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EDC7
Electrical System
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MAN EDC7 Electrical System

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Page 1
ElectricalSystem
Common-railInjectionSystem
EDC7
Copydeadline07.2010
SystemDescription
81.99298-68426theditionT18
MANNutzfahrzeugeAktiengesellschaft DachauerStr.667 80995MÜNCHEN oder Postfach500620 80976MÜNCHEN
SpeichereinspritzungCommonRailSystemEDC7
SystembeschreibungT18,6.Ausgabe
ElektrischeAnlage
PrintedinGermany
-Englisch-
Page 2
Page 3
SystemDescriptionT18
6thedition
ElectricalSystem
Common-railInjectionSystem EDC7
81.99298-6842
1
Page 4
PREFACE/PRINTER’SIMPRINT

PREFACE

Thisrepairmanualisintendedtoprovideassistanceinperformingrepairscorrectlyonvehiclesandunits. Thetechnicaldetailswerecorrectatthetimeofgoingtopress.
Thispublicationassumesthatpersonswhouseitpossesstherequisitetechnicalknowledgeinhandling vehiclesandunits.
Picturesandthecorrespondingdescriptionsaretypicalone-timerepresentations;theydonotalways correspondtotheunitorperipheralsinquestion,butthisdoesnotmeantheyareincorrect.Insuchcases, planandcarryouttherepairworkinaccordancewiththesenseoftheinstructions.
Repairworkoncomplexadd-onunitsshouldbeentrustedtoourcustomerserviceortothecustomerservice ofthemanufacturingcompany.Specialreferenceismadetotheseunitsinthetext.
Importantinstructionsrelatingtosafetyandaccidentpreventionarespeciallyhighlightedinthetextasfollows.
CAUTION Typeandsourceofdanger
Referstoworkingandoperatingprocedureswhichmustbefollowedexactlyinordertoavoid exposingpeopletorisk.
WARNING Typeandsourceofdanger
Referstoworkingandoperatingprocedureswhichmustbefollowedexactlyinordertoavoid seriousorirreparabledamagetoproperty.
Note
Explanatorydescriptiontoaidunderstandingoftheworkingandoperatingproceduresinvolved.
Complywithgeneralsafetyregulationswhenperforminganyrepairwork.
Bestwishesfrom
MANNutzfahrzeugeAG

PRINTER’SIMPRINT

©2010MANNutzfahrzeugeAG
Reprinting,copyingortranslation,evenofextracts,isnotallowedwithoutthewrittenapprovalofMAN.All rightsunderthecopyrightlawarestrictlyreservedbyMAN.Ifanychangesaremadewithoutthewritten approvalofMANNutzfahrzeugethenMANNutzfahrzeugeAGshallnotbeliableforanywarrantyorguarantee claimsarisingfromdamageanddefectsattributabletotheunauthorisedmodication.Furthermore,MAN NutzfahrzeugeAGshallnotbeliableforanydamageresultingfromtheunapprovedmodication.
Redaktion:SAWET-S,TS,07.2010
Satz:SAWET-Salzgitter
Druck:MAN-Werksdruckerei
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TABLEOFCONTENTS
ContentChapter/Page
Index5
Abbreviations11
Introduction
Safetyinstructions.......................................................................................................17
Devicedescription
Systemdescription......................................................................................................24
Generalinformation.................................................................................................24
Structureandoperationofthecommon-railsystem..........................................................24
Functionaldescription..................................................................................................26
Controlunit,EDC7(A435,A570).................................................................................26
High-pressurepump................................................................................................45
Meteringunit(proportionalvalveforfuel,MProp)(Y332,Y356)...........................................47
High-pressureaccumulator(rail)..................................................................................48
Pressure-limitingvalve.............................................................................................49
Rail-pressuresensor(B487,B514)..............................................................................50
Injector(Y341-Y350)..............................................................................................51
Crankshaftspeedsensor(speedincrementsensor)(B488)................................................52
Camshaftspeedsensor(speedsegmentsensor)(B489)...................................................53
Oilpressuresensor(B104)........................................................................................54
Fuelpressuresensor(B377)......................................................................................55
Kavlicocharge-pressuresensor(B125).........................................................................56
BoschLDF6charge-pressuresensor(B125)..................................................................57
BoschLDF6Tcharge-pressuresensor(B623,B694)........................................................58
Chargeairtemperaturesensor(B123)..........................................................................59
Coolanttemperaturesensor(B124,B1049)....................................................................60
Exhaustgastemperaturesensor(B561,B633)................................................................61
Exhaustgastemperaturesensor(B561,B634)................................................................62
AdBlue
®
lllevel/temperaturesensor(B628)...................................................................63
NOxsensor(B994)..................................................................................................64
Oxygensensor(B322)..............................................................................................65
Exhaustgasdifferentialpressuresensor(B565)..............................................................66
Exhaustgasrelativepressuresensor(B683)..................................................................67
Turbochargerpulsevalve(Y340,Y493).........................................................................68
Exhaustgasrecirculation(EGR)controller(Y280)............................................................69
Position-controlledEGRcontroller(E-EGR)withtravelsensor(B673)....................................70
ProportionalvalveE-EGR(Y458)................................................................................71
Compressedairshut-offvalve(Y460)...........................................................................72
Shut-off/pressure-reducingvalve,LTcooler(Y496)...........................................................73
Componentdescription/installationpositions.....................................................................74
ControlunitEDC7(A435,A570)..................................................................................74
CP3.4high-pressurepump........................................................................................76
CP9V4high-pressurepump.......................................................................................78
Meteringunit(MProp)(Y332,Y356)............................................................................79
High-pressureaccumulator(rail)..................................................................................80
Pressurelimitingvalve..............................................................................................82
Rail-pressuresensor(B487,B514)..............................................................................83
Injector(Y341-Y350)..............................................................................................84
Crankshaftspeedsensor(speedincrementsensor)(B488)................................................85
Camshaftspeedsensor(speedsegmentsensor)(B489)...................................................86
Oilpressuresensor(B104)........................................................................................88
Fuelpressuresensor(B377)......................................................................................89
Kavlicocharge-pressuresensor(B125).........................................................................91
BoschLDF6,LDF6Tcharge-pressuresensor(B125,B623,B694)......................................92
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TABLEOFCONTENTS
Chargeairtemperaturesensor(B123)..........................................................................93
Coolanttemperaturesensor(B124,B1049)....................................................................95
Exhaustgastemperaturesensor(B561,B633)................................................................97
Exhaustgastemperaturesensor(B561,B634)................................................................98
AdBlue
®
lllevel/temperaturesensor(B628).................................................................100
NOxsensor(B994)................................................................................................101
Oxygensensor(B322)............................................................................................102
Exhaustgasdifferentialpressuresensor(B565)............................................................103
Exhaustgasrelativepressuresensor(B683)................................................................104
Turbochargerpulsevalve(Y340,Y493).......................................................................105
Exhaustgasrecirculation(EGR)controller(Y280)..........................................................106
Position-controlledEGRcontroller(E-EGR)withtravelsensor(B673)..................................107
ProportionalvalveE-EGR(Y458)..............................................................................108
Compressedairshut-offvalve(Y460).........................................................................109
Shut-off/pressure-reducingvalve,LTcooler(Y496).........................................................110
Diagnosis...............................................................................................................111
K-linesystemstructure,diagnosissockets...................................................................111
SPNlistEDC7(C32andC3)....................................................................................120
TeststeplistEDC7C32Euro4(4-cylinderand6-cylinder)...............................................143
TeststeplistEDC7C32Euro5within-engineEGR(4-cylinderand6-cylinder)......................147
TeststeplistEDC7C32Euro5incombinationwithMANAdBlue
®
system(4-cylinderand
6-cylinder)...........................................................................................................151
TeststeplistEDC7C32Master/SlaveEuro5incombinationwithMANAdBlue
®
system(V8
engine)..............................................................................................................155
TeststeplistEDC7C3Euro3(4-cylinderand6-cylinder).................................................161
TeststeplistEDC7C3Master-SlaveEuro3(10-cylinderand12-cylinderVengine)................165
Hydraulicteststeplist............................................................................................169
TroubleshootingwithMAN-cats
®
...............................................................................195
Troubleshootingchart.............................................................................................206
Troubleshootingprogram........................................................................................209
Wiringdiagrams
Overviews...............................................................................................................377
Overview,EDC7C32Euro5OBD1withNOxmonitoring.................................................378
Overview,EDC7C32Euro5Master/SlaveOBD1withNOxmonitoring...............................380
Overview,EDC7C32Euro5EGROBD2....................................................................382
Overview,EDC7C32Euro4OBD1...........................................................................384
Overview,EDC7C32Euro4OBD1withNOxmonitoring.................................................386
Overview,EDC7C3Euro3......................................................................................388
Overview,EDC7C3Euro3Master/Slave....................................................................390
Overview,AdBlue Overview,AdBlue
®
dosingcontrolunitDCU15..............................................................392
®
dosingcontrolunitDCU15Master/Slave.............................................394
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INDEX
CatchwordPage
A
Adaptercable,HD-OBD..............................................................................................................................114
AdBlue
®
lllevel/temperaturesensor(B628)
Description...............................................................................................................................................63
Installationposition.................................................................................................................................100
Pinassignment.........................................................................................................................................63
B
Basicinformationabouttroubleshooting.....................................................................................................169
BoschLDF6charge-pressuresensor(B125)
Description...............................................................................................................................................57
Pinassignment.........................................................................................................................................57
BoschLDF6,LDF6Tcharge-pressuresensor(B125,B623)
Installationposition...................................................................................................................................92
C
Camshaftspeedsensor(speedsegmentsensor)(B489)
Description...............................................................................................................................................53
Installationposition...................................................................................................................................86
Pinassignment.........................................................................................................................................53
Chargeairtemperaturesensor(B123)
Description...............................................................................................................................................59
Installationposition...................................................................................................................................93
Pinassignment.........................................................................................................................................59
Charge-pressuresensor,BoschLDF6T(B623,B694)
Description...............................................................................................................................................58
Pinassignment.........................................................................................................................................58
Compressedairshut-offvalve(Y460)
Description...............................................................................................................................................72
Installationposition.................................................................................................................................109
Pinassignment.........................................................................................................................................72
ControlunitEDC7(A435,A570)
Installationposition...................................................................................................................................74
ControlunitEDC7C3Euro3(A435)
Pinassignment,engineconnectorA........................................................................................................37
Pinassignment,injectorconnectorC.......................................................................................................39
Pinassignment,vehicleconnectorB.......................................................................................................38
ControlunitEDC7C3MasterEuro3V10(A435)
Pinassignment,engineconnectorA........................................................................................................40
Pinassignment,injectorconnectorC.......................................................................................................42
Pinassignment,vehicleconnectorB.......................................................................................................41
ControlunitEDC7C3SlaveEuro3V10(A570)
Pinassignment,engineconnectorA........................................................................................................42
Pinassignment,injectorconnectorC.......................................................................................................44
Pinassignment,vehicleconnectorB.......................................................................................................43
ControlunitEDC7C32MasterEuro5V8(A435)
Pinassignment,engineconnectorA........................................................................................................31
Pinassignment,injectorconnectorC.......................................................................................................33
Pinassignment,vehicleconnectorB.......................................................................................................32
ControlunitEDC7C32SlaveEuro5V8(A570)
Pinassignment,engineconnectorA........................................................................................................34
Pinassignment,injectorconnectorC.......................................................................................................35
Pinassignment,vehicleconnectorB.......................................................................................................35
Controlunit,EDC7(A435,A570)
Description...............................................................................................................................................26
Controlunit,EDC7C32Euro4/5(A435)
Pinassignment,engineconnectorA........................................................................................................27
Pinassignment,injectorconnectorC.......................................................................................................30
Pinassignment,vehicleconnectorB.......................................................................................................29
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INDEX
Coolanttemperaturesensor(B124)
Installationposition...................................................................................................................................95
CP9V4high-pressurepump
Description...............................................................................................................................................46
Installationposition...................................................................................................................................78
Crankshaftspeedsensor(speedincrementsensor)(B488)
Description...............................................................................................................................................52
Installationposition...................................................................................................................................85
Pinassignment.........................................................................................................................................52
Cylindershut-offtest....................................................................................................................................203
D
DeletingtheOBDdiagnosticmemory.........................................................................................................118
Diagnosissockets(X200)
Adaptercable,HD-OBD.........................................................................................................................114
Description.............................................................................................................................................113
DescriptionofdiagnosissocketHD-OBD...............................................................................................114
Installationposition-TGA,TGL,TGM...................................................................................................115
Installationposition-TGX,TGS.............................................................................................................116
Installationpositionforregular-servicebuses........................................................................................116
Pinassignment,1stversion...................................................................................................................113
Pinassignment,diagnosissocketHD-OBD...........................................................................................114
DLScoiltester.............................................................................................................................................198
DLScoiltestsequence...........................................................................................................................198
Measuringprincipleforleakagedetectionontheinjector......................................................................198
PLVOpenTest.......................................................................................................................................200
E
Exhaustgasdifferentialpressuresensor(B565)
Description...............................................................................................................................................66
Installationposition.................................................................................................................................103
Pinassignment.........................................................................................................................................66
Exhaustgasrecirculation(EGR)controller(Y280)
Description...............................................................................................................................................69
Installationposition.................................................................................................................................106
Pinassignment.........................................................................................................................................69
Exhaustgasrelativepressuresensor(B683)
Description...............................................................................................................................................67
Installationposition.................................................................................................................................104
Pinassignment.........................................................................................................................................67
Exhaustgastemperaturesensor(B561,B633)
Description...............................................................................................................................................61
Installationposition...................................................................................................................................97
Pinassignment.........................................................................................................................................61
Exhaustgastemperaturesensor(B561,B634)
Description...............................................................................................................................................62
Installationposition...................................................................................................................................98
Pinassignment.........................................................................................................................................62
F
Faultcodelist..............................................................................................................................................120
FaultindicationMAN-cats
®
..........................................................................................................................1 19
Faultsandfaultmemory..............................................................................................................................117
FMI(FailureModeIdentication)statusindicators......................................................................................119
Frequentfaultsandinformationaboutcorrectingthem...............................................................................170
Fueldiagram,D0836LFEuro3engine......................................................................................................193
Fueldiagram,D0836LFLEuro3/4engine.................................................................................................194
Fueldiagram,D20/D26engineEuro4/5.....................................................................................................190
Fueldiagram,D2066Euro3engine............................................................................................................191
Fueldiagram,D2876LFEuro3engine......................................................................................................192
Fueldiagram,general
Fuel-lubricatedhigh-pressurepumpCP3.4+..........................................................................................187
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Oil-lubricatedhigh-pressurepumpCP3.4..............................................................................................186
Oil-lubricatedhigh-pressurepumpCP3.4D2868...................................................................................188
Oil-lubricatedhigh-pressurepumpCP9V4D2840/42/48.......................................................................189
Fuelpressuresensor(B377)
Description...............................................................................................................................................55
Installationposition...................................................................................................................................89
Fuelpressure,checking..............................................................................................................................176
G
Generalinstructionsfortroubleshootinginthefuelarea.............................................................................171
H
High-pressureaccumulator(rail)
Description...............................................................................................................................................48
Installationposition...................................................................................................................................80
High-pressurepumpCP3
Description...............................................................................................................................................45
High-pressurepumpCP3.4/CP3.4+
Installationposition...................................................................................................................................76
High-pressuretest.......................................................................................................................................196
Hydraulicteststeplist..................................................................................................................................169
INDEX
I
Injector(Y341-Y350)
Description...............................................................................................................................................51
Installationposition...................................................................................................................................84
K
K-linesystemstructure,diagnosissockets..................................................................................................111
Kavlicocharge-pressuresensor(B125)
Description...............................................................................................................................................56
Installationposition...................................................................................................................................91
Pinassignment.........................................................................................................................................56
M
Meteringunit(proportionalvalveforfuel,MProp)(Y332,Y356)
Description...............................................................................................................................................47
Installationposition...................................................................................................................................79
Pinassignment.........................................................................................................................................47
N
NOxsensor(B994)
Description...............................................................................................................................................64
Installationposition.................................................................................................................................101
Pinassignment.........................................................................................................................................64
O
OBDdiagnosticmemory..............................................................................................................................117
DeletingtheOBDdiagnosticmemory....................................................................................................118
Withdrawaloftorquelimiting..................................................................................................................1 19
Oilpressuresensor(B104)
Description...............................................................................................................................................54
Installationposition...................................................................................................................................88
Pinassignment.........................................................................................................................................54
Overview,AdBlue Overview,AdBlue
®
dosingcontrolunitDCU15...........................................................................................393
®
dosingcontrolunitDCU15Master/Slave.....................................................................395
Overview,EDC7C3Euro3.........................................................................................................................389
Overview,EDC7C3Euro3Master/Slave...................................................................................................391
Overview,EDC7C32Euro4OBD1...........................................................................................................385
Overview,EDC7C32Euro4OBD1withNOxmonitoring..........................................................................387
Overview,EDC7C32Euro5EGROBD2..................................................................................................383
Overview,EDC7C32Euro5Master/SlaveOBD1withNOxmonitoring....................................................380
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INDEX
Overview,EDC7C32Euro5OBD1withNOxmonitoring..........................................................................378
Oxygensensor(B322)
Description...............................................................................................................................................65
Installationposition.................................................................................................................................102
Pinassignment.........................................................................................................................................65
P
Position-controlledEGRcontroller(E-EGR)withtravelsensor(B673)
Description...............................................................................................................................................70
Installationposition.................................................................................................................................107
Pinassignment.........................................................................................................................................70
Pressurelimitingvalve
Installationposition...................................................................................................................................82
Pressuremeasuringlines............................................................................................................................178
Pressure-limitingvalve
Description...............................................................................................................................................49
Procedurefor“blacksmokefromengine”...................................................................................................173
Procedurefor“enginedoesnotrunsmoothly”............................................................................................174
Procedurefor“enginedoesnotstart”..........................................................................................................172
Procedurefor“engineknock”......................................................................................................................174
Procedurefor“enginestartspoorly”............................................................................................................171
Procedurefor“excesspressureinthefueltank”.........................................................................................173
Procedurefor“whitesmokefromengine”...................................................................................................173
ProportionalvalveE-EGR(Y458)
Description...............................................................................................................................................71
Installationposition.................................................................................................................................108
Pinassignment.........................................................................................................................................71
Pulsevalve,turbocharger(Y340,Y493)
Description...............................................................................................................................................68
Installationposition.................................................................................................................................105
Pinassignment.........................................................................................................................................68
R
Rail-pressuresensor(B487,B514)
Description...............................................................................................................................................50
Installationposition...................................................................................................................................83
Pinassignment.........................................................................................................................................50
ResettingofOBDmalfunctionlamp(MIL)...................................................................................................119
Rev-uptest..................................................................................................................................................202
S
Safetyinstructions.........................................................................................................................................17
Generalinformation..................................................................................................................................17
Schematicdiagramofthecommonrailsystem.............................................................................................25
Shut-off/pressure-reducingvalve,LTcooler(Y496)
Description...............................................................................................................................................73
Installationposition.................................................................................................................................110
Pinassignment.........................................................................................................................................73
Smooth-runningcontrol...............................................................................................................................204
SPNlistEDC7.............................................................................................................................................120
Structureandoperationofthecommon-railsystem......................................................................................24
Systemdescription........................................................................................................................................24
T
Temperaturesensor,coolant(B124,B1049)
Description...............................................................................................................................................60
Pinassignment.........................................................................................................................................60
Testboxwithtestcable...............................................................................................................................210
Teststeplists
Hydraulicteststeplist............................................................................................................................169
TeststeplistEDC7C3Euro3(4-cylinderand6-cylinder).....................................................................161
TeststeplistEDC7C3Master-SlaveEuro3(10-cylinderand12-cylinderVengine)............................165
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INDEX
TeststeplistEDC7C32Euro4(4-cylinderand6-cylinder)...................................................................143
TeststeplistEDC7C32Euro5incombinationwithMANAdBlue
®
system(4-cylinderand6-cylinder).151
TeststeplistEDC7C32Euro5within-engineEGR(4-cylinderand6-cylinder)...................................147
TeststeplistEDC7C32Master/SlaveEuro5incombinationwithMANAdBlue
®
system(V8).............155
Torquelimiter
Withdrawaloftorquelimiting..................................................................................................................1 19
Troubleshootingchart..................................................................................................................................206
Troubleshootinginthehigh-pressuresystem..............................................................................................181
Troubleshootinginthelow-pressuresystem...............................................................................................179
Troubleshootingprogram............................................................................................................................209
TroubleshootingwithMAN-cats
®
Compressiontest...................................................................................................................................195
Cylindershut-offtest..............................................................................................................................203
DLScoiltester........................................................................................................................................198
High-pressuretest..................................................................................................................................196
Rev-uptest.............................................................................................................................................202
Smooth-runningcontrol..........................................................................................................................204
U
Universaltestadapterforpressuremeasurement......................................................................................178
W
Wiringdiagrams...........................................................................................................................................389
Withdrawaloftorquelimiting.......................................................................................................................119
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LISTOFABBREVIATIONS
Abbreviations
A
aAcceleration ABEGeneralcertication ABSAnti-lockBrakingSystem ABVAnti-skidsystem ACAirConditioning ACCAdaptiveCruiseControl ACKAcknowledge ADCAnalogue-DigitalConverter ADREuropeanagreementforcross-bordertransportofdangerousgoodsbyroad(Frenchtitle:Accord
européenrelatifautransportinternationaldesmarchandisesDangereusesparRoute) AGBAutomaticroadspeedlimiter AGNDAnalogueGround AGRExhaustGasRecirculation(EGR) AHKTrailercoupling AHVTrailerbrakevalve ALBAutomaticloadbalancing AMAAntennamastsystem AMRAnisotropMagnetoResistive ANHTrailer/semitrailer ASAutomaticgearbox ASDTrailersocket ASMTrailercontrolmodule ASRAnti-spinregulator(tractioncontrol) ASVTrailercontrolvalve ATCAutomaticTemperatureControl ATFAutomaticTransmissionFluid AUStatutoryexhaustemissiontest AVExhaustvalve AVSAutomaticgearpreselection
B
BAOperator'smanual BBAServicebrakesystem BBVServicebrakevalve BITEBuilt-InTestEquipment BKRBrakepowerregulator BUGHFrontheater BVBackupvalve BVABrakewearindicator BVSBrakewearsensor BVVBrakewearsensorsupply BWGermanArmy BWGBrakepowersensor BZBrakecylinder
C
CANControllerAreaNetwork CAN-HCAN-highdataline CAN-LCAN-lowdataline CATSComputer-assistedtestinganddiagnosticsystem CBUCentralBrakeUnit CDCContinuousDampingControl CCVSCruisecontrolvehiclespeed CKDCompletelyKnockedDown CNGCompressedNaturalGas CPUCentralProcessingUnit CRTContinuouslyRegeneratingTrap(exhaustmufer,two-waycatalyticconverter,dieselparticulate
lter) CRCCyclicRedundancyCheck
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LISTOFABBREVIATIONS
CSComfortShift
D
DAHLRoofventilator DBRAuxiliarybrakerelay DCUDosingControlUnit(forAdBlue) DFSpeedsensor DFÜDatatransmission DIADiagnosisandinformationdisplay DIAGDiagnosis,entirevehicle DIAG­MUX DIAKDiagnosis,K-line(dataline) DIALDiagnosis,L-line(interrogationline) DIARDiagnosis,furtherinterrogation DINGermanindustrialstandard DKEThrottlevalveincrease(ASRcontrol) DKHRoofductheating DKLRoofaps DKRThrottlevalvereduction(reductionrequestfromASRtoEDC/EMS) DKVThrottlevalvespecication(loadsensorsignalfrompedalvaluesensor,EDC/EMS) DLBCompressedairbrakesystem DMDiagnosticMessage DNRDriveNeutralReverse(selectorleverswitchforautomatic) DPFDieselparticulatelter DRMPressurecontrolmodule DRSRotationalspeedsensor DSPressuresensor DSVPressurecontrolvalve DTCDiagnosticTroubleCode(OBDfaultcode) DTCODigitaltachograph DVThrottlevalve DWAAnti-theftwarningsystem DZGSpeedsensor DZMRevcounter
Diagnosis,entirevehicle–centralcomputer,Multiplex(busesandcoachesonly)
E
EBSElectronicbrakesystem ECAMElectronicallyControlledAirManagement ECASElectronicallyControlledAirSuspension ECEEmergencyshut-offtoECE36 ECUElectronicControlUnit EDCElectronicDieselControl EDCSElectronicDieselControlSlave EDMElectronicdieselconsumptionmeter EDRMaximumspeedgovernor EECElectronicenginecontroller EEPROMElectricallyerasableandprogrammableread-onlymemory EFRElectronicshockabsorbercontrol EFSElectricdriver'sseat EHABElectro-hydraulicshut-offdevice ELABElectricalshut-offdevice ELFElectronicallycontrolledairsuspension EMSElectronicthrottlecontrol(ETC) EMVElectromagneticcompatibility(EMC) EOLEnd-of-line(programming) EPInjectionpump EREngineretarder(enginebrake) ESACElectronicShockAbsorberControl ESPElectronicStabilityProgram ESRElectricsun-blind
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ESTElectroniccontrolunit EVIntakevalve EVBExhaustValveBrake
F
FAPDriver'sarea FAQFrequentlyAskedQuestions FBAParkingbrakesystem FBMPedalbrakemodule FDRVehicledynamicscontrol FDFVehicledatale FFRVehiclemanagementcomputer FGBRoadspeedlimiter(RSL) FGRRoadspeedgovernor(RSG) FHSCab FINVehicleidenticationnumber(17digits) FMVehiclemanagement FMIFailuremodeidentication FMSFleetManagementStandard(globaltelematicsstandard) FMRVehicle/enginemanagement FOCFrontOmnibusChassis(bus/coachchassiswithfront-mountedengine) FSCHWindscreenheater FSGGroundreinforcementsystem FSHWindow/mirrorheating FTWDriver'spartition FUNKRadiocommunicationunit FZADestinationsystem FZNRVehiclenumber(7digits)
LISTOFABBREVIATIONS
G
GDKClosed-loopdieselcatalyst GENAlternator GETGearbox GGVSEuropeanagreementforcross-bordertransportofdangerousgoodsbyroad(Frenchabbreviation:
ADR) GNDGround GPGearboxplanetarygeargroup(range-changebox) GSGearboxcontrol GVGearboxsplittergeargroup(splitterbox)
H
HARearaxle HBAAuxiliarybrakesystem HD-OBDHeavyDutyOn-BoardDiagnosis HDSUreadosingsystem HGBMaximumroadspeedlimiter HGSHydraulicgearshift HLUEHydrostaticfan HOCRearOmnibusChassis(bus/coachchassiswithrear-mountedengine) HSSHighsideswitch HSTMainswitchboard HUMaininspection HYDHydronicauxiliaryheater HYDRIVEHydrostaticfrontaxledrive HYDROMANHydroDrive HVAHydrostaticfrontaxledrive HzHertz(numberofcyclespersecond) HZABusstopindicatorsystem HZGAuxiliaryspeedsensor
I
IBELInteriorlighting
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LISTOFABBREVIATIONS
IBISIntegratedon-boardinformationsystem ICIntegratedCircuit IDIdentication IMRIntegratedmechanicalrelay(startercontrol) INAInformationindicator(e.g.checklamp) INSTInstrumentation IRIndividualcontrol(ABS) IRMModiedindividualcontrol(ABS) ISOInternationalStandardsOrganisation IWZIncrementalangle/timemeasuringsystem
K
KBZCombinationbrakecylinder KFHFuellterheater KITASKienzleintelligenttachographsensor KLIAir-conditioningsystem KNEELKneeling KSMCustomer-speciedcontrolmodule(controlunitforexternaldataexchange) KSWCustomer'sspecialrequest KWPKeyWordProtocol(protocolforMAN-catsdiagnosisKWP2000)
L
LBHAirreservoir LCDLiquidCrystalDisplay LDAManifold-pressurecompensator(boostcontrol) LDFCharge-pressuresensor LDSAirspring/dampersystem LEDLightemittingdiode LFAirsuspension LGSLaneGuardSystem LLIdlingspeed LLAIdlingspeedincrease LLRIdlingspeedcontrol LNASteeringtrailingaxle LNGLiqueedNaturalGas LOESteeringoilmonitor LPGLiqueedPetroleumGas LSVADistance-basedheavyvehicletoll LWRHeadlightbeamregulator LWSSteeringanglesensor
M
M-TCOModularEUtachograph MABSolenoidvalveshut-off(engineshut-offbyhigh-pressuresolenoidvalveininjectionpump) MAN-catsMANcomputer-assistedtestinganddiagnosticsystem MARSolenoidvalveshut-offrelay(redundantengineshut-offrelay) MDBEnginespeedrange MESFuelquantityactuator MLMidline MMIMan-machineinterface MOTBEnginebrake MPMotorpowerbox(cableductonengineblock) MREnginegovernor-ASR MSGEnginecontrolunit(EDC) MUXCentralcomputer,Multiplex(bus/coachonly) MVSolenoidvalve MZDiaphragmcylinder
N
nSpeed NAPowertake-off(PTO) NBFNeedlemovementsensor
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NESNewelectronicstructure NFZCommercialvehicles NLATrailingaxle NOxNitrogenoxides NSLRearfoglamp NSWFoglamps
O
OBDOn-BoardDiagnosis OBDUOnboardDiagnosticUnit(subsystemofcentralon-boardcomputer) OCOccurrenceCount(frequencycounterofafault) OEABOilseparator OENFOiltop-up
P
pPressure PPowertrain PBMPulseBreadthModulation(alsoseePWM) P-CodePowertraincode(faultcode) PDFParticulateDieselFilter PLMProgrammableLogicModule PM-KatParticulatemattercatalyticconverter PSCPneumaticSupplyController–ReplacementforECAM PSGPumpcontrolunit(EDC) PTMPowertrainmanager(replacementforFFR) PTOPowertake-off PWGPedalvaluesensor PWMPulseWidthModulation(alsoseePBM)
LISTOFABBREVIATIONS
R
RARepairmanual RAHInteriorheating RAMRandomAccessMemory RASRearAxleSteering RAS-ECRearAxleSteeringwithElectronicControl RDRATyrepressurecontrolsystem RDSRadioDataSystem RETRetarder RETPPrimaryretarder RETSSecondaryretarder RKLPriorityvehiclelight RKSTyremonitoringsystem–replacedbyTPM RLVRelayvalve RMERapeseedoilmethylester(biodiesel) ROMReadOnlyMemory
S
SASpecialequipment SAESocietyofAutomotiveEngineers SAMTSemi-automaticmechanicaltransmission SBServiceoutlet SBW-RASteerByWireRearAxle(electronicallycontrolledsteeringtrailingaxle) SCRSelectiveCatalyticReduction secSecond SERStandard SGControlunit SHSelect-highcontrol(ABS) SKDSemiKnockedDown SLSelect-lowcontrol(ABS) SMLSidemarkerlights SPNSuspectParameterNumber STAEnginestart/stop
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LISTOFABBREVIATIONS
SWRHeadlightcleaningsystem
T
tTime TBMOn-boardtelematicsmodule TCTractionControl TCMTrailerControlModule TCOTachograph(MTCO,DTCO,TSUetc.) TCUTransmissionControlUnit TEPSTwinElectronicPlatformSystems(bus/coachonly) TGATrucknologyGenerationA TGLTrucknologyGenerationLight TGMTrucknologyGenerationMid TKUTechnicalcustomerdocument TMCTrafcMessageChannel TPMTyrePressureModule TRSTechnicalroadtransportdirective TSCTorqueSpeedControl(brakingtorque) TSUTachographSimulatingUnit(vehicleswithoutMTCO/DTCO) TUERDoorcontrol
U
U
Bat
Batteryvoltage UDFConversionle UDSCrashrecorder
V
vRoadspeed VAFrontaxle VDFVehicledatale VGTransfercaseorreferencetodefenceequipmentstandards VLALeadingaxle VSMTransfercaselockmanagement
W
WAMaintenanceManual WABWaterseparator WaPuWaterpumpIntarder WLESwap-bodyunit WRWarningrelay WSPositionsensor WSKT orqueconverterandclutchunit
Z
zBrakingrate/deceleration ZBRCentralon-boardcomputer ZBROCentralon-boardbuscomputer ZDRIntermediatespeedgovernor(ISG) ZECentralelectricalsystem ZFRAuxiliaryvehiclecomputer ZRCentralcomputer ZSCentrallubrication ZUSHAuxiliaryheater ZWSTime-basedmaintenancesystem λSlip µCoefcientoffriction µCMicrocontroller(microprocessor)
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INTRODUCTION

INTRODUCTION

SAFETYINSTRUCTIONS

Generalinformation

Onlytrainedpersonnelareallowedtoperformoperating,maintenanceandrepairworkontrucks,busesand coaches.
Thefollowingsectionsincludesummariesofimportantregulations,listedaccordingtomajortopics,which mustbecompliedwith.Theintentionistoprovidetheknowledgeneededtoavoidaccidentswhichcould leadtoinjury,damageandenvironmentalpollution.Pleasenotethatthesearemerelybriefextractstaken fromvariousaccidentpreventionregulations.Ofcourse,allothersafetyregulationsmustbefollowedand thenecessarymeasuresmustbetaken.
Additionalreferencestodangerarecontainedintheinstructionsatpointswherethereisapotentialdanger.
Accidentsmayhappeninspiteofallprecautionarymeasureshavingbeentaken.Insuchaneventuality, obtainimmediatemedicalassistancefromadoctor.Thisisparticularlyimportantiftheaccidentinvolvesskin contactwithcorrosiveacid,fuelpenetrationundertheskin,scaldingbyhotoil,antifreezesprayingintoeyes, crushingoflimbsetc.
1.Regulationsforpreventingaccidentsleadingtoinjurytopersonnel
Checking,settingandrepairwork –Secureunitsduringtheirremoval. –Supporttheframewhenworkingonthepneumaticorspringsuspensionsystem. –Keepunits,ladders,stairs,stepsandthesurroundingareafreefromoilandgrease. –Onlyusetoolsthatareinperfectcondition. –Onlyauthorisedtechnicalpersonnelareentitledtoperforminspection,adjustmentandrepairwork.
Workingonthebrakesystem –Adustextractormustbeusedifdustisreleasedwhenworkingonthebrakesystem. –Performvisual,functionandeffectivenesschecksonthebrakesystemaftercarryingoutanyworkonit
whatsoever.Thesechecksmustbemadeinaccordancewiththesafetyinspection(SP).
–CheckthefunctionofABS/ASRsystemsusingasuitabletestsystem(e.g.MAN-cats). –Collectanybrakeuidthatleaksout. –Brakeuidispoisonous!Donotallowittocomeintocontactwithfoodoropenwounds. –Treathydraulicuid/brakeuidashazardouswaste!
Complywiththesafetyregulationsforpreventingenvironmentalpollution.
Workingonvehicleswithcompressednaturalgas(CNG)system –Vehicleswithadefectivecompressednaturalgassystemmaynotbebroughtintotheworkshop.Thisalso
appliestovehicleswhoseenginecannotbeswitchedoffbyautomaticemptyingoftheremovallines.
–Whenworkingonvehicleswithacompressednaturalgassystem,setupagaswarningdeviceabovethe
vehicleroofandintheenginecompartmentabovethepressurecontroller.Furthergaswarningdevices mustbecarriedbythepersonsworkingonthevehicle.
–Smokingisnotallowedinareaswhereworkonvehicleswithcompressednaturalgassystemsiscarried
out.Allsourcesofignitionmustberemovedfromtheseareas.
–Beforecarryingoutweldingwork,thecompressedgastanksmustberemovedandthegas-carryinglines
mustbeushedwithinertgas.
–Compressedgastanksareonlyallowedtobeexposedtotemperaturesupto60°Cinpaint-dryingbooths.
Ifthetemperaturesareanyhigher,thecompressedgastanksmustberemovedordegassedusinganinert gassuchasnitrogen.Thegas-carryinglinesmustalsobeushedwithinertgas.
Workingonthecompressednaturalgas(CNG)system –Workonthecompressednaturalgassystemmayonlybecarriedoutbypersonswhohavebeenspecically
trainedtodoso.
–Theworkingareaforthecompressednaturalgassystemmustbeequippedwithanadequateventilation
system.Theventilationsystemmustreplacetheairintheroomwithnewairatleastthreetimesperhour.
–Afterexchangingstandard-tcomponentsofthecompressednaturalgassystemusingtheprescribed
procedures,checktheassemblypointsforleaks.Performthesechecksusingleakindicatorsprayoragas warningdevice.
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INTRODUCTION
Engineoperation –Onlyauthorisedpersonnelarepermittedtostartandoperateanengine. –Donotapproachmovingpartsofarunningenginetoocloselyanddonotwearbaggyclothing.Usean
extractorsystemifworkinginenclosedspaces.
–Dangerofburnswhenworkingonenginesatoperatingtemperature. –Dangerofscaldingwhenopeningthehotcoolingcircuit.
Suspendedloads –Peoplearenotallowedtostandbelowsuspendedloads. –Onlyusesuitableliftingandgearthatisinperfectworkingorder.Useliftingdeviceswithsufcient
load-carryingcapacity.
Attachmentsandspecialbodies –Complywiththesafetyinstructionsandregulationsissuedbythebodymanufacturerinquestionif
attachmentsorspecialbodiesaretted.
Workingonhigh-pressurelines –Donotattempttotightenorloosenpipelinesandhoseswhentheyareunderpressure(e.g.lubrication
circuit,coolantcircuitandhydraulicoilcircuit). Riskofinjuryduetopressuriseduidsemerging!
Checkinginjectornozzles –Wearsuitableprotectiveequipment. –Donotholdanypartofyourbodyunderthejetoffuelwhencheckingtheinjectornozzles. –Donotinhalefuelvapours.Ensurethatthereisadequateventilation.
Workingonthevehicleelectricalsystem –Donotdisconnectbatterieswhilsttheengineisrunning! –Alwaysdisconnectbatterieswhenworkingonthevehicleelectronicsystem,centralelectricalsystem,
alternatorandstarter!Whendisconnectingbatteries,removethenegativeterminalsrst.Whenconnecting batteries,tthepositiveterminalsrst.
–Alwaysusesuitabletestlinesandtestadapterswhenmeasuringatplugconnections! –Iftemperaturesofover80°Caretobeexpected(e.g.inadryingovenafterpainting),switchthebattery
masterswitchto"OFF"andthenremovethecontrolunits.
–Thechassisisnotintendedforuseasanearthreturn.Ifattachmentsaretobettedtothevehicle(e.g.
awheelchairlift),additionalearth(ground)lineswithanadequatecross-sectionmustbettedaswell. Otherwisetheearthconnectionmaybecreatedalongwirecables,wiringharnesses,gearboxshafts,gears etc.Severedamagecouldresult.
Important!Batterygasesareexplosive! –Oxyhydrogengasmayforminenclosedbatteryboxes.Takeparticularcareafterlongjourneysandafter
chargingthebatterieswithabatterycharger.
–Whenthebatteriesaredisconnectedthisgasmaybeignitedbysparksproducedbyothercontinuously
operatingconsumers,thetachographetc.thatcannotbeshutdown.Blowcompressedairthroughthe batteryboxbeforedisconnectingthebatteries!
–Alwaysleavethebatteriesconnectedwhentowingthevehicle!Onlytowthevehicleifthechecklampsare
stilldimlylitbutthebatterystartingpowerisnotreached. Donotusearapid-chargertojump-startthevehicle!
–Alwaysdisconnectthepositiveandnegativeleadsbeforechargingandrapid-chargingbatteries! –Donotrapid-chargelead-gelandmaintenance-freebatteries!(notinthecaseof"maintenance-freeacc.to
DIN")Themaximumchargingcapacityis10%oftheindicatedcapacityperbattery.Inparallelcircuits,the capacityisincreased,inaccordancewiththetotalnumberofbatteriesconnectedinparallel.
–Riskofshort-circuitsduetoincorrectbatterypolarity! –Donotputmetalobjects(spanners,molegrips,etc.)onthebatteries,sincetheymayconnecttheterminals
together.Riskofshort-circuit!
–Disconnectthebatteriesandrechargethemevery4weeksifthevehicleisnotinuseforprolongedperiods.
Caution!Batteryacidispoisonousandcorrosive! –Wearappropriateprotectiveclothing(gloves)whenhandlingbatteries.
Donottiltbatteries,acidmayleakout.Similarly,donottiltgelbatteries.
–Measurevoltageonlyusingsuitablemeasurementdevices!Theinputresistanceofameasuringdevice
shouldbeatleast10MΩ.
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INTRODUCTION
–Onlydisconnectandconnectplugconnectionsforelectroniccontrolunitwhentheignitionisswitchedoff!
Electricwelding –Connectthe“ANTIZAPSERVICESENTRY”protectiondevice(MANitemnumber80.78010.0002)as
describedintheinstructionsaccompanyingthedevice.
–Ifthisdeviceisnotavailable,disconnectthebatteriesandconnectthepositivecabletothenegativecable
inordertomakearmconductiveconnection.
–Ifthebatterymasterswitchismanuallyoperated,moveittothedrivingposition.Ifanelectronicbattery
masterswitchistted,bridge“Negative”attheload-disconnectingrelaycontacts(jumpercable>1mm and“Positive”attheload-disconnectingrelayloadcontacts.Inaddition,switchonmanyloadssuchas: starterswitch(ignition)indrivingposition,hazardwarninglightsswitch“on”,lightingswitchin“drivinglights on”position,ventilationblowerin“maximum”position.Thegreaternumberofconsumersthatareswitched on,thegreatertheprotection. Aftercompletingweldingwork,rstswitchoffalltheconsumersandremovealljumpers(re-createoriginal state),thenconnectthebatteries.
–Alwaysearththeweldingequipmentascloseaspossibletotheweldingarea.Donotlaythecablestothe
weldingequipmentinparalleltoelectricalcablesinthevehicle.
Workingonplastictubes–Dangerofdamageandre! –Mechanicalorthermalloadingofplastictubesisnotpermitted.
Painting –Ifpaintsprayingistobecarriedout,donotexposetheelectroniccomponentstohightemperatures(max.
95°C)formorethanbriefperiods;atimeofupto2hoursispermissibleatamaximumof85°C.Disconnect thebatteries. Paintingofscrewconnectionsinthehigh-pressuresectionoftheinjectionsystemisnotpermitted.Riskof dirtingressintheeventofrepairs.
2
)
Workingwiththecabtiltedforwards –Keepthetiltingareainfrontofthecabclear. –Keepoutoftheareabetweenthecabandthechassisduringthetiltingprocess.Thisisadangerarea! –Alwaystiltthecabpastthetiltingpointandsecurethecabusingasupportrod.
Workingontheair-conditioningsystem –Refrigerantuidsandvapoursrepresentahealthhazard,avoidcontactwiththemandprotectyoureyes
andhands.
–Donotdraingaseousrefrigerantsinenclosedrooms. –DonotmixCFC-freerefrigerantR134awithR12(CFC)refrigerant. –Disposeofrefrigerantinaccordancewithregulations.
Workingonairbagorbelttensionerunits –Workonairbagorbelttensionerunitsmayonlybecarriedoutbystaffwhohaveveriablycompleteda
competencecourseattheMANServiceAcademy.
–Mechanicalloads,vibrations,heatingtoover140°Candelectricalpulses,includingelectrostaticdischarge,
cancauseunintentionalringoftheairbagorbelttensionerunits.
–Hotgasesarereleasedexplosivelywhentheairbagorbelttensionerunitisred.Thenon-mountedairbag
orbelttensionerunitcanbetossedarounduncontrollably.Thisposesaninjuryrisktopeopleinornearthe cab.
–Riskofburnswhentouchingthehotsurfacesaftertheairbaghasred. –Donotopenaredairbag. –Donottouchared,destroyedairbagwithyourbarehands.Wearnitrilerubbergloves. –Beforeallworkandtestingonairbagorbelttensionerunitsorworkonthevehiclethatcancausevibrations,
switchofftheignition,removetheignitionkey,disconnectthegroundlinefromthebatteryanddisconnect thepowersupplyplugconnectionfortheairbagandbelttensioner.
–Mountthedriverairbagrestraintsystem,MANpartnumber81.66900-6035,ontheairbagsteeringwheel
inaccordancewiththeoperatinginstructions.
–Onlyusespeciallydesignateddevicesfortestingairbagandbelttensionerunits.Donotusetestlamps,
voltmetersorohmmeters.
–Afterallworkandtests,rstswitchofftheignition,thenconnecttheplugconnection(s)forairbagandbelt
tensioner.Thenconnectthebattery.Theremustbeno-oneinthecabwhilstthisworkisgoingon.
–Alwaysdeposittheairbagsindividuallyandwiththeimpactcushionupwards. –Donottreatairbagsorbelttensionerswithgreaseorcleaners.
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INTRODUCTION
–Alwaysstoreandtransportairbagandbelttensionerunitsintheiroriginalpackaging.Transportinthe
passengercompartmentisnotpermitted.
–Alwaysstoreairbagandbelttensionerunitsinlockablestorageareas,uptoamaximumof200kg.
Workingontheindependentheater –Beforecommencingwork,switchofftheheaterandallowallhotcomponentstocooldown. –Ensurethatsuitablecollectingcontainersareavailableandnosourcesofignitionarepresentwhenworking
onthefuelsystem.
–Keepsuitablereextinguishingequipmentnearbyandwithineasyreach!! –Theheatermaynotbeoperatedinenclosedareassuchasgaragesorworkshopsunlessanextractor
systemisused.

2.Notesonpreventingdamageandprematurewearonunits

Generalinformation –Unitsareonlydesignedfortheirspeciedpurpose-denedbythemanufacturer(designateduse):Any
otheruseisclassiedasnotinaccordancewiththedesignateduse.Themanufacturerisnotliablefor damagecausedasaresultofsuchotheruse.Intheeventofsuchotheruse,theuseralonebearstherisk.
–Designatedusealsoincludescompliancewiththeoperating,maintenanceandrepairconditionsspecied
bythemanufacturer.
–Theunitmayonlybeused,maintainedandrepairedbypersonswhoarefamiliarwithitandarefullyaware
oftherisks.
–Arbitrarychangestotheenginemeanthatthemanufacturerisnolongerresponsibleforanydamage
incurredasaresultofsuchchanges.
–Similarly,tamperingwiththeinjectionandcontrolsystemcanaffecttheunit'sperformanceandexhaust-gas
characteristics.Thismeansthatcompliancewiththestatutoryenvironmentalrequirementsisnolonger assured.
–Ifmalfunctionsoccur,determinethecauseandremedytheproblemimmediately . –Cleanunitsthoroughlybeforerepairs,ensuringthatallopeningswheredirtisnotallowedtoenterforsafety
orfunctioningreasonsareclosed.
–Neverrunaunitdry,inotherwordsalwaysmakesurethatithasbeenlledwithoilbeforerunningit. –Neverrunengineswithoutcoolant. –Applyasuitableinformationsigntounitsthatarenotreadytobeoperated. –OnlyuseserviceproductsaspertheMANRecommendedServiceProductsbooklet,otherwisethe
manufacturerwarrantywillbeinvalidated. Detailsofapprovedproductscanbefoundonlineat:http://www.man-mn.com/>Products&Solutions> E-Business.
–Complywiththespeciedmaintenanceintervals. –Donotllengine/gearoilabovethemaximumlevelmark.Donotexceedthemaximumpermittedoperational
tilt.
–ThespecialmeasuresdescribedinMANWorksStandardM3069Part3applyifbusesortrucksaretobe
withdrawnfromserviceorstoredforaperiodlongerthan3months.

3.Limitedliabilityforpartsandaccessories

Generalinformation
OnlyuseaccessoriesandgenuineMANpartsthathavebeenexpresslyapprovedbyMANNutzfahrzeuge AGforyourMANvehicle.MANNutzfahrzeugeAGacceptsnoliabilityforanyotherproducts.
4.Regulationsforavoidinginjuryandenvironmentalcontamination
Healthprotectionprecautions
Avoidprolonged,excessiveorrepeatedskincontactwithserviceproducts,excipients,thinnersorsolvents. Protectyourskinusingasuitableskinprotectionagentorprotectivegloves.Donotuseserviceproducts, excipients,thinnersorsolventstocleantheskin.Applyagreasyskincreamaftercleaningyourskin.
Serviceproductsandexcipients
Donotusefoodordrinkcontainersfordrainingandstoringserviceproductsorexcipients.Complywith local-authorityregulationswhendisposingofserviceproductsandexcipients.
Coolant
Treatundilutedantifreezeashazardouswaste.Followtheinstructionsissuedbytherelevantlocalauthority whendisposingofusedcoolant(mixtureofantifreezeandwater).
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INTRODUCTION
Cleaningthecoolingcircuit
Donotpourcleaninguidsandrinsingwaterdownthedrainifthispracticeisrestrictedbyspeciclocal regulations.However,thecleaninguidandrinsingwatermustinallcaseshavebeenpassedthroughanoil trapwithasludgetrap.
Cleaningthelterinsert
Whenblowingcompressedairthroughthelterinsert,makesurethelterdustiscollectedbyavacuumor isblownintoadustcollectionbag.Otherwise,usearespiratoryprotectionmask.Wearrubberglovesor useaskinbarrierhandcreamwhenwashingouttheelements,becausecleaningagentshaveaggressive grease-dissolvingcharacteristics.
Engine/gearoil,ltercartridges,insertsandbox-typelters,desiccantcartridges
Filterinserts,cartridgesandbox-typelters(oilandfuellters,desiccantcartridgesfortheairdryer)are classiedashazardouswaste.Complywithlocal-authorityregulationswhendisposingoftheaboveparts.
Usedengine/gearoil
Lengthyorrepeatedskincontactwithanytypeofengine/gearoilremovesgreasefromtheskin.Thiscan causedryskin,irritationorskininammation.Inadditiontothesehazards,usedengineoilcontainsdangerous materialswhichcantriggerdangerousskindiseases.Weargloves,especiallywhenchangingtheoil.
HandlingAdBlue®
AdBlue®isasyntheticallyproduced32.5%urea/watersolutionwhichisusedasanNOxreductionadditive fordieselengineswithSCRcatalyticconverter.AdBlue®isnotahazardoussubstancebutdoesdecompose intoammoniumhydroxideandcarbondioxidewhenstoredforprolongedperiods.Forthisreason,AdBlue® isclassiedasawaterhazard(waterhazardclass1)inGermanyandisnotallowedtoentersewageorthe ground.EnsuregoodventilationintheworkplacewhenworkingontheAdBlue®system.Donoteat,drink orsmokeintheworkplace.AvoidskinandeyecontactwithAdBlue®,thoroughlywashyourhandsanduse askinprotectioncreambeforetakingbreaksandbeforenishingwork.Ifyourskincomesintocontactwith AdBlue®,washtheskinusingwaterandaskincleaner,changeoutofdirtyclothesimmediately.Iftheskin isirritated,consultadoctor.IfAdBlue®getsintoyoureyes,rinseyoureyeswithwateroraneye-rinsing productsforatleast10minutes,keepingyoureyelidsopen.Removeanycontactlensesbeforehand.If symptomspersist,consultadoctor.IfAdBlue®isswallowed,consultadoctorimmediately.StoreAdBlue® containersclosedinliquid-tightstorageareas.Thestoragetemperaturemustnotexceed25°C.Soakup leakedorspiltAdBlue®usingbindingagentanddisposeofinthecorrectmanner.

5.Informationforworkingonthecommonrailsystem

Generalinformation –Ajetoffuelcancutthroughtheskin.Riskofreduetofuelatomisation. –Neverundothescrewedconnectionsonthefuelhigh-pressuresideofthecommon-railsystemwhilstthe
engineisrunning(high-pressurelinefromthehigh-pressurepumpto/ontherailandonthecylinderhead totheinjector).Whilsttheengineisrunning,thelinesareconstantlycarryingfuelunderapressureof1800 barormore.Beforethescrewconnectionsareopened,waitatleastoneminuteuntildepressurisationhas occurred,usingMAN-catstocheckthedepressurisationontherailasnecessary.
–Avoidstandingneartherunningengine. –Donottouchthelivepartsattheinjectorelectricalconnectionwhilsttheengineisrunning. –Anychangestotheoriginalwiringcanleadtothelimitvaluesspeciedinpacemakerregulationsbeing
exceeded.Examplesofsuchchangesincludenon-twistedinjectorwiringortheadditionofthetestbox (contactbox).
–ThereisnodangertooperatorsandpersonswearingapacemakerifunitswithMANcommon-railengines
areusedfortheirintended,i.e.approved,purpose.
–Ajetoffuelcancutthroughtheskin.Riskofreduetofuelatomisation. –Neverundothescrewedconnectionsonthefuelhigh-pressuresideofthecommon-railsystemwhilstthe
engineisrunning(injectionlinefromthehigh-pressurepumpto/ontherailandonthecylinderheadtothe injector).
–Avoidstandingneartherunningengine. –Whilsttheengineisrunning,thelinesareconstantlycarryingfuelunderapressureof1800barormore. –Beforeopeningthescrewedconnections,waitforatleastoneminutesothatthesystemcanbe
depressurised.
–CheckdepressurisationoftherailusingMAN-catsifnecessary. –Donottouchthelivepartsattheinjectorelectricalconnectionwhilsttheengineisrunning.
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INTRODUCTION
Informationforpeoplewithpacemakers –Anychangestotheoriginalenginewiringcanleadtothelimitvaluesspeciedinpacemakerregulations
beingexceeded.Examplesofsuchchangesincludenon-twistedinjectorwiringortheadditionofthetest box(contactbox).
–Thereisnodangertodriversandco-driverswearingapacemakerifthevehicleisusedforitsintended,i.e.
approved,purpose.
–ThereisnodangertooperatorswearingapacemakerifunitswithMANcommon-railenginesareusedfor
theirintended,i.e.approved,purpose.
–Initsoriginalstate,theproductdoesnotviolateanyofthecurrentlyknownpacemakerlimitvalues.
Dangerofdamageduetodirtingress –Diesel-injectionsystemsconsistofprecisionengineeredcomponentsthataresubjecttoextremeloads;Due
tothehighlyprecisenatureofthistechnology,allworkonthefuelsystemrequiresthehighestpossible degreeofcleanliness.
–Evendirtparticlesover0.2mmcancausecomponentfailure.
Beforecommencingworkonthecleanside –Cleantheengineandenginecompartmentwiththefuelsystemclosed.Donotuseapowerfuljetwhen
cleaningelectricalcomponents.
–Drivethevehicleintoacleanareaoftheworkshopwherenoneoftheworkcausesdusttobeswirledup
(sanding,welding,brakerepairs,brakechecks,performancetestsetc.).
–Avoidairmovements(possibleswirlingupofdustduetostartingofengines,theworkshop
heating/ventilationsystem,duetodraughtsetc.).
–Cleananddrytheareaofthestillclosedfuelsystemusingcompressedair. –Useasuitableextractorunit(industrialextractorunit)toremoveloosedirtparticlessuchaspaintchippings
andinsulatingmaterial.
–Useanewandcleancoverinareasoftheenginecompartmentwheredirtparticlescanbecomeloose,e.g.
tiltedcab,busenginecompartment.
–Beforeremovinganycomponents,washyourhandsandputoncleanworkingclothes.
Afteropeningthecleanside –Theuseofcompressedairforcleaningisnotpermitted. –Duringassembly,removeloosedirtusingasuitableextractorunit(industrialextractorunit). –Onlylint-freecleaningclothsareallowedtobeusedonthefuelsystem. –Cleantoolsandequipmentbeforecommencingwork. –Onlyusetoolsthatshownosignsofdamage(crackedchromecoatings). –Donotusematerialssuchascloths,cardboardorwoodwhenremovingandinstallingcomponentsasthese
materialscanproduceparticlesandbres.
–Iftheundoingofconnectionscausesthepainttochip(duetopossibleexcesspaint),carefullyremovethese
paintchippingsbeforefullyundoingtheconnection.
–Allremovedcomponentsonthecleansideofthefuelsystemmustbepluggedimmediatelyattheir
connectionopeningsusingsuitablecaps.
–Thesecapsmustbestoredindustproofpackaginguntiltheyareusedanddisposedofaftertheyhavebeen
usedonce.
–Thenstorethecomponentsinaclean,sealedcontainer. –Neveruseusedcleaningortestuidsforthesecomponents. –Newpartsmustnotberemovedfromtheiroriginalpackaginguntilimmediatelybeforeuse. –Workonremovedcomponentsmayonlybecarriedoutinasuitablyequippedworkplace. –Ifremovedpartsareshipped,alwaysusethenewpart'soriginalpackaging. Whencarryingoutworkonbusengines,theinstructionsbelowmustalsobefollowedwithoutfail:
Dangerofdamageduetodirtingress –Beforeopeningthecleansideofthefuelsystem:
Cleantheareasoftheenginearoundpressurelinettings,injectionlines,therailandvalvecoverusing compressedair.
–Removethevalvecoverandthenre-cleantheareasoftheenginearoundthepressurelinettings,injection
linesandrail.
–Onlyloosenrailconnectionsatrst:
Undotheunionnutsontherailconnectionsandunscrewby4turns. Raisetherailconnectionsusingaspecialtool. Reason:onlyremovetherailconnectionscompletelyoncetheinjectorshavebeenremovedsothatnodirt canfallintotheinjectorsfromabove.
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INTRODUCTION
–Removetheinjectors. –Afterremoval,rinseouttheinjectorswithacleaninguid,makingsurethatthehigh-pressureconnection
holeisfacingdownwards.
–Removetherailconnectionsbyunscrewingtheirunionnuts. –Cleantheinjectorholeinthecylinderhead.

6.Limp-homeprogramforunitswithelectroniccontrolunits

Generalinformation
Theunitshaveanelectroniccontrolsystemthatmonitorstheunitaswellasitself(self-diagnosis).
Assoonasamalfunctionoccurs,themalfunctionisevaluatedandoneofthefollowingmeasuresis implementedautomatically:
–Outputofafaultmessagewithfaultcode. –Switchovertosuitabledefaultfunctionforfurtheroperation,albeitwithrestrictions.Havemalfunctions
remediedbyMANafter-salesimmediately.
–IfMAN-catsisused,thefaultcodeisoutputdirectly.

7.Installationinstructions

Installationofpiping –Mechanicaldeformationofpipingisnotpermittedwhenperforminginstallationwork-riskoffracture!
Installationofgaskets –OnlyusegenuineMANgaskets –Makesurethematingfacesareundamagedandclean. –Donotuseadhesivesorsealingcompounds.Ifnecessary,tofacilitateinstallation,usealittlegreaseto
stickthegaskettotheparttobemounted.
–Tightentheboltsevenlytothespeciedtighteningtorque.
InstallationofO-rings –OnlyusegenuineMANO-rings –Makesurethematingfacesareundamagedandclean.
Engineoverhaul –Arangeofverydifferentfactorsaffecttheengineservicelife.Itisthereforenotpossibletoindicatethe
exactnumberofoperatinghoursormilesbeforeamajoroverhaulisdue.
–Inourjudgement,itisnotadvisabletoopenanengineorperformamajoroverhauliftheenginehasgood
compressionvaluesandthefollowingoperatingvalueshavenotchangedsignicantlysincetheywere measuredandtakenduringtheinitialstart-up:
–Chargepressure –Exhaustgastemperature –Coolantandlubricatingoiltemperature –Oilpressureandoilconsumption –Smokecharacteristics
Thefollowingcriteriahaveamajorinuenceontheengineservicelife: –Correctpowersettingfortheapplicationtype –Correctinstallation –Approvaloftheinstallationbyauthorisedpersonnel –Regularmaintenanceasperthemaintenanceschedule
T186thedition23
Page 26

DEVICEDESCRIPTION

DEVICEDESCRIPTION

SYSTEMDESCRIPTION

Generalinformation

Inrecentyears,dieselengineshavefacedincreasinglystringentlegislativeandcustomerdemandsregarding environmentalcompatibility,fuelconsumption,constantpower-takeoffspeedsaswellasexhaustandnoise emissions.Thistrendissettocontinueinthefuture.
Thecommon-railinjectionsystemfullsalltherequirementsthathavetobemetbystate-of-the-artinternal combustionengines.
Inconjunctionwithelectronicallycontrolledgearshiftsystems,anti-lockbrakesystems,anti-spinregulators andothersystemsforcontrollingtherunninggearorbrakesetc.,theEDCsystemcanimprovevehicle economy,increasedrivingcomfortandtakesomeoftheburdenoffboththedriverandtheenvironment.

Structureandoperationofthecommon-railsystem

Efcientcombustionisonlypossibleifthereisgoodmixtureformation.Thisiswheretheinjectionsystem playssuchacentralrole.Therightquantityoffuelmustbeinjectedattherighttimeandwithahighpressure. Thecommon-railsystemisatrend-settinghigh-pressureinjectionsystemwhichinvolvestheseparationof pressurisationandinjection.Thefuelfortheindividualcylinderscomesfromasharedaccumulatorwhichis constantlykeptathighpressure.Theaccumulatorispressurisedbyahigh-pressurepump.Thispressure canbechangedtosuittheoperatingconditionsinquestion.Eachcylinderisequippedwithaninjector whichiscontrolledbyasolenoidvalve.Theinjectionquantityisdeterminedbytheoutletcross-sectionof theinjector,thesolenoidvalveopeningdurationandtheaccumulatorpressure.Asystempressureofupto 1800barcanbereached.Separationofthepressurisationandinjectionfunctionsallowsabetterinjection characteristicand,therefore,improvescombustiondevelopment.Anyinjectionpressurewithinthemapcan beselected.Multipleinjections,i.e.pre-injectionsandpost-injections,arepossible.Thefuelquantity,startof injection,pre-injectionandpost-injectionarecontrolledbyextremelyfastsolenoidvalves.Anotheradvantage ofcommon-railsystemsisthattheycanbettedtoexistingengineswithouthavingtomodifythecylinder head.
24T186thedition
Page 27
Schematicdiagramofthecommon-railsystem
DEVICEDESCRIPTION
1Quantity-controlledhigh-pressurepump 2High-pressureaccumulator(rail) 3Pressurelimitingvalve 4Rail-pressuresensor 5Injectors 6Electroniccontrolunit 7Furthersensorsandactuators
T186thedition25
Page 28
DEVICEDESCRIPTION

FUNCTIONALDESCRIPTION

Controlunit,EDC7(A435,A570)

(A)Engineconnector,89-pin
(C)Injectorconnector,16-pin
(B)Vehicleconnector,36-pin
ThemaintasksoftheEDCcontrolunitaretocontroltheinjectionquantity,controlthepointofinjectionand activatethestarter.Theoptimalinjectionquantityandpointofinjectionarecalculatedtoensureoptimum combustioninallengineoperatingstates.
Thecontrolunitevaluatesthesensorsignalsandthencalculatestheactivationsignalsfortheinjectors.
Thecontrolunit(software/hardware)isdesignedforamaximumofsixcylinders.Asecondcontrolunitis thereforeneededforoperatingaV-engine.ThetwocontrolunitscommunicateviaCANandoperatein “Master/Slave”mode.
Thecontrolunitsoftwarecontainsthefollowingfunctiongroupings: –Fuelquantitysetpointformation,fuelmetering –Fuelpressurecontrolwithhigh-pressurepump –Fuelpressuredeactivation(limp-homefunction) –Idlingspeedcontrol –Maximumspeedcontrol,smokeandtorquelimitation –Adaptiveindividualcylindertorquecontrol –Cylindershut-off –Exhaustgasrecirculation –Airsystem/exhaustgasaftertreatment –Exhaustgastemperatureandexhaustgasmanagement –Chargepressurecontrol(wastegatecontrol) –Signalacquisitionandcalculationofoperatingvariables –Diagnosisandmonitoringfunctions –OBDfunctionality
26T186thedition
Page 29
Controlunit,EDC7C32Euro4/5(A435)Pinassignment,engineconnectorA
DEVICEDESCRIPTION
Pin
A0160034
A0260384
A0331000
A0460383
A0560401
A0660400
A0760035
A0860373Activation,meteringunit
A0931000
A1060374
A11
A1260036
A1360033
A1431000
A1531000
A1660314
Lineno./colour
Supply,controlunit(battery+)
Activation,proportionalvalve,turbocharger1(PWM)
Ground,controlunit(battery–)
Ground,proportionalvalve,turbocharger1
Ground,shut-off/pressure-reducingvalve,LTcooler
Activation,shut-off/pressure-reducingvalve,LTcooler
Supply,controlunit(battery+)
Ground,controlunit(battery–)
Ground,meteringunit
60340/60393Ground,activation,uncontrolledEGR/proportionalvalve,controlled
EGR(E-EGR)
Supply,controlunit(battery+)
Supply,controlunit(battery+)
Ground,controlunit(battery–)
Ground,controlunit(battery–)
Activation,IMR(starter),highsignal
Function
A17
A1890316
A1931330
A2060137
A2160134
A2260153
A2360031
A2460156
A2560159
A26
A27191
A28-A31
A3260180
A33-A35
60367/60392Supply,activation,uncontrolledEGR/proportionalvalve,controlled
EGR(E-EGR)
Supply,activation,EGRthrottlevalve(CRT)
Activation,IMR(starter),lowsignal
Signalinput,fuellow-pressuresensor
Signalinput,oilpressuresensor
Feedbacksignal,EGR(foruncontrolledEGRonly)
Ground,feedbacksignal,EGR(foruncontrolledEGRonly)
Supply,oilpressuresensor(5V)
Supply,charge-pressuresensor(5V)
—
—
—
Notused
ExhaustgasaftertreatmentCANHigh
Notused
Supply,positionsensor(feedback),controlledEGR(5V)
Notused
T186thedition27
Page 30
DEVICEDESCRIPTION
Pin
A3631000
A3760158
A3860135
A3960182
A4060155
A4190126
A4290005
A4360161
A44
A45192
A46-A50
A5190132
A52-A53
A54
A55
A56
Lineno./colour
Ground,activation,EGRthrottlevalve(CRT)
Ground,fuellow-pressuresensor
Ground,oilpressuresensor
Ground,positionsensor(feedback),controlledEGR
Supply,fuellow-pressuresensor(5V)
Supply,exhaustgasdifferential/exhaustgasrelativepressuresensor (5V)
Ground,feedbacksignal,EGRthrottlevalve(CRT)
Supply,rail-pressuresensor(5V)
—
Notused(spare,signaloutput,camshaftspeed)
ExhaustgasaftertreatmentCANLow
—
Notused
Checklamp,OBD(MIL)
—
Notused
grey/brownGround,speedsensor,camshaft
grey/whiteGround,speedsensor,crankshaft
—
Ground,temperaturesensor,fuel(option)
Function
A5760100
A5860101
A5960127
A60
A6160160
A6260141
A63-A64
A6560191
A66-A69
A7090121
A71
A72
A73
A74
A75
A7660151
A7760131
Ground,temperaturesensor,chargeairupstreamofcylinderinlet
Ground,coolanttemperaturesensor
Ground,exhaustgasdifferential/exhaustgasrelativepressuresensor
—
Notused
Ground,rail-pressuresensor
Ground,charge-pressuresensor(LDF6andLDF6-T)
—
Notused
Ground,temperaturesensor,coolant,LTcooler
—
Notused
Signalinput,temperaturesensor,chargeair(integratedin charge-pressuresensorLDF6-T)
—
grey
Notused
Signalinput,speedsensor,camshaft
grey/greenSignalinput,speedsensor,crankshaft
—
—
Notused
Signalinput,temperaturesensor,fuel(option)
Signalinput,temperaturesensor,chargeairupstreamofcylinderinlet
Signalinput,coolanttemperaturesensor
A7890128
Signalinput,exhaustgasdifferential/exhaustgasrelativepressure sensor
A7990129
A8060162
A8160102
A82
A83
—
—
Feedbacksignal,EGRthrottlevalve(CRT)
Signalinput,rail-pressuresensor
Signalinput,charge-pressuresensorLDF6-T
Notused
Ground,engineoiltemperaturesensor(option)
28T186thedition
Page 31
DEVICEDESCRIPTION
Pin
A8460192
A85
A86
A8760181
A88-A89
Lineno./colour
Signalinput,temperaturesensor,coolant,LTcooler —
—
Signalinput,engineoiltemperaturesensor(option)
Notused
Signalinput,positionsensor(feedback),controlledEGR —
Notused
Function
ControlunitEDC7C32Euro4/5(A435)Pinassignment,vehicleconnectorB
Pin
B01
Lineno./colour
—
Notused
Function
B0260394
B03
B0460398
B0560397
B0660395
B07
B0860396
B09
B1060187
B11
B1290315
B1360399
B14-B17
B1860190
B1931000
B2060188
Ground,compressedairshut-offvalve —
Notused
Ground,proportionalvalve,turbocharger2
Supply,heating,oxygensensor(+U
)
bat
Activation,compressedairshut-offvalve —
Notused
Heatercycle,heating,oxygensensor(–) —
Notused
Signalinput,temperature,chargepressure/temperaturesensor,LT
cooler —
Notused
Activation,engineairowsensorap(CRT)
Activation,proportionalvalve,turbocharger2(PWM) —
Notused
Signalinput,charge-pressuresensor,chargepressure/temperature
sensor,LTcooler
Ground,engineairowsensorap(CRT)
Ground,chargepressure/temperaturesensor,LTcooler
B21
B22
green/black(160)M-CANlow
black/green(159)M-CANhigh
B2360185Virtualground,oxygensensor
B2460183Pumpcurrent,oxygensensor
B25185
B26
B2790123
60100/90119Ground,exhaustgastemperaturesensor1(upstreamoflter)
HD-OBD-CANhigh
Ground,exhaustgastemperaturesensor2(downstreamoflter)
T186thedition29
Page 32
DEVICEDESCRIPTION
Pin
B2860189
B29
B3060186Nernstvoltage,oxygensensor
B3160184
B32186
B3390122
B3490124
B3560201
B3615014
ControlunitEDC7C32Euro4/5(A435)Pinassignment,injectorconnectorC
Lineno./colour
Supply,chargepressure/temperaturesensor,LTcooler(5V)
—
Notused
Trimmingresistor(trimcurrent)oxygensensor
HD-OBD-CANlow
Signalinput,exhaustgastemperaturesensor1(upstreamoflter)
Signalinput,exhaustgastemperaturesensor2(downstreamoflter)
ISOK-line
Supply,controlunit(terminal15)
Function
C07-C10
Pin
C01
C02
C03
C04
C05
C06white/red
C11
C12white/black
C13white/black
C14white/red
C15white/red
C16white/black
Lineno./colour
blackInjector,cylinder5,highsignal
redInjector,cylinder6,highsignal
redInjector,cylinder4,highsignal
blackInjector,cylinder1,highsignal
blackInjector,cylinder3,highsignal
Injector,cylinder2,lowsignal
—
redInjector,cylinder2,highsignal
Notused
Injector,cylinder3,lowsignal
Injector,cylinder1,lowsignal
Injector,cylinder4,lowsignal
Injector,cylinder6,lowsignal
Injector,cylinder5,lowsignal
Function
30T186thedition
Page 33
DEVICEDESCRIPTION
ControlunitEDC7C32MasterEuro5V8(A435)Pinassignment,engineconnectorA
Pin
A0160034
A02
A0331000
A04-A06
A0760035
A0860373Activation,meteringunit
A0931000
A1060374
A11
A1260036
A1360033
A1431000
A1531000
A1660314
A17-A19
A2060137
Lineno./colour
Supply,controlunit(battery+)
—
—
—
—
Notused
Ground,controlunit(battery–)
Notused
Supply,controlunit(battery+)
Ground,controlunit(battery–)
Ground,meteringunit
Notused
Supply,controlunit(battery+)
Supply,controlunit(battery+)
Ground,controlunit(battery–)
Ground,controlunit(battery–)
Activation,IMR(starter)
Notused
Signalinput,fuellow-pressuresensor
Function
A2160134
A22-A23
A2460156
A2560159
A26
A27
A28-A36
A3760158
A3860135
A39
A4060155
A41-A42
A4360161
A4460546
A45
—
—
brown/blackCANhighMaster/Slave
—
—
—
black/blueCANlowMaster/Slave
Signalinput,oilpressuresensor1
Notused
Supply,oilpressuresensor1(5V)
Supply,charge-pressuresensor(5V)
Notused
Notused
Ground,fuellow-pressuresensor
Ground,oilpressuresensor1
Notused
Supply,fuellow-pressuresensor(5V)
Notused
Supply,rail-pressuresensor1
Output,speedsignal2
T186thedition31
Page 34
DEVICEDESCRIPTION
Pin
A46-A50
A5190132
A52-A53
A54
A55
A56-A57
A5860101
A59-A60
A6160160
A6260141
A63-A69
A7090121
A71
A72
A73
A7460545
Lineno./colour
—
Notused
Checklamp,OBD(MIL)
—
Notused
grey/brownGround,speedsensor,camshaft
grey/whiteGround,speedsensor,crankshaft
—
Notused
Ground,coolanttemperaturesensor
—
Notused
Ground,rail-pressuresensor1
Ground,charge-pressuresensor
—
Notused
Signalinput,temperaturesensor,chargeair(integratedin charge-pressuresensorLDF6-T)
—
grey
Notused
Signalinput,speedsensor,camshaft
grey/greenSignalinput,speedsensor,crankshaft
Output,speedsignal1
Function
A75-A76
A7760131
A78-A79
A8060162
A8160102
A82-A89
—
Notused
Signalinput,coolanttemperaturesensor
—
Notused
Signalinput,rail-pressuresensor1
Signalinput,charge-pressuresensor
—
Notused
ControlunitEDC7C32MasterEuro5V8(A435)Pinassignment,vehicleconnectorB
B01-B20
Pin
Lineno./colour
—
Notused
Function
B21160
B22159
B23-B24
B25191
B2690116
—
M-CANlow
M-CANhigh
Notused
ExhaustgasaftertreatmentCANHigh
Ground,exhaustgastemperaturesensor1(upstreamofAdBlue mixer)
B27-B31
—
Notused
32T186thedition
®
Page 35
DEVICEDESCRIPTION
Pin
Lineno./colour
B32192
B3390115
ExhaustgasaftertreatmentCANLow
Signalinput,exhaustgastemperaturesensor1(upstreamofAdBlue
Function
mixer)
B34
B3560201
B3615014
—
Notused
ISOK-line
Supply,controlunit(terminal15)
ControlunitEDC7C32MasterEuro5V8(A435)Pinassignment,injectorconnectorC
Pin
Lineno./colour
Function
®
C06-C08
C14-C15
C01
C02
C03
C04
C05
C09
C10
C11
C12
C13
C16green/black
brownInjector,cylinder2,Highsignal
brownInjector,cylinder4,Highsignal
—
Notused
brownInjector,cylinder1,Highsignal
brownInjector,cylinder3,Highsignal
—
60661
60661
—
Notused
CodingMaster/Slave
CodingMaster/Slave
Notused
blackInjector,cylinder3,Lowsignal
blackInjector,cylinder1,Lowsignal
—
Notused
Injector,cylinder2,Lowsignal
T186thedition33
Page 36
DEVICEDESCRIPTION
ControlunitEDC7C32SlaveEuro5V8(A570)Pinassignment,engineconnectorA
Pin
A0160039
A02
A0331000
A04-A06
A0760038
A08
A0931000
A10-A11
A1260037
A1360040
A1431000
A1531000
A16-A20
A2160178
A22-A23
A2460177
Lineno./colour
Supply,controlunit(battery+)
—
—
—
—
—
—
Notused
Ground,controlunit(battery–)
Notused
Supply,controlunit(battery+)
Notused
Ground,controlunit(battery–)
Notused
Supply,controlunit(battery+)
Supply,controlunit(battery+)
Ground,controlunit(battery–)
Ground,controlunit(battery–)
Notused
Signalinput,oilpressuresensor2
Notused
Supply,oilpressuresensor2(5V)
Function
A25-A26
A27
A28-A37
A3860176
A39-A42
A4360165
A44
A45
A46-A60
A6160164
A62-A71
A7260546
A7360545
A74-A79
A8060163
A81-A89
34T186thedition
—
brown/blackCANHighMaster/Slave
—
—
—
black/blueCANLowMaster/Slave
—
—
—
—
Notused
Notused
Ground,oilpressuresensor2
Notused
Supply,rail-pressuresensor2(5V)
Notused
Notused
Ground,rail-pressuresensor2
Notused
Signalinput,speedsignal1
Signalinput,speedsignal2
Notused
Signalinput,rail-pressuresensor2
Notused
Page 37
DEVICEDESCRIPTION
ControlunitEDC7C32SlaveEuro5V8(A570)Pinassignment,vehicleconnectorB
Pin
B01-B20
B21160
B22159
B23-B24
B25185
B26-B31
B32186
B33-B34
B3560205
B3615014
ControlunitEDC7C32SlaveEuro5V8(A570)Pinassignment,injectorconnectorC
Lineno./colour
—
—
—
—
Notused
M-CANLow
M-CANHigh
Notused
HD-OBD-CANHigh
Notused
HD-OBD-CANlow
Notused
ISOK-line
Supply,controlunit(terminal15)
Function
Pin
C01
C02
C03
C04
C05
C06
C07
C08
C09-C11
C12green/black
C13
Lineno./colour
brownInjector,cylinder7,Highsignal
brownInjector,cylinder8,Highsignal
—
brownInjector,cylinder5,Highsignal
brownInjector,cylinder6,Highsignal
—
60662
60662
—
blackInjector,cylinder5,Lowsignal
Notused
Notused
Coding,Slave
Coding,Slave
Notused
Injector,cylinder6,Lowsignal
T186thedition35
Function
Page 38
DEVICEDESCRIPTION
Pin
C14
C15green/black
C16
Lineno./colour
—
Notused
Function
Injector,cylinder8,Lowsignal
—
Notused
36T186thedition
Page 39
ControlunitEDC7C3Euro3(A435)Pinassignment,engineconnectorA
DEVICEDESCRIPTION
Pin
A0160034
A02
A0331000
A04-A05
A0760035
A0860373Activation,meteringunit
A0931000
A1060374
A1160340
A1260036
A1360033
A1431000
A1531000
A1660314
A1760367
A18
Lineno./colour
Supply,controlunit(battery+) —
—
—
Notused
Ground,controlunit(battery–)
Notused
Supply,controlunit(battery+)
Ground,controlunit(battery–)
Ground,meteringunit
Ground,activation,uncontrolledEGR
Supply,controlunit(battery+)
Supply,controlunit(battery+)
Ground,controlunit(battery–)
Ground,controlunit(battery–)
Activation,IMR(starter),Highsignal
Supply,activation,uncontrolledEGR
Notused
Function
A1931330
A2060137
A2160134
A2260153
A2360031
A2460156
A2560159
A26-A36
A3760158
A3860135
A39
A4060155
A41-A42
A4360161
A44
Activation,IMR(starter),Lowsignal
Signalinput,fuellow-pressuresensor
Signalinput,oilpressuresensor
Feedbacksignal,EGR
Ground,feedbacksignal,EGR
Supply,oilpressuresensor(5V)
Supply,charge-pressuresensor(5V) —
—
—
—
Notused
Ground,fuellow-pressuresensor
Ground,oilpressuresensor
Notused
Supply,fuellow-pressuresensor(5V)
Notused
Supply,rail-pressuresensor(5V)
Notused(spare,signaloutput,camshaftspeed)
T186thedition37
Page 40
DEVICEDESCRIPTION
Pin
A45-A53
A54
A55
A56
A5760100
A5860101
A59-A60
A6160160
A6260141
A63-A71
A72
A73
A74-A75
A7660151
A7760131
A78-A79
Lineno./colour
—
grey/brownGround,speedsensor,camshaft
grey/whiteGround,speedsensor,crankshaft
—
—
—
grey
grey/greenSignalinput,speedsensor,crankshaft
—
—
Notused
Notused
Ground,temperaturesensor,chargeair
Ground,coolanttemperaturesensor
Notused
Ground,rail-pressuresensor
Ground,charge-pressuresensor
Notused
Signalinput,speedsensor,camshaft
Notused
Signalinput,temperaturesensor,chargeair
Signalinput,coolanttemperaturesensor
Notused
Function
A8060162
A8160102
A82-A89
ControlunitEDC7C3Euro3(A435)Pinassignment,vehicleconnectorB
Pin
B01-B20
B21
B22
B23-B34
green/black(160)M-CANLow
black/green(159)M-CANHigh
—
Lineno./colour
—
—
Signalinput,rail-pressuresensor
Signalinput,charge-pressuresensor
Notused
Function
Notused
Notused
B3560201
B3615014
38T186thedition
ISOK-line
Supply,controlunit(terminal15)
Page 41
ControlunitEDC7C3Euro3(A435)Pinassignment,injectorconnectorC
DEVICEDESCRIPTION
C07-C10
Pin
C01
C02
C03
C04
C05
C06white/red
C11
C12white/black
C13white/black
C14white/red
C15white/red
C16white/black
Lineno./colour
blackInjector,cylinder5,Highsignal
RedInjector,cylinder6,Highsignal
RedInjector,cylinder4,Highsignal
blackInjector,cylinder1,Highsignal
blackInjector,cylinder3,Highsignal
Injector,cylinder2,Lowsignal —
Notused
redInjector,cylinder2,Highsignal
Injector,cylinder3,Lowsignal
Injector,cylinder1,Lowsignal
Injector,cylinder4,Lowsignal
Injector,cylinder6,Lowsignal
Injector,cylinder5,Lowsignal
Function
T186thedition39
Page 42
DEVICEDESCRIPTION
ControlunitEDC7C3MasterEuro3V10(A435)Pinassignment,engineconnectorA
Pin
A0160034
A02
A0331000
A04-A06
A0760035
A0860373Activation,meteringunit1
A0931000
A1060374
A1160340
A1260036
A1360033
A1431000
A1531000
A1660314
A1760367
A18
Lineno./colour
Supply,controlunit(battery+)
—
—
—
Notused
Ground,controlunit(battery–)
Notused
Supply,controlunit(battery+)
Ground,controlunit(battery–)
Ground,meteringunit1
Ground,EGRcontroller
Supply,controlunit(battery+)
Supply,controlunit(battery+)
Ground,controlunit(battery–)
Ground,controlunit(battery–)
Activation,IMR(starter),Highsignal
Activation,EGRcontroller
Notused
Function
A19
A2060137
A2160134
A2260153
A2360031
A2460156
A2560159
A26
A27
A28-A36
A3760158
A3860135
A39
A4060155
A41-A42
40T186thedition
31330/31321Activation,IMR(starter),lowsignal
Signalinput,fuellow-pressuresensor
Signalinput,oilpressuresensor
Feedback,EGRpositionsensor
Supply,EGRpositionsensor(5V)
Supply,oilpressuresensor(5V)
Supply,charge-pressuresensor(5V)
—
brown/blackCANHighMaster/Slave
—
—
—
Notused
Notused
Ground,fuellow-pressuresensor
Ground,oilpressuresensor
Notused
Supply,fuellow-pressuresensor(5V)
Notused
Page 43
DEVICEDESCRIPTION
Pin
A4360161
A4460546
A45
A46-A53
A54
A55
A56
A5760100
A5860101
A59-A60
A6160160
A6260141
A63-A71
A72
A73
A7460545
Lineno./colour
Supply,rail-pressuresensor1
Output,speedsignal2
black/blueCANLowMaster/Slave
—
grey/brownGround,speedsensor,camshaft
grey/whiteGround,speedsensor,crankshaft
—
—
—
grey
grey/greenSignalinput,speedsensor,crankshaft
Notused
Notused
Ground,temperaturesensor,chargeair
Ground,coolanttemperaturesensor
Notused
Ground,rail-pressuresensor
Ground,charge-pressuresensor
Notused
Signalinput,speedsensor,camshaft
Output,speedsignal1
Function
A75
A7660151
A7760131
A78-A79
A8060162
A8160102
A82-A89
ControlunitEDC7C3MasterEuro3V10(A435)Pinassignment,vehicleconnectorB
Pin
Lineno./colour
—
—
—
Notused
Signalinput,temperaturesensor,chargeair
Signalinput,coolanttemperaturesensor
Notused
Signalinput,rail-pressuresensor
Signalinput,charge-pressuresensor
Notused
Function
B01-B20
B21160
B22159
B23-B34
B3560201
B3615014
—
—
Notused
M-CANLow
M-CANHigh
Notused
ISOK-line
Supply,controlunit(terminal15)
T186thedition41
Page 44
DEVICEDESCRIPTION
ControlunitEDC7C3MasterEuro3V10(A435)Pinassignment,injectorconnectorC
Pin
C01
C02
C03
C04
C05
C06
C07-C08
C09
C10
C11
C12
C13green/black
C14
C15green/black
C16green/black
ControlunitEDC7C3SlaveEuro3V10(A570)Pinassignment,engineconnectorA
Lineno./colour
brownInjector,cylinder5,highsignal
brownInjector,cylinder3,highsignal
—
brownInjector,cylinder1,highsignal
blackInjector,cylinder2,highsignal
blackInjector,cylinder4,lowsignal
—
60561
60561
brownInjector,cylinder4,highsignal
brownInjector,cylinder2,lowsignal
—
Notused
Notused
Coding,Master/Slave
Coding,Master/Slave
Injector,cylinder1,lowsignal
Notused
Injector,cylinder3,lowsignal
Injector,cylinder5,lowsignal
Function
Pin
A0160039
A02
A0331000
A04-A06
A0760038
A0860375Activation,meteringunit2
42T186thedition
Lineno./colour
Supply,controlunit(battery+)
—
—
Notused
Ground,controlunit(battery–)
Notused
Supply,controlunit(battery+)
Function
Page 45
DEVICEDESCRIPTION
Pin
A0931000
A1060376
A11
A1260037
A1360040
A1431000
A1531000
A16-A26
A27
A28-A42
A4360165
A44
A45
A46-A60
A6160164
A62-A71
Lineno./colour
—
—
brown/blackCANHighMaster/Slave
—
—
black/blueCANLowMaster/Slave
—
—
Function
Ground,controlunit(battery–)
Ground,meteringunit
Notused
Supply,controlunit(battery+)
Supply,controlunit(battery+)
Ground,controlunit(battery–)
Ground,controlunit(battery–)
Notused
Notused
Supply,rail-pressuresensor(5V)
Notused
Notused
Ground,rail-pressuresensor
Notused
A7260545
A7360546
A74-A79
A8060163
A81-A89
ControlunitEDC7C3SlaveEuro3V10(A570)Pinassignment,vehicleconnectorB
Pin
B01-B20
B21160
Lineno./colour
—
—
—
Signalinput,speedsignal1
Signalinput,speedsignal2
Notused
Signalinput,rail-pressuresensor
Notused
Function
Notused
M-CANLow
B22159
B23-B34
B3560205
B3615014
M-CANHigh
—
Notused
ISOK-line
Supply,controlunit(terminal15)
T186thedition43
Page 46
DEVICEDESCRIPTION
ControlunitEDC7C3SlaveEuro3V10(A570)Pinassignment,injectorconnectorC
C09-C10
Pin
C01
C02
C03
C04
C05
C06
C07
C08
C11
C12
C13green/black
C14
C15green/black
C16green/black
Lineno./colour
brownInjector,cylinder10,highsignal
brownInjector,cylinder8,highsignal
—
brownInjector,cylinder6,highsignal
blackInjector,cylinder7,highsignal
blackInjector,cylinder9,lowsignal
60562
60562
—
brownInjector,cylinder9,highsignal
brownInjector,cylinder7,lowsignal
—
Notused
Coding,Slave
Coding,Slave
Notused
Injector,cylinder6,lowsignal
Notused
Injector,cylinder8,lowsignal
Injector,cylinder10,lowsignal
Function
44T186thedition
Page 47
DEVICEDESCRIPTION

High-pressurepump

Thetasksofthehigh-pressurepumparetogeneratethehighpressurerequiredforinjectionandtosupply anadequatequantityoffuelinalloperatingstates.Thehigh-pressurepumpisdrivenbytheengineand,in thecaseofD08andD28in-lineengines,ismountedinthesamepositionontheengineasaconventional injectionpump.TheD20/D26engineisanewdesignwithoverheadcamshaft.Thehigh-pressurepumpis drivenbyspurgears.Thesamespurgeardrivealsodrivesthealternator,thewaterpumpand,iftted,the air-conditioningcompressoronthefrontsideoftheenginebymeansofapulley.
Thefuelisforcedfromapre-supplypumptothefuelservicecentreviafuellinesandthenintothe high-pressurepump“suctionchamber”viathemeteringunit.Thepre-supplypumpisange-mountedonthe high-pressurepump.Themeteringunit(MProp)ismountedonthesuctionsideofthehigh-pressurepump. Themeteringunitisanactuatorforcontrollingthefuelpressureinthehigh-pressureaccumulator(rail).
Currentlytwohigh-pressurepumpvariantsofdifferingdesignareused:
–RadialpistonpumpCP3.3,CP3.4 –In-linepistonpumpCP9V4
High-pressurepumpCP3
(1)High-pressurepump
(3)Deliverypump
(2)Meteringunit(MProp)
Thehigh-pressurepumpCP3isaradialpistonpumpwith3cylinders.ThispumpisusedinthecaseofD08, D20,D26andD28in-lineenginesaswellasD2868V8engines.Dependingontheapplication,high-pressure pumpswithfuellubricationorhigh-pressurepumpswithengineoillubricationcanbeused.
FuellubricatedpumpsCP3.4+aregenerallyusedforEuro4engines.InthecaseofEuro5/EEVengineswith 1800barsystempressure,fuel-lubricatedpumpsCP3.4H+areusedforD20/D26enginesandfuel-lubricated pumpsCP3.3NHH+areusedforD08engines.
Theratiorelativetothecrankshaftis1:1.33inthecaseofD08enginesand1:1.67inthecaseofD20,D26 andD28engines,i.e.thehigh-pressurepumprotatesfasterthanthecrankshaft.
Note:Afterthepumpisexchanged,thefuelsystemmustbebledbeforetherststart(alsoseeOperator's Manual,“Do-it-yourselfjobs,fuelsystem”section).Fuel-lubricatedpumpsdonotrequireaninitialllwithfuel. Inthecaseofoil-lubricatedpumps,bleedingcanonlybeperformedwiththehigh-pressure-pumpreturnline pulledoffandclosedduetothehot/coldcircuit.
T186thedition45
Page 48
DEVICEDESCRIPTION
CP9V4high-pressurepump
(1)High-pressurepump (2)Meteringunit(2pcs.,oneperbankof
cylinders)
(3)Speedsensor(crankshaftspeed
acquisition)
(4)Supplypump
TheCP9V4high-pressurepumpisanin-linepistonpumpwith4cylindersarrangedinaV-shape.Thispump isusedinthecaseofD2848,D2840andD2842seriesVengines.
Theratiorelativetothecrankshaftis2:1,i.e.thispumprotatesatthecamshaftspeed,thatistosayhalfas fastasthecrankshaft.
Note:Thedesignationofthehigh-pressurepumphaschanged.Previousname:CP2/4,currentdesignation: CP9V4.
46T186thedition
Page 49
DEVICEDESCRIPTION

Meteringunit(proportionalvalveforfuel,MProp)(Y332,Y356)

Themeteringunit(MProp)isanactuatorforcontrollingthefuelpressureinthehigh-pressureaccumulator (rail).Themeteringunitislocatedonthelow-pressureside(inputside)ofthehigh-pressurepumpand isscrewedintotheCP3high-pressurepumphousing.TheCP2/4orCP9V4high-pressurepumpforthe V-engineisequippedwithtwometeringunitsastwohigh-pressureaccumulatorsarecontrolledinthiscase (onehigh-pressureaccumulatorperbankofcylinders).
ThemeteringunitiscontrolledusingaPWMoutput(pulsewidthmodulatedsignal):
Dutyfactor100%Meteringunitclosed(zerofuelquantitydelivery)
Dutyfactor0%Meteringunitopen(maximumdelivery)
Thecontrolcircuitconsistsofarail-pressuresensor,controlunitandmeteringunit.
Terminologynote:Themeteringunitcanalsobedesignated“MProp”.Bothtermsareusedinthismanual. MPropistheGermanabbreviationfor(fuel)quantityproportionalvalve.

Pinassignment

PinLinenumberFunction
1
2
60373/60375
60374/60376Ground
Inputsignal,PWMA08A08
ControlunitA435pinControlunitA570pin
A10A10
T186thedition47
Page 50
DEVICEDESCRIPTION

High-pressureaccumulator(rail)

Thename“commonrail”isderivedfromthedesignandfunctioningofthehigh-pressureaccumulator.The fuelisinjectedintotheindividualcylindersviathiscommonaccumulatorwhichisalsoafueldistributoror distributorrail.Herethefuelisconstantlyunderhighpressureandonlyneedstobedrawnattherighttime.
Thehigh-pressureaccumulatorhasthefollowingtasks:
–Storingthefuel –Preventingpressureuctuations
Thehigh-pressureaccumulatorisapipemadefromforgedsteel.Thediameterandlengthofthispipe dependsontheengine.Topreventpressureuctuations,thelargestpossiblevolumemustbeaimedfor,i.e. pipeaslongaspossibleandpipediameteraslargeaspossible.However,asmallvolumeisbetterforfast startingoftheengine.Therefore,thevolumehastobeconguredaspreciselyaspossibletosuittheengine inquestion.Theillustrationaboveisthereforeacongurationexampleonly.Thepressurelimitingvalve(1) andtherail-pressuresensor(2)arealsomountedonthehigh-pressureaccumulator.
Thefuelowsfromthehigh-pressurepumptothehigh-pressureaccumulatorviaaline.Thereisaporton thehigh-pressureaccumulatorforeachcylinder.Thefuelowstotheinjectorviathisportandaline.
Note:Aspartoffurthertechnicaldevelopment,thepressurelimitingvalvehasbeenintegratedinthe high-pressureaccumulatortoformanintegratedunitwiththerail.
48T186thedition
Page 51
DEVICEDESCRIPTION

Pressure-limitingvalve

Thepressurelimitingvalveismountedonthehigh-pressureaccumulator(rail)andfunctionsasapressure reliefvalvewithpressurelimiting.Thepressurelimitingvalvelimitsthepressureintherail.Ifthepressureis toohigh,ituncoversadischargehole.Atnormaloperatingpressure,aspringpushesapistontightintothe valveseatsothattherailremainsclosed.Onlyoncethemaximumsystempressureisexceededisapiston pressuredagainstaspringbythepressureintherail.
Thepressurelimitingvalveconsistsoftwopistons.Iftherailpressureistoohigh(atapprox.1800bar)the rstpistonmovesanduncoverspartofacross-sectionpermanentlysothatthefuelcanowoutoftherail. Therailpressureisthenkeptconstantataround700to800bar.Theenginecontinuesrunningandthe vehiclecanbedriventothenearestMANServiceoutletatreducedfull-loadquantity.
Thepressurelimitingvalvedoesnotcloseagainuntiltheenginehasbeenstoppedandtherailpressurehas fallenbelow50bar,i.e.onceithasopened,the2ndstageremainsopenforaslongastheengineisrunning.
Ifthepressurelimitingvalvedoesnotopenquicklyenough,itisforcedopen.T oforceopenthepressure limitingvalve,thefuelmeteringunitisopenedbyinterruptingthevoltagesupplyandthedrawingoffuelvia theinjectorsisblocked.Therailpressurerisesrapidlyuntilthepressurelimitingvalveopeningpressureis reached.Ifforcingopenthevalvedoesnotbringaboutthedesiredsuccess,e.g.duetojammingofthe pressurelimitingvalve,theengineisstopped.
Note:Aspartoffurthertechnicaldevelopment,thepressurelimitingvalvehasbeenintegratedinthe high-pressureaccumulatortoformanintegratedunitwiththerail.ThePLVhasthesamefunctionasthe previouspartandcanbereplacedasbefore.
T186thedition49
Page 52
DEVICEDESCRIPTION

Rail-pressuresensor(B487,B514)

Therail-pressuresensormonitorsthefuelpressureinthehigh-pressureaccumulator(rail).Theaimisto ensureaspeciedpressurefortheoperatingpointconcernedinthehigh-pressureaccumulator(rail).The rail-pressuresensorismountedonthehigh-pressureaccumulator.
D2840seriesengines(V-engines)havetwohigh-pressureaccumulatorstted(oneforeachbankof cylinders).Thereforetherearealsotworail-pressuresensors.
Sensorcurve

Pinassignment

PinLineno.Function
1
60160/60164Sensorground
2
60162/60163Outputsignal
3
60161/60165
ControlunitA435pinControlunitA570pin
A61A61
A80A80
Voltagesupply5VA43A43
50T186thedition
Page 53

Injector(Y341-Y350)

DEVICEDESCRIPTION
Theinjectorisusedtoinjectfuelintothecombustionchamber.TheEDC7speciestheinjectionperiod (injectorcoilactivationperiodforpre-injection,maininjectionandpossiblypost-injection)andtheinjection pointandactivatesanextremelyfastsolenoidvalveintheinjector.Thesolenoidvalvearmatureopensor closesthecontrolchamberdischargethrottle.Ifthedischargethrottleisopen,thepressureinthecontrol chamberfallsandtheinjectorneedleopens.Ifthedischargethrottleisclose,thepressureinthecontrol chamberrisesandtheinjectorneedleisclosed.Theopeningbehaviouroftheinjectorneedle(openingand closingspeed)isthereforedeterminedbythefeedanddischargethrottleintheinjectorcontrolchamber.
Theinjectorleakagequantity(leakageviadischargethrottleandinjectorneedle)isreturnedtothetankviathe returnline.Theexactinjectionquantityisdeterminedbytheoutletcross-sectionoftheinjector,thesolenoid valveopeningdurationandtheaccumulatorpressure.
T186thedition51
Page 54
DEVICEDESCRIPTION

Crankshaftspeedsensor(speedincrementsensor)(B488)

Thissensorontheywheelisusedtomeasure(calculate)thecrankshaftangle(crankangle).Thisinformation isvitalforensuringthecorrectactivationpointoftheinjectorsfortheindividualcylinders.
Thepulse-generatingwheelisdesignedasanincrementwheel.Thisspeedsensoristhereforereferredto asaspeedincrementsensor.Theincrementwheelispartoftheywheelandhas60–2=58holes(6x5mm) spacedat6°intervals.Twooftheholesaremissinginordertoformagap.Thepurposeofthegapisto determinethe360°crankangleoftheengine(onecrankshaftrevolution)andisassignedtoadenedcylinder 1crankshaftposition.Theenginecanalsostartwithcrankshaftsensoronlyorwithcamshaftsensoronly .In thecaseofoperationwithcrankshaftsensoronly,testinjectionsarecarriedoutatgasowTDCandignition TDCastheEDCwithoutcamshaftsensorrsthastolocatethecorrectignitionTDC.Ifthecontrolunitdetects aspeedreaction(ignition),ithasfoundthecorrectTDC.Theenginethenstartsandrunsaswithbothsensors.
Thespeedincrementsensorconsistsofapermanentmagnetandacoilwithalargenumberofwindings. Themagnet“touches”therotatingcomponent–inthiscasetheincrementwheelmountedonthecrankshaft –withitsmagneticeld.Thecurrentowisampliedwheneveraholemovespastthesensor.Thecurrent owisweakerinthegapsin-between.Thisgivesrisetoaninductivevoltageinthesensorcoil.Thisvoltage isevaluatedbytheECU.Thegapbetweenthesensorandtheincrementwheelisapprox.1mm.
Note:Thersthalfwavemustbepositive,otherwiseafaultisentered:SPN3753.

Pinassignment

Pin
Cablecolour
1(2)yellow(grey/green)Outputsignal
2(1)black(grey/white)Sensorground
Function
ControlunitA435pin
A73
A55
52T186thedition
Page 55
DEVICEDESCRIPTION

Camshaftspeedsensor(speedsegmentsensor)(B489)

Thecamshaftcontrolstheengineintakeandexhaustvalves.Itrotatesathalfthespeedofthecrankshaft. Itspositiondetermineswhetherapistonisinthecompressionstrokeortheexhauststrokewhilstitmoves towardsTDC.Thisinformationcannotbeobtainedbasedonthecrankshaftpositionduringstarting.However, whendriving,theinformationgeneratedbythespeedincrementsensoronthecrankshaftissufcientfor determiningtheenginestate.Thismeansthat,ifthespeedsensoronthecamshaftfailsduringdriving,the controlunitisstillawareoftheenginestate.Thepulse-generatingwheelisdesignedasasegmentwheel andisdrivenbythecamshaft.Thisspeedsensoristhereforereferredtoasaspeedsegmentsensor.The segmentwheelisalsoreferredtoasaphasewheel.Ithasonephasemarkpercylinder(e.g.6marksinthe caseof6-cylinderenginesor4marksinthecaseof4-cylinderengines)andasynchronisationmark.The phasemarkisatoothonthephasewheel.Thephasemarksareequallyspreadaroundthephasewheel. Thesynchronisationmarkisanadditionalmarkonthephasewheelrightbehindoneofthephasemarks.Its purposeistodeterminetheengineanglepositionwithin720°crankangle.Theenginecanalsostartwith camshaftsensoronlyorwithcrankshaftsensoronly.Inthecaseofoperationwithcrankshaftsensoronly,test injectionsarecarriedoutatgasowTDCandignitionTDCastheEDCwithoutcamshaftsensorrsthasto locatethecorrectignitionTDC.Ifthecontrolunitdetectsaspeedreaction(ignition),ithasfoundthecorrect TDC.Theenginethenstartsandrunsaswithbothsensors.Inthecaseofoperationwithcamshaftsensor only,anglecorrectionsarestoredinthecontrolunitsothattheinjectionpointcanalsobedeterminedcorrectly withoutpreciselycalculatingthecrankangleusingtheincrementsensor.Thespeedsegmentsensorhas thesamedesignandoperationasthespeedincrementsensorforacquiringthecrankshaftspeed.Signal
sequence:Atpin2,the1sthalfwaveappearspositivewhenamagneticallyconductivematerialpassesby.
Notes:

Pinassignment

Pin
1(2)yellow(grey)Outputsignal
2(1)black(grey/brown)Sensorground
–Thersthalfwavemustbepositive,otherwiseafaultisentered:SPN3752 –InD2840/42andD2848seriesVengines,thesensorismountedinthehousingof
high-pressurepumpCP9V4
–InthecaseofD2876seriesengines,thesensorwithcableisused
Cablecolour
Function
ControlunitA435pin
A72
A54
T186thedition53
Page 56
DEVICEDESCRIPTION

Oilpressuresensor(B104)

Theoilpressuresensorprotectstheengine.Itmonitorstheoilpressure.Thepressuremeasuringrangeis from0bar(0.5V)to6bar(4.5V).
Sensorcurve

Pinassignment

PinLinenumberFunction
160156
260135
360134
4
———
Supplyvoltage5V
Sensorground
Outputsignal
ControlunitA435pin
A24
A38
A21
54T186thedition
Page 57
DEVICEDESCRIPTION

Fuelpressuresensor(B377)

Thefuelpressuresensormonitorsthefuelpressureatthepumpfeed(low-pressureside).Thepressure measuringrangeisfrom0bar(0.5V)to15bar(4.5V).
Note:ThesensorwasnotinitiallyinstalledinD08seriesengines.
Sensorcurve

Pinassignment

PinLinenumberFunction
160155
260158
360137
4
———
Supplyvoltage5V
Sensorground
Outputsignal
ControlunitA435pin
A40
A37
A20
T186thedition55
Page 58
DEVICEDESCRIPTION

Kavlicocharge-pressuresensor(B125)

Thecharge-pressuresensormeasurestheabsolutechargepressure.Thesensorelementandanelectronic controlunit(forsignalamplicationandtemperaturecompensation)areintegratedonasiliconchip.The activesurfaceofthesiliconchipisexposedtoareferencevacuum.Theintakemanifoldpressureisforwarded viaadischargestubtotherearofthediaphragmwhichisresistanttothemeasuringmedium.
Thecharge-pressuresensorismountedontheintakemanifold.Ifthecharge-pressuresensorisclassied asdefective(SPN102),adefaultvalueisspecied,i.e.anintactsensorissimulated.Therearetherefore nooperatingrestrictions.
Sensorcurve

Pinassignment

Pin
2(3)
3(2)
Cablecolour
1
——
green
red60159
LinenumberFunction
60141
Notused
Sensorground
Supplyvoltage5V
ControlunitA435pin
—
A62
A25
4(1)
black60102
56T186thedition
Outputsignal
A81
Page 59
DEVICEDESCRIPTION

BoschLDF6charge-pressuresensor(B125)

TheBoschLDF6charge-pressuresensorhasbeen/willbeintroducedforallmodelseries.TheKavlico sensorwillcontinuetobettedasstandardfordiscontinuedenginedesigns.
OperationandthesensorcurveareexactlythesameasfortheKavlicosensor.
Sensorcurve

Pinassignment

PinLinenumberFunction
160141
2
—
360159
460102
Sensorground
Notused
Supplyvoltage5V
Outputsignal
ControlunitA435pin
A62
—
A25
A81
T186thedition57
Page 60
DEVICEDESCRIPTION

BoschLDF6Tcharge-pressuresensor(B623,B694)

TheBoschLDF6Tcharge-pressuresensorisusedinD08andD20/D26seriesEuro4/5engines.TheLDF6T charge-pressuresensorisalsoequippedwithatemperaturesensor.T ogetherwiththechargeairtemperature sensor(B123),itspurposeistomonitorEGR.TheLDF6TisttedupstreamoftheEGRinletlinewhilstthe chargeairtemperaturesensoristteddownstreamoftheinletline.Thedifferenttemperaturesofthetwo sensorsenablestheplausibilityoftheEGRratetobechecked.
InthecaseofD20/D26engineswhichmeettherequirementsoftheEuro5emissionstandardwithoutMAN AdBlue
®
system,afurtherchargeair/temperaturesensor(B694)isinstalledtomonitorthelow-temperature
circuit.
IftheMANAdBlue
®
systemistted,theLDF6Tpressureandtemperatureinformationisusedtocalculate
theair-massow.Thechargeairtemperaturesensor(B123)isnotttedinthesesystems.

Measuredvalues

Temperaturein°C
120100806040200–20–40
Resistanceinohms1121863225951175250058961546245313
Voltageinvolts0.6430.9821.4802.1702.9803.7404.3004.6134.754

Pinassignment,B623

PinLinenumberFunction
160141
290121
360159
460102
Sensorground
Outputsignal,temperature
Supplyvoltage5V
Outputsignal,chargepressure
ControlunitA435pin
A62
A70
A25
A81

Pinassignment,B694

PinLinenumberFunction
160188
260187
360189
460190
Sensorground
Outputsignal,temperature
Supplyvoltage5V
Outputsignal,chargepressure
ControlunitA435pin
TheconnectorpatternandsensorcurveforchargepressureareidenticaltotheLDF6sensor(B125)
58T186thedition
B20
B10
B28
B18
Page 61
DEVICEDESCRIPTION

Chargeairtemperaturesensor(B123)

Thechargeairtemperaturesensormonitorstheexhaustgasrecirculationtogetherwiththechargeair temperaturesensorLDF6T(B623).TheLDF6TisttedupstreamoftheEGRinletlinewhilstthecharge airtemperaturesensor(B123)istteddownstreamoftheinletline.Thedifferenttemperaturesofthetwo sensorsenablestheplausibilityoftheEGRratetobechecked.
IfMANAdBlue
®
systemistted,thechargeairtemperaturesensorB123isnotinstalled.

Measuredvalues

Temperaturein°C
120100806040200–20–40
Resistanceinohms1121863225951175250058961546245313
Voltageinvolts0.6430.9821.4802.1702.9803.7404.3004.6134.754

Pinassignment

PinLinenumberFunction
160151
2
—
360100
4
—
Outputsignal
Notused
Sensorground
Notused
ControlunitA435pin
A76
—
A57
—
T186thedition59
Page 62
DEVICEDESCRIPTION

Coolanttemperaturesensor(B124,B1049)

ThecoolanttemperaturesensorB124providesthecontrolunitwithinformationaboutthecoolanttemperature. Thecontrolunitcallsupvariousengineoperatingmaps,dependingonthecoolanttemperature.
InthecaseofD20/D26engineswhichmeettherequirementsoftheEuro5emissionstandardwithoutMAN AdBlue
®
system,afurthercoolanttemperaturesensor(B1049)isinstalledtomonitorthelow-temperature
circuit.

Measuredvalues

Temperaturein°C
120100806040200–20–40
Resistanceinohms1121863225951175250058961546245313
Voltageinvolts0.6430.9821.4802.1702.9803.7404.3004.6134.754

Pinassignment,B124

PinLinenumberFunction
160131
2
—
360101
4
—
Outputsignal
Notused
Sensorground
Notused
ControlunitA435pin
A77
—
A58
—

Pinassignment,B1049

PinLinenumberFunction
160191
Outputsignal
ControlunitA435pin
A65
2
360192
4
—
Sensorground
—
60T186thedition
Notused
Notused
—
A84
—
Page 63
DEVICEDESCRIPTION

Exhaustgastemperaturesensor(B561,B633)

ThetemperaturesensorB561monitorstheexhaustgastemperatureupstreamofthePMcatalyticconverter (EGRsystem).ThetemperaturesensorB633monitorstheexhaustgastemperatureupstreamofthecatalytic converter(MANAdBlue
®
system).Thesensorsareidentical.Dependingontheengine(LF ,LOH,LUH),the
straightversionofthetemperaturesensorB561mayalsobetted.
Note:InD08seriesengineswithOBDstage1,thetemperaturesensorB561isomittedfollowingthe introductionofthesoftwareversionP362V25.However,inthecaseofOBDStage1withNOxmonitoring measurement,thesensorfordewpointdetectionand,therefore,foractivatingtheoxygensensor,hasbeen re-introduced.
Dewpointdetection:Duringnormaloperation,theoxygensensor'soperatingtemperatureis780°C.After theengineisstarted,thereisariskoftheoxygensensorceramicbeingdamagedordestroyedbycondensing water.Toensurethatnofurtherdropletsform,theamountofheatgenerated(functionofexhaustgasmass owrateandtemperature)isdetermined.Oxygensensorheatingisenableddependingontheamountof heatgenerated.

Measuredvalues

Temperaturein°C
025200400600800
Resistanceinohms200220352494627751

Pinassignment

PinLinenumberFunction
1
2
90122/90115Outputsignal
90119/90116Sensorground
ControlunitA435pin
B33
B26
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DEVICEDESCRIPTION

Exhaustgastemperaturesensor(B561,B634)

ThetemperaturesensorB561monitorstheexhaustgastemperatureupstreamofthePMcatalyticconverter (EGRsystem).ThetemperaturesensorB634monitorstheexhaustgastemperaturedownstreamofthe catalyticconverter(MANAdBlue
®
system).Thesensorsareidentical.Dependingontheengine(LF ,LOH,
LUH),theangledversionofthetemperaturesensorB561mayalsobetted.
Note:InD08seriesengineswithOBDstage1,thetemperaturesensorB561isomittedfollowingthe introductionofthesoftwareversionP362V25.However,inthecaseofOBDStage1withNOxmonitoring measurement,thesensorfordewpointdetectionand,therefore,foractivatingtheoxygensensor,hasbeen re-introduced.
Dewpointdetection:Duringnormaloperation,theoxygensensor'soperatingtemperatureis780°C.After theengineisstarted,thereisariskoftheoxygensensorceramicbeingdamagedordestroyedbycondensing water.Toensurethatnofurtherdropletsform,theamountofheatgenerated(functionofexhaustgasmass owrateandtemperature)isdetermined.Oxygensensorheatingisenableddependingontheamountof heatgenerated.

Measuredvalues

Temperaturein°C
025200400600800
Resistanceinohms200220352494627751

Pinassignment,B561

PinLinenumberFunction
1(2)
2(1)
90122
90119
Outputsignal
Sensorground
ControlunitA435pin
B33
B26

Pinassignment,B634

PinLinenumberFunction
1(2)
2(1)
90117
90118
Sensorground
Outputsignal
ControlunitA808pin
22
23
62T186thedition
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DEVICEDESCRIPTION
AdBlue
ThesensormonitorsthelllevelandthetemperatureintheAdBlue
®
lllevel/temperaturesensor(B628)
®
tank.Thelllevelisdeterminedbased onanultrasonicmeasurementprocess(i.e.bymeansofacousticwaves).AnNTCthermistorisusedto determinethetemperature.ThesensorcommunicateswiththeAdBlue
®
dosingcontrolunitDCU15viaCAN
bus.

Pinassignment

PinLinenumberFunction
1
2
195/90008Supply,sensor(term.15)
196/3100Ground
Earthingpoint,cabX1644
Connection
FuseF894
3191
ExhaustgasCANHigh
EDCcontrolunitA435pinA27
(jumperedwithpin5)
4192
ExhaustgasCANLow
EDCcontrolunitA435pinA45
(jumperedwithpin6)
5
191
ExhaustgasCANHigh
AdBluecontrolunitA808,pin8
(jumperedwithpin3)
6192
ExhaustgasCANLow
AdBluecontrolunitA808,pin7
(jumperedwithpin4)
Note:inthecaseofEDC7C32Master/Slave,theexhaustCANisonpinB25(line191)andpinB32(line
192)oftheMastercontrolunitA435.
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DEVICEDESCRIPTION

NOxsensor(B994)

InengineswithMANAdBlue
®
system,theNOxsensormeasuresthenitrogenoxideconcentrationandthe
oxygencontentintheexhaustgasstream.
TheoperatingprincipleoftheNOxsensorisbasedonthedecompositionofnitrogenoxidebymeansofa catalyticallyactiveelectrode.
Themeasurementoftheoxygenproducedhereisknownfromthelinearoxygensensor.Thelayoutofthe multi-layerZirconiumdioxidesensorceramic(ZrO
)includestwochambers:Intherstchamber,theoxygen
2
containedintheexhaustgasisreducedorincreasedtoaconstantpartialpressureofseveral10ppmby applyingapumpcurrent.Thenecessarycurrentisproportionaltotheairratioreciprocalvalue.Inthesecond chamber,theNOxreductiontakesplaceatthemeasuringelectrode.Thecurrentrequiredforkeepingthe electrodeareafreeofoxygenisproportionaltothenitrogenoxideconcentrationandformsthemeasuring signal.
Thesensorelectronicsprovidethemeasuredgasconcentrationsforothercontrolunitsviatheexhaustgas CAN.ThemeasuredvaluesareevaluatedintheAdBlue
®
dosingcontrolunit.TheNOxsensorisequipped withanelectricalheatingelementthatisactivatedwhentheignitionisswitchedon.Anyrequestsforswitching theheatingelementonoroffaresentbytheAdBlue
®
dosingcontrolunitviatheexhaustgasCAN.

Pinassignment

PinLinenumberFunction
1
2
195/90008Supply+U
196/31000Sensorground
bat
Connection
FuseF894(term.15)
Earthingpoint,cab,
nexttocentralelectrical
systemX1644
3192
4191
5
—
ExhaustgasCANLowEDCcontrolunitA435pinA45
ExhaustgasCANHighEDCcontrolunitA435pinA27
Notused
—
Note:inthecaseofEDC7C32Master/Slave,theexhaustCANisonpinB25(line191)andpinB32(line
192)oftheMastercontrolunitA435.
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DEVICEDESCRIPTION

Oxygensensor(B322)

Theoxygensensorisusedinengineswithexternallycooledexhaustgasrecirculation,asanalternative methodtomeasuringbymeansofNOxsensor.Thebasisofthismonitoringconceptforengineswithexhaust gasrecirculationistheprimarydependenceoftheNOxemissionsontheoxygencontentandthecharge mass(airmassandmassoftherecirculatedexhaustgas)inthecylinderatstationaryoperatingpoints.
Theoxygensensormeasuresthedifferenceinoxygenconcentrationbetweentheambientairandtheexhaust gasstream.Thismeansthatthemeasuringsignalemittedbythesensorisadirectindicatoroftheairratioin theexhaustgas.Heatingofthesensorevenallowsanalysisoftheairratioforexhaustgastemperaturesof around150°C.TheLSU4.9oxygensensorusedhereisabroadbandsensor,i.e.,itispossibletomeasure innitelyvariablelambdavaluesbetweenλ=0.65andair.Thisispossiblebecauseapracticallylinear“pump current”servesasavariableforthecontrolunit.Thebroadbandsensorhastwocells:onepumpcelland onesensorcell(Nernstconcentrationcell).Thepumpcurrentisusedtopumpinasmanyoxygenionsas requireduntilthereisavoltagevalueof450mVbetweentheelectrodesinthereferenceairductandinthe measuringcell.Thepumpcurrentisthevariableforthelambdavalue.Therefore,acorrespondingevaluation circuitisabletousetheoxygensensorformonitoringtheEGRrate.TheEGRratehasadirecteffectonthe NOxvalues(aninsufcientEGRrateleadstoanexcessiveNOxconcentrationandSPN3930isset).

Pinassignment

Pin
Linenumber/
Function
ControlunitA435pin
linecolour
1
2
3
4
5
6
60183/red
60185/yellow
60396/whiteActivation,heatercycle,sensorheating(–)
60397/greySupply ,sensorheating(+U
60184/greenTrimmingresistor(trimcurrent)
60186/black
PumpcurrentB24
VirtualgroundB23
)
bat
NernstvoltageB30
B08
B05
B31
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DEVICEDESCRIPTION

Exhaustgasdifferentialpressuresensor(B565)

Theexhaustgasdifferentialpressuresensormonitorsthepressuredrop(differentialpressure)overthetwo connectingpointsonthemeasurementsectioninthecaseofvehicleswithCRTlter.Comparedtothe exhaustgasrelativepressure,thedifferentialpressureisabetterindicatorofthepressuredrop,asthe varyingambientpressureisdiscounted.
Note:InthecaseofvehicleswithPMcatalyticconverter,theexhaustgasdifferentialpressuresensorwas temporarilyusedasaback-upsolutioninthecongurationofarelativepressuresensorinplaceoftheexhaust gasrelativepressuresensor.

Measuredvalues

PressureinkPa0.05.010152030405065
Voltageinvolts0.500.901.301.702.102.903.704.504.50

Pinassignment

PinLinenumberFunction
190126
290127
390128
Supplyvoltage5V
Sensorground
Outputsignal
ControlunitA435pin
A41
A59
A78
66T186thedition
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DEVICEDESCRIPTION

Exhaustgasrelativepressuresensor(B683)

Theexhaustgasrelativepressuresensorhasthesameelectricalinterfaceastheexhaustgasdifferential pressuresensor.However,itonlymeasurestherelativepressureoftheexhaustgas,i.e.thepressure currentlyexistingagainstatmosphericpressure.Thedifferentialpressuresensor,ontheotherhand,shows thepressuredropoverthetwoconnectingpointsonthemeasurementsection(ltersystemorcatalytic convertersystem).Theexhaustgasrelativepressuresensorreplacestheexhaustgasdifferentialpressure sensor(exceptCRTlter).

Measuredvalues

PressureinkPa0.05.010152030405065
Voltageinvolts0.500.901.301.702.102.903.704.504.50

Pinassignment

PinLinenumberFunction
190126
290127
390128
Supplyvoltage5V
Sensorground
Outputsignal
ControlunitA435pin
A41
A59
A78
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DEVICEDESCRIPTION

Turbochargerpulsevalve(Y340,Y493)

Thepulsevalvesforturbocharger1(Y340)andturbocharger2(Y493)areactivatedbytheEDCcontrolunit bymeansofPWMoutput(pulsewidthmodulatedsignal).inlinewiththesesignals,thepulsevalveconcerned variesthepressureattheturbochargerwastegatecapsuleand,therefore,thepositionofthewastegateap, i.e.thechargepressure.ThePWMsignallimitvaluesarebetween0%correspondingtomaximumopened wastegate(minimumchargepressure)and100%,i.e.wastegateclosed(maximumchargepressure).
D08seriesengineswith2-stageturbochargingonlyhaveonepulsevalve(Y340)installedtocontrolthe chargepressureatthehigh-pressurecompressorbymeansofwastegate.SeriesD20/D26engineswhich meettherequirementsoftheEuro5emissionstandardwithoutMANAdBlue
®
system(in-engineEGR)use 2-stageturbochargingwithintercooling.Hereafurtherpulsevalve(Y493)isinstalledforchargepressure controlatthelow-pressurecompressorbymeansofwastegate.Thiswastegateisneededtooperatethe low-pressurestageintheoptimumefciencyrangeintheeventofhighexhaustgasmassowrates.
Inthe2-stagesuperchargingsystem,theexhaustgasrstowsthroughasmallturbocharger(high-pressure stage)andthenthroughalargerturbocharger(low-pressurestage).Thehigh-pressurestageallowsahigh chargepressuretobuildup,evenatlowrevs,meaningthatthehighamountofairrequiredforlow-particulate combustionisachieved.Theintercoolingisrequiredtolimitthechargeairtemperaturesduringcompression andthuspreventcoking(carbondeposits)ofthecompressorwheelandthecompressorhousing.The intercoolingalsoincreasesthehigh-pressurecompressor'sefciency.

Pinassignment,Y430

PinLinenumberFunction
1(+)
2(–)
60383Activation+A04
60384Activation–A02
ControlunitA435pin

Pinassignment,Y493

PinLinenumberFunction
1(+)
2(–)
60398Activation+B04
60399Activation–B13
ControlunitA435pin
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DEVICEDESCRIPTION

Exhaustgasrecirculation(EGR)controller(Y280)

Inthecaseofcooledexternalexhaustgasrecirculation,asmallpartbranchesofffromthemainexhaustgas owandowsthroughaspecialheatexchanger.Thenowcooledexhaustgasismixedwiththefreshairin theintaketractviaavalvesystemontheenginefrontside.Thecombustiontemperaturethereforeremains lower.Lessnitrogenoxide(NO
)isproduced.TheEGRcontrollerisactivatedbytheEDCcontrolunit.EGR
X
isdeactivatedundercertaintemperatureconditions,rstlytopreventthecondensationofsulphurousacidsat lowchargeairtemperaturesandsecondlytopreventexcessiveheatingofthechargeairbytherecirculated exhaustgas.TheEGRcontrollerhasabuilt-indry-reedcontactwhichmonitorstheEGRapposition,to detectwhethertheEGRapisopenorclosed.
Theexhaustgasrecirculationcontroller(EGRcontroller)consistsofthefollowingcomponents:
–Compressedaircylinderforactuatingtheexhaustgasrecirculationap –Solenoidvalveforactivatingthecylinder –Dry-reedcontactforpistonpositionfeedback Note:Intherestposition(pistonretracted),thedry-reedcontactisclosed.Pleaseobservethedifferent
representationonthewiringdiagrams.

Pinassignment

Pin
1(4)
2(3)
3(2)
4(1)
Cablecolour
grey
black60367Activation+A17
white60031Feedback+A23
yellow60153FeedbackA22
LinenumberFunction
ControlunitA435pin
60340Activation–A11
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DEVICEDESCRIPTION
Position-controlledEGRcontroller(E-EGR)withtravelsensor(B673)
Inthecaseofposition-controlledexhaustgasrecirculation,thepneumaticEGRpositioningcylinder(E-EGR) variesthepositionoftheEGRapinnitely.Thismeansthattheamountofrecirculatedexhaustgascan bemeteredasrequired,dependingontheengineoperatingstate.Thisresultsinextremelylowpollutant emissionsacrosstheentireengineoperatingrange.Fuelconsumptioncanbefurtherreduced,especially duringdynamicengineoperation.TheEGRappositionismonitoredbythetravelsensormountedonthe positioningcylinder(B673).

Pinassignment

PinLinenumberFunction
1(4)
2(3)
3(2)
4(1)
60182
60181
60180
—
Ground,positionsensor
Outputsignal
Supplyvoltage5V
Notused
ControlunitA435pin
A39
A87
A32
—
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DEVICEDESCRIPTION

ProportionalvalveE-EGR(Y458)

Theproportionalvalve(Y458)controlstheposition-controlledEGRcontroller(E-EGR).Theoperatingmedium isairataminimumoperatingpressureofabout7bar.AdutyfactorparameterisspeciedbytheEDCcontrol unitasanactivationsignal.

Pinassignment

PinLinenumberFunction
160392
Ground
ControlunitA435pin
260393ProportionalvalveactivationA11
A17
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DEVICEDESCRIPTION

Compressedairshut-offvalve(Y460)

Thecompressedairshut-offvalve(Y460)suppliestheE-EGR,EVBecandPritardersystemswithcompressed air,whiletheengineisrunningandisclosedwhende-energised.Thispreventsapressurelosswhenthe engineisstopped.
ThevalveismountedontheengineandcontrolledbytheEDCcontrolunit.
Dependingonthevehicle,activationcanalsobeviaaseparaterelaythatisactivatedwhentheengineis running(term.D+)andswitchesthroughterm.15.Thisvalveismountedonthesolenoidvalveblockonthe framecrossmember.

Pinassignment

PinLinenumberFunction
160395
Pressureshut-offvalveactivation
260394
Ground
ControlunitA435pin
B06
B02
72T186thedition
1Connection,reservoirline 2Notused 3Connection,PriT arder 4Connection,EVBec 5Connection,E-AGR
Page 75
DEVICEDESCRIPTION

Shut-off/pressure-reducingvalve,LTcooler(Y496)

Thecombinedshut-offandpressure-reducingvalvepreventsenginecoolingduringcoldoperationbyshutting offandlimitsthepressure(max.2bar)forthelow-temperaturecoolantradiator(LTcooler).
TheLTcoolerandthefanareusedforrecoolingtheenginecoolantandthelow-temperaturewaterforindirect coolingofthechargeair,takingaccountoftheconditionsduetotheEuro5emissionstandard.

Pinassignment

PinLinenumberFunction
160400ActivationA06
260401
Ground
ControlunitA435pin
A05
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DEVICEDESCRIPTION

COMPONENTDESCRIPTION/INSTALLATIONPOSITIONS

ControlunitEDC7(A435,A570)

Description
ThemaintaskoftheEDCcontrolunitistocontrolthecorrectinjectionoffuelandtoadaptthiscontrolto thedifferentoperatingconditionsandthereforetocontroltheengineoutputandemissions.Thecontrolunit (software/hardware)canbeusedforamaximumofsixcylinders.Asecondcontrolunitisthereforerequired foroperatinganenginewithmorethansixcylinders.ThetwocontrolunitscommunicateviaCANandoperate in“Master/Slave”mode.
Installationposition
Thecontrolunitismountedonthesideoftheengineblockinin-lineengines.Thispictureshowsaninstallation exampleonaD20engine.
D2840V10engine
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DEVICEDESCRIPTION
Thecontrolunitsarelocatedonacarriedbehindthecab.Thispictureshowstheinstallationpositionswith thecabtilted.
1Mastercontrolunit(right,asseenlookingindirectionoftravel) 2Slavecontrolunit(left,asseenlookingindirectionoftravel)
D2868V8engine
Thecontrolunitsareattachedtotheengineunderacover.
1Slavecontrolunit(left,asseenlookingindirectionoftravel) 2Mastercontrolunit(right,asseenlookingindirectionoftravel)
T186thedition75
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DEVICEDESCRIPTION

CP3.4high-pressurepump

Description
TheCP3.4high-pressurepumpisaradialpistonpumpwith3cylinders.Thispumpisusedinthecaseof D08,D20,D26andD28in-lineenginesaswellasD2868V8engines.
Installationposition
D08engine
Thehigh-pressurepumpisdrivenbytheengineandismountedinthesamepositionontheengineasa conventionalinjectionpump.
D28in-lineengine
Thehigh-pressurepumpisdrivenbytheengineandismountedinthesamepositionontheengineasa conventionalinjectionpump.
76T186thedition
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DEVICEDESCRIPTION
D20/D26engine
TheD20/26engineisanewdesignwithoverheadcamshaft.Thehigh-pressurepumpisdrivenbyspur gears.Thesamespurgeardrivealsodrivesthealternator,thewaterpumpand,iftted,theair-conditioning compressoronthefrontsideoftheenginebymeansofapulley.
D2868V8engine
Thehigh-pressurepumpislocatedbelowtheaircompressorandcanonlybeaccessedaftertheair compressorhasbeenremoved.
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DEVICEDESCRIPTION

CP9V4high-pressurepump

Description
TheCP9V4high-pressurepumpisanin-linepistonpumpwith4cylinders.Thispumpisusedinthecaseof D2840seriesengines(V10engines).
Installationposition
Thehigh-pressurepumpisdrivenbytheengineandismountedinthesamepositionontheengineasa conventionalinjectionpump.
78T186thedition
Page 81

Meteringunit(MProp)(Y332,Y356)

Description
Themeteringunit(MProp)isanactuatorforcontrollingthefuelpressureinthehigh-pressureaccumulator (rail).
Installationposition
DEVICEDESCRIPTION
CP3.4high-pressurepump
Themeteringunitislocatedonthelow-pressuresideofthehigh-pressurepumpandisscrewedintothe high-pressurepumphousing.
CP9V4high-pressurepump
TheCP9V4high-pressurepumpfortheV10engineisequippedwithtwometeringunitsastwohigh-pressure accumulatorsarecontrolledinthiscase(onehigh-pressureaccumulatorperbankofcylinders).
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DEVICEDESCRIPTION

High-pressureaccumulator(rail)

Description
Thename“commonrail”isderivedfromthedesignandfunctioningofthehigh-pressureaccumulator.The fuelisinjectedintotheindividualcylindersviathiscommonaccumulatorwhichisalsoafueldistributoror distributorrail.Herethefuelisconstantlyunderhighpressureandonlyneedstobedrawnattherighttime.
Installationposition
D08,D20andD28in-lineengine
D2840V10engine
D2840seriesengines(V10engines)havetwohigh-pressureaccumulatorstted(oneforeachbankof cylinders).
80T186thedition
Page 83
DEVICEDESCRIPTION
D2868V8engine
D2868seriesengines(V8engines)havetwohigh-pressureaccumulatorstted(oneforeachbankof cylinders).
T186thedition81
Page 84
DEVICEDESCRIPTION

Pressurelimitingvalve

Description
Thepressurelimitingvalvelimitsthepressureintherail.Ifthepressureistoohigh,ituncoversadischarge hole.Thepressurelimitingvalvefunctionsasapressurereliefvalve.
Installationposition
Thepressurelimitingvalveismountedonthehigh-pressureaccumulator(rail).Thispictureshowsan installationexampleonaD08engine.
Note:Aspartoffurthertechnicaldevelopment,thepressurelimitingvalvehasbeenintegratedinthe high-pressureaccumulatortoformanintegratedunitwiththerail.ThePLVhasthesamefunctionasthe previouspartandcanbereplacedasbefore.
82T186thedition
Page 85

Rail-pressuresensor(B487,B514)

Description
Therail-pressuresensormonitorsthefuelpressureinthehigh-pressureaccumulator(rail).Twohigh-pressure accumulators(onepercylinderbank)areinstalledinVengines.Thereforetherearealsotworail-pressure sensors.
DEVICEDESCRIPTION
Installationposition
Therail-pressuresensorismountedonthehigh-pressureaccumulator(rail).Thispictureshowsaninstallation exampleonaD08engine.
T186thedition83
Page 86
DEVICEDESCRIPTION

Injector(Y341-Y350)

Description
Theinjectorisusedtoinjectfuelintothecombustionchamber.TheEDC7controlunitspeciestheinjection quantityandtheinjectionpointandactivatesanextremelyfastsolenoidintheinjector.Thesolenoidopens thevalveandthefuelisinjectedintothecombustionchamberusingthepressureinthehigh-pressure accumulator.
Installationposition
Theinjectorsarelocatedatthesamepositionastheconventionalinjectorsinthecylinderhead.Thispicture showsaninstallationexampleonaD28engine.
84T186thedition
Page 87
DEVICEDESCRIPTION

Crankshaftspeedsensor(speedincrementsensor)(B488)

Description
Thespeedincrementsensorrecordstheenginecrankshaftspeedandforwardsthisinformationtothecontrol unitintheformofaninducedvoltage.
Installationposition
Thespeedincrementsensorismountedontheywheelhousing.Thispictureshowsaninstallationexample onaD08engine.
T186thedition85
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DEVICEDESCRIPTION

Camshaftspeedsensor(speedsegmentsensor)(B489)

Description
Thespeedsegmentsensorrecordstheenginecamshaftspeedandforwardsthisinformationtothecontrol unitintheformofaninducedvoltage.
Installationposition
D08engine
Thespeedsegmentsensorismountedontheendoftheengineonthecamshaftdrive.
D20engine
Thespeedsegmentsensorismountedatthecylinderheadinthecamshaftdrivearea.
86T186thedition
Page 89
D28in-lineengine
Thespeedsegmentsensorislocatedabovethehigh-pressurepump.
D28V10engine
DEVICEDESCRIPTION
Thespeedsegmentsensorismountedinthehigh-pressurepumphousing.
T186thedition87
Page 90
DEVICEDESCRIPTION

Oilpressuresensor(B104)

Description
Theoilpressuresensorprotectstheengine.Itmonitorstheoilpressure.
Installationposition
Theoilpressuresensorismountedontheoillter.ThispictureshowsaninstallationexampleonaD08 engine.
88T186thedition
Page 91
DEVICEDESCRIPTION

Fuelpressuresensor(B377)

Description
Thefuelpressuresensormonitorsthefuelpressureatthepumpfeed(low-pressureside).Thesensorwas notinstalledintherstD08seriesengines.
Installationposition
Thefuelpressuresensorismountedonthefuelservicecentre.Thispictureshowsaninstallationexample onaD20engine.
D2840V10engine
Thefuelpressuresensorismountedononeofthefuelservicecentres.Thefuelservicecentresaremounted onthecarrierbehindthecab.
T186thedition89
Page 92
DEVICEDESCRIPTION
D2868V8engine
Thefuelpressuresensorismountedonthefuellter.
90T186thedition
Page 93

Kavlicocharge-pressuresensor(B125)

Description
Thecharge-pressuresensormeasurestheabsolutechargepressure.
Installationposition
DEVICEDESCRIPTION
Thecharge-pressuresensorismountedontheintakemanifold.Thispictureshowsaninstallationexample onaD28engine.
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DEVICEDESCRIPTION

BoschLDF6,LDF6Tcharge-pressuresensor(B125,B623,B694)

Description
TheLDF6charge-pressuresensormeasurestheabsolutechargepressure.
AtemperaturesensorisalsointegratedintheLDF6Tcharge-pressuresensor.T ogetherwiththechargeair temperaturesensor(B123),itspurposeistomonitorEGRintheEuro4engines.InthecaseofD20/D26 engineswhichmeettherequirementsoftheEuro5emissionstandardwithoutMANAdBlue
®
system,afurther
chargeair/temperaturesensor(B694)isinstalledtomonitorthelow-temperaturecircuit.
Installationposition
Thecharge-pressuresensorismountedontheintakemanifold.Thispictureshowsaninstallationexample onaD20engine.
92T186thedition
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DEVICEDESCRIPTION

Chargeairtemperaturesensor(B123)

Description
Thechargeairtemperaturesensormonitorstheexhaustgasrecirculationtogetherwiththechargeair temperaturesensorLDF6T(B623).
Installationposition
D08engine
Thechargeairtemperaturesensorismountedontheintakemanifold.
D20engine
Thechargeairtemperaturesensorismountedontheintakemanifold.
T186thedition93
Page 96
DEVICEDESCRIPTION
D28in-lineengine
Thechargeairtemperaturesensorismountedontheintakemanifold.
D28V10engine
Thechargeairtemperaturesensorismountedontheintakemanifold.
94T186thedition
Page 97
DEVICEDESCRIPTION

Coolanttemperaturesensor(B124,B1049)

Description
Thecoolanttemperaturesensorprovidesthecontrolunitwithinformationaboutthecoolanttemperature. Thecontrolunitcallsupvariousengineoperatingmaps,dependingonthecoolanttemperature.Inthecase ofD20/D26engineswhichmeettherequirementsoftheEuro5emissionstandardwithoutMANAdBlue system,afurthercoolanttemperaturesensor(B1049)isinstalledtomonitorthelow-temperaturecircuit.
®
Installationposition
D08engine
ThecoolanttemperaturesensorislocatedinthecoolantcircuitinthecaseofD08engineswithoutEGR.This pictureshowsaninstallationexampleonaD08enginewithEGR.Herethetemperaturesensorisscrewed intotheEGRmodulewhichdoublesupasawaterdistributor.
D20engine
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DEVICEDESCRIPTION
Thecoolanttemperaturesensorislocatedinthecoolingcircuit.
D28in-lineengine
Thecoolanttemperaturesensorislocatedinthecoolingcircuit.
D28V10engine
Thecoolanttemperaturesensorislocatedinthecoolingcircuit.
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DEVICEDESCRIPTION

Exhaustgastemperaturesensor(B561,B633)

Description
ThetemperaturesensorB561monitorstheexhaustgastemperatureupstreamofthePMcatalyticconverter (EGRsystem).ThetemperaturesensorB633monitorstheexhaustgastemperatureupstreamofthecatalytic converter(MANAdBlue®system).Thesensorsareidentical.Dependingontheengine(LF ,LOH,LUH),the straightversionofthetemperaturesensorB561mayalsobetted.
Note:SeriesD08engineswithOBDStage1donothavethetemperaturesensorB561tted.However,itis installedagainforOBDStage1withNOxmonitoringmeasurement.
Installationposition
ThetemperaturesensorB633ismountedontheAdBluemixerupstreamofthecatalyticconverter.
TemperaturesensorB561ismountedupstreamofthePMcatalyticconverter.Thisillustrationshowsasample installationonabuschassis(HOC).
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DEVICEDESCRIPTION

Exhaustgastemperaturesensor(B561,B634)

Description
ThetemperaturesensorB561monitorstheexhaustgastemperatureupstreamofthePMcatalyticconverter (EGRsystem).ThetemperaturesensorB634monitorstheexhaustgastemperaturedownstreamofthe catalyticconverter(MANAdBlue®system).Thesensorsareidentical.Dependingontheengine(LF,LOH, LUH),theangledversionofthetemperaturesensorB561mayalsobetted.
Note:SeriesD08engineswithOBDStage1donothavethetemperaturesensorB561tted.However,itis installedagainforOBDStage1withNOxmonitoringmeasurement.
Installationposition
ThetemperaturesensorB634ismountedintheexhaustsilencertailpipedownstreamofthecatalytic converter.
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