MAN EDC MS5 User Manual
Foreword
Dear Customer
These instructions are intended to help you to repair the electronic Diesel control system properly.
In writing these instructions, we have assumed that you have the necessary knowledge of control systems
for working on and with the electronic diesel control.
Important instructions which concern technical safety and protection of persons are emphasised as shown
below.
Caution:
This refers to working and operating procedures which must be complied with in order to prevent
damage to or destruction of material.
Note:
Explanations useful for understanding the working or operating procedure to be performed.
Best regards
MAN Nutzfahrzeuge Aktiengesellschaft
Nuremberg Plant
Since our products are in continuous development, we reserve the right to make technical modifications.
2003 MAN Nutzfahrzeuge Aktiengesellschaft
Reprint, duplication or translation, as a whole or in part without the written approval of MAN is prohibited.
MAN reserves all rights accorded by the relevant laws on copyright.
MTDA Technical status: 09.2002 51.99598-8112
1
Contents
Foreword 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety information 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Diesel Control 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System description 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component description 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control unit plug connector 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MS 5 injection pump 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MS 5 Electromagnetic fuel volume regulator 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control-slider adjusting mechanism 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistor bank 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Redundant cut-out device Safety relay 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive stage selection 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge-air, coolant and fuel temperature sensors 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge-air pressure sensor (51.27421-0181) 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RPM sensor 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injector and needle movement sensor 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes on operation 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Self-diagnosis 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check-list 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting chart 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting program 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plug connections 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EDC diagnostic tools 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAN-Cats Diagnostics System 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAN-Cats - Software Description 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rating data sheet 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EDC-Connection diagram 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Diesel Control -Description of inputs and outputs 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Diesel Control -Guidelines for Preparing Wiring Harnesses 119 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plug connections 129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes on design and assembly for wiring harnesses of electronic systems 131 . . . . . . . . . . . . . . . . . . . . . . .
Cable cross-section 134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine electrics 137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flamme starter 139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensores and limit-value switch 149 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection diagram 157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection diagram monitoring 158 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 159 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Safety information
ËË
General
Important safety regulations are summarized in this quick-reference overview and arranged by topic to effectively convey the knowledge necessary to avoid accidents causing injury, damage or environmental hazard.
The engine operating manual contains further information.
Important:
Should an accident occur despite all precautionary measures, particularly one involving contact with corrosive acid, penetration of fuel under the skin, scalding by hot oil, antifreeze splashing into the eyes etc. you
must seek medical assistance immediately.
1. Instructions for avoiding accidents likely to cause injury
Only authorized and qualified personnel are permitted to carry out inspection, adjustment and repair work
D Secure and chock vehicles to prevent the vehicle rolling
D Firmly secure units and assemblies on disassembly
D Only authorized personnel are permitted to start and operate the engine
D Do not stand too close to rotating parts while the engine is running
Wear close-fitting working clothes
D Do not touch a hot engine with bare hands:
Risk of burns
D Keep area surrounding engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences
D Only work with tools which are in good condition. Damaged or worn spanners and
wrenches can slip off: Risk of injury
D Persons must not stand under an engine suspended on a crane hook. Keep lifting gear
in perfect condition
D Only open coolant circuit once the engine has cooled down. Follow the instructions
given under “Care and Maintenance” in the Operating Manual exactly if it is not possible
to avoid opening the coolant circuit with the engine at operating temperature
3
Safety information
D Do not tighten or loosen pipes and hoses that are under pressure (lubricant circuit,
coolant circuit and any downstream hydraulic oil circuits): Risk of injury caused by
liquids escaping under pressure
D Do not place hands under the fuel jet when checking injection nozzles.
Do not inhale fuel mist
D Always disconnect battery when working on the electrical system
D Do not use rapid charger to start the engine. Rapid charging of batteries is only per-
mitted with the positive and negative leads disconnected!
D Disconnect batteries only with the ignition turned off
D Observe manufacturer’s instructions for handling batteries.
Caution:
Battery acid is toxic and corrosive. Battery gasses are explosive
D Only use suitable measuring instruments to measure voltages! The minimum input
resistance of a measuring instrument should be 10 MΩ
D Only disconnect or connect wiring harness connectors on electronic control units with
the ignition turned off!
Disconnect batteries and connect the positive lead to the negative lead such that they are
electrically conductive before carrying out any electric welding work. Earth the welding set
as close to the weld as possible. Do not place cables of welding set parallel to electrical
lines in the vehicle.
Refer to the “Welders Code of Practice” for further accident prevention measures.
D When carrying out repaint jobs, electronic components may be subject to high tem-
peratures (max. 95°C) for only very short periods; a period of up to approx. 2 hours is
permissible at a max. temperature of 85°C, disconnect batteries
Limitation of liability for parts and accessories
In your own interest, we strongly recommend you use only accessories and original MAN parts expressly
approved by MAN for your MAN engine. The reliability, safety and suitability of these parts and accessories
have been tested specially for MAN engines. Despite us keeping a constant eye on the market, we cannot
assess and be held responsible for these properties in other products, even if they bear TÜV (German testing and inspection institute) approval or any other official approval in any particular case.
Laying up or storage
Special measures must be implemented in accordance with MAN Company Standard M 3069 Part 3 if engines are to be laid up or placed into storage for more than 3 months.
4
Electronic Diesel Control
Electronic Diesel Control EDC
General
The requirements set by customers and legislation in respect of fuel consumption, exhaust emission and
noise characteristics etc. on Diesel engines have grown over the years and will be even more stringent in
the future.
The fact that conventional mechanical injection systems have reached their performance limits has made
electronically controlled fuel injection systems necessary.
Such systems increase engine efficiency, improve driving comfort and lessen the burden on the environment.
EDC (Electronic Diesel Control) meets these requirements.
5
System description: EDC MS5
System description
Engine
speed 1
Engine
speed 2
Charge air
temperature
Needle movement sensor
Boost
pressure
Safety relay
Power supply
Fuel temperature
Coolant
temperature
Control
unit
Intermediate engine
terminal 30
Terminal 15
PWM signal
speeds
ISO diagnosis
Diagnosis request
Idle speed setting
Diagnosis
warning lamp
CAN bus
Throttle
lever signal
The engine can be triggered
- elektrically with the 2,9 - 4,5V signal or alternatively CAN bus
The controller contains
- the linear solenoid
- the control rod position transducer
The linear solenoid is actuated by the electronic control unit.
The control unit processes information which it receives via
- the control rod position transducer
- the drive position selection
- charge-air pressure sensor
- coolant temperature sensor
- charge-air temperature sensor
- the engine rpm sensors
- the needle movement sensor
- and the fuel temperature sensor (in the injection pump).
The diagnosis request pushbutton and the EDC indicator lamp are used in detecting faults and signalling
them through a code.
An ISO interface provides a communication with the MAN-cats test and diagnostic computer.
The control unit, with its program adapted to the engine model concerned, determines the optimum setting
of the control rod from all the measured values.
To ensure the vehicle can reach the nearest workshop in the event of one or several sensors failing, an
emergency operation function is integrated in the control unit which, depending on the situation, enables
the vessel to continue on its way, albeit with restricted functions.
When the brakes are applied, the system operates as an intermediate engine speed controller with a proportional degree of 0, i.e. a set intermediate engine speed is maintained exactly provided the engine develops sufficient power output for this purpose.
6
System description
The idle speed control operates in the same way as the intermediate engine speed control. The idle speed
is exactly maintained by means of the idle speed governor as long as the engine output is sufficient for this.
The regulated idle speed can be varied within certain limits.
Starting-fuel delivery is output when either a lower start recognition speed is exceeded. The starting fuel
volume and cold idle speed are limited as a function of the coolant temperature to avoid impermissible
smoke emission and unnecessary revving of the engine after starting.
7
Component description
Control unit plug connector
Pinouts
19 1. . . . . . . . . . . . . . . . . . . . . . .
37 20. . . . . . . . . . . . . . . . . . . . . .
55 38. . . . . . . . . . . . . . . . . . . . . .
Pin assignments of control unit plug connector
EDC Pin Connection to component (O=Output, I=Input)
1 Injection pump controller pin 8 O
Jumper to pin 2 (activation of fuel volume regulator) O
2 Jumper to pin 1 (activation of fuel-delivery regulator) O
3 Control-slide mechanism
4 Control-slide mechanism
5 Not used
6 Not used
7 Not used
8 Not used
9 Injection pump controller pin 5 (control rod position sensor, instrument coil)
10 Injection pump controller pin 1 (control rod position sensor, reference coil)
11 Injection pump controller pin 6 (control rod position sensor, centre pick-off)
12 Not used
13 Negative from control unit for (Sensor ground)
- rpm sensor
- charge-air pressure sensor
- drive stage selection
- charge-air temperature sensor
- coolant temperature sensor
- resistor bank
- fuel temperature sensor
14 Safety-relay O
15 Control unit power supply battery + (via main relay and fuse) I
16 Control unit power supply battery + (via main relay and fuse) I
17 Earth for auxiliary rpm sensor and needle movement sensor
18 Power supply battery 19 Power supply battery 20 EDC indicator lamp and diagnostic lamp O
21 RPM sensor (twisted with cable pin 13) I
22 Auxiliary rpm sensor (twisted with cable pin 17) I
23 Intermediate engine speed control ZDR 1 I
24 Not used
8
Component description
EDC Pin Connection to component (O=Output, I=Input)
25 Not used
26 Not used
27 Drive stage selection (signal) I
28 Engine speed signal output from control unit (square-wave pulses) O
29 Multiplex signal O
30 CAN-L
31 CAN-H
32 Needle movement sensor (signal)
33 Charge-air pressure sensor (supply) O
34 Fuel temperature sensor I
35 Resistor bank
36 Turbo pressure sensor (signal) I
37 Not used
38 Not used
39 Empty fuel switch signal
40 External engine cut-out
41 Intermediate engine speed control ZDR 2 I
42 Not used
43 Not used
44 Resistance group I
45 Drive stage selection (supply)
46 Relay power supply batt.+ (main relay) O
47 Relay power supply n/o contact I
48 Diagnostic connection (K-link)
49 Diagnostic connection (L-link)
50 Not used
51 Resistor bank 3 kW
52 Assigned to batt.+ (to enable multiplex signal) I
53 Coolant temperature sensor I
54 Resistance group
55 Turbo air temperature sensor I
9
Component description
MS 5 injection pump
The MS 5 injection pump, also known as a “control-slide pump” has a mechanism which regulates the start
of injection by performing a “lifting / sliding” movement. The pump comprises a heavy-duty conventional
injection module, as used on the familiar P-pumps, a flange-mounted electromagnetic fuel volume regulator, in place of the mechanical regulator, and an electromagnetic regulator for the start of injection (pilot
stroke / start of delivery regulator).
The difference between this system and the familiar P-pump is primarily in the plunger.
10
Component description
MS 5 Electromagnetic fuel volume regulator
1
2
3
4
5
6
1 Actuating solenoid for start of delivery 4 Control rod position sensor
2 Control-slider adjusting shaft 5 Electrical connection
3 Control position actuating solenoid 6 Plate for blocking start of delivery
and part of the oil pressure delivery pump
The fuel volume regulator works in the same way as the familiar EDC-RE regulators which use the P-pump
(MS 5). The most important component of the fuel-delivery regulator is a linear solenoid whose armature
acts directly on the control rod thus determining the injection volume by means of the control position.
When no current is supplied, the control rod is held in the stop position by means of a spring.
The pilot feed / start of delivery regulator also contains a linear solenoid, whose armature, by means of an
adjusting lever, causes the control-slider adjusting shaft to rotate. When no current is supplied, the adjusting shaft is also held in position by a spring, so that the control-slider is in its uppermost position, in the
“late” start of delivery position.
The regulator also has a control rod position sensor and an oil pump (viscous pump).
PIN:
Designation:
4
3
5
8
2
6
1
7
Control rod position sensor
Actuating solenoid
Actuating solenoid
2
free
RWG M
RWG Y
RWG R
Q
Start of injection
MES 1
MES 0
3478561
MVS 1
MVS 0
11
Component description
Control-slider adjusting mechanism
1
2
3
4
1 Pump plunger 3 Control-slider adjusting shaft
2 Control-slider 4 Control rod
The difference between this system and the P-pump is primarily in the pumping element. The element cylinder contains a window and a control-slider which slides on the element plunger. The control-slider contains the control bore for the start and end of delivery. Because the control-slider can be height-adjusted,
the start and end of delivery can be changed.
The pump housing contains a rotating adjusting shaft with drivers which engage in a groove on the controlslider. When the shaft is rotated, the height of all the control-sliders is adjusted evenly, thereby changing
the pilot stroke and the start of delivery.
12
Component description
Resistor bank
On commercial vehicles, certain items of data are fed to the EDC which are not required for railway operation.
An example of such data is a signal from the tachograph (speedometer, tachograph) which is used for controlling or limiting the driving speed (see Page 36).
Some unused EDC connections must be closed by resistors since the EDC constantly conducts a signalrange check, as described on Page 20.
Interior circuit
3
1
2
5
6
4
R1 0.511 kOhm
R5 0.511 kOhm
R2 1.37 kOhm
R6 1.37 kOhm
R7 3.08 kOhm
R3 3.08 kOhm
R8 8.20 kOhm
R4 8.20 kOhm
8
9
7
2 84357691
Redundant cut-out device Safety relay
The relay (redundant cut-out device) is a safety-critical component.
If certain faults occur in the EDC system the relay interrupts the voltage supply for the control-rod travel
operating magnet.
The control rod is pulled back to the stop position by a return spring.
The safety relay is under current throughout operation. To activate it (e.g. emergency switch-off of the en-
gine) the EDC control unit interrupts the current circuit.
13
Component description
Drive stage selection
Function
The drive stage selection device transfers driver’s requests in the form of voltages to the control unit. The
control unit then derives the corresponding engine speed or volumetric charge from these voltages.
Block diagram
Pin 13
Pin 39
Pin 13
Pin 27
U = Reference voltage, approx. 5 V from the EDC control unit
u = Setpoint
Pedal travel sensor simulation values
Upper idle speed: 257-539 V / high idle speed 2944-4501 mV
Empty fuel switch: switch-on point at 569-976 mV (typically 800 mV)
top idle
speed
Pin 45
lower idle
speed
257 mV 976 mV 2944 mV 4501 mV [ mV ]
539 mV 569 mV
Fault registration
Empty fuel switch range
(typically 880 mV)
Exceptionally, the voltage “u” is produced electronically as drive position selection, or the setpoint selection
(drive position selection) takes place via the CAN bus.
14
Charge-air, coolant and fuel temperature sensors
Charge-air B197 (51.27421-0165)
Characteristic R=f (-í)
Component description
2
4
3
1
Plug connection
Coolant / Fuel B124 (51.27421-0172)
Characteristic R=f (-í)
2
4
3
1
Plug connection
Function
The temperature sensors for charge air, coolant and fuel are NTC resistors.
The coolant temperature sensor is located in the coolant circuit and the turbo air temperature sensor in the
turbo air circuit after the intercooler. They supply the control unit with information relating to the coolant and
turbo air temperature.
The fuel temperature sensor is part of the injection pump and measures the fuel temperature for determination of the fuel density.
Depending on the fuel density the control unit determines the injection quantity and thus also the duration
of injection.
15
Component description
Charge-air pressure sensor (51.27421-0181)
1
Ground - Supply +
Plug connection
Function
The pressure sensor element consists of an Si-diaphragm which contains several piezo-resistive (pressuresensitive) semiconductor resistors. The pressure to be measured “deflects” the sprung diaphragms. As a
result, extended or compressed zones are created on the surface of the diaphragms. The action of these
forces changes the electrical ratings of semiconductor resistor arrays arranged in these zones. These values are a measure for the pressure to be measured.
Curve
(VDC)
4.650 MIN
4,500
4
32
Output
Overpressure
0,500
0.350 MIN
Vacuum
0,5 4,0
VS
16
Pressure (bar)
Component description
RPM sensor
Housing: grey
Coding A
Function
The rpm sensor consists of a permanent magnet and a coil with a high number of windings. The magnet
“touches” the rotaring component to be measured, normally a crown gear or grooved ring gear; with its
magnetic field.
With the EDC MS5 system, there are 6 grooves on the flywheel.
When a groove passes the sensor, the magnetic current is reduced. This generates an induction voltage in
the sensor coil which is measured by the electronic control. The distance between the sensor and the
grooved ring gear is approx. 1 mm.
Two rpm sensors are required to ensure reliable operation of the EDC system.
Both rpm sensors are installed in the flywheel housing.
A distinction is made between the rpm sensor and the auxiliary rpm sensor.
The rpm sensor is installed in the flywheel housing such that an rpm pulse is triggered 10°after TDC.
The auxiliary rpm sensor is installed in the flywheel housing in such a way that an auxiliary speed pulse is
triggered 18° after TDC. The signals of the auxiliary rpm sensor are used only for redundant engine speed
sensing.
2
Plug connection
RPM sensor (1)
1
21
Plug connection
Auxiliary rpm sensor
(2)
Housing: black
Coding B
Caution:
Do not confuse installation locations of the rpm sensor (1) and the auxiliary rpm sensor (2), nor
the “+” and “-” wires of the sensors.
17
Component description
Injector and needle movement sensor
1
2
12
Plug connection
1 Coil
2 Pressure pin
The needle movement sensor records the start of injection using a sensor which is incorporated directly
into the injector holder. This sensor, through its detection of the needle movement, is used to calculate the
fuel injection timing.
18
Notes on operation
Start procedure
The gear stage must be selected (idle speed request setpoint specification) to start the engine.
Changing idle speed
Idle speed setting is possible using EOL programming (MAN Cats), but this should only be performed by
MAN customer service personnel.
Intermediate engine speed control
Different intermediate engine speeds can be programmed by means of MAN-Cats:
D ZDR 1, ZDR 2 and ZDR 3
These intermediate engine speeds are set by corresponding pin connection.
The intermediate engine speeds can be changed using EOL programming (MAN-Cats), but this should only
be performed by MAN customer service personnel.
19
Self-diagnosis
General
The EDC system continuously checks itself. It does this by running a signal-range check. During this
check, all signals are scanned for presence and plausibility within a certain time frame (determined by the
software).
The control unit itself is also constantly checked the whole time the program is running. The first check is
always carried out when the ignition is turned on.
Any faults occurring during operation are stored for the purpose of subsequent diagnosis.
A maximum of 5 faults can be stored simultaneously in the fault memory. The faults are stored in the order
in which they occurred. If more than 5 faults occur, the least significant fault is deleted.
Fault storage includes
D allocation of fault priority,
D identification of the type of fault,
D recording of fault frequency.
Sporadic faults are recorded by a frequency counter the first time they occur. This means that a certain frequency number is set which is decremented by one during every start procedure. If the fault no longer occurs, it is deleted when the counter reaches zero.
To report the fault, the diagnostic lamp either comes on permanently or remains off, depending on the significance of the fault. If several faults are stored, the steady light has priority over OFF.
Only faults currently present are indicated. Faults which are stored but which are not currently present are
not indicated.
There are two fault memories:
D Fault memory for diagnosis via ISO interface. This memory can be read out and cleared with MAN-Cats
D Fault memory for diagnosis via flash code. The flash code memory can be read out and cleared with the
aid of the diagnosis button.
Faults are always entered in both fault memories simultaneously and can be read out even after the ignition
has been switched off and back on again.
Indicator lamp check:
The EDC indicator lamp lights as a lamp test for approximately 2 seconds after the ignition is switched on.
20
Self-diagnosis
The following measures are implemented automatically depending on the significance of the fault:
D Changeover to suitable substitute function to enable continued yet restricted operation
D Reduction of engine speed to idle speed (drive stage 0)
D Immediate shut-down of the engine if required for safety reasons. Depending on the type of fault, engine
shut-down is done by reducing the fuel delivery volume to zero or by way of an emergency shut-down
with safety relay.
Flash code
To read out the fault memory
D With the engine stationary or running and the “ignition“ switched on, press and hold the diagnosis re-
quest button for at least 2 seconds. The diagnosis lamp will not come on
D The flash procedure starts after a pause of approximately 3 seconds. The flash code is divided into long
and short pulses
D The diagnostic system always outputs only one fault at a time. In order to check whether several faults
are stored, the fault scanning procedure must be repeated until the fault that was shown first reappears
Example of a flash code output
On
Lamp
Off
20
18/19
49
0.5 sec
Fault 2x long, 5x short
OFF phase before output: 3 seconds
ON duration of a long pulse: 2 seconds
OFF phase between two long pulses: 1 second
OFF phase between long and short pulses: 5 seconds
ON duration of a short pulse: 0,5 seconds
OFF phase between two short pulses: 0,5 seconds
To clear fault memory
1. Press request button
2. Switch on ignition
3. Press and hold request button for a further 3 seconds but not longer than 10 seconds
21
Self-diagnosis
R
Fault code output MAN MS5 EDC
Overview of flash codes
Number of
flashes
Long Short
0 0 No fault stored
1 1 11h Fuel temperature sensing No 1 3 13h Undervoltage No 1 6 96h Control unit (computer coupling) Yes a)
1 7 17h Overrevving Yes b)
1 8 18h Start of injection control deviation Yes b)
1 10 1AH Needle movement sensor No 1 12 1CH Resistor bank control unit pin 35 No 1 13 1DH Control box Yes b)
1 15 1FH Control unit (CAN-System) No 2 5 25h Main relay Yes b)
2 7 A7H Resistance bank, control unit pin 54 Yes b)
2 8 A8H Atmospheric pressure sensing Yes b)
2 13 2DH FM message Yes b)
3 1 31h Safety relay No 3 2 32h EEPROM processor 1 error No 3 3 33h EEPROM processor 2 error No 3 4 34h Stop-extern-input No 3 6 36h Intercooler Yes b)
3 7 37H * Output stage error No 3 8 38h Afterrunning not completed No 3 9 39H Afterrunning watchdog error No 3 10 3AH Control rod position sensor - loose contact No 3 11 3BH * AGR-Fault (control deviation) Yes b)
* MS5 stage 5
a) Reset by “Ignition” Off / On (cold restart)
b) Reset takes place automatically once the fault is rectified
Fault code Fault path Steady
light fault
1 81h Pedal value transmitter / Drive stage selection Yes b)
3 83h Boost air temperature sensing Yes b)
4 84h Engine speed sensing (primär) Ye s b)
5 85h Boost pressure sensor Yes b)
6 86h Control rod position sensing Yes a)
7 87h Coolant temperature sensing Yes b)
10 8AH Fuel volume regulator monitoring Yes a)
14 8EH Auxiliary rpm sensor Yes b)
Maintai-
ned light
eset
a) / b)
22
Check-list
1. Resistance checks
- Engine stop, ignition off
- Engine temperature ≈ 25°C
- Control unit not (!!!) connected, cable harness adapter connected
- Measure resistance between PIN+ and PIN- with multimeter
Component
Control rod position sensor
RPM sensor (DZG) 21 13 0,8–1,0 kΩ kΩ
Auxiliary rpm sensor (HZG) 22 17 0,8–1,0 kΩ kΩ
Fuel-delivery regulator
Control-slide mechanism
Ground 13 18 >10 MΩ MΩ
Needle movement sensor 32 17 90–130 Ω Ω
Safety relay 14 19 200–300 Ω Ω
À
Ã
Â
PIN+ PIN- Setpoint Measured value Remark
11 9 18–25 Ω Ω
11 10 18–25 Ω Ω
18 9 >10 MΩ MΩ
18 10 >10 MΩ MΩ
15 1 0,7–1,3 Ω Ω
18 1 >10 MΩ MΩ
16 2 0,7–1,3 Ω Ω
15 3 1,2–2,0 Ω Ω
18 3 >10 MΩ MΩ
16 4 1,2–2,0 Ω Ω
17 19 >10 MΩ MΩ
AGR-input
AGR-output
Coolant temperature sensor 53 13 1,3–3,6 kΩ kΩ
Fuel temperature sensor 34 13 1,3–3,6 kΩ kΩ
Boost pressure sensor 55 13 1,3–3,6 kΩ kΩ
Multistage switch neutral 35 13 500–520 Ω Ω
Â
Â
Torque reduction active 35 13 1,2–1,5 kΩ kΩ
Speed reduction active 35 13 7,6–9,0 kΩ kΩ
7 18 39–49 Ω Ω
15 24 < 1 Ω Ω
À Exact measurements are possible only at defined temperatures
Á Engine operating temperature ~80°C resistor approx. 230–460 Ω
 EURO 3 - engine only
à Safety relay (K324): For measurement of resistor take of the relay and connect contact 30 and 87.
2. Speed measurement
- Engine running
- Coolant temperature >30°C
- Wiring harness adapter connected
- EDC control unit connected
- Checking with MAN-Cats monitoring 2
Sensor Setpoint Measured speed Remark MAN-Cats
rpm sensor Low Idle speed rpm Drive signal min. Engine speed
High Idle speed rpm Drive signal max. (Monitoring 2)
Auxiliary rpm sensor Low Idle speed rpm Drive signal min. Engine speed
High Idle speed rpm Drive signal max. (Monitoring 2)
23
Check-list
3. Voltage measurement
- Engine running
- Measure voltage between PIN+ and PIN - with multimeter
Component PIN+ PIN- Setpoint Measured value Remark Engine speed
Battery voltage 15 18 U-Bat V V Low idle
(U-Bat) 47 19 U-Bat V V Low idle
Reference voltage 45 13 4,75–5,25 V V Low idle
33 13 4,75–5,25 V V Low idle
Drive signal /
Pedal position
Idle speed switch
Fuel temperature
sensor
Coolant temperature
sensor
Charge-air
temperature sensor
Charge-air pressure 36 13 0,94–1,20 V V 0 – 0,1 bar Low idle
sensor 36 13 1,10–1,70 V V 0,3 – 0,6 bar High idle
Ä
Ä Not in case of CAN control
27 13 0,30–0,42 V V Min. Low idle
27 13 2,90–4,50 V V Max. High idle
Ä
39 13 4,5–5,25 V V Min. Low idle
39 13 0–2,0 V V Max. High idle
34 13 4,17–2,62 V V 10 – 50°C Low idle
53 13 3,46–1,22 V V 30 – 90°C Low idle
55 13 4,17–2,62 V V 10 – 50°C Low idle
4. Check main relay
- Measure voltage between PIN+ and PIN- with multimeter
- Pin 46 must switch to U-Batt within 0.5 to 5 seconds after ignition has been switched off
Component PIN+ PIN- Setpoint Measured value Remark Engine speed
Main relay 47 18 U-Bat V V Ignition
“ON”
47 18 0 V V Ignition
“OFF”
46 18 0 V V Ignition
“ON”
46 18 U-Bat V V Ignition
“OFF”
Low idle
0
Low idle
0
5. ZDR-Intermediate engine speed control test
- Wiring harness adapter connected
- EDC control unit connected, engine running
- Connection between PIN 15 and PIN 23 and / or PIN 41
Intermediate engine
speed control
ZDR 1 24 V 0 V rpm rpm
ZDR 2 0 V 24 V rpm rpm
ZDR 3 24 V 24 V rpm rpm
Pin 23 Pin 41 Set point (EOL) Measured value Remark
24
Check-list
6. Flash code diagnosis check
- Wiring harness adapter connected
- EDC control unit connected
- Engine running
Check procedure
Short-circuit rpm sensor; connect pin 21 to pin 13 to do this
Diagnosis lamp lights up
Engine speed is measured by auxiliary rpm sensor
Disconnect connection between pin 21 and pin 13
Press diagnosis button for at least 3 seconds but no more than 10 seconds
Check flash code (4x short = rpm sensor)
Deleting the fault memory; do this by turning off ignition pressing diagnosis button, turning on ignition,
pressing and holding button for at least 3 seconds but not longer than 10 seconds
Result:
7. Safety relay check
- Wiring harness adapter connected
- EDC control unit connected
- Engine running
Check procedure
Disconnect pin 14
Engine should shut down after no more than 3 seconds.
Result:
8. Capacitance reserve check
The power capacitance of the line leading to the control rod position transducer must not exceed the specified
maximum capacitance.
The capacitance increases if the line is dirty or moist. This check is designed to establish how much capacitance
reserve is still available.
- Wiring harness adapter connected
- EDC control unit connected
Check procedure
- Connect capacitance decade between pin 11 and pin 13
at wiring harness adapter.
- Connect additional capacitance until the engine no longer starts or MAN-Cats signals the fault “Control rod
position sensor”
Set point >300 pF mit additional capacitance (wiring harness adapter)
- Record value
Result:
9. Deleting the fault memory
The fault code memory must be deleted on completion of the checks. No fault must be stored when the “ignition” is
turned on again.
If this is not the case, the fault must be located and eliminated in accordance with the troubleshooting procedure.
Caution:
If the fault in the fault memory is deleted only via the button, it will continue to be present in the 2nd memory
and indicated by MAN-Cats.
Result:
25
Troubleshooting chart
1. EDC self-diagnosis or flash code output
2. Starter turns over engine only slowly or not at all
3. Starter turns, engine does not start, engine does not start / difficult to start when cold
4. Engine stalls (dies) during operation, no longer starts (starter turns),
engine does not start / starts with difficulty when hot
5. . Sudden, temporary engine shut-down, engine does not reach full revs
6. Engine only runs at idle speed, no throttle response
7. Engine only runs at elevated idle speed, no throttle response
8. Rated engine speed distinctly reduced (even under no load)
9. Reduced output in all ranges
10. Irregular engine operation, traction loss
11. Unstable idle speed, engine hunting, misfiring, knocking in engine
12. Engine judder
13. Unusual combustion noise
14. Excessive smoke emission: White smoke / blue smoke
15. Excessive smoke emission: Black smoke
16. Engine temperature too high (coolant loss)
17. Intermediate engine speed control cannot be activated / does not switch off, engine revs too
high
18. Fuel consumption too high
19. Lubricating oil pressure too low
20. Lubricating oil pressure too high
21. Lubricating oil consumption too high
22. Engine too loud / mechanical noise
Possible causes
x x Batteries discharged, battery lead connections loose or corroded,
x Crank gear blocked
x x Starter solenoid switch sticking (clicks) / defective, cable connection loose or dama-
x x Starter / starter interlock relay defective (carbon brushes worked loose / worn,
x x x x Engine oil viscosity unsuitable, not suitable for ambient temperature, lubricating oil
x x Oil level in sump too high
x Oil level in sump too low, oil in sump too thin (mixed with condensate or fuel)
x Engine temperature too high
x Oil filter clogged
x x Oil pressure gauge faulty
x Safety valve in oil circuit defective
x x Bearing wear
x Oil pump gears worn
x x x Engine cold
x Lubricating oil entering combustion chamber (piston rings worn, piston rings broken)
x x Piston rings heavily worn, broken
x x Piston pin or crankshaft bearing worn
x x x Valve clearance not correct
x x Valves jam
x x x x Compression deficient, or more than 3-4 bar pressure difference between individual
x x x Valve seats leaking
o x x Increased power consumption due to faulty secondary consumers such as hydrau-
x x x x x Air cleaner soiled or clogged, charge-air system leaking,
break in power circuit
ged
winding defective, short to ground)
quality does not correspond to specifications
(does not close, spring fatigued or broken)
x Crankshaft timing gears worn, tooth flank backlash too great
- valve stem guide worn - overpressure in crankcase (crankcase vent clogged)
x Relief valve in oil circuit faulty (does not open), oil lines / oil galleries clogged
x Leaks in lubricating oil circuit, particularly at turbocharger and oil cooler
x Valve stems worn
cylinders
lic pumps, fan, etc, power take-off engaged
air inlet / exhaust lines clogged / leaking
x = Probable
o = Possible
26
Troubleshooting chart
1. EDC self-diagnosis or flash code output
2. Starter turns over engine only slowly or not at all
3. Starter turns, engine does not start, engine does not start / difficult to start when cold
4. Engine stalls (dies) during operation, no longer starts (starter turns),
engine does not start / starts with difficulty when hot
5. . Sudden, temporary engine shut-down, engine does not reach full revs
6. Engine only runs at idle speed, no throttle response
7. Engine only runs at elevated idle speed, no throttle response
8. Rated engine speed distinctly reduced (even under no load)
9. Reduced output in all ranges
10. Irregular engine operation, traction loss
11. Unstable idle speed, engine hunting, misfiring, knocking in engine
12. Engine judder
13. Unusual combustion noise
14. Excessive smoke emission: White smoke / blue smoke
15. Excessive smoke emission: Black smoke
16. Engine temperature too high (coolant loss)
17. Intermediate engine speed control cannot be activated / does not switch off, engine revs too
high
18. Fuel consumption too high
19. Lubricating oil pressure too low
20. Lubricating oil pressure too high
21. Lubricating oil consumption too high
22. Engine too loud / mechanical noise
Possible causes
x x x x x x x x x Fuel low pressure system: Fuel tank, prefilter, water trap faulty / clogged / mould /
x x x x x x x x Fuel low pressure system: Fuel lines leaking, broken, clogged
x x x x x x x Fuel low pressure system: Air in system (turn on ignition when bleeding system)
x x x x x x x x x Fuel low pressure system: Fuel pump, overflow valve, main filter
x x x x x o x x Fuel high pressure system: Jets defective / clogged / leaking / coked
x x x x o Fuel high pressure system: Pressure lines - constriction, cavitation, leaking
x x o x x x x o Fuel high pressure system: Injection pump worn/set incorrectly
o x o o Fuel high pressure system: Injection pump constant-pressure control valve / return
x x x o x Safty relay defective, drive faulty
o o o x o x x x Injection pump-engine allocation: Start of delivery incorrect (basic installation),
x x x x o x o Injection pump-controller: Stiff movement-fuel delivery controller
x x x x o Control rod position transducer in controller: Connection lines, break, short-circuit
o o o Control rod position transducer in controller: Set incorrectly
x x o Control rod position transducer in controller: Capacitance reserve of wiring harness
x o x o o Injection pump: Delivery set incorrectly / uniform delivery, lower idle speed set too
x o x x x x Delivery actuating solenoid in controller: Connection lines, break, short-circuit, or
x x x x x o Drive stage selection defective: Connection lines, break, short-circuit
x EDC rpm sensor faulty, implausible with auxiliary rpm sensor, line fault
x o EDC rpm sensor, polarity reversed
x EDC rpm sensor faulty, implausible with auxiliary rpm sensor, line fault
x x x x o o o o EDC detects incorrect engine speed (interference signal on rpm sensor line)
x x x x o Both rpm sensors faulty, line fault
x x x EDC boost pressure sensor: faulty, incorrect, implausible with atmospheric pres-
x x o x Exhaust turbocharger leaking or faulty
x Intercooler leaking, faulty
x x Flame starting system defective
x o x x o x EDC coolant temperature sensor: faulty, line fault
x = Probable
o = Possible
fungal attack, fuel unsuitable / contaminated (paraffin added)
flow restrictor defective
start of delivery set incorrectly
(control deviation)
too low (e.g. water penetrated wiring harness)
low
CAN-Bus
sure sensor, line fault
x Turbine and compressor rotor in turbocharger dirty (out-of-balance, irregular run-
ning)
27
Troubleshooting chart
1. EDC self-diagnosis or flash code output
2. Starter turns over engine only slowly or not at all
3. Starter turns, engine does not start, engine does not start / difficult to start when cold
4. Engine stalls (dies) during operation, no longer starts (starter turns),
engine does not start / starts with difficulty when hot
5. . Sudden, temporary engine shut-down, engine does not reach full revs
6. Engine only runs at idle speed, no throttle response
7. Engine only runs at elevated idle speed, no throttle response
8. Rated engine speed distinctly reduced (even under no load)
9. Reduced output in all ranges
10. Irregular engine operation, traction loss
11. Unstable idle speed, engine hunting, misfiring, knocking in engine
12. Engine judder
13. Unusual combustion noise
14. Excessive smoke emission: White smoke / blue smoke
15. Excessive smoke emission: Black smoke
16. Engine temperature too high (coolant loss)
17. Intermediate engine speed control cannot be activated / does not switch off, engine revs too
high
18. Fuel consumption too high
19. Lubricating oil pressure too low
20. Lubricating oil pressure too high
21. Lubricating oil consumption too high
22. Engine too loud / mechanical noise
Possible causes
x x x EDC charge-air temperature sensor: faulty, line fault
o x x Radiator dirty or cooling system failure (temperatures too high)
x Coolant level too low, air in coolant circuit
x V-belt for water pump drive not tensioned correctly
x Incorrect V-belt tension
x Water pump leaking, faulty / thermostat faulty, does not open
x Coolant lines leaking, clogged or twisted
x Coolant entering combustion chamber (cylinder head / gasket leaking)
x Resistor bank EDC control unit pin 51
x x x o o Power supply to EDC control unit interrupted or battery voltage too low / Relay K1
x x o o Line terminal 15 to EDC control unit (pin 47) interrupted/loose contact
x Line defective: Line defective: Pin 23 or 41
x o o o EDC control unit faulty (internal fault)
x x x x o o o x Incorrect EDC control unit (check MAN part number)
x x o Intermediate engine speed activated
x EOL programming terminated / voltage interrupt
x Afterrunning not completed (e.g. shutdown via EMERGENCY STOP)
x EOL programming: Configuration incorrect
x Engine bearings worn
x o x Injection pump pilot stroke / start of delivery regulator: stiff movement
faulty
x = Probable
o = Possible
28
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