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TRAINEE manual

IVECO EDC7 Common Rail Engine

Management

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 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

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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

ie1.3.10 Engine temperature sensor

1.3.11 Fuel temperature sensor
1.3.12 Water in fuel presence sensor
1.3.13 Fuel filter heater
1.3.13 Stop switch
1.3.14 Clutch switch
1.3.15 Engine brake management
1.3.16 Pre-heating resistance relay
1.4 Euro 4/5 hydraulic circuit
13
14
15
15
15
16
16
17
17
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1.4.1 Prefilter 17
1.4.2 Fuel filter 18
1.4.3 Fuel Pump 19
1.4.4 Rail 19
1.4.5 Overpressure valve 19
1.4.6 Pressure relief valve 19
1.5 EDC7 UC31 Euro 4/5 ECU 19
1.6 Euro 4/5 version components 20
1.6.1 ECU 20
1.6.2 Intake air temperature/pressure sensor 21
1.6.3 Engine rpm sensor 22
1.6.4 Camshaft rpm sensor 22
1.6.5 Fuel pressure sensor 22
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1.6.6 Engine oil temperature/pressure sensor 23

1.6.7 Engine temperature sensor 23
1.6.8 Fuel temperature sensor 23
1.6.9 Electro-injectors 23
1.6.10 Water-in-fuel sensor 24
1.6.11 Pre-heating resistance relay 24
1.6.12 Fuel filter heater 24
1.6.13 Engine brake solenoid valve 25
1.6.14 Air temperature and humidity sensor 25
1.6.15 VCM ECU 25 Legend:
1.6.16 Accelerator pedal sensor 26
1.6.17 STOP switch 26
1.6.18 Clutch switch 27
Warning
1.6.19 Engine Brake Switch
and Engine Brake mode selection Switch 27 Information/Notes

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 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

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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

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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.
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Figure 1:  F4A Euro 3 engine hydraulic circuit

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 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.

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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.

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Legend:
A) To the high pressure pump
Figure 2:  Eurocargo Tector fuel filter support

B) Return from the injectors and the rail

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C) From the mechanical transfer pump
D) Return to the tank

Figure 4:  CP3.3 pump

Legend:
A) From the ECU heat exchanger
B) To the main filter
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C) From the main filter

D) To the high pressure circuit
E) Return to the main filter support

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.

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 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;

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•  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.

ie The pre-injection is available for all engine speeds.

•  it controls the Rail pressure via a feedback signal of
the pressure sensor;
•  it manages, by mappings, the exact injection point;
•  it balances the idle speed by correcting the flow rates
on the injectors and the Rail pressure;
•  it limits the engine speed (at 2700 rpm the flow rate is
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reduced, at 3000 rpm it is stopped);
•  it controls the cut-off phase, by cancelling the com-
mand on the injectors and acting on the flow rate re-
gulator;
•  it controls the smokiness at exhaust during accelera-
Figure 5:  Pressure relief valve tion by activating the injectors and the flow rate regu-
lator according to the actual instant engine load;
The valve is in the middle of the head on the back of the •  it reduces the engine performance if the return fuel
engine. temperature exceeds 75° C. Over 90° C the power is
reduced by 60%;
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•  after Run: at engine shut-down the ECU remains po-

wered to complete all started processes and to save
the operating parameters;
•  it manages the overheating protection by reducing the
engine performance if its temperature exceeds 110°
Figure 6:  Section of the pressure relief valve C. It reverts to normal operation under 100° C.

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 S1T “IVECO EDC7 Common Rail Engine Management” - Automotive Training Courses

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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

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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

1.3 Euro 3 version components

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13) Fuel pressure sensor
14) Air pressure and temperature sensor 1.3.1 ECU
15) Camshaft sensor
16) Engine temperature sensor
17) Start/Stop buttons on engine The EDC 7 ECU is directly installed on the engine by means
18) Engine rpm sensor
of a cooling radiator and some rubber brackets to reduce
vibration.
It has 3 connectors and is powered by means of a 20A fuse
located on the UCI (F19).
The main power relay is directly integrated in the ECU.
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Figure 8:  Outputsignals of EDC7 Euro 3

Legend:
1) Electro-injectors
2) Flow regulator MPROP
3) Fuel filter heater
4) Pre-heating resistance relay
5) Starter motor relay
6) Engine brake solenoid valve
7) A/C system relay

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 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-

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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 --

ie 16 Pre post heating relay

17 --
18 --
19
START/STOP switches from engine/Neutral
switch/Handbrake switch
20 Start signal
21 Engine brake switch
22 Engine brake mode switch
23 --
Negative control
--
--
Ground
+50
Positive signal
Positive signal
--
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24 -- --
25 -- --
26 Speed limiter Control signal
27 Blink-Code button Positive signal
Figure 10:  EDC7 ECU connector 28 Blink-Code led Control positive
29 Speed limiter lamp Control signal
30 Diagnostic socket L line
Pin Component
31 Diagnostic socket K line
1 -- --
32 PTO
2 -- --
33 -- --
3 Cylinder 2 injector Positive control
4 Cylinder 3 injector Positive control 34 -- --
5 Cylinder 4 injector Positive control 35 -- --
36 Fuel filter heating relay Positive
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6 Cylinder 2 injector Ground

7 Ground 37 Starter motor Positive control
8 Ground 38 Engine brake mode switch Positive signal
9 Cylinder 1 injector Positive control 39 Power supply +15
10 Cylinder 6 injector Positive control 40 Engine brake switch-off Negative control
11 Cylinder 5 injector Positive control 41 Handbrake switch Negative signal
12 Cylinder 3 injector Ground 42 Cab released switch
13 Cylinder 1 injector Ground 43 Neutral switch Positive signal
14 Cylinder 4 injector Ground 44 START switches from engine Positive signal
15 Cylinder 6 injector Ground 45 STOP switches from engine Positive signal
16 Cylinder 5 injector Ground 46 Pre-post-heating lamp Control signal
Table 2:  EDC7 ECU connector A 47 Engine brake indicator lamp Control signal

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 S1T “IVECO EDC7 Common Rail Engine Management” - Automotive Training Courses

Pin Component Pin Component

48 Diagnostic socket Camshaft signal 1 -- --
49 Rpm counter Engine rpm signal 2 -- --
50 Accelerator pedal idle switch Power supply 24V 3 -- --
51 -- -- 4 -- --
52 CAN line L 5 M-Prop Ground
53 CAN line H 6 -- --
54 -- -- 7 M-Prop PWM control
55 Accelerator pedal sensor Power supply 5 V 8 -- --

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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
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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
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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.

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 The sensor is installed on the cover of the intake manifold
on the rear left side, visible under the Rail.

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ie Figure 11:  Intake air pressure/temperature sensor installation position

The sensor uses a piezo-resistive membrane and allows

measuring the absolute pressure. The signal is insensitive
to external disturbance and it has the temperature compen-
sation. The lower terminal of the sensor has an NTC element
for measuring the temperature.
Figure 14:  Diagrams for sensor Pressure/Voltage and Temperature/Resistance

1.3.3 Engine rpm sensor

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The engine rpm sensor is a inductive sensor and is positio-
ned on the front left side of the engine. It detects the engine
rpm by means of the phonic wheel installed on the drive
shaft, behind the damper.

Figure 12:  Intake air temperature/pressure sensor

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Figure 13:  Intake air temperature/pressure sensor connections

Measurement point Description Value

Pin 1 and 3 Power supply 5V
Pin 1 and 4 Signal See diagram
Pin 2 and 1 Resistance See diagram
Figure 15:  Engine rpm sensor installation position
Table 5:  Sensor electric controls

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 S1T “IVECO EDC7 Common Rail Engine Management” - Automotive Training Courses

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Figure 16:  Engine rpm sensor

The sensor signal is also used as rpm counter on the

Instrument Panel. Figure 19:  Camshaft rpm sensor installing position

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Pin 1 and 2
Pin 1 and 2
Figure 17:  Engine rpm sensor electric connections

Measurement point Description

Resistance
Signal
900 ohm
Value

SEE OSCILLOGRAM
Table 6:  Engine rpm sensor reference values
Figure 20:  Camshaft sensor
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Figure 21:  Camshaft rpm sensor electric connections

Measurement point Description Value

Pin 1 and 2 Resistance 900 ohm
Pin 1 and 2 Signal SEE OSCILLOGRAM
Table 7:  Engine rpm sensor reference values

Figure 18:  Engine rpm signal

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1.3.4 Camshaft rpm sensor

The camshaft sensor is an inductive sensor and is located

on the rear left side of the engine and is visible over the
injection pump. It detects the camshaft rpm by means of
some holes in the spliced gearing on the shaft itself inside
the timing case.
Figure 22:  Segnale giri albero a camme

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 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.

The accelerator pedal includes: 1.3.6 Fuel pressure sensor

•  position potentiometer;

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•  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.

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Measurement point Description
Figure 23:  Accelerator pedal

The signal is used to determine the engine torque. If the

signal is lacking, a Recovery strategy is activated (accele-
rated idle speed).

Value
Figure 25:  Rail pressure sensor mounting position

The sensor uses a thin metal film on which a Wheatsto-

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Pin 2 and 3 Power supply 5V
ne jumper is connected. This way the signal is precise and
Pin 1 and 3 Signal See diagram
Pin 2 and 3 Resistance 1000 ohm has the temperature compensation. The generated signal is
Pin 4 and 5 Pressed pedal 0 ohm opportunely amplified by an electronic circuit built-in in the
Pin 4 and 5 Released pedal -- sensor. The electronic circuit also integrates the diagnosis
Table 8:  Sensor electric controls function, which allows identifying the break of the measu-
rement cell, of the electric connections and the absence of
power supply or ground. The sensor works with pressure
up to 1800 or 2000 bar.
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Figure 26:  Fuel pressure sensor

There are different versions of the sensor combined with

different Rails, so the thread pitch of the connection can
Figure 24:  Accelerator pedal signal

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 S1T “IVECO EDC7 Common Rail Engine Management” - Automotive Training Courses

change: The sensor used has a silicon membrane on which the

•  M12 x 1,5; diaphragm including a Wheatstone jumper is fixed.
•  M18 x 1,5. The silicon membrane also includes the sensitivity
adjustment electronic circuit. The sensor has a vacuum
chamber which allows adjusting the absolute 0 of the pres-
sure. The pressure variation causes a deformation of the
Figure 27:  Fuel pressure sensor connections membrane and therefore a variation in the resistance. The
lower terminal of the sensor has an NTC element for mea-

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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

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Figure 28:  Pressure/Voltage diagrams: pmax = 1800 or 2000 bar
Figure 30:  Engine oil pressure/temperature sensor
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The maximum manageable overpressure is 2100 or
2300 bar according to the version.
Figure 31:  Engine oil temperature/pressure sensor connections

1.3.7 Engine oil temperature/pressure sensor

Measurement point Description Value
Pin 1 and 3 Power supply 5V
The engine oil pressure/temperature sensor is used to ma- Pin 1 and 4 Signal See diagram
nage the low pressure indicator on the Instrument Panel. Pin 2 and 1 Resistance See diagram
The sensor is installed on the oil filter support. Table 10:  Sensor electric controls
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Figure 29:  Engine oil pressure/temperature sensor location

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