C = 1%
• 95-112°C = 1-100% • 75-115°C = 1-100%
• >112°C = 100% • >115°C = 100%

Charge air compensated temperature (measured on engine via canbus and in front of cooling pack):
The fan is controlled to maintain a maximum 25°C rise in charge air temperature in respect to the ambient temperature.

The reference ambient temperature is measured in the front of the cooling package.
If the ambient temperature is < 25°C the reference is set to 25°C.
If the ambient temperature is > 55°C the reference is set to 55°C.

o Temperature difference (charge air – reference):

• <=0°C = 0%
• 1-15°C = 1%
• 15-25°C = 1-100%
• >25°C = 100%
If any of the above sensors is missing of faulty the fan speed is forced to 100%.

DA Series Training - April / 2012 Doosan Infracore Norway

 Display
Functions and parameters

Quick warm-up function

This is only a function and it doesn’t have any light warning or alarm.
The quick warm-up function is using the ZF retarder to add heat into transmission oil and engine coolant water.
NOTE! The ZF software may need an upgrade to accept this feature.

The quick warm-up is automatically activated when the following conditions are met:
• Engine speed = 400..900rpm
• Engine coolant temperature < 60/70°C
• Charge air temperature < 15°C
• Accelerator pedal = IDLE
• Park brake = ENGAGED
• Transmission and gear selector = NEUTRAL
• No clutch calibration running
• First accumulator charge after startup is finished

When all these criteria are met for at least 30 seconds the quick warm-up will engage. If any of the above criteria is violated the quick
warm-up will immediately be disabled.
When the quick warm-up is active the engine coolant temperature will act as a hysteresis to enable/disable the function keeping the
coolant temperature between 60 to 70°C.
(A practical test starting at 0°C the coolant temperature reached 70°C in approx. 8 minutes)

DA Series Training - April / 2012 Doosan Infracore Norway

 Display
Functions and parameters
Cool down function
The cool down function is implemented to protect the engine turbo during shutdown of the
machine. A 3 minute timer is used for this purpose.
This timer is reset every time the following criteria are met:
• Engine speed > 1000rpm and fan drive > 40% or
• Engine speed > 1000rpm and charge air pressure > 0.14bar
If the timer is still running at the time the ignition is turned off the engine will continue to run.
The engine and other functions will automatically shut down when the timer has reached 3
minutes.
The following functions are influenced when the cool down is activated:
• Turn off Radio/CD, CB, Climate system and outside lights.
• The engine will run at idle speed and the transmission will be forced to neutral.
• Park brake will be activated.

Alternative engine speed

The F1 button on the panel is used to control the engine rated speed.
• F1 inactive = 2100rpm
• F1 active = 1950rpm
Changing mode is only possible when the transmission is in NEUTRAL.
NOTE! The ZF software may need an upgrade to accept this feature.
When the 1950rpm rated speed is selected the VCU2 will control the engine droop via the CanBus. Also an alternate shift table in the ZF
transmission is used.
Interior light
Delay light function when entering vehicle. 15 seconds delay from door close to light off.
If ignition is turned on within 15 seconds the light will immediately turn off.
A timer will turn off the interior light automatically after 15 minutes to preserve battery capacity.
The interior light has a red light source that is used for alarm purpose. The red light is flashing
together with the audible alarm.
DA Series Training - April / 2012 Doosan Infracore Norway
 Display
Functions and parameters
Retarder and Engine brake (Icons number 24 and 25 on the display list – Page 2)
The retarder and engine brake will automatically engage when the vehicle is moving and the accelerator pedal is released.
The retardation force is set to 100% when the accelerator pedal is released.
The retarder force can be reduced to 50% by activation the retarder limit button on the panel.
The retarder force can also be adjusted with the accelerator pedal by slightly pressing the pedal after activation.
LH fender
Emergency Stop Close to steps
The engine can be stopped by pressing the outside emergency stop switch. This switch
must be released to enable start of the engine again.
For emergency steering test an engine stop function has been added to the button panel
inside cab also.
Press and hold the override and hazard light buttons until the engine is fully stopped.

Fuel Heater
The fuel heater is enabled with a button on the switch panel.
The fuel heater is located inside the diesel filter on the engine. The heater also has an
integrated thermostat that will switch off at approx. 25°C to not overheat the diesel fluid.

A/C compressor control

The A/C clutch is controlled by the VCU2. There are two pressure transmitters connected in the A/C system together with the A/C request
from the climate control panel to control the clutch.
To enable clutch the following conditions must be met:
• Request signal from control panel = ACTIVE
• LP pressure between 0.3/0.4 to 19/22bar
• HP pressure between 1.8/2.0 to 19/22bar
To extend compressor lifetime the minimum off time is set to 15 seconds.

DA Series Training - April / 2012 Doosan Infracore Norway

Display
Functions and parameters
To be implemented
General Hydraulic 1 (Icon number 8 on the display list – Page 2)

Red Alarm – loud alarm Amber Warning – short beep

Sensor error on A(TIP)
TIP-UP proportional solenoid abnormal value Hydraulic tank level too low
TIP-UP proportional solenoid open circuit
TIP-DOWN proportional solenoid abnormal value
TIP-DOWN proportional solenoid open circuit
FLOAT solenoid short circuit
FLOAT solenoid open circuit
Hydraulic tank level sensor error
General Hydraulic 2 (Icon number 8 on the display list – Page 2)

Red Alarm – loud alarm Amber Warning – short beep

Sensor error on PB OUT
PB OUT pressure too low
PB OUT pressure too high
PARK-BRAKE solenoid short circuit
PARK-BRAKE solenoid open circuit
FAN proportional solenoid abnormal value
FAN proportional solenoid open circuit
FAN-STOP solenoid short circuit
FAN-STOP solenoid open circuit
DA Series Training - April / 2012 Doosan Infracore Norway
Display
Functions and parameters

General Hydraulic 3 (Icon number 8 on the display list – Page 2)

Red Alarm – loud alarm Amber Warning – short beep

Sensor error on PUMP1
PUMP1 pressure too low High temperature warning in HYDRAULIC-TANK
PUMP1 pressure too high
Sensor error on PUMP2 (*3)
PUMP2 pressure too low (*3)
PUMP2 pressure too high (*3)
Sensor error on HYDRAULIC-TANK
Too high temperature in HYDRAULIC-TANK
REAR-DIFF solenoid short circuit (*4)
REAR-DIFF solenoid open circuit (*4)
EB proportional solenoid abnormal value
EB proportional solenoid open circuit

Sensor 1

Red Alarm – loud alarm Amber Warning – short beep

SIFU1 supply short circuit
Fuel tank level sensor error

DA Series Training - April / 2012 Doosan Infracore Norway

Display
Functions and parameters

General Hydraulic 3 (Icon number 8 on the display list – Page 2)

Red Alarm – loud alarm Amber Warning – short beep

Sensor error on PUMP1
PUMP1 pressure too low High temperature warning in HYDRAULIC-TANK
PUMP1 pressure too high
Sensor error on PUMP2 (*3)
PUMP2 pressure too low (*3)
PUMP2 pressure too high (*3)
Sensor error on HYDRAULIC-TANK
Too high temperature in HYDRAULIC-TANK
REAR-DIFF solenoid short circuit (*4)
REAR-DIFF solenoid open circuit (*4)
EB proportional solenoid abnormal value
EB proportional solenoid open circuit

Sensor 1

Red Alarm – loud alarm Amber Warning – short beep

SIFU1 supply short circuit
Fuel tank level sensor error

DA Series Training - April / 2012 Doosan Infracore Norway

Display
Functions and parameters
Sensor 2

Red Alarm – loud alarm Amber Warning – short beep

Accelerator/tip joystick 5V error
Accelerator pedal signal error
Tip joystick signal error
Gear selector signal error

Engine / TM external

Red Alarm – loud alarm Amber Warning – short beep

EP400 oil level sensor error
Coolant level low
Engine air filter clogged

A/C System

Red Alarm – loud alarm Amber Warning – short beep

A/C clutch short circuit
Sensor error on HP
Sensor error on LP
A/C clutch open circuit

DA Series Training - April / 2012 Doosan Infracore Norway

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Questions?

DA Series Training - April / 2012 Doosan Infracore Norway