Professional Documents
Culture Documents
Texaedu s1t en
Texaedu s1t en
TRAINEE manual
www.texaedu.com
INDEX
1. EDC 7 SYSTEM APPLIED TO IVECO GROUP 3
1.1 Euro 3 hydraulic circuit 3
1.1.1 Prefilter 3
1.1.2 Fuel filter 4
1.1.3 Fuel Pump 4
1.1.4 Rail 4
1.1.5 Overpressure valve 5
1.1.6 Pressure relief valve 5
1.2 EDC7 Euro 3 control unit 5
1.3 Euro 3 version components 6
w
1.3.1 ECU 6
1.3.2 Intake air temperature/pressure sensor 8
1.3.3 Engine rpm sensor 9
1.3.4 Camshaft rpm sensor 10
1.3.5 Accelerator pedal sensor 11
1.3.6 Fuel pressure sensor 11
1.3.7 Engine oil temperature/pressure sensor 12
1.3.8 M-Prop regulator 13
1.3.9 Electro-injectors 13
TEXA S.p.A. - Copyright © All rights reserved. Images and texts are property of TEXA S.p.A. Unauthorized disclosure and reproduction, even partial, are prohibited – 8200000_2014 <1
1. EDC 7 SYSTEM APPLIED TO IVECO GROUP
The EDC7 system, in combination with a II generation Com- Location Digit Meaning
mon Rail, is applied to F4A engines... (3.9 and 5.9 litres up 1e2 F4 Engine family
3 A Evolution level
to EU5 EEV, 4.5 and 6.7 litres starting from EU6 version) of
4 E Engine
the IVECO group starting from Euro 3 version. Cycle and cylinders position 3: 4 strokes,
5 3
The F4A engine is also marked with Tector, so all vehicles vertical engine with post-treatment
6 6 Number of cylinders
with Tector engines (Eurocargo and derivated) are provided 7 8 Type of feeding/injection
with Common Rail system. Use
The complete engine code gives a set of indications on the 1 Trucks
w
2 Coaches
engine features. 8 1
4 Earthmoving and agricultural machine
Tector engines are both in the 4 and 6 in-line cylinder ver- 6 Marine engine
9 Military
sion.
9 A Power
Emission level
C = Euro 3
10 P
P = Euro 4
M = Euro 5
Table 1: Engine coding example F4AE3681A*P
ie
1.1 Euro 3 hydraulic circuit
1.1.1 Prefilter
On the chassis, behind the cabin on the right a pre-filter with a priming pump and water-in-fuel sensor is installed.
ev
pr
TEXA S.p.A. - Copyright © All rights reserved. Images and texts are property of TEXA S.p.A. Unauthorized disclosure and reproduction, even partial, are prohibited – 8200000_2014 <3
S1T “IVECO EDC7 Common Rail Engine Management” - Automotive Training Courses
1.1.2 Fuel filter The fuel filter support conveys the returns to the tank from:
• injectors;
The main fuel filter is located near the high pressure pump • overpressure valve;
on the left side of the engine. The fuel filter is connected to • filter;
the mechanical transfer pump, to the high pressure pump • high pressure pump.
and the return circuit.
The filter support also includes a housing for the fuel tem-
perature sensor and for the filter heater.
w
1.1.3 Fuel Pump
The fuel pump unit includes the transfer pump and the high
pressure pump. The pump shaft is connected to the engine
timing by gear. The operating pressure is between 250 and
1450 bar.
ie
Legend:
A) To the high pressure pump
Figure 2: Eurocargo Tector fuel filter support
Legend:
A) From the ECU heat exchanger
B) To the main filter
pr
Figure 3: Eurocargo Restyling Euro 3 fuel filter support 1.1.4 Rail
Legend:
A) From the mechanical transfer pump The rail is a calibrated volume in order to guarantee:
B) Return to the tank • a fast pressure increase at the starting point;
C) To the high pressure pump
• the compensation of the pressure due to the pulses
D) Return from the high pressure pump
E) Return from the injectors and the rail generated by the pump and the injections.
4> TEXA S.p.A. - Copyright © All rights reserved. Images and texts are property of TEXA S.p.A. Unauthorized disclosure and reproduction, even partial, are prohibited – 8200000_2014
Moreover, the Rail includes the housing for: The valve keeps a pressure of 1.3 – 2.0 bar inside the return
• the pressure sensor; circuit thus guaranteeing the filling of the injectors.
• the overpressure valve.
1.2 EDC7 Euro 3 control unit
1.1.5 Overpressure valve
The overpressure valve used in F4A engines is a dual stage EDC7 Euro 3 has the following features:
type. The adjustment pressures are 1750 and 800 bar. • engine lock via Immobilizer;
w
• check of pre-heat resistance at temperatures under
1.1.6 Pressure relief valve 5° C;
• RPM sensor/timing synchronisation for the sequen-
The fuel coming back from the injectors is led outside via tial control of the injection;
a single channel inside the engine head by means of the • it manages the injection process by controlling the
pressure relief valve. flow rate regulator, the pre-injection and the main
injection.
TEXA S.p.A. - Copyright © All rights reserved. Images and texts are property of TEXA S.p.A. Unauthorized disclosure and reproduction, even partial, are prohibited – 8200000_2014 <5
S1T “IVECO EDC7 Common Rail Engine Management” - Automotive Training Courses
w
Figure 9: Eurocargo Euro3 CAN Network
Legend:
EDC) Electronic Diesel Control
IMMO) Immobilizer
Figure 7: Input signals of EDC7 Euro 3 IC) Instrument Panel
Legend: DIA) Diagnostic socket
1) Accelerator pedal sensor IBC) Body Controller
2) Stop switch ECAS) Air suspension ECU
ie
3) Clutch switch
4) Engine brake switch
5) Engine brake selector
6) Steering column switch unit
7) Key start request
8) Cab released switch
9) Parking brake switch activated
10) “N” gear switch
11) Oil pressure and temperature sensor
12) Fuel temperature sensor
DMI) FMS interface
ABS) ABS ECU
MTCO) Tachograph
CC) Mirror control unit
CAT) Allison transmission control unit
RET) Retarder control unit
6> TEXA S.p.A. - Copyright © All rights reserved. Images and texts are property of TEXA S.p.A. Unauthorized disclosure and reproduction, even partial, are prohibited – 8200000_2014
Pin Component
1 Power supply +30
2 Fuel filter heating relay Ground
3 Ground
Pre post-heating relay/Engine brake solenoid
4 Power supply
valve
5 Air conditioning relay Signal
6 Coolant Level Warning Lamp Command
7 Power supply +30
Clutch pedal switch/Blink-Code button/Engi-
w
Power sup-
8 ne brake button/Brake pedal switch/Cruise
ply 24 V
control lever
9 Ground
10 Air conditioning relay Signal
11 Engine brake solenoid valve Negative control
12 Power supply +30
13 Power supply +30
14 Ground --
15 Ground --
TEXA S.p.A. - Copyright © All rights reserved. Images and texts are property of TEXA S.p.A. Unauthorized disclosure and reproduction, even partial, are prohibited – 8200000_2014 <7
S1T “IVECO EDC7 Common Rail Engine Management” - Automotive Training Courses
w
9 Oil pressure/temperature sensor Power supply 5 V
56 -- --
10 Intake air temperature/pressure sensor Power supply 5 V
57 -- --
11 -- --
58 -- --
12 Rail pressure sensor Power supply 5 V
59 RESUME button Positive signal
13 -- --
60 Cruise control OFF button Positive signal
14 -- --
61 SET - signal Positive signal 15 -- --
62 Clutch pedal switch Negative signal 16 -- --
63 Low oil pressure warning light Control signal 17 Fuel temperature sensor Ground
64 Blink-Code led Ground
65
66
67
68
69
70
71
72
73
ie Fuel high temperature lamp
Oil pressure indicator signal
--
--
--
--
--
Accelerator pedal idle switch
Accelerator pedal idle switch
--
--
--
--
--
--
--
Negative signal
Negative signal
18
19
20
21
22
23
24
25
26
27
Engine temperature sensor
Oil pressure/temperature sensor
Rail pressure sensor
Intake air temperature/pressure sensor
--
Camshaft sensor
Engine rpm sensor
Engine rpm sensor
--
Rail pressure sensor
Ground
Ground
Ground
Ground
--
Signal
Ground
Signal
--
Signal
ev
74 Vehicle speed C3 signal 28 Intake air pressure sensor Signal
75 -- -- 29 Intake air temperature sensor Signal
76 Brake pedal switch Signal 30 Camshaft sensor Ground
77 Speed limiter switch Signal 31 -- --
78 -- -- 32 -- --
79 SET + signal Positive signal 33 Engine oil pressure sensor Signal
80 -- -- 34 Fuel temperature sensor Signal
81 Accelerator pedal sensor Ground 35 Oil temperature sensor Signal
82 -- -- 36 Engine temperature sensor Signal
83 Accelerator pedal sensor Signal Table 4: EDC7 ECU connector C
84 -- --
85 -- --
1.3.2 Intake air temperature/pressure sensor
pr
86 -- --
87 PTO
88 -- -- The intake air pressure/temperature sensor is used to check
89 -- -- the actual air quantity that enters the cylinders and therefore
Table 3: EDC7 ECU connector B
it allows metering, with a certain precision, the fuel flow rate
to reduce emissions and consumptions.
8> TEXA S.p.A. - Copyright © All rights reserved. Images and texts are property of TEXA S.p.A. Unauthorized disclosure and reproduction, even partial, are prohibited – 8200000_2014
The sensor is installed on the cover of the intake manifold
on the rear left side, visible under the Rail.
w
ie Figure 11: Intake air pressure/temperature sensor installation position
TEXA S.p.A. - Copyright © All rights reserved. Images and texts are property of TEXA S.p.A. Unauthorized disclosure and reproduction, even partial, are prohibited – 8200000_2014 <9
S1T “IVECO EDC7 Common Rail Engine Management” - Automotive Training Courses
w
Figure 16: Engine rpm sensor
ie
Pin 1 and 2
Pin 1 and 2
Figure 17: Engine rpm sensor electric connections
SEE OSCILLOGRAM
Table 6: Engine rpm sensor reference values
Figure 20: Camshaft sensor
ev
Figure 21: Camshaft rpm sensor electric connections
10 > TEXA S.p.A. - Copyright © All rights reserved. Images and texts are property of TEXA S.p.A. Unauthorized disclosure and reproduction, even partial, are prohibited – 8200000_2014
Even if the camshaft sensor and the rpm sensor are The accelerator pedal test with the use of a Voltmeter
electrically identical they cannot be swapped. does not allow to verify the “noise” of the signal due to
wear or to micro-breaks of the potentiometer. These are
1.3.5 Accelerator pedal sensor easily identifiable by using an oscilloscope.
w
• idle speed NA switch. The fuel pressure sensor, installed on the Rail, generates
the feedback signal that the ECU uses to adjust the injection
pressure.
ie
Measurement point Description
Figure 23: Accelerator pedal
Value
Figure 25: Rail pressure sensor mounting position
TEXA S.p.A. - Copyright © All rights reserved. Images and texts are property of TEXA S.p.A. Unauthorized disclosure and reproduction, even partial, are prohibited – 8200000_2014 < 11
S1T “IVECO EDC7 Common Rail Engine Management” - Automotive Training Courses
w
Measurement point Description Value suring the temperature.
Pin 1 and 3 Power supply 5V
Pin 1 and 2 Signal See diagram
Table 9: Sensor electric controls
ie
Figure 28: Pressure/Voltage diagrams: pmax = 1800 or 2000 bar
Figure 30: Engine oil pressure/temperature sensor
ev
The maximum manageable overpressure is 2100 or
2300 bar according to the version.
Figure 31: Engine oil temperature/pressure sensor connections
12 > TEXA S.p.A. - Copyright © All rights reserved. Images and texts are property of TEXA S.p.A. Unauthorized disclosure and reproduction, even partial, are prohibited – 8200000_2014