FUSO 4M4 – EMISSION CONTROL – STRUCTURE AND OPERATION – Exhaust Gas Recirculation System

1.1 Overview
• In the exhaust gas recirculation system, the engine electronic control unit and multiple electronic drive units control the exhaust gas recirculation valve and intake throttle in accordance with information from sensors on various
aspects of the engine (engine speed, intake air quantity, coolant temperature, throttle opening, etc.).
• Exhaust gas recirculation involves the introduction of inert gases in the post-combustion exhaust emissions into the intake manifold. By reducing the combustion temperature, it reduces the amount of nitrogen oxides (NOx), which are harmful, in the exhaust emissions.
Further, an exhaust gas recirculation cooler cools the recirculated exhaust emissions, thereby reducing the peak combustion temperature.
• The intake air quantity is adjusted by means of intake throttle control such that the effectiveness of exhaust gas recirculation is maximized.

1.2 Electronic control system
(1) System block diagram

(2) Exhaust gas recirculation valve control function
• In accordance with data from sensors, the engine electronic control unit determines the exhaust gas recirculation valve opening that suits the operating condition and sends a control signal (this indicates the target exhaust gas recirculation valve opening) to the exhaust gas recirculation electronic drive unit.
When necessary to prevent black smoke emissions and engine speed instability (for example, when the engine is heavily loaded, when the engine is lightly loaded, and when the exhaust brake is operating), the engine electronic control unit stops exhaust gas recirculation valve control.

(2.1) Exhaust gas recirculation electronic drive unit
• The exhaust gas recirculation electronic drive unit activates the exhaust gas recirculation valve motor. At the same time, it monitors the extent of valve lift using a position sensor and sends this information (this indicates the actual exhaust gas recirculation valve opening) to the engine electronic control unit.
This operation makes it possible for the target exhaust gas recirculation valve opening indicated by the engine electronic control unit to be precisely maintained.

(2.2) Exhaust gas recirculation valve
• Exhaust gas recirculation valve is used to mix exhaust gas flowing in the exhaust manifold into intake air flowing in the intake manifold.
• Exhaust gas recirculation valve incorporates a motor to open and close the valve and a position sensor to detect the lift amount of the valve.
• DC motor in the exhaust gas recirculation valve is driven by control signals from the exhaust gas recirculation electronic drive unit. Via a rod, the motor’s operation opens and closes the valve.

(3) Intake throttle control function
• When the engine electronic control unit determines from sensor data on the engine speed and engine loading that the vacuum pressure in the intake manifold is low, it increases the amount of exhaust emissions introduced into the intake manifold by determining an appropriate butterfly valve opening and by sending corresponding control signals (these indicate the target throttle opening) to the throttle electronic drive unit.

(3.1) Throttle electronic drive unit
• The throttle electronic drive unit activates the valve motor. At the same time, it monitors the valve opening using a position sensor and sends this information (this indicates the actual throttle opening) to the engine electronic control unit.
This operation makes it possible for the target throttle opening indicated by the engine electronic control unit to be precisely maintained.

(3.2) Intake throttle
• In accordance with signals from the throttle electronic drive unit, the motor opens and closes the butterfly valve, thereby adjusting the intake air amount such that the effectiveness of exhaust gas recirculation is maximized.

(4) Fault diagnosis function
• The engine electronic control unit continuously monitors the electronic drive units and sensors for faults. In the event that the engine electronic control unit finds a component faulty, it causes an indication to be made in the meter cluster to alert the driver. At the same time, it memorizes the fault location in the form of a diagnosis code and starts a control during fault.
• While the engine is running, the exhaust gas recirculation electronic drive unit and throttle electronic drive unit continuously monitor communication with the position sensor and motor of the exhaust gas recirculation valve, communication with the position sensor and motor of the throttle actuator, and communication with the engine electronic control unit. In the event that they identify a fault, they send fault data to the engine electronic control unit.
• While control necessitated by a fault is taking place, the system’s functionality is limited to ensure vehicle and driver safety. It is possible to read the memorized diagnosis code using a Multi-Use Tester or from flashing of the warning lamp. (See Gr00.)

1.3 Electronic control unit connection diagram

 

 

 

 

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