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

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

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 Â EURO 3 - engine only Ã 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

Troubleshooting program

The following troubleshooting program contains all faults which can be detected by the diagnostic system. The order corresponds to the numerical sequence of the flash code, irrespective of the significance of the

fault. It is therefore not arranged on the basis of “fault is indicated by EDC indicator lamp” or “fault is not indicated by EDC indicator lamp”.

The entire fault code memory should always be read out and all stored fault codes noted down before starting the engine test.

This is important because lines or components need to be disconnected when troubleshooting the system and this can cause the corresponding fault codes to be set and stored. For this reason, the fault memory should always be cleared after intermediate checks.

The “test lines” test stage must always be performed as follows:

- Break or contact resistance

Set-point: approx. 0 Ω

- Short to negative

Set-point value: ∞ Ω

- Short to positive

Set-point value: ∞ Ω

- Short to adjacent lines

Set-point value: ∞ Ω

- Loose contacts

After rectifying faults and checking, repeat test and delete fault code memory. All checks which refer to the control unit plug connector are conducted with the aid of the socket box. The

pin designations on the control unit plug connector are identical to those of the test sockets on the socket box.

Note:

The connection to the control unit must be disconnected at the socket box when resistance measurements are being carried out.

29

Testing

Drive stage selection / Pedal position sensor

Flash code: 1x short Fault indication: Fault is indicated by the EDC indicator lamp coming on continuously

Fault path: Drive stage selection

- Signal too high

- Signal too low

- Signal implausible with idle speed switch

Effect of fault: Engine assumes lower idle speed Possible cause: Line break, short-circuit, power supply interrupted, pedal travel sensor faulty,

control unit faulty

Test precondition: Socket box connected

Ignition switched on

Test Measurement Corrective measures

Power supply Measure voltage at the socket box across

pin 45 (+) and pin 13 (-)

Set-point value: 4,75-5,25 V

Drive stage selection

PWG Min. 0 % PWG Max. 100 %

Idle speed switch

Measure voltage at socket box across pin 27 (+) and pin 13 (-)

Set-point value:

Idle speed setting: 0,3-0,5 V Full load setting: 2,9-4,5 V

Measure voltage at socket box across pin 39 (+) and pin 13 (-)

- Check lines

- Check plug connections

- If no fault found, replace control unit (disconnect the control unit only when the current is switched off)

- Check lines

- Check plug connections

- Replace drive stage selection

- Check lines

- Check plug connections

PWG Min. 0 % PWG Max. 100 %

Set-point value:

Idle speed setting: 4,75-5,25 V Full load setting: 0,0-2,0 V

30

Switch open Switch closed

Testing

Charge-air temperature sensor

Flash code: 3x short Fault indication: Fault is indicated by the EDC indicator lamp coming on continuously

Fault path: Charge-air temperature sensor Effect of fault: Reduced full load quantity to 70%

Possible cause: Line break, short-circuit, charge-air temperatur sensor faulty, control unit

faulty, charge-air temperatur >85°C, intercooler contaminated, fan regulator defective

Test precondition: EDC control unit connected

Socked box connected

Test Measurement Corrective measures

Sensor resistance Measure resistance at the socket box

across pin 55 and pin 13

Set-point value: 3.8-0.8 kΩ at 10-50°C

Sensor voltage Measure voltage at socket box across pin

55 and pin 13

Set-point value: 4,17-2,62 V at 10-50°C

At charge air temperatures > 70°C the full-load quantity is reduced via the vehicle management system by 2% per °C.

At 85°C the charge air temperature sensor is recognised as being defective and a fault entry is made.

- Check lines

- Check plug connections

- Replace temperatur sensor

- If no fault found, replace control unit

- clean intercooler

- check fan regulator

31

Testing

RPM sensor

Flash code: 4x short Fault indication: Fault is indicated by the EDC indicator lamp coming on continuously

Fault path: rpm sensor

- Statically implausible

- Dynamically implausible

- Implausible with auxiliary rpm sensor

Effect of fault: If the auxiliary rpm sensor also fails, the engine will be shut down by safty re-

lay

Possible cause: Line break, short to ground, rpm sensor faulty, control unitfaulty

Test precondition: Disconnect EDC control unit to ensure the engine can not start up

Socked box connected

Test Measurement Corrective measures

Resistance Measure resistance at socket box across

pin 21 and pin 13

Set-point value: 800-1000 Ω

Engine speed signal Check signal at socket box at starting

speed across pin 21 (+) and pin 13 (-) with oscilloscope

Set-point value: see diagram

- Check lines

- Check plug connections

- If no fault found, replace rpm sensor

U > 2 V

32

Testing

Boost pressure sensor

Flash code: 5x short Fault indication: Fault is indicated by the EDC indicator lamp coming on continuously

Fault path: Boost pressure sensor

- Signal too high

- Signal too low

- Signal implausible with atmospheric pressure sensor (in control unit)

Effect of fault: 60 to 70 % reduction in power Possible cause: Line braek, short-circuit to ground, boost pressure sensor faulty,

control unit faulty

Test precondition: EDC control unit connected

Corrective measures Ignition switched on

Test Measurement Corrective measures

Power supply Measure voltage at socket box across pin

33 (+) and pin 13 (-)

Set-point value: 4,75-5,25 V

Signal voltage Measure voltage at socket box across pin

36 (+) and pin 13 (-)

Set-point value:

Lower Idle speed: 0,94-1,20 V Upper Idle speed: 1,10-1,70 V

If all the values are OK, the atmospheric pressure sensor in the control unit may be faulty

- Check lines

- Check plug connections

- If no fault found, replace control unit (disconnect the control unit only when the current is switched off)

- Replace control unit (only disconnect control unit once the current is switched off)

33

Testing

Control rod position sensor

Flash code: 6x short Fault indication: Fault is indicated by the EDC indicator lamp coming on continuously

Fault path: Control rod position sensor

- Signal too high

- Signal too low

Effect of fault: This fault results in the engine being shut down by setting the control rod tra-

vel to 0. The engine cannot be started if this fault is currently present (EDC indicator lamp permanently on).

Possible cause: Line break, short-circuit to ground, too little capacitance reserve,

control rod position sensor set incorrectly, injection pump faulty

Test precondition: EDC control unit disconnected

Socked box connected

Test Measurement Corrective measures

Instrument coil Measure resistance at socket box across

pin 11 and pin 9

Set-point value: 18-25 Ω

Reference coil Measure resistance at socket box across

pin 11 and pin 10

Set-point value: 18-25 Ω

Measure resistance at socket box across pin 18 and pin 9

Set-point value: > 10 MΩ

Measure resistance at socket box between pin 18 and pin 10

Set-point value: > 10 MΩ

In addition to the possibility of an electrical fault, the fault described here may also be caused by incorrect setting of the control rod position sensor

- Check lines

- Check plug connections

- If no fault found, repair injection pump

- Remove injection pump

- Adjust control rod position sensor

34

Testing

Coolant temperature sensor

Flash code: 7x short Fault indication: Fault is indicated by the EDC indicator lamp coming on continuously

Fault path: Coolant temperature sensor Effect of fault: Reduction in power output to 45%

Possible cause: Line break, short-circuit, temperature sensor faulty, control unit faulty, failure or

contamination of cooling system, coolant temperature >105°C

Test precondition: EDC control unit disconnected / connected

Socked box connected

Test Measurement Corrective measures

Sensor resistance (control unit disconnected)

Sensor voltage (control unit connected)

At coolant temperatures > 96°C the full-load quantity is reduced by some 5% per °C. At 106°C the coolant temperature sensor is recognised as being defective and a fault entry is made.

Measure resistance at the socket box across pin 53 and pin 13

Set-point value:

1.3-3.6 kΩ at 15-30°C 230-460 Ω at 75-80°C

Measure voltage at socket box between pin 53 and pin 13

Set-point value: 3,46-1,22 V at 30-90°C

- Check lines

- Check plug connections

- Replace temperatur sensor

- If no fault found, replace control unit (disconnect the control unit only when the current is switched off)

35

Testing

Resistor bank

Driving speed Flash code: 8x long Fault indication: Fault is indicated by the EDC indicator lamp coming on continuously

Fault path: Resistance for the sensors not present - speed of travel (pin 51) and torque

limit (pin 35) Resistor bank defective, Resistance values incorrect

Effect of fault: Reduction in power output Possible cause: Line break, short-circuit to ground, resistor bank

Test precondition: EDC control unit disconnected

Socked box connected

Test Measurement Corrective measures

Resistor bank Measure resistance across

Set-point values:

Pin 13 and Pin 35 500-520 Ω Pin 13 and Pin 51 2.8-3.2 kΩ

- Check lines

- Check plug connections

- If no fault found, replace resistor bank

36

Testing

Fuel volume regulator

Flash code: 10x short Fault indication: Fault is indicated by the EDC indicator lamp coming on continuously

Fault path: Fuel volume regulator monitoring Effect of fault: The setpoint - actual value comparison for activating the fuel volume regulator

has resulted in a control deviation which has exceeded a specified time threshold. This fault results in the engine being shut down. The engine can only be restarted when the fault is no longer present and the ignition is switched off and on again once.

Possible cause: Line break, short-circuit, injection pump faulty (internal fault in regulator or stiff

movement), capacitance reserve of line leading to control rod position sensor too low

Test precondition: EDC control unit disconnected

Socked box connected

Test Measurement Corrective measures

Actuating solenoid Measure resistance at socket box across

pin 15 and pin 1, pin 16 and pin 2

Set-point value: 0,7-1,3 Ω

Measure resistance at the socket box across pin 18 and pin 1

Set-point value: > 10 MΩ

- Check lines

- Check plug connections

- If no fault found, replace injection pump

37

Testing

Auxiliary rpm sensor

Flash code: 14x short Fault indication: Fault is indicated by the EDC indicator lamp coming on continuously

Fault path: Auxiliary rpm sensor

- Statically implausible

- Dynamically implausible

- Implausible with rpm sensor

Effect of fault: If the rpm sensor also fails, the engine will be shut down Possible cause: Line break, short to ground, rpm sensor faulty, control unitfaulty

Test precondition: Disconnect EDC control unit to ensure the engine cannot start up

Socked box connected

Test Measurement Corrective measures

Resistance Measure resistance at the socket box

across pin 22 and pin 17

Set-point value: 800-1000 Ω

Engine speed signal Check signal at socked box at starting

speed across pin 22 (+) and Pin 17 (-) with oscilloscope

Set-point value: see diagram

- Check lines

- Check plug connections

- If no fault found, replace auxiliary rpm sensor

U > 2 V

38

Testing

Fuel temperature sensor

Flash code: 1x long, 1x short Fault indication: Fault is not indicated by the EDC indicator lamp

Fault path: Fuel temperature sensor Effect of fault: This fault has no direct effect.

The substitute value provided in the control unit for such events may result in a slight reduction in power output.

Possible cause: Line break, short-circuit, fuel temperature sensor faulty, control unit faulty, fai-

lure or contamination of cooling system.

Test precondition: EDC control unit disconnected

Socked box connected

Test Measurement Corrective measures

Sensor resistance (control unit disconnected)

Sensor voltage (control unit connected)

Measure resistance at the socket box across pin 34 and pin 13

Set-point value: 1.3-3.6 KΩ at 15-30°C

Measure voltage at socket box between pin 34 and pin 13

Set-point value: 4,17-2,62 V at 10-50°C

- Check lines

- Check plug connections

- Replace temperatur sensor

- If no fault found, replace control unit

39

Testing

Undervoltage

Flash code: 1x long, 3x short Fault indication: Fault is not indicated by the EDC indicator lamp

Fault path: Control unit power supply (battery voltage too low) Effect of fault: The EDC system or the engine can behave in various ways depending on the

magnitude of the voltage drop:

- No power

- Highly irregular engine operation

- No engine operation

- Excessive smoke emission

- Contradictory fault memory entries

Possible cause: Battery discharged or faulty, alternator faulty, line break, short-circuit, main

relay faulty

Test precondition: EDC control unit disconnected

Socked box connected Ignition switched on

Test Measurement Corrective measures

Power supply To activate the main relay K1, connect

jumper across pin 46 and pin 19

Measure voltage at socket box across pins 15/16 (+) and pins 18/19 (-)

Set-point value: 24-28 V

- Check lines

- Check plug connections

- Replace main relay

40

Testing

Control unit

Flash code: 1x long, 6x short Fault indication: Fault is indicated by the EDC indicator lamp coming on continuously

Fault path: Control unit fault (processor coupling) Effect of fault: Engine is shut down by “no power applied to fuel delivery output stage” and

control position set to 0 If this fault occurs only temporarily, the engine can be restarted after switching the “ignition” off and on again

Possible cause: Injection pump defective, control unit defective, wiring harness defective

Test precondition: EDC control unit connected

Test Measurement Corrective measures

Control unit This fault signal can also occur in the

event of extremely low power supply (loose contacts or undervoltage)

Internal fault in control unit

- Check lines

- Check plug connections

- Replace control unit (only disconnect control unit once the current is switched off)

41

Testing

Engine overspeed

Flash code: 1x long, 7x short Fault indication: Fault is indicated by the EDC indicator lamp coming on continuously

Fault path: Engine overspeed Effect of fault: Fuel delivery is interrupted. Safty relay is deactivated.

If no other fault is present, fuel delivery will continue once the engine overspeed range has been left.

Possible cause: Stiff control rod. Injection pump defective, control unit defective, wiring har-

ness defective, engine being towed

Test Measurement Corrective measures

If no other faults are present, no further action is necessary

Injection pump If the fault occurs more frequently, check

injection pump, control unit and lines.

- Deleting the fault memory

- Replace lines

- Replace control unit (only disconnect control unit once the current is switched off)

- Replace injection pump

42

Testing

Start of injection control deviation / Pilot stroke regulator

Flash code: 1x long, 8x short Fault indication: Fault is indicated by the EDC indicator lamp coming on continuously

Fault path: Start of injection regulator control deviation Effect of fault: Reduced full load quantity

Reduction in power output Possible increased smoke emissions The set-point actual value comparison of the pilot stroke regulator has resulted in a control deviation which has exceeded a specified time threshold. The system switches from closed-loop control to open-loop control with a fixed pre-set start of injection map.

Possible cause: Line break, short-circuit, plug connections to injection pump / bulkhead / con-

trol unit: oxidised, expanded, pushed back, damagedneedle movement sensor faulty, rpm sensor faulty, fault in fuel system (leaking, clogged, air in system), air cleaner (clogged, faulty), injection pump faulty (internal fault in regulator or stiff movement)

Test precondition: Socked box connected Note: When this fault occurs, always check the needle movement sensor and rpm

sensor function paths, even if there is no corresponding fault in the fault memory.

Test Measurement Corrective measures

Actuating solenoid Measure resistance at the socket box

across pin 15 and pin 3 and pin 16 and pin 4

Set-point value: 1,2-2,0 Ω

Measure resistance at the socket box across pin 18 and pin 3

Set-point value: > 10MΩ

Needle movement sensor

rpm sensor see rpm sensor test see rpm sensor test

see needle movement sensor test see needle movement sensor test

- Check lines

- Check plug connections

- If no fault found, replace injection pump

43

Testing

Needle movement sensor (NBF)

Flash code: 1x long, 10x short Fault indication: Fault is not indicated by the EDC indicator lamp

Fault path: Needle movement sensor

- not enough pulses

- too many pulses

- internal resistance incorrect

Effect of fault: Reduced full load quantity

Reduction in power output The system switches from closed-loop mode to open-loop mode with a fixed, pre-set start of injection map. If the fault is no longer present, the system will switch back to normal closedloop control.

Possible cause: Line break, short-circuit to ground, Needle movement sensor faulty Test precondition: Socked box connected

Test Measurement Corrective measures

Internal resistance Measure the resistance at the socket box

across pin 32 and pin 17

Set-point value: 90-130 Ω

Other possible causes:

- Faulty pulses from the rpm sensor (including without fault message)

- Interference pulses between control unit and needle movement sensor (e.g. from switching relays)

- Needle movement sensor affected by structure-borne noise resulting from mechanical damage (e.g. valve gear, pistons)

- Jamming nozzle needle

- Fault in the fuel low pressure system caused by faulty or incorrect overflow valve, air or leaks in the system, faulty safty relay, faulty fuel pump, clogged filters or faulty injection pump

- Check lines

- Check plug connections

- Replace needle movement sensor

44

Testing

Voltage signal of the needle movement sensor at 600 rpm

Oscilloscope setting: AC range

0 V

The diagram above shows the qualitative curve of the NBF signal at an engine speed of 600 rpm.

Voltage signal of the needle movement sensor at 1200 rpm

Oscilloscope setting: AC range

0 V

45

Testing

Resistance bank (control unit Pin 35)

Flash code: 1x long, 12x short Fault indication: Fault is not indicated by the EDC indicator lamp

Fault path: Multistage switch for engine speed reduction

- Voltage to high

- Voltage to low

- Wrong voltage

Effect of fault: None with standard circuit Function: Voltage signals are ascertained via the multistage input (control unit pin 35),

their values are determined by external resistor interrupters in the EDC control box.

Possible cause: Line break, short-circuit, resistor bank defective, control unit defective Test precondition: EDC control unit disconnected

Socked box connected

Test Measurement Corrective measures

Resistor bank Measure resistance at the socket box

across pin 35 and pin 13

Set-point value: Torque limit inaktiv: 0,4-0,7 kΩ Torque limit aktiv: 6,2-11,6 kΩ The fault also occurs when the resistance is 0 Ω or ∞ Ω

Check lines

- Check plug connections

- Replace EDC control box

46

Testing

Control box

Flash code: 1x long, 13x short Fault indication: Fault is not indicated by the EDC indicator lamp

Fault path: Operating unit defective

- Voltage values incorrect or implausible

Effect of fault: The idle position can no longer be activated.

If the fault was only temporary (e.g. operating unit activated several times) the system will be ready for operation after switching the “ignition” off an on again.

Function: The operating unit is resistor-coded, i.e. the control unit recognizes each

switching state according to the voltage level supplied. Faults are detected when incorrect values are output over a certain period of time; e.g. electrical fault or multiple operation (incorrect operation) of the operating unit.

Possible cause: Line break, short-circuit, operating unit defective, incorrect operation

Test precondition: EDC control unit connected

socket box connected ignition switched on

Test Measurement Corrective measures

Control box Measure voltage at the socket box across

pin 44 and pin 13

Switch through all settings of the operating unit and determine relevant voltage value

Setpoints:

Not activated: 3.15-3.55 V

- Check lines

- Check plug connections

- Replace the control box

- If no fault found, replace control unit as a check (disconnect the control unit only when the current is switched off)

47

Testing

Resistance bank (control unit Pin 54)

Flash code: 2x long, 7x short Fault indication: Fault is not indicated by the EDC indicator lamp

Fault path: Multistage switch for engine speed reduction

- Voltage to high

- Voltage to low

- Wrong voltage

Effect of fault: None with standard circuit Function: Voltage signals are ascertained via the multistage input (control unit pin 54),

their values are determined by external resistor interrupters in the EDC control box.

Possible cause: Line break, short-circuit, resistor bank defective, control unit defective 9 (eg

cold soldering joint. In this case the fault “multi-stage switch for torque limitation” 1x long, 12x short is read out too)

Test precondition: EDC control unit disconnected

Socked box connected

Observe the vehicle-specific circuit diagrams.

Test Measurement Corrective measures

Resistor bank Measure resistance at the socket box

across pin 54 and pin 13

Set-point value:

0,4-0,7 kΩ

- Check lines

- Check plug connections

- Replace resistance bank

48

Testing

CAN system (control unit)

Flash code: 1x long, 15x short Fault indication: Fault is not indicated by the EDC indicator lamp

Fault path: Control unit faulty Effect of fault: The data exchange has been interrupted. Some engine data (speed, tempera-

ture of water and charge air, boost pressure and fuel consumption) no longer displayed.

Possible cause: Line break, short-circuit

Test Measurement Corrective measures

Control unit No further testing necessary - Replace control unit (only di-

sconnect control unit once the current is switched off)

49

Testing

Main relay

Flash code: 2x long, 5x short Fault indication: Fault is not indicated by the EDC indicator lamp

Fault path: Main relay

Contact sticks or jams (does not open)

Effect of fault: Under certain conditions, this fault may not be detected Function: The negative side of the relay coil is triggered by the EDC control unit via the

control unit output pin 46. The main relay switch-off is delayed after the ignition is switched off (run-on). During the run-on phase, various processor functions are checked and any faults stored in the fault memory.

Possible cause: Short to ground, main relay faulty Test precondition: EDC control unit connected

Socked box connected

Test Measurement Corrective measures

Main relay Measure voltage at socket box between

pin 47 and pin 18

Set-point values:

0 V at “ignition” off U-Batt at “ignition” on

Measure voltage at socket box between pin 46 and pin 18

Set-point values:

U-Batt at “ignition” off 0 V at “ignition” on

Note:

Pin 46 must switch to U-Batt within 5 seconds of the ignition being switched off (processor runon).

- Check lines

- Check plug connections

- If line OK, replace main relay

50

Testing

Atmospheric pressure sensor (in control unit)

Flash code: 2x long, 8x short Fault indication: Fault is indicated by the EDC indicator lamp coming on continuously

Fault path: Atmospheric pressure sensor in control unit faulty Effect of fault: The power reduction at high altitudes for the protection of the exhaust turbo-

charger is not activated

Possible cause: Control unit faulty

Test Measurement Corrective measures

Control unit If only this fault code is stored in the me-

mory, testing is not possible, as the sensor is located in the control unit.

If, however, a faulty boost pressure sensor is also detected, this should be chekked first in accordance with the boost pressure sensor test (page 33).

- Replace control unit (only disconnect control unit once the current is switched off)

51

Testing

CAN system (TSC1-FM message)

Flash code: 2x long, 13x short Fault indication: Fault is indicated by the EDC indicator lamp coming on continuously

Fault path: EDC - CAN communication is faulty Effect of fault: Idle speed

Possible cause: Line break, error in vehicle management system, no CAN message from vehi-

cle control

Test precondition: EDC control unit and CAN computer disconnected

Socket box connected to EDC plug

Test Measurement Corrective measures

Resistance

Resistance measurement between pin 30 (CAN-L) on the socket box and a downstream computer

Set-point value: 0 Ω Resistance measurement between pin 31

(CAN-H) on the socket box and a downstream computer

Set-point value: 0 Ω

- Check line

- Check plug connection

- Activate vehicle control

52

Testing

Safety relay

Flash code: 3x long, 1x short Fault indication: Fault is not indicated by the EDC indicator lamp

Fault path: Safety relay Effect of fault: Engine is shut down

Engine will not start

Function: The safety relay performs an important safety function in its capacity as an

independent, higher-ranking (redundant) engine shut-off device The safety relay is activated in certain emergency situations when the engine can no longer be shut off by controlling fuel delivery to zero - e.g. when the control rod has jammed. The safety relay interrupts the positive power supply (pins 15 and 16) to the quantity magnet.

Possible cause: Possible cause: Line break, short-circuit, safety relay defective, faulty activa-

tion from control unit (control unit defective)

Test precondition: Socked box connected

Test Measurement Corrective measures

Check Safety relay

Power supply Switch on “ignition”

Coil resistance Safety relay

Start engine and let it idle Pull off bridge at pin 14 on test box Engine must stop within approx. 3 seconds

Measure voltage at socket box across pin 14 (+) and pin 19 (-)

Set-point value: U-Batt Switch off ”ignition”

Disconnect control unit Measure resistance at socket box across Pin 14 and Pin 19

Set-point value: 200-300 Ω

- Check line

- Check plug connection

- Replace safety relay

- Check line

- Check plug connection

- Replace safety relay If no fault found:

- Replace control unit

- Check line

- Check plug connection

- Replace safety relay

53

Testing

Complete EOL program

Control unit, EEPROM processor 1 fault

Flash code: 3x long, 2x short Fault indication: Fault is not indicated by the EDC indicator lamp

Fault path: Processor 1 in control unit faulty (EEPROM 1) Possible cause: Control unit faulty, EOL programming not completed (voltage supply interrup-

ted)

Effect of fault: Engine is shut off

Engine will not start

Test Measurement Corrective measures

Power supply

Control unit

No further testing necessary - Delete error; for this purpose

switch ignition off and on again

- Complete EOL programming, clear fault codes

- Replace control unit (only disconnect control unit once the current is switched off)

54

Testing

Complete EOL program

Control unit, EEPROM processor 2 fault

Flash code: 3x long, 3x short Fault indication: Fault is not indicated by the EDC indicator lamp

Fault path: Processor 2 in control unit faulty (EEPROM 2) Possible cause: Control unit faulty, EOL programming not completed (voltage supply interrup-

ted)

Effect of fault: Engine is shut off

Engine will not start

Test Measurement Corrective measures

Power supply

Control unit

No further testing necessary - Delete error; for this purpose

switch ignition off and on again

- Complete EOL programming, clear fault codes

- Replace control unit (only disconnect control unit once the current is switched off)

55

Testing

External stop

Flash code: 3x long, 4x short Fault indication: Fault is not indicated by the EDC indicator lamp

Fault path: Extern idle switch (control unit pin 50) Effect of fault: Request for idle-speed quantity

Function: This function was originally developed as an “anti-driveaway protection” for

buses when the doors are open.

Only mode = 1 is active, ie request for idle-speed quantity. No entry is made in the fault memory. Only in the event of mode = 2, ie “engine stop” an entry is made in the fault memory.

In data sets only mode = 1 is used as standard

Possible cause: “Engine stop” is requested (only mode = 2) Test precondition: Socked box connected

Observe the vehicle-specific circuit diagrams.

Test Measurement Corrective measures

Idle switch Measure resistance at the socket box

across pin 54 and pin 13

Set-point value: ∞ Ω

- no fault

56

Testing

Output stage error

Flash code: 3x long, 7x short Fault indication: Fault is not indicated by the EDC indicator lamp

Fault path: Cables / actuators for the relevant function Effect of fault: The relevant output stage in the control unit is not triggered. Function not avai-

lable

Possible cause: Control unit faulty (Hardware-error)

Note vehicle-specific circuit diagrams

Test Measurement Corrective measures

Output stage component

Depends on the component - Check lines

- Check plug connections

- Check the component

- Replace control unit (only disconnect control unit once the current is switched off)

57

Testing

Control unit (processor run-on)

Flash code: 3x long, 8x short Fault indication: Fault is not indicated by the EDC indicator lamp

Fault path: Control unit

- Processor run-on did not take place

Effect of fault: No direct effect Function: Every time the engine is turned off, run-on takes place automatically for the

purpose of checking the various processor functions

Possible cause: Control unit faulty, main relay faulty, battery voltage switched off before “igni-

tion” of

Test precondition: EDC control unit disconnected

Socked box connected

Test Measurement Corrective measures

Control unit Test same as for undervoltage (page 40) and

main relay (page 50)

Other possible causes:

- Engine was shut down via battery + (e.g. by disconnecting the battery or actuating the main fuse switch)

- Power supply fault (e.g. undervoltage, main relay faulty, loose contact)

- Switch ignition on and off again, clear fault code

- Same as pages 40 and 50

- Replace control unit (only disconnect control unit once the current is switched off)

58

Testing

Control unit watchdog run-on fault

Flash code: 3x long, 9x short Fault indication: Fault is not indicated by the EDC indicator lamp

Fault path: Control unit faulty (watchdog test) Effect of fault: None

Test Measurement Corrective measures

Control unit No further testing necessary - Replace control unit (only di-

sconnect control unit once the current is switched off)

Other possible causes:

- Engine was shut down via battery + (e.g. by disconnecting the battery or actuating the main fuse switch)

- Power supply fault (e.g. undervoltage, main relay K1 faulty, loose contact)

59

Testing

Control rod position sensor - loose contact

Flash code: 3x long, 10x short Fault indication: Fault is not indicated by the EDC indicator lamp

Fault path: Control rod position sensor

- Signal too high

- Signal too low

Effect of fault: None Possible cause: Line break, short-circuit, too little capacitance reserve (see page 25), control

rod position sensor set incorrectly, injection pump faulty

Test precondition: EDC control unit disconnected

Socked box connected

Test Measurement Corrective measures

Instrument coil Measure resistance at socket box across

pin 11 and pin 9

Set-point value: 18-25 Ω

Reference coil Measure resistance at socket box across

pin 11 and pin 10

Set-point value: 18-25 Ω

Measure resistance at socket box across pin 18 and pin 9

Set-point value: > 10 MΩ

Measure resistance at socket box between pin 18 and pin 10

Set-point value: > 10 MΩ

In addition to the possibility of an electrical fault, the fault described here may also be caused by incorrect setting of the control rod position sensor

- Check lines

- Check plug connections

- If no fault found, repair injection pump

- Remove injection pump

- Adjust control rod position sensor

60

Testing

EGR actuator (permanent deviation)

Flash code: 3x long, 11x short Fault indication: Fault is not indicated by the EDC indicator lamp

Fault path: EGR actuator Effect of fault: EGR function not available

Possible cause: Cable interrupted, short-circuit, check-back switch defective, mechanical de-

fect on actuator

Test precondition: Socket box connected

Note: In diagnosis mode the EGR actuator test can be activated via MAN-Cats. If

the fault memory is read out after the actuator test it always contains the fault 3B Hex. “EGR actuator, permanent deviation” (3x long, 11x short), even if the fault was deleted before the actuator test. Although it is unsatisfactory for service, this behaviour is unfortunately unavoidable and is correct for the coded software. The fault memory must therefore be deleted without fail after the EGR actuator test.

Note vehicle-specific circuit diagrams

Test Measurement Corrective measures

Check-back switch (reed contact)

Solenoid valve triggering

Measure resistance at the socket box across pin 15 and pin 24

Set-point value: >1 Ω

Measure resistance at the socket box across pin 39 and pin 18

Set-point value: 39-47 Ω

- Check lines

- Check plug connections

- If no fault found, replace control unit

- Check lines

- Check plug connections

- If no fault found, replace control unit

61

Testing

PBM interface

Flash code: None Fault indication: Fault is not indicated by the EDC indicator lamp

Fault path: Control unit input pin 52

- Faulty

- Interrupted

Effect of fault: No PBM signal at pin 29 (steady voltage U-Batt) Possible cause: Short to negative, line break

Test precondition: EDC control unit connected

Socked box connected “Ignition” switched off

Test Measurement Corrective measures

Lines

Note:

Battery voltage must be applied at pin 52 against pin 18/19 with the “ignition” switched on.

Measure resistance at socket box across pin 52 and pin 19

Setpoint: ∞ Ω Measure resistance at socket box across pin

29 and pin 19

Setpoint: ∞ Ω

- Check line

- Check plug connection

62

Testing

Overvoltage protection

Flash code: None Fault indication: Fault is not indicated by the EDC indicator lamp

Fault path: Overvoltage protection

- Faulty

- Interrupted

Effect of fault: Engine will not start Possible cause: Short circuit to negative terminal or to earth

Test precondition: EDC control unit disconnected

Socked box connected “Ignition” switched off

Test Measurement Corrective measures

Lines Measure resistance at overvoltage protection

across contact 3 and contact 4

Setpoint: ∞ Ω

Contact OUT3 and OUT4 OUT3 and OUT4 and Setpoint: >10 MΩ

Fig. 1 Overvoltage protection

IN1 IN2

- Replace overvoltage pro-

tection

OUT3

OUT4

Fig. 2 Installation instructions for lines

1

2

63

Plug connections

Pin No. Abbreviation Description

1 MES O Activation for fuel-delivery actuator

- Output, fuel-delivery control circuit

-I

11 A temporarily, on average 4.5 A, against batt., pulsed f=variable, pulse-width modulated

max

2 MES O Activation for fuel-delivery actuator

- Output, fuel-delivery control circuit 3 VHS O Control-slide mechanism 4 VHS O Control-slide mechanism 5 MBR 1 Not used 6 LEB 1 Not used 7 ARS 1 EGR actuator 8 SHGB 1 Heavy load maximum speed limitation 9 RWG M Control rod position transducer measuring coil (RWG 2)

- Control rod position evaluator circuit

10 RWG R Control rod position transducer reference coil (RWG O)

- Control rod position evaluator circuit

11 RWG Y Control rod position transducer centre pick-off (RWG 1)

- Control rod position evaluator circuit

12 CAN O Not used 13 GND A Sensor ground 14 EAB 1 Electrical shut-down

- Output (switch)

-I

1 A, U

max

15 Bat + Batt.+ via main relay

- Input battery +

- I with engine stationary 0.9 A, idle speed 1.5 A, operation 4.5 A, temporarily 16 A

16 Bat + Batt.+ via main relay

- Input battery +

17 NBF 0, HZGO Needle movement sensor and auxiliary rpm sensor

- Reference ground

18 Bat - Battery negative

- Input battery -

- I same as batt.+ (terminals 15 and 16)

19 Bat - Battery negative

- Input battery -

20 DIA-B Diagnosis lamp

- Output (switch)

-I

1 A, U

max

21 DZG 1 RPM sensor signal

- Input, dynamic

- Alternating voltage UPP idle speed approx. 2 V, max. 80 V, f=number of cyl. XN sec.

22 HZG 1 Auxiliary rpm sensor signal

- Input, dynamic

- Alternating voltage UPP idle speed approx. 2 V, max. 80 V, f=number of cyl. XN sec.

23 ZDR-E1 Intermediate engine speed control 1

- Input, static

Batt.+ 24 ARS-E EGR check-back switch 25 FMS-E Not used 26 KUP-E Not used 27 PWG 1 Pedal travel sensor signal

- Input, analog

- Direct voltage, U approx. 0.4 to 4 V

28 TDS-A Engine speed signal

- Output

-U

against batt. -, square-wave signal, f=number of cyl. X N sec.

batt.

29 MPS-A Multiplex signal

- Interfaces

against batt. -,

batt.

against batt. -,

batt.

-1

64

Plug connections

DescriptionAbbreviationPin No.

30 CAN-L Controller Area Network

- Interfaces

31 CAN-H Controller Area Network

- Interfaces

32 NBF 1 Needle movement sensor

- Input, dynamic approx. 2 V

-U

PP

33 LDF 2 - boost pressure sensor

- Output, supply

- Controlled direct voltage, U approx. 5 V

34 KTF 1 Fuel temperature sensor

- Input, analog

35 MDB 1 Multi-stage input (torque limitation)

- Input, analog

- Input by change in resistance

36 LDF 1 Boost pressure sensor signal

- Input, analog

37 FGB 1 Not used 38 EOL E Not used 39 LGS-E Idle speed switch signal

- Input, static

- against GND-O (terminal 13)

40 MST-E External engine cut-out 41 ZDR-E2 Intermediate engine speed control 2

- Input, static

Batt.+ 42 MBR-E Not used 43 BRE-E Not used 44 FGR 1 Speed control device 45 PWG 2 Pedal travel sensor

- Output, supply

- Controlled direct voltage, U approx. 5 V

46 HRL O Main relay

- Output (switch)

-I

0.3 A, batt. - against batt.+

max

47 K15-E Terminal 15, digit. Data for control unit

- Input, static

Batt.+ 48 ISO-K ISO-K link to ISO protocol

- Interfaces

49 ISO-L ISO-L link to ISO protocol

- Interfaces

50 TKS-E Door contact switch

- Input, static

Batt.+ 51 FGG 1 Driving speed sensor signal

- Input, dynamic

- Square-wave voltage UPP 8.5 V, f. variable

52 PBM-E Pulse-width modulated input signal 1

- Interface

53 WTF 1 Coolant temperature sensor

- Input, analog

54 HGB 1 Multi-stage input, maximum speed limitation

- Input, analog

- Input by change in resistance

55 LTF 1 Charge-air temperature sensor

65

EDC diagnostic tools

Bosch socket box Y261 A30 186

Fig. 1 Connection between control unit and EDC cable

harness in terminal box for testing EDC Arrow: Control unit plug

MAN-Cats interface 93.09000-6015 (Connection between adapter cable and note book)

Fig. 2

1

À Connector for note book Á Connector for MAN-Cats interface in terminal

box

Notebook computer

minimum equipment: Fig. 3

S 386 processor S 4 MB RAM S RS 232 Com 1 interface S MS-DOS 5.0 or higher

2

3

66

MAN-Cats Diagnostics System

MAN CATS is a diagnostics system for the engine electronics which operates with the aid of a laptop computer.

The features the following functions:

1. Reading EDC errors in text format 2 Clearing the fault memory

3. Monitoring the following operational parameters:

S Boost pressure S Control rod position S Engine speed S Coolant temperature S Charge air temperature S Fuel temperature S Pedal travel sensor position, i.e. throttle lever position S Battery voltage S Additional EDC parameters S Needle movement sensor

However, the monitoring data cannot be stored or printed.

The following equipment is necessary to work with the laptop:

S Interface, white

MAN Item no. 93.09000-6015

S MAN-Cats software

Operating system disk D1 MAN Item no. 81.99298-8130 German

81.99298-8071 French

81.99298-8082 English

81.99298-8033 Spanish

81.99298-8014 Italian

S Diagnostic software

EDC Bosch MS 5, Disk D 12 MAN ltem no. 81.99298-8300 German

81.99298-8231 French

81.99298-8222 English

81.99298-8193 Spanish

81.99298-8134 Italian

67

MAN-Cats Diagnostics System

Caution:

An existing laptop should meet the following minimum criteria for EDC:

S 386 processor S 4 MB RAM S 9-pin serial port

The MAN Cats software may only be run on MS DOS 5.0 or higher.

The following PC is required for the MMDS diagnostics system

Laptop with the following specification

Suitable for the MMDS diagnostics system for MAN marine engines:

S 266 MHz processor S 32 MB RAM S Min. 1,0 GByte hard drive S CD-ROM drive S Floppy disk drive S Lithium battery charger (without memory effect) S Trackball S Serial interface, cable-based S TFT display, 800 x 600 resolution (pixels width x height), min. 256 colours

68

MAN-Cats - Software Description

The software can be installed under DOS (version 5) or Windows.

Installation under Windows 95, 98, NT, WIN 2000:

Create a folder named “MAN-Cats” on hard disc C:. Copy the contents of the floppy disk labelled “D1” from the floppy disk drive to a new folder on the hard

disk. Run “Install.exe” from the hard disk. When requested, select installation of the D12 diagnostics software and at the same time deselect D43. When requested to do so, insert the next D12 disk and continue.

In DOS, the software is run by entering “C:man_cats diagnose”.

The following will appear on the screen:

Use the arrow keys to highlight “Diagnostics”, then press “Enter”.

69

MAN-Cats - Software Description

The following will appear on the screen:

Using the arrow keys, select “Mot” engine control. The following will appear on the screen:

Using the arrow keys, select “EDC Bosch MS5/M(S)5”.

70

MAN-Cats - Software Description

The following screens will appear:

71

MAN-Cats - Software Description

72

MAN-Cats - Software Description

EDC is being

scanned

73

MAN-Cats - Software Description

After this stage, the contents of the fault memory are shown first (see screenshot below).

Fault description:

↑ : too great ¢ measured value too high ↓ : too small ¢ measured value too low

- : no signal ¢ possible line break, sensor faulty ? : implausible ¢ unknown fault

J : saved ¢ fault has been stored

n : present ¢ fault exists at present

~ : sporadic ¢ momentary fault

Frequency: Depending on the channel, the EDC counts the faults from 1 to 40 or 1 to 210. If the fault is no

longer present when ignition is switched back on again, the frequency of the fault is reduced by 1. (Our example therefore shows 3 faults which were present at least once).

Peripheral conditions: shows other important channels as additional information, e.g. the engine speed at

which the fault occurred and the magnitude of the fault.

Once the fault memory has been examined and noted, press “Enter” to go the submenu where you select the “Bus” function.

74

MAN-Cats - Software Description

75

MAN-Cats - Software Description

Guided by the menu, you now come to the “Instructions / Questions” dialogue box. Depending on the version of the software, here you will find various submenus which are explained in detail

on the following pages.

76

MAN-Cats - Software Description

In the “Control unit identification” submenu, you will find, for example, the engine number, which must be checked. If the wrong control unit has been assigned to the wrong engine, it is essential that you inform MAN. For further details, see the screenshot below.

The next submenu, “Fault memory contents” once again shows the current fault memory of the EDC (see screenshot below as an example).

The “Actuator test” submenu item contains an “EHAB” test and will not be dealt with in greater detail here.

77

MAN-Cats - Software Description

“Monitoring 1-3” shows various engine parameters, see the following screenshots. The measured data cannot be stored.

78

MAN-Cats - Software Description

Depending on the software version, there is also a “Monitoring X” or “Definition monitoring X” submenu. In Definition Monitoring X, up to 6 freely selectable measuring channels can be selected by pressing “Enter” (see screenshot below).

79

MAN-Cats - Software Description

When you have finished selecting the measuring channels, select “Complete definition of monitor window”. After this, you can view the selected measuring channels in “Monitoring X” (see screenshot below).

80

MAN-Cats - Software Description

After diagnosing or measuring the engine parameters, select “End”. The following window will appear.

Once you have left the “Instructions / Questions” main menu by pressing “Enter”, the following will appear on the screen (see screenshot below).

81

MAN-Cats - Software Description

Confirm with “Yes”. You will then be guided through the menu, using “Enter” to confirm (see ...)

82

MAN-Cats - Software Description

Following the instructions above will return you to the beginning of the program.

You can now quit the “MAN_CATS” software by selecting “Exit”.

83

Notes

.............................................................................................................................................

84

Rating data sheet

85

Notes

.............................................................................................................................................

86

Rating data sheet

1. Revision list

Date Revisions

30.05.1994 First issue

26.04.1999 New edition

2. Scope This data sheet comprises the specifications and tests for the electronic control unit EDC-MS5 requi-

red to guarantee the functions listed in the following under the specified ambient conditions.

3. General features

3.1 Place of installation Frame (chassis)

3.2 Electrical connection 55-pin plug connection

3.3 Weight approx. 1.4 kg

3.4 Degree of protection Protection against shock-hazard and foreign

bodies in accordance with DIN 40 050, Part 9; IP 54 A

Protection against water ingress with connector plugged in in accordance with DIN 40 050, Part 9; IP 54 A without protecting sleeve in accordance with DIN 40 050, Part 9; IP 30

87

Rating data sheet

4. Temperature range Ta: Temperature of mounting surface

Tu: Temperature of ambient air

4.1 Storage temperature Permanent, not installed -40°C ... +85°C

Temporary, max. 1h in installed position -40°C ... +100°C

4.2 Operating temperature

Still air Ambient temperature Tu, permanent -40°C ... +65°C

Mounting surface Ta, permanent -40°C ... +65°C

Moving air Ambient temperature Tu, permanent -40°C ... +70°C

Mounting surface Ta, permanent -40°C ... +70°C

Tu =Ta, temporary -40°C ... -85°C See diagram:

Tu= Ta

85°C

70°C

*

-

0 5 t [min.]

Control unit switched off Control unit switched on

88

Rating data sheet

5. Mechanical characteristics

5.1 Vibration stress

5.1.1 Sinusoidal vibration test in accordance with DIN 40046 Part 8 ,Fc (IEC 68-2-6) Max. acceleration amplitude 50 m/s

Frequency range 10 Hz ... 200 Hz Frequency change rate 1 okt./min.

Test duration 24 h per main coordinate

5.1.2 Broadband noise test in accordance with DIN 40046 Part 22, Fd (IEC 68-2-34) Total acceleration (effective value) 45 m/s

Frequency range: 10 Hz ... 1000 Hz Test duration 24 h per main coordinate

5.2 Shock stress, test in accordance with DIN 40046 Part 7, (IEC 68-2-27) Max. acceleration amplitude 1000 m/s

2

Shock form Semi-sinusoidal

Duration of nominal shock 6 ms Test duration 3 shocks per main coordinate in both directions

(18 shocks)

The frequency and acceleration value specified in 5.1 and 5.2 apply to the vibration testing table.

89

Rating data sheet

6. Electrical ratings

6.1 Supply voltage range

6.1.1 Rated voltage 24 V

6.1.2 Permissible supply voltage 7.0 ... 32 V normal operation (measured at the batt.+, batt.- min. 16 V for 50 ms after switching on terminals of the control unit) the control unit

The definition provided in Section 7 applies to the voltages U-batt+ ≤ 7 V or U-bat- ≥ 32 V.

6.1.3 Residual ripple of supply voltage (Operation without battery not permitted) Effective value of supply voltage: U-batt eff = 500 mV max.

(Measured at the batt+, batt- terminals of the control unit with the control unit switched on and the engine running. The value need not be maintained during the start procedure)

6.2 Power loss, control unit

(idle speed, engine at operating temperature) approx. 18 W

6.3 Polarity reversal protection By coded control unit connector,

polarity reversal of battery does not result in destruction of control unit when the main relay is activated by the control unit.

6.4 Short-circuit strength

- Conditions: Max. 1 short-circuit simultaneously For all plug connections against batt+, batt-

- Ta and Tu≤65°C, and against one another except for BAT+, BAT-,

- U-Batt ≤28V GND 0. NBF 0. CAN H and L

- control unit is powered with U-batt

Restricted: RWGR. RWGM. RWGY short-circuit at max. 26 V permissible for max. duration of 1 min.

6.5 Heat radiation max. 20 W

90

Rating data sheet

7. Immunity to interference Pulses in accordance with ISO 7637-2 are permitted on the batt+/batt- line if they are within the fol-

lowing rated values. The control unit can switch off as a precautionary measure in the case of supply voltages outside the range 7V ≤ U-Bat+ ≤ 32V. The function is resumed on returning to the permissible voltage range.

7.1 ISO pulses 1 to 4

Test pulse Vs [Volt] Ri [Ohm] tl [s] Number of pul-

1a -200 10 5 5 000 -

2 +100 10 0,5 5 000 -

3a -200 50 100µ - 1 3b +200 50 100µ - 1

7.2 ISO pulse 5 (load dump) Vs = 57 V Ri = 2 Ω td = 200ms (at +U-Batt = 28V)

Set-up temperature Ta ≤ 65°C Ambient air Tu ≤ 65°C

Minimum wait time between subsequent pulses 1 min Number of pulses 10

Voltage limitation by the internal load dump feature cuts in at min. 34 V.

7.3 EMV

7.3.1 Irradiation immunity Frequency range 1 MHz ... 1000 MHz

(measure up to 400 MHz)

Test duration [h]

ses

Field strength 100 V/m sinusoidal, non-modulated

(stripline measurement)

Criterion Engine overrevving or shutting down

not permitted. Accuracy deviation permissible.

7.4 Interference suppression In accordance with VDE 0879 Part 3, interference suppression level 2.

91

Rating data sheet

8. Resistance to motor vehicle-specific liquids / fluids The control unit is resistant to diesel fuel, petrol, engine oil, engine cleaner, brake fluid, battery acid,

windscreen washer fluid, isooctane / toluene

9. Mechanical test data

9.1 Vibration stress As Point 5.1

9.2 Shock stress As Point 5.2

9.3 Alternating temperature Test Nb in accordance with DIN 2 Part 14 Clause 3 (IEC 68-2-14 Nb)

Lower test temperature -40°C

Upper test temperature +85°C Number of cycles 100

Temperature change rate < 10K/min Holding time at upper stress temperature 15 minutes each

9.4 Moisture resistance

9.4.1 Test in accordance with DIN standard Test Db in accordance with FW 2 DIN 30 (IEC 68-2-30)

Number of cycles 28 Function test after 7 cycles

9.4.2 Active moisture-alternating temperature test

Rel. humidity 95% Normal temperature phase at 40°C

Duration 240 h

Low temperature phase at -10°C

Duration 2 h

Changeover time < 3 min

10. Service life test

The service life test comprises a mechanical test in accordance with Points 5.1 and 5.2 as well as a climatic test in accordance with Points 9.3 and 9.4. Function measurements in accordance with the test and adjustment specifications are conducted after the individual tests.

92

EDC-Connection diagram

HRL 0

RWG R

K15 E

CAN L

ISO K

CAN H

ISO L

GND 0

NBF 1

LDF 2

FGG 1

MDB 1

WTF 1

LFD 1

HGB 1

BAT -

LTF 1

BAT -

NBF 0

BAT +

KTF 1

TKS E

EAB 1

RWG Y

TDS A

PWG 2

PWG 1

RWG M

FGR 1

ARS 1

ARS E

ZDR E2

VHS 0

ZDR E1

VHS 0

HZG 1

MES 0

DZG 1

MES 0

DIA B

Batterie battery

Hauptrelais K170 main relay

Einschalt- Relais K264 switch on relay

Diagnoselampe 1,2 - 2W diagnosis lamp

Taster Blinkcodeanforderung key for flash code request

Diagnosesteckdose X200 MAN - Cat diagnosis socket

Widerstandsgruppe R134 resistance group

-

+

Kl.15

15A

Sensor -

Batterie -

battery

19

18

2

6

2,5

2

18/19

87

30

15/16

46

85

86

87

30

47

18/19

86

85

18/19

20

18/19

49

Z

18/19

A

48

a

15/16

+

D

13

5

54

2

511

35

8

511

51

6

3K

sensor

13

2

2,5

Batterie +

battery

15

16

2

EMV-Stoerschutz 51.25902-0079

2,5

EMV-protector 51.25902-0079

2,5

1

2

1 2

55

37

19

18

2

2,5

3 4

3

4

52

54

53

51

50

36

35

34

16

17

2

2,5

32

33

15

13

14

2

2,5

47

49

31

12

46

48

30

11

45

43

42

40

39

29

10

44

28

27

26

9

8

7

41

24

23

25

5

6

4

2

2,5

38

22

21

20

EDC-

2

3

2

2,5

Steuergeraet

1

control unit

2

2,5

K324/87 (15/16)

1 2

3 4

15/16

9

10

11

34

13

21

13

22

17

33

36

13

X337

A

C

E

G

f

m

r

g

H

e

F

N

P

n

h

J

ws

sw

ws

sw

br

sw

bl

ws-sw

vio-ws

ws

sw

rt

sw

vio

ge

ws-sw

2,5

2

7

2

4

2

3

5

1

6

3

1

2

1

2

1

2

3

1

4

3

2

Stellwerk fuel control rack

Hubschieber control slide

Regelweggeber control rod travel transmitter

Kraftstofftemperaturfuehler fuel temperature sensor

Drehzahlgeber speed transmitter

Hilfsdrehzahlgeber auxiliary speed transmitter

Ladedruckfuehler charge air sensor

Pedalwertgeber B127 accelerator pedal position sensor

Drehzahlbedienteil S157 speed control element

Relais K324 Redundante Abstellung relay for redundant shutdown

Verdrillte Leitungen

=

min 20/m twisted cables

= abgeschirmte Leitung MAN-Nr. 07.08233-7582 shielded cable

15/16

s

t

v

u

w

l

k

d

b

a

c

Motorstecker

engine plug

2,5

53

13

32

17

55

13

24

15/16

18/19

7

2

3

13

1K

6

39

5

13

4

45

1K

2

27

1K

13

62

680

200

Sp-

+

1K

Aus

44

87

863085

X337/C

18/19

Allgemeiner EDC-Schaltplan MS5.5 EDC MS5.5, general wiring diagram

Fahrzeugspezifische Schaltplaene beachten! Note vehicle specific wiring diagrams!

31

CAN 1

30

CAN 2

28

50

Signal Motordrehzahl

signal engine speed

15/16 (BAT+)

Motorstop extern

engine stop extern

13 (GND 0)

41

23

15/16 (BAT+)

Zwischendrehzahl 1

Zwischendrehzahl 2

intermediate speed

14

bl

grue

ws-rs

ws-br

sw

gr

gr-sw

sw-ws

sw

bl

rt-sw

3

1

2

1

3

1

4

3

2

4

1

3

2

Kuehlmitteltemperaturfuehler coolant temperature sensor

Nadelbewegungsfuehler needle movement sensor

Ladelufttemperaturfuehler

B123 B198 B124 B125 B200 B199 B197 Y130

charge air temperature sensor

AGR-Zylinder

Y280

Am Motor

at engine

8112

93

Electronic Diesel Control

Description of inputs and outputs

95

1. Key to definitions

C

: EMC capacitor

EMC

f: Frequency

F

: Absolute error

abs

Io: Output current

KS: Short-circuit

LL: Idle speed

Rpu: Pull-up resistor Rq: Shunt Rpd: Pull-down resistor Rin: Input resistance R

: Internal alternator resistance

Gen

Sn: Threshold correction

tr: Rise time tf: Fall time t0: Dead time for detecting signal 0

passage from high to low between connector pin and processor

t: Time constant tAL: Charge time constant tEL: Discharge time constant

Uo: Output voltage UL: Switching threshold for logical

LOW UH: Switching threshold for logical HIGH U

: Hysteresis

Hys

UGr: Basic threshold ULL: Idle speed voltage UR: Reference voltage of ADC, UR=5V ± 4% Uin: Input voltage U

: Minimum or maximum permiss-

inz

ible input voltage U

: Cutout threshold

off

U

: Short-circuit at output set to

oLK

logical LOW U

: Short-circuit at output set to

oHK

logical HIGH

96

2. General information

The control unit must be connected in accordance with circuit diagram 51.17099-8087 together with the assemblies belonging to the system.

If not otherwise specified, all inputs and outputs are short-circuit-proof to ground and +U

≤ 28 V, TU ≤

batt

65°C.

Operation without the battery is not permitted.

The control unit may be damaged as the result of the increased power loss in the event of a short-circuit in more than two plug connections against on another or against the supply voltage.

Supply voltages and ground connections are not short-circuit-proof and are not protected against polarity reversal.

If not otherwise specified, all values apply in the temperature and voltage range as specified by TKU.

Control unit supply: BATT+ across pin 15, 16 (connected internally, must be connected externally) BATT- across pin 18, 19 (connected internally, must be connected externally)

The time constant values t apply at an internal alternator resistance of 0W.

The current directions are defined in accordance with the load count system: Positive currents flow into the control unit. Negative currents flow out of the control unit.

If not otherwise specified, the working range for analog inputs is from 0 .. UR.

Data acquisition accuracy is always referred to U

Rnominal

=5.000V

97

3. Description of inputs and outputs

3.1Analog inputs

Plug connection: 27 Function group: Analog input

Connector designation: PWG 1 Reference ground: GND 0 (13)

Description of input

Characteristic

Conditions Dim. Min. Typ. Max.

parameter

EMC capacitor C Input resistance R

Idle speed voltage U

EMC

in

LL

Input filter t R

U

in

=0W m

Gen

nF 1.2 1.5 2.2 kW 97 100 103

V GND 0

s

0.9 1.5 2.1

Input voltage Evaluation range U

Data acquisition accu-

inz

F

abs

Uin is in range of U

inz

V 0.1 UR-0.1

% ±2

racy DUin from input pin up to number of processors

Remarks:

- The data acquisition accuracy is based on radiometric signal processing with sensor supply PEG 2.

Plug connection: 45 Function group: Sensor supply,

short-circuit-proof

Connector designation: PWG 2

Characteristic para-

Conditions Dim. Min. Typ. Max.

meter

EMC capacitor C Output voltage U

Output short-circuit

EMC

o

Io≤-10 mA V UR-0.01 UR=5V UR+0.01

[Ik] Uo=0V mA 10 25

current

Remarks:

Description of output

nF 1.2 1.5 2.2

98

MAN EDC MS5 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Foreword

Contents

Safety information

Electronic Diesel Control

System description

Component description

Control unit plug connector

MS 5 injection pump

MS 5 Electromagnetic fuel volume regulator

Control-slider adjusting mechanism

Resistor bank

Redundant cut-out device Safety relay

Drive stage selection

Charge-air, coolant and fuel temperature sensors

Charge-air pressure sensor (51.27421-0181)

RPM sensor

Injector and needle movement sensor

Notes on operation

Self-diagnosis

Flash code

Check-list

Troubleshooting chart

Troubleshooting program

Testing

Drive stage selection / Pedal position sensor

Charge-air temperature sensor

RPM sensor

Boost pressure sensor

Control rod position sensor

Coolant temperature sensor

Resistor bank

Fuel volume regulator

Auxiliary rpm sensor

Fuel temperature sensor

Undervoltage

Control unit

Engine overspeed

Start of injection control deviation / Pilot stroke regulator

Needle movement sensor (NBF)

Resistance bank (control unit Pin 35)

Control box

Resistance bank (control unit Pin 54)

CAN system (control unit)

Main relay

Atmospheric pressure sensor (in control unit)

CAN system (TSC1-FM message)

Safety relay

Control unit, EEPROM processor 1 fault

Control unit, EEPROM processor 2 fault

External stop

Output stage error

Control unit (processor run-on)

Control unit watchdog run-on fault

Control rod position sensor - loose contact

EGR actuator (permanent deviation)

PBM interface

Overvoltage protection

Plug connections

EDC diagnostic tools

MAN-Cats Diagnostics System

MAN-Cats - Software Description

Rating data sheet

1. Revision list

2. Scope This data sheet comprises the specifications and tests for the electronic control unit EDC-MS5 requi-

3. General features

4. Temperature range Ta: Temperature of mounting surface

5. Mechanical characteristics

6. Electrical ratings

7. Immunity to interference Pulses in accordance with ISO 7637-2 are permitted on the batt+/batt- line if they are within the fol-

8. Resistance to motor vehicle-specific liquids / fluids The control unit is resistant to diesel fuel, petrol, engine oil, engine cleaner, brake fluid, battery acid,

9. Mechanical test data

10. Service life test

EDC-Connection diagram

1. Key to definitions

2. General information

3. Description of inputs and outputs