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EDC 15system

The document provides an overview of the electronic diesel control system used in BS III engines. It describes the open and closed loop controls, various sensors and actuators that are part of the system, troubleshooting guidelines, and location of components on the vehicle.

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farid salmani
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100% found this document useful (2 votes)
481 views30 pages

EDC 15system

The document provides an overview of the electronic diesel control system used in BS III engines. It describes the open and closed loop controls, various sensors and actuators that are part of the system, troubleshooting guidelines, and location of components on the vehicle.

Uploaded by

farid salmani
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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EDC SYSTEM (VP37)

(FOR HA6DTI3N, HA4CTI3N & HA57L135/


HA57L135LT H SERIES BS III ENGINES)

MAY 2012
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES 12.01
Service Manual

CONTENTS

EDC SYSTEM FOR H SERIES BS III ENGINE

Section Subject Page No.

12.0 Electronic Diesel Control System - Overview........................................................... 12.02


12.1 Controls........................................................................................................................ 12.02
12.2 Diagnostics................................................................................................................... 12.03
12.3 Limp Home Functions................................................................................................. 12.04
12.4 BS III Engine Start Procedure:.................................................................................... 12.04
12.5 Engine Stop Procedure............................................................................................... 12.04
12.6 Trouble Shooting Guidelines...................................................................................... 12.05
12.7 Inspection/Checking Of Parts & Connections Against Complaint.......................... 12.06
12.8 Sensors......................................................................................................................... 12.08
12.8.0 Boost Pressure Cum Temperature Sensor.............................................................. 12.08
12.8.1 Accelerator Pedal Module........................................................................................ 12.09
12.8.2 Engine Speed Sensor.............................................................................................. 12.10

12.8.3 Coolant Temperature Sensor.................................................................................. 12.11


12.8.4 Needle Movement Sensor (NBF)............................................................................. 12.12
12.8.5 Vehicle Speed Sensor............................................................................................. 12.13
12.9 Switches....................................................................................................................... 12.14
12.9.0 Brake Switch............................................................................................................ 12.14
12.9.1 Clutch Pedal Switch................................................................................................. 12.15
12.10 Actuators...................................................................................................................... 12.15
12.10.0 Fuel Shut Off Solenoid / ELAB................................................................................ 12.15
12.10.1 Diagnostic Lamp ..................................................................................................... 12.16
12.10.2 Fuel Timing Actuator (Timer Solenoid).................................................................... 12.17
12.10.3 Fuel Quantity Actuator............................................................................................. 12.18
12.10.4 ECU - Related Group Error Codes:......................................................................... 12.22
12.11 DC-DC Converter......................................................................................................... 12.22
12.12 Do's and Don'ts For Sensors...................................................................................... 12.23
12.13 Guidelines for Checking Sensors And Component................................................. 12.23
12.14 Relay and Fuse Interconnection Diagram (24V)....................................................... 12.25
12.15 Relay and Fuse Interconnection Diagram (12V)....................................................... 12.25
12.16 Relay and Fuse Interconnection Diagram (12V) with 2 Relay Circuit..................... 12.26
12.17 EDC Schematic Circuit Diagram................................................................................. 12.27
12.18 Do's and Don'ts (During Regular Service and Body Building):............................... 12.28
12.19 Hints During The Bodybuilding Phase...................................................................... 12.28
12.20 Location on The Vehicle.............................................................................................. 12.29
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES
12.02
Service Manual

12.0 ELECTRONIC DIESEL CONTROL SYSTEM - 12.1 CONTROLS


OVERVIEW
Towards legislative requirement, Current engine Open and Closed Loop Electronic Control
development is aimed at lowering of harmful
exhaust gas emissions. To meet the above
demand, the importance on fuel injection and Open Loop
engine management system has increased, The actuators are operated by the ECU output
specifically with regard to signals which the ECU has calculated using the
1. High fuel injection line pressure input variables, stipulated data, characteristic
2. Water/coolant Temperature dependant fuel maps, and algorithms without any feedback.
quantity delivery - for starting
3. Control of close idling speed Close loop control
The actual value at the output is continually
4. Determined fuel quantity and timing in
monitored against the desired value, and as soon
Engine start phase to suit geographical/
climatic conditions. as a deviation is detected this is corrected by a
change in the actuator control. The advantage of
5. Integral timing function adjusting start of
delivery as a function of engine speed to close loop control lies in the fact that disturbances
meet the emission norms. from outside are detected and taken into account.
6. Regulated fuel quantity in ref to load and In our system close loop control is used for fuel
Engine speed. quantity actuator and timer solenoid.
7. Metered fuel quantity to control and
maintain free acceleration smoke. Fuel - Injection control
The EDC (Electronic diesel control) system is In order that the engine can run with optimum
capable of meeting the demands outlined above. combustion under all operating conditions, the
In EDC system, the driver has no direct control ECU calculates exactly the right injected fuel
over the injected fuel quantity through the quantity at right time in different conditions. Here
accelerator pedal. the values of various parameters are considered.
The injected fuel quantity is based on
1. The vehicle response desired by the driver Start quantity
communicated through the accelerator The injected fuel quantity is calculated as a
pedal sensor with the help of ECU. function of coolant temperature and cranking
2. The engine operating conditions speed. Start quantity is realised until the engine
reaches idling speed of 600 ± 25 rpm.
3. The engine operating coolant temperature
4. Boost pressure
Drive mode
5. Engine speed When the vehicle is in drive mode, the injected
EDC system is also capable of data exchange fuel quantity is a function of the accelerator
with other electronic systems such as Automatic pedal position and engine speed. This operates
transmission through CAN (Control Area Network).
the engine in safe mode. The Map designed in
EDC system is subdivided into the ECU considers various conditions like high
fuel temperature, high coolant temperature, etc.
1. Sensors
Hence the system will operate the engine safely.
Detects the engine operating conditions and
the driver's demand. They convert physical
variables into electrical signals. Engine Idle speed control
When the accelerator pedal is not pressed, the
2. Electronic control unit (ECU)
Processes the information received from system has low idler governor function which will
the sensors. It controls the actuators ensure smooth driving of vehicles. For instance,
through electrical output signals. It also with the engine cold the idle speed is maintained
provides interfaces with other systems like by adjusting to the desired fuel quantity in ref
diagnostic tool, ABS etc. to water temp and the set speed is maintained
3. Actuators similarly at increased water temp.
Convert the electrical signal from the ECU
into physical variable.
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES 12.03
Service Manual

Engine Maximum speed control 12.2 DIAGNOSTICS


ECU integrated diagnostics belong to the basic scope of
This control ensures that the engine shall not to be run
electronic engine management systems. During normal
at excessive speeds. To avoid damage to the engine, the vehicle monitoring algorithms checks operation, input
engine manufacturer stipulates a permissible maximum and output signals and the overall system is checked
rotational speed that may only be exceeded for a very for malfunctions and faults. If faults are discovered
brief period. Beyond that an error recording is registered. in the process, these are stored in the ECU memory.
In our case the recorded speed is 3100 rpm. When the vehicle is checked in the workshop, this stored
information is retrieved only by a diagnostic tool through
Intermediate set -speed control a serial interface and provides the basis for rapid and
efficient trouble shooting and to attend repair.
Intermediate speed control enables to run the engine at
constant speed for applications like crane, ambulances Diagnostic Interface
/ trucks mounted with generator sets. There is a serial interface between diagnostic tool and
ECU. This is effected with KWP2000 protocol. This OBD
Cruise control connector is as per SAEJ1939 standard. A standard
Enables to drive the vehicle at a constant speed by universal diagnostic tool also can be used to read the
selection of a separate switch. This has not been stored error codes.
applicated as it is not of pre selective on vehicle and Dearborn diagnostic tool refers the DTC (Diagnostic
Vehicle owners are skeptical considering sleep mode of Trouble Codes) and the universal tool like Crypton-ACT
the driver and it is purely a requirement driven feature. II address P codes in reference to SAE standard.

Vehicle speed limiter Operating concept

The vehicle speed limiting function in the ECU limits the Input signal monitoring
vehicle's maximum speed to a set value. This can be set These checks serve to uncover not only sensor faults,
but also short-circuit to the battery voltage and ground,
by the customized Diagnostic tool.
as well as open circuits in line. The following processes
are applied.
Injected fuel quantity limit
- Monitoring the sensor's power supply
Max fuel quantity has been predetermined and set at
- Checking that the measured values are within the
factory. Deviation to that will have the following effect correct range
- Excess emission - If auxiliary information is available, the same is
- Excessive soot subjected to a plausibility check
- Important sensors (such as accelerator pedal
- Higher Free Acceleration smoke. sensor) are designed with redundancy to monitor
- Mechanical overloading due to high torque. the signal output for the limp home mode operation
in case of abnormal conditions.
Engine exhaust brake function
Output Signal Monitoring
When the Exhaust brake is applied, In general, the In addition to the connections to the ECU, the actuators
injected fuel quantity is either reduced to zero or to the are also monitored using the results of these checks open
idle fuel quantity. This function is not applicated currently. circuits and short circuits in the lines and the connections
can be detected in addition to the actuator faults. The
Altitude compensation following processes are applied here :
In order that the injected fuel quantity is reduced at high - The circuit is checked for open circuit and short
altitudes, the sensor mounted in the ECU measures the circuits to battery voltage and to ground.
atmospheric pressure. Atmospheric pressure also has - The actuators' influence on the system is checked
an effect upon boost pressure control and fuel limitation. for plausibility.
This eliminates the problem of turbo overspeed & white Monitoring the internal ECU functions
smoke. In order that the functional integrity of the ECU is ensured
at all times, monitoring functions are incorporated in the
Start of injection control hardware and in the software.
Start of injection has a critical effect on power output, fuel These check the individual ECU components (e.g.
consumption, noise, and emissions. The desired value for the micro controller, flash - EPROM, RAM). Many of
start of injection depends on engine speed and injected the checks are performed immediately the engine is
fuel quantity. With the help of Needle movement sensor switched on. During normal operation, further checks are
in the First cylinder control is achieved. performed regularly so that the defect /malfunctioning of
a part is detected.
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES
12.04
Service Manual

12.3 LIMP HOME FUNCTIONS


This function enables the vehicle to reach the workshop for service attention, in case of any sensor failure /
malfunctioning.
Maximum engine speed during this condition will be 1000 - 1200 rpm. The table given below indicates the details
of sensor failure and its effect on the vehicle.
Sl. No. Description Effect on the Vehicle
Water Temperature Loss of pickup / acceleration and loss of engine power, since full load fuel
1
sensor malfunction quantity is limited to 80%. Cold start ability is disturbed.
Boost pressure
2 Less pickup due to loss in engine power as fuel quantity is limited.
sensor Malfunction
Engine speed sensor
3 Engine stops
failure
4 No Needle lift pulse Emission affected. Vehicle continues to run.
Vehicle performance will not be affected in case of normal operation.
5 Vehicle speed sensor fails During top speed function, vehicle will run with default setting by indicating
loss of pickup to the driver.
Accelerator pedal Engine idling speed will be increased to 1200 rpm. No further increase in
6
Sensor Malfunction engine rpm will be felt by the driver while pressing the pedal.
During mechanical stuck / binding of accelerator pedal sensor and when
7 Brake Switch brake is pressed, limp home function is activated. Max. engine speed
during this condition is set to 1200 rpm

12.4 BS III ENGINE START PROCEDURE: 12.5 ENGINE STOP PROCEDURE


Before starting ensure that the gear is in neutral position To stop the engine, switch OFF the Ignition, by turning
and the parking brake is applied. the ignition switch with couplers anti-clockwise once.
To reduce transmission drag on cold vehicles, depress
the clutch pedal. Dos and Don'ts:

If it is required to start the vehicle in a Idle the engine always about 2 mins after starting and
garage or workshop, ensure that adequate before switching off.
CAUTION ventilation is provided. Do not switch-off the engine through gears.
Engine Start Procedure Do not operate the starter motor for more then 10 sec.
continuously. Wait for 30-60 Seconds before trying again.
Do not Park / leave the Vehicle with Ignition switch in
ON position.

1. Ignition Switch (KeyType-combined with ECU)


2. Diagnostic Connector (With Cap)
3. Diagnostic Lamp
Insert the Ignition key, turn clockwise for 24V supply on
to the vehicle electrical system and electronic control
unit and then turn further to crank the engine.

In case the engine does not start, Switch


off the Ignition switch and wait for 5-10 sec
CAUTION and then restart.
In case of diagnostic lamp blink/ON: Error to
be read through tester and cleared/rectified.
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES 12.05
Service Manual

12.6 TROUBLE SHOOTING GUIDELINES Location on the Vehicle


Use Dearborn diagnostic equipment or Crypton
Diagnostic tool for reading the Error recorded in the ECU.
The diagnostic socket is provided in the instrument panel.

Diagnostic Connector
This is a 16 pin D type connector provided with cap for
On Board Diagnostics (OBD II). Diagnostics tool / tester
with the mating connector to be plugged in to this 16 pin
connector for trouble shooting, current data monitoring
and erasing the fault codes stored in the ECU memory.

Always ensure that the diagnostic


connector is covered with cap when not
CAUTION in use. 1. Ignition Switch (Key Type - combined with ECU)
2. Diagnostic Connector (Provided with Cap)
Diagnostic connector Female (Wiring Harness side) 3. Diagnostic Lamp
In case of no power supply to the diagnostic tester check
the following
- Condition of 5 amp fuse on fuse and relay box
- Continuity of the wires between ECU and the
diagnostic connector on the instrument panel.

Diagnostic Diagnostic Diagnostic


connector. connector cap connector wih cap

DIAGNOSTIC CONNECTOR
Pin Configuration & Connection Details

Diagnostic Connector Pin configuration

Once the defective circuit is identified with the help of the diagnostic tool, please refer the service instruction
pertaining to that sensor / actuator circuit. Please refer chart for further guidelines.
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES
12.06
Service Manual

REFERENCE CHART FOR FAULT CODE IDENTIFICATION

Dearborn /
Crypton code Component involved
Pragathi code
P0235 P0237, P0238, P1162 Boost pressure sensor
P0105 P0107, P0108 Atmospheric pressure sensor - ECU

P0314 P0300, P0301, P0302, P0303, P0304, Misfiring - Injectors


P0305, P0306
P0571 P0572, P0573, P0624, P0504 Brake switch
P105A P1061, P1062, P1063 Diagnostic lamp
P0725 P0219, P0728, P0727 Engine speed sensor
P1063 P1064, P1065 Electrical shut off solenoid
P1009, P1012, P1010, P1013, P1014, P1142, P1143, ECU related
P10E1, P10AB, P1112, P1113, P1114, P1001, P1002,
P1000, 1075, P1003, P1004, P1076, P1077, P1078,
P1051, P107E, P1052, P1053, P1054, P1055, P1085,
P1080
P0500 P0501, P1108, P1109, P1110 Vehicle speed sensor
P1099, P0180, P1100, P1101, P1115, P1116, P1082, FIP Related
P10A2, P1087 P1083, P1081, P1103, P1104, P1105,
P1106, P1088, P1089
P1024 P1025 Main relay shut off time high -ECU
P102D P1034 Ignition switch
P106C P1073, P1074 Needle movement sensor
P120, P220 P0222, P0223, P0224, P0221, P0122, Accelerator pedal sensor
P0123, P0124, P0121, P2299, P2135
P0560 P0562, P0563 Battery voltage
P0115 P0116, P0117, P0118, P0119 Coolant temperature sensor
P1090 P1091, P1092 ECU
P0617 Starter control short circuit error
P0817 Starter control open circuit error
P0704 Clutch switch plausibility error

12.7 INSPECTION/CHECKING OF PARTS & CONNECTIONS AGAINST COMPLAINT

Required Instruments:

a) Diagnostic Tool (Dearborn / Crypton)

b) Laptop / Desktop PC -in case use of Dearborn Diagnostic tool

c) Analog / Digital Multimeter

d) Test sockets with Flying leads - If required.

e) Removal & Fitment of Sensors & Connectors - Circuit.


EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES 12.07
Service Manual

SENSOR LOCATIONS

COOLANT TEMPERATURE ACCELERATOR ENGINE SPEED


SENSOR SENSOR SENSOR

INJECTOR BOOST PRESSURE


SENSOR SENSOR
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES
12.08
Service Manual

12.8 SENSORS Boost Pressure sensor location


12.8.0 Boost Pressure cum Temperature Sensor

6 Cylinder Engine 4 Cylinder Engine

Connectors

Functions and Working


The sensor serves to measure the absolute intake
manifold pressure. The pressure Sensor Element
consists of a Silicon diaphragm, which contains Piezo
resistive Semiconductor. The Pressure acts on the
diaphragm causes change in electrical resistance in
Circuit thus change in Output voltage.
Installation
a) The pressure nozzle project into the intake-manifold
and is sealed by using an O-ring, ensuring leak
proof. Smear lubricant on O-ring (non-acid paraffin
oils) during fitment.
Pin configuration & Connection Details
b) Maximum tightening torque of screws: 4-6 Nm
Specifications:
Operating Voltage - From ECU : 5V DC
Max. Absolute Pressure (System)
For 6 Cylinder Engines : 2.5 to 3 bar
For 4 Cylinder Engines : 3 bar
Fault Path
Group Error code (DTC) : P0235
DTC code Description
P0237 Signal low
Pin No: 2 - NTC Thermal Resistor Air
P0238 Signal high Temperature Sensor is not used / Applicated
10FA Supply voltage too low NOTE in AL - 122 Kw / AL - 88 Kw EDC System).
10FB Supply voltage too high
10FC Plausibility vs. Atmospheric pressure sensor RESISTANCE VALUES TABLE 1
Effect of fault in Vehicle Ambient Resistance in ohms
- Loss of power / vehicle speed limited to 40-50 kmph temp. in oC Minimum Nominal Maximum
as it would refer to the default value of 1.050 bar as 20 ± 1 2308 2500 2726
set in the application. 30 ± 1 1586 1715 1853
Possible cause of fault 40 ± 1 1113 1199 1291
- Open circuit of signal wire / Earth wire & Short Circuit 50 ± 1 729 851 913
of Signal Wire to Earth wire. Circuit Diagram
- Boost Pressure sensor defective
- Loose connection of end fittings in the sensor side
as well as in the ECU Side
Service Recommendation
- Check resistance and continuity
- Measure the resistance between Pin 1 & 2 (Refer
Table 1) at sensor end male connector.
- Measure the voltage between pin 1 & 4 for boost
pressure sensor supply Voltage (5V DC) at sensor
end male connector.
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES 12.09
Service Manual

12.8.1 Accelerator Pedal Module Redundant sensor


Function and working: P0222 Signal low
The Sensor serves to measure demand from the driver and P0223 Signal high
communicates to the ECU. It detects the pedal position by
P0224 Supply voltage too low
means of hall effect sensor and transfers this information
to the ECU in terms of Voltage. It consists of two hall effect P0221 Supply voltage too high
sensors for measuring the position of accelerator pedal Effect of Plausibility fault
module from 0% travel position to 100% travel position. The Engine idling rpm will get increased to 1200 rpm and set.
second sensor is incorporated as redundant and reports No further increase in Engine rpm irrespective of Pedal
error in case of malfunction of the first sensor. Voltage across movement.
redundant sensor is almost half of the 1st sensor.
Accelerator pedal Module - Floor Mounted Type Accelerator pedal Module - Pendant Type
1. Mounting screws
2. Sensor
3. Nut
4. Body
5. Fixed plug
6. Rocker
7. Lever arm
8. Bracket
9. Screw
10. Spring outer
11. Spring inner
12. Wear Liner
13. Shaft
16. Wiring Harness

Connectors

1. Roller 4. Bush 7. Mounting Screws


2. Roller Shaft 5. Nut 8. Wiring Harness
3. Tradle Pin 6. Sensor 9. Tradle Cover
Installation: Pin configuration and connection details
The accelerator pedal sensor is mounted on accelerator
pedal module.
Tightening torque of the retaining screws: 9 Nm. Pedal
return spring has to be maintained and replace in case
of breakage. Ensure proper gap between pedal and the
roller of the sensor lever and maintain 95 - 100% of pedal
sensor displacement with use of Diagnostic tool by setting
the max. adjustment screw provided on the pedal module.
Specification:
Operating voltage : 5 V DC
Temperature range : - 40 to 80°C Circuit diagram
Fault Path
Group error code (DTC): P0120, P0220
DTC Code Description
P0122 Input Signal low
P0123 Input Signal high
P0124 Supply voltage too low
P0121 Supply voltage too high
P2299 Plausibility error with brake
P2135 Plausibility error with redundant Pin 1 , 2 & 3 Main Sensor
Pin 4 , 5 & 6 Redundant Sensor
accelerator pedal position sensor 2
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES
12.10
Service Manual

Fault Diagnosis
Sl. No Possible causes of fault Service Recommendation
1 Line interruption Check continuity between 1 & 69, 2&12,3 & 50,4&70, 5&31 and 6
&51 of Sensor & ECU Respectively.
2 Short circuit of Supply Voltage There should not be any Continuity between Pin 2 & 3
wire to earth wire (Pot1) and Pin 5 & 6 (Pot2). Check for it.
3 Open circuit of Supply Voltage Check continuity between 1 & 69, 2 & 12, 3 & 50, 4 & 70,
wire / Earth wire 5 & 31 and 6 &51 of Sensor & ECU Respectively.
4 Sensor Defective Measure voltage at sensor output terminal for both main and
redundant sensors.
12.8.2 Engine Speed Sensor Engine speed sensor location
Function and working:
Engine speed sensor is an inductive type. It is mounted
on the flywheel housing. Electric pulses are generated
when the formed slots on the flywheel pass thro the
sensor axis.

The Electric pulse - Frequency (Sine Wave) generated


by the sensor is proportional to the engine speed.

Installation:
The sensor is to be mounted perpendicular to the surface
of the flywheel housing using respective mounting
aluminum plate. Use recommended aluminium mounting
plate according to the flywheel. Sensor

Do not use force / Hammer to fit the sensor. After Fitment


ensure seating of the sensor mounting face.

Tightening torque of the mounting Screws: 6 - 10 Nm.

Specification:
Resistance : 860 ohms ± 10% at 20 °C

Fault path
Group error code (DTC): P0725
Error Code Description
Connectors
P0219 Over speed-detection
P0728 Dynamic plausibility
P0727 Static plausibility
Effect of fault
Engine shut down

Possible cause of fault


- Engine Over speed during Overrun operation
- Defective sensor
- Open Circuit of Signal Wire / Short circuit to earth
- Line interruption Pin Configuration & Connection Details
- Increase in air gap (Spec: 1 to 2 mm)
- Dust accumulation on the sensor tip

Service recommendation
- Measure resistance between pin 1 & 2
- Check continuity between Pin no 110 and 2 and
Pin no 86 and 3.
- Keep Sensor tip free from dust, grease / oil and iron
particles
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES 12.11
Service Manual

12.8.3 Coolant Temperature Sensor Coolant Temperature Sensor


Function and working:
It is a thermistor, mounted on coolant return line from
cylinder head. A semiconductor Material changes its
resistance when exposed to variable temperature source.
Resistance decrease as temperature Increase (NTC
type)
Installation:
Tightening torque : 20 - 24 Nm
Specifications :
Temperature range : -40/130°C
Rated voltage : Operation by pull up resistance
Connectors
of 1 Kilo Ohms in ECU
Fault path
Group code (DTC) : P0115
DTC Code (Crypton) Description
P0117 Signal low
P0118 Signal high
P0119 Temperature too low
P0116 Signal implausible
(dynamic)
Effect of fault:
In case of sensor failure,
Pin Configuration & Connection Details
1) It has been programmed to switch over to default
value of 96°C. The Default Value Specified in
the control unit for such cases can lead to a fuel
Quantity reduction and may produce white smoke
output during cold start.
2) This reduction in fuel quantity will show an activated
effect of limp home function - Refer Limp Home
Function.
Possible cause of fault:
- Voltage Supply Line interruption
- Signal wire Short circuit to earth wire
- Sensor defective
Service instruction
Measure Resistance between Pin 1 & 2
At 20°C - 2.315 to 2.649 Kilo Ohms
At 40°C - 1.118 to 1.231 Kilo Ohms
At 80°C - 0.313 to 0.332 kilo Ohms
Measure Voltage between Pin 104 & 112 and at the
connector of the wiring harness near to sensor : > 4V
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES
12.12
Service Manual

12.8.4 Needle Movement Sensor (NBF) Needle Movement Sensor location

Function and working:


The needle movement sensor is to detect begining of
injection by means of Lift of the needle .
A ferromagnetic core attached to the needle disturbs the
flux created by the coil.
The needle movement induces a voltage pulse in that
coil, which is sensed by ECU and considered as start
of injection.

Injector to be handled carefully without


causing any damage to the Connector
CAUTION and the attached cable. Needle Movement Sensor
Ensure proper positioning of the first
injector mechanical clamp. This is to
avoid damage to the cable due to undue
mechanical stress.
Ensure fitment of corrugated sleeve on
the first injector to avoid damage.
Ensure clamping of cable after refitment
of Injector.
Installation:
First cylinder Injector is fitted with Needle movement
sensor. Remaining cylinders are fitted with normal
Connectors
injectors.
Fault path
Group code (DTC) : P106C
DTC Code Description
P1073 Signal low
P1074 Signal high

Effect of fault:
Selected timing as per the defined map with fixed values
shall prevail at all speed range. The performance may
not be as that of normal.
Smoke and misfire
Possible cause of fault Pin Configuration & Connection Details
- Supply voltage line interruption
- Signal wire short circuit to earth / negative
- Needle movement sensor defective
Service instruction:
- Measure the resistance between pin 1 & 2 at sensor
- about 100 +/-10 ohms (20 °C)
- Check continuity between point no. 109 and 1 &
101 and 2.
- As the effect disturbs the control of emission,
complaint to be attended.
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES 12.13
Service Manual

12.8.5 Vehicle Speed Sensor Vehicle Speed Sensor

Function and working:


Working on Hall effect principle, produces 8 pulses per
revolution, Pulse output is used for calculating the distance
traveled and speed of the vehicle. Refer Table to determine
the exact speed for different configurations. System
provides correct speed for the tyre and RAR configuration.
Installation:
Vehicle speed sensor is mounted on the gearbox at
Speedo drive output or remote mounted on frame and
connected with a short drive cable.
Specifications:
Operating Voltage : 4.5v to 28V
Connectors
Supply Current : 9mA
Output Current : 25mA
Direction of rotation : Clockwise and Anti-Clockwise

Fault path
Group code (DTC): P0500
DTC code Signal high
P1108 Frequency too high
P0501 Signal high - Open Circuit

Effect of fault:
Nil - As such. To be decided after activating the vehicle
set speed limitation.
Pin Configuration & Connection Details
Possible cause of fault:

- Output Short circuit to earth / Negative

- No input Supply voltage ~ 0 to 24V

- Sensor defective

Service instruction:

1) Check for Supply voltage (12V) across terminal 1


& 2 of the male end - Wiring Harness side

2) Check for continuity between Sensor Ground and


Battery negative / Earth

3) Check matching of Power Supply signal and ground


between Sensor and wiring harness.

TABLE - 1
Speedo Ratio 1:1.545
RAR RAR RAR RAR RAR RAR
Combination 6.167 6.167 5.833 5.833 5.57 5.57
Tyre Tyre Tyre Tyre Tyre Tyre
9 x 20 10 x 20 9 x 20 10 x 20 9 x 20 10 x 20
Rear Axle ratio and Tyre size has been provided since VSS senses Speedo speed. Gearbox ratio is not
relevant.
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES
12.14
Service Manual

12.9 SWITCHES
12.9.0 Brake switch
Function and working:
The switch is of electro-pneumatic type. Switch is mounted on the dual-control Valve. It indicates the altered voltage
level from the switch and output is fed to ECU as information. Switch operates for pressure greater than 0.5 Bar.
This information is used by the ECU to activate the limp home mode in case of defective accelerator pedal sensor.
Installation:
Ensure there is no air leak after fixing.
Tightening Torque: 15 - 18 Nm
Specifications:
Four Terminals with NC and NO Contact
Supply & Output Voltage : 12VDC
In the vehicle, an additional brake switch relay is provided and this will be operated when service brake switch is
activated. ECU will sense this dual contact signal.
Fault path
Group code - DTC : P0571
DTC code Description
P0504 Plausibility with accelerator pedal sensor
PO61E Plausibility with second brake switch after ECU initialization
P0573 Input signal high
P0572 Input signal low
Effect of fault: Service Instruction:
Limp home function (Engine runs at 1000 rpm) is activated Check voltage as given below
in conjunction with defective accelerator pedal sensor. - Pedal pressed pin 46 & ground - 12V
Disconnected / absence of Brake switch will record - Pedal pressed pin 65 & ground - 0V
DTC - P0504 and will not produce limp home function or
- Pedal normal position pin 46 & ground - 0V
Disturbance to normal operation when accelerator pedal
sensor is in good working condition. - Pedal normal position pin 65 & ground - 12V

Possible cause of fault:


- Defective switch
- Open/short circuit of Supply voltage - 12V
Pin Configuration & Connection Details

Circuit Diagram
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES 12.15
Service Manual

12.9.1 Clutch Pedal Switch


Function and working:
It is mounted on the clutch cross shaft housing mounting bolts. It is used to detect the gear ratio. Currently it is
not applicated.
Installation:
Ensure correct setting of the switch to make positive opening and closing of the contact in the switch.
Checking Procedure
Pedal Released - 12V
Pedal Pressed - 0V

Circuit Diagram Pin Configuration and Connection details

FROM ECU
CLUTCH END
SWITCH

12.10 ACTUATORS
12.10.0 Fuel shut off solenoid / ELAB
Function and Working
It is a solenoid switch located on the distributor head of the fuel injection pump. The solenoid receives power supply
(12V) from the ECU. When it is energized fuel will be supplied to the engine.
Installation:
Max. Tightening torque of Terminal nut: 2 Nm
Group Error code (DTC) : P1063
DTC Description Effect
P1064 Output Circuit Defect Engine will not start - No fuel
P1065 Plausibility in ref. to start test Repeated test cycle interruption till plausibility is corrected.
Error is reported - No effect.

Cause of fault Circuit Diagram

- Defective solenoid
- Open / short circuit
- Loose connection
Service information
Check
- 12V supply for the solenoid.
- Resistance 7.4 Ohms at 20°C (body earth)
- Continuity of cable from Point no 120 of ECU to
solenoid.
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES
12.16
Service Manual

12.10.1 Diagnostic Lamp


Function
Diagnostic lamp is provided on the instrument panel. In event of any errors reported by the ECU in course of
operation of the vehicle, the diagnostic lamp glows, indicating that there are errors reported in the system and
recorded by the ECU. Only selected errors, which can have a direct effect on the engine / vehicle performance,
are reported to the diagnostic lamp.
Depending on the criticality of the error reported, the ECU could either switch off the engine or change to limp home
mode. Details of the errors can be viewed with the help of the diagnostic tool.

Diagnostic lamp is only an indicator of any error reported.


NOTE

Group Error code - DTC : P105A


DTC code Description
P105C Lamp - Open Circuit
P105B Lamp - Short Circuit
P105D Plausibility Error

Effect of fault
No effect of fault. No visual indication for the driver in case of any error reported in the EDC System.
Cause of fault
- Loose connection
- Short circuit / Open Circuit
Service instruction
Use multimeter and measure voltage and continuity.

Pin Configuration and Connection details

80 Diagnostic
ECU Lamp

V1
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES 12.17
Service Manual

12.10.2 Fuel Timing Actuator (Timer Solenoid) Fuel Timing Actuator

Function and working:

The solenoid valve controls the start of injection. The


pump interior pressure is dependant upon pump speed.
Similar to the mechanical timing device, this pressure is
applied to the timing piston device. A clocked solenoid
valve modulates this pressure on the timing device
pressure side.

With the solenoid valve permanently opened (pressure


reduction) , start of injection is retarded, and with it
fully closed (pressure increase) , start of injection is
advanced. In the intermediate range , the on/off ratio Connectors
(the ratio of solenoid valve open to solenoid valve closed)
can be infinitely varied by the ECU.

Specifications:
Resistance : At 25°C ± 10 : 13.3 to 16.3 Ohms

Supply Voltage : 12V


Group Error Code - DTC P1087
DTC code Description
P1088 Short Circuit
P1089 Open Circuit
Effect of fault
Pin configuration & Connection Details
Timing as per the defined map with fixed values shall
prevail at all speed range. The performance may not be
as that of normal. Emission would be affected. Fault to
114 2
be rectified.
Possible cause of fault Fuel Timing
ECU
Actuator
- Defective solenoid
- Loose connection V1 1

- Short circuit / cable cut


Service instruction:
Check resistance between pin 1 & Pin 2 of the connector
available at the FIP end
Check continuity between point no 1 & V1 and point
no 2 & 114.

In case of defective timer solenoid send


the FIP to Mico dealer for Warranty
NOTE
/ Service attention. For removal and
refitment of the pump refer the procedure
given under fuel actuator.
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES
12.18
Service Manual

12.10.3 Fuel Quantity Actuator


Function and Working
The solenoid actuator (rotary actuator) engages with the control collar through a shaft. Similar to mechanically
governed rotary fuel injection pump, the cut off ports are opened or closed depending upon the control collar's
position. The HDK unit ( Fuel quantity Adjuster ) is integrated in the pump .The task of the adjuster is to generate
the correct quantity from the Control Signal from ECU. It is a inductive type electric motor which adjusts the position
of the control collar and thus regulates quantity continuously from Zero to Max. delivery in reference to Fuel map.
It is a closed loop control by monitoring the position of the Control collar.

Effect of fault

Dearborn
Effect of Fault Error Path
Error Code
Fuel Qty actuator - Negative and positive
P10A2 Engine will shut down
governor deviation in hot and cold condition
P10B4, P1099 Engine will shut down Fuel actuator Governor feedback signal
Drop in engine power –Limp
P0180 Fuel temperature sensor
home mode

Cause of fault
- Defective actuator
- Defective temperature sensor
- Control collar stickiness
- Loose connection at connector end
Service instruction:
Check resistance at 15 - 35°C

FIP end connector Resistance value


Pin no 4 &7 0.35 – 1.0 Ohms
Pin no 1 & 3 5.8 – 6.5 Ohms
Pin no 2 & 3 5.8 – 6.5 Ohms
Pin no 1 & 2 9.7 – 12.9 Ohms

At 25°C 0.5 – 3.5 KOhms


Pin no 5 & 6 (fuel temp)
At 60°C 0.15 – 1.05 KOhms

Pin configuration & Connection Details

V3
4
116
V1 7
121
108 1

106 3

107 2

111 6

103 5
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES 12.19
Service Manual

To Remove and Refit Fuel Injection Pump and To C. To Refit the Fuel Injection Pump and adjusting
Adjust the Injection Timing the Fuel Injection Timing (6 Cylinder Engine)

In case of defective fuel actuator remove the FIP and 1. Bring the no.1 cylinder at TDC on compression
send to Mico dealer for warranty / service attention. stroke. ( Hint: there is no need to remove the rocker
cover. At the first cylinder compression the double
Use special Tool 0102019 - Wrench for Engine Cranking. groove in the Inj. Pump drive coupling, which can
be felt with hand from the open end rear end of the
A. Removal of FIP from Engine: Inj. Pump drive housing, will be 12 O'clock position).

1. Isolate battery.

2. Remove high pressure pipe connections, remove


over flow pipe connectio n from the fuel injection
pump.

3. Remove the speed sensor holder fitted on the


flywheel timing window (For 6 Cylinder Engines
only) . Also remove connectors and cables from
the FIP.

4. Bring the no.1 cylinder at TDC on compression


stroke by rotating the crank pully suitably (Hint: 2. Check the FIP mounting Gasket in good condition.
there is no need to remove the rocker cover. At
the first cylinder compression the double groove in
the Inj. Pump drive coupling, which can be felt with
hand from the open rear end of the Inj. Pump drive
housing, will be 12 O'clock position).

5. Loosen the 3 nuts mounting the FIP onto the injection


pump drive housing, and remove the FIP. There is
no need to remove the injection pump drive housing.

B. Bench Calibration:

1. Remove the splined bush by a suitable tool.

The FIP can now be put on bench for calibration. 3. Fit the FIP onto the engine aligning the double tooth
with the double groove in the injection pump drive
2. After bench calibration, fix the splined bush and coupling (Hint: at the correct timing the double tooth
torque tighten to the specified value. on the splined bush would be 12 O'clock position).

3. Ensure position of the double tooth of the splined


bush at 12 O'clock position.

4. The FIP is now ready for fitment onto the engine.

5. Ensure that the inlet adaptor on the FIP fuel inlet,


Overflow (‘OUT’) Banjos are fitted back onto the
FIP after bench calibration.

For latest Calibration chart refer MICO


NOTE dealer.
4. Tighten the 3 FIP mounting nuts, by pushing the
pump towards cylinder block.
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES
12.20
Service Manual

11. Tighten the three nuts to torque (25 + 10 Nm) secure


the FIP firmly.

12. Remove the dial indicator and fit the dummy plug.

13. Fit the over flow pipe, fuel inlet / outlet pipes, high
pressure pipes and FIP support bracket properly.

Clean the speed sensor tip and fit the speed


sensor holder and torque tighten the fixing bolts
to 10 - 15 Nm.

Ensure proper connections of governor, timer and


shut off solenoid connectors.

D. To Refit the Fuel Injection Pump and adjusting


the Fuel Injection Timing (4 Cylinder Engine)
The static timing spec for HA4CTI3N is 0.3±0.02mm
plunger lift at TDC.

5. Remove the dummy plug on the distributor head


and fix the special tool.
6. Rotate the engine in the opposite direction of
rotation. Stop the rotation when the pointer of the
dial indicator stops moving.
7. Set Zero on the dial.
8. Rotate the engine in the direction of rotation and
align the 1/6 mark on the engine flywheel to the
flywheel housing ref. 1. Bring the no.1 cylinder at TDC on compression
stroke by rotating the crank pully suitably
( Hint: there is no need to remove the rocker cover.
At the first cylinder compression, the double groove
in the Inj. Pump drive coupling, which can be felt
with hand from the open end rear end of the Inj.
Pump drive housing, will be 12 O'clock position).

9. The dial indicator should now read pre-stroke


specified for the engine.
10. If not, loosen the three nuts holding the FIP to the
housing-inj. Pump drive and turn the FIP towards
or away from the engine so that the dial reads the
required pre-stroke value.
Engine Static Timing (When No.1 cylinder is on
Spec compression stroke)
2. Check the FIP mounting Gasket.
HA6DTI3N MKI 0.2 ± 0.2 mm plunger lift at TDC.
HA6DTI3N MKII 0.8 ± 0.2 mm plunger lift at TDC.
HA57L135 HT 0.6 mm ± 0.2 mm plunger lift at TDC.
HA57L135 LT 0.8 mm ± 0.2mm plunger lift at TDC.
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES 12.21
Service Manual

3. Fit the FIP onto the engine aligning the double tooth
6. Rotate the engine in the opposite direction of rotation.
with the double groove in the injection pump drive
Stop the rotation when the pointer of the dial indicator
coupling (Hint: at the correct timing the double tooth
stops moving.
on the splined bush would be 12 O'clock position).
7. Set Zero on the dial.
8. Rotate the engine in the direction of rotation and align
the 1/4 mark on the engine flywheel to the flywheel
housing ref.
9. The dial indicator should now read pre-stroke
specified for the engine.
Static timing - 0.3 ± 0.02 mm plunger lift at TDC.

4. Tighten the 3 FIP mounting nuts, by pushing the


pump towards cylinder block.

10. If not, loosen the three nuts holding the FIP to the
housing-inj. Pump drive and turn the FIP towards
or away from the engine so that the dial reads the
required pre-stroke value.

Remove the dummy plug from the distributor head.

11. Tighten the three nuts to torque (25 + 10 Nm) secure


the FIP firmly.
12. Remove the dial indicator and fit the dummy plug.
13. Fit the over flow pipe, fuel inlet / outlet pipes, high
5. After removing the dummy plug from the distributor pressure pipes and FIP support bracket properly.
head, fix the special tool. Ensure proper connections of governor, timer and
shut off solenoid connectors.
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES
12.22
Service Manual

12.10.4 ECU - Related Group Error Codes:

DEARBORN CRYPTON
ERROR PATH
CODE CODE

P1001, P1002, Error encountered during overrun monitoring during overrun


P1000
P1003, P1004 monitoring. Recovery from an erroneous state.

Communication error between micro controller and EPROM –


P1009 P1010
Should not come in Production Series ECU.

P1012 P1013, P1014 EPROM

P1052, P1053,
P1051 A/D converter
P1054, P1055

P1090 P1091, P1092 Reference voltage high / low

P10E1 P1142, P1143 Error path changing over

Service Information
- Verify and confirm supply voltage to ECU.
- Clear the errors with diagnostic tool after attending to the error related EDC parts
- Switch off the ignition  Switch on the ignition  start the engine
- Look for the errors  If the above errors repeat then replace the ECU/If the errors of frequent repeatable
in nature, refer with MICO

12.11 DC-DC CONVERTER


A DC-DC converter is a component, which converts the DC voltage from one level to another. It performs similar
function of a transformer in AC circuits, i.e. steps down the voltage keeping the power constant. In the Electronic
Diesel Control System, DC converter changes the 24V dc from the battery to 12V dc. This 12V dc is used as an
input to the EDC system. This is required as the EDC system is designed for 12V. Below is the specification of the
DC-DC converter required for the EDC system.

Sl. No. Specifications AL Requirements

1 Input Voltage range 14 - 36V DC

2 Output Voltage Range 12V DC

3 Output Voltage Regulation over input range ± 2%

4 Maximum output voltage ripple 200 mv

5 Maximum Output current (Continuous) 10A

6 Maximum Instantaneous Spike current 15A for 20 ms

7 Output Short circuit protection Yes

8 Reverse Polarity protection Yes

9 Over Voltage protection Yes

10 Input load dump protection Able to suppress load dump as per ISO 7637-2.
Withstand Positive spike of 100V for 50ms
Repetition rate:5Hz for 5000 times Withstand
11 Conducted Disturbances
Negative spike of-100 V for 2ms.
Repetition rate:0.2Hz for 5000 times
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES 12.23
Service Manual

12.12 DO'S AND DON'TS FOR SENSORS


Sl. No. Sensor Do's and Don'ts

1 Engine speed - Replace damaged O-Ring.


0 281 002 214
(DG- 6) - Fix with only partially self-sealing cylindrical screw M6X12.

- Do not keep near any strong Magnetic Materials.

2 Boost pressure - The pressure sensor must not fall to concrete ground from more
0 281 002 514 than 1m height.
(LDF6T)
- After removing the pressure sensors have to be stored in their
original packing to avoid introduction of foreign substances in the
pressure ports.

- Do not install the sensor with a hammer.- Replace damaged O-


Ring.

- Do apply screws, tightening torques, and wiring harness connector


only strictly in accordance with the offer drawing.

- Label on the sensor should not be removed or damaged.

- Dipping of sensor in any kind of liquids is not allowed.

3 Water temperature - After removing temperature sensor, existing Aluminum washer


is to be carefully cut / removed (without damaging the brass
threading on the sensor) and taken out.
- Replace new Copper washer

12.13 GUIDELINES FOR CHECKING SENSORS AND COMPONENT

1. Checking Voltage / Resistance at Component or ECU end - Allowed with proper instrument & care.

2. Few test to be carried out with Ignition 'OFF"/'ON' and Engine running mode condition to confirm the fault and
after erasing the error.

3. Avoid Checking at ECU end. In case of utmost requirement ensure ECU body is always connected to Starter
Negative.

4. Measure resistance of the sensor at the Connector end and on the connector at the ECU end after connecting
the respective sensor. Given resistance values are as measurable at the sensor end. While measuring resistance
at the ECU connector end with sensors connected, the resistance of the wire will get accounted.

5. Care to be taken not to short the supply voltage / Sensor Output with earth / Negative.
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES
12.24
Service Manual

Example of checking Temperature Sensor

Disconnect the Socket and check the Resistance


Example of checking Input voltage

Disconnect the Socket and check the Input voltage


Example of checking boost pressure output voltage without disconnecting the socket by using
'Y' connector

Measurement at ECU with Help of Break out Box or Using 'Y" Connector at Wiring Socket are
NOTE shown in figures.
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES 12.25
Service Manual

12.14 RELAY AND FUSE INTERCONNECTION DIAGRAM (24V)

12 V
DIAGNOSTIC
2 POLE SOCKET
COUPLER

DIODE
ECU / IGNITION SWITCH F3-5A

24V 12 V
30 87
24V / 12V
DC / DC
COUPLER

F2-30A F1-30A
2 POLE

8 86
24V GND
HOLD RELAY - R1(12V)

F5-10A * 30
87 30 87 37
86
86 85
18 E
85
SINGLE
F-15A

1
24V

POLE
MAIN RELAY - R2(12V)
ISOLATED
SWITCH
IGNITION RELAY - R3(24V)
GND
4
C
30 87 TO 4ST RELAY ON 62
+ VE
85 86 STARTER MOTOR
87 U
STARTER
*
DC BATTERY

MOTOR
EDC STARTER RELAY - R4(12V)
12V X 2

- VE
24V

24V

F4-15A
30 87
GND

86 85

STARTER SWITCH STARTER S / W RELAY - R5(24V) *

*
FUSES
* *
RELAYS

R1 R2 R3 R4 R5

F1 F2 F3 F4 F5

FUSE & RELAYS BOX


* - ONLY FOR 124 KW MARK 2 APPLICATION

12.15 RELAY AND FUSE INTERCONNECTION DIAGRAM (12V)

Fuses Relay
Fuses & Relays Layout
F1 F2 F3 R1
FUSE & RELAYS BOX

F3 - 15A F1 - 5A To Diagnostic
socket

Single
V Pole
V connector IGN SW
Main relay R1
12V
Fuse
15 A 30 87 1
2 E
86
C
85 18 U
+VE

Starter 37
Motor 4
12V DC
Battery -VE 5

F2 - 15A
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES
12.26
Service Manual
RELAY AND FUSE INTERCONNECTION DIAGRAM (12V) WITH 2 RELAY CIRCUIT
12.16
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES 12.27
Service Manual

* - ONLY FOR 124 KW MARK 2 APPLICATION


EDC SCHEMATIC CIRCUIT DIAGRAM

*
12.17
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES
12.28
Service Manual

12.18 DO'S AND DON'TS (DURING REGULAR 12.19 HINTS DURING THE BODYBUILDING PHASE:
SERVICE AND BODY BUILDING): Extreme care should be taken while assembling the body
- Check the battery condition regularly and keep the on the chassis with respect to the ECU.
battery in a healthy condition. 1.1 The ECU should be disconnected from the harness
- No undue pressure to be applied on the ECU during and a dummy cap/cover with plastic bags should be
service. put on the ECU connector. There should be no ingress
of water through the wiring harness on the ECU.
- Ensure proper connectivity of ECU/Sensor
connectors with wiring Harness and maintain 1.2 The ECU as such should be covered in a box so that
harness clamps. if any washing is done, the ECU will be protected.
1.3 Maximum cleanliness in the work area and the tools
- Keep the ignition switch 'OFF' while removing &
should be employed . Check to see if the ECU
Fitment of the battery connections in the vehicle.
has become dirty during the body building phase
- ECU must be connected or disconnected to the especially at the connector end and pins. Use a soft
wiring harness only when the ignition switch is in clean & dry paint brush to remove the dust.
OFF position.
Ashok Leyland specific:
- Electrical tapping not allowed: Tapping should not Ensure that the intermediate connector (supply +ve and
be taken as this can severely affect the performance -ve for ECU) between the DC to DC converter and wiring
of the ECU and Sensors (additional current drawn harness is properly locked and intact.
by the new load will drain the battery faster / damage
the DC/DC Converter). EDC System
Have a clear space in front of the EDC panel cover for
- Do not relocate the ECU from the given location. easy removal and fitment of electrical/electronic parts
- Correct Tightening torques should be used for of EDC panel.
mounting the ECU.
Instructions
- Ensure paint removal on the surface before 1. Before and during welding
connecting the DC negative connection of EDC
system. - Disconnect battery terminals (Positive and Negative
terminals of 24V supply).
- Care should be taken while washing the vehicle. Do
- Disconnect Two connectors of the ECU and have
not splash water directly on to the ECU, Accelerator
the panel cover refitted.
pedal module and other electrical components.
- Avoid falling of hot weld spatters on wiring harness,
- Diagnostic connector should not be left hanging sensors and Accelerator Pedal Module.
loose and should be handled with care. The
protective cap is to be removed only at the time of - Do not use Accelerator Pedal as a support during
connecting diagnostic tester. body building.
- Avoid falling of any sharp/Heavy objects on the
- Reverse polarity protection: Care needs to be
accelerator pedal module and its connecting wire.
taken while removing and connecting the battery
connection during body building - Do not disturb the clamps of EDC System wiring
harness unless it is very essential, but ensure it is
- No intermittent connector in the EDC wiring system replaced/refitted properly.
should be practiced.
2. Do not disturb/remove the connected EDC
- Correct tightening torques should be used for Negative connection of the system. EDC negative
mounting the ECU and other electrical/electronic is connected at the following places
parts on EDC panel. 8 ± 2 Nm torque (M6 - 8.8 Gr).
a. Starter Motor Negative
- Mounting position of the ECU should not be b. EDC pane 1
changed.
c. Earth Strap to be connected for ELAB ground.
3. Do not remove or cut wires of the EDC system wiring
harness. No extension or intermediate joints are
permitted.
4. Before connecting the engine wiring harness,
the battery terminals (Both positive and negative
terminals) are to be disconnected.
5. Make sure that the lock of the connectors are fitted
properly.
6. Clip/clamp the wiring harness every 500 mm.
7. Wrap insulation tape wherever the tapings has been
taken. Make sure that no part of the wire is left un-
insulated.
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES 12.29
Service Manual

COVER (BACK
EDC PANEL

DIAGRAM
STICKER
CIRCUIT
VIEW)

SCHEMATIC DIAGRAM : FUSES AND RELAYS - EDC SYSTEM

12 V
DIAGNOSTIC
2 POLE SOCKET
COUPLER
DIODE

ECU / IGNITION SWITCH F3-5A

24V 12 V
30 87
24V / 12V
DC / DC
COUPLER

F2-30A F1-30A
2 POLE

8 86
24V GND
HOLD RELAY - R1(12V)

F5-10A * 30
87 30 87 37
86
86 85
18 E
85
F-15A

SINGLE 1
24V

POLE
MAIN RELAY - R2(12V)
ISOLATED
SWITCH
IGNITION RELAY - R3(24V)
GND
4
C
30 87 TO 4ST RELAY ON 62
+ VE
85 86 STARTER MOTOR
87 U
STARTER
*
DC BATTERY

MOTOR
EDC STARTER RELAY - R4(12V)
12V X 2

- VE
24V

24V

F4-15A
30 87
GND

86 85

STARTER SWITCH STARTER S / W RELAY - R5(24V) *

*
FUSES
* *
RELAYS

R1 R2 R3 R4 R5

F1 F2 F3 F4 F5

FUSE & RELAYS BOX


LOCATION ON THE VEHICLE
12.20

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