EDC 17 For H-Series BSIII and BSIV Engines-Pass

EDC17 SYSTEM
( FOR H SERIES CRS BSIII & BSIV ENGINES

FITTED WITH CRS ECU ( X3995300 ) )
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
EDC 17 SYSTEM FOR H SERIES BSIII & BSIV ENGINE
Section Subject Page No.
12.0 Electronic Diesel Control................................................................................ 12.01
12.1 Engine Start / Stop Procedure...................................................................... 12.04

12.2 Sensors And Actuators................................................................................... 12.05
12.2.0 Boost Pressure & Temp Sensor.................................................................. 12.09
12.2.1 Accelerator Pedal Sensor............................................................................ 12.10

12.2.2 Engine Speed Sensor.................................................................................. 12.12
12.2.3 Camshaft Speed Sensor.............................................................................. 12.13
12.2.4 Metering Unit............................................................................................... 12.14
12.2.5 Injectors For 6 Cylinder Engine................................................................... 12.15
12.2.6 Injectors For 4 Cylinder Engine................................................................... 12.17
12.2.7 Coolant Temperature Sensor....................................................................... 12.18
12.2.8 Oil Pressure & Temperature Sensor............................................................ 12.19
12.2.9 Rail Pressure Sensor................................................................................... 12.20
12.2.10 Vehicle Speed Sensor................................................................................. 12.20
12.2.11 Exhaust Gas Recirculation........................................................................... 12.21
12.3 Switches........................................................................................................... 12.22
12.3.0 Brake Signal Switch ................................................................................... 12.22
12.3.1 Clutch Signal Switch.................................................................................... 12.22
12.4 Diagnostic Lamp And Request Switches...................................................... 12.23
12.4.0 Water In Fuel Sensor And Lamp................................................................. 12.23
12.5 AC Switch Signal............................................................................................. 12.24
12.6 CAN Backbone................................................................................................. 12.25
12.7 Diagnostics...................................................................................................... 12.26
12.7.0 Diagnostic Concept...................................................................................... 12.26
12.7.1 Diagnostic Tester......................................................................................... 12.26
12.7.2 Diagnostic Request Switch And Blink Code................................................ 12.28
12.8 Limp Home And Edc Failure Reaction Functions........................................ 12.31
12.9 Inspection Of Parts & Connections Against Complaint............................... 12.34
12.10 EDC Engine Wiring Harness On Common Rail Engine With CB28 FIE System. 12.35
12.11 EDC Engine Wiring Harness On Common Rail Engine With CB18 FIE System. 12.39
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
12.01
Service Manual
12.0 ELECTRONIC DIESEL CONTROL - Clutch pedal switch

EDC17 (CRS H Series Engine) - Vehicle speed sensor
- Wiring harness.
Modern engine development is driven by legislative
In EDC system, the injected fuel quantity is based
emission requirements and growing vehicle electronic
on the following.
architecture in the market. Following are the legislation
and market driven needs. - The vehicle response desired by the driver,
communicated through the accelerator pedal
1. High fuel injection pressure position sensor.
2. Fuel injection independent of pressure generation - The engine operating temperature
and engine speed. - Boost pressure and temperature
3. Multiple injections ( BSIII - Main, Pilot & Post - Engine speed Atmospheric pressure Proper
Injection) functionality of EDC components.
4. Flexible in fuel quantity, injection timing and fuel
injection pressure independent of engine speed. EDC system is subdivided into
5. Environmental (Ambient, Coolant temperature etc.,) 1. Sensors
/ Altitude dependent fuel quantity adjustment. Detect the engine operating conditions and the driver’s
6. Integration with other vehicle systems (Automatic demand. They convert physical variables into electrical
transmission, ABS etc.,) signals.
The EDC (Electronic diesel control) system is capable
2. Electronic Control Unit (ECU)
of meeting the demands outlined above.
Processes the information received from the sensors. It
In EDC system, the driver has no direct control over the controls the actuators through electrical output signals.
injected fuel quantity through the accelerator pedal It also provides interfaces with other systems like
diagnostic tool, ABS etc.
The injected fuel quantity is based on
3. Actuators
1. The vehicle response desired by the
driver communicated through the accelerator Convert the electrical signal from the ECU into physical
pedal sensor with the help of ECU. variable.
CONTROLS
2. The engine operating conditions
Open and Closed Loop Electronic Control
3. The engine operating coolant temperature
Open Loop control
4. Boost pressure
The actuators are operated by the ECU output
5. Engine speed signals which the ECU has calculated using the input
variables, stipulated data, characteristic maps, and
EDC system is also capable of data exchange algorithms. The final results are not checked.
with other electronic systems such as Automatic
Close Loop Control
transmission through CAN (Control Area Network).
The actual value at the output is continually monitored
Major components of EDC system against the desired value and as soon as a deviation
Electronic Diesel Control system comprises of the is detected this is corrected by a change in the actuator
following. control. The advantage of close loop control lies in the
fact that disturbances from outside are detected and
- Electronic Control Unit (ECU) taken into account. In our system close loop control
- Common rail CRS pump Fuel injection pump. is used for rail pressure governing through activating
metering unit.
- Solenoid type Injector for all cylinders.
- Coolant temperature sensor Fuel - Injection Control
- Boost pressure & temperature sensor. In order that the engine can run with optimum
- Camshaft speed sensor combustion under all operating conditions, the ECU
calculates exactly the right injected fuel quantity at right
- Crank shaft speed sensor
time in different conditions. Here the values of various
- Rail pressure sensor parameters are considered.
- Water in fuel sensor
Starting Torque Requirement
- Oil pressure and temperature sensor.
- Accelerator pedal position sensor
- Brake switch
Service Manual
The injected fuel quantity is calculated as a function Sensors, Actuators and ECU
of coolant temperature and cranking speed. This will
generate from the moment the starting switch turned Electronic Control Unit (ECU)
and until minimum engine speed is realised.
The ECU is the brain of the system that process the
Drive Mode requirements thru sensors and the accelerator pedal
movement with the fuel mappings already calibrated in
When the vehicle is being driven normally, the driving the ECU and decides on the fuel delivery thru injectors.
torque is a function of the accelerator pedal position and It operates on 24V DC.
engine speed and boost pressure. Calculation depends
upon maps, which also consider high fuel temperature. Common rail CRS pump Fuel injection pump.
This permits best possible alignment of the engine’s This pump is mechanically driven and electronically
output to the driver’s wishes and also protect FIP parts.
controlled by ECU. Output signals from ECU triggers
Engine Idle Speed Control the governor there by controls the fuel quantity of fuel
injected and the start of injection.
When the accelerator pedal is not pressed, it is the job
of the idle speed control to ensure that a determined Accelerator Pedal Position Sensor
idle speed is maintained. For instance, with the engine
being cold, the idle speed is maintained by adjusting The Sensor serves to measure demand from the driver
to the desired torque in reference to water temperature and communicates to the ECU. It detects the pedal
and the set speed is maintained similarly at increased position by means of potentiometer and transfers this
water temperature. information to the ECU in terms of Voltage. It consists
of two potentiometers for measuring the position of
Engine Maximum Speed Control accelerator pedal module from 0% travel position to
100% travel position.
This control ensures that the engine shall
not to be rotated at excessive speeds. To avoid damage Engine Coolant Temperature Sensor
to the engine,the engine manufacturer stipulates a
permissible maximum rotational speed that may only be It is a thermistor, mounted on coolant return line from
exceeded for a very brief period. In our case Engine rated cylinder block. It measures the engine coolant outlet
speed is 2300 rpm and Fuel Cut off speed is 2550 rpm. temperature.
Maximum engine speed or vehicle speed can be
controlled through ECU. Engine Speed Crank Sensor
Intermediate Set -Speed Control The Crank shaft speed sensor is mounted on the cylinder
block. The sensor works on Magnetic induction principle.
Intermediate speed control enables to run the engine at
The tooth space on the crankshaft trigger wheel causes
constant speed for applications like crane, ambulances
/ trucks mounted with generator sets. a change in magnetic flux thereby generating output
pulses, the frequency of which determines the speed.
Vehicle Speed Limiter
Engine Speed Cam Sensor
The vehicle speed limiter function limits the vehicle’s
maximum speed to a set value. This can be applied and The Cam shaft sensor is mounted on the cylinder head.
proper activation can be performed by the customized The sensor works on Magnetic induction principle. The
Diagnostic tool. tooth space on the camshaft trigger wheel causes a
change in magnetic flux thereby generating output
Engine Torque Limitation pulses, the frequency of which determines the position.
Max torque limitation has been predetermined and Back up for Crank Sensor
set at factory. Deviation to that will have the following
effect The crankshaft position signal combined with
camshaft position signal indicates the cylinder that is
- Excess emission on compression and the ECU can determine from its
- Excessive soot programming the engine firing order.
- Higher Free Acceleration smoke. If either crank or cam sensor will malfunction the cam
- Mechanical overloading due to high torque. or crank sensor will aid to start the engine.
Start Of Injection Control
Engine Boost Pressure & Temperature Sensor
Start of injection has a critical effect on power
output, fuel consumption, noise, and emissions. The Engine Boost Pressure sensor is mounted on the intake
desired value for start of injection depends on engine manifold to measure the absolute intake manifold
speed and injected fuel quantity. With the use of injector pressure & temperature.
energisation, it is achieved.
12.03
Service Manual
Common Rail System Do’s and Don’ts
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.
Service Manual
12.1 ENGINE START / STOP PROCEDURE To warm up the engine
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.
Engine Start Procedure - Check oil pressure minimum 0.5kg/cm2 at Idling.
- After starting the engine proceed slowly and keep

engine at average speed untill normal temperature
is reached.
BY THIS METHOD IT IS POSSIBLE TO OBTAIN:
- Optimum oil flow throughout the lubrication

circuit
CK AC
LO
- Exhaust gases within the specified limit.
C
ON STAR
- Fuel economy.
T
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. Leave 15 - 20 secs
before cranking the engine.
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.

Wait for 10 seconds to completely switch off the engine.
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.
12.2
Input Sensors / Switches Electronic Control Unit Output Actuators / Lamp

EDC 17
Crank Speed Sensor
Metering Unit
Signal Inputs / Signal Evaluation (Proportional
Cam Speed Sensor Control Valve)
Signal Processing &
Coolant Temp Sensor Quantity Calculation (Torque
Structure)
Injectors
Rail Pressure Sensor (Both
Injection Control (Fuel Quantity
SENSORS AND ACTUATORS
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
ALTC/VEE/EDC / 19Sep2011 6
12.05
Service Manual
LOCATION OF SENSORS, ACTUATORS AND CONNECTORS ON ENGINE FOR 6 CYLINDER
Coolant temp. sensor Rail Pr. sensor

Injectors Engine speed
sensor
Intermediate conne
Metering Unit
Cam shaft speed
EGR
Oil Pr. Sensor
Cam sensor Metering Unit Boost Pr.

sensor EGR Actuator
il Pr. sensor
Engine speed
sensor
Intermediate connector
Metering Unit
Cam shaft speed sensor
Oil Pr. Sensor
Boost Pr.
sensor EGR Actuator
12.07
Service Manual
LOCATION OF SENSORS, ACTUATORS AND CONNECTORS ON ENGINE FOR 4 CYLINDER
Coolant temp. sensor Rail Pr. sensor Engine

Injectors speed
sensor
Cam sensor Metering Unit Boost Pr. EGR Ac

sensor
EGR Actuator
Service Manual
Continuity checking for sensor with respect to ECU side connector

Note:
• Remove sensor side connector & ECU side connector also.
• If carefully seen we can find numbers written (Example 1 2 3) on the sensor connector.
• There are three types of ECU connectors one big and one small in size and one for Engine interface connector.
Refer Below sketches.
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
Big Connector (K type connector) Small Connector (A type connector)
N−4
W/H EDC−Engine
(External)
60002982:HSG 62 P MCP RECP
62600679
COVER 62 WAY F HOUS
1 60
Engine Inteface Connector (A type connector)

12.09
Service Manual
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
Boost Pressure & Engine ECU (A)

Temperature Interface Connector
Sensor Connector
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.
Service Manual
12.2.1 ACCELERATOR PEDAL SENSOR

Function and working: C
The Sensor serves to measure demand from the
A
driver and communicates to the ECU. It detects the
pedal position by means of potentiometer sensor and
B
transfers this information to the ECU in terms of Voltage.
It consists of two potentiometer sensors for measuring D
the position of accelerator pedal module from 0% travel
position to 100% travel position. The second sensor is F
incorporated as redundant and reports error in case of
malfunction of the first sensor. Voltage across redundant E
sensor is almost half of the first sensor.
Installation:
PIN PURPOSE PIN PURPOSE
The accelerator pedal sensor is mounted on accelerator
pedal module. K45 V_V_5V_APP1 K44 V_V_5V_APP2
Tightening torque of the retaining screws: 9 Nm. K61 I_A_APP1 K83 I_A_APP2
Specification: K62 G_R_APP1 K84 G_R_APP2
Operating voltage : 5 V DC
Temperature range : - 40 to 80°C Pin Configuration & Connection Details
Fault Path
DTC code Description

(Hand held
diagnostic tool)
P0122 Accelerator pedal sensor 1 signal
voltage above upper limit
Pin 1, 2 & 3 Main Sensor
voltage below lower limit Pin 4, 5 & 6 Redundant Sensor
P1421 Diagnostic fault check to report the
accelerator pedal position error
P2135 Non-plausibility error between APP1
& APP2
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
K84 6 - E- Pin A, B & C Main Sensor

U
Pin D, E & F Redundant Sensor
12.11
Service Manual
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
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.
Service Manual
12.2.2 ENGINE SPEED SENSOR Service Recommendation

Function and working: - Check the signal output in terms of rpm from
Engine speed sensor is an inductive type. It is mounted diagnostic tester.
on the flywheel housing. Electric pulses are generated - Check the continuity of the sensor connector with
when the formed slots on the flywheel pass through the the ECU connector. If found break in signal replace
sensor axis. the wiring harness.
The electric pulse - frequency (Sine Wave) generated - Check if the sensor is offset with respect to
by the sensor is proportional to the engine speed. Flywheel holes.
- Check for sensor mounting plate for specification.
Installation: Ensure the air gap with the sensor and flywheel
between 0.5 to 1.5 mm
- Check for resistance of the sensor across the two
pins. It should read 860 Ohms at 20°C
Circuit Diagram
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 )
12.13
Service Manual
12.2.3 CAMSHAFT SPEED SENSOR Circuit Diagram
A52
34
35
A37
Cam Speed Engine ECU (A)

Sensor Interface Connector
Connector
Function and working:
Cam speed sensor is Reluctance type. The Cam shaft
sensor is mounted on the cylinder head. The sensor works
on Magnetic induction principle. The tooth space on the
crankshaft trigger wheel causes a change in magnetic
flux thereby generating output pulses, the frequency of N
which determines the position. The crankshaft position
signal combined with camshaft position signal indicates
the cylinder that is on compression and the ECU can
determine from its programming the engine firing order.
Cam sensor is used to synchronize with crank speed
S
sensor while starting the engine & back up for crank
sensor while engine is running.
Installation: Pin Configuration and Connector Details
Smear grease on the O ring of the Camshaft Sensor and
insert the sensor on the respective hole in the cylinder
head with the help of M6 screw (as shown in the figure).
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:
Refer Chapter: Trouble shooting using error code / Blink

code
Service Manual
12.2.4 METERING UNIT Effect of Fault
Failure in metering unit system - 40% Torque limitation.

PRV open or Rail pressure limitation to 800-1000 bar in
all engine operating range.
Possible cause of fault and Service
Recommendation:
code
Circuit Diagram:
Function and working:

It is mounted on the FIE and it regulates fuel from
low pressure circuit to rail as per engine quantity and
A19
A04
pressure requirement defined in the ECU. It is controlled 20
by PWM signal from the ECU.
21
Fuel metering unit( MeUn) is used to regulate the fuel A49
A05
delivery to common rail with the input of Rail pressure
sensor (closed loop system). Metering Engine ECU (A)
Unit Interface Connector
Fault Path Connector
Error Code
(Hand held Description
diagnostic tool)
Pin Configuration and Connector Details
Metering unit (ECU) Over
P1103
temperature error
Maximum negative rail pressure
deviation with metering unit on
P1106
lower limit is exceeded (Actual Rail
pressure exceeded the set point)
Leakage is detected based on
fuel quantity balance (Leakage is
P1109
detected based on Metering unit
flow volume exceeded the set point)
Intermittent contact between ECU
P1116
and Metering Unit
Setpoint of metering unit in idle
P1117
mode not plausible
Metering unit high side short circuit
P1119
to battery error
Metering unit high side short circuit
P1120
to ground error
Metering unit output short circuit to
P1121
battery error
Metering unit output short circuit to
P1122
ground error
Setpoint of metering unit in overrun
P1126
mode not plausible
P0096 Metering unit output open load error
Faults for checks in MeUn controlled
mode - maximum positive deviation
P0088
of governor exceeded concerning
set flow of fuel
12.15
Service Manual
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
P0264
WASHER P0267
INJECTOR CLAMP P0270
P0273
P0276
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.
- 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
Effect of Fault on Vehicle
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
Service Manual
Possible Cause of Fault and Service instruction:
Refer Chapter: Trouble shooting using error code / Blink code
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
Engine ECU (A)

Injector
Inter Connector
Terminal
connector (IC)
Service Recommendation
- Physically check for any loose connection of the Injector terminal.
- 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
12.17
Service Manual
12.2.6 INJECTORS FOR 4 CYLINDER ENGINE ECU/Injector Defective - Diagnostic

P1416 fault check to report that WDA is not
working correct
Electrical - connector
ECU/Injector Defective - OS timeout

Magnet - moulding
Protection cap
P1417 in the shut off path test. Failure set-

(for HP - connector) Magnet - nut
Protection cap
(for Electrical - connector) HP - connector
Retaining ring
ting the alarm task period.
Clamping - ﬂats

(clamping saddle)
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
Copper seal - ring

Nozzle - shaft
overvoltage monitoring
Protection cap (for Nozzle)
ECU/Injector Defective - DFC to set
a torque limitation once an error is
P1431
Function and Working of Injector terminal detected before MoCSOP’s error
reaction is set
- Solenoid injector will deliver the calculated fuel & ECU/Injector Defective - Diagnostic
pressure into the engine with respect to engine P1432 fault check to report that the posi-
operating range based on electrical input from tive test failed
ECU.
Effect of Fault on Vehicle
Fault Path - 4 CYLINDER
RPM limited to 1750 if injector system fails.
Error Code
(Hand held Description Severe engine hunting, pick up loss & vibration will be
diagnostic tool) observed if more injectors system is disconnected
P0201 Injector 1 open load Possible Cause of Fault and Service instruction:
P0203 Injector 3 open load code
P0204 Injector 4 open load Circuit Diagram
P1342 Bank 1 application dependant error
4 CYLINDER
P0215 Injection cut off demand from ECU
3 A33
Injector 1 - Short circuit between Cyl 1- Injector
P0261 A16
positive and negative 4

5
Injector 2 - Short circuit between A47
P0264 Cyl 2- Injector
positive and negative 6 A17

Injector 3 - Short circuit between 10 A31
positive and negative 9 A01

Injector 4 - Short circuit between 12 A32
11 A02
Injector Engine ECU (A)
ECU/Injector Defective - Loss of Terminal Interface Connector
P1411 synchronization sending bytes to Connector
the MM from CPU.

Service Recommendation
ECU/Injector Defective - Wrong set
P1412
response time - Physically check for any loose connection of the
ECU/Injector Defective - Too many SPI Injector terminal.
P1413
errors during MoCSOP execution.
- Check for physical contact of injector terminal or
ECU/Injector Defective - Diagnos- wiring harness short with each other.
undervoltage monitoring - Check for continuity of the injector terminal with
ECU side connector as per terminal Diagram
Service Manual
12.2.7 COOLANT TEMPERATURE SENSOR At 40°C - 1.118 to 1.231 Kilo Ohms

At 80°C - 0.313 to 0.332 kilo Ohms
Measure Voltage between Pin A58 and A41 and the
connector of the wiring harness near to sensor : > 4 V
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
DTC code Description

(Hand held
diagnostic tool) Continuity Check:
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
12.19
Service Manual
12.2.8 OIL PRESSURE & TEMPERATURE SENSOR Effect of fault in Vehicle

(Applicable only for 6 cylinder engine ) - Failure in Oil pressure sensor system - 40% Torque
limitation + RPM limited to 1750
Function and working: - Failure in Oil temperature sensor system:
This sensor is mounted on the Oil Cooler Module and used
1. Engine RPM limited to 1750
to measure the absolute Oil pressure. On the version with
integral temperature sensor, the temperature of the oil is also 2. 80% torque reduction if both Coolant & Oil
measured. The piezo-resistive pressure sensor element and temperature sensor systems fails
a suitable circuitry for signal amplification and temperature Possible cause of Fault and Service
compensation are integrated on a silicon chip. The active Recommendation:
surface of the silicon chip is exposed to a reference vacuum, Refer Chapter: Trouble shooting using error code / Blink
that is formed by an evacuated kind of a TO-housing. The code
pressure is lead up by a pressure nozzle to the back side of
Circuit Diagram
the diaphragm, which is resistant to the measured medium.
The temperature sensor element is a NTC-resistor.
Installation: 1 Ground
Smear grease on the O ring of Oil temp and pressure
sensor. Place the sensor on the mounting hole provided
on the Oil cooler alumimum housing.
2 Temperature
Tightening torque : 11.5 Nm
Specifications: 3 +5V
Pressure
Measuring range Sensor
4 Pressure
Pressure - 50 ……. 600 kpa
Temperature - 40 …… 130 °C
Supply voltage - 5V DC
Rated voltage
and current
- For Temperature sensor:
Operation by pull up resistance 1
of 2.056k Ω (1.990k Ω to 2.123k 43 A57
2
Ω) at 25˚C. 44 A59
For Pressure sensor: 0.87V at 3
45 A24
ambient pressure =101kPa 4
46 A44
Fault Path:
Oil Temperature Engine ECU (A)
DTC code and pressure Sensor Interface Connector
(Hand Held Description Connector
diagnostic tool)
Oil Temperature sensor signal
P0197
Pin Configuration and connection details
Oil Temperature sensor signal
P0198
Oil pressure sensor signal voltage (OIL PRESSURE AND TEMPERATURE SENSOR )
P0522
below lower limit
Oil pressure sensor signal voltage
P0523
above upper limit
Minimum oil pressure error in
P0524
plausibility check
P1500 Oil Pressure lamp open load error
Oil Pressure lamp short circuit to
P1501
battery error
Oil Pressure lamp short circuit to
P1502
ground error
ECU Defective - Oil Pressure
P1517 Continuity Check:
lamp over temperature error
Connect multimeter across connector pins 2 and 1,
Maximum oil pressure error in the resistance should be beyond the limit of 2.056k Ω
P1700
plausibility check (1.990k Ω to 2.123k Ω) at 25˚C.
Service Manual
12.2.9 RAIL PRESSURE SENSOR P2290 Check of minimum rail pressure

Possible Causes of Fault and Service
Recommendation:
code
Circuit Diagram:
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
- Stainless steel diaphragm with strain gauges in

metal thin film technology
12.2.10 VEHICLE SPEED SENSOR
- Electrical circuit with analog output
- Piezo resistor type pressure sensor Function and working:
- Range up to 1800 bar abs Working on proximity principle, produces 6 or 8 pulses
Effect of fault in Vehicle: per revolution, pulse output is used for calculating the
distance travel and speed of the vehicle.
Failure in Rail pressure sensor system - 40% Torque
Installation:
limitation & Rail pressure limitation to 800-1000 bar in
all engine operating range Vehicle speed sensor is mounted on the gearbox at
speedo drive output shaft for Manual transmission.
Fault Path
Note: In Automated Manual Transmission (AMT),
DTC code Description Vehicle speed signal will be sent to Engine ECU through
(Hand held CAN by AMT ECU.
diagnostic tool) Specifications:
P0192 Rail Pressure Sensor signal voltage Operating Voltage : 9 to 32 V
below lower limit
Supply Current : 18mA max
P0193 Rail Pressure Sensor signal voltage
Output Signal : V Bat - 1.5 V
above upper limit
Circuit Diagram
P1104 Maximum positive deviation of rail
pressure exceeded (Actual Rail
pressure below the set point) ECU PIN
P1106 Maximum negative rail pressure K11 -ve

deviation with metering unit on lower Vehicle
K34 A1 (Signal)
limit is exceeded (Actual Rail pressure Speed
exceeded the set point) K68 +ve Sensor
P1108 Maximum rail pressure exceeded
P1118 Rail pressure raw value is intermittent
Pin Configuration & Connection details :
P1123 maximum rail pressure exceeded
(second stage)
A1 A2
P1125 Rail pressure droped below required
minimum rail pressure
P1136 Averaged rail pressure is outside the
expected tolerance range
P1429 Diagnostic fault check to report the
plausibility error in rail pressure
monitoring
12.21
Service Manual
12.2.11 EXHAUST GAS RECIRCULATION Circuit Diagram:
20
53
NC
52 19
54 12
55 40
56 22
Function and Working
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)
P0401 EGR valve position governor deviation

max / EGR valve jammed at closed
P1205 position
(MS code)
P0402 EGR valve position governor deviation

min / EGR valve jammed at open
Female End (WH side)
P1206 position
(MS code)
EGR valve Short circuit to battery at
P2142
Out1 / Out2
EGR valve Short circuit to ground at
P2141
Out1 / Out2
P0487 EGR Valve Open load error
EGR Valve position sensor signal

P0405
EGR Valve position sensor signal
P0406
Effect of Fault
40% torque limitation after 50 hours- P0405 & P0406

Male End
Possible cause of fault and service recommendation:

code. NOTE
Do not touch EGR motor male terminal by hand.
Service Manual
12.3 SWITCHES 12.3.1 CLUTCH SIGNAL SWITCH
12.3.0 BRAKE SIGNAL SWITCH Function and working:
Function and working: It is mounted on the clutch pedal to detect whether

clutch is pressed or not.
The switch is of electro-pneumatic type. Switch is
mounted on the dual-control brake valve. It indicates Installation:
the altered voltage level from the switch and output is
fed to ECU as information. Switch operates for pressure Ensure correcting setting of the switch makes positive
greater than 0.5 Bar. This information is used by the opening and closing of the contact in the switch.
ECU to activate the limp home mode in case of defective Pin Configuration & Connection details and Circuit
accelerator pedal sensor (Pedal stuck - Pressing brake Diagram
implies this condition).
Installation:
Ensure there is no air leak after fixing.
Tightening Torque: 15 - 18 Nm ECU PIN K 15

I_S_CONV
K68
Specifications:
Four Terminals with NC and NO Contact
Supply & Output Voltage : 24VDC
Pin Configuration & Connection details and Circuit

Diagram
I_S_BRKMN Brake Main

Switch
K41
ECU
PIN
K68
K14
I_S_BRKREDOP Redundant
Brake Switch
12.23
Service Manual
12.4 DIAGNOSTIC LAMP AND REQUEST The following counters can be read through diagnostic
SWITCHES tester:
Function and Working 1. Water Detection counter: No of times Vehicle

switched off and restarted without water in bowl
Diagnostic lamp is provided on the dashboard. In event emptied
of any errors reported by the ECU in course of operation
of the vehicle, the diagnostic lamp glows, indicating that 2. Water Detection Duration: Duration in seconds
there are errors reported in the system and recorded by for which the vehicle runs and Sensor detects
the ECU. Only selected errors (which can have a direct water
effect on the engine / vehicle performance) are reported
to the diagnostic lamp. These counters should be reset (through diagnostic
tester) after draining the water from the water separator
Depending on the criticality of the error reported, the bowl.
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 or using diagnostic
request switch with the help of blink code.
24 V Supply Via SA FUSE
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
Diagram
O_V_DIA Diagnosis Lamp

K70
ECU PIN
X Water in Fuel Lamp
K65 Water in fuel lamp is provided on the dashboard. Water
Diagnosis in fuel sensor is a part of pre-filter which senses the
Request Input
Switch water level in diesel. When the predefined threshold
I_S_DIAREQ 24 V Supply exceeds, the Water in fuel lamp starts blinking indicating
ECU PIN K66
the excess amount of water in diesel and brings a need
for draining the water in pre-filter. Excess water in
the fuel system could damage precision fuel injection
equipment and engine.
12.4.0 WATER IN FUEL SENSOR AND LAMP
Water in Fuel Sensor Diagram
Water-in-Fuel sensor is a part of the Fuel Pre-filter
and has a water collecting bowl in which the sensor is
mounted. As the water gets separated and collected in
the bowl, level of water in the fuel is used for identifying Water in Fuel
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)
When the water level exceeds the threshold following

are the actions performed
- Indicate the driver that a critical error has occurred

which needs an immediate attention
- Torque reduction by 40%
- A Dedicated Tell-Tale lamp is made to

“BLINK”
- Error is assigned as high priority to store in ECU

memory for longer duration to be read by the tester
Service Manual
12.5 AC SWITCH SIGNAL
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.
Pin Configuration & Connection details and Circuit Diagram
Specification:
AC request SW relay and AC switch are 24V type.
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.
Pin Configuration & Connection details and Circuit Diagram
Specification:
Starter relay is 24V type.
Note: The starter motor could not start without starter relay.
12.25
Service Manual
12.6 CAN BACKBONE

CAN – Controller Area Network is used for communication between the Electronic Control Units (ECUs) in the
vehicle. The advantages of CAN are,
1. Same sensor input can be used by different ECUs
2. One ECU can give control message to another in case of safety/emergency conditions
CAN backbone wire harness is used for this CAN communication. CAN backbone wiring is connected between
EDC wiring and Main wiring for communication of Engine ECU, AMT ECU, SCR ACU and Diagnostic tester,
Cluster /Display.
CAN connection layout given below.
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.
Pin A – CAN high
Pin B – CAN low
Pin C – CAN shield
Terminating resistor 120 ohms has been used in the CAN backbone to ensure proper communication.
Service Manual
12.7 DIAGNOSTICS
ECU integrated diagnostics belong to the basic scope of

electronic engine -management systems. During normal
vehicle monitoring algorithms checks operation, input
and output signals and the overall system is checked for
malfunctions and faults. If faults are discovered in the
process, these are stored in the ECU memory. When
the vehicle is checked in the workshop, this stored
information is retrieved only by a diagnostic tool through
a serial interface and provides the basis for rapid and
efficient trouble shooting and to attend repair.
12.7.0 DIAGNOSTIC CONCEPT

FOR GOODS MODELS
1. Using Diagnostic Tester
2. Using Diagnostic request switch and Blink code

Use diagnostic equipment tool for reading the Error
12.7.1 DIAGNOSTIC TESTER recorded in the ECU. The diagnostic socket is provided
beneath dashboard.
Diagnostic Connector and Circuit Diagram
24V
FOR BOSS TRUCK MODELS
Battery +ve
16
Diagnostic Connector
K2 4
E
14 Can Low
K76
5
C
K54 6 Can High
U
K59 7
FOR PASSENGER MODELS

12.27
Service Manual
Diagnostic connector Female (Wiring Harness side)
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.
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.
Once the defective circuit is identified with the help of the diagnostic tool, please refer the service instruction
pertaining to that sensor / actuator circuit.
Service Manual
12.7.2 DIAGNOSTIC REQUEST SWITCH AND BLINK CODE
When the Diagnostic Lamp is 'Blinking' or continuously 'ON',
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).
3. Repeat Step: 1 for the next error.
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.
ERROR CODES AND BLINK CODES
Refer end of the manual for Error codes and Blink codes.
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 %
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
12.31
Service Manual
12.8 LIMP HOME AND EDC FAILURE REACTION FUNCTIONS

The table shown indicates the details of sensor failure and its effect on the vehicle. This function enables the vehicle to reach the
nearest dealership point for service attention, in case of any sensor failure / malfunctioning.
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
8 ECU failure or Rail pressure exceeds 1890 bar Engine shutoff
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)
13 Identified faults that causes NOx above OBD limit 1 MIL ON
14 Identified faults that causes NOx above OBD limit 2 40% Torque Limitation + MIL ON
Service Manual
CIRCUIT DIAGRAM - RELAYS AND FUSES FOR CRS EDC 17 SYSTEM - EDC17CV54
Sl. No. NAME DEVICE TYPE CURRENT RATING

1 F FUSE 30A
2 F1 FUSE 30A
3 F2 FUSE 5A
4 F3 FUSE 5A
5 F4 FUSE 5A
6 F5 FUSE 30A
FUSE F (S.NO.1) WILL BE AN INLINE FUSE IN THE
BATTERY POSITIVE CABLE FOR EDC SYSTEM
12.33
Service Manual
R−1
RELAY
1 4 7
2 5 8
3 6 9
Fuse Base 6 Way

60002512
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
Dwg View Relay Base Relay Pin
2 E 87
4 A 86
8 B 30
6 C 85 30 85 86 87 87a
Service Manual
12.9 INSPECTION OF PARTS & CONNECTIONS AGAINST COMPLAINT
Required Instruments:
a) Diagnostic Tool
b) Analog / Digital Multimeter
c) Test sockets with flying leads - If required.
Removal & Fitment of Sensors & Connectors
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.
• Crankshaft Speed Sensor (Crs - DG6) - Mounted on the Flywheel housing.
• Camshaft Speed Sensor (CaS - DG6) - Mounted on the FIE mounting flange.
• Rail Pressure Sensor (RDS4) - Integrated with common rail
• Coolant Temperature Sensor (CTS) - Mounted on the Thermostat housing.
• Oil Pressure and Temperature Sensor (OPTS) - Mounted on the Aluminum housing of Oil cooler unit.
• Boost Pressure cum Temperature Sensor (LDFT6) - Mounted on intake manifold
• Metering Unit (MeUn) - Integrated with FIP
• Injector Solenoid connection - Integrated with injectors.
• Intermediate Connector - Fitted on a bracket (on Intake manifold)
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.
12.35
Service Manual
12.10 ASSEMBLY OF EDC ENGINE WIRING

HARNESS ON COMMON RAIL ENGINE
WITH CB28 FIE SYSTEM
(FOR 6 CYLINDER ENGINE)
Assemble the bracket for intermediate connector

on intake manifold
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.
1. Bracket for intermediate connector

2. Wiring Harness intermediate connector
Intermediate connector – 1 No.
Assemble the Intermediate connector of wiring harness

on the Bracket with 4 nos of screws.
2
Injector Routing 3
1. Injector terminals on wiring harness to

be connected on injectors
2. Injector Cap – part of wiring harness
3. sticker marked with Cylinder No.
Tighten the wiring harness terminal on the injectors.

(Tightening torque 1.5 Nm). Make sure that the cylinder
no. on the sticker matches with the corresponding
injectors.
The two terminals for an injector can be connected on

any of the two terminals on that injector.
Route the corrugated sleeve containing injector cables

to the top of intake manifold through clip (FM01300) on
the bracket of intermediate connector.
After tightening of injector terminals, make sure that the

caps are properly fitted on all the injectors.
Service Manual
Route the corrugated sleeve containing connectors Coolant temperature sensor

for Boost Pressure sensor, Coolant temp sensor,
toward front side of engine taking it through behind
the intermediate connector.
Part of wiring harness
The cable for coolant temp sensor is to be tied using fur

clip on the bracket fitted with intake manifold.
Sleeve containing BPS, CTS, Oil Pressure Sensor Cam Sensor

(to be routed to the left taking through, behind the
intermediate connector)
Boost Pressure Sensor

3
1
1
2 2
1. Tie the fuel temp sensor with cable tie

2. Camshaft Speed sensor
3. Furr-Tree clip on bracket
1. Coolant temp sensor connection

2. Boost Pressure sensor connection
Connect the connectors of wiring harness for boost

pressure sensor and coolant temp sensor to the
respective sensors on engine. The wiring harness 1
cables contain the sticker marked with labels BPS, CTS
for identification.
1. Furr-tree clipping
Connect the connectors of wiring harness for Fuel

temperature sensor and Camshaft Speed sensor to the
respective sensors on FIP.
12.37
Service Manual
Engine Speed Sensor
3 1
2
4
2
1. Cable for rail pressure sensor

2. Fur Clip
3. Cable routing along with the bracket
4. Grid heater pigtail to be tied with the bracket
1
Route the corrugated sleeve containing branch for
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
The cable to be tied on bracket using fur clip.
Rail Pressure Sensor
1. Crankshaft speed sensor connection

1
2. Wrapping of cable branching for
vehicle speed sensor connection
2
Connect the Crankshaft speed sensor branch to the
Speed sensor mounted on flywheel housing.
Wrap the cable branching for vehicle speed sensor
2 connection and tie it using cable strap X0600360.
Electromagnetic Fan
1. Rail Pressure sensor connection

2. Fur clip
1
Connect the connector of wiring harness branch for Rail
Pressure sensor to the sensor integrated with rail.
The cable for EMF is to be tied using fur clip on the

bracket fitted with breather.
Service Manual
Oil Pressure Sensor (Non-Ac Model alternator Oil Pressure Sensor (AC-Model alternator bracket)
bracket)
1 2
1. Cable Tie - Air compressor pipe

1. Oil Pressure sensor W/H
2. Furr clip on thermostat
2. Furr clip on thermostat
1
2
1. Cable Tie
1. Oil Pressure Sensor
2. Water filter pipe
1. Furr clip on alternator mounting bracket

12.39
Service Manual

WITH CB18 FIE SYSTEM
(FOR 4 CYLINDER ENGINE)
Assemble the bracket for intermediate connector

on intake manifold

1 injectors. Each branch contains a sticker with cylinder
2 insertion on bracket hole.
1. Bracket for intermediate connector

2. Wiring Harness intermediate connector
Intermediate connector – 1 No.

on the Bracket with 4 nos of screws.
Injector Routing
• All Injector have the mating connector
and all injector have sticker marked
with cylinder no.
Route the corrugated sleeve containing connectors
toward front side of engine taking it through behind
the intermediate connector.

to the top of intake manifold through clip (FM01300) on
the bracket of intermediate connector.
Sleeve containing BPS, CTS, Oil Pressure Sensor

(to be routed to the left taking through, behind the
intermediate connector)
Service Manual
Boost Pressure Sensor Cam Sensor
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.
Coolant temperature sensor 1
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.
The cable for coolant temp sensor is to be tied using fur 1

clip on the bracket fitted with intake manifold.
2
3
2
4
1. Cable for rail pressure sensor

2. Fur Clip
3. Cable routing along with the bracket
4. Grid heater pigtail to be tied with the bracket
12.41
Service Manual
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.
The cable to be tied on bracket using fur clip.
Rail Pressure Sensor 1
2
1
2
1
1. Rail Pressure sensor connection 2

2. Fur clip
Connect the connector of wiring harness branch for Rail

Pressure sensor to the sensor integrated with rail.
1. Crankshaft speed sensor connection
2. Wrapping of cable branching for
vehicle speed 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
The cable for EMF is to be tied using fur clip on the

bracket fitted with breather.
Service Manual

WITH CB18 FIE SYSTEM (FOR 6 CYLINDER
EGR ENGINE)
Intermediate connector
Assemble the bracket for intermediate connector on
intake manifold
Wiring
Harness
intermediate
connector
Part of wiring harness.
Route the corrugated sleeve containing connectors
toward front side of engine taking it through behind the
Bracket for intermediate connector.
intermediate
connector

on the Bracket with 4 no's of screws.
Injector Routing
Sleeve containing BPS, CTS, Oil Pressure Sensor (to

be routed to the left) & route the above corrugated tube
away from hot pipe with necessary gap of 10 mm.

on the top of intake manifold through supporting bracket
plug the furr clip on the bracket wherever holes are
provided.
Sleeve containing Crank Speed, Vehicle speed, EGR (to

be routed to the right) and refer the cable tie X0600360
for necessary routing.

injectors. Each branch contains a sticker with cylinder
insertion on bracket hole.
12.43
Service Manual
Boost Pressure Sensor
Boost Pressure sensor

connection
Clamp with rubberized/pvc F6M01300 1

sleeve - 25mm
Route the corrugated sleeve through clip (F6M01300)
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.
Service Manual
Cam Sensor EGR Connection

Route the corrugated sleeve containing branch for
EGR, Engine speed Sensor, vehicle speed sensor rear
side of the engine along with the holes available on the
bracket for cable tie.
Connect the connectors of wiring harness for Fuel

temperature sensor and Camshaft Speed sensor to the Cable Tie
respective sensors on FIP. EGR Connection
• Rout the vehicle speed sensor with cable tie, later

vehicle speed sensor to be connected to the vehicle
side EDC wiring harness
• Grid heater connection to be tied if not required.
• Use furr-tree clip to secure the
wiring harness for EGR connector
Rail Pressure Sensor
Furr-tree clipping
Rail Pressure
sensor connection
• Connect the connector of wiring harness branch for

Rail Pressure sensor to the sensor integrated with
rail.
• Branch connector is available after the 6th injector.
Engine Speed sensor
12.45
Service Manual
Avoid the fouling of wiring harness to the

hot pipe by maintaining the proper gap
Crankshaft speed sensor connection
Secure the wiring

harness by using
F4R00260
Wrapping of
cable
branching for
vehicle speed
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.
Service Manual
Oil Pressure Sensor
Tie the cable on EGR cooler pipe using F4R00260
Furr clip on Breather bracket
Tie the cable on EGR cooler pipe using F4R00260
Cable-tie on alternator Mounting
Oil Pressure Sensor

12.47
Service Manual
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.
Service Manual
12.14 PRECAUTIONS FOR ELECTRONIC 2. Do not disturb/remove the connected DC negative

DIESEL CONTROL SYSTEM (EDC) connection of EDC system. DC negative is
DURING BODY BUILDING connected at two places
Extreme care to be taken while assembling the body on a) Chassis
the chassis with respect to the ECU.
b) Starter Motor Negative to Engine Block
General
3. Do not remove or cut wires of the EDC system
1. The ECU should be disconnected from the harness wiring harness. No unprescribed extension or
and a dummy cap/cover with plastic bags should intermediate joints are permitted.
be put on the ECU connector. There should be no
ingress of water through the wiring harness on the 4. Ensure fuse and connectors of the EDC system
ECU. power cable (closer to the battery cable terminal
ends) are kept inside the battery box.
2. The ECU as such should be covered in a box
so that if any washing is done, the ECU will be 5. To power ECU and the ECU system minimum 18
protected. Volts at battery is required.
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.
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.
Service Manual
12.15 MAINTENANCE PROGRAMME
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
Service Manual
EDC17 ERROR CODES
Sl.No P codes Description Possible causes Check Points Further Actions

Loose connection / poor contact of socket.
(between sensor & connector)
Visual Inspection - Ensure proper locking of the connector and socket
Improper locking of the connector over the
sensor socket
1.Check continuity between pin no 2 on the sensor and A39 on the ECU
connector. (interconnector pin 24)
Connection swapped in the circuit 2. Check continuity between pin no 1 on the sensor and A54 on the ECU
connector. (interconnector 25) Rectify / replace Wiring Harness If continuity is missing
There should be continuity in both the case
Short circuit b/w positive & negative of crank Check thecontinuity between A39 & A54/ at sensor end 1 & 2/ 25 & 24 at
sensor circuit. Interconnector [Thershould not be any continuity]
Crank shaft sensor signal Error - dis- Crank shaft sensor failure Measure resistance across the terminals it should be 774ohm to 946 ohm If the resistance is out of specified limit - Replace sensor
1 P0336
turbed signal
Visual inspection Ensure proper tightening.
Remove sensor & check at the sensor tip for any burr / metal
Incorrect air gap between tooth & sensor chip presence. If so, clean and refit it.
Check air gap and check for foreign particle deposited on sensor
(spec 0.3mm - 1.8mm). Also mention the correct thickness of sensor mounting plate for
all 14” / 15” & diaphragm clutch.
No of holes on flywheel not as per spec 1. Ensure no of holes
Visual inspection
(58holes equally and two missing holes) 2. check for hole blocking by foreign particles
Electrical Noise in crank sensor signal due to Visual inspection
Replace WH with proper WH
Shielding is not available for crank signal line. Check the continuity between shield at sensor end to A38.
If all the above check points are ok Replace ECU / Faulty ECU
ECU defective No check points
to be sent for investigated
Visual Inspection Ensure proper connections
sensor socket
Check continuity b/w end of sensor connector pin no 1 to A54 (intercon-
No electrical continuity between ECU to crank
nector pin 25) & check continuity end of sensor connector pin no 2 to Rectify / Replace WH if there is no continuity.
P0337 sensor connector.
Crank shaft sensor signal Error - no A39 (inter connector pin 24)
2 P0336 Crank shaft sensor failure Measure resistance across the terminals it should be 774ohm to 946 ohm If the resistance is out of specified limit - Replace sensor
signal Sensor mounting bolt loosen. Visual inspection Ensure proper tightening.
(OBD)
Remove sensor & check at the sensor tip for any burr / metal
Air gap between tooth & sensor above spec chip presence. If so, clean and refit it.
Check air gap.
(spec 0.3mm - 1.8mm). Also mention the correct thickness of sensor mounting plate for
all 14” / 15” & diaphragm clutch.
1. Check continuity between pin no 1 on the sensor connector and pin no
A52 on the ECU connector / pin no 34 on the interconnector.
Connection swapped in the circuit 2.Check continuity between pin no 2 on the sensor connector and pin
no A37 on the ECU connector / pin no 35 on the interconnector.
Rectify / replace Wiring Harness If continuity is there
There should be continuity in both the case.
1.Check continuity between pin no 2 on the sensor connector and pin no
Short circuit b/w positive & negative of cam
P0341 A37 on the ECU connector / pin no 35 on the interconnector
Cam shaft sensor signal Error - dis- sensor circuit.
3 P0344 There should be continuity in both the case.
turbed signal 1. Visual inspection of condition of shield
(OBD) Electrical Noise in crank sensor signal due to
2. Check the continuity between shield at sensor end to A53. [Thershould Replace WH with proper WH
Shielding is not available for cam signal line.
be Continuity]
Cam shaft sensor failure Measure resistance across the terminals it should be 774ohm to 946 ohm If the resistance is out of specified limit - Replace sensor
Sensor loosen. Visual inspection Ensure proper tightening
Ensure proper tightening .
Cam shaft tone wheel wobbling Visual inspection
Replace the trigger wheel if wobbling after proper tightening
Service Manual
EDC17 ERROR CODES

Check continuity between check continuity b/w end of sensor connector
No electrical continuity between ECU to cam
P0342 pin no 1 to A52 (inter connector pin 34) & check continuity end of sensor Rectify / Replace WH
4 Cam shaft sensor signal Error - no signal sensor connector. connector pin no 2 to A37 (inter connector pin 35)
P340(OBD) Cam shaft sensor failure Measure resistance across the terminals it should be 774ohm to 946 ohm If the resistance is out of specified limit - Replace sensor
Sensor loosen. Visual inspection Ensure proper tightening
Deviation between cam and crank sensors
1. Ensure the both crank and cam sensor proper installation (without any 1. Ensure proper sensor installation and connection.
signals exceeds +/- 10deg Crank during
Camshaft to Crankshaft offset angle loose connection).
5 P0016 plausibility check.
exceeded check proper angle between tone & trigger wheel mounting slot to sync
Defective trigger wheel / tone wheel Replace the defective tone & trigger wheel.
tooth and missing tooth respectively as per the spec.
FIP timing Check and align FIP timing. Remove & refit FIP with correct timing procedure
SRC High for Fuel temperature sensor 1. Sensor not connected 1.Check for proper connection in the connector
2. Short circuit to battery 2. Check wiring harness for short circuit/continuity (sensor connector pins
6 P0183 Replace wiring harness or sensor based on requirement
Fuel temp sensor open circuit or short 3. Wiring harness problem 1,2 and ECU pins A11, A29 respectively).
to batery 4. Wrong sensor fitted 3. Change the sensor if the problem persists
1.Check for proper connection in the connector
SRC Low for Fuel temperature sensor 1. Short circuit to ground
2. Check wiring harness for short circuit/continuity (sensor connector pins
7 P0182 2. Wiring harness problem Replace wiring harness or sensor based on requirement
1,2 and ECU pins A11, A29 respectively).
Fuel temp sensor short to ground 3. Wrong sensor fitted
3. Change the sensor if the problem persists
Ensure the atnmospheric preaaure reading is same to boost
Environment pressure sensor signal volt- pressure in ignition on condition ie current atmospheric pressure
8 P2229 Sensor failure at ECU. No check points
age below lower limit. at the location.(for chennai1000mbar)
Replace ECU Faulty ECU to be sent for investigation
Ensure the atnmospheric preaaure reading is same to boost
Environment pressure sensor signal volt- pressure in ignition on condition ie current atmospheric pressure
9 P2228 Sensor failure at ECU. No check points
age below lower limit at the location.(for chennai1000mbar)
Replace ECU , Faulty ECU to be sent for investigation
Loose connection / poor contact of socket. Visual Inspection Ensure proper connections
1. Check continuity between pin no 4 on the sensor connector and pin
no A43 on the ECU connector / pin no 32 on the interconnector
No electrical continuity between ECU to Boost
no A09 on the ECU connector / pin no 31 on the interconnector Rectify / Replace WH if there is no continuity.
pressure sensor connector
There should be continuity in any of the case.
Check the continuity between
1. pin no 3 & 4 on the sensor connector
Signal line short to supply (5Volts) 2. pin no A09 & A43 on the ECU connector Rectify / Replace WH if there is a continuity.
3. pin no 31 & 32 on the interconnector
Thershould not be any continuity in any of the case.
Boost pressure sensor signal voltage Check the voltage between
10 P0238 1. pin no 4 & 1 on the sensor connector
above upper limit Signal line short to battery (greater than 5 Rectify / replace Wiring Harness If the measured voltage is
2. pin no A43 & A42 on the ECU connector
Volts) above 5 V.
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 Tester
If Error is registered, then connect the sensor end connector and erase
Sensor defective If the voltage spec is not matching replace the sensor
the error code
4. Check the Sensor signal voltage thru tester (Parameter 3)
5. Voltage should be 1.18V at standard atmoshpheric pressure
(pamb=101kPa)
Service Manual
EDC17 ERROR CODES
Check thecontinuity between

1. pin no1 & 4 on the sensor connector
Signal line short to ground 2. pin no A42 & A43 on the ECU connector Rectify / Replace WH if there is a continuity.

Boost pressure sensor signal voltage 2. Remove sensor end connector
11 P0237
below lower limit 3. Check for the sensor error in Tester
Sensor defective If the voltage spec is not matching replace the sensor
the error code
(pamb=101kPa)
1. Mal function of Boost or environmental
Check the atmospheric & boost value through tester and ensure both
Boost Pressure sensor High plausibil- pressure sensor / actual engine boost pres- 1. Change boost pressure sensor.
12 P0236 the pressure values are same at ignition on condition(ie atmosheric
ity error sure is not changing with respect to engine 2.Change ECU if problem persists
prresure reading only)
speed.
1. Mal function of Boost or environmental
Check the atmospheric & boost value through tester and ensure both
Boost Pressure sensor low plausibility pressure sensor / actual engine boost pres- 1. Change boost pressure sensor.
13 P0235 the pressure values are same at ignition on condition(ie atmosheric
error sure is not changing with respect to engine 2.Change ECU if problem persists
prresure reading only)
speed.
1. Loose connection. Visual Inspection Ensure proper connections
2. No electrical continuity between ECU to
no A26 on the ECU connector / pin no 37on the interconnector Rectify / Replace WH if there is no continuity.
sensor connector.
Rail Pressure Sensor signal voltage
14 P0193
above upper limit Check the voltage between
Signal line short to battery (greater than 5 Rectify / replace Wiring Harness If the measured voltage is above
Volts) 5 V.

Sensor defective If Error is registered, then connect the sensor end connector and erase If the voltage is out of specified limit - Replace sensor
the error code
5. Voltage should be 500±48mV.
Service Manual
EDC17 ERROR CODES

Check thecontinuity between pin no
1. 2 & 1 on the sensor connector
Rail Pressure Sensor signal voltage 2. Remove sensor end connector
15 P0192
below lower limit 3. Check for the sensor error in Tester
Sensor defective If Error is registered, then connect the sensor end connector and erase If the voltage is out of specified limit - Replace sensor
the error code
5. Voltage should be 500±48mV.
If all the above check points are ok Replace ECU / Faulty ECU to
be sent for investigated
Rail pressure deviation exceed the spec 1. Check for the bends/crimps in the fuel suction line. Change the fuel return lines
below the set point. 2. Check the fuel level in fuel tank Fill fuel in sufficient level
Set value of metering unit delivery exceeds
the defined upper limit w.r.t to
engine speed (Rail_dvolMeUnCtlUpLim_CUR)
Chocked fuel return lines,zero delivery throttle
Remove the return line and check for blockage Change the fuel return lines
clogged up.
Check the common rail return line pipe outer surface tem (If temp ob-
Leaking in PRV served very high, might be problem with PRV opening- Leakage in PLV Change the rail if the PRV open count & time is elapsed
P1104 (Ms maximum positive deviation of rail pres-
return).
16 code) sure exceeded (Actual Rail pressure
Leakage in the high pressure line Check the leakage in the high pressure pipes line. Rectify the leakage
P0087 (OBD) below the set point) Leakage in the Low pressure line Check for leakage in low pressure cicuit Rectify the leakage
Worn high pressure pump No check points Remove the pump and get it checked from the authorised dealer
Gear pump input pressure too low No check points
Gear pump outlet pressure too low No check points
Remove the injector and get it checked from the authorised
Worn injector No check points
dealer
Injector nozzle stuck in the open position No check points
1. Change the fuel filter
Filter clogged Fuel filter functionality check.
2. Clean the strainer
incorrect/small/sharp bend in diameter fuel
Visual inspection-Check for the bends/crimps in the fuel return line. Change the fuel return lines
return lines.
clogged up.
return).
Leakage in the Low pressure line Check for leakage in low pressure cicuit Rectify the leakage
Leakage is detected based on fuel quan- Worn high pressure pump No check points Remove the pump and get it checked from the authorised dealer
P1109 (Ms tity balance (Leakage is detected based Possible error in low pressure stage Metering
17 No check points
code) on Metering unit flow volume exceeded unit reflux too low
the set point) Possible error in low pressure system Zero
delivery is not present for metering unit leak- No check points
age in metering unit is more
dealer
No check points
Injector nozzle stuck in the open position
Filter/ fuel tank strainer clogged Check fuel filter/strainer
2. Clean the fuel tank strainer
Service Manual
EDC17 ERROR CODES

Incorrect/small/sharp bend in diameter fuel
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
diagnostics--->Diesel--->Engine---> Autodetect--->Actuators test.
P1106 maximum negative rail pressure devia- Pump metering unit is stuck in open position ii) Select metering unit from the list. Replace the metering unit.
(Ms code) tion with metering unit on lower limit iii) Increase the duty cycle to 40% in engine idling condition.
18
P0088 is exceeded (Actual Rail pressure iv) Engine should shut off
(OBD) exceeded the set point)
Injector struck in closed possition engine vibration check, MORSE test for Injector through tester . Repalce the injector .
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.
Remove the return line and check for blockage
tle clogged up.
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

tle clogged up.
Check the common rail return line pipe outer surface tem (If temp
Leaking in PRV observed very high, might be problem with PRV opening- Leakage in Change the rail if the PRV open count & time is elapsed
PLV return).
P1125
(Ms code) Leakage in the Low pressure line Check for leakage in low pressure cicuit Rectify the leakage
20 minimum rail pressure exceeded
P0112 Remove the pump and get it checked from the authorised
Worn high pressure pump No check points
(OBD) dealer
Gear pump input pressure too low No check points
Gear pump outlet pressure too low No check points
dealer
No check points
Filter clogged Check fuel filter/strainer
2. Clean the fuel tank strainer
Service Manual
EDC17 ERROR CODES

incorrect/small/sharp bend in diameter fuel
return lines.
clogged up.
return).
P1117 Leakage in the Low pressure line Check for leakage in low pressure cicuit Rectify the leakage
(Ms code) Worn high pressure pump No check points Remove the pump and get it checked from the authorised dealer
setpoint of metering unit in idle mode not Possible error in low pressure stage Metering
21 P0089 No check points
plausible unit reflux too low
(OBD) Possible error in low pressure system Zero
delivery is not present for metering unit leak- No check points
age in metering unit is more
dealer
No check points
Filter clogged Fuel filter functionality check.
2. Clean the strainer
Rail pressure exceed the max value of
1890bar
Incorrect/small/sharp bend in diameter fuel
return lines.
clogged up.
P1123 i) Using omitec diagnostic scan tool goto actuators test via Ashok
(Ms code) maximum rail pressure exceeded (sec- diagnostics--->Diesel--->Engine---> Autodetect--->Actuators test.
22
P0088 ond stage) Pump metering unit is stuck in open position ii) Select metering unit from the list. Replace the metering unit.
(OBD) iii) Increase the duty cycle to 40% in engine idling condition.
iv) Engine should shut off
Injector struck in closed possition engine vibration check, MORSE test for Injector through tester . Repalce the injector .
Ensure the metering unit wiring harness check. (Refer check point ---
Pump metering unit wiring ahrness issues Remove the pump and get it checked from the authorised dealer
P0193 & P0192 (Sl no16 & 17 )
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 )
No electrical continuity between ECU to Boost
2. Check continuity between pin no 2 on the sensor connector and pin Rectify / Replace WH if there is no continuity.
temperature sensor connector
P0113 3. pin no 31 & 30 on the interconnector
Boost temperature sensor signal voltage Thershould not be any continuity in any of the case.
23 P0098 Check the voltage between
above upper limit
(OBD) 1. pin no 1 & 2 on the sensor connector
Signal line short to battery (greater than 5 Rectify / replace Wiring Harness If the measured voltage is
Volts) above 5 V.
3. pin no 29, 30 on the interconnector
Check the resistance value b/w pin no 2 & 1 of boost pressure sensor - It
should be in between
Sensor defective If the resistance is out of specified limit - Replace sensor
1) 1990 Ohms to 2123 kOhms (25°C), 2) 1139 ohms to 1209(40°C)
3) 579.7 ohms to 611 ohms(60°C), 4.) 315 ohms to 330 ohms(80°C)
Service Manual
EDC17 ERROR CODES

P0112
Boost temperature sensor signal voltage Check the resistance value b/w pin no 2 & 1 of boost pressure sensor - It
24 P0097
below lower limit should be in between
(OBD)
1) 1990 Ohms to 2123 kOhms (25°C)
2) 1139 ohms to 1209(40°C)
3) 579.7 ohms to 611 ohms(60°C)
4. 315 ohms to 330 ohms(80°C)
No electrical continuity between ECU to Cool-
2. Check continuity between pin no 2 on the sensor connector and pin Rectify / Replace WH
ant temperature sensor connector
Check the voltage between
Signal line short to battery (greater than 5 Rectify / replace Wiring Harness If the measured voltage is
Coolant temperature sensor signal volt- 2. pin no A28 & A29 on the ECU connector
25 P0118 Volts) above 5 V.
age above upper limit 3. pin no 27, 28 on the interconnector
Check the resistance value b/w pin no 2 & 1 of coolant pressure sensor -
It should be in between
1) 1940 Ohms to 2173 kOhms (25°C)
2) 1118 ohms to 1231(40°C)
3) 573 ohms to 618 ohms(60°C)
4. 313 ohms to 332 ohms(80°C)
P0117 Check the resistance value b/w pin no 2 & 1 of coolant pressure sensor -
Coolant temperature sensor signal volt-
26 It should be in between
age below lower limit
1) 1940 Ohms to 2173 kOhms (25°C)
2) 1118 ohms to 1231(40°C)
3) 573 ohms to 618 ohms(60°C)
4. 313 ohms to 332 ohms(80°C)
1. Check any blockage in oil flow path. 1. Engine relief valve functionality to be ensured.
Engine oil pressure exceeds 7 bar (absolute).
2. Ensure oil grade spec against the specified 2. Use correct oil spec.
P1700 (MS Maximum oil pressure error in plausibility Engine oil pressure relief valve failure at oil
27 Ensure engine pressure relief valve functionality. Rectify /Change the Engine oil cooler module
code) check module.
Check the voltage of the sensor signal with respect to ground (Spec
Sensor faulty
0.87V) (Check the value with tester)
1. Engine minimum oil pressure 1.5 bar at
Check any oil leakgae in the engine. Arrest oil leakage.
Minimum oil pressure error in plausibil- idling.
28 P0524 Minimum Oil level in engine Check oil level Fill sufficient oil level.
ity check
Oil filter clogged. Check whether the oil filter is clogged. Replace oil filter
Service Manual
EDC17 ERROR CODES

1. pin no1 & 4 on the sensor connector
Signal line short to ground 2. pin no A57 & A44 on the ECU connector Rectify / replace Wiring Harness
Oil pressure sensor signal voltage below
29 P0522 3. Check for the sensor error in Tester
lower limit
Sensor defective Replace sensor - If the voltage out of specified limit
the error code
(pamb=101kPa)
Loose connection / poor contact between
sensor socket & connector.
Visual Inspection Ensure proper locking of the connector and sensor socket
sensor socket
No electrical continuity between ECU to sen-
sor connector.
1. pin no 3 & 4 on the sensor connector Rectify / replace Wiring Harness If continuity is there.
Signal line short to supply (5Volts) 2. pin no A24 & A44 on the ECU connector
Oil pressure sensor signal voltage above 3. pin no 45 & 46 on the interconnector.
30 P0523 Thershould not be any continuity in any of the case.
upper limit Check the voltage between
Signal line short to battery (greater than 5
Volts)
There should not be more than 5V in any of the case.
Sensor defective Replace sensor - If the voltage out of specified limit
the error code
(pamb=101kPa)
1. Fill suficient oil level
1. Ensure the oil level. 2. Use correct oil grade.
2. Check the correct oil grade. 3. Rectify the oil leakage
Oil temperature exceeds 115degC.
3. Check for oil Leakage . 4. Clean the oil circuit pipes
4. Any blockage in the oil circuit. 5. Replace / Rectify wiring harness
6. Replace sensor if faulty
31 P0298 Oil temperature too high plausibility error 5. Check the wiring harness connection of the Oil temperature sensor as 1. Replace / Rectify wiring harness
Oil temperature sensor drift.
mentioned for Refer check point --- P0198 & P0197 (Sl no26 & 27 ) 2. Replace sensor if faulty
1.Check the coolant temperature through tester.
1. Rectify coolant leakage.
2. Check the coolant leakage.
Cooling system failure. 2. Replace / Rectify wiring harness
3. Check the wiring harness connection of the coolant temp sensor Refer
3. Replace sensor if faulty
check point --- P0118 & P0117 (Sl no30 & 31)
Service Manual
EDC17 ERROR CODES

Loose connection / poor contact of socket. Visual Inspection Ensure proper locking of the connector and sensor socket

No electrical continuity between ECU to Oil
temperature sensor connector

1. pin no 3 & 2 on the sensor connector Rectify / replace Wiring Harness
Signal line short to supply (5Volts) 2. pin no A24 & A59 on the ECU connector
P0198 Thershould not be any continuity in any of the case.
Oil Temperature sensor signal voltage
32 P0019
above upper limit Check the voltage between
(OBD)
Volts)
3. pin no 44, 43 on the interconnector
Check the resistance value b/w pin no 2 & 1 of oil pressure sensor - It
should be in between
1) 1990 Ohms to 2123 kOhms (25°C)
Sensor defective Replace sensor - If the resistance is out of specified limit.
2) 1139 ohms to 1209(40°C)
3) 579.7 ohms to 611 ohms(60°C)
4. 315 ohms to 330 ohms(80°C)

Signal line short to ground 2. pin no A59 & A57 on the ECU connector Rectify / Replace WH
P0197 Check the resistance value b/w pin no 2 & 1 of oil pressure sensor - It
Oil Temperature sensor signal voltage
33 P0019 should be in between
below lower limit
(OBD) 1) 1990 Ohms to 2123 kOhms (25°C)
2) 1139 ohms to 1209(40°C)
3) 579.7 ohms to 611 ohms(60°C)
4. 315 ohms to 330 ohms(80°C)
Loose connection. Visual Inspection Ensure proper connections
2. Check continuity between pin no 2 on the sensor connector and pin Rectify / Replace WH if there is no continuity.
sor connector.
P0090 There should be continuity in both the case.
34 P0251 Metering unit output open load error i) Using omitec diagnostic scan tool goto actuators test via Ashok
(OBD) diagnostics--->Diesel--->Engine---> Autodetect--->Actuators test.
Actuator defective (Fuel metering unit failure) ii) Select metering unit from the list. Replace Metering unit if the resistance value is not as per spec.
iii) Increase the duty cycle to 40% in engine idling condition.
iv) Engine should shut off
Service Manual
EDC17 ERROR CODES

Check continuity between A04 on the ECU connector / pin 20 on Inter-
connector and supply pins (K01/K03/K05/K88) on the ECU connector.
P1119 There should be continuity in any of the case. 1. Rectify / Replace wire harness if ther is a continuity & do one
(Ms code) Metering unit high side short circuit to Check continuity between afterrun check the error
35 Short circuit with battery supply.
P0254 battery error 1. pin no A04 & A05 on the ECU connector 3. If error still there, change ECU and do one afterrun.
(OBD) 2. pin no 20 & 21 on Interconnector
3. pin no 1 &2 on metering unit connector
1. Rectify / Replace wire harness if ther is a continuity.clear the
error and heck for error.
P1120 (Ms Check continuity between A04 on the ECU connector / pin 20 on Inter- 2. Change the metering unit(pump) if error present & check for
Metering unit high side short circuit to
36 code) 1. Short circuit with gnd. connector and supply pins (K02/K04/K06) on the ECU connector. error.
ground error
P0253(OBD) There should be continuity in any of the case 3. If error still there, change ECU
4. After changing the ECU, clear the error anc check, if error still
present, check with the different Metering unit(pump)
No electrical continuity between ECU to injec- Check the continuity between pin no A33 & A16 with (Interconnector 3 &
Rectify / Replace wire harness if ther is a continuity
tor connector. 4 ) injector connector 1 & 2
Injector terminals(nut) loosen. Visual inspection Ensure proper tightening
Check the resistance value b/w terminal of injector- It should be in be-
tween 218mohm to 241mohm.
Check the injector1 functionality thru tester.
37 P0201 Open load Injector1
Injector(Actuator) defective diagnostics--->Diesel---> Engine--->Autodetect--->Actuators test. If the resistance is out of specified limit - Replace injector
ii) Select Cylinders shutoff from the list.
iii) Select 4 or 6 Cylinders menu.
iv) Turn OFF individual cylinders and observe the engine vibrations on
number of injectors turned off.
No electrical continuity between ECU to Check the continuity between pin no A47 & A17 with (Interconnector 5 &
injector connector. 6 ) injector connector 1 & 2.
Injector terminals loosen. Visual inspection Ensure proper tightening
38 P0202 Open load Injector2 i) Using omitec diagnostic scan tool goto actuators test via Ashok
Actuator defective diagnostics--->Diesel---> Engine--->Autodetect--->Actuators test. If the resistance is out of specified limit - Replace injector
No electrical continuity between ECU to injec- Check the continuity between pin no A48 & A18 with (Interconnector 7 &
tor connector. 8 ) injector connector 1 & 2.
Injector terminals loosen. Visual inspection Ensure proper tightening (Tightening torque - 1.5 ±0.25Nm)
Service Manual
EDC17 ERROR CODES
No electrical continuity between ECU to Check the continuity between pin no A31 & A01 with (Interconnector 9 &
injector connector. 10 ) injector connector 13 & 14

Check the resistance value b/w terminal of injector- It should be in
between 218mohm to 241mohm.
No electrical continuity between ECU to Check the continuity between pin no A46 & A03 with (Interconnector 13
injector connector. & 14 ) injector connector 1 & 2.

No electrical continuity between ECU to Check the continuity between pin no A32 & A02 with (Interconnector 11
injector connector. & 12 ) injector connector 1 & 2

42 P0206 Open load Injector6
Check continuity between A33 (Interconnector pin 3) to ECU K02/04/06
Injector low side line short with High side
or K01/03/05/88 (there should not be any continuity)
Check continuity between A16 (Interconnector pin 4) to ECU
43 P0262 Injector 1 general short circuit Injector low side line short with supply
K01/03/05/88 or K02/04/06 (there should not be any continuity)
Injector electrical connection short with Remove injector from clyinder head, check continuity between injector
replace the injector
injector body terminal to injector body. There should not be any body short
Service Manual
EDC17 ERROR CODES

1. Injector high side line short with gnd.
44 P0265 Injector 2 general short circuit Check continuity between A17 (Interconnector pin 6) to ECU
1. Injector low side line short with supply.
45 P0268 Injector 3 general short circuit 1. Injector low side line short with supply.
or K01/03/05/88 (there should not be any continuity) Rectify / Replace wire harness if ther is a continuity
Injector electrical connection short with injec- Remove injector from clyinder head, check continuity between injector
tor body terminal to injector body. There should not be any body short
or K01/03/05/88 (there should not be any continuity) Rectify / Replace wire harness if ther is a continuity
Check continuity between A03(Interconnector pin 14) to ECU
K02/04/06 or K01/03/05/88 (there should not be any continuity) Rectify / Replace wire harness if ther is a continuity
Check the continuity between A33 & A16 / 1 & 2 of injector connector of
Injector 1 short circuit Low Side to High Injector wires short circuit. internal wiring harness / 3 & 4 of Interconnector.(there should not be any Rectify / Replace wire harness if there is a continuity
49 P0261 continuity)
Side
Injector terminals loosen & short circuit. Visual inspection. Ensure proper fitment
Check the continuity between A47 & A17 / 1 & 2 injector connector of
Injector 2 short circuit Low Side to High Injector wires short circuit. internal wiring harness / 5 & 6 of Interconnector.(there should not be any Rectify / Replace wire harness if ther is a continuity
50 P0264
Side continuity)
Injector 3 short circuit Low Side to High Injector wires short circuit. internal wiring harness / 7 & 8 of Interconnector.(there should not be any Rectify / Replace wire harness if ther is a continuity
51 P0267
continuity)
Injector 4 short circuit Low Side to High Injector wires short circuit. internal wiring harness / 9 & 10 of Interconnector.(there should not be Rectify / Replace wire harness if ther is a continuity
52 P0270
Side any continuity)
53 P0273 Side any continuity)
54 P0276 any continuity)
Side
Service Manual
EDC17 ERROR CODES

Check continuity between,
1) pin no 1 on the injector connector / pin no 3 on the interconnector /pin
no A33 on the ECU connector and K02/K04/K06.
Any One cyl in Bank 1 (Cyl 1,2,3) 2) pin no 1 on the injector onnector / pin no 5 on the interconnector /pin
High side short to gnd no A47 on the ECU connector and K02/K04/K06.
There should not be continuity in any of the case.
no A33 on the ECU connector and K01/K03/K05/K88.
55 P2148 Injector Bank 1 short circuit Any One cyl in Bank 1 (Cyl 1,2,3) 2) pin no 1 on the injector onnector / pin no 5 on the interconnector /pin
High side short to battery no A47 on the ECU connector and K02/K04/K06.
no A48 on the ECU connector and K01/K03/K05/K88.
low side short to gnd no A17 on the ECU connector and K02/K04/K06.
1) pin no 1 on the injector connector / pin no 10 on the interconnector /
pin no A01 on the ECU connector and K02/K04/K06.
High side short to gnd no A02 on the ECU connector and K02/K04/K06.
pin no A01 on the ECU connector and K01/K03/K05/K88.
56 P2151 Injector Bank 2 short circuit Rectify / Replace wire harness if ther is a continuity
High side short to battery no A02 on the ECU connector and K02/K04/K06.
pin no A03 on the ECU connector and K01/K03/K05/K88.

low side short to gnd no A02 on the ECU connector and K02/K04/K06.
Engine speed exceeds 3000 rpm. 1. Advise Proper driving

Down hill drive. Do not downshift the gear by higher shifts (eg.from 5th gear to
57 P0219 Engine Overspeed detected Ensure engine/ exhaust brake functionality if applicable
Improper downshifting of gears during down- 2nd gear)
hill drive 2. Use exhaust brake when descending from hills
Service Manual
EDC17 ERROR CODES

sensor socket
1. Check continuity between pin no 3 (Tyco connector)/ pin no B (Metri
connector) on the sensor connector and pin no K62 on the ECU con-
Open circuit of ground
nector.
1. Check continuity b/w
1. pin no K61 & K45 on the ECU connector
2. pin no A & C (metri connector)/ pin no 1 & 2 (tyco connector)
Signal line short to supply (5Volts) 2. Check continuity b/w Rectify / replace Wiring Harness
P0123 (Ms Accelerator pedal sensor 1 signal volt- 2. pin no A & D (metri connector)/ pin no 1 & 5 (tyco connector)
58 Thershould not be any continuity in both the case.
code) age above upper limit
pin no A & B (metri connector)/ pin no 1 & 3 (tyco connector)
Volts)
1. Check resistance of the Acc ped sensor(Pin no 1 &3) : 2.21 kOhms
± 0.4 kOhms in Zero Position and 1.44 kOhms ± 0.4 kOhms in Max. Posi-
tion.
Sensor defective 2. Check accelearator pedal 1 and pedal 2 raw voltage and ensure the If resistance is not as per spec replace sensor
pedal voltage 2 is half of pedel voltage 1
3.Enure with diagnostic tool by pressing the accped from 0 to 100%
reading
sensor socket
1. Check continuity between pin no 1 (Tyco connector)/ pin no A (Metri
nector.
2. Check continuity between pin no 2 (Tyco connector)/ pin no C (Metri
sor connector.
nector.
There should be continuity in both the case. Rectify / Replace WH if there is no continuity.
P0122 (Ms Accelerator pedal sensor 1 signal volt-
59 2. pin no A & B (metri connector)/ pin no 1 & 3 (tyco connector)
code) age below lower limit
Signal line short to gnd 2. Check continuity b/w
2. pin no A & E (metri connector)/ pin no 1 & 6 (tyco connector)
There should not be continuity in both the case.
1.Check resistance of the Acc ped sensor (Pin no A & B) : 2.21 kOhms
tion.
reading
Service Manual
EDC17 ERROR CODES

sensor socket
1. Check continuity between pin no 6 (Tyco connector)/ pin no E (Metri
Open circuit of ground
nector.
2. pin no F & D (metri connector)/ pin no 4 & 5 (tyco connector)
Signal line short to supply (5Volts) 2. Check continuity b/w Rectify / replace Wiring Harness
P0223 (Ms 1. pin no K83 & K45 on the ECU connector
60
code) Accelerator pedal sensor 2 signal volt- 2. pin no F & C (metri connector)/ pin no 4 & 2 (tyco connector)
age above upper limit Thershould not be any continuity in both the case.
Signal line short to battery
pin no F& E (metri connector)/ pin no 4 & 6 (tyco connector)
(greater than 5 Volts)
1.Check resistance of the Acc ped sensor(Pin no 1 &3) : 2.21 kOhms
tion.
reading
61 ECU defective No check points
sensor socket
1. Check continuity between pin no 4 (Tyco connector)/ pin no F (Metri
nector.
2. Check continuity between pin no 5 (Tyco connector)/ pin no D (Metri
sor connector.
nector.
Rectify / Replace WH if there is no continuity.
P0222 (Ms Accelerator pedal sensor 2 signal volt- 2. pin no F & E (metri connector)/ pin no 4 & 6 (tyco connector)
62
code) age below lower limit Signal line short to gnd 2. Check continuity b/w
2. pin no F & B (metri connector)/ pin no 4 & 3 (tyco connector)
There should not be continuity in both the case.
1.Check resistance of the Acc ped sensor(Pin no 4 &6) :
2.80 kOhms 0.4 kOhms in Zero Position and 2.26 kOhms ± 0.4 kOhms in
Max. Position.
reading
Service Manual
EDC17 ERROR CODES

ACC pad1
Check resistance of the Acc ped sensor(Pin no 1 &3) : 2.21 kOhms ± 0.4
1.Replace the accelarator pedal.
P2135 (Ms Non-plausibility error between APP1 & 1. Sensor defective. kOhms in Zero Position and 1.44 kOhms ± 0.4 kOhms in Max. Position.
63
code) APP2 2. WH problem ACC pad2
2. Rectify/Replace the WH.
Check resistance of the Acc ped sensor (Pin nos 4 & 6) :2.80 kOhms ±
0.4 kOhms in Zero Position and 2.26 kOhms ± 0.4 kOhms in Max. Position.
1. Ensure vehicle speed sensor proper installation
2. Check wiring harness
no K11 on the ECU connector
1. Vehicle speed exceeds the maximum 1. Change the vehicle speed sensor
Maximum threshold error for Vehicle 2. Check continuity between pin no 2 on the sensor connector and pin
64 P0297 setpoint speed
speed sensor no K34 on the ECU connector
2. Faulty sensor. 2. Rectify/Replace the WH.
There should be continuity in all the case.
4. Check 5A fuse in fuse module.
1. Ensure vehicle speed sensor proper installation
1. Change the vehicle speed sensor
1. Vehicle speed sensor loose connection. no K11 on the ECU connector
2. Sensor not connected 2. Check continuity between pin no 2 on the sensor connector and pin
65 P0501 Plausibility defect for vehicle speed 2. Rectify/Replace the WH.
3. Mounting loose no K34 on the ECU connector
4. Wiring harness problem 3. Check continuity between pin no 3 on the sensor connector and pin
3. Replace fuse.
There should be continuity in all the case.
4. Check 5A fuse in fuse module.
Replace Battery
66 P0563 SRC high for battery voltage sensor 1. Battery raw signal exceeds 3832mv at ECU Check the Battery Voltage (32V)
Change ECU if problem perstists
Replace Battery
67 P0562 SRC low for battery voltage sensor 1. Battery raw signal below 1040mv at ECU Check the Battery Voltage 9V (consider start condition)
Change ECU if problem perstists
1 Adjust the clutch sw if required
1. Ensure the clutch switch (loose connection / stuck at one position)
1. Clutch switch connector not connected
2. Loose connection of clutch connector 2. Rectify/Replace the WH.
( Check continuity/shortcircuit between K15 & K68 to clutch connector
68 P0704 Clutch not plausible
end)
Wiring harnes faulty 3. Replace Clutch switch
3. Check for the clutch switch status through diagnostic tester
3. Clutch switch failure
4.Ensure the IPU connection setting
4.Reset the IPU connection
1. Ensure the brake switch (loose connection / stuck at one position)
2. Check for the brake switch status through diagnostic tester Replace Brake switch
If the main brake contact Brk_stMn and the
69 P0504 Plausibility check for Brake redundant brake contact Brk_stRed are not in
( Check continuity/shortcircuit between K41, K14 & K68 to brake switch
the same state.
connector end) Reset the IPU connection
4.Ensure the IPU connection setting
P1639 (MS ECU temperature sensor signal voltage
70 Sensor failure at ECU. Replace ECU & faulty ECU to be sent for investigation
code) above upper limit
P1640 (MS ECU temperature sensor signal voltage
71 Sensor failure at ECU. Replace ECU & faulty ECU to be sent for investigation
code) below lower limit
1. Check for the proper connection of connector to the instrument cluter
2. Check wiring harness (K70 continuity)
3. Check for the blown fuse and replace if required
1. Lamp not connected
4. Check the functionlity of the lamp through tester.Procedure is men-
P1503 (MS 2. Wiring harness problem
72 Diagnostic lamp Open load error tioned below, Change the lamp
code) 3. Lamp is damaged
4. Lamp failure
ii)select Diagnostic Lamp from the list.
iii) Turn ON & OFF the lamp and verify the lamp functionality.
Service Manual
EDC17 ERROR CODES

1. Switch ON & Off the ignition key(with complete afterrun)
P1504 (MS ECU Defective - Diagnostic lamp over
73 ECU defective 2. Clear the error. Still error is present, check with a diff ECU
code) temperature error
3. Try the above step once again
1. Check the functionlity of the lamp through tester.

P1505 (MS Diagnostic lamp Short circuit to battery 1.Wiring harness problem
74 2. Check the continuity between Pin K70 on the ECU connector and ECU If problem still persists, replace SVS lamp
code) error 2.Short circuit to Battery
supply pins K01/K03/K05.
There should not be continuity in this case

P1506 (MS 1.Wiring harness problem
75 Short circuit to ground error 2. Check the continuity between Pin K70 on the ECU connector and ECU If problem still persists, replace SVS lamp
code) 2.Short circuit to Ground

P1608 (MS
ECU Defective - CY33X is defect 2. Clear the error.
76 code) ECU defective No check points
(injector chip error) 3. Try the above step once again
P062B(OBD)
4. Still error is present, check with a diff ECU
P1338 (Ms Number of injections is limited by charge
77 Low battery voltage (lower than 8.7V) Check the battery voltage Change the battery
code) balance of booster capacity
P1339 (Ms Number of injections is limited by charge
78 Low battery voltage (lower than 8.7V) Check the battery voltage Change the battery
code) balance of booster capacity
P1340 (Ms
79 Number of injections is limited by system Low battery voltage (lower than 8.7V) Check the battery voltage Change the battery
code)
Number of injections is limited by Number of injections requested is more than
P1115 (Ms
80 runtime allowed injections for current battery volatage Check the battery voltage Change the battery
code)
and engine speed
P2290 (Ms
81 check of minimum rail pressure Not enough rail pressure in the system Check the fuel circuit for fuel starvation
code)
Reported SPI and COM-Errors of a 1. Switch ON & Off the ignition key(with complete afterrun)
P1630 (Ms
82 Cy146 Hardware failure inside the ECU 2. Clear the error. Still error is present, check with a diff ECU
code)
SPI/COM-Errors of the Cy320
P1631 (Ms 1. Communication errors in Cy320 chip
83 2. Clear the error. Still error is present, check with a diff ECU
code) 2.damaged cy320 chip.
Not clear - Need more clarity
1. ECU internal error - EEPROM erase not 1. Switch ON & Off the ignition key(with complete afterrun)
P1629 (Ms EEP Read Error based on the error for
84 possible 2. Clear the error. Still error is present, check with a diff ECU
code) more blocks
2.damaged EEPROM 3. Try the above step once again
1. ECU internal error - EEPROM read not 1. Switch ON & Off the ignition key(with complete afterrun)
P1601 (Ms EEP Read Error based on the error for
code) more blocks
1. ECU internal error - EEPROM write not 1. Switch ON & Off the ignition key(with complete afterrun)
P1602 (Ms EEP Write Error based on the error for
code) one block
P1636 (Ms
87 Visibility of SoftwareResets 0 in DSM Not Applicable 2. Clear the error. Still error is present, check with a diff ECU
code)
P1637 (Ms
88 Visibility of SoftwareResets 1 in DSM Not Applicable 2. Clear the error. Still error is present, check with a diff ECU
code)
Service Manual
EDC17 ERROR CODES

1. If injection happens during overrun condi-
tion (e.g. downhill drive)
P1638 (Ms 2. Low Battery voltage (<5V)
89 Visibility of SoftwareResets 2 in DSM 2. Clear the error. Still error is present, check with a diff ECU
code) 3.Memory monitoring (MOC) related errors
Note: For all MOC related errors, SWReset is
hard -coded
ECU Defective - Diagnostic fault check 1. Switch ON & Off the ignition key(with complete afterrun)
P1632 (Ms
90 to report WDA active due to errors in Hardware failure inside the ECU 2. Clear the error. Still error is present, check with a diff ECU
code)
query-/response communication 3. Try the above step once again

P1633 (Ms Diagnostic fault check to report “ABE ac-
91 Hardware failure inside the ECU 2. Clear the error. Still error is present, check with a diff ECU
code) tive” due to under voltage detection

P1634 (Ms Diagnostic fault check to report “ABE
code) active” due to overvoltage detection

P1635 (Ms Diagnostic fault check to report “WDA/
code) ABE active” due to unknown reason
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.
95 code) Error Sensor power supply 2 2. Check all the component connected to SSPMon2 is shorted with bat- 2. replace ECU.
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.
96 code) Error Sensor power supply 3 2. Check all the component connected to SSPMon3 is shorted with bat- 2. replace ECU.
P0697(OBD) tery/ground 3. replace Rail pressure sensor
Components are
1.Rail pressure sensor (A07)
Service Manual
EDC17 ERROR CODES
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)
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)
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
(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)
Starter relay
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
Service Manual
EDC17 ERROR CODES
1. Leakage in the high pressure section

2. worn high pressure pump/defective high
pressure 1. Replace the High pressure lines with leakage
3. injection nozzle stuck in open position 3. Change the rail
1. Check for leakage in high pressure circuit /check tightness of hydraulic
P1126 (Ms setpoint of metering unit in overrun 4. worn injector 4. Remove the pump and get it checked from the authorised
101 circuit.
code) mode not plausible 5. leaking pressure limiting valve dealer
2.PLV return line check for fuel
6. Possible error in low pressure system Zero 5. Remove the injector and get it checked from the authorised
delivery is not present for metering unit (leak- dealer
age in metering unit is more)/Possible error
in low pressure system metering unit faulty
1. Check whether the pump metering unit connector is connected prop-

1. Pump metering unit connector loose/not
erly.
connected 1. Change the rail
2. Check whether the rail pressure sensor connector is connected
2. Pump metering unit failure
P1100 (Ms properly.
102 PRV open 3. Rail pressure sensor connector loose/not
code) 3. Check the check points of Metering unit, Rail pressure sensors & SW
connected 2. Change the metering unit.
reset related errors (refer 1. P0193, P0192,
4. Rail pressure sensor failure.
2. P0090, P01119, P1120, P1121, P1122 &
5. overrun monitoring error
3. P1636, P1637, P1638)
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
1. Check whether the pump metering unit connector is connected

properly
1. Pump metering unit connector loose/not properly
connected 3. Check the connectivity between metering unit connector pin and ECU 1. Change the pump
P1113 (Ms PRV is forced to open; perform pressure 2. Pump metering unit failure connector pin
105
code) increase 3. Rail pressure sensor connector loose/not 4. Check the connectivity between rail pressure sensor connector pin and
connected ECU connector pin 2. Change the rail
4. Rail pressure sensor failure 5. Check the check points of Metering unit, Rail pressure sensors & SW
2. P0090, P01119, P1120, P1121, P1122 &
3. P1636, P1637, P1638)
1. Check whether the pump metering unit connector is connected

properly
1. Pump metering unit connector loose/not properly
connected 3. Check the connectivity between metering unit connector pin and ECU 1. Change the pump
P1101 (Ms 2. Pump metering unit failure connector pin
106 PRV forced open (pressure shock)
code) 3. Rail pressure sensor connector loose/not 4. Check the connectivity between rail pressure sensor connector pin and
connected ECU connector pin 2. Change the rail
4. Rail pressure sensor failure 5. Check the check points of Metering unit, Rail pressure sensors & SW
2. P0090, P01119, P1120, P1121, P1122 &
3. P1636, P1637, P1638)
P1118 (Ms
107 Rail pressure raw value is intermittent
code)
Maximum rail pressure in limp home
108 P1127
mode with PRV
Service Manual
EDC17 ERROR CODES

Visusal inspection
Fleet guard
Check the wiring harenss continuity from K36 on ECU pin to 1 on the
sensor pin.
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.
sensor pin.
There should be continuity in both the cases.
For Fleet guard fuel filter

Measure resistance across the terminals of crank shaft sensor, it should
be 2.63K ohm
Sensor defective Change the sensor
ohm to 4940K ohm.
For MHBI fuel filter
No check points
fuse blown Check the 5A fuse in fuse box Replace the fuse.
Fleetguard
Check the wiring harenss continuity between
1. pin no K36 & K21 on ECU
2. pin to 1 on the sensor & 2 /ECU ground pins K02/K04/K06
Signal line short to ground MHBI Rectify/Replace the WH
Check the wiring harenss continuity between
1. pin no K36 & K21 on ECU
P1522 (Ms Water-in-Fuel Sensor signal voltage 2. pin to 2 on the sensor & 3 /ECU ground pins K02/K04/K06
110
code) below lower limit There shoul not be any continuty in any of the case
For Fleet guard fuel filter
Measure resistance across the terminals of crank shaft sensor, it should
be 2.63K ohm
Sensor defective ohm to 4940K ohm. Change sensor with filter
For MHBI fuel filter

No check points
P1523 (Ms 1. Excess water accumulated in the water 1. Drain the accumulated water in the fuel filter through the drain
111 water in Fuel Detection Visusal inspection
code) separator cock
P1103 (Ms 1. Switch ON & Off the ignition key(with complete afterrun)
Metering unit (ECU) Over temperature
112 code) _ 2. Clear the error. Still error is present, check with a diff ECU
error
P0252(OBD) 3. Try the above step once again
1. Check any loose connection for A04/A05
P1116 (Ms Intermittent contact between ECU and Intermettent Loose connection of MeUn
113 2. Check any signal distubace on the connector due to stress & vibration 1. Replace/Rectify the W.H
code) Metering Unit (A04/05)
3. check for any wire backout
P1121 (Ms Check the continuity between pin no A05 on the ECU connector and ECU
Metering unit output short circuit to bat- 1. Pump metering unit short circuit to battery 1. Replace/Rectify the W.H
114 code) supply lines K01/03/05/K88/A04
tery error 2. Wiring harness loose connection on -ve 2. If still error persists, change the Metering Unit(Pump)
P0254(OBD) There should not be any continuity in this case.
Service Manual
EDC17 ERROR CODES

P1122 Check the continuity between pin no A05 on the ECU connector and
Metering unit output short circuit to 1. Replace/Rectify the W.H
115 (Ms code) Short circuit with Ground ECU supply lines K02/04/06
ground error 2. If still error persists, change the Metering Unit(Pump)
P0253(OBD) There should not be any continuity in this case.
Powerstage diagnosis could be disabled Replace Battery
116 P0659 Batery voltage is high (32V) Check the Battery Voltage
due to high Battery voltage Change ECU if problem perstists
Powerstage diagnosis could be disabled Replace Battery
117 P0658 Batery voltage is low (9V) Check the Battery Voltage (consider start condition)
due to low Battery voltage Change ECU if problem perstists
ECU Defective - Diagnostic fault check 1. Error detectetd in the plausibility check of
P1405 (Ms 1. Clear the error through the diagnostic tester.
118 to report the NTP error in ADC monitor- the ADC by no load test pulse test. The ECU No check points
code) 2. If the problem persists, replace the ECU
ing has an internal error.( ADC error)
1.Error detected in the plausibility check of
P1406 (Ms ECU Defective - Diagnostic fault check 1. Clear the error through the diagnostic tester.
119 the ADC by voltage test signal. The ECU has No check points
code) to report the ADC test error 2. If the problem persists, replace the ECU
an internal error. ( ADC error)
ECU Defecive - Diagnostic fault check to 1. Error detected in the plausibility check of
120 report the error in Voltage ratio in ADC the ADC in the voltage ratio. The ECU has an No check points
monitoring internal error. (ADC error)
ECU Defective - Diagnostic fault check
P1408 (Ms 1. Error in the plausbility of FC and MM com- 1. Clear the error through the diagnostic tester.
121 to report errors in query-/response- com-
code) munication. The ECU has an internal error. 2. If the problem persists, replace the ECU
munication
P1409 (Ms ECU Defective - Diagnostic fault check 1. Clear the error through the diagnostic tester.
122 error in SPI-communication No check points
code) to report errors in SPI-communication 2. If the problem persists, replace the ECU
Diagnostic fault check to report multiple
P1410 (Ms 1. Injector error 1. Clear the error through the diagnostic tester.
123 error while checking the complete ROM- No check points
code) 2. The ECU has an internal error. 2. If the problem persists, replace the ECU
memory
Check for injector related error in the tester, if any take corrective action
P1411 (Ms Loss of synchronization sending bytes to 1. Injector error 1. Clear the error through the diagnostic tester.
124 (Pcodes are P0201, P0202, P0203, P0204,P0205,P0206, P0262, P0265,
code) the MM from CPU. 2. The ECU has an internal error. 2. If the problem persists, replace the ECU
P0268, P0271, P0274, P0277, P2148, P2151)
DFC to set a torque limitation once an Check for injector related error in the tester, if any take corrective action
125 error is detected before MoCSOP’s error (Pcodes are P0201, P0202, P0203, P0204,P0205,P0206, P0262, P0265,
reaction is set P0268, P0271, P0274, P0277, P2148, P2151)
126 Wrong set response time (Pcodes are P0201, P0202, P0203, P0204,P0205,P0206, P0262, P0265,
P0268, P0271, P0274, P0277, P2148, P2151)
P1413 (Ms Too many SPI errors during MoCSOP 1. Injector error 1. Clear the error through the diagnostic tester.
code) execution. 2. The ECU has an internal error. 2. If the problem persists, replace the ECU
P0268, P0271, P0274, P0277, P2148, P2151)
P1415 (Ms Diagnostic fault check to report the error 1. Injector error 1. Clear the error through the diagnostic tester.
code) in under voltage monitoring 2. The ECU has an internal error. 2. If the problem persists, replace the ECU
P0268, P0271, P0274, P0277, P2148, P2151)
P1416 (Ms Diagnostic fault check to report that 1. Injector error 1. Clear the error through the diagnostic tester.
code) WDA is not working correct 2. The ECU has an internal error. 2. If the problem persists, replace the ECU
P0268, P0271, P0274, P0277, P2148, P2151)
P1417 (Ms OS timeout in the shut off path test. 1. Injector error 1. Clear the error through the diagnostic tester.
code) Failure setting the alarm task period. 2. The ECU has an internal error. 2. If the problem persists, replace the ECU
P0268, P0271, P0274, P0277, P2148, P2151)
P1432 (Ms Diagnostic fault check to report that the 1. Injector error 1. Clear the error through the diagnostic tester.
code) positive test failed 2. The ECU has an internal error. 2. If the problem persists, replace the ECU
P0268, P0271, P0274, P0277, P2148, P2151)
P1419 (Ms Diagnostic fault check to report the 1. Injector error 1. Clear the error through the diagnostic tester.
code) timeout in the shut off path test 2. The ECU has an internal error. 2. If the problem persists, replace the ECU
P0268, P0271, P0274, P0277, P2148, P2151)
P1420 (Ms Diagnostic fault check to report the error 1. Injector error 1. Clear the error through the diagnostic tester.
code) in overvoltage monitoring 2. The ECU has an internal error. 2. If the problem persists, replace the ECU
P0268, P0271, P0274, P0277, P2148, P2151)
1. Error in the plausibility of current energising
Diagnostic fault check to report the error time with maximum permitted energising time
134 due to Over during overrun. The ECU has an internal No check points
Run error.
2. Violation of Overrun condition
Service Manual
EDC17 ERROR CODES

Injection cut off demand (ICO) for shut Overrun monitoring fault (DFC_MoFOvR) will 1. Clear the error through the diagnostic tester.
135 P0215 No check points
off coordinator trigger this error 2. If the problem persists, replace the ECU
136 P1641
1. Visual inspection
2. Check the ECU connector K92 control line is not short circuited
3. Check the functionlity of the lamp through tester.Procedure is men-
1. Connector open or loose connection.
tioned below, 1. Ensure proper connections.
137 P1533 No Load Error 2. No electrical continuity between ECU &
i) Using omitec diagnostic scan tool goto actuators test via Ashok 2.. Rectify/ Replace wiring harness
stop lamp
ii) select water in fuel Lamp from the list.

Over temperature error in ECU power 2. Clear the error.
138 P1534 Permanent Short Circuit to Battery -
stage 3. Try the above step once again
4. Still error is present, check with a diff ECU
1.Wiring harness problem Check the ECU connector K92 control line is not short circuited to Bat- If problem still persists, replace stop lamp
139 P1535
2.Short circuit to Battery tery.
1.Wiring harness problem Check the ECU connector K92 control line is not short circuited to If problem still persists, replace stop lamp
140 P1536
2.Short circuit to Ground Ground.
1. Pump metering unit connector loose/not 1. Check whether the pump metering unit connector is connected prop-
connected erly.
P1136 1. Change the rail
Averaged rail pressure is outside the 2. Pump metering unit failure 2. Check whether the rail pressure sensor connector is connected
141 P0113 2. Change the metering unit.
expected tolerance range 3. Rail pressure sensor connector loose/not properly.
(OBD)
connected 3. Check the check points of Metering unit, Rail pressure sensors (refer
4. Rail pressure sensor failure P0193, P0192, P0090, P1119, P1120, P1121, P1122)
1. Error in the plausibility of current energising
time with maximum permitted energising time
1. Clear the error through the diagnostic tester.
142 P1435 during overrun when cooling injections are No check points
2. If the problem persists, replace the ECU
active. The ECU has an internal error.
2. Violation of Overheat protection
1. The positive limit for the EGR deviation 1. Check the deviation between set and actual EGR valve in diagnostic 1. Clean the EGR valve for accumulation of dust/ soot
EGR valve position governor deviation
P0401 (EGR Desired -EGR actual) of +15% has toolwhich would be more than the threshold 2.Replace or rectify the wiring harness if any problem in WH.
143 max / EGR valve jammed at closed
been exceeded 2. Check for any physical monement blockage & Ensure the proper 3. If still problem persists, change the EGR Valve
position
2. EGR valve sticky & EGR valve stuck electrical to EGR valve.
1. Check the deviation between set and actual EGR valve in diagnostic 1. Clean the EGR valve for accumulation of dust/ soot
EGR valve position governor devia- 1. The positive limit for the EGR deviation of
P0402 toolwhich would be more than the threshold 2.Replace or rectify the wiring harness if any problem in WH.
144 tion min / EGR valve jammed at open -15% has been exceeded
2. Check for any physical monement blockage & Ensure the proper 3. If still problem persists, change the EGR Valve
position 2. EGR valve sticky & EGR valve stuck
electrical to EGR valve.
1. Check the continuity between pin no A19 on ECU connector / pin no
52 on interconnector and K01 /K03/K05/K88.
(or)
1. Short circuit of actuator lines with battery. Check the continuity between A20 / pin no 53 on interconnector and K01
EGR valve Short circuit to battery at 1. Rectify / Replace WH
145 P0490 2. H Driver stage check – for short circuit to /K03/K05/K88
Out1 / out2 2. If problem still persists replace EGR Valve/ECU.
battery supply (internal ECU)
Thereshould not be any continuity in both the cases
2. Check with another H bridge ECU

1. Check the continuity between pin no A19 on ECU connector / pin no 52
on interconnector and K02 /K04/K06. (or)
1. Short circuit of actuator lines with ground
EGR valve Short circuit to ground at Check the continuity between A20 / pin no 53 on interconnector and K02 1. Rectify / Replace WH
146 P0489 2. H Driver stage check – for short circuit to
Out1 / out2 /K04/K06 2. If problem still persists replace EGR Valve/ECU.
ground (internal ECU)
Thereshould not be any continuity in both the cases
Service Manual
EDC17 ERROR CODES

Loose connection / poor contact between sen-
sor socket & connector.
sensor socket
147 P0487 EGR Valve Open load error 1. Check continuity between pin no 1 on the sensor connector and pin no
A19on the ECU connector / pin no 52 on the interconnector
sor connector.
1. Check thecontinuity between pin no 4 on the sensor connector / pin no
A12 on the ECU connector/ pin no 54 on the interconnector
Signal line short to ground 2. Check thecontinuity between pin no 2 on the sensor connector / pin no Rectify / Replace WH
A40on the ECU connector/ pin no 55 on the interconnector
Thershould not be any continuity in both the case.
EGR Valve position sensor signal voltage 2. Remove sensor end connector
148 P0405 3. Check for the sensor error in Tester
below lower limit
Sensor defective If Error is registered, then connect the sensor end connector and erase Replace EGR with cooler - If the voltage out of specified limit
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
If all the above check points are ok Replace ECU / Faulty ECU to
be sent for investigated
Loose connection / poor contact between sen-
sor socket & connector.
sensor socket
A40 on the ECU connector / pin no 55 on the interconnector
sor connector.
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
Volts)
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
The voltage spec should be 0.6V to 0.8V when ignition ON condition
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.
Service Manual
EDC17 ERROR CODES
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.
1.1.Thermostat is always open

2. Coolant temperature sensor not connected Rectify / Replace WH
P0116(OBD) Check the Sensor signal voltage thru tester (Parameter 3) when ignition
defect fault check for Absolute plausibil- properly to Engine block. Rectify / replace Wiring Harness If the measured voltage is
152 P251D is on.
ity test 3. Coolant temperature signal wire shorted to above 5 V
(MS Code) Voltage should be 500±48mV.
battery/Gnd wire If the resistance is out of specified limit - Replace sensor
4.Wrong specification sensor / faulty sensor

.1.Thermostat is always open 3. pin no 27 & 28 on the interconnector
2. Coolant temperature sensor not connected Rectify / Replace WH
P0116(OBD)
defect fault check for dynamic plausibility properly to Engine block. Thershould not be any continuity in any of the case. Rectify / replace Wiring Harness If the measured voltage is
153 P251E
test 3. Coolant temperature signal wire shorted to Check the resistance value b/w pin no 2 & 1 of coolant pressure sensor - above 5 V
(MS Code)
battery/Gnd wire It should be in between If the resistance is out of specified limit - Replace sensor
4.Wrong specification sensor / faulty sensor 1) 1940 Ohms to 2173 kOhms (25°C)
2) 1118 ohms to 1231(40°C)
3) 573 ohms to 618 ohms(60°C)
4. 313 ohms to 332 ohms(80°C)
Short circuit to ground error on the
154 P1526
engine speed output
155 P1527 Engine speed Open load
Engine Coolant Over Temperature
156 P0217 Engine Over heating 1. Inspect the cooling system
Condition
157 P0127 Intake Air Temperature Too High Engine Over heating Inspect the air intake system
1. Check for the proper connection of connector to the instrument cluter
3. Check for the blown fuse and replace if required
1. Lamp not connected 4. Check the functionlity of the lamp through tester.Procedure is men-
P0650 Malfunction indication lamp Open load 2. Wiring harness problem tioned below,
158 Change the lamp
(MS code) error 3. Lamp is damaged i) Using omitec diagnostic scan tool goto actuators test via Ashok
4. Lamp failure diagnostics--->Diesel--->Engine---> Autodetect--->Actuators test.
ii)select MIL Lamp from the list.

P0651 Malfunction Indication lamp over tem- 2. Clear the error.
159 ECU defective Still error is present, check with a diff ECU
(MS code) perature error 3. Try the above step once again

P0652 Malfuntion Indication lamp Short circuit 1.Wiring harness problem
160 2. Check the continuity between Pin K71 on the ECU connector and ECU If problem still persists, replace MIL lamp
(MS code) to ground error 2.Short circuit to Battery

Service Manual
EDC17 ERROR CODES

P0653 Malfunction Indication lamp Short circuit 1.Wiring harness problem
161 2. Check the continuity between Pin K71 on the ECU connector and ECU If problem still persists, replace MIL lamp
(MS code) to ground error 2.Short circuit to Ground
162 P2535 Defective T50 switch Wiring harness problem Check continuity between K35 and T50 switch.
1. Check Starter relay

163 P0615 Starter relay No load error Wiring harness problem 2. Check Continuity bw K28 to Starter relay (85) & K35 to Starter If problem still persists, Change starter relay
relay(86).
1. Check Starter relay

1. Wiring harness problem
164 P0618 Starter relay short circuit to battery error 2. Check Continuity bw K28 to Starter relay (85) & K35 to Starter If problem still persists, Change starter relay
2. Short circuit to Battery
relay(86).
P1019(MS
Timeout Error of CAN-Receive-Frame
165 Code)
TSC1VE(SCR)
P0113(OBD)
1. The positive limit for the EGR devia-

166 P1205 tion of +10% has been exceeded longer EGR valve is stuck in closed position 1. Check for any physical monement blockage If the still persist Change the EGR Valve
than the applicated value of 10 sec.
1. The Negative limit for the EGR devia-
167 P1206 tion of -10% has been exceeded longer EGR valve is stuck in open position 1. Check for any physical monement blockage If the still persist Change the EGR Valve
than the applicated value of 10 sec.
Service Manual
EDC17 ERROR CODES RELATED TO EGR
S.No P-Code Description Reactions Possible causes Check Points Further Actions
1. Check the deviation between set and actual EGR valve in

diagnostic tool which would be more than the threshold
2. Check for any physical movement blockage & Ensure the proper
No Reaction only MIL 1. The positive limit for the EGR deviation 1. Clean the EGR valve for accumulation of dust/ soot
EGR valve position 3. i) Using omitec diagnostic scan tool go to actuators test via Ashok
ON after 3DC (EGR Desired -EGR actual) of +15% has 2.Replace or rectify the wiring harness if any problem
governor deviation max diagnostics--->Diesel--->Engine---> Auto-detect--->Actuators test.
1 P0401 (MIL =Malfunction been exceeded in WH.
/ EGR valve jammed at ii) Select EGR actuator from the list.
Indicator Lamp &
closed position iii) Increase the setting in ignition key ON condition 3. If still problem persists, change the EGR Valve
DC=Driving cycle) 2. EGR valve sticky & EGR valve stuck
iv) EGR valve spring should compress and expand as per setting.
v) Humming noise can be heard during actuation
4. Check live data (Parameter Set 4) for EGR Raw voltage/position
values changing during EGR learning after ignition Off.
1. Check the deviation between set and actual EGR valve in
diagnostic tool which would be more than the threshold
2. Check for any physical movement blockage & Ensure the proper
EGR valve position 3. i) Using Omitec diagnostic scan tool go to actuators test via Ashok 1. Clean the EGR valve for accumulation of dust/ soot
1. The positive limit for the EGR deviation
governor deviation min No Reaction only MIL diagnostics--->Diesel--->Engine---> Auto-detect--->Actuators test. 2. Replace or rectify the wiring harness if any problem
2 P0402 of -15% has been exceeded
/ EGR valve jammed at ON after 3DC ii) Select EGR actuator from the list. in WH.
2. EGR valve sticky & EGR valve stuck
open position iii) Increase the setting in ignition key ON condition 3. If still problem persists, change the EGR Valve
iv) EGR valve spring should compress and expand as per setting.
v) Humming noise can be heard during actuation
4. Check live data (Parameter Set 4) for EGR Raw voltage/position
values changing during EGR learning after ignition Off.
52 on interconnector and K01 /K03/K05/K88. (or) Check the continuity
1. Short circuit of actuator lines with between A20 / pin no 53 on interconnector and K01 /K03/K05/K88
EGR valve Short circuit
No Reaction only MIL battery. There should not be any continuity in both the cases 1. Rectify / Replace WH
3 P2142 to battery at Out1 /
ON immediately 2. H Driver stage check – for short circuit 2. Check with another H bridge ECU 2. If problem still persists replace EGR Valve/ECU.
out2
to battery supply (internal ECU) 3. Check the continuity between pin no 1 & 5 on EGR connector/ pin
no A19 & A20 on ECU connector There should not be any continuity in
both the cases

1. Short circuit of actuator lines with 52 on interconnector and K02 /K04/K06.
EGR valve Short circuit
No Reaction only MIL ground (or) Check the continuity between A20 / pin no 53 on interconnector 1. Rectify / Replace WH
4 P2141 to ground at Out1 /
ON immediately 2. H Driver stage check – for short circuit and K02 /K04/K06 2. If problem still persists replace EGR Valve/ECU.
out2
to ground (internal ECU) There should not be any continuity in both the cases

sensor socket & connector. Ensure proper locking of the connector and sensor
Visual Inspection
Improper locking of the connector over the socket
sensor socket Terminal backout
EGR Valve Open load No Reaction only MIL

5 P0487
error ON immediately
no A19on the ECU connector / pin no 52 on the interconnector
No electrical continuity between ECU to
sensor connector.
Service Manual
EDC17 ERROR CODES RELATED TO EGR
S.No P-Code Description Reactions Possible causes Check Points Further Actions
1. Check the continuity between pin no 4 on the sensor connector / pin

no A12 on the ECU connector/ pin no 54 on the interconnector
Signal line short to ground 2. Check the continuity between pin no 2 on the sensor connector / pin Rectify / Replace WH
no A40on the ECU connector/ pin no 55 on the interconnector
There should not be any continuity in both the case.
EGR Valve position MIL ON immediately & 1. Check Wiring Harness continuity & short Circuit
6 P0405 sensor signal voltage 40% Torque Limitation 2. Remove sensor end connector
below lower limit after 50 hours 3. Check for the sensor error in Tester If Error is registered, then Replace EGR with cooler - If the voltage out of specified
Sensor defective
connect the sensor end connector and erase the error code limit
The voltage spec should be 0.6V to 0.8V when engine idling condition
If all the above check points are ok Replace ECU /
Faulty ECU to be sent for investigated
Ensure proper locking of the connector and sensor
Improper locking of the connector over the Visual Inspection
socket
sensor socket
Terminal back out
No electrical continuity between ECU to
sensor connector.
EGR Valve position MIL ON & 40% Torque Signal line short to supply (5Volts) 2. pin no A12 & A22 on the ECU connector
7 P0406 sensor signal voltage Limitaion after 50 3. pin no 54 & 56 on the interconnector
above upper limit hours There should not be any continuity in any of the case.
Signal line short to battery (greater than
5 Volts)
Replace EGR with cooler - If the voltage out of specified
Sensor defective If Error is registered, then connect the sensor end connector and
limit
erase the error code
The voltage spec should be 0.6V to 0.8V when engine idling condition
ECU defective No check points If all the above check points are ok Replace ECU

EDC 17 For H-Series BSIII and BSIV Engines-Pass

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EDC17 SYSTEM

( FOR H SERIES CRS BSIII & BSIV ENGINES

EDC 17 SYSTEM FOR H SERIES BSIII & BSIV ENGINE

Section Subject Page No.

12.0 Electronic Diesel Control................................................................................ 12.01

12.1 Engine Start / Stop Procedure...................................................................... 12.04

12.2.1 Accelerator Pedal Sensor............................................................................ 12.10

12.0 ELECTRONIC DIESEL CONTROL - Clutch pedal switch

Common Rail System Do’s and Don’ts

12.1 ENGINE START / STOP PROCEDURE To warm up the engine

Engine Start Procedure - Check oil pressure minimum 0.5kg/cm2 at Idling.

- After starting the engine proceed slowly and keep

BY THIS METHOD IT IS POSSIBLE TO OBTAIN:

- Optimum oil flow throughout the lubrication

1. The ignition switch is provided in the steering

2. Turning this key further will crank the engine. After

Engine Stop Procedure

To stop the engine turn the ignition key anticlockwise.

Do’s and Don’ts:

- Idle the engine always about 2 mins after starting

- Do not switch-off the engine through engaging the

- Do not operate the starter motor for more than 10

Input Sensors / Switches Electronic Control Unit Output Actuators / Lamp

LOCATION OF SENSORS, ACTUATORS AND CONNECTORS ON ENGINE FOR 6 CYLINDER

Coolant temp. sensor Rail Pr. sensor

Cam sensor Metering Unit Boost Pr.

Oil Pr. Sensor

LOCATION OF SENSORS, ACTUATORS AND CONNECTORS ON ENGINE FOR 4 CYLINDER

Coolant temp. sensor Rail Pr. sensor Engine

Cam sensor Metering Unit Boost Pr. EGR Ac

Continuity checking for sensor with respect to ECU side connector

Big Connector (K type connector) Small Connector (A type connector)

Engine Inteface Connector (A type connector)

Boost Pressure & Engine ECU (A)

12.2.1 ACCELERATOR PEDAL SENSOR

DTC code Description

K84 6 - E- Pin A, B & C Main Sensor

ACCELERATOR PEDAL MODULE

12.2.2 ENGINE SPEED SENSOR Service Recommendation

12.2.3 CAMSHAFT SPEED SENSOR Circuit Diagram

Cam Speed Engine ECU (A)

Refer Chapter: Trouble shooting using error code / Blink

12.2.4 METERING UNIT Effect of Fault

Failure in metering unit system - 40% Torque limitation.

Function and working:

Possible Cause of Fault and Service instruction:

Refer Chapter: Trouble shooting using error code / Blink code

Engine ECU (A)

- Physically check for any loose connection of the Injector terminal.

12.2.6 INJECTORS FOR 4 CYLINDER ENGINE ECU/Injector Defective - Diagnostic

ECU/Injector Defective - OS timeout

P1417 in the shut off path test. Failure set-

ECU/Injector Defective - Diagnostic

Copper seal - ring

P0262 Injector 1 general short circuit

P0265 Injector 2 general short circuit

P0268 Injector 3 general short circuit

the MM from CPU.

12.2.7 COOLANT TEMPERATURE SENSOR At 40°C - 1.118 to 1.231 Kilo Ohms

DTC code Description

12.2.8 OIL PRESSURE & TEMPERATURE SENSOR Effect of fault in Vehicle

12.2.9 RAIL PRESSURE SENSOR P2290 Check of minimum rail pressure