EDIC Controller build from scratch

[Bandit_guy]

Lately I’ve been having issues with my EDIC on by 24 volt BJ42. Sometimes the engine wouldn’t stop, sometimes it wouldn’t start and other times I would get what is often called the funky chicken where the EDIC motor just keeps on running. After some research and lot’s of testing the conclusion is the EDIC motor is fine but the controller is pooched. It’s been filled with water and road salt more than once and it’s 30 years old so it’s time for a new one. All the problems described earlier were due to corrosion of the printed circuit board and bad contacts in the relays. It is possible to wire new relays but the printed board was so bad that new was the way to go. In all after the figuring out of the wiring diagram a couple of hours was all it took to build the box.


All the parts common enough to find in an electronic store, your local auto parts store and the easiest of all E-bay.

 

[Bandit_guy]

Here's the main culprit. (top picture) Often the contacts inside get corroded or get loose in the plastic casing from vibration and rough roads. I've wired regular 5 pin relays into the circuit board to replace these. It's not pretty but if the circuit board is good then it will fix a lot of issues.

The second picture is the guts of it all. The circuit board is just a regular prototype circuit board with each hole independent. To make the connections you just solder across to the next hole.


The third picture is the bottom side where I use wire to mak the connections that were to far to run solder across.
The plastic box has ridges inside that the board fits right on top of and is squeezed together to hold everything tight. Best of all is water tight.

 

[lostmarbles]

.. In all after the figuring out of the wiring diagram a couple of hours was all it took to build the box.
All the parts common enough to find in an electronic store, your local auto parts store and the easiest of all E-bay.

Excellent work Bandit.

My electronics skills are very limited but if my cruiser was 24V and I needed a new EDIC relay I'd certainly use your diagram to try and make one.

 

[hj 60]

Thanks a lot for the research and sharing but I dont think I can make one if I had the parts.
I would not know were to start even with the pictures and diagram. My edic could fail any minute so I am eager to fix it but must admit that this is probably impossible to make by me.
I did not know the relay has 11 wires out!

Would you know a way to make a manual switchboard and what wires to connect? So if the relay goes bad, remove it and what color wires manually to connect to get driving again?
(I ask this because I think you know all the wire colours without looking because of all the work you did)
So three positions: stop, start (overinject) and drive is what the relay does?
I think if you make a few you can sell them?

If the owner knows the oil pressure is ok that check can be bypassed:

To make the info complete here is the edic from manual:

st21

st22

st23

 

[amaurer]

Very nice job.

 

[Bandit_guy]

HJ 60 the set up for wire colours is:

Red = Stop
Yellow = Over inject
Green = Drive
Blue = Main Power

The wiring diagram I have for an HJ 60 shows an extra ground wire which is not on the 40 model. It could be something or it could be nothing, just the way the motor is built but controlled in the same way. Look on your relay for the part number and if they match the one I put one the wiring diagram. If it does I would gladly make you one and send it to you. It will be a while but PM me your adress and we can figure something out.


The mechanical relay parts are the weak link in the chain if you think it's failed or about to you can wire one in like this or all three for that matter. The relays I used were generic 5 pin 24volt from the auto parts store.

White Wire = Pin 86
Black wire cloest to the other Relay = Pin 85
Red = Pin 87A
Green Pin 87
other Black closest to the edge of the circuit board = Pin 30

 

[hj 60]

Hi Thanks for the info, and for the offer to make one
Mine is ok and has done 250000 kms now so maybe it will last a while longer, but I am looking for an sort of trial fix.
So at one moment the engine will not shutdown with the key, then get out of the car and open the hood and move the lever of the edic to stop.
If it goes bezerk and keeps spinning around remove the cable or it will burn out I think?
-but then over inject is gone so maybe hard to start?

I think if I need one I will search for a used one or ask you (I dont think I can make one, or end up with a really bad headache )
In summer I will get mine opened up and see how it looks (water/rust/bad solder) and maybe I also should clean/regrease the edic motor.

 

[schems75]

Ok so wot wires do l tap into the loom with as my wiring loom is to suit a 12h-t but the motor is a 2h?

 

[kim]

Nice Job. I have this exact same problem right now.

I guess I will now immerse myself in wiring and circuit boards. Thanks!

 

[Diesel42]

Excellent work. A solution to a very old problem. Subscribed.

 

[Bandit_guy]

Thanks for all the encouragement from everyone , next step superglow controller.

 

[Gengis]

Bandit- I don't want to nit pic, but all ( most) the wires on your circuit diagram terminate with the EARTH symbol, when clearly they dont all go to earth. ( Look at the main relay normally closed circuit, that would send the live straight to earth with many sparks ect.
What program did you use to draw up the circuit?? I would gladly tidy it up if you like, or did I get it all wrong again??? I do sometimes.

 

[Bandit_guy]

Bandit- I don't want to nit pic, but all ( most) the wires on your circuit diagram terminate with the EARTH symbol, when clearly they dont all go to earth. ( Look at the main relay normally closed circuit, that would send the live straight to earth with many sparks ect.
What program did you use to draw up the circuit?? I would gladly tidy it up if you like, or did I get it all wrong again??? I do sometimes.

Gengis there are lot's of connections that do go to ground. The main relay, is normally closed to ground. If you put a jumper across to from a power source to blue while it's connected in the relay it will spark, but if you disconnect the whole thing and put power to blue you run the motor continuously.
I guess my choice of symbol for the wires that don't connect to ground is not the proper one, I'm not an electrical engineer but the ones that are not Connected to ground have a little plus symbol and the ones that got to ground a little minus symbol.

Here's another drawing with the symbols removed it might clear it up a bit

 

[togril]

consider yourself subscribed to Sir.

My EDIC relay has just gone - 2H HJ60. 12 Volt.

I opened it up - having already cleaned it and sealed it and found it full of Ants.
Yes, Ants in The Northern Territory eat your truck.

I wanted to ask - is there an easy way of wiring up a SIMPLE electrical switch for OFF OVERINJECT and RUN (or OFF / RUN)? (my oil switch is disconected i think).

I could put a pto manual cable in there I guess - though am unsure of the Aus Road Legal side of that.???? (anyone know?)
Also don't really want to start in reverse cycle...makes me nervous. Does this happen?


Tog.

 

[Bandit_guy]

Tog, there is a way for sure, now what that way is I'm not so sure. I thought of this set up first when I started this adventure. There is one aspect of the mechanics of the motor I'd have to check to confirm my idea for a manual switch set up. When it came down to the wire, yes pun intended, it was easier to build a relay. If you post a picture of your 12 volt controller to be able to see the parts I betting that the same wiring diagram would apply except replacing the 24 volt coils with 12volt ones. The resistors, transistors and capacitors are there to route the electrons in a specific sequence to make the things happen when we want them to, the voltage is only relavent to the electromagnets in the coils. That being said I've never worked on a 12 volt rig so maybe it's all different I don't know.

 

[togril]

Hi Bandit,
yes It's a pretty much plain jane version (stole a pic from this site) see below.

I checked mine against your circuit diagram, found perhaps 2 resistors with different values on mine, but the rest matched.
Went and sourced the parts from Jaycar. Had a few issues finding a c945 PNP. Got a "generic" one that should cover it.

For Relays, I am going to use 3 12v 30amp Horn Relays. Not sure of the amps so thought I would aim high.

I'll let you know how it goes.

TOg

 

[rustybucket]

I wonder if solid state relays would be a good choice to use for long trouble free service.

 

[DogDigger]

I wonder if solid state relays would be a good choice to use for long trouble free service.

Well they don't burn out like relays can.....

Wow... Nice job building that EDIC Relay! After seeing the schematic, I thought that you could probably build one if you knew a bit about electronics. I was considering attempting to build one because my EDIC system doesn't work but since I've found that it's probably not the relay, I didn't pursue it but I knew it could be done! Nice job!

 

[AJAEbj42]

Impressive...most impressive. Thanks for sharing

 

[Bandit_guy]

Solid state eh ? I might try this on version 2.