ELECTRONIC DIESEL CONTROL

SYSTEM
BY Ankit kumar
ELECTRONIC DIESEL CONTROL
SYSTEM
Modern engine development is driven by legislative emission
requirements and growing vehicle electronic architecture in the market.
Following are the legislation and market driven needs.
1. High fuel injection line pressure
2. Multiple injections (Main and Pilot)
3. Flexible in fuel quantity, injection timing and fuel injection pressure
independent of engine speed.
4. Environmental (Ambient, Coolant température etc.,) / Altitude
dependent torque requirement.
5. Integration and communication with other vehicle and exhaust
treatment systems Electronic control units through CAN (Automatic
transmission, ABS, ACU, BCU etc.,)
The EDC (Electronic Diesel Control) system is capable of meeting the
demands outlined above.
ELECTRONIC DIESEL CONTROL
SYSTEM
In EDC system, the driver has no direct control over the injected fuel
quantity through the accelerator pedal.
The injected fuel quantity is calculated and injected based on
1. Engine operating conditions such as Boost pressure and
temperature, accelerator position and ambient pressure, coolant
temperature and engine speed.
EDC system is subdivided into-

1. Sensors
Detects the engine operating conditions and the driver's
demand. They convert physical variables into electrical signals.
2. Electronic Control Unit (ECU)
Processes the information received from the sensors. It controls
the actuators through electrical output signals. It also provides
interfaces with other systems like diagnostic tool, ABS,
Automatic transmission etc.
3. Actuators
Convert the electrical signal from the ECU into physical
variable for controlling actuators such as Injectors, Metering
unit.
 Speed sensor (Crank)

Speed sensor (Cam)

Injectors

Boost Pressure/Temp

Coolant Temp sensor

Outputs
Metering Unit
Rail Pressure sensor

Fuel temp sensor

Accelerator pedal

Alarms & Service Tester

 CONTROLS
Open and Closed Loop Electronic Control

Open Loop
The actuators are operated by the ECU output signals which the
ECU has calculated using the input variables, stipulated data,
characteristic maps, and algorithms. The final results are not
checked.
Close loop control
The actual value at the output is continually monitored against the
desired value and as soon as a deviation is detected this is
corrected by a change in the actuator control. The advantage of
close loop control lies in the fact that disturbances from outside
are detected and taken into account. In our system close loop
control is used for rail pressure governing through activating
Fuel - Injection control
In order that the engine can run with optimum combustion
under all operating conditions, the ECU calculates exactly
the right injection fuel quantity at right time in different
conditions. Here the values of various parameters are
considered.
Starting Torque Requirement
The injection fuel quantity is calculated as a function of
coolant temperature and cranking speed. This will generate
from the moment the starting switch is turned ON until
minimum engine speed is reached.
Fuel - Injection control
Drive mode
When the vehicle is being driven normally, the driving torque is a
function of the accelerator pedal position and engine speed and boost
pressure. Calculation depends upon maps, which also consider high
fuel temperature. This permits best possible alignment of the engine's
output to the driver's wishes and also protect FIP parts.
Engine Idle speed control
When the accelerator pedal is not pressed, it is the job of the
idle speed control to ensure that a determined idle speed is
maintained. For instance, with the engine being cold, the idle
speed is maintained by set value defined with respect to water
temperature and the set speed is maintained similarly at
increased water temperature.
Fuel - Injection control
Engine Maximum speed control
This control ensures that the engine shall not to be rotated at
excessive speeds. To avoid damage to the engine, the engine
manufacturer stipulates a permissible maximum rotational
speed that may only be exceeded for a very brief period.
Beyond that an error recording is registered. In our case the
recorded speed is 3000 rpm. Error code is P381.
Intermediate set - Speed control
Intermediate speed control enables to run the engine at
constant speed for applications like crane, ambulances /
trucks mounted with generator sets.
Fuel - Injection control
Vehicle speed limiter
The vehicle speed limiter function limits the vehicle's maximum speed
to a set value. This can be applicated and proper activation can be
performed by the customized Diagnostic tool.
Engine Torque Limitation
Max torque limitation has been predetermined and set at factory.
Deviation to that will have the following effect
- Excess emission in form of smoke
- Mechanical overloading due to high torque.
Engine exhaust brake function
When the Exhaust brake is applied, in general, the injected fuel quantity
is either reduced to zero or to the idle fuel quantity is reduce to zero.
Fuel - Injection control
Start of injection control
Start of injection has a critical effect on power output, fuel
consumption, noise, and emissions. The desired value for start
of injection depends on engine speed and injection fuel
quantity. With the use of injector energisation, it is achieved
ENGINE START / STOP PROCEDURE:
Before starting ensure that the gear is in neutral position and
the parking brake is applied.
To reduce transmission drag on cold vehicles, depress the
clutch pedal.
If it is required to start the vehicle in a garage or workshop,
ensure that adequate ventilation is provided.
Engine Start Procedure
Engine Start/Stop Procedure

1 Accelerator 2 Brake 3 Clutch

1. The ignition switch is provided in the steering column.
Insert the ignition key in the ignition switch, turn clockwise
for 24 V supply to vehicle electricals & EDC system.
2. Turning this key further will crank the engine. After
starting the engine release the key immediately to avoid any
starter motor damage.
Engine Stop Procedure
To stop the engine turn the ignition key anticlockwise.
Engine Start/Stop Procedure

Do’s and Don’ts:

Idle the engine always about 2 mins after starting and
before switching off the engine.
Do not switch-off the engine through engaging the gears
and brake.
Do not operate the starter motor for more than 10 sec.
continuously. Wait for 30-60 Seconds before trying again.
SENSORS AND ACTUATORS
FOR H SERIES 6 CYLINDER SENSOR
BOOST PRESSURE SENSOR
Function 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.
Also, Suitable circuitry for signal conditioning is provided.
Installation
a) The pressure sensor package is inserted 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.
b) Maximum tightening torque of screws : 4 - 6 Nm
BOOST PRESSURE SENSOR

Specifications :
Operating Voltage - From ECU : 5V DC
Max. Absolute Pressure (System) : 3 bar
H SERIES 6 CYLINDER
Boost pressure sensor location
Fault Path

DTC code Description

(Hand held
diagnostic tool)

P0238- Boost pressure sensor Voltage above upper limit

P0237- Boost pressure sensor Voltage below lower limit
U1001- Boost pressure sensor signal from CAN not
OK .
P0236- Boost pressure sensor Plausibility error.
Effect of fault in Vehicle

Loss of power / vehicle speed limited to 40-50 KmpH as it

would refer to the default value of 1200 mbar as set in the
application.
Possible cause of fault
- Open circuit of signal wire / Earth wire & Short Circuit of
Signal Wire to Earth wire.
- 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.
 ACCELERATOR PEDAL SENSOR

Function and working:

The Sensor serves to measure demand from the driver and communicates to
the ECU. It detects the pedal position by means of potentiometer sensor and
transfers this information to the ECU in terms of Voltage. It consists of two
potentiometer sensors for measuring the position of accelerator pedal module
from 0% travel position to 100% travel position. The second sensor is
incorporated as redundant and reports error in case of malfunction of the first
sensor. Voltage across redundant sensor is almost half of the first sensor.
Installation:
The accelerator pedal sensor is mounted on accelerator pedal module as
shown in the figure.
Tightening torque of the retaining screws: 9 Nm.
Specification:
Operating voltage : 5 V DC
Temperature range : - 40 to 80°C
ACCELERATOR PEDAL
MODULE

1. Roller
2. Roller Shaft
3. Tradle Pin
4. Bush
5. Nut
6. Sensor
7. Mounting Screws
8. Wiring Harness
9. Tradle Cover
ENGINE SPEED SENSOR

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 through the sensor axis.
The electric pulse - frequency (Sine Wave)
generated by the sensor is proportional to the
engine speed.
ENGINE SPEED SENSOR

Installation:
The sensor is to be mounted perpendicular to the surface of
the flywheel housing using respective mounting aluminum
plate. Use recommended aluminum mounting plate
according to the flywheel.
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 Ohm ± 10% at 20 °C
ENGINE SPEED SENSOR
CAMSHAFT SPEED SENSOR
CAMSHAFT SPEED SENSOR

Function and working:

Cam speed sensor is an inductive type. It is mounted on the
FIE .Electric pulses are generated when the formed slot
inside the pump passes through sensor axis.
The electrical pulse frequency (sine wave) generated by the
sensor is proportional to the engine speed.
Installation:
Mounting as per pump guide lines. Camshaft sensor should
not be removed from the FIE
Specification:
860 Ohm ± 10% at 20ºC
 METERING UNIT

Function and working:

It is mounted on the FIE and it regulates fuel
from low pressure circuit to rail as per engine
quantity and pressure requirement defined in
the ECU. It is controlled by PWM signal from
the ECU.
 INJECTORS
Function and Working of Injector
terminal
- Timing controlled by electrical
signals to the injector solenoid.
- Injector solenoid does not directly
actuate the injector needle but it
controls the pressure in the control
volume which inturn opens the
needle.

1.Injector 2.Washer 3. Injector clamp

4 .Washer 5. Nut