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1、OPERATING AND FITTING INSTRUCTIONS FOR SYSTEM 80M (NT)TOP SPEED CONTROL UNITVehicle Efficiency EquipmentItemPageCONTENTS1SAFETY INSTRUCTIONS3OPERATIONSystem Overview4Component Layout4System Schematic Diagram5Component Installation Diagram6INSTALLATIONFuel Control Solenoid Valve7Pre-setting the Fuel
2、Control Solenoid Valve9ELECTRONIC CONTROL UNIT (ECU)The Printed Circuit Board (PCB)10Understanding the ECU11Wiring the ECU to an Electronic Tachograph or Speedometer12Wiring the ECU to a Gearbox Sensor or Transducer12WIRING DIAGRAMSSpeedometer or Tachograph Wiring Diagram15Mechanical Gearbox Sensor
3、Wiring Diagram16TACHOGRAPH SPEED LIMITER CONNECTIONS17TEST AND CALIBRATION UNIT TCU318Understanding the TCU19CALIBRATIONCalibrating the Speed Limiter 20Calibrating the ECU20Calibrating the ECU using the K Factor21Road Testing21Checking the ECU22Re-calibrating the ECU with the TCU22SEALING THE LIMITE
4、R AFTER INSTALLATIONGeneral Guidelines23Sealing the Fuel Control Solenoid Valve23Sealing the ECU23FAULT FINDING PROCEDURESIf the Vehicle Will Not Start or is Under Powered24If the Limiter Does Not Work24If the Limiter is Surging25STANDARD AND OPTIONAL FEATURESStandard Features26ECU Operation26Operat
5、ions26TECHNICAL DATA27PARTS LIST28Sensor Applications29 2014. Autokontrol Limited. All rights reserved. System 80MTop Speed Limiter Diesel AK4004 A Issue 24SAFETY INSTRUCTIONSSafety must always be thought of when working on a vehicle. The potential risks should be considered and suitable precautions
6、 taken.It is important that personnel working on the vehicles are familiar with operating instructions and workshop procedures.The following points are general guidelines only and are not intended to be all-inclusive:1. Never work under a vehicle supported solely by jacks. Always use chassis stands
7、and make sure that they are resting on a firm, flat surface.2. Always use wheel locks to prevent the vehicle rolling if the brakes have to be released.3. The vehicle should always be left out of gear.4. It is advisable to always disconnect the vehicle batteries, as this acts as a precaution against
8、inadvertent starting and reduces the risk of electrical fires. It also prevents accidental flattening of the batteries.5. Airbags (Supplementary Restraint System- SRS)Many of the models covered by this manual are fitted with airbags as standard equipment. When working on a vehicle fitted with such a
9、 system, extreme caution must be taken to avoid accidental firing of the airbag, which could result in personal injury.Unauthorised repairs to the system could render it inoperative, or cause it to inflate accidentally.NEVER attempt to test the system using a test lamp.NEVER tamper with or disconnec
10、t the airbag wiring harness.NEVER make extra connections to any part of the system wiring harness or terminals.ALWAYS ensure that the airbag wiring harness has not been trapped or damaged in any way when working on adjacent components or systems.6. We recommend that all electrical work is undertaken
11、 using a high impedance multi-meter that includes a 0-20 voltage scale and a low (0-200) and a high (0-20K) range OHM scale for measuring voltage and resistance of the systems components.Above all, do not jeopardize your own safety or the operational safety of the vehicle.Any additional holes requir
12、ed to mount equipment on the chassis frame must be drilled in accordance with the individual manufacturers instructions.7OPERATIONSYSTEM OVERVIEWAn Electronic Control Unit (ECU), mounted in the driving compartment, receives a speed signal from either the electronic tachograph or speedometer or a mec
13、hanical gearbox sensor, depending on the vehicle. The ECU monitors this speed signal until the vehicle reaches the calibrated speed. The ECU sends a signal to the Fuel Control Solenoid Valve inserted into the vehicles fuel line, controlling the fuel flow to the injector pump. As the calibrated speed
14、 is reached the valve closes, limiting the fuel, which is diverted through an integrated adjustable by-pass controlled by a needle valve. This needle valve is adjusted to supply the engine with just enough fuel to maintain the vehicle at its limiting speed.A component layout is shown below. A system schematic diagram and component installation diagram are shown on pages 5 and 6 respectively.COMPONENT LAYOUTThis diagram illustrates the system drawing a speed signal from the tachograph/speedometer.Dashboard Monitor (Optional)SYSTEM SCHEMATIC DIAGRAMAUTOKONTROLAUTOKONTROLPART No. E550 SERIAL No.
