EDC 15system
EDC 15system
MAY 2012
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES 12.01
Service Manual
CONTENTS
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
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.
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.
DIAGNOSTIC CONNECTOR
Pin Configuration & Connection Details
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
Dearborn /
Crypton code Component involved
Pragathi code
P0235 P0237, P0238, P1162 Boost pressure sensor
P0105 P0107, P0108 Atmospheric pressure sensor - ECU
Required Instruments:
SENSOR LOCATIONS
Connectors
Connectors
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.
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
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
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
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
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:
- Sensor defective
Service instruction:
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
Circuit Diagram
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES 12.15
Service Manual
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.
- 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
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.
80 Diagnostic
ECU Lamp
V1
EDC SYSTEM FOR HA6DTI3N, HA4CTI3N & HA57L135/HA57L135LT ENGINES 12.17
Service Manual
Specifications:
Resistance : At 25°C ± 10 : 13.3 to 16.3 Ohms
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
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.
B. Bench Calibration:
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).
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.
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.
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.
DEARBORN CRYPTON
ERROR PATH
CODE CODE
P1052, P1053,
P1051 A/D converter
P1054, P1055
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
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
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.
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
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 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
*
FUSES
* *
RELAYS
R1 R2 R3 R4 R5
F1 F2 F3 F4 F5
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
*
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)
12 V
DIAGNOSTIC
2 POLE SOCKET
COUPLER
DIODE
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
*
FUSES
* *
RELAYS
R1 R2 R3 R4 R5
F1 F2 F3 F4 F5