Electrical equipment

April 2022 333

ELECTRICAL EQUIPMENT

New Engine control module: MD1CE101 (1/7)

April 2022 334

April 2022 335
New Engine control module: MD1CE101 (2/7)

April 2022 336

New Engine control module: MD1CE101 (3/7)
Main features

April 2022 337

New Engine control module: MD1CE101 (4/7)
Main features

April 2022 338

New Engine control module: MD1CE101 (5/7)
Main features

April 2022 339

New Engine control module: MD1CE101 (6/7)
Can bus architecture

Vehicle CAN (CAN A) SAE J1939 and ISO 14229 – 250 kbps
ECM

Calibration CAN B VCM

eExhFIp SAE J1939 1 Mbps
Actuator

Diag CONNECTOR

Upstream
Nox sensor Engine CAN (CAN C)
SAE J1939 – 250 kbps
Urea quality Other
sensor ECU (s)

Downstream
Nox sensor
FPT Installation

Customer Installation

April 2022 340

New Engine control module: MD1CE101 (7/7)
Electric devices absorptions

April 2022 341

Components location (1/4) 8 9 10
F2CGE612A*P062
F2CGE612B*P060
F2CGE612B*P061
F2CGE612D*P063
F2CGE612D*P064

1. Air pressure and

temperature sensor
2. Alternator
7 1
3. MD1 Engine Control Unit
4. Oil pressure and
temperature sensor
5. Starter motor
6. Fuel high pressure pump
metering unit
6
7. Timing sensor
8. Fuel temperature sensor /
fuel filter clogging sensor 2
9. Grid heater resistance for
engine pre-heating
10. Crankcase pressure sensor 5 4

3
April 2022 342
Components location (2/4) 8
7
F2CGE612A*P062
1
F2CGE612B*P060
F2CGE612B*P061 *
F2CGE612D*P063
F2CGE612D*P064
#
1. eVGT actuator / turbine speed sensor *
2. Engine speed sensor (crankshaft)
3. Motorized throttle valve
6
4. Oil level sensor
5. Coolant temperature sensor
6. Engine decompression valve * 2
7. Electro-injectors
8. Rail presure sensor (LWRN18)

5
* F2CGE612A*P062

# F2CGE612B*P060
F2CGE612B*P061
F2CGE612D*P063 3
F2CGE612D*P064
4
* #

April 2022 343

Components location (3/4) 8 9 10
F2CGE612A*P065

1. Air pressure and

temperature sensor
2. Alternator
3. MD1 Engine Control Unit 1
4. Oil pressure and
temperature sensor 7
5. Starter motor
6. Fuel high pressure pump
metering unit
7. Timing sensor
8. Fuel temperature sensor /
fuel filter clogging sensor 6
9. Grid heater resistance for
engine pre-heating
10. Crankcase pressure sensor 2

5 4

3
April 2022 344
Components location (4/4) 7
1
F2CGE612A*P065

6
1. eVGT actuator / turbine speed sensor
2. Motorized throttle valve
3. Engine speed sensor (crankshaft)
4. Oil level sensor
5. Coolant temperature sensor 2
6. Rail presure sensor (LWRN18)
7. Electro-injectors

3
4

April 2022 345

Engine side wiring (1/3)
1
Topographic view

F2CGE612B*P060
F2CGE612B*P061
F2CGE612D*P063 14 15 16 17 18 19
F2CGE612D*P064
20 21
2
22
13

12
11
3

10

7 6 5 4
9 8

April 2022 346

Engine side wiring (2/3) 1
Topographic view

F2CGE612A*P062
23
17 18 19 20 21 22

2
24
16 25
3

15

14

13 5

12 11

9 8 7 6
4
10

April 2022 347

Engine side wiring (3/3)
1
Topographic view

F2CGE612A*P065
21

15 16 17 18 19 20
3
22 23 2
14
24

5
13 11

9 8 7 6
12
10

April 2022 348

Engine side wiring pin out (1/5)
Connector 6 (CODE H) (Engine sensors and actuators) (1/3) Pin Description
1 -
2 Coolant temperature sensor - signal
3 -
4 Fuel metering unit – Low side
5 Fuel metering unit – High side
6 Air pressure and temperature sensor – temperature signal
7 -
8 -
9 -
10 Coolant temperature sensor - ground
11 -
12 -
13 -
14 Oil pressure and temperature sensor – temperature signal
15 -
16 Fuel temperature sensor - ground

April 2022 349

Engine side wiring pin out (2/5)
Connector 6 (CODE H) (Engine sensors and actuators) (2/3)
Pin Description
17 Increment speed sensor (crankshaft) - negative
18 Increment speed sensor (crankshaft) - positive
19 -
20 -
21 Air pressure and temperature sensor - supply
22 Air pressure and temperature sensor - ground
23 Oil pressure and temperature sensor - ground
24 -
25 -
26 Fuel temperature sensor - signal
27 -
28 -
29 Oil pressure and temperature sensor - supply
30 -
31 Oil pressure and temperature sensor – pressure signal
32 Air pressure and temperature sensor – pressure signal

April 2022 350

Engine side wiring pin out (3/5)
Connector 6 (CODE H) (Engine sensors and actuators) (3/3)
Pin Description
33 -
34 -
35 -
36 -
37 -
38 -
39 Segment speed sensor (camshaft) - positive
40 Segment speed sensor (camshaft) - negative
41 -
42 -
43 -
44 SAM (Optional)
45 -
46 Exhaust flap / eVGT actuator CAN L
47 Exhaust flap / eVGT actuator CAN H
48 -

April 2022 351

Engine side wiring pin out (4/5)
Connector 8 (CODE D) (Injectors and cylinder head)

Pin Description Pin Description Pin Description

1 Electro-injector cylinder 1 – Low side 13 Electro-injector cylinder 6 – Low side 25 Engine decompression valve *
2 Electro-injector cylinder 1 – High side 14 Electro-injector cylinder 6 – High side 26 -
3 - 15 - 27 Rail pressure sensor - ground
4 Electro-injector cylinder 2 – Low side 16 Electro-injector cylinder 4 – Low side
28 Engine decompression valve *
5 Electro-injector cylinder 2 – High side 17 Electro-injector cylinder 4 – High side
29 -
6 - 18 -
30 Rail pressure sensor - signal
7 Electro-injector cylinder 3 – Low side 19 -
31 -
8 Electro-injector cylinder 3 – High side 20 -
32 Rail pressure sensor - supply
9 - 21 -
33 Crankcase pressure sensor - signal
10 Electro-injector cylinder 5 – Low side 22 -
34 -
11 Electro-injector cylinder 5 – High side 23 -
35 Crankcase pressure sensor - supply
12 - 24 -
36 Crankcase pressure sensor - ground

* F2CGE612A*P062 only
April 2022 352
Engine side wiring pin out (5/5)
Connector 5 (CODE C) (Engine sensors and actuators)

F2CGE612A*P062 - F2CGE612A*P065

Pin Description Pin Description Pin Description

1 - 13 - 25 -
2 - 14 - 26 -
3 - 15 - 27 -
4 - 16 - 28 -
5 - 17 - 29 -
6 - 18 - 30 Turbo speed sensor - positive
7 - 19 - 31 -
8 - 20 - 32 -
9 - 21 - 33 Turbo speed sensor - negative
10 - 22 - 34 -
11 - 23 - 35 -
12 - 24 - 36 -

April 2022 353

Vehicle side wiring pin out (1/7)
Connector 1 (CODE A) (Aftertreatment)

Pin Description Pin Description Pin Description

1 SCR heating valve LS 13 - 25 DPF upstream temp. sensor - ground

SCR pump motor 14 - 26 SCR upstream temp. sensor - ground

2
control LS
15 - 27 SCR downstream temp. sensor - ground
3 -
16 - 28 DPF upstream temp. sensor - signal
4 SCR reverting valve LS
17 - 29 SCR upstream temp. sensor - signal
5 SCR reverting valve HS
18 - 30 SCR downstream temp. sensor - signal
6 -
19 CAN 4 HS 31 -
7 SCR dosing valve LS
20 CAN 4 LS 32 SCR pressure sensor - signal
SCR pump motor
8 21 - 33 -
control HS
22 SCR pump motor - ground 34 SCR pressure sensor - ground
9 SCR heating valve HS
35 -
10 SCR dosing valve HS 23 SCR pressure sensor - supply
36 -
11 - 24 -
12 -

April 2022 354

Vehicle side wiring pin out (2/7)
Connector 2 (CODE F) (Vehicle sensors and Actuators) (1/3)
Pin Description
1 -
2 -
3 -
4 Water in fuel switch
5 -
6 -
7 DPF delta pressure sensor - supply
8 -
9 DOC upstream temperature sensor - ground
10 Intake air humidity & intake air temperature sensor
11 -
12 -
13 -
14 DOC upstream temperature sensor - signal
15 -
16 Water in fuel switch - supply

April 2022 355

Vehicle side wiring pin out (3/7)
Connector 2 (CODE F) (Vehicle sensors and Actuators) (2/3)
Pin Description
17 -
18 Grid heater relay 1 HS
19 -
20 -
21 -
22 -
23 -
24 -
25 -
26 -
27 -
28 Intake air humidity sensor
29 -
30 -
31 Intake air humidity & intake air temperature sensor - supply
32 -

April 2022 356

Vehicle side wiring pin out (4/7)
Connector 2 (CODE F) (Vehicle sensors and Actuators) (3/3)
Pin Description
33 Starter release LS
34 -
35 Intake air temperature sensor - signal
36 -
37 -
38 DPF delta pressure sensor - ground
39 -
40 -
41 DPF delta pressure sensor - signal
42 Water in fuel switch - signal
43 Grid heater relay 1 LS
44 -
45 -
46 Starter release HS
47 -
48 -

April 2022 357

Vehicle side wiring pin out (5/7)
Connector 3 (CODE G) (Cabin and dashboard)
Pin Description Pin Description Pin Description
1 Accelerator pedal 1_1 (analog) - ground 17 Accelerator pedal 1_1 (analog) - supply 33 Cruise control (set -)
2 Accelerator pedal 1_2 (analog) - ground 18 Accelerator pedal 1_1 (analog) - supply 34 Cruise control (set +)
3 - 19 - 35 Cruise control (off)
4 - 20 - 36 Cruise control (resume)
5 - 21 - 37 -
6 Fuel filter heating relay LS 22 - 38 Redundant brake switch
7 Engine compartment start switch 23 - 39 -
8 - 24 - 40 -
9 Accelerator pedal 1_1 (analog) - signal 25 - 41 -
10 Accelerator pedal 1_2 (analog) - signal 26 - 42 -
11 - 27 - 43 -
12 - 28 Engine compartment stop switch 44 -
13 - 29 Hand brake switch 45 Cabin & dash board supply 1
14 - 30 - 46 Cabin & dash board supply 2
15 - 31 - 47 -
16 - 32 - 48 -

April 2022 358

Vehicle side wiring pin out (6/7) Pin Description

Connector 4 (CODE B) (ECM Supply) (1/2) 1 Terminal 30 (battery plus) 1

2 -
3 -
4 Terminal 30 (battery plus) 2
5 Terminal 30 (battery plus) 4
6 Terminal 31 (battery minus) 1
7 Terminal 30 (battery plus) 3
8 Terminal 30 (battery plus) 5
9 -
10 Terminal 31 (battery minus) 2
11 Terminal 31 (battery minus) 4
12 -
13 Terminal 31 (battery minus) 3
14 -
15 -
16 Terminal 31 (battery minus) 5
17 -
18 -

April 2022 359

Vehicle side wiring pin out (7/7) Pin Description

Connector 4 (CODE B) (ECM Supply) (2/2) 19 Power relay (to supply ATS component) HS
20 Power relay (to supply ATS component) LS
21 -
22 -
23 -
24 -
25 -
26 -
27 -
28 CAN 1 (EoL CAN) LS
29 CAN 1 (EoL CAN) HS
30 -
31 Terminal 50 signal
32 -
33 -
34 -
35 -
36 Terminal 15 signal

April 2022 360

361

Main electrical equipment

components

April 2022 361

Electro-injectors
36 CRIN 3 (1/2)
2

Technical data
Max. working pressure 1800 bar
Min. working pressure 250 bar

1. Electric connection
2. Coil
3. High-pressure fuel inlet fitting
4. Injector closing force
5. Nozzle
6. Vaporiser nozzle
2
7. Fuel return hole
8. IQA codes
9. Production code
1. Electro-injector – 2. Bracket – 3. Screw

April 2022 362

Electro-injectors
36 CRIN 3 (2/2)
3
Injector Pin connector 8
1. Coil Description
PIN (CODE D)
2. High-pressure fuel inlet fitting
3. Filter 2 Injector cyl. 1 – Low side 1
4. Pressure rod 1 Injector cyl. 1 – High side 2
5. Needle 2 Injector cyl. 2 – Low side 4
6. Nozzle 1 Injector cyl. 2 – High side 5
7. Pressure chamber 2 Injector cyl. 3 – Low side 7
8. Control volume 1 Injector cyl. 3 – High side 8
9. Pilot valve shutter 2 Injector cyl. 4 – Low side 16
1 Injector cyl. 4 – High side 17
2 Injector cyl. 5 – Low side 10
1 Injector cyl. 5 – High side 11
2 Injector cyl. 6 – Low side 13
1 Injector cyl. 6 – High side 14

April 2022 363

Fuel high pressure pump metering unit

1 2

Fuel metering unit

Ref. Description Connector 6 (CODE H)

1 Low side 4
2 High side 5

April 2022 364

Rail pressure sensor (RPS4)

Connector

Ref. Description Connector 8 (CODE D)

1 Ground 27
2 Signal 30
3 Supply 32
WIRING DIAGRAM

April 2022 365

Segment speed sensor (camshaft)

Connector

Ref. Description Connector 6 (CODE H)

1 Positive 39
2 Negative 40

Description Tightening torques

Sensor M6 x1 8 ± 2 Nm

Description
Resistance 860 ± 10% Ω Note: temperature 20 °C
Inductance 370 ± 60 mH Note: frequency 1 kHz
Wiring diagram
April 2022 366
Engine speed sensor (crankshaft)

Connector

Ref. Description Connector 6 (CODE H)

1 Positive 18
2 Negative 17

Description Tightening torques

Sensor M6 x1 8 ± 2 Nm

Description
Resistance 860 ± 10% Ω Note: temperature 20 °C
Inductance 370 ± 60 mH Note: frequency 1 kHz
Wiring diagram
April 2022 367
Air pressure and temperature sensor (1/3)

Wiring diagram
April 2022 368
Air pressure and temperature sensor (2/3)

CHARACTERISTIC AT 5.000 V SUPPLY TOLERANCEAT BROADENING AS A FUNCTION

VOLTAGE OF TEMPERATURE

Ref. Description Connector 6 (CODE H)

CHARACTERISTIC TOLERANCE AT 5.000 V 1 Ground 22
2 NTC signal (temperature) 6
3 +5 V power input 21
4 Signal (pressure) 32

April 2022 369

Air pressure and temperature sensor (3/3)
TOLERANCE – NOMINAL VALUES TOLERANCE – NOMINAL VALUES
TEMP. RESISTANCE R [Ohm] TOLERANCE TEMP. RESISTANCE R [Ohm] TOLERANCE
T [° C] nominal minimal maximal [K] T [° C] nominal minimal maximal [K]
-40 45303 43076 47529 ± 0.9 60 595.4 579.7 611 ± 0.8
-35 34273 32643 35902 ± 0.9 65 508.2 495.3 521.1 ± 0.8
-30 26108 24907 27309 ± 0.9 70 435.6 424.9 446.4 ± 0.8
-25 19999 19108 20889 ± 0.9 75 374.1 365.2 383.1 ± 0.8
-20 15458 14792 16124 ± 0.8 80 322.5 315 329.9 ± 0.8
-15 12000 11499 12501 ± 0.8 85 279.5 273.2 285.8 ± 0.8
-10 9395 9015 9775 ± 0.8 90 243.1 237.8 248.4 ± 0.8
-5 7413 7123 7704 ± 0.8 95 212.6 208.1 217.1 ± 0.8
0 5895 5671 6118 ± 0.8 100 186.6 182.9 190.3 ± 0.8
5 4711 4537 4884 ± 0.8 105 163.8 160.3 167.2 ± 0.8
10 3791 3656 3927 ± 0.8 110 144.2 141 147.3 ± 0.9
15 3068 2962 3174 ± 0.8 115 127.3 124.4 130.1 ± 0.9
20 2499 2416 2583 ± 0.8 120 112.7 110.1 115.2 ± 1.0
25 2056 1990 2123 ± 0.8 125 100.2 97.81 102.5 ± 1.0
30 1706 1643 1760 ± 0.8 130 89.28 867.13 91.43 ± 1.1
35 1411 1368 1455 ± 0.8 135 79.63 77.67 81.59 ± 1.1
40 1174 1139 1209 ± 0.8 140 71.18 69.39 72.97 ± 1.2
45 987.4 959 1016 ± 0.8 145 63.85 62.21 65.48 ± 1.2
50 833.8 810.5 857 ± 0.8 150 57.39 55.89 58.89 ± 1.3
55 702.7 683.7 721.7 ± 0.8

April 2022 370

Engine oil pressure and temperature sensor

PRESSURESENSOR
4

Wiring diagram

Connector

Ref. Description Connector 6 (CODE H)

1 Ground 23
2 NTC signal (temperature) 14
3 +5 V power input 29
4 Signal (pressure) 31

April 2022 371

Coolant temperature sensor

1
Wiring diagram

F2CGE612A*P062 F2CGE612A*P065 140

F2CGE612B*P060 120
F2CGE612B*P061
100
F2CGE612D*P063

Temperature [°C]
F2CGE612D*P064 80
60
40
Ref. Description Connector 6 (CODE H)
20
1 Ground 10
0
2 NTC signal (temperature) 2
-20 0 10 20 30 40 50 60

Description Tightening torques -40

-60 Resistence
Sensor M12 x1.5 20 ± 5 Nm

April 2022 372

Fuel temperature sensor

WIRING DIAGRAM

1 2 140
Connector 120
100

Temperature [°C]
80
Ref. Description ECU pin (connector 6 – code H)
60
1 NTC signal (temperature) 26 40
2 Ground 16 20
0
Description Tightening torques -20 0 10 20 30 40 50 60

Sensor (1 fitting M14 x1.5) 24 ± 4 Nm -40

-60 Resistence [kOhm]
April 2022 373
Fuel filter clogging (pressure drop) sensor

Air temperature and pressure sensor Nominal

Nominal voltage 12 – 24 V
Connector WIRING DIAGRAM
Differential opening pressure 210 ± 10 kPa
Operating temperature -40 ÷ +120 °C
Tightening torque 30 ± 2 Nm

April 2022 374

Crankcase pressure sensor (1/2)

Connector

1 2 3

A. Section not supplied by KAVLICO – B. Feed-THRU – C. Hybrid

– D. Custom ASIC – E. Case ground - * 1000pF min.

April 2022 375

Crankcase pressure sensor (2/2)

Crankcase pressure sensor Nominal

Input pressure range -200 ÷ +200 mbarG

Max. proof pressure +500 mbarG

Min. burst pressure +1000 mbarG

Operating supply voltage range (Vs) 5.000 ± 0.250 VDC

0.500 VDC @ -200
Nominal output voltage at RT (calibrated at Vs=5.000
mbarG to 4.500 VDC @
± 0.002 VDC)
+200 mbarG
Max. excitation current 10 mA

Output impedance <100 Ω

Operating & storage temperature range -40 ÷ 125 °C

Ref. Description Connector 8 (CODE D)

1 Supply 35
2 Ground 36
3 Signal 33

April 2022 376

Oil level sensor

4
F2CGE612A*P062 F2CGE612A*P065
F2CGE612B*P060
F2CGE612B*P061
1. Connector – 2. Cable - 3. Pipe – 4. Sensor F2CGE612D*P063
SENSOR RESITENCE @ 20 °C: 17.1 ± 0.5 Ω F2CGE612D*P064

April 2022 377

Engine brake decompression valve

F2CGE612A*P062

1. 2 pin connector – 2. Valve body

Technical data
Voltage range 18 ÷ 32 V
Power reqiurement 13.9 W
Coil resistance 41.5 ± 2.2 Ω
Nominal pressure 8 bar
Electric connection Symbol Temperature range -25 ÷ 90 °C
Flow rate P A 10 l/min @ ∆p 0.55 bar, 30 l/min @ ∆p 3.3 bar
Flow rate A T 10 l/min @ ∆p 0.5 bar, 30 l/min @ ∆p 3 bar
April 2022 378
Pre-heating resistance (grid heater)

A B Grid-heater performances
Rated voltage D.C. 24V
Inrush current 160A - 290A @ 24V
120A - 150A @ 24V
Stable current
(temp. -25 °C / air flow 400 kg/h)
Pressure loss < 2 kPa (air flow 22m3 / min)
A. - B. Connection terminals Airtightness < 20 ml / min @ 196 kPa
Insulation resistance > 1 MΩ (500 V D.C.)

April 2022
EVGT actuator

F2CGE612A*P062 - F2CGE612A*P065

1 1. EVGT actuator

Technical data
Ref. Description Connector 6 (CODE H)
Inductance (reference) 32 mH
1 CAN-H 47
Insulation resistance > 1 MΩ
2 CAN-L 46
3 Ground - Communication types CAN 250 kbps or 500 kbps
4 Supply - Peak of inrush current < 50 A

April 2022 380

Turbine speed sensor F2CGE612A*P062 - F2CGE612A*P065

Ref. Description Connector 5 (CODE C)

1 Signal 30
2 Ground 33
3 Shield -

ECU interface
April 2022 381
Motorized throttle valve (exhaust flap) (1/3) F2CGE612B*P060 - F2CGE612B*P061
F2CGE612D*P063 - F2CGE612D*P064

Ref. Description Connector 6 (CODE H)

1 Supply -
2 Ground -
3 CAN L 46
4 CAN H 47

April 2022 382

Motorized throttle valve (exhaust flap) (2/3) F2CGE612A*P062

Ref. Description Connector 6 (CODE H)

1 Supply -
2 Ground -
3 CAN L 46
4 CAN H 47

April 2022 383

Motorized throttle valve (exhaust flap) (3/3) F2CGE612A*P065

Ref. Description Connector 6 (CODE H)

1 Supply -
2 Ground -
3 CAN L 46
4 CAN H 47

April 2022 384

Alternator (1/3)
1: W F2CGE612A*P062
F2CGE612B*P060
2: L F2CGE612B*P061
F2CGE612D*P063
3: I5 F2CGE612D*P064

4: BS

5: DFM

F2CGE612A*P065

Terminal B1+
Technical data
Sense of rotation: clockwise
Supplier BOSCH
Technical specifications : 28 V – 150 A
Current at ≤ 1600 rpm 0A
Current at ≤ 1800 rpm 30 A
Current at ≤ 6000 rpm 150 A
Terminal B2+ Weight 9.2 kg

April 2022 385

Alternator (2/3)

CM
COM
LS
S
S1

ELECTRICAL CIRCUIT GRAPH OF VOLTAGE IN RELATION TO AIR

TEMPERATURE

April 2022 386

Alternator (3/3)

PERFORMANCE
SAFETY CURVE
CURVE

April 2022 387

Electric starter motor (1/2)
Model “DENSO” 24 V – 4.5kW

Technical data

Rated voltage: 24 V
Nominal power: 4.5 kW
Coupling system Positive shift drive
Adjusted time 30 s
Direction of rotation Clockwise seen from pinion end
Max. operating voltage (at 20 °C) 16 V
Weight 8.4 kg
Activation circuit maximum current of
40A max. @ 20V (20 °C)
starter solenoid
Tightening torque for terminal +30 17.6 ÷ 24.5 Nm (M10x1.5)
Tightening torque for terminal +50 2.6 ÷ 4.6 Nm (M5x0.8)
Wire resistance battery - terminal 50 200 mΩ MAX.
Wire resistance battery - terminal 30 2 mΩ MAX.
Operating temperature -30 ÷ 120 °C

April 2022 388

 Starter electric motor (2/2)
Model “DENSO” 24 V – 4.5kW

Terminal 50

Terminal 30

Performance at 20 °C
Wiring diagram
Load Test conditions Specification
No load 23 V 90 A (3,500 rpm) MIN
Load 17 V (39.2 Nm) 530 A (950 rpm) MIN
Stall 6V 900 A (49 Nm) MIN

April 2022 389