1300 Series EDi IOPU

1
General information 1

Introduction
Once an engine build list has been selected from the Engine Specification Manual, this installation guide
provides the necessary information required to configure and apply the electronics of the 1300 series EDi
engine for use in an Industrial Open Power Unit (IOPU) application.
The 1300 series EDi is available as a charge cooled or non-charge cooled engine. The engine uses the HEUI
(hydraulically actuated, electronically controlled, unit injector) fuel injection system. This system provides in-
built electronic governing combined with additional features such as engine warning and protection.
The engine is supplied complete with an ECM (engine control module), essential on engine sensors and an
‘engine side wiring harness’.

Engine control module

Chassis side
connector
(60 pin black plug)
Engine side
connector
(60 pin grey plug)

W1014/1

Caution: The ECM must never be painted.

It must be stated at point of order whether the installation requires a 12V or 24V ECM. In addition, all electronic
application options must be specified at the point of order, albeit some of these options may subsequently be
changed using the electronic service tool. Selection of these options defines an electronic package number
(EPN) – repeat orders should quote the same EPN.
Having ordered the appropriate engine build list and EPN it is necessary to provide a ‘chassis side wiring
harness’ to interface between the engine and the IOPU application. If required, a prewired chassis side
connector, with a 3-metre long ‘pigtail’ of wires, can be ordered to help with this task. The ‘pigtail’ contains all
the wires required to implement any of the IOPU configurations and options detailed in the subsequent pages.

Electrical Installation Guide, TPD 1404E, issue 1 5

1 1300 Series EDi IOPU
On-engine sensor location
MAP ICP
MANIFOLD ABSOLUTE INJECTION CONTROL
EOT PRESSUE SENSOR PRESSURE SENSOR
ENGINE OIL
TEMPERATURE
SENSOR

ECM location
for IOPU’s

IPR
INJECTION PRESSURE
REGULATOR

EOP
ENGINE OIL
PRESSURE SENSOR W1059

ECT
ENGINE COOLANT
TEMPERATURE
SENSOR

CMP
CAMSHAFT POSITION
SENSOR

W1060

6 Electrical Installation Guide, TPD 1404E, issue 1

1300 Series EDi IOPU 1
Abbreviations
AAT.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Ambient air temperature sensor
APS . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Accelerator pedal sensor
ATA.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... American Trucking Association
BAP . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Barometric air pressure sensor
CLS.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Coolant level switch
ECM. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Engine control module
EDi... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Electronic Direct injection
EPN . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Electronic package number
FBO . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Feature Based Option (mechanical)
HSO. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... High Side Output
IOPU ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Industrial Open Power Unit
IPR... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Injection pressure regulator
IVPWR . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Ignition voltage power
Lhs ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Left hand side, when viewed from the flywheel end
Rhs .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Right hand side, when viewed from the flywheel end
MPR. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Main power relay
N/A... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Naturally aspirated
OWL ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... oil water light
PTO . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Power take off
PTO control . ... ... ... ... ... ... ... ... ... ... ... ... ... ... Control mode (provides isochronous speed control)
RAS . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Resume accelerator switch (cruise control)
REPTO ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Rear power take off
RPRE... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Remote pre-set speed enable
RPS or RAPS .. ... ... ... ... ... ... ... ... ... ... ... ... ... Remote pedal sensor or Remote accelerator pedal sensor
SCS . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Set coast switch
SIL ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Service interval light
STI ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Self test input
Vbat . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Battery voltage (application voltage, 12v or 24v)
Vbref ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Voltage reference
Vbrefgnd .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Voltage reference ground
Vign . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ‘Ignition’ voltage (battery voltage switched through main key
switch)
WARN.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Engine warning light
Note: All dimensions are in mm unless otherwise stated.
Engine type codes
Engine type Type code
7,6 litres (466 cu in) turbocharged WP
7,6 litres (466 cu in) turbocharged/charge cooled WQ
8,7 litres (530 cu in) turbocharged WR
8,7 litres (530 cu in) turbocharged/charge cooled WS
Electrical Installation Guide, TPD 1404E, issue 1 7
1 1300 Series EDi IOPU
Order form
To be used in conjunction with the engine build list selected from the Engine Specification Manual.
An electronic specification must be defined for all 1300 Series EDi engine orders.
When the following order form has been completed and checked for compatibility, an electronic package
number (EPN) will be assigned. This (EPN) may be used for repeat orders.

1300 Series EDi IOPU

Electronic Package Number (EPN)
Order Form
Customer Delivery date required
Customer order No. / Ref: Engine build list No.

Application configuration - select one of the following

IOPU1 IOPU3 see note (1)

IOPU2 IOPU4 see note (2)

Application voltage - select one of the following

12 volts 24 volts

Engine warning and protection - select one of the following

If the final application is not know at this point, then ‘3 way protection’ should be ordered. The Service Tool can
be used later to make changes, if required.
No warning 3 way warning

2 way warning 3 way protection

2 way protection

Additional options available

Coolant level switch type
Select normally open contacts (plastic) or normally closed contacts (metal)

Radiator shutter control

Note (1) If IOPU3 is selected, set the following, see “Configuration specific options” on page 16 for details.
PTO control - engine speed ramp rate
(If not specified, the ECM will be set at 1500 rev/min per second)

PTO control - max engine speed

Note (2) If IOPU4 is selected, set the following, see “Configuration specific options” on page 16 for details.
PTO control - pre-set speed 1

PTO control - pre-set speed 2

8 Electrical Installation Guide, TPD 1404E, issue 1

1300 Series EDi IOPU

2
IOPU applications 2

In order to simplify the task of applying the 1300 Edi IOPU, four main modes of operation and control have
been predefined. The default parameters for the main modes of operation and control are listed on page 10.
If a particular application cannot be met using the predefined configurations then the engine should be ordered
making reference to the full engine specification manual. The predefined configurations are detailed below:
Configuration IOPU1 – Variable speed droop control
This configuration provides variable speed droop control from low idle to high idle, see “Wiring diagram -
IOPU1 (variable speed droop control)” on page 26
Speed adjustment is achieved via a potentiometer type throttle input which, for safety purposes must
include an idle validation switch.
The throttle can be hand or foot operated.
This configuration is suitable for both mobile and static applications.
Configuration IOPU2 – Variable speed isochronous control
This configuration provides variable speed isochronous control from low idle to high idle, see “For non-moblie
applications only.” on page 27
Speed adjustment is achieved via a potentiometer type throttle. An idle validation switch is not required.
The throttle can be hand or foot operated.
This configuration is only suitable for static applications.
Configuration IOPU3 – Variable Set speed isochronous control
This configuration provides variable speed isochronous control from low idle to high idle, see “Wiring diagram
- IOPU3/4 (variable set/pre-set speed isochronous control)” on page 28
Following start-up the engine will run at low idle.
Speed adjustment is achieved via separate accelerate and decelerate buttons. These buttons are used to
set the engine to the desired running speed. Isochronous governing is controlled by the engine to this
speed until the demand is changed (via the buttons) or the engine is shutdown.
The acceleration/deceleration rate achieved whilst the speed demand buttons are depressed will be set to
a default of 1500 rpm/sec unless otherwise requested at the point of order. However this can subsequently
be altered via the service tool.
This configuration is only suitable for static applications.
Configuration IOPU4 – Pre-set speed isochronous control
This configuration provides isochronous speed control at the two selected pre-set speeds, see “Wiring diagram
- IOPU3/4 (variable set/pre-set speed isochronous control)” on page 28
Following start-up the engine will run at low idle.
Speed demand is achieved by depressing one of the speed select buttons. The engine will accelerate to
the chosen pre-set speed and provide isochronous control. Depressing the other speed select button will
cause the engine to control to the other pre-set speed.
The pre-set speeds can be set anywhere between low idle and high idle and may be set to the same value
if only one pre-set speed is required. The speeds need to be specified at the point of order but can
subsequently be altered using the service tool.
This configuration is only suitable for static applications.

Electrical Installation Guide, TPD 1404E, issue 1 9

2 1300 Series EDi IOPU
Default parameters
The following table identifies the default parameters that will be ordered when IOPU1 to IOPU4 configurations
are selected.
Application IOPU1 IOPU2 IOPU3 IOPU4
Strategy AK AK AK AK
Option Codes / values
Parameter Name Unit of Measure
(definition of option code in brackets)
IVPWR-Level select select select select N/A
3 3 3 3
Transmission Type (no trans. (no trans. (no trans. (no trans. N/A
specified) specified) specified) specified)
0 0 0 0
Two Speed Rear Axle Enable N/A
(off) (off) (off) (off)
Transmission Top Gear Ratio 1 1 1 1 number
Tyre Revolutions per Mile 501 501 501 501 Tyre revs /mile
Rear Axle Ratio High Limit 4.1 4.1 4.1 4.1 number
Rear Axle Ratio Low Limit 4.1 4.1 4.1 4.1 number
Tail Shaft Number of Teeth 11 11 11 11 teeth
0 1 2 2
PTO Control Mode Selection N/A
(off) (remote) (in cab) (in cab)
Max Road Speed for Mobile Control 20 20 20 20 mph
0 3 2 1
In Cab PTO Control Mode Select N/A
(off) (mobile) (variable) (pre-set)
1 1 1 1
Disable Cab interface for PTO N/A
(yes) (yes) (yes) (yes)
0 1 0 0
Remote Throttle for PTO Control N/A
(no) (yes) (no) (no)
Resume Engine Speed (Speed 1) 1200 1200 1200 select rpm
Set Engine Speed (Speed 2) 1000 1000 1000 select rpm
Engine Response Rate for PTO 1500 1500 select 1500 rpm / second
Max PTO Engine Speed 2400 2400 select 2400 rpm
0 0 0 0
Retarder - Service Brake Interface N/A
(off) (off) (off) (off)
Engine Protection Mode Selection select select select select N/A
0 0 0 0
Cold Ambient Protection Mode N/A
(off) (off) (off) (off)
1 1 1 1
Enable Engine Oil Pressure Sensor N/A
(enable) (enable) (enable) (enable)
0 0 0 0
Engine Crank Inhibit Selection N/A
(off) (off) (off) (off)
Engine Crank Inhibit Time 2 2 2 2 second
1 1 1 1
Over Temperature Protection N/A
(on) (on) (on) (on)
0 0 0 0
Idle shut-down mode (IST) N/A
(off) (off) (off) (off)
Idle shut-down time 5 5 5 5 second
max intake temp for IST 44 44 44 44 degC
min intake temp for IST 16 16 16 16 degC
Radiator Top Tank Material Type (This
parameter refers to the coolant level switch select select select select N/A
type option, see page 14)
0 0 0 0
Coolant Fan Enable Mode N/A
(off) (off) (off) (off)

10 Electrical Installation Guide, TPD 1404E, issue 1

1300 Series EDi IOPU 2
Application IOPU1 IOPU2 IOPU3 IOPU4
Strategy AK AK AK AK
Option Codes / values
Parameter Name Unit of Measure
(definition of option code in brackets)
0 0 0 0
Air Condition Demand Enable Switch N/A
(off) (off) (off) (off)
Radiator Shutter Enable select select select select N/A
Customer Password 00000000 00000000 00000000 00000000 alpha numeric
0 0 0 0
Engine Torque Tailoring N/A
(off) (off) (off) off)
0 0 0 0
Service Interval Enable N/A
(off) (off) (off) (off)
Serv Int Fuel Interval 1500 1500 1500 1500 US Gallons
Serv Int Hour Interval 450.0 450.0 450.0 450.0 hr
Serv Int Distance Interval 12000 12000 12000 12000 miles
Serv Int Service Soon pct 100 100 100 100 %
0 0 0 0
Serv Int Lamp Cont On N/A
(off) (off) (off) (off)
Serv Int Lamp Active Time 30 30 30 30 sec

Strategy Release Date 16-Jun-99 16-Jun-99 16-Jun-99 16-Jun-99

Electrical Installation Guide, TPD 1404E, issue 1 11

 This page is intentionally blank

12
1300 Series EDi IOPU

3
IOPU options and accessories 3

General options
In addition to the choice of IOPU configuration there are a number of additional options available, which have
to be specified at the point of order:
Engine warning and protection
Radiator shutter
Coolant level switch type
Engine warning and protection
All wiring schematics for the 1300 EDi IOPU must include the OWL (oil water light), and the WARN (engine
warning light).
The WARN light will be lit when non-critical faults are observed by the ECM. The OWL light generally relates
to a potentially critical fault being observed by the ECM – e.g. low oil pressure, high coolant temperature, low
coolant level.
Some IOPU installations may specify a CLS (coolant level switch) to be fitted - this must be stated at the point
of order. The CLS feature is a switched input to the ECM (chassis side connector pin 10). Whether the sensor
is a ‘normally open’ or ‘normally closed’ contact must also be stated at the point of order - this can subsequently
be changed via the service tool. For an example of how to use this feature, see “Wiring diagram - IOPU Option”
on page 25
To allow each IOPU installation to be configured individually, various engine warning and protection options
are available at the point of order. These options are shown in the table below:

Engine overspeed
Coolant temp high Oil pressure low Coolant level low
warning

2 way warning Lights OWL Lights OWL N/A Lights WARN

Lights OWL, plus Lights OWL, plus

2 way protection* N/A Lights WARN
shutdown shutdown

3 way warning
Lights OWL Lights OWL Lights OWL Lights WARN
(recommended option)

Lights OWL, plus Lights OWL, plus Lights OWL, plus

3 way protection Lights WARN
shutdown shutdown shutdown

Notes:
* 2 way protection is achieved by selecting 3 way protection and ‘normally open (plastic tank)’ for the CLS
type. No connection should then be made to the CLS input.
If 3 way warning or 3 way protection is required then a coolant level sensor must be fitted.
For ‘protection’ selections the OWL lamp is illuminated when the appropriate warning level is exceeded but
when the critical level is exceeded the OWL lamp flashes on and off. If this condition continues for 30
seconds then the engine shuts down.
For ‘warning’ selections the OWL lamp is illuminated when the appropriate warning level is exceeded and
remains illuminated when the critical level is exceeded.
The engine warning and protection level needs to be selected at the point of order. However there is a
limited scope for changing this via the diagnostic tool. It is possible to change between ‘2 way’ and ‘3 way’
options and it is also possible to change from ‘protection’ to ‘warning’. However it is not possible to change
from ‘warning’ to ‘protection’ with the diagnostic tool. Therefore if a ‘protection’ strategy is required it must
be specified at point of order.
Continued

Electrical Installation Guide, TPD 1404E, issue 1 13

3 1300 Series EDi IOPU
if the final application is not known at the point of order, then ‘3 way protection’ should be ordered and the
service tool used to make changes, if required, at a later date.
In all applications care must be taken to assess whether the automatic shutdown associated with the
‘protection’ mode is suitable for the application.
In addition to lighting a lamp, the OWL output can further be used in IOPU installations as a ‘request to
shutdown’ feature. This would allow the IOPU operator to either manually or automatically remove load from
the engine before shutting it down in a controlled manner. However, in some installations it may be desired
that the engine shut itself down directly if a potentially critical fault is observed and in these cases the protection
option should be selected.
In addition to the warning and protection options there is a coolant temperature compensation function (CTC)
which is permanently enabled for all IOPU’s. If the engine is operating near to the pre-set coolant temperature
threshold point then this feature will derate the engine. This feature supplements the coolant over temperature
protection and the combined effect of the CTC function and the warning and protection feature can be seen in
the table below.

Temperature Action Indication

CTC is activated, ECM applies a derate of 6%/ °C of

107 °C (224.6 °F) Diagnostic code 325 set.
temperature increase

OWL lamp illuminated

109 °C (228.2 ° F) High coolant temperature warning level and diagnostic code 321
set.

CTC derate transition point. Switch to 3%/ °C of temperature

109.5 °C (229.1 °F) No change.
increase

High coolant temperature critical level.

OWL lamp flashes and
112.5 ° C (234.5 °F) If the critical level is exceeded for thirty seconds then the ECM
diagnostic code 322 set.
will initiate an engine shut down

The level of derate associated with this function has been defined to reach a maximum 24% derate before a
shutdown is initiated. This maximum derate and the rates at which it is applied are fixed and cannot be
changed.
Note: This feature is designed to protect the engine. It does not alter the 103 OC coolant temperature limit
stated in the engine specification manual.
Radiator shutter control
A radiator shutter control feature is available to assist in keeping the engine warm during cold weather
operation and for rapid warm-up. This feature allows the ECM to control the opening and closing of customer
supplied solenoid actuated radiator shutters at the temperatures specified below:
Engine coolant temp < 83 °C = radiator shutters closed (solenoid energised)
Engine coolant temperature > 85 °C = radiator shutters open (solenoid de-energised)
This option must be activated within the ECM. This can either be stated at the point of order, or it can be
changed via the service tool.
Use of this feature requires the radiator shutter solenoid to be interfaced to the ECM via the trailing 2 pin
connector which is supplied as part of the engine side wiring harness.
The electrical current limit for this circuit is 1amp.
For an example of how to use this feature, see “Wiring diagram - IOPU Option” on page 25
Coolant level switch type
This option is used to configure the input for a ‘normally open’ or a ‘normally closed’ coolant level switch type.
If a coolant level switch is not fitted then this option can be used in conjunction with the engine warning and
protection options described previously, to achieve ‘2 way protection’.
For an example of how to use the coolant level switch feature, see “Wiring diagram - IOPU Option” on page 25

14 Electrical Installation Guide, TPD 1404E, issue 1

1300 Series EDi IOPU 3
General options – via service tool only
Customer security code
It is possible to specify a customer specific password to protect the electronic programming options that are
changeable with the service tool. The password must be a combination of letters and numbers, between 4 and
8 characters long. The engine is supplied with the password factory set to 00000000 (8 zeros). This password
can be changed at a later date via the service tool. If a different password is specified or changed via the
service tool and subsequently lost, the ECM will have to be fully re-programmed via the aftermarket re-
programming service.
Service interval light
If fitted, the service interval light will be illuminated when a customer programmable service interval has been
reached. These limits can be set up in terms of engine hours or calculated fuel consumption. The feature is
activated or deactivated and the service interval limits adjusted via the service tool.
The parameters which are relevant to the service interval function, and which can be programmed via the
service tool are as follows:
Service Interval Mode: This option is used to turn the service interval function on and off.
Fuel Used Interval: This parameter allows the customer to programme the service interval as a function of fuel
used since the last service, before lighting the service interval light.
Engine Hour Interval: This parameter allows the customer to programme the service interval as a function of
engine hours since the last service, before lighting the service interval light.
Starting Fuel: This is a read only parameter that shows when the last service was carried out.
Starting Hour: This is a read only parameter that shows when the last service was carried out.
Service Soon Percent: This parameter indicates at what percentage of the service intervals the service interval
light should begin to flash as a warning.
Change Oil Lamp Mode: This parameter indicates if the service interval lamp is always to be left on after the
engine start once the service interval limit has been reached.
Change Oil lamp On Time: This parameter indicates how long to activate the service interval lamp for, after
the engine start, if it is not always on.
Service Interval Request: This parameter is used to reset the starting values for fuel and hours following an
engine service.

Electrical Installation Guide, TPD 1404E, issue 1 15

3 1300 Series EDi IOPU
Configuration specific options
In addition to the general options listed above, which apply to all 4 configurations, there are a number of options
which are specific to configurations IOPU3 and IOPU4. These options must be specified at the point of order,
but can be changed at a later date, with the service diagnostic tool. The options are listed and explained below:
For IOPU3
PTO Control’ – engine speed ramp rate
This option is used to limit the rate at which the engine speed changes in response to the accelerate and
decelerate buttons. The parameter has a range of 1-1500rpm/sec with a default value of 1500rpm/sec. The
ECM will be set to the default value at point of order unless otherwise requested. This value can be changed
via the service tool.
PTO Control’ – max engine speed
This option enables a maximum engine speed to be specified for ‘PTO control mode’. The valid range for this
parameter is low idle to high idle and it is programmable via the service tool.
For IOPU4
PTO Control’ – pre-set speed 1
This option is used to define the engine speed that is selected when the operator presses the ‘pre-set speed
1’ select button. Any speed between low idle and high idle is valid, but this value should be equal to or lower
than pre-set speed 2. It is possible to alter this parameter value via the service tool.
PTO Control’ – pre-set speed 2
This option is used to define the engine speed that is selected when the operator presses the ‘pre-set speed
2’ select button. Any speed between low idle and high idle is valid, but this value should be equal to or higher
than pre-set speed 1. It is possible to alter this parameter value via the service tool.

Electrical off-engine accessory requirements

The following tables contain details of parts that are essential in the installation of these engines as IOPU’s.
Non proprietary parts such as fuses and warning lamps are not included as they are standard and can be
sourced locally.
Groups of parts designed for a specific purpose have been grouped together as ‘kits’ and should be ordered
as such using the ‘ZZ’ number.

16 Electrical Installation Guide, TPD 1404E, issue 1

1300 Series EDi IOPU 3
Essential equipment for all IOPU’s
Description Part Number Quantity
Pressure sensor kit ZZ00548 2638C351 1
Barometric pressure sensor (BAP) 1807253C1 1
Connector 2016703C1 1
Lock 2016704C1 1
Terminal 2501082C1 3

Air temperature sensor kit ZZ00549 2638C352 1

Air temperature sensor (ATS) 1814320C1 1
Connector 1689462C1 1
Lock 1689463C1 1
Terminal 1689464C1 2

Diagnostic data link kit ZZ00550 2638C353 1

Diagnostic data link connector 1621959C1 1
Terminal 500397C1 4
Cover 1621960C3 1

Wiring 'pigtail' / chassis harness ZZ00551 1(1)

connector loom 3161C011 1

System relay kit – 12 volt ZZ00552 2638C354 1(2)

ECM main power relay 12volt 1688314C1 1

System relay kit – 24 volt ZZ00553 1(2)

ECM main power relay 24volt 2848A226 1

(1) The chassis connector kit may be ordered in place of the wiring ‘pigtail’/chassis harness.
(2) Select only one system relay kit from the two. 12 volt or 24 volt dependant upon application.

Depending on the option selected for ‘Engine Warning and Protection’ then a coolant level probe may be
required.
Note: The probe must be fitted when 3 way warning or 3 way protection are selected, unless 2 way protection
is being configured in line with the notes on page 13.

Description Part Number Quantity

Coolant level probe kit ZZ00554 2638C355 1

Coolant level sensor

874592C91 1
normally closed contacts (metal) only

Electrical Installation Guide, TPD 1404E, issue 1 17

3 1300 Series EDi IOPU
Essential engine speed control equipment
Three throttle options are offered. These are:
Description Part number Quantity
ZZ00555 - Electronic throttle pedal kit, suspend mounted 2638C356 1
Electronic throttle pedal, suspend mounted 2016247C92 1
Connector 1687790C1 1
Terminal 1651943C1 5
Void cavity plug 2041421C1 1

ZZ00556 - Electronic throttle pedal kit, floor mounted 2638C357 1

Electronic throttle pedal, floor mounted 3500972C91 1
Connector 1687790C1 1
Terminal 1651943C1 5
Void cavity plug 2041421C1 1

ZZ00557 - Electronic throttle pedal kit, pedal pot 2638C358 1

Electronic throttle pedal, pedal pot 1695251C91 1
Connector 1687790C1 1
Terminal 1651943C1 5
Void cavity plug 2041421C1 1

For IOPU1 choose one of the kits above.

For IOPU2 there are many aftermarket potentiometers available for throttle controls and we encourage you to
investigate using one of these. However, the kits above can be specified but it should be noted that they are
more applicable to mobile, rather than stationary applications and have strong return springs fitted.
Note: A dummy APS input must be supplied to pin 8 as shown in the IOPU2 wiring diagram.
For IOPU3 and IOPU4 a dummy APS input must be supplied to pin 8 and speed selector switches are
required, as shown on the wiring diagram.

Speed Select Switches Part number Quantity

Speed select switch

These must be supplied by the customer 2
(normally open/momentary close)

Note: For those customers who do not want to use the ready assembled wiring ‘pigtail’ chassis harness kit
then “ZZ00558 - Chassis connection kit” must be ordered in it’s place.

Description Part number Quantity

ZZ00558 - Chassis connection kit 2638C359 1
Chassis connector 2041416C2 1
Chassis wire cover 2041417C1 1
Locking wedge 2041418C1 1
Terminal, 18 AWG 2041419C1 50
Terminal, 14 - 16 AWG 2041420C1 25
Void cavity plug 2041421C1 50
Sealing kit 1831252C1 1
Knob assembly 1831415C91 1
Screw, M3 40086R1 1

18 Electrical Installation Guide, TPD 1404E, issue 1

1300 Series EDi IOPU 3
Summary of IOPU Requirements

Description IOPU1 IOPU2 IOPU3 IOPU4

Pressure sensor kit ZZ00548 Y Y Y Y

Air temperature sensor kit ZZ00549 Y Y Y Y

Diagnostic data link kit ZZ00550 Y Y Y Y

Wiring ‘pigtail’ kit ZZ00551 or chassis connector kit ZZ00558 Y Y Y Y

System relay kit 12volt ZZ00552 or 24volt ZZ00553 Y Y Y Y

Dependant upon engine warning and protection

Coolant level probe ZZ00554 level selected. 3-way warning and 3-way pro-
tection must have a coolant level probe fitted.

Throttle pedal kit ZZ00555 or ZZ00556 or ZZ00557 Y Y (1) N N

Speed select switches – customer supply N N Y Y

Dummy APS input – customer supply N Y Y Y

(1) Or customer to supply a simple throttle potentiometer.

Electrical Installation Guide, TPD 1404E, issue 1 19

 This page is intentionally blank

20
1300 Series EDi IOPU

4
Diagnostic information 4

The 1300 series EDi engine has in-built diagnostic software. This diagnostic information can be accessed in
one of three ways:
Flash codes – pressing the self test input (STI) switch (see wiring diagrams) will initiate ‘flash code fault
reading’. The red OWL light and the amber WARN light flash out a series of three figure numerical codes
which indicate ‘active’ and ‘inactive’ faults within the ECM. Please refer to the workshop manual for more
details.
MPSI Pro-Link – This hand held service tool should be connected to the ECM via the chassis harness
diagnostic connector. In addition to fault code reading, this tool allows various built-in self test diagnostic
routines to be initiated – e.g. injector cut out test. Please refer to the workshop manual for more details.
PC based diagnostic software – This requires a suitable PC, and data translation module, to be connected
to the ECM via the chassis harness diagnostic connector (see wiring diagrams). This tool provides similar
functionality to the Pro-link.
Electrical installation guidelines
A prewired chassis side connector with a 3-metre long ‘pigtail’ of wires can be ordered to simplify installations.
The ‘pigtail’ contains all the wires required to implement any of the IOPU configurations and options. All unused
wires on the ‘pigtail’ must be clipped and capped to avoid spurious input signals to the ECM.
On installations where the prewired chassis side connector is not used the unused pins on the chassis side
wiring harness must be protected by ‘void cavity plugs’.
Wires must be twisted together where shown on the wiring diagrams (i.e. diagnostic data link, and speed/
demand input signal).
Route and clip wiring to minimise chaffing and exposure to weather. Use conduit, loom, and/or tape to achieve
this.
Spliced wires must be twisted and soldered. Use a heat shrink tube with a meltable inner wall to seal the
connection. Do not expose splices to the weather.
Sealed switches and connectors must be used when they are exposed to weather, high pressure washers, salt
spray, etc.
Terminals must be properly crimped to make a reliable electrical contact that does not introduce additional
impedance into the circuit. Each type of connector and terminal requires its own crimping. Note: special tools
are required to remove the terminal from the connector cavity, refer to the diagnostic manual for a list of special
tools.
The ECM must have independent battery connections as shown in the wiring diagrams - additional current
loading (e.g. from a starter motor) could cause voltage fluctuations that may cause the control system to
operate improperly or unreliably.
Do not make ground connections to the installation frame – all ground connections should be connected to the
battery to avoid ground loops/shifts/electrical noise and to facilitate diagnosing of wiring defects.
All components that have a power and/or signal interface to the ECM must receive their ground reference from
the ECM.
Power connections to the ECM shown on the wiring diagrams via the on/off switch (Vign) must not be replaced
with connections directly to the battery (Vbat). Connecting ECM pins directly to battery power will result in
undesirable current draw when the ECM is switched off - this may cause unreliable ECM performance.
Fuses must be sized as per the wiring diagrams. Larger fuses will not blow if an increased current flow is
observed. An increased current flow can cause overheated wiring which may ignite its insulation and
surrounding material.

Electrical Installation Guide, TPD 1404E, issue 1 21

4 1300 Series EDi IOPU
The on/off switch (see wiring diagrams) should be used as the normal means of stopping the engine. This
allows the ECM to close down in a controlled manner before disconnecting itself from the battery (de-
energising the main power relay).
If welding is done on any part of the installation, both the power and ground connections of the batteries must
be disconnected. The electronic components may easily be damaged from the high voltage used and R.F.
energy present in the arc. The welder's ground cable should be connected as close as possible to the joint
being welded, and if it is necessary to weld close to an electronic component, it is recommended that the
electronic component be temporarily removed.
Caution: To allow heat to dissipate from the ECM, the ECM must not be painted.
During operation, the surface temperature of the ECM must not exceed 105 °C.
When the engine is not operating the surface temperature of the ECM must not exceed 150 °C for more than
0.5 minutes.
The battery voltage seen at the ECM must not fall below the following limits at any time other than shutdown:
For 12 volt installations: 4.8 volts
For 24 volt installations: 8.0 volts.

22 Electrical Installation Guide, TPD 1404E, issue 1

1300 Series EDi IOPU 4
ECM pin definitions
Chassis side connector
Name Pin Description
Power relay control out 25 ECM output – switches to ground to energise MPR (main power relay)
DC/DC converter
21 +ve feed for DC/DC converters – connected via MPR to Vbat.
(+) feed (1)
DC/DC converter (+) feeds (2) 22 +ve feed for DC/DC converters – connected via MPR to Vbat.
HSO (+) feed 41 +ve feed for high side outputs – connected via MPR to Vbat.
HSO ground feed 23 -ve feed for high side outputs – connected to battery ground.
ECM ground feed 42 Low power ground – connected to battery ground.
DC/DC converter ground feed (1) 1 -ve feed for DC/DC converters – connected to battery ground.
DC/DC converter ground feeds (2) 2 -ve feed for DC/DC converters – connected to battery ground.
CLS input 10 Coolant level switch input.
VIGN – IPR (+) feed 24 Switch to Vbat to energize ECM.
RPRE input 37 Switch to Vign to activate isochronous ‘PTO’ mode (variable or pre-set speed).
Switch to Vign for engine speed decrease adjustment signal or reset speed 1
SCS input 32
select signal, dependant upon installation
5V ± 0.5V supply – used as reference voltage in variable speed installations.
VBREF (5V) 3
Max current source = 100mA
0 to 5V speed/demand input for droop speed governing installations. Working
APS input 8 range = 0.5V to 4.5V. (accelerator pedal sensor)
Note: must be used in conjunction with the IVS INPUT
0 to 5V speed/demand input for isochronous speed governing installations
RPS input 30
Working range = 0.5V to 4.5V. (remote pedal sensor)
0V – used as ground reference in variable speed installations.
VBREF GND 11
Max current sink = 1A
OWL output (press/temp) 54 Oil/Water light output, also used as ‘request to shutdown’ output.
Warn output 55 Engine warn light output.
ATA (+) data link 16 +ve connection for the diagnostic tool (J1708/J1587).
ATA (-) data link 17 -ve connection for the diagnostic tool (J1708/J1587).
STI 34 Self test input – switch to ground to initiate flash codes.
5V ± 0.5V supply – used as reference voltage in variable speed installations.
VCREF (5V) 5
Max current source = 100mA
0V – used as ground reference in variable speed installations.
RPS_RTN (VCref gnd) 6
Max current sink = 1A
AIT/AAT input 12 0 to 5V input for Ambient Air Temperature signal
IVS input 27 0 or Vign for Idle Validation Signal input
BAP input 29 0 to 5V input for Barometric Air Pressure signal
Switch to Vign for engine speed increase adjustment signal or pre-set speed
RAS input 31
2 elect signal dependant upon installation
SIL output 45 Engine service interval light output

Engine side connection

Name Pin No. Description

ECM switches this output to ground (dependant

Radiator shutter enable Pin (B) of trailing 2 pin connector supplied
on coolant temperature) to provide a current
(b) as part of the ‘engine side wiring harness’
path for solenoid actuated radiator shutters.

Electrical Installation Guide, TPD 1404E, issue 1 23

4 1300 Series EDi IOPU
Check lists
Installation type

Variable speed droop control – IOPU1

Variable speed isochronous control – IOPU2

Variable set speed isochronous control – IOPU3

Pre-set speed isochronous control – IOPU4

All applications

Wiring is connected as per relevant schematic

Fuses have been fitted in a secure and accessible location

Wiring is secure and routed sensibly

Wires have been twisted where stated on the wiring diagrams

Power and ground connections are as per the guidelines

ECM has not been painted

OWL and WARN lamps are visible

STI momentary switch is accessible

Diagnostic connection is accessible

Main power relay has been mounted in a secure and accessible location

ECM on/off switch has been interfaced appropriately into application

Where relevant to application

Wiring connections as per ‘IOPU Options’

Coolant level sensor type matches that ordered for the EPN. Either Normally open

or Normally closed

Service Interval Light is visible

Total load placed on the OWL (request to shutdown) output must not exceed 1 Amp

Radiator shutter solenoid is connected to trailing 2 pin connector

Speed select switches wired as per drawing

Dummy APS signal wired as per drawing

Unused wires have been clipped and capped

24 Electrical Installation Guide, TPD 1404E, issue 1

1300 Series EDi IOPU 4
Wiring diagrams
Wiring diagram - IOPU Option
W1298
Radiator shutter
control relay

87a
30 connector
87 Two pin
86 B 9 Radiator shutter
10 AMP A

ENGINE HARNESS CONNECTOR

Standard operating mode circuit SIL Output (Service Interval Light)

See main wiring diagrams 45

54 OWL Output (pressure / temperature)

ON/OFF 10 AMP
- -
Battery Battery
Request to
+ + shutdown

10 Coolant level switch

Emergency Vbat Coolant

Stop level switch
CHASSIS HARNESS CONNECTOR

(1) Maximum total current from OWL (54) output = 1Amp (including lamp and 'request to shutdown' signal).
(2) Coolant level switch operation depends on EPN option selected:
'normally closed contacts (metal tank)'
'normally open contacts (plastic tank)'.
Customers must specify the relay, the wiring and appropriate fuses for the radiator shutter control circuit.

Electrical Installation Guide, TPD 1404E, issue 1 25

4 1300 Series EDi IOPU
Chassis side diagrams
Wiring diagram - IOPU1 (variable speed droop control)
Note: Accelerator Pedal Sensor can be foot or hand throttle but must incorporate an IVS

FUSE VALUE REQUIRED FOR

PC BOARD PROTECTION
IGNITION SWITCH FUSE 5 ECM
OFF ON AMP MAX
24 VIGN - IPR (+) FEED

MAIN POWER
RLY (12V OR 24V)
+ 86 85
POWER RELAY CTRL OUT
FUSE 30 AMP 25
BATTERY 21 DC/DC CONVERTER
87
30 22 (+) FEEDS
- 87a 41 HSO (+) FEED
23 HSO GROUND FEED
42 ECM GROUND FEED
1 DC/DC CONVERTER
12v or 24v 2 GROUND FEEDS
dependant upon
ECM ordered

DIAGNOSTIC
SWITCH

DIAGNOSTIC 34 STI INPUT (SELF TEST)

CONNECTOR C E B A
FUSE 10 AMP 16 ATA (+) DATA LINK
17 ATA (-) SAE J1708

FUSE 10 AMP
27 IVS IN (IDLE VALIDATION)
ACCELERATOR AP 3 VBREF (5V) SENSOR SUPPLY
PEDAL POSITION S 8 APS INPUT
SENSOR 11 VBREF GND SENSOR SUPPLY

BAROMETRIC 2
AIR PRESS BAP 1
SENSOR 3 29 BAP INPUT

AMBIENT
AIR TEMP AAT
SENSOR 12 AAT INPUT
ENGINE WARNING
AMBER
55 WARN OUTPUT
FUSE 10 AMP
54 OWL OUTPUT (PRESS/TEMP)
RED
OIL/WATER LIGHT

W1295

26 Electrical Installation Guide, TPD 1404E, issue 1

1300 Series EDi IOPU 4
Wiring diagram - IOPU2 (variable speed isochronous control)
Note: For non-moblie applications only.

FUSE VALUE REQUIRED FOR

PC BOARD PROTECTION
IGNITION SWITCH CEC MODULE
OFF ON FUSE 5AMP
24 VIGN - IPR (+) FEED

MAIN POWER
RLY
+ 86
POWER RELAY CTRL OUT
FUSE 30 AMP 25
BATTERY 21 DC/DC CONVERTER
87
30 22 (+) FEEDS
- 87a 41 HSO (+) FEED
23 HSO GROUND FEED
42 ECM GROUND FEED
1 DC/DC CONVERTER
Battery can
12V or 24V, 2 GROUND FEEDS
this will effect
selection of
and main
relay

DIAGNOSTIC
SWITCH

DIAGNOSTIC 34 STI INPUT (SELF TEST)

CONNECTOR C E B A
FUSE 10 16 ATA (+) DATA LINK
17 ATA (-) SAE J1708

FUSE 10
37 RPRE INPUT

REMOTE R 6 RPS_RTN - SIGNAL RETURN

ACCELERATOR P 30 RPS INPUT
PEDAL POSITION S 5 VBREF GND SENSOR SUPPLY
SENSOR

APS Dummy A 3 VBREF (5V) SENSOR SUPPLY

Input P 8 APS INPUT
See note 1 S 11 VBREF GND SENSOR SUPPLY

BAROMETRIC 2
AIR PRESS BAP 1
SENSOR 3 29 BAP INPUT

AMBIENT
AIR TEMP AAT
SENSOR 12 AAT INPUT

0.25k ohm FUSE 10

55 WARN OUTPUT
2.0k ohm
0.25k ohm 54 OWL OUTPUT (PRESS/TEMP)

FIGURE A

W1296

(1) A 2.5k ohm potentiometer set to give approx. 0.6v to APS input.
(2) All wire into ECM connector is 1.5mm² , connections to battery are 2.5mm².
(3) RPS is fed with a 5 volt reference signal. The RPS input signal has a working range from 0.5 to 4.5 volts. The potentiometer used
for the RPS input should be selected to achieve this or balasted as shown in figure A.

Electrical Installation Guide, TPD 1404E, issue 1 27

4 1300 Series EDi IOPU
Wiring diagram - IOPU3/4 (variable set/pre-set speed isochronous control)

Notes:
For non-moblie applications only
IOPU3 is variable set speed isochronous control; IOPU4 is pre-set speed isochronous control

FUSE VALUE REQUIRED FOR

PC BOARD PROTECTION
IGNITION SWITCH FUSE 5 CEC MODULE
OFF ON AMP MAX
24 VIGN - IPR (+) FEED

CEC MAIN
POWER RLY
+ 86 85
POWER RELAY CTRL OUT
FUSE 30 AMP 25
BATTERY 21 DC/DC CONVERTER
87
30 22 (+) FEEDS
- 87a 41 HSO (+) FEED
23 HSO GROUND FEED
42 ECM GROUND FEED
1 DC/DC CONVERTER
12v or 24v will
affect selection of 2 GROUND FEEDS
ECM and Main
power relay

DIAGNOSTIC
SWITCH

DIAGNOSTIC 34 STI INPUT (SELF TEST)

CONNECTOR C E B A
FUSE 10 AMP 16 ATA (+) DATA LINK
17 ATA (-) SAE J1708

37 RPRE INPUT

Press and
release for
speed
increase
31 RAS INPUT (high speed)
Press and
release for
speed
decrease
32 SCS INPUT (low speed)

APS Dummy 3 VBREF (5V) SENSOR SUPPLY

APS

Input 8 APS INPUT

See note 1 11 VBREF GND SENSOR SUPPLY

BAROMETRIC 2
AIR PRESS BAP 1
SENSOR 3 29 BAP INPUT

AMBIENT
AIR TEMP AAT
SENSOR 12 AAT INPUT

FUSE 10 AMP
55 WARN OUTPUT

54 OWL OUTPUT (PRESS/TEMP)

W1297

(1) A 2.5k ohm potentiometer set to give approx. 0.6v to APS input.
(2) All wire into ECM connector is 1.5mm² , connections to battery are 2.5mm².

28 Electrical Installation Guide, TPD 1404E, issue 1