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Technical training - ASTRA

HD8 Euro 5 Series


x Engines CURSOR Euro 5
x Electrical/Electronic System

TECHNICAL DOCUMENTATION FOR


TRAINING PURPOSES ONLY. NO
REGULAR UPDATES PROVIDED
Technical training - ASTRA

HD8 Euro 5 Series


x Engines CURSOR Euro 5
x Electrical/Electronic System
The company ASTRA VEICOLI INDUSTRIALI reserves the right to make any
modifications to vehicles for technical or commercial reasons at any time ; the information,
description and illustrations contained in this publication are therefore correct at the time of
going to press.

ASTRA Veicoli Industriali


Product Support
Via Caorsana, 79 - 29100 PIACENZA (Italy)
Tel. 0523/5431 - Fax 0523/543459

Publication nr. A3501075


Prima edizione: September 2006
Prepared by SIPAL S.p.A. - TORINO (Italy)
NOx EMISSIONS CONTROL SYSTEM ASTRA – Technical Training

NOx EMISSIONS
CONTROL SYSTEM

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NOx EMISSIONS CONTROL SYSTEM ASTRA – Technical Training

CONTENTS

Page

NOx emissions control system (SCR)........................................................................... 5


Overview....................................................................................................................... 5
Functional princple........................................................................................................ 5
Function ........................................................................................................................ 6
AD BLUE ...................................................................................................................... 7
Urea .............................................................................................................................. 7
Characteristics of the AdBlue solution .......................................................................... 8
Particular features of AdBlue ........................................................................................ 8
Safety sheet.................................................................................................................. 9
AD BLUE storage ......................................................................................................... 10
AD BLUE storability ...................................................................................................... 11

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NOx EMISSIONS CONTROL SYSTEM ASTRA – Technical Training

NOx EMISSIONS CONTROL SYSTEM (SCR)

Overview
To limit the emissions of nitrogen oxides (NOx) in exhaust gases to within the limits required by
Euro 5, with low fuel consumption, the vehicle has been fitted with a system for post-treating
these substances in exhaust gases, based on SCR technology (Selective Catalytic Reduction)..

SCR technlogy foresees use of an additive – known as AdBlue – added to the exhaust gases
that are then conveyed to a catalytic converter, which transforms nitrous oxides into inert
compounds: free nitrogen (N2 and water vapour (H2O)

Functional principle
The pump module draws up the reagent solution (AdBlue) from the reservoir and delivers it
under pressure to the dosing unit for injection into the exhaust pipe upstream of the catalytic
converter.
The first phase of the process takes place in the pipe upstream of the converter: by effect of the
exhaust gas temperature, the reagent solution vaporises, and by hydrolysis converts into
ammonia (NH3) and carbon dioxide (CO2).
At the same time, the evaporation of the solution causes a drop in exhaust gas temperature,
bringing it down to the temperature required by the conversion process.
The exhaust gas at the correct temperature for the reaction and with added ammonia is
delivered to the converter where the second phase of the process takes place: reacting with the
oxygen in the exhaust gas, the ammonia converts into free nitrogen (N2) and water vapour
(CO2).

NITROGEN +
WATER VAP.

High ex.
gas temp
TITANIUM, VANADIUM

Ammonia +
CO2 AMMONIA

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ASTRA – Technical Training NOx EMISSIONS CONTROL SYSTEM
Function
The pump module draws up the reagent solution (AdBlue) from the reservoir and delivers it
under pressure to the dosing module for injection into the exhaust pipe upstream of the catalytic
converter.

The SCR system is electronically controlled by the DCU (Dosing Control Unit), which regulates
the flow-rate of the AdBlue solution injected into the system according to:

- Engine speed,

- Torque level

- Exhaust gas temperature

- Nitrogen oxide content

- Intake air humidity

AdBlue may only be injected into the SCR system in certain conditions:

Engine temperature must be greater than 40°C

Catalytic converter temperature must be greater than 180°C

Engine speed must be greater than 400 rpm

Engine torque demand must be greater than 5%

In addition, the engine control unit must be showing no current errors related to:

- Injectors

- Turbo pressure

- Injection pressure

- Engine revs sensors

- Humidity sensors

- Air temperature sensors

There must be now current errors in the DCU related to its control systems (AdBlue pressure
sensors, doser, etc.).

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NOx EMISSIONS CONTROL SYSTEM ASTRA – Technical Training
AD BLUE

AdBlue is the European level brand name of a high quality water-based urea solution, made up
of urea and demineralised water, necessary for SCR function.

Urea
Chemical formula of urea: N2 H4
Discovered in urine in 1773, this was the first organic compound to be synthetically reproduced
using lead cynate and a water based ammonia solution.
Urea is used in the production of fertilisers for agriculture, as well as in the foodstuffs,
pharmaceutical and cosmetics industries.
Urea is present in the blood and in urine, since it is the final product of the metabolic breakdown
of proteins. The excretion function is carried out by the kidneys, through urine, in varying
quantities.

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ASTRA – Technical Training NOx EMISSIONS CONTROL SYSTEM
Characteristics of the AdBlue solution
It is classified as a non-hazardous substance (EU Directive 67/548/EC) both for human health
and the environment.
It has the following characteristics:
Transparent, odourless liquid
Non-inflammable
Non-esplosive
Non-corrosive
May cause irritation
Crystallisation temperature = – 11 °C
Sold by the litre
Specification DIN V 70070

Specific composition of Std. DIN V 70700:


32.5% urea
67.5% water.

The concentration of 32.5% was chosen


because this gives a freezing point of –11°C.

Particular features of AdBlue

The remainder, when all the water has evaporated, consists of white crystals of urea. These
crystals are completely innocuous.
If burned, they may release toxic fumes containing ammonia, carbon dioxide and nitrogen
oxides.

The materials compatible and widely used with AdBlue are:

Carbon steel
Stainless steel
Aluminium
Polyethylene (PE)
Polyvinylchloride (PVC)
Polypropylene (PP)
Ethenpropendimonomer (EPDM) for gaskets

Do not use with copper, zinc and related alloys

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NOx EMISSIONS CONTROL SYSTEM ASTRA – Technical Training
SAFETY SHEET

Contact with eyes


x Repeated or prolonged contact may cause irritation.

Contact with the skin


x Repeated or prolonged contact may cause irritation.
• Wash abundantly with water
• Rinse with water for 15 minutes. If symptoms persists, consult a doctor.

Swallowing
x Small quantities do not have toxic effects.
x Large quantities may cause gastro-intestinal problems
• Do not induce vomiting,
• Administer ½ a litre of water or milk,
• Consult a doctor

Extinguishers
If the product is involved in a fire, use high volume water extinguishers.

Environmental precautions
Do not allow the product to pollute drains, surface water or the water table.

Cleaning
Soak up the product with earth, sand or other non-combustible material, and store in suitable
waste containers.

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ASTRA – Technical Training NOx EMISSIONS CONTROL SYSTEM
AD BLUE STORAGE

10 Litre drum

1000 litre IBC container

4500 litre MiniBulk container

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NOx EMISSIONS CONTROL SYSTEM ASTRA – Technical Training
AD BLUE STORABILITY

The following environmental conditions must be maintained for storage and transport:

1) Recommended storage temperature –10 °C to i 30 °C.


The product begins to freeze at –11°C.
Prolonged storage a temperature over 30°C causes hydrolysis with consequent
formation of ammonia and increased pressure.

2) Store the product away from direct sunlight (to prevent the growth of algae)

3) Keep containers well closed to prevent contamination.


Avoid contact with: strong corrosives, acids, alkalis, nitrates, nitrites and sodium/calcium
hypochlorite.

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CURSOR ENGINES

EURO 5

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EURO 5 Engines ASTRA – Technical Training

CONTENTS

Page

View of engine .............................................................................................................. 5


Technical denomination ................................................................................................ 6
Principal innovations ..................................................................................................... 7
Technical specifications ................................................................................................ 8
Crankcase..................................................................................................................... 9
Pistons .......................................................................................................................... 10
Cylinder head................................................................................................................ 12
Valve train..................................................................................................................... 13
Valve springs ................................................................................................................ 14
Camshaft adjustment for euro 5 application.................................................................. 15
Fuel system .................................................................................................................. 16
F3A/F3B engine pump injector ..................................................................................... 17
Pressure damper .......................................................................................................... 19
Filter cartridge............................................................................................................... 20
Turbocharger ................................................................................................................ 21
Lubrication .................................................................................................................... 22
Control unit ................................................................................................................... 23
Sensors......................................................................................................................... 27
SCR system scheduled maintenance ........................................................................... 29
NOx emissions control system (SCR)........................................................................... 30
SCR SYSTEM FUNCTIONAL OUTLINE ...................................................................... 34
SCR system components ............................................................................................. 36

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EURO 5 Engines ASTRA – Technical Training

VIEW OF ENGINE

0051570t

0051571t

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TECHNICAL SPECIFICATION

TYPE PART NUMBER

F 3 B E 3 6 8 1 A * F 0 0 1 -

Progressive production number


Version number within the B.o.M.

Exhaust gas level (euro 4)

Engine power output or torque level

Use (eg I = truck)

Fuel feed + injection (TCA, direct injection diesel engine)

Number of cylinders

Number of strokes and cylinders' position (eg 0 = 4 strokes, vertical)

Engine

Engine family evolution (also irrespective of the displacement)

Engine range identification

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PRINCIPAL INNOVATIONS

The main differences between Cursor Euro 5 engines and Cursor Euro 3 engines regard the
following components:
- Crankcase modified with new control unit suport;
- Modified cylinder head;
- pistons modified to fit lower thickness piston rings;
- lower thinkness piston rings for oil and oil vapour consumption control;
- use of new jets for pistons;
- different profile injector pump control cam on camshaft;
- Modified rocker shaft;
- Modified damper flywheel
- coaxial injector pump;
- fuel system with pressure damper on fuel delivery line from fuel filter to cylinder head;
- EDC7 engine control unit;
- EDC7 control unit programming software with OBD (On Board Diagnostic) and interface with
VCM (Vehicle Control Module) and DCU (Dosing Control Unit);
- engine wiring harness (head internal and engine external wiring);
- New sensors;
- heat exchanger with seat for oil pressure and temperature sensor.
- Modified turbo group;
- SCR exhaust gas treatment system

Part of the modifications have been introduced to comply with Euro 5 legislation,
others to improve product performance.

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TECHNICAL SPECIFICATIONS

The differences between the Cursor – Euro 5 and Cursor - Euro 3 engines are as follows:

ENGINE

F2B F3A F3B

Compression ratio 16:1 16,5:1 16,5:1

Loadless idle speed [rpm] 600 ± 50 550 ± 50 550 ± 50

Loadless maximum speed [rpm] 2660 ± 50 2420 ± 50 2320 ± 50

Intake valve play [mm] 0,40 ± 0,05 0,40 ± 0,05 0,40 ± 0,05

Exhaust valve play [mm] 0,40 ± 0,05 0,50 ± 0,05 0,60 ± 0,05

Injection presure [bar] 1600 2000 2000

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CRANKCASE
Mountings modified to fit the new control unit and mountings for new oil sprayers.

2
1

0051572

1. ECU support
2. External wiring

WIRING
The engine is fitted with new internal wiring (injectors) and new external wiring (sensors and
ECU).

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PISTONS
Lubricated by new sprayers incorporating a valve to permit passage of oil only above the
threshold pressure of 1.7 bar.
Lowering the pressure in the lubrication circuit assures optimal circuit filling and full lubrication of
the most important parts.
In the F3A and F3B engines, bushes have been inserted in the pistons
The pistons have been modified to fit thinner rings to control oil and oil vapour consumption.

109080

CROSS-SECTION OF PNEUMATIC VALVE BUILT-IN TO PISTON OIL SPRAYERS

Aperture pressure = 1,7 bar

F2B Engines

109108

MAIN PISTON, PISTON RINGS AND PIN SPECIFICATONS

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F3A ENGINE

109045

MAIN PISTON, PISTON RINGS AND PIN SPECIFICATONS

F3B ENGINE

108837

MAIN PISTON, PISTON RINGS AND PIN SPECIFICATONS

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CYLINDER HEAD

On F3A/F3B engines the head is reinforced to support the increased internal pressure. The
rocker cover has screening to reduce noise above all in the driver’s cabin.

0051573

1. Oil/Diesel fuel repellent black felt – 2. Low density porous layer with galss fibre reinforcing (10
mm thickness) – 3. Carbon black felt

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VALVE TRAIN

The introduction of the new UIS N3.1 injectors (F3A/F3B engines) has also required changes to
the injector cam profile on the camshaft.
Lthe rocker bushes are reinforced with new springs due to the increased loading. The profile of
the rocker has also been changed due to the different in size of the new injectors (F3A/F3B
engine only).

0051574

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VALVE SPRINGS
The throttle type engine brake on the exhaust manifold requires greater spring loading than the
previous type used for engines with decompression type engine brake, to prevent unwanted
valve aperture during engine brake use.

F2B Engines

Valve closed

Valve open

109107

F3A Engine

109060

F3B engine

108842

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CAMSHAFT ADJUSTMENT FOR EURO 5 APPLICATION

The new camshaft adjustments are:

F2B: 4.90 ± 0.05 mm (as Euro3)

F3A: 5.30 ± 0.05 mm

F3B: 5.30 ± 0.05 mm

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FUEL SUPPLY

Fuel is delivered by the fuel pump through filter and pre-filter, to 6 injectors actuated by the
camshaft through rockers and controlled by the electronic control unit.

CIRCUIT OF DELIVERY

CIRCUIT OF RETURN

108847

FUEL SUPPLY DIAGRAM

1. Fuel filter – 2. Pressure damper – 3. Pressure regulator valve (start aperture at 5 bar) – 4.
Fuel pump – 5. Fuel prefilter with primer pump – 6. Fuel recirculation valve from injectors built-in
to fuel pump (start aperture at 3.5 bar) – 7. Control unit – 8. Heat exchanger – 9. Overpressure
valve for fuel return to tank – 10. Pump injectors
A. Fuel delivery to injectors – B. Fuel return to tank

The innovations in the fuel supply circuit regard::


- the introduction of a pressure damper to reduce peak pressure in injector return piping
- increased volume of filter element
- modifications to control unit, pump and head input piping

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F3A/F3B ENGINE PUMP INJECTOR

102405

CROSS SECTION OF UIS N3.1 INJECTOR

Thanks to the increased injection pressure, the new UIS N3.1 injectors atomise fuel in the
combustion chamber more efficiently, improving combustion and consequently reducing
pollutant emissions in exhaust gases.

The injectors used on CURSOR 8 EURO 5 engines are the same as used on the
EURO 3 version

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F3A/F3B injector replacement

102935

To remove the injector from the cylinder head, use tool 99342155 proceeding as follows:

R attach part (3) of tool 99342155 to the injector (4);


R to part (3) fit part (2), resting the latter on the cylinder head;
R tighten the nut (1) and extract the injector (4) from the cylinder head.

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PRESSURE DAMPER

The fuel pressure damper on the piping between fuel filter and cylinder head serves to dampen
the return back pressure due to the increased injection pressure.

0051575t

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FILTER CARTRIDGE
Increased volume filter cartridge introduced on F3A/F3B engines

0051576t

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TURBOCHARGER

On F3B engies the exhaust manifold is reinforced to support the increased weight of the VGT.
Modifications to the VGT turbines only regard internal parts.

F2B engines have a new fixed pitch turbine with consequent modifications to the exhaust
manifold due to the new turbine position.

Engines with fixed pitch turbine are fitted with a CEB device (Combined Engine Brake),
mounted on the turbine output to permit flow regulation in the various running conditions.
The CEB functions like a traditional type engine brake (with betterfly valve on the exhaust)
where the braking action is provided exclusively by backpressure of the gas in the exhaust
manifold.

F3B engine CEB with fixed pitch turbine

0051577t

F3B engine CEB with fixed pitch turbine

0051578t

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LUBRICATION
New oil pump to reduce flow-rate and pressure in lubrication circuit.
Modified heat exchanger body to house new oil pressure/temperature sensor for the EDC7.
New oil sprayers in pistons with built-in valve already described in pistons section.

F2B engine oil pump

0051579t

F3A / F3B engine oil pump

0051580t

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CONTROL UNIT
New EDC 7 UC31 control unit introduced to interface with the new electronics systems.

0051261t

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Electroinjectors connector “A”


Colour code 12 16
B black nero
R red rosso
U blue blu
W white bianco
P purple viola 6 11
G green verde
N brown marrone
Y yellow giallo
O orange arancione

1 5 102374

F3A-F3B
ECU F3A-F3B F2B wire F2B
wire
Pin function colour function
colour
Injection electrovalve
1 - Free W
cylinder 1
Injection electrovalve
2 - Free R
cylinder 1
Electronic injection electrovalve Injection electrovalve
3 B Y
cylinders (4-5-6) cylinder 2
Injection electrovalve
4 - Free R
cylinder 2
Injection electrovalve
5 - Free G
cylinder 3
Electronic injection electrovalve Injection electrovalve
6 Y R
cylinder 2 cylinder 3
Engine brake control Injection electrovalve
7 O U
electrovalve cylinder 4
Engine brake control Injection electrovalve
8 N E
electrovalve cylinder 4
Injection electrovalve
9 - Free P
cylinder 5
Injection electrovalve
10 - Free E
cylinder 5
Engine brake control Injection electrovalve
11 R B
electrovalve cylinders (1-2-3) cylinder 6
Engine brake control Injection electrovalve
12 G E
electrovalve cylinder 3 cylinder 6
Electronic injection electrovalve
13 W - -
cylinder 1
Electronic injection electrovalve
14 U - -
cylinder 4
Electronic injection electrovalve
15 E - -
cylinder 6
Electronic injection electrovalve
16 P - -
cylinder 5

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Sensors connector "C"

6 8 16 9 15 22

Colour code

B black nero
R red rosso
U blue blu 4
W white bianco 5
P purple viola
G green verde
N brown marrone
Y yellow giallo
O orange arancione
E grey grigio
K pink rosa 1 3 23 30 36 29
102375

ECU Wire
Function
Pin colour
1 N Variable pitch turbine control electrovalve
2 - Free
3 B Variable pitch turbine control electrovalve
4÷8 - Free
9 W Camshaft flywheel sensor
10 R Camshaft flywheel sensor
11 ÷ 14 - -
15 K Coolant fluid temperature sensor
16 - Free
17 Free
18 O/B Fuel temperature sensor
19 B Flywheel sensor
20 N Turbocompressor speed sensor
21 ÷ 22 - Free
23 W Flywheel sensor
24 N Engine oil/pressure sensor ground
25 W Air pressure/temperature sensor power supply
26 Y Coolant fluid temperature sensor
27 O/B Oil temperature signal from engein oil pressure/temperature sensor
28 U Oil pressure signal from engein oil pressure / temperature sensor
29 - Free
30 W Turbocompressor speed sensor
31 - Free
32 O Engine oil pressure / temperature sensor power supply
33 R Air temperature / pressure sensor power supply
34 G Pressure signal from air temperature / pressure sensor
35 W/R Fuel temperature sensor
36 O Temperature signal from air pressure / temperature sensor

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Frame connector "B"

71 89 72 54 6 11

1
7
12

53 35 18 36 17 102376

Pin
Wire Function
ECU
2 7151 Positive +30
3 7151 Positive +30
5 0150 Ground
6 0150 Ground
8 7151 Positive +30
9 7151 Positive +30
10 0150 Ground
11 0150 Ground
12 0094 Pre-warming enable relay ground
26 5173 Intake air relative humidity sensor signal
27 5174 Intake air temperature sensor signal
28 0173 Intake air temperature and humidity sensor ground
29 5163 EDC system diagnostics power switch (fitting)
34 GN/Ve CAN L ECB line
35 WS/Bi CAN H ECB line
40 8015 +15
55 9966 Engine brake and/or stop control electrovalve power supply
58 0043 Ground
68 8173 Intake air temperature and humidity sensor power supply
75 9164 EDC pre-warming relay activation signal
85 0163 EDC diagnostics switch power supply
89 2298 EDC diagnostics control unit K line

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SENSORS

New sensors fitted for the EDC7 control unit

0051582t
FLYWHEEL REVS SENSOR

0051583t
CAMSHAFT REVS SENSOR

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0051581t

OIL TEMPERATURE / PRESSURE SENSOR

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SCR SYSTEM SCHEDULED MAINTENANCE

100.000 km

150.000 km

300.000 km
Every

Every

Every
Check on AdBlue CURSOR 8 X X
system using
diagnostics instrument CURSOR 10/13 X X

CURSOR 8 X X
Replacement of AdBlue
filter/prefilter
CURSOR 10/13 X X

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NOX EMISSIONS CONTROL SYSTEM (SCR)

Overview
To limit the emissions of nitrogen oxides (Nox) in exhaust gases to within the limits required by
Euro 4, with low fuel consumption, the vehicle has been fitted with a system for post-treating
these substances in exhaust gases, consisting essentially of an electronically controlled
catalytic oxidiser.
By means of then SCR process (Selective Catalytic Reduction) the system converts nitrogen
oxies (NOX) into inert compounds: free nitrogen (N2) and water vapour (H2O).

Description
The system consists essentially of:
- a reagent solution reservoir (water – urea: AdBlue) with level indicator;
- an H2O switching valve;
- a pump module;
- a mixing and injection module (dosing module);
- a catalytic converter;
- two exhaust gas temperature sensors upstream and downstream of the cataytic converter;
- a humidity sensor mounted on the engine air intake piping downstream of the air filter.

The system is electronically managed by the DCU (Dosing Control Unit) built-in to the pump
module, which, according to engine speed, torque delivered, exhaust gas temperature, quantity
of nitrogen oxides and intake air humidity, regulates the flow-rate of AdBlue solution injected
into the system.
The pump module draws the reagent solution from the reservoir and delivers it under pressure
to the dosing module for injection into the exhaust pipe upstream of the catalytic converter.
The first phase of the process takes place in the first part of the converter: by effect of exhaust
gas temperature, the reagent solution vaporises and by hydrolysis converts into ammonia (NH3)
and carbon dioxide (CO2), at the same time, evaporation of the solution causes exhaust gas
temperature to drop to close to the ideal temperature for the process.
The exhaust gas with added ammonia and at the correct reaction temperature enters the
catalytic converter where the second phase of the process takes place: reacting with the oxygen
in the exhaust gas, the ammonia transforms into free litrogen (N2) and water vapour (H2O).

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Nox emissions control system – functional principle

31 HD8 EURO 5
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List of SCR system electrical components

Name Description
42XXX3 AdBlue solution pressure sensor
47XXX Ad Blue solution temperature sensor
72069 16-pin OBD coupling (On-Board Diagnostics)
78266 Dosing module electrovalve with SCR
78267 Engine water circulation electrovalve for warming UREA reservoir with
SCR.
84XXX Volumetri e/pump with pressure regulator and recirculation valve
85140 Electronic control for SCR sensor pump module
85141 Catalytic converter with SCR output temperature sensor
85142 UREA reservoir level and temperature sensor
85143 Catalytic converter intake temperature sensor
85144 NOX nitrogen oxide densor (if present)
85150 EDC control unit
85161 Intake air relative humidity and temperature sensor
72021 30-pin diagnostics socket

SCR system component locations aboard vehicle (see following page)

1. Water – urea solution reservoir: AdBlue


2. AdBlue level indicator
3. Pump module
4. H2O switching valve
5. Dosing module
6. Catalytic converter
7. Intake air humidity sensor
8. Exhaust gas temperature sensor upstream of converter
9. Exhaust gas temperature sensor downstream of converter

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33 HD8 EURO 5
HD8 EURO 5
Pump module

Membrane
pump

Main filter
ASTRA – Technical Training

Pre-filters
SCR SYSTEM FUNCTIONAL OUTLINE

34
Reservoir vent

Dosing module

AdBue reservoir with grill Mixer


EURO 5 engines
EURO 5 Engines ASTRA – Technical Training
Functional logic

Components Function
MV 1 4/2 multi-way magnetic AdBlue system filling-draining
valve

MV 2 Dosing valve AdBlue dosing module


MV 3 Cooling valve Drainage
MV 4 Reservoir heater valve AdBlue heating with engine
coolant
p1 AdBlue pressure sensor AdBlue system pressure
p measurement
t° 1 AdBlue reservoir AdBlue temperature
temperature measurement
t° 2 AdBlue dosin module AdBlue temperature
temperature measurement
t
t° 3 Cat. intake temperature Catalytic converter gas
temperature
t° 4 Cat. output temperature Catalytic converter gas
temperature
Q AdBlue reservoir level AdBlue level in reservoir
Q sensor

NOX NOX q.ty sensor: at present Application foreseen as from


NOX not foreseen 2007

35 HD8 EURO 5
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SCR SYSTEM COMPONENTS

Reservoir

The reservoir contains the reducing substance required by the SCR process, consisting of a
solution of 35% urea and water, known as AdBlue.
The reservoir has a level indicator (1) that also includes the AdBlue fluid heating coil.

The AdBlue filler cap is fitted with a magnet, which when detected by the filler pistol
permits opening of the piston nozzle.
This prevents the possibility of mistakenly filling the fuel tank with AdBlue.
On the other hand, the diameter of the AdBlue filler does not fit a fuel pump nozzle.
This prevents the possibility of mistakenly filling the AdBlue tank with fuel.

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AdBlue level indicator

0051311t

1. AdBlue liquid intake pipe - 2. AdBlue fluid return pipe -


3. Hot engine coolant input pipe - 4. NTC sensor-
5. Hot engine coolant output pipe - 6. Float -
7. AdBlue liquid heating coil

102308

CIRCUIT DIAGRAM)

The AdBlue level indiator consists of a series of resistors, a float, and NTC temperature sensor
and a heating coil to warm the liquid in low temperature conditions.
The device transmits variations in current proportional to resistance (determined by the position
of the float in relation to the AdBlue liquid level) to the control unit.

37 HD8 EURO 5
ASTRA – Technical Training EURO 5 engines
AdBlue heating system using engine coolant fluid

Engine coolant is sent via the magnetic switch valve to the pump module through specific
piping, then on to the dosing module and finally to the AdBlue reservoir, to prevent
crystallization of the urea at low temperature.
The conditions for activating the valve are defined by the engine control unit.

From cooling system

Magnetic valve

Pump
Dosing module
module

To cooling
system

Delivery Return
AdBlue reservoir

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Switching valve

108127

1. Coolant intake - 2. Coolant output - 6. Electrical connection

The NC type valve permits heating of the AdBlue reservoir and piping by hot coolant from the
engine.

The NTC sensor (above) controls the switching valve that, according to temperature, closes or
opens delivery of hot engine coolant to the heating coil.

39 HD8 EURO 5
ASTRA – Technical Training EURO 5 engines

Pump module

108128

1. AdBlue return piping to reservoir - 2. AdBlue return piping from dosing module - 3. AdBlue
solution output - 4. AdBlue solution intake - 5. Electrical connection -
6. DCY control unit connector - 7. Filter - 8. Prefilter

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EURO 5 Engines ASTRA – Technical Training

View of connector – cable input side

0051246t

Wire colour
Ref. Description
code
1 Engine coolant circulation electrovalve positive 7542
2 Urea filter output heating power 7546
3 +30 power supply 7540
4 +30 power supply 7540
5 CAN - H line (ECB) Bianco
6 CAN - L line (ECB) Verde
11 Urea dosing module control 9541
12 Dosing module electrovalve power supply with SCR 7541
14 Ground 0000
15 Ground 0000
17 Ground wire for catalytic converter input temperature sensor 0544
18 Urea reservoir level sensor signal cable 6543
19 Urea reservoir level and temperature sensor ground 0543
23 Urea reservoir heating electrovalve ground 9542
24 +15 positive 8540
25 Catalytic converter temperature sensor ground wire 0541
26 Catalytic converter output temperature sensor signal 6541
28 Catalytic converter input temperature sensor cable 6544
29 Urea reservoir temperature sensor signal cable 6542
31 SCR control unit diagnostics line “K” 2257
33 Urea filter output heating control 9546

41 HD8 EURO 5
ASTRA – Technical Training EURO 5 engines
Dosing module

108129

1. Ad Blue intake - 2. Electrical connection - 3. Ad Blue output

The module doses the AdBlue solution for delivery to the exhaust pipe upstream of the catalytic
converter.

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Catalytic converter

With sound absorbing material, the catalytic converter (1) takes the place of the traditional
exhaust muffler.

Inside the converter, the nitrogen oxides in the exhaust gas react with ammonia and are
converted into free nitrogen and water vapour.

The catalytic converter is fitted with temperature sensors upstream (2) and downstream (3).

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Exhaust gas temperature sensor

102303

102304

CIRCUIT DIAGRAM

1. Supply voltage - 2. Variable output voltage - 3. Connector -


4. Grey signal cable - 5. White ground cable - 6. Sensor

This serves to transmit converter input and output exhaust gas temperature values to the
control unit that calculates the quantity of urea to inject into the system.

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EURO 5 Engines ASTRA – Technical Training

Humidity sensor

102311

1. Temperature - 2. Ground - 3. Percentage humidity - 4. Power supply

Located on the output from the air filter, this serves to deliver the percentage humidity value of
the intake air to the control unit, to calculate nitrogen oxide emissions.

102312

ELECTRICAL BLOCK DIAGRAM

1. Ground - 2. Temperature - 3. Power supply - 4. Percentage humidity - A. Sample


frequency generator - B. Reference oscillator - C. NTC temperature sensor -
D. Low pass filter amplifier

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