EDC 17 For H-Series BSIII and BSIV Engines-Pass
EDC 17 For H-Series BSIII and BSIV Engines-Pass
MAR 2019
12.02 EDC 17 SYSTEM FOR H SERIES ENGINE
Service Manual
EDC 17 SYSTEM FOR H SERIES ENGINE
Service Manual
CONTENTS
GROUP - 12
12.12 EDC Engine Wiring Harness On Common Rail Engine With CB18 FIE System
(For 6 Cylinder Egr Engine)........................................................................... 12.42
12.13 Guidelines For Checking Sensors And Component..................................... 12.47
12.14 Precautions For EDC During Body Building................................................. 12.48
12.15 Maintenance Programme................................................................................. 12.50
Trouble Shooting Using Error Code / Blink Code........................................ 12.51
EDC 17 SYSTEM FOR H SERIES ENGINE
12.01
Service Manual
Accumulator of high pressure fuel around 1600 bar in - Electrical tapping not allowed: Tapping should
the system. not be taken as this can severely affect the
performance of the ECU and Sensors (additional
The rail volume dampens the pressure oscillates current drawn by the new load will drain the battery
generated during pumping and after needle closing. faster).
Function as a fuel distribution point to different pointers. - Care should be taken while washing the vehicle.
Do not splash water directly on to the ECU,
Advantages Accelerator pedal sensor and other electrical
components.
Separation of pressure generation and injection
allowing flexibility in controlling both the injection rates - Diagnostic connector should not be left hanging
and timing. Fuel pressure doesn’t depend on the engine loose and should be handled with care. The
speed and load conditions protective cap is to be removed only at the time of
connecting diagnostic tester.
High injection pressures and good spray preparations
are possible at even at low engines speeds and loads. - Reverse polarity protection : Care
needs to be taken while removing and connecting
Capability to deliver stable, small post injections can be
the battery connection during body building
used for decreased NOx emissions and noise.
- Check the battery condition regularly and keep the
Option for post injections may be used together with battery in a healthy condition.
such emission control technologies as particulate filters,
lean NOx, catalysts, or NOx adsorbers. - Ensure proper connectivity of ECU/ Sensor
connectors with wiring Harness and maintain
Fuel pumps operates with low drive torque. harness clamps.
Rail pressure sensor - No intermittent connector in the EDC wiring system
should be practiced ( this is not relevant from the
The rail pressure sensor sensing the pressure maintain service point of view as the harness would have
common rail and sends the signal to ECU to and ECU already been made and put on the vehicle and
sends the signal to metering unit to regulate volume of there will be no question of intermittent connector).
fuel in common rail. Stainless steel sensing element
with metal thin film strain gauges - Keep the ignition switch ‘OFF’ while removing &
Fitment of the battery connections in the vehicle.
Digital circuit concept with analogue output signal.
- Correct Tightening torques should be used for
Metering Unit mounting the ECU.
Metering unit function is controlled by a electro magnet - Do not relocate the ECU from the given location.
principle of having solenoid, present inside. As the - ECU must be connected or disconnected to the
declaration came from the ECU via Rail pressure sensor, wiring harness only when the ignition switch is in
the ECU sends the signal to regulate the fuel flow. The OFF position.
Rail pressure sensor and Metering unit are inter related to
maintain the fuel pressure in Common rail. - No undue pressure to be applied on the ECU
during service.
Injectors
- Do not let dirt or dust get inside the actuator /
Injectors functions are controlled by a electro magnet sensors or EDC components. Cover them properly.
principle of having solenoid situated at top side. When
the solenoid coil is energized, it lifts the plunger and - When disconnecting the connectors,
try to pull them out in a straight line, disengaging
allows the high pressure fuel from high pressure
the lock by holding the housing.
connector to injector inlet and the fuel fills inside the
stem of injector and finally it delivers to the combustion - Do not try to disconnect connectors by gripping
chamber. the wires or twisting them, as this could bend the
contacts.
Water in Fuel Sensor
Water in fuel sensor located at the Bottom of Prefilter.
When the water in fuel got settled at bowl, the sensing
lead senses the presence of water and sends the alarm
signals to the Dashboard. As per this alarm we have
to drain the water from the bowl by turn the cork Anti
Clockwise. Please refer the water draining procedure
follows below.
12.04 EDC 17 SYSTEM FOR H SERIES ENGINE
Service Manual
Before starting ensure that the gear is in neutral position - Switch ON the ignition
and the parking brake is applied.
- Do not depress the accelerator pedal.
If it is required to start the vehicle in a garage or
workshop, ensure that adequate ventilation is provided. - Crank engine (10 seconds maximum) until it starts.
- Fuel economy.
T
Quantity &
/ start of Injection / Pilot
Timing)
Engine
Boost Temp & Injection & Timing)
Pressure Sensor
Rail pressure Control
Oil Temp & Pressure Diagnostic Lamp
Sensor
Accelerator Pedal
Sensor
Brake Switch
Clutch Switch
Vehicle
Vehicle Speed Sensor
Dashboard Switches
Service Manual
EDC 17 SYSTEM FOR H SERIES ENGINE
ALTC/VEE/EDC / 19Sep2011 6
12.05
12.06 EDC 17 SYSTEM FOR H SERIES ENGINE
Service Manual
Metering Unit
Cam shaft speed
EGR
Oil Pr. Sensor
il Pr. sensor
Engine speed
sensor
Intermediate connector
Metering Unit
Cam shaft speed sensor
Boost Pr.
sensor EGR Actuator
EDC 17 SYSTEM FOR H SERIES ENGINE
12.07
Service Manual
EGR Actuator
12.08 EDC 17 SYSTEM FOR H SERIES ENGINE
Service Manual
H13
ECU (K)
94 POLE ASSY ECU CONNECTOR
19002829
Black
94 72 50 28
60
93 71 49 27
92 70 48 26
91 69 47 25
90 68 46 24
89 67 45 23
88 66 44 22
87 65 43 21
86 64 42 20
85 63 41 19
84 62 40 18
46
83 61 39 17
ECU (A)
82 60 38 16
81 59 37
36 14
15 H−14
80 58
79 57 35 13
78 56 34 12 5 94
77 55 33 11
76 54 32 10
75 53 31 9
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
CON 284742−60F
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
74 52 30 8
13500680
73 51 29 7
6 4 2
5 3 1
N−4
W/H EDC−Engine
(External)
60002982:HSG 62 P MCP RECP
62600679
COVER 62 WAY F HOUS
1 60
12.2.0 BOOST PRESSURE & TEMP SENSOR Boost temperature sensor signal
P0113
voltage below upper limit
Boost Pressure sensor low plausibility
P0235
error
Boost Pressure sensor High
P0236
plausibility error
Boost pressure sensor signal voltage
P0237
below lower limit
Boost pressure sensor signal voltage
P0238
below upper limit
Effect of fault in Vehicle
Function and Working - No torque/ RPM reduction but without this input to
This sensor is mounted on the intake pipe and used to ECU, smoke limitation function will not be active
measure the absolute intake-manifold pressure. On the results mild smoke & pick up loss.
version with integral temperature sensor, the temperature Possible cause of fault and Service
of the drawn-in airflow is also measured. The piezo- Recommendation:
resistive pressure sensor element and a suitable circuitry - Refer Trouble shooting using Error code / Blink
for signal amplification and temperature compensation code.
are integrated on a silicon chip. The measured pressure
operates from above to the active side of the silicon Circuit Diagram:
diaphragm. Between the backside and a glass socket a
reference vacuum is enclosed. The temperature sensor
element is an NTC-resistor. By a suitable coating process 1 Ground
the pressure and temperature sensor are resistant against
vapors and fluids existing in the intake-manifold.
2 Temperature
Installation:
3 +5V
a) The pressure sensor package is inserted into the Pressure
intake manifold and is sealed by using an O-ring, Sensor
4 Pressure
ensuring leak proof. Smear lubricant on O-ring
(non -acid paraffin oils) during fitment.
b) Maximum tightening torque of screws : 6 to10 Nm Pin configuration & Connection Details:
Specifications :
- Measuring range Pressure : 50 ……. 300 kpa A 42
29
- Temperature : -40 …… 130 °C 30 A 27
- Supply voltage : 5V DC
31 A 09
Boost pressure sensor location: 32
A 43
FAULT PATH
DTC code
(Hand held Description
Continuity check:
diagnostic tool)
Connect Multimeter across connector pins 2 and 1,the
Boost temperature sensor signal
P0112 resistance should be beyond the limit of 2.056k Ω
voltage below lower limit
(1.990kΩ to 2.123k Ω) at 25˚C.
12.10 EDC 17 SYSTEM FOR H SERIES ENGINE
Service Manual
Circuit diagram:
E K61 1 - A
K45 2 - C
K62 3 - B Accelerator
Pedal
C K83 4 - F Module Metripack Male Metripack Female
K44 5 - D
1. Roller
2. Roller Shaft
3. Tradle Pin
4. Bush
5. Nut
6. Sensor
7. Mounting Screws
8. Wiring Harness
9. Tradle Cover
FLOOR MOUNTED
1. Sensor 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
PENDANT TYPE
Check continuity at wiring harness. If error occurs replace APM and check again.
12.12 EDC 17 SYSTEM FOR H SERIES ENGINE
Service Manual
25 A54
24 A39
Engine Speed Engine ECU (A)
Sensor Interface Connector
The sensor is to be mounted perpendicular to the Connector
surface of the flywheel housing using respective
mounting aluminum plate. Use recommended aluminum A54 - (-ve), A39 - (+ve)
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:
N
Resistance : 860 Ohm ± 10% at 20 °C
S
Fault Path
Error code Description
(Hand held
diagnostic tool)
Pin Configuration & Connection Details
P0337 No crankshaft signal
P0336 Wrong crankshaft signal
P0016 Offset between camshaft and
crankshaft
P0335 Crankshaft Pos. Backup mode active
Effect of fault
Engine will run in backup mode with signal from cam
shaft sensor.
Possible cause of fault
- Faulty sensor.
- Loose contact of the sensor pin with the wiring
harness connector.
- Dust on the sensor pin or sensor tip got worn out
due to contact with the flywheel. Continuity check:
- Fitment of incorrect flywheel. Connect pins 1 and 2 of the connector to a multimeter
- Check for Sensor mounting plate faulty or sensor and check for the resistance of the coil. The resistance
mounting bolt loose. should be beyond the limit of 860 Ω ±10% (774 to 946 )
EDC 17 SYSTEM FOR H SERIES ENGINE
12.13
Service Manual
A52
34
35
A37
Specification:
Resistance : 860 Ohm ± 10% (774 to 946) at 20ºC
Air gap : 0.3 …. 1.8 mm
Fault Path
Error code Description
(Hand held
diagnostic tool)
Continuity check:
P0016 Camshaft to Crankshaft offset angle
exceeded Connect pins 1 and 2 of the connector to a multimeter
P0341 Cam shaft sensor signal Error - and check for the resistance of the coil. The resistance
disturbed signal should be beyond the limit of 860 Ω ±10%(774 Ω to
946 Ω)
P0342 Cam shaft sensor signal Error - no
signal
Effect of fault:
Engine RPM limited to 1750 if crank sensor fails / WH
problem.
Long starting time and Engine starts & runs with cam
shaft sensor signal
Possible cause of fault and Service
Recommendation:
Circuit Diagram:
12.2.5 INJECTORS FOR 6 CYLINDER ENGINE P0215 Injection cut off demand from ECU
Injector 1 - Short circuit between
P0261
positive and negative
P0262 Injector 1 general short circuit
MOUNTING BOLT
Injector 2 - Short circuit between
P0264
positive and negative
P0265 Injector 2 general short circuit
Injector 3 - Short circuit between
WASHER P0267
positive and negative
P0268 Injector 3 general short circuit
Injector 4 - Short circuit between
INJECTOR CLAMP P0270
positive and negative
P0271 Injector 4 general short circuit
Injector 5 - Short circuit between
P0273
positive and negative
P0274 Injector 5 general short circuit
Injector 6 - Short circuit between
P0276
positive and negative
P0277 Injector 6 general short circuit
INJECTOR ECU/Injector Defective - Loss of
P1411 synchronization sending bytes to
the MM from CPU.
ECU/Injector Defective - Wrong set
P1412
response time
ECU/Injector Defective - Too many SPI
P1413
errors during MoCSOP execution.
ECU/Injector Defective - Diagnos-
P1415 tic fault check to report the error in
undervoltage monitoring
ECU/Injector Defective - Diagnostic
P1416 fault check to report that WDA is not
working correct
COPPER WASHER ECU/Injector Defective - OS timeout
P1417 in the shut off path test. Failure set-
Function and Working of Injector terminal ting the alarm task period.
ECU/Injector Defective - Diagnostic
- Solenoid injector will deliver the calculated fuel & P1419 fault check to report the timeout in
pressure into the engine with respect to engine the shut off path test
operating range based on electrical input from ECU/Injector Defective - Diagnos-
ECU. P1420 tic fault check to report the error in
Fault Path - 6 CYLINDER overvoltage monitoring
ECU/Injector Defective - DFC to set
Error Code a torque limitation once an error is
P1431
(Hand held Description detected before MoCSOP’s error
diagnostic tool) reaction is set
P0201 Injector 1 open load ECU/Injector Defective - Diagnostic
P1432 fault check to report that the posi-
P0202 Injector 2 open load
tive test failed
P0203 Injector 3 open load
Effect of Fault on Vehicle
P0204 Injector 4 open load
P0205 Injector 5 open load RPM limited to 1750 if injector system fails.
P0206 Injector 6 open load Severe engine hunting, pick up loss & vibration will be
observed if more injectors system is disconnected
P1342 Bank 1 application dependant error
12.16 EDC 17 SYSTEM FOR H SERIES ENGINE
Service Manual
Circuit Diagram
6 CYLINDER
3 A33
Cylinder 1
Injector 4 A16
5 A47
Cylinder 2
Injector 6 A17
7 A48
Cylinder 3
Injector 8 A18
10 A31
Cylinder 4
Injector 9 A01
Cylinder 5 14 A46
Injector
13 A03
Cylinder 6 12 A32
Injector 11 A02
Service Recommendation
- Check for physical contact of injector terminal or wiring harness short with each other.
- Check for continuity of the injector terminal with ECU side connector as per terminal Diagram
EDC 17 SYSTEM FOR H SERIES ENGINE
12.17
Service Manual
Retaining ring
ting the alarm task period.
Clamping - flats
Injector - body
Protection cap
P1419 fault check to report the timeout in
(for Return - flow connector)
the shut off path test
ECU/Injector Defective - Diagnos-
Nozzle - nut
Circuit Diagram
A28
27
28
A29
Function and working: Engine
It is a thermistor, mounted on coolant return line to Coolant ECU (A)
measure the coolant outlet temperature. It’s based on Temp Interface Connector
NTC (NTC = Negative Temperature Coefficient) principle Sensor Connector
which when exposed to external heat, resistance drops
drastically and, provided the supply voltage remains
constant, their input current climbs rapidly. This property Pin Configuration & Connection Details
can be utilized for temperature measurement
Installation
Tightening torque : 20 - 25 Nm
Specifications
Temperature range : - 40 to 130°C
Rated voltage : Operation by pull up resistance
of 2.056k Ω (1.940k Ω to 2.173k
Ω) at 25˚C.
Fault Path
P0118 Coolant temperature sensor signal Connect a multimeter across the two terminals and
voltage above upper limit measure the resistance across it. It should show a
resistance beyond the limit of 2.056k Ω (1.940k Ω to
P0117 Coolant temperature sensor signal
2.173k Ω)at 25˚C.
voltage above lower limit
Effect of fault
In case of sensor failure,
1) It has been programmed to switch over to default
value of 99.5°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.
The vehicle will run in a reduce power mode.
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
EDC 17 SYSTEM FOR H SERIES ENGINE
12.19
Service Manual
R
Rohm
36 A25
37 A26
38 A07
Function:
Rail pressure sensor is used to measure and maintain Rail Pressure Engine Interface ECU (A)
the required fuel pressure inside the common rail. Sensor Connector Connector
20
53
NC
52 19
54 12
55 40
56 22
It is mounted on the EGR cooler and regulates the Pin Configuration and Connector details
NOx emission by recirculating a portion of the engine
exhaust gas from exhaust manifold to the combustion
chamber through the air intake system. It is controlled
by PWM signal from Engine ECU.
Fault Path
Error Code
(Hand Held Description
Diagnostic tool)
Effect of Fault
Installation:
Specifications:
ECU
PIN
K68
K14
I_S_BRKREDOP Redundant
Brake Switch
EDC 17 SYSTEM FOR H SERIES ENGINE
12.23
Service Manual
12.4 DIAGNOSTIC LAMP AND REQUEST The following counters can be read through diagnostic
SWITCHES tester:
NOTE
1 1 1
Diagnostic lamp is only an indicator of any error K36 2
3 Pole Water In
Intermediate
reported. ECU
(Optional)
2 2 Fuel
Sensor
K21 3 3 3
Pin Configuration & Connection details and Circuit
Diagram
X
O_S_WFLP Lamp
the change in conductivity in turn gives a voltage output. K92
This is sensed by the ECU and water level threshold ECU PIN
O_V_RH
is identified with the voltage threshold range as per
K89
specification and finalized after trials (partial, slow fill,
gradient etc)
AC switch status read from AC request SW relay (R06) and the output of the relay is given to engine ECU for RPM
shifting. Engine rpm will be shifted from idling rpm (w/o AC request) to 800rpm if AC switch is on.
Specification:
Starting control
The starter motor is controlled by Engine ECU. The ECU control starting feature is for protection against re-
cranking, over cranking and inching. Hence the starter motor life will be increased.
Crank position output from the ignition switch is given to ECU. The ECU will energize the starter relay and start the
engine when the driver starts the engine.
Specification:
Note: The starter motor could not start without starter relay.
EDC 17 SYSTEM FOR H SERIES ENGINE
12.25
Service Manual
L H
y AMT CAN
L H
y Cluster CAN UREA
TANK
L
& ACU
H
y Diagnostic CAN
L H
L H L H
y
y y
VEHICLE VEHICLE
Engine ACU CAN Terminating
FRONT REAR
Resistor
L H
y Engine CAN
Specific 3 way triangular connectors (Deutsch make) have been used in the CAN backbone wire harness.
Terminating resistor 120 ohms has been used in the CAN backbone to ensure proper communication.
12.26 EDC 17 SYSTEM FOR H SERIES ENGINE
Service Manual
12.7 DIAGNOSTICS
24V
Battery +ve
16
Diagnostic Connector
K2 4
E
14 Can Low
K76
5
C
K54 6 Can High
U
K59 7
59
This is a 16 pin D type connector provided with cap for On Board Diagnostics (OBD). 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.
CAUTION
Always ensure that the diagnostic connector is covered with cap when not in use.
Once the defective circuit is identified with the help of the diagnostic tool, please refer the service instruction
pertaining to that sensor / actuator circuit.
12.28 EDC 17 SYSTEM FOR H SERIES ENGINE
Service Manual
1. Press the Diagnostic Request Switch, hold for 3 - 5 seconds and release it.
2. The Diagnostic Lamp in the instrument cluster will start blinking in a pattern to show a blink code (refer
attached list - 1st digit at a higher interval & 2nd digit at a lower interval of time).
4. The blink code will be displayed for priority errors (up to 10) stored in the ECU error memory.
With the help of blink code and the vehicle behaviour, Diagnosis and fault finding is possible. Rectification of
particular error clears the error memory.
Refer end of the manual for Error codes and Blink codes.
EDC 17 SYSTEM FOR H SERIES ENGINE
12.29
Service Manual
Live Data
Sl.No Description Unit
Parameter Set 1
1 Engine Speed rpm
2 Vehicle speed kmph
3 Accelerator pedal Unfiltered value %
4 Injection qty - current mg/st
5 Injection quantity - torque generating mg/st
6 Boost pressure hpa
7 Atmospheric pressure hpa
8 Engine coolant temperature ºC
9 Oil temperature filtered value ºC
10 Boost temperature filtered value ºC
11 Oil pressure filtered value hpa
12 Battery voltage mV
13 Camshaft speed rpm
14 Engine Speed gradient rpm/s
15 Low Idle Speed rpm
16 Gear number -
17 Fuel Temperature deg C
Parameter Set 2
17 Rail pressure - actual hpa
18 Rail pressure - setpoint hpa
19 Metering unit set point current mA
20 Metering unit filtered actual current mA
21 Metering unit PWM signal output %
22 Metering unit set volume flow mm3 / sec
23 Rail pressure control loop status -
24 Ratio of the torque to the max torque %
25 Final torque Nm
26 Torque limitation status -
27 Main injection qty mg/st
28 Pilot 1 injection qty mg/st
29 Post 2 injection qty mg/st
30 Exhaust flap Duty Cycle to power stage %
Parameter Set 3
31 Accelerator pedal 1 raw value mV
32 Accelerator pedal 2 raw value mV
33 Raw voltage of Rail pressure mV
34 Boost pressure sensor raw voltage mV
35 Boost temperature sensor raw voltage mV
36 Atmospheric pressure raw voltage mV
37 Metering unit sensor output raw voltage mV
38 Engine coolant temperature raw voltage mV
39 Oil pressure sensor raw voltage mV
40 Fuel temperature sensor raw voltage mV
Parameter Set 4
40 EGR Proportional valve duty cycle %
41 EGR raw voltage at open position mV
42 EGR position sensor raw voltage mV
43 EGR position - demand %
44 EGR position - actual %
12.30 EDC 17 SYSTEM FOR H SERIES ENGINE
Service Manual
Live Data
Sl.No Description Unit
45 EGR raw voltage at closed position mV
46 EGR Governor+Duty cycle output %
Parameter Set 5
47 Engine operation status - Cranking/Start/Afterrun -
48 Syncronization status -
49 Clutch status -
50 Brake status -
51 Brake status main -
52 Brake status redundant -
53 Ignition status - On/Off -
54 Engine Brake swtich signal raw value -
55 SVS request status -
56 MIL request status -
57 Glow lamp status -
Parameter Set 6
58 AC switch status -
59 Air conditioner On/Off Status -
60 Fan Speed filtered rpm
61 Fan speed setpoint %
62 Fan duty cycle output %
63 Cruise Control Plus Switch -
64 Cruise Control Minus Switch -
65 Cruise Control Off Switch -
66 Cruise Control Resume Switch -
67 PTO switch raw input voltage mV
68 PTO switch status -
Parameter Set 7
69 Fuel quantity - Cumulative
70 Total time PRV Closed minutes
71 Number of times PRV opened -
72 Engine ON time - Cumulative sec
73 Engine operation kilometer - Cumulative km
74 Water in Fuel detection timer -
75 Water in Fuel detection counter -
Parameter Set 8
Value of the rail pressure sensor voltage during active
76 hpa
monitoring in the starting phase
EDC 17 SYSTEM FOR H SERIES ENGINE
12.31
Service Manual
Sl.
Description Vehicle Behaviour in case of Failures
No.
Limp home functions
Limp home - Engine speed limited to 1450 rpm and accelerator pedal
1 Accelerator Pedal sensor failure
no response
Torque reduction and engine stop
Crank or Cam Speed sensor or oil temperature Engine speed limited to 1750 rpm for 6 cylinder and 1580 rpm for 4
2
sensor failure cylinder engines
One Injector failure or Open load and short circuit
3 Engine speed limited to 1750 rpm and drop in pick-up.
between injectors
4 Rail Pressure sensor or Metering Unit failure 40% Torque reduction and Pressure Relief Valve (PRV) open
Oil pressure sensor failure or water in fuel sensor
5 40% Torque reduction and engine speed limited to 1750 rpm
detects water in fuel
Low oil Pressure in system or Both coolant and oil
6 80% Torque reduction
temperature sensor failure
7 Engine coolant sensor failure 30% torque reduction and engine over heat
9 Both crank and cam sensor failure Engine will not start
10 Improper connectivity or malfunction of starter relay Engine will not start (ECU controlled start function)
Other malfunctions
11 Vehicle speed sensor Engine speed limited to specific rpm (as per legislation)
Brake switch or Clutch switch or Dashboard lamps
12 No Reaction
or switches failure
OBD II related malfunctions (Applicable only for BS IV vehicles)
14 Identified faults that causes NOx above OBD limit 2 40% Torque Limitation + MIL ON
12.32 EDC 17 SYSTEM FOR H SERIES ENGINE
Service Manual
CIRCUIT DIAGRAM - RELAYS AND FUSES FOR CRS EDC 17 SYSTEM - EDC17CV54
R−1
RELAY
1 4 7
2 5 8
3 6 9
O/P I/P
1 2
F−1 3 4
Fuse Base 5 6
7 8
9 10
11 12
60000608
Cross referance for Relay Base & Relay
Relay Ckt Diagram
2 E 87
4 A 86
8 B 30
6 C 85 30 85 86 87 87a
12.34 EDC 17 SYSTEM FOR H SERIES ENGINE
Service Manual
Required Instruments:
a) Diagnostic Tool
Electronic fuel injection equipment is used along with sensors for precise control of injected fuel quantity.
Common rail engines has the following electronic components and sensors.
• Camshaft Speed Sensor (CaS - DG6) - Mounted on the FIE mounting flange.
• Oil Pressure and Temperature Sensor (OPTS) - Mounted on the Aluminum housing of Oil cooler unit.
Above components on the engine are coupled with the connectors in Engine Wiring Harness which terminates at
an Intermediate Connector. This is recoupled with the mating connector of Vehicle Wiring Harness.
Through Intermediate Connector sensors/ actuators on engine are connected to Electronic Control Unit (ECU),
which is mounted on chassis
The fuel injection system is electronically controlled by the ECU. It receives signal from the sensors on engine /
vehicle and actuates the Metering Unit and Injectors for optimum fuel injection to achieve desired performance.
For satisfactory and safe operation of Electronic Diesel Control System, proper connection of sensors, actuators
and wiring harness is necessary.
EDC 17 SYSTEM FOR H SERIES ENGINE
12.35
Service Manual
2
The corrugated sleeve contains 6 branches for 6
injectors. Each branch contains a sticker with cylinder
no. printed on it. (e.g. Cyl 1, Cyl 2 etc.) & Furr Clip for
insertion on bracket hole.
Injector Routing 3
2 2
1. Furr-tree clipping
3 1
2
4
2
Electromagnetic Fan
Oil Pressure Sensor (Non-Ac Model alternator Oil Pressure Sensor (AC-Model alternator bracket)
bracket)
1 2
1
2
1. Cable Tie
1. Oil Pressure Sensor
2. Water filter pipe
Injector Routing
• All Injector have the mating connector
and all injector have sticker marked
with cylinder no.
Route the corrugated sleeve containing connectors
for Boost Pressure sensor, Coolant temp sensor,
toward front side of engine taking it through behind
the intermediate connector.
1
3
1
1. Coolant temp sensor connection 1. Tie the fuel temp sensor with cable tie
2. Boost Pressure sensor connection 2. Camshaft Speed sensor
3. Furr-Tree clip on bracket
Connect the connectors of wiring harness for boost
pressure sensor and coolant temp sensor to the
respective sensors on engine. The wiring harness
cables contain the sticker marked with labels BPS, CTS
for identification.
1. Furr-tree clipping
Part of wiring harness Connect the connectors of wiring harness for Fuel
temperature sensor and Camshaft Speed sensor to the
respective sensors on FIP.
3
2
4
Route the corrugated sleeve containing branch for Engine Speed Sensor
Rail Pressure sensor, crankshaft speed sensor, grid
heater and vehicle speed sensor towards rear side of
the engine along with the bracket (X0400911) fitted with
intake manifold.
2
1
2
1
Electromagnetic Fan
Wiring
Harness
intermediate
connector
Part of wiring harness.
Route the corrugated sleeve containing connectors
for Boost Pressure sensor, Coolant temp sensor,
toward front side of engine taking it through behind the
Bracket for intermediate connector.
intermediate
connector
Connect the connectors of wiring harness for boost pressure sensor The wiring harness cables contain the sticker
marked with labels BPS for identification.
Coolant temperature sensor
The cable for coolant temp sensor is to be tied using fur clip on the bracket (X0400811) fitted with intake manifold.
Route the corrugated sleeve through mounting bracket containing Coolant , OIL and Cam speed sensors, with
necessary furr cilp on the holes.
12.44 EDC 17 SYSTEM FOR H SERIES ENGINE
Service Manual
Furr-tree clipping
Rail Pressure
sensor connection
• Connect the Crankshaft speed sensor branch to the Speed sensor mounted on flywheel housing.
• Wrap the cable branching for vehicle speed sensor connection and tie it using cable strap X0600360.
Electromagnetic Fan
EMF Connection
• Wrap the cable branching for EMF connection and tie it using cable strap X0600360.
12.46 EDC 17 SYSTEM FOR H SERIES ENGINE
Service Manual
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.
12.48 EDC 17 SYSTEM FOR H SERIES ENGINE
Service Manual
3. Maximum cleanliness in the work area and the 6. Push start is possible when starter motor is not
tools should be employed . Check to see if the functioning properly and battery output is 18 Volts
ECU has become dirty during the body building is minimum.
phase especially at the connector end and pins. 7. Before connecting the engine wiring harness,
Use a soft clean & dry paint brush to remove the the battery terminals (Both positive and negative
dust. terminals) are to be disconnected.
Ashok Leyland specific: 8. Make sure that the lock of the connectors are fitted
Ensure that the intermediate connector (supply +ve properly.
and -ve for ECU) between the DC to DC converter and 9. Clip/clamp the wiring harness every 500 mm.
wiring harness is properly locked and intact.
EDC System
Have a clear space in front of the EDC panel cover for
easy removal and fitment of electrical/electronic parts
of EDC panel.
Instructions
1. Before and during welding
- Disconnect battery terminals (Positive and
Negative terminals of 24V supply).
- Disconnect Two connectors of the ECU and have
the panel cover refitted.
- Avoid falling of hot weld spatters on wiring harness,
sensors and Accelerator Pedal Module.
- Do not use Accelerator Pedal as a support during
body building.
- Avoid falling of any sharp/Heavy objects on the
accelerator pedal module and its connecting wire.
- Do not disturb the clamps of EDC system wiring
harness unless it is very essential, but ensure it is
replaced/refitted properly.
EDC 17 SYSTEM FOR H SERIES ENGINE
12.49
Service Manual
Do’s and Don’ts for Body builders, Field service 16. Ensure proper fitment of 15A fuse of the battery
positive cable. The spare fuses (30A - 1 no. and 5A
Do’s
- 2 nos.) is available in the relay and fuse module.
1. Reverse polarity protection: Care needs to be
17. Ensure that the ignition switch and battery isolator
taken while removing the battery connection
switch is off when the vehicle is in parked condition.
during body building and reconnect the terminals
in correct polarity. Dont’s
2. Check the battery condition regularly and keep the 1. Electrical tapping (EDC 24V/5V) not allowed from
batteries in healthy condition. EDC wiring. Tapping should NOT be taken as this
can severely affect the performance of the ECU
3. Ensure proper connectivity of ECU/Sensor
and sensor (Discourage use of 24V by centre
connectors with wiring harness.
tapping method from batteries for additional loads)
4. Keep the ignition “Switch Off” while removing/
2. Care should be taken while washing the vehicle.
reconnecting the battery connections in the
Do not direct jet of water on to the ECU, accelerator
vehicle.
pedal sensors and other electrical components.
5. Correct tightening torques should be used for
3. Diagnostic connector should not be left hanging
mounting the ECU and other electrical/electronic
loose and should be handled with care.
parts on EDC panel. 8 ± 2 Nm torque (M6 - 8.8 Gr).
4. Do not allow / provide intermittent connections
6. Connectors of the ECU must be connected or
/ junction in the EDC wiring harness. Maintain
disconnected only when the power is switched off/
routing and clamping of wiring as provided by AL.
ignition switch is in off position.
5. Do not change mounting position of the ECU/EDC
7. Carryout trouble shooting of EDC system with
panel.
diagnostic tool.
6. No undue pressure to be applied on the ECU
8. Continuity check on the wiring harness with
during the service.
opened connector ends (No power supply to ECU
can be done, if it is found extremely essential and 7. Do not touch the pins of the ECU to avoid damage
unavoidable. Care must be taken not to damage due to electrostatic discharge.
the terminals, pins and seals.
8. Never attempt to connect negative battery cable
9. Attempt verification/checking of EDC system parts to positive terminal of battery and positive battery
including wiring harness after confirming and cable to negative terminal of battery. This will
clearing identified mechanical troubles as there damage the EDC system electronic / electrical
might be a wrong lead of EDC malfunction due to units.
effect of mechanical troubles.
9. Do not test (continuity check) ECU pins with
10. Advice drivers on Limp home functions, Speed multimeter.
lImitations and Torque reduction functions.
10. Developed independent wiring harness for EDC
11. Ensure diagnostic connector cap is present always system is provided with prewired connectors to
to avoid dust / water entry and shorting. Protect avoid any disturbances and disconnection unless
diagnostic connector from tampering / damage. it is induced.
12. Run EDC system engine always with batteries 11. Do not use spanners / other heavy tools to remove
connected. the sensor and ECU connectors.
13. Ensure paint removal on the surface / clean 12. While coiling or bending of cables / wires avoid
surface before connecting the negative connection sharp bends or folding.
of EDC system and the high current negative of
13. Do not lift the wiring harness bunch by the end
vehicle electrical connection.
connectors.
14. Check if all the connectors are positioned properly
14. Do not jump start the vehicle (by connecting
and well connected. Positive locking to be ensured.
external batteries - master / slave method). This
15. Check if the relays and fuses are properly inserted will cause series damage to the ECU.
in the relay and fuse module respectively.
12.50 EDC 17 SYSTEM FOR H SERIES ENGINE
Service Manual
Customer Workshop
Check Check
SL.
MAINTENANCE ACTIVITY Remarks
No.
Weekly
Every
Daily
km x 1000
PDI
1 Check for engine full acceleration (Throttle response) ü
Check tightness of all mating connectors and ensure they are connected
2 ü
properly
Check and secure wiring harness away from temperature zones on the
3 ü 40
engine/vehicle
Check tightness of engine speed sensors and clean the sensor tip for any
4 ü 40
dirt/dust deposits
After
body
Check functioning of EDC and sensors with diagnostic tool & clear error
5 ü 80 building
codes if any. Also check the correctness of data set ID
if sold as
chassis.
Check proper functioning of MIL lamp and EDC lamp. Both lamp should
6 ü
turn off in Engine running condition.
Check and note - Idle rpm and flyup rpm achieved with 100% accelerator
7 ü
position in static condition.
Switch off Ignition key and isolator switch - Check and ensure proper
8 ü
locking of all ECU and Sensor connectors.
EDC 17 SYSTEM FOR H SERIES ENGINE 12.51
Service Manual
TROUBLE SHOOTING
USING ERROR CODE / BLINK CODE
12.52 EDC 17 SYSTEM FOR H SERIES ENGINE
Service Manual
Ensure the metering unit wiring harness check. (Refer check point --- Remove the pump and get it checked from the authorised
Pump metering unit wiring ahrness issues
P0193 & P0192 (Sl no16 & 17 ) dealer
Ensure Rail pressure wiring harness check. (Refer check point of p code
Rail pressure sensor wiring harness issues Replace / Rectify the wiring harnness
---P0090, P1119 & P1120 (Sl no32, 33 & 34 )
Incorrect/small/sharp bend in diameter fuel Change the fuel return lines
Visual inspection-Check for the bends/crimps in the fuel return line.
return lines.
Chocked fuel return lines,zero delivery throt-
Remove the return line and check for blockage
tle clogged up.
i) Using omitec diagnostic scan tool goto actuators test via Ashok
P1108 diagnostics--->Diesel--->Engine---> Autodetect--->Actuators test.
(Ms code) Pump metering unit is stuck in open position ii) Select metering unit from the list. Replace the metering unit.
19 maximum rail pressure exceeded iii) Increase the duty cycle to 40% in engine idling condition.
P0088
(OBD) iv) Engine should shut off
Injector struck in closed possition engine vibration check, MORSE test for Injector through tester . Replace the injector .
Ensure the rail pressure wiring harness check. (Refer check point ---
Replace / Rectify the wiring harnness
Rail pressure sensor wiring harness issues P0193 & P0192 (Sl no16 & 17 ) -
Ensure pump metering unit wiring harness check. (Refer check point of Remove the pump and get it checked from the authorised
Pump metering unit wiring ahrness issues
p code ---P0090, P1119 & P1120 (Sl no32, 33 & 34 dealer
Rail pressure below the min value w.r.t
1. Check for the bends/crimps in the fuel suction line. Change the fuel return lines
engine speed
2. Check the fuel level in fuel tank Fill fuel in sufficient level
No check points
Injector nozzle stuck in the open position
1. Change the fuel filter
Filter clogged Check fuel filter/strainer
2. Clean the fuel tank strainer
EDC 17 SYSTEM FOR H SERIES ENGINE 12.57
Service Manual
No electrical continuity between ECU to Check the continuity between pin no A31 & A01 with (Interconnector 9 &
Rectify / Replace wire harness if ther is a continuity
injector connector. 10 ) injector connector 13 & 14
1. Isolate the W.H and Check for SSPMon1pin[A09, A21, A24, K43, K44]
(connecter end) short circuit with Battery/ground
P1800 (Ms 2. Check all the component connected to SSPMon1 is shorted with bat- 1. replace/rectify W.H.
SSPMon1 Supply line(incl of Sensor, W.H,
94 code) Error Sensor power supply 1 tery/ground.Components are 2. replace ECU.
ECU) short with Battery/Ground
P0641(OBD) 1. Boost pressure sensor (A09) 3. replace Booat pressure and Oil pressure sensor
2. Oil pressure and temperature sensor (A24)
1. Isolate the W.H and Check for SSPMon2pin[A08, A22, K23, K45, K46
(connecter end) continuity with Battery/ground
P1801 (Ms - If continuity is there, replace/rectify W.H 1. replace/rectify W.H.
SSPMon2 Supply line(incl of Sensor, W.H,
95 code) Error Sensor power supply 2 2. Check all the component connected to SSPMon2 is shorted with bat- 2. replace ECU.
ECU) short with Battery/Ground
P0651(OBD) tery/ground.Components are 3. replace EGRVlv position sensor and Accelerator pedal
1. EGR valve position sensor (A22)
2. Accelarator pedal(K45)
1. Isolate the W.H and Check for SSPMon3pin[A07, K24] (connecter end)
continuity with Battery/ground
P1802 (Ms - If continuity is there, replace/rectify W.H 1. replace/rectify W.H.
SSPMon3 Supply line(incl of Sensor, W.H,
96 code) Error Sensor power supply 3 2. Check all the component connected to SSPMon3 is shorted with bat- 2. replace ECU.
ECU) short with Battery/Ground
P0697(OBD) tery/ground 3. replace Rail pressure sensor
Components are
1.Rail pressure sensor (A07)
12.70 EDC 17 SYSTEM FOR H SERIES ENGINE
Service Manual
1. Isolate the W.H and Check for UB2(connecter end) continuity with
K01/03/05
- If continuity is there, replace/rectify the W.H
2. Check any short in ECU connector side between UB2[….] and battery
pin
3. Check all the component connected to UB2 is shorted with battery
UB2 connected components K68
1. Brake switch (K68, K41 & K14)
UB2 lines [K68, K41, K14, K18, K37, K32, 2. Cruise control (K18, K37, K32)
K15, K38, K22, K66, K71, K48, K40, K29, 3. Clutch switch (K15)
K72, K27, K47, K70, K65, A35, A45] inlcusive 4. Parking brake switch (K38)
P1A00 (Ms Acuator relay Short circuit to battery
97 of component, W.H & ECU shorted with 5. AC request switch (K22) replace WH/Components connected
code) error
Battery 6. Diagnostic request switch (K66)
7. OBD lamp (K71)
(this error reports only during afterrun) 8. Cold start lamp (K48)
9. Engine brake switch (K40)
UB2 connected components K29
10. Grid heater relay (K72)
11. Fuel heater relay (K27)
12. Exhaust flap (K47)
13. Diagnostic lamp (K70, K65)
UB2 connected components A45
14. EGR valve (A35, A45)
1. Isolate the W.H and Check for UB3(connecter end) continuity with
K01/03/05
- If continuity is there, replace/rectify the W.H
2. Check any short in ECU connector side between UB3[….] and battery
pin
3. Check all the component connected to UB3 is shorted with battery
UB3 lines [K51, K26, K25, K89, K92, K93, UB3 connected components K51
K94, K50, K90, K28] inlcusive of component, AC compressor relay(K26)
P1A01 (Ms Acuator relay Short circuit to battery
98 W.H & ECU shorted with Battery Fan relay(K25) replace WH/Components connected
code) error
UB3 connected components K89
(this error reports only during afterrun) Water in fuel lamp(K92)
Coolant temperature warning lamp (K93)
Oil pressure warning lamp (K94)
EGR shut off valve (K50)
UB3 connected components K90
Starter relay
1. Isolate the W.H and Check for UB2(connecter end) continuity with
UB2 lines [K68, K41, K14, K18, K37, K32,
P1A02 Ground/K02/04/06
K15, K38, K22, K66, K71, K48, K40, K29,
(Ms code) Acuator relay Short circuit to ground - If continuity is there, replace/rectify the W.H
99 K72, K27, K47, K70, K65, A35, A45] inlcusive If error still persists, replace the ECU
P02670 error 2. Check any short in ECU connector side between UB2[….] and any
of component, W.H & ECU shorted with
(OBD) ground pin
Ground
3. Check all the component connected to UB2 is shorted with ground
1. Isolate the W.H and Check for UB3 pins (connecter end) continuity
with Ground/K02/04/06
UB3 lines [K51, K26, K25, K89, K92, K93,
P1A03 (Ms Acuator relay Short circuit to ground - If continuity is there, replace/rectify the W.H
100 K94, K50, K90, K28] inlcusive of component, If error still persists, replace the ECU
code)(OBD) error 2. Check any short in ECU connector side between UB3 pins and any
W.H & ECU shorted with Ground
ground pin
3. Check all the component connected to UB3 is shorted with ground
EDC 17 SYSTEM FOR H SERIES ENGINE 12.71
Service Manual
P1111 (Ms PRV reached maximun allowed open Total time for PLV open condition exceeded
103 Check total time through tester Change the rail
code) time the limit
P1110 (Ms PRV reached maximun allowed opening Total counter for PLV open condition ex-
104 Check count through tester Change the rail
code) count ceeded the limit
Fleet guard
Check the wiring harenss continuity from K36 on ECU pin to 1 on the
sensor pin.
Check the wiring harenss continuity from K21 on ECU pin to 2 on the
sensor pin.
MHBI
Check the wiring harenss continuity from K68 on ECU pin to 1 on the Rectify/Replace the WH
No electrical continuity / shortcircuit between
sensor pin.
ECU to waterlevel sensor.
P1521 (Ms Water-in-Fuel Sensor signal voltage Check the wiring harenss continuity from K36 on ECU pin to 2 on the
109
code) above upper limit sensor pin.
Check the wiring harenss continuity from K21 on ECU pin to 3 on the
sensor pin.
EGR Valve position sensor signal voltage Signal line short to supply (5Volts) 2. pin no A12 & A22 on the ECU connector
149 P0406 3. pin no 54 & 56 on the interconnector
above upper limit
Thershould not be any continuity in any of the case.
Check the voltage between
1. pin no 2 & 4 on the sensor connector
Signal line short to battery (greater than 5
2. pin no A12 & A40 on the ECU connector
Volts)
3. pin no 54 & 55 on the interconnector
Ther should not be more than 5V in any of the case.
1. Check Wiring Harness continuity & short Circuit
2. Remove sensor end connector
3. Check for the sensor error in TesterIf Error is registered, then connect
Sensor defective Replace EGR with cooler - If the voltage out of specified limit
the sensor end connector and erase the error code
4. Check the Sensor signal voltage thru tester (Live data-Parameter 3)
The voltage spec should be 0.6V to 0.8V when ignition ON condition
If all the above check points are ok Replace ECU / Faulty ECU
ECU defective No check points
to be sent for investigated
Check the Sensor signal voltage thru tester (Parameter 3) when ignition
P0191(OBD) Rail pressure raw value is below mini-
150 1. Rail pressure sensor malfunction/ drift is on. Replace sensor if the voltage is not with in specification.
P25E6 mum offset
Voltage should be 500±48mV.
12.76 EDC 17 SYSTEM FOR H SERIES ENGINE
Service Manual
Check the Sensor signal voltage thru tester (Parameter 3) when ignition
P0191(OBD) Rail pressure raw value is below Maxi-
151 1. Rail pressure sensor malfunction/ drift is on. Replace sensor if the voltage is not with in specification.
P25E5 mum offset
Voltage should be 500±48mV.
162 P2535 Defective T50 switch Wiring harness problem Check continuity between K35 and T50 switch.
P1019(MS
Timeout Error of CAN-Receive-Frame
165 Code)
TSC1VE(SCR)
P0113(OBD)
S.No P-Code Description Reactions Possible causes Check Points Further Actions
S.No P-Code Description Reactions Possible causes Check Points Further Actions