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TRAINEE manual

MAN EDC7/C32 Common Rail Engine

Management

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INDEX
1. EDC 7 SYSTEM APPLIED TO MAN GROUP 3 1.6.21 FFR ECU 39
1.1 Euro 3 hydraulic circuit 5 1.6.22 Accelerator pedal sensor 39
1.1.1 KSC (Kraftstoff Service Center) 5 1.6.23 Tempomat/Gearshift multifunction lever 39
1.1.2 Fuel pump 6 1.6.24 FGR/FGB change over switch 39
1.1.3 Rail 7 1.6.25 Continuous brake lever 39
1.1.4 2-stages DBV overpressure valve 7 1.6.26 Engine Brake Management 39
1.1.5 Pressure relief valve 7 1.6.27 Glow plug 39
1.2. EDC7 Euro 3 control unit 8 1.7 Euro 5 hydraulic circuit 40
1.3 Euro 3 version components 9 1.7.1 Fuel pump 40
1.3.1 ECU 9 1.8 Euro 5 control unit EDC7 C32 40
1.3.2. Intake air pressure sensor 10 1.9 Euro 5 version components 40
1.3.3 Engine rpm sensor 11 1.9.1 ECU 40
1.3.4 Camshaft sensor 12 1.9.2 Intake air temperature sensor 42
1.3.5 Fuel pressure sensor  13 1.9.3 2-stage turbocharging 42
1.3.6 Rail pressure sensor 13 1.9.4 Intake air cooling circuit 43
1.3.7 Engine oil pressure sensor 14 1.9.5 Electro-injectors 44
1.3.8 ZME Regulator (M-Prop) 15 1.9.6 Exhaust gas temperature sensor  44
1.3.9 Electro-injectors 15 1.9.7 Compressor disengagement solenoid valve  44
1.3.10 Engine temperature sensor  16 1.9.8 Lambda Probe 44
1.3.11 Intake air temperature sensor 17 1.10 EDC 7 system test 45
1.3.12 Exhaust gas recirculation 18 1.10.1 Cylinder shut-off test 45
1.3.13 IMR Relay 20 1.10.2 Compression test 46
1.3.14 FFR ECU 20 1.10.3 Cylinder Balance test 46
1.3.15 Accelerator pedal sensor 21 1.11 Hydraulic circuit analysis 46
1.3.16 Tempomat/Gearshift multifunction lever 21 1.11.1 Low pressure circuit test 46
1.3.17 FGR/FGB change over switch 22 1.11.2 High pressure circuit test 48
1.3.18 Continuous brake lever  22
1.3.19 Engine Brake Management 22
1.3.20 Glow Plug 24
1.4 Euro 4 hydraulic circuit 25
1.4.1 KSC (Kraftstoff Service Center) 25
1.4.2 Fuel pump 26
1.4.3 Rail 26
1.4.4 2-stage DBV overpressure valve  26
1.4.5 Pressure relief valve  26
1.5 Euro 4 EDC7 C32 control unit 27
1.6 Components version Euro 4 29
1.6.1 ECU 29
1.6.2 Intake air temperature/pressure sensor 31
1.6.3 2-stage turbocharging 31
1.6.4 Engine rpm sensor 33
1.6.5 Camshaft sensor 33
1.6.6 Fuel pressure sensor 33
1.6.7 Rail pressure sensor 33
1.6.8 Engine oil pressure sensor 34
1.6.9 ZME Regulator (M-Prop) 34
1.6.10 Electro-injectors  34
1.6.11 Engine temperature sensor 35
1.6.12 Intake air temperature sensor 35
1.6.13 Exhaust gas recirculation 36
1.6.14 CRT back pressure throttle valve 37
1.6.15 PM-Kat 37 Legend:
1.6.16 Exhaust gas temperature sensor 38
1.6.17 Pressure sensor related to exhaust gases 38 Warning
1.6.18 CRTec 38
1.6.19 Differential pressure sensor 39
1.6.20 IMR Relay 39 Information/Notes

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1. EDC 7 SYSTEM APPLIED TO MAN GROUP
The EDC7 system combined with a Common Rail of second generation is today applied to the whole range of MAN road vehi-
cles.

Engine
Engine Displacement Regulations Post-treatment Overboost High pressure pump
Adjustment
D0834 4,58 I
Euro 3 with/without AGR 1 stage EDC+FFR CP3.3, CP3.4
D0836 6,87 I
D0834 4,58 I Euro 4 Step 1+
AGR + PM-Kat 2 stages EDC+ FFR CP3.3
D0836 6,87 I NOx check
D0834 4,58 I
Euro 5 Step 2 AGR + PM-Kat 2 stages EDC+FFR CP3.3, CP3.3NH
D0836 6,87 I
D0834 4,58 I AGR + PM-Kat or 2 stages with inter-
Euro 5 EEV Step 2 EDC+FFR CP3.3, CP3.3NH
D0836 6,87 I SCR mediate cooling
2 Stages with inter-
D0836 LOH 6,87 I Euro 5 EEV Step 2 AGR EDC+FFR CP3.3
mediate cooling
D2066 LOH-LUH 10.52 I Euro 3 PM-Kat 1 Stage EDC+FFR CP3.4 +
AGR+ PM-Kat or
D2066LOH-LUH 10.52 I Euro 4 1 Stage EDC+FFR CP3.4+
CRT
AGR+ PM-Kat or 2 Stages with inter-
D2066 LOH-LUH 10.52 I Euro 5 EDC+FFR CP3.4 +
CRT mediate cooling
AGR+PM-Kat or 2 Stages with inter-
D2066 LOH-LUH 10.52 I Euro 5 EEV EDC+FFR CP3.4 +
CRT mediate cooling
D2066 10.52 I Euro 3 AGR 1 stage EDC+FFR CP3.4, CP3.4+
Euro 4 Step 1+
D2066 10.52 I AGR+PM-Kat 1 stage EDC+FFR CP3.4+
NOx check
Euro 5, Euro 5 EEV
D2066 10.52 I SCR 1 stage EDC+FFR CP3.4+
Step 2
AGR+PM-Kat or
D2676 LOH 12.42 I Euro 3 1 Stage EDC+FFR CP3.4+
CRT
AGR+PM-Kat or
D2676 LOH 12.42 I Euro 4 1 Stage EDC+FFR CP3.4+
CRT
AGR+PM-Kat or 2 Stages with inter-
D2676 LOH 12.42 I Euro 5 EDC+FFR CP3.4+
CRT mediate cooling
AGR + PM-Kat or 2 Stages with inter-
D2676 LOH 12.42 I Euro 5 EEV EDC+FFR CP3.4+
CRT mediate cooling
Euro 4 Step 1+
D2676 12.42 I AGR+PM-Kat 1 Stage EDC+FFR CP3.4+
NOx check
Euro 5, Euro 5 EEV
D2676 12.42 I SCR 1 Stage EDC+FFR CP3.4+
Step 2
Euro 5, Euro 5 EEV
D2868 16.2 I SCR 1 Stage EDC+FFR
Step 2
D2876 12.80 I Euro 3 AGR EDC+FFR CP3.4
18.27 I
D284x Euro 3 AGR EDC+FFR CP2/4
21.93 I
Table 1:  Overview of MAN solutions

D08 engines (150 – 340 HP) for industrial vehicles and D08, D20 and D26 engines (250 – 505 HP) for passengers
transport vehicles adopt the Pure Diesel Technology consisting of an EGR with 2-stages overboost and intermediate cooling.
On buses it is possible to have the CRT (Continuously regenerating trap) upon request, instead of the PM-Kat.

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S2T “MAN EDC7/C32 Common Rail Engine Management” - Automotive Training Courses

MAN engine code identifies a series of characteristical data.

Common Rail engines can work with fuels com-
Position Digit Meaning plying with regulation EN590. Operation with fuels as
D Diesel FAME needs to be specifically defined.
E Methane
G LPG
1 D
H Hydrogen
M Methanol
O Gasoline
2 and 3 20 Cylinder bore = (xx + 100) mm
Piston stroke = (10x+ 100) mm (3=125 mm,
4 6
4=142 mm, 6=155, 7=166 mm)
5 6 Cylinder number (0 = 10, 2 = 12)
D: 3-way catalytic converter
L: with turbocharger and Intercooler
6 L
T: by payment
No character: Suctioned
H vertical engine for LHD trucks
HR vertical engine for RHD trucks
HA vertical engine for LHD on-off-road trucks
HG vertical engine with special feature for LHD on-
off-road trucks
F front vertical engine for trucks
GF front vertical engine for trucks (special feature
only for D08)
GFA special feature on-off-road GF
FR front vertical engine for RHD trucks
FA front vertical engine for LHD GF on-off-road
trucks
FG vertical engine with special feature for LHD on-
7 F off road truck
FGR vertical engine with special feature for RHD
on-off-road trucks
FO front vertical engine for buses
OF front vertical engine for LHD buses
OFR front vertical engine for RHD buses
OH rear vertical engine for buses
H horizontal engine for trucks
UH rear horizontal engine for buses
UM central horizontal engine for buses
E vertical engine for other vehicles
UE horizontal engine for other vehicles
..L added engine indication only for L2000
Usage mode if installed on other vehicles:
1 engine for processing machines
2 engine unit
3 Engine for cogeneration, auxiliary marine engine
8
4 Marine engine
5 Engine for farming machine
6 Train engine
7 Short engine
9,10 01 Variant
Table 2:  Engine code definition. Example of D2066 LF01

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1.1 Euro 3 hydraulic circuit

1.1.1 KSC (Kraftstoff Service Center)

On MAN vehicles the KSC is fitted, which represents the fuel management unit. It integrates:
•  pre-filter with priming pump;
•  main filter;
•  water separator;
•  fuel pressure sensor;
•  heater.

Figure 1

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S2T “MAN EDC7/C32 Common Rail Engine Management” - Automotive Training Courses

In the lower side we can find the connection of the control This valve has 2 calibrated holes:
solenoid valve of the glow plug, located on the intake mani- •  1 keeps (approx.) 5 bar on the delivery towards the
fold for cold start. high pressure pump;
•  1 keeps 1.3 – 1.8 bar on the filter return and at the
same time supplies the glow plug.

Figure 4:  KUV valve of D28 engines

1.1.2 Fuel pump

The fuel pump assembly consists of the transfer pump and

Figure 2:  MAN KSC
Legend: the high pressure pump. The pump shaft is connected to
A) Main filter the engine timing through a gear wheel. The work pressure
B) Fuel pressure sensor
varies up to 1400 – 1600 bar. Euro 3 MAN vehicles are
C) Heater
D) Pre-filter with priming pump equipped with a pump CP3.4 o CP3.4+ (CP2/4 on V10 en-
gines). The pump is located:
•  on the rear left side where the inline pump (D28) was
fitted;
•  on the left front side (D08, D20, D26);
Legend:
A) From the tank
•  on the rear side in the center of the V (V10).
B) Towards the mecha-
nical transfer pump
C) From the mechanical
transfer pump
D) Towards the high
pressure pump
E) Return to the tank

Figure 3:  KSC hydraulic connections

D28 series engines are equipped with the KSC already in- Figure 5:  Pump CP3.4
stalled on versions with EDC MS6.1 while for D20 and D08 Legend:
A) Return to the tank
engines a new KSC is fitted. On the KSC lower side of D28 B) From the main filter
a fitting connects the glow plug with a pressure relief valve C) To the high pressure circuit
towards the return manifold. D) From the pre-filter
E) To the main filter

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 Figure 6:  Pump CP3.4+ Figure 7:  DBV valve in D20 engines
Legend:
A) From the tank
B) To the transfer pump In case of overpressures on the Rail, if the valve doesn’t
C) From the main filter open, the ECU controls the M-Prop in order to increase
D) To the high pressure circuit
pressure to speed up the overpressure valve opening. If it
E) Return circuit
doesn’t open anyway, the engine shuts down.
The engine shaft-pump transmission ratio is 1:1.67 for D20
1.1.5 Pressure relief valve
and D28, 1:1.33 for D08 and 2:1 for V10. The lubricating oil
returning from the pump is sent to the pre-filter suction of
The fuel returning from the injectors is conveyed towards
the oil module.
the tank through the pressure relief valve that allows to keep
the pressure on the return circuit at a value of 1.2 - 1.4
1.1.3 Rail
bar. In D08 and D20 engines, a single return manifold is
obtained in the head and the valve is screwed on the head
The Rail, manufactured in forged steel, has different diame-
itself. In D28 engines, the injector returns are taken outside
ters and lenghts according to the kind of engine it is used
each cylinder head and are conveyed towards a valve which
on. It presents a calibrated volume in order to guarantee:
operates as return manifold and keeps the pressure on the
•  a quick pressure increase at start up;
circuit at 1.2 – 1.4 bar (the first version is set at 0.5 bar).
•  the pressure compensation due to the pulses genera-
ted by pump and injections.

The Rail has also a casing for:

•  pressure sensor;
•  overpressure valve.

1.1.4 2-stages DBV overpressure valve

The overpressure valve used in MAN engines is a double

stage valve. The pressure settings are 1800 and 700-800
bar. Once the second stage is opened, the valve remains
open until the pressure falls under 50 bar.

Figure 8:  Return manifold in D28 engines

Legend:
A) Return from the injectors C) Return from DBV valve
B) Return to the tank D) Return from the glow plug

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S2T “MAN EDC7/C32 Common Rail Engine Management” - Automotive Training Courses

pre-injection is available for all engine speeds;

•  it checks the pressure on the Rail through the
feedback signal of the pressure sensor;
•  it manages, using the proper mappings, the precise
injection point;
•  it stabilizes the idle speed correcting the flows on the
injectors and the pressure on the Rail;
•  it limits the engine speed;
•  it controls the Cut-off phase, cancelling the control on
the injectors and acting on the flow regulator;
•  it controls the exhaust smoke during acceleration by
activating the injectors and the flow regulator accor-
ding to the actual istantaneous engine load;
Figure 9:  Pressure relief valve in D08 and D20 engines •  activation of the Limp-Home mode when the fuel
pressure reaches abnormal values;
1.2. EDC7 Euro 3 control unit •  activation of performance limitations according to
occurring failures;
•  after Run: at engine shutdown the ECU remains po-
The Euro 3 version of EDC7 has the following features: wered in order to terminate all existing processes and
•  pre-heating control at low temperatures; to store operating parameters.
•  rpm/timing synchronization at start up for injection
sequential control; The control unit can manage max. 6 cylinders, there-
•  it manages the injection process by checking the flow fore V10 engines use 2 control units (Master/Slave).
regulator, the pre-injection and the main injection. The

Legend:
1) Engine rpm sensor
2) Camshaft sensor
3) Air pressure sensor
4) Engine temperature sensor
5) Air intake temperature sensor
6) Rail pressure sensor
7) Fuel pressure sensor
8) Oil pressure sensor
9) EGR position sensor
10) Intarder/Engine Brake Lever
11) Cruise Control Management
12) Accelerator pedal sensor
13) Clutch travel sensor
14) FGR/FGB switch
15) M-Prop flow regulator
16) Electro-injectors
17) Turbocharger proportional
solenoid valve
18) EGR solenoid valve
19) Starter motor IMR relay
20) Engine Brake Solenoid Valve

Figure 10:  EDC7 Euro3 input/output signals

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1.3 Euro 3 version components 22 AGR position sensor Signal
23 AGR position sensor Power supply 5 V
24 Engine oil pressure sensor Power supply 5 V
1.3.1 ECU 25 Intake air pressure sensor Power supply 5 V
26 -- --
27 -- --
The EDC 7 ECU is directly fitted on the engine, left side (in 28 -- --
V10 engines the 2 ECUs are fitted on the frame behind the 29 -- --
30 -- --
cabin in 2 protective boxes). The ECU has 3 connectors. 31 -- --
32 -- --
33 -- --
34 -- --
35 -- --
36 -- --
37 Fuel pressure sensor Ground
38 Engine oil pressure sensor Ground
39 -- --
40 Fuel pressure sensor Power supply 5 V
41 -- --
42 -- --
43 Rail pressure sensor Power supply 5 V
44 -- --
45 -- --
46 -- --
47 -- --
48 -- --
49 -- --
50 -- --
51 -- --
52 -- --
53 -- --
54 Camshaft sensor Ground
55 Engine rpm sensor Ground
Figure 11:  EDC7 ECU connector
56 -- --
57 Intake air temperature sensor Ground
58 Engine temperature sensor Ground
Pin Component 59 -- --
1 Power supply +30 60 -- --
2 Turbocharger solenoid valve Positive control 61 Rail pressure sensor Ground
3 Ground 62 Intake air pressure sensor Ground
4 Turbocharger solenoid valve Ground 63 -- --
5 -- -- 64 -- --
6 -- -- 65 -- --
7 Power supply +30 66 -- --
8 M-Prop regulator PWM control 67 -- --
9 Ground 68 -- --
10 M-Prop regulator Ground 69 -- --
11 AGR solenoid valve Negative control 70 -- --
12 Power supply +30 71 -- --
13 Power supply +30 72 Camshaft sensor Signal
14 Ground 73 Engine rpm sensor Signal
15 Ground 74 -- --
16 IMR relay Positive control 75 -- --
17 AGR solenoid valve Positive control 76 Intake air temperature sensor Signal
18 -- -- 77 Engine temperature sensor Signal
19 IMR relay Ground 78 -- --
20 Fuel pressure sensor Signal 79 -- --
21 Engine oil pressure sensor Signal 80 Rail pressure sensor Power supply 5 V
81 Intake air pressure sensor Signal

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S2T “MAN EDC7/C32 Common Rail Engine Management” - Automotive Training Courses

82 -- -- 1.3.2. Intake air pressure sensor

83 -- --
84 -- --
85 -- -- The intake air pressure sensor is used to determine the ac-
86 -- -- tual quantity of air entering the cylinders and therefore al-
87 -- -- lows to dose with a higher precision the fuel flow to reduce
88 -- --
89 -- --
emissions and consumptions.
Table 3:  ECU EDC7 connector A The sensor is located on the intake manifold, left front side.
The piezoelectrical sensor and an electronic system for si-
Pin Component Pin Component gnal amplification and temperature compensation are inte-
1 -- -- 19 -- -- grated on a silicon chip.
2 -- -- 20 -- --
The chip active surface is exposed to a vacuum reference
3 -- -- 21 CAN line CAN L
4 -- -- 22 CAN line CAN H value. The vacuum pipe pressure is transmitted through an
5 -- -- 23 -- -- appropriate fitting on the rear side of the membrane that
6 -- -- 24 -- -- resists the measuring aid.
7 -- -- 25 -- --
8 -- -- 26 -- --
9 -- -- 27 -- --
10 -- -- 28 -- --
11 -- -- 29 -- --
12 -- -- 30 -- --
13 -- -- 31 -- --
14 -- -- 32 -- --
15 -- -- 33 -- --
16 -- -- 34 -- --
17 -- -- 35 Diagnostic socket K line
18 -- -- 36 Power supply + 15
Table 4:  ECU EDC7 connector B Figure 12:  Kavlico intake air pressure sensor (D28)

Pin Component
1 Cylinder 5 injector Positive control
2 Cylinder 6 injector Positive control
3 Cylinder 4 injector Positive control
4 Cylinder 1 injector Positive control
5 Cylinder 3 injector Positive control
6 Cylinder 2 injector Ground Figure 13:  Connections of Kavlico intake air pressure sensor (D28)
7 -- --
8 -- --
9 -- -- In D20 engines the intake air pressure sensor is a Bosch
10 -- -- sensor with the same features of the previous sensor.
11 Cylinder 2 injector Positive control
12 Cylinder 3 injector Ground
13 Cylinder 1 injector Ground
14 Cylinder 4 injector Ground
15 Cylinder 6 injector Ground
16 Cylinder 5 injector Ground
Table 5:  ECU EDC7 connector C

Figure 14:  Connections of Bosch intake air pressure sensor (D20)

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 Measurement point Description Value
Pins 3 and 2 (Kavlico) Power supply 5V
Pins 3 and 1 (Bosch) Power supply 5V
Pins 4 and 2 (Kavlico) Signal See diagram
Pins 4 and 1 (Bosch) Signal See diagram
Table 6:  Sensor electric controls

Figure 17:  Engine rpm sensor

The engine can also be started only with this sen-

sor signal. Near TDC the ECU performs some injections to
identify the correct ignition order.

Figure 15:  Sensor Pressure/Voltage Diagram

In case of sensor failure a replacement value is pre-

set; this way, there is no operation limitation. The signal is
verified through an atmospheric pressure sensor integrated
in the ECU, which evaluates the signal when the engine is
working at idle speed. Figure 18:  Electrical connections of the engine rpm sensor

1.3.3 Engine rpm sensor Measurement point Description Value

Pins 1 and 2 Resistance 750 – 1100 ohm
The engine rpm sensor is an inductive sensor and it is posi- Pins 1 and 2 Signal SEE OSCILLOGRAM
Table 7:  Reference values of the engine rpm sensor
tioned on the rear side of the engine on the flywheel box. It
detects the engine rpm through the gear on the flywheel that
has 60-2 = 58 holes.
There is therefore 1 hole every 6° and 2 holes are missing in
line with the first cylinder.
The distance between sensor and gear is 1 mm (not adju-
stable value).

Figure 19:  Signal of engine rpm at idle

The first half wave at start up must be positive. If

not, error code 3753 is generated.
Figure 16:  Rpm sensor mounting position

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S2T “MAN EDC7/C32 Common Rail Engine Management” - Automotive Training Courses

1.3.4 Camshaft sensor

The camshaft sensor is an inductive sensor. It detects the

camshaft rpm through some notches on the camshaft gear.
The sensor position differs according to the engine.
In D28 engines where the valves rocker arms operate throu-
gh rods, the camshaft is on the case.
The sensor here is visible on the engine rear left side, over
the high pressure pump.
The reading occurs through 7 pins fixed on the timing gear.
The sensor in this case is equipped with a connection cable.
In D20 and D26 engines, with overhead camshaft, the sen-
sor is at the rear left hand on the top, under the valve cover. Figure 21:  Camshaft sensor

In D08 engines, where the valves rocker arm operates

through rods, the camshaft is on the case. Figure 22:  Electrical connections of the camshaft sensor

The sensor here is visible on the engine front right side, on

the camshaft bracket behind the drive belt. Measurement
Description Value
point
The reading occurs through 5 or 7 protrusions on the timing
Pins 1 and 2 Resistance 750 – 1100 ohm
gear.
Pins 1 and 2 Signal SEE OSCILLOGRAM
In D08, D20 and D26 engines the sensor directly integrates
Table 8:  Reference values of the camshaft sensor
also the connection pin.
In V10 engines the sensor is inside the CP2/4 pump.

Figure 23:  Camshaft rpm signal

The engine can be started also with only this sensor

signal.
In the ECU all skew corrections are stored so that the injec-
tion point can be calculated without knowing the engine
shaft rotation angle.

The first half wave at start up must be positive. If

Figure 20:  Camshaft rpm sensor mounting position
not, error code 3753 is generated.

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