Académique Documents
Professionnel Documents
Culture Documents
EDC
for EURO 3 engines
Publication number:
51.99496.8145
Receipt
of the
Installation Directive
We confirm the complete receipt of _________ copies of the above installation directive
______________________ ______________________
(Company) (Name, in letters)
_______________________ ______________________
(Place, date) (Signature)
D-80976 Mnchen
Installation directive EDC for EURO 3 engines
MS5 stage 5 and MS6.4 stage 2
Installation directive
EDC MS5/St.5
EDC MS6.4/St.2
Directive
for the installation of MAN diesel engines
in vehicles and automotive
machinery
1. General ................................................................................................................................... 5
1.1 Introduction .............................................................................................................................. 5
1.2 Warranty .................................................................................................................................. 5
7. Installation inspection......................................................................................................... 26
7.1 Testing the EDC components (installation and functioning) .................................................. 26
7.1.1 First-time installation.............................................................................................................. 26
7.1.2 Series production................................................................................................................... 26
7.2 EMC testing ........................................................................................................................... 27
7.3 End-of-Line programming (EOL) ........................................................................................... 27
8. Appendices
1. General
1.1 Introduction
This present installation directive is a supplement to the general directive for the installation of MAN die-
sel engines in vehicles and automotive machinery to 51.99493-8283, describing specifically the installa-
tion of MAN engines with EDC (version MS5 stage 5 and MS6.4 stage 2) in vehicles from other
manufacturers.
functional risks
1.2 Warranty
the genuine MAN parts contained in the extent of delivery are used
the first-time installation has been cleared by MAN after an installation inspection (see Point 7),
the series-production vehicles of the model approved correspond to the first-time installation
cleared,
MAN guarantees EMC for the individual components (e.g. EDC control unit) contained in the extent
of delivery.
Reprinting, copying or translation, even of extracts, is not allowed without written permission from MAN. All rights
under the copyright law are strictly reserved by MAN.
1.3 Abbreviations
2. Installation manual
2.1 Description
2.1.1.1 Structure
(30) (8)
(28) (9)
(10)
EDC-Steuergert (11)
EDC control unit (12)
(13)
(14)
(27) (26) (25) (24) (23) (22) (21) (20) (19) (18) (17) (16) (15)
Apart from the injection pump and the EDC control unit, the main constitutents are:
The EDC system consists of a control-slide injection pump. The electro-magnetic control rack, in which
the two main constructional components, namely the fuel control rack and the pre-stroke/delivery start
control rack, are housed, is flanged on to the injection pump. The most important components of the con-
trol rack are the linear magnets for adjusting the fuel quantity and the pre-stroke/start of delivery.
Apart from the linear magnets the control rack also contains
The pre-stroke/delivery-start control rack also contains a linear magnet, whose armature effects a rotary
motion of the control-slide adjusting shaft via an adjusting lever.
In the individual elements of the injection pump this rotary motion is converted into a longitudinal motion
of the control-slide elements sliding on the pistons in the injection-pump elements. The even height ad-
justment of the control slides results in a change of delivery start and delivery end.
In the de-energised condition the adjusting shaft too is set by a spring so that the control slides are in
top position, ie in late start-of-delivery position.
The control unit controls the entire process of the injection system. For this purpose it processes the data
from the sensors and triggers the linear magnets in the control rack and the shutoff flap in the AGR cy-
linder as a function of the maps stored. In addition, the control unit assumes the monitoring and substi-
tute functions.
The speed pickup is installed in the flywheel housing in such a way that 10 after TDC an engine-speed
pulse is triggered. The time difference between the needle motion sensor pulse and the first subsequent
engine-speed pulse is used by the EDC for calculating its start of injection.
The auxiliary speed pickup is installed in the flywheel housing in such a way that 18 after TDC an en-
gine-speed pulse is triggered. The signals from the auxiliary speed pickup are used for redundant ascer-
tainment of the engine speed and have no function with regard to the calculation of the injection timing.
The two transmitters, which are installed in the same way, must not be mixed up, as otherwise the EDC
will set a start of delivery which is 8 too late, which would cause excessive formation of white smoke
and may result in the destruction of the injection-pump camshaft.
The needle motion sensor records the start of injection by means of a sensor which is directly integrated
into the nozzle holder. This sensor indicates the time of fuel injection by recording the motion of the
needle.
Further components fitted to the engine are the two transmitters for coolant and fuel temperatures. The
EDC unit controls the injection quantity and the start of delivery as a function of the coolant and fuel tem-
peratures. In addition the coolant temperature transmitter has an engine overheating prevention
function, ie between 95 C and 110 C the output is linearly reduced to 50%.
The fuel temperature is a yardstick for the EDC's compensation of the change in the fuel delivery as a
result of temperature fluctuations.
The charge-air pressure sensor basically performs the functions of the aneroid device in a mechanical
injection pump, ie the fuel quantity is controlled as a function of the charge-air pressure.
As a function of the engine's operating condition the electro-pneumatic shutoff flap is triggered by the
EDC, which means that part of the flow of exhaust gases is admixed to the compressed intake air. This
measure helps reduce the combustion temperature and, consequently, the formation of oxides of nitro-
gen.
In addition, the temperature of the compressed intake air is recorded and processed by the EDC for trig-
gering the lamp in the AGR cylinder.
2.1.2.1 Structure
Apart from the injection pump and the EDC control unit, the main constitutents are:
1 Speed pickup 14 ISO interface
2 Pedal value transmitter 15 Terminal 15
3 Needle motion sensor 16 Terminal 30
4 Charge-air pressure sensor 17 PBM interface (ASR)
5 Coolant temperature sensor 18 CAN interface
6 Stalk switch 19 Engine brake
7 FGB/FGR switch 20 Engine brake
8 Check lamp, FGB set 21 Speed signal
9 Proximity switch for brake pedal 22 Antigas
10 Proximity switch for clutch pedal 23 Redundant shutoff
11 Engine speed signal 24 Multi-stage input (mom. & eng. speed limiter)
12 PWG > threshold 25 Multi-stage input (for HGB)
13 Check lamp for EDC 26 ISG
The EDC system consists of a radial-piston distributor injection pump. The pump control unit is integra-
ted into the injection pump; data are transferred between the pump control unit and the EDC control unit
via a CAN data bus.
The radial-piston distributor injection pump consists of the following components installed inside or fitted
to the pump housing:
Vane-type delivery pump with pressure control valve and overflow reducing valve
Radial-piston high-pressure pump with distributor shaft and exhaust valve
High-pressure solenoid valve
Injection timer with solenoid valve
Angle sensor
Pump control unit.
In the radial-piston distributor injection pump a vane pump delivers the fuel. A radial-piston pump with
cam ring and two to four radial pistons generates and delivers the high pressure. A high-pressure sole-
noid valve meters the injection quantity. The start of delivery is adjusted by turning the cam ring with the
injection timer.
The EDC control unit and the pump control unit control the entire injection system. While the pump con-
trol unit records pump-internal signals for the rotation angle and the fuel temperature and specifies the
start of delivery and the injection quantity with the data from the EDC control unit, the EDC control unit
records additional sensor signals. These together with the maps stored in the EDC control unit are used
for calculating the corresponding adjustment. In addition, within the safety concept the EDC control unit
performs various monitoring and substitute functions.
The needle motion sensor records the start of injection by means of a sensor which is directly integrated
into the nozzle holder. It indicates the time of fuel injection by recording the motion of the needle.
Further components fitted to the engine are the two transmitters for coolant and fuel temperatures.
The EDC unit controls the injection quantity and the start of delivery as a function of the coolant and fuel
temperatures. In addition the coolant temperature transmitter has an engine overheating prevention
function, i.e. between 95 C and 110 C the output is linearly reduced to 50%.
The charge-air pressure sensor basically performs the functions of the aneroid device in a mechanical
injection pump, ie the fuel quantity is controlled as a function of the charge-air pressure.
The pedal value transmitter has the same function as is known from the E-gas system.
The stalk switch incorporates various functions which depending on the vehicle's operating condition can
be activated and programmed.
With the FGR/FGB switch it is possible to switch over from the road speed control function to the road
speed limitation function.
The sensors at the clutch and brake cause the shutoff of the cruise control if the pedal is actuated. If no
cruise control is installed, the brake signal should be connected as well as a redundance of an incorrect
accelerator.
Apart from indicating faults, the "EDC" (H296 for MS5 stage 5 and H141 for MS6.4 stage 2) check lamp
together with a diagnosis request button also has the function of signalling/emitting fault codes (see also
chapter 2.2.1).
The ISO interface makes it possible to emit fault codes via MAN-CATS, MAN's diagnostic system (see
also chapter 2.2.2).
Speed signal
To ensure that the EDC functions faultlessly, the following parameter data for the road speed pulse (eg
signal output B7 from tachograph) must be strictly observed:
If there is no fitting value for the speedometer to be found in the vehicle, a stopping of the vehicle can
be simulated. To avoid the entry of a fault, the input for the road speed pulse at the control unit pulse
(EDC control pin 51 for MS5 stage 5 and pin B29 for MS6.4. stage 2) must be provided with a resistor
of approx. 1.55 k from sensor mass pin 13 for MS5 stage 5 and pin 35 for MS6.4 stage 2 to mass
of engine/vehicle.
(1)
(2)
(3)
(4)
The reference potential is supplied to plug connection X852 or also to the control unit pin 45(5V) for MS5
stage 5 and pin B16 for MS6.4 stage 2 or pin 13 for MS5 stage 5 and pin B35 for MS6.4 stage 2
sensor mass. The reference potential (signal mass) must not be connected with other mass potentials.
In the range between 569976 mV the idle speed switch must be simulated for reasons of plausibility
monitoring by applying the signal mass via a 1k resistor to the EDC control unit pin 39 for MS5 stage
5 and pin B16 MS6.4 stage 2.
2.2 Diagnosis
The EDC system itself monitors computer functions, the control rack and sensors. Depending on the
fault occurring, the following measures are automatically initiated:
Switching over to suitable substitute functions or restricting of certain engine functions. With the aid
of this emergency driving program it is usually possible to continue the journey to the nearest work-
shop.
Immediate engine shutoff insofar as this is required for reasons of safety. Depending on the fault
occurring, the engine is switched off either by a reduction of the fuel quantity to zero or by an emer-
gency shutoff, which is effected by means of a redundant relay which de-energises the fuel control
rack.
As a warning the check lamp H296 for MS5 stage 5 and H141 for MS6.4 stage 2 indicates critical
system faults by being permanently lit. Non-critical faults are not indicated, but they are stored.
To carry out diagnosis or measurements while the vehicle is in motion, the diagnostic socket X200 and
the plug X210 must be installed inside the vehicle, if possible in a well-accessible position.
To facilitate subsequent fault identification, faults recognised - including those occurring only temporarily
- are stored by an integrated self-diagnostic system. A flash code makes it possible to locate faulty
function paths. In such cases the check lamp H296 for MS5 stage 5 and H141 for MS6.4 stage 2 dou-
bles as a diagnostic lamp.
The flash code is triggered by a request button according to the following circuit diagram. When required,
the request button, which is provided with a cable and a plug, is connected up to plug X210.
If no check lamp is integrated into the request button, flash codes can also be read from check
lamp H296 for MS5 stage 5 and H141 for MS6.4 stage 2.
While the engine is stationary and the ignition is switched on, keep diagnostic request button pressed
for at least 2 seconds. The EDC check lamp H296 for MS5 stage 5 and H141 for MS6.4 stage 2 and
the check lamp in the request button come on.
CAUTION: Before the ignition is switched on (switching on of the EDC) the request button must
neither be actuated, nor must it be subsequently kept pressed for more than 2.5
seconds, as otherwise the fault memory will be deleted after the button has been
released.
After a brief dark phase of approx. 3 seconds the flashing commences, the number of flashing pulses
indicating the faulty function.
Lamp in request button Ein= ON, Aus = OFF "Long flash 2, short flash 5"
If more than one fault is stored, they will be indicated one after the other. For this purpose the request
button is to be pressed for each and every fault until the flash code for the first fault is displayed again.
Delete the fault memory after rectification of the fault. Switch on the EDC while keeping the request but-
ton pressed. After the EDC has been switched on the button must be kept actuated for at least 2.5 se-
conds but not for more than 10 seconds. Once the button is released the fault memory will be deleted.
To carry out diagnosis with MAN-CATS, the X200 test plug is absolutely necessary. The diagnostic
system is available from MAN.
3. Safety regulations
To prevent injury to persons and damage to the engine and the EDC system, the following rules are to
be observed:
Never start engine unless the batteries are firmly connected up. The battery terminals must be
tightened.
Wrong poling of the control unit supply voltage (eg wrong poling of batteries) may lead to the
destruction of the control unit. Polarity reversal is to be ruled out through supply via the EDC main
relay.
Do not use a quick charger for starting the engine. Starting aid is to be provided only with the aid of
separate batteries.
Always connect up the EDC via the main relay (K170), as otherwise after-running and, conse-
quently, the storing of faults are not possible.
To quick-charge batteries, disconnect them from the vehicle electrics. Observe the operator's
instructions for the quick charger.
Never pull off or connect up the cable plug of the control unit while the power supply is switched on
(ignition).
Remove control unit if the temperatures are above +80 C (drying oven / excessive heat).
To avoid damage to electronic assemblies, e.g. EDC control unit, while performing electric welding,
the following instructions have to be observed:
- Disconnect negative and positive cable of the batteries, connect loose terminals of the cables
with each other (- and +).
- Switch on main battery switch (mechanical switch) and/or bridge electric battery switch at magnet
(disconnect cables and join them).
- To achieve good conductivity attach mass tongs of the welding unit directly to the spot to be
welded.
- If two parts are to be welded together they are to be connected so as to be highly conductive
(e.g. connect both parts with mass tongs).
- Electronic assemblies do not have to be disconnected if the above precautions are taken.
Only those relays may be used whose technical data conform to the MAN specifications "Relays for
commercial vehicles".
IMPORTANT: Each and every control unit is allocated to a certain engine with the aid of the respective
engine number and ought to be installed only together with this engine.
Temperature range:
Operating temperature, stationary air:-40 C to +65 C
Operating temperature, air in motion: -40 C to +70 C
Voltage supply:
A check lamp for indicating faults and emitting flash codes is to be provided.
Installation location: Good view of the check lamp while the vehicle is in motion or the engine is
running must be ensured (e.g. instrument panel).
Installation location: The switch should be within easy reach while the vehicle is in motion
(e.g. attachment to steering column).
The air gap between sensor and switching bar must be 20.2 mm.
The switch must be actuated at the start of the pressure triggering action for the service brake.
The air gap between sensor and switching bar must be 20.2 mm.
The switch must be actuated before clutch separation.
5. Installation variants
On request, the road-speed control and limitation functions integrated into the EDC system can be
realised according to the circuit diagram example (see Appendix).
MS5 stage 5
The switch for FGR/FGB is not necessary for road-speed control alone. However, if the road-speed limita-
tion function is to be realised alongside the road-speed control function, the switch is to be connected up
according to the circuit diagram example (see Appendix).
During brake actuation +UBAT is applied to the EDC control pin 43; when the brake is not actuated
approximately 0 Volt (0 2.0 Volt) will be present at pin 43.
During clutch actuation +UBAT is applied to the EDC control pin 26; when the clutch is not actuated approxi-
mately 0 Volt (02.0 Volt) will be present at pin 26.
MS6.4 stage 2
The switch for FGR/FGB is not necessary for road-speed control alone. However, if the road-speed limita-
tion function is to be realised alongside the road-speed control function, the switch is to be connected up
according to the circuit diagram example (see Appendix).
During brake actuation +UBAT is applied to the EDC control unit/pin B/26; when the brake is not actuated
approximately 0 Volt (02.0 Volt) will be present at pin B/26.
During clutch actuation +UBAT is applied to the EDC control unit/pin B/20; when the clutch is not actuated
approximately 0 Volt (02.0 Volt) will be present at pin B/20.
If necessary, the brake and clutch signals may be used for clearing engine-speed and PTO functions.
If a retarder is used, cruise control may be switched off as soon as the retarder is activated.
The relay should be triggered according to the circuit diagram example (see Appendix).
The engine brake function depends on the engine speed and is performed by the EDC control unit.
During engine brake operation the injection quantity is reduced to zero. Below a certain engine speed
(approx. 1000 rpm) the engine brake is switched off.
The button and the solenoid valve should be triggered according to the circuit diagram example
(see Appendix).
5.4 Antigas
In automatic gearboxes, the gearbox electronics emits a signal (24V for ZF-HP) "Antigas" for approx. 1
second when a gear is being engaged from neutral position. This signal must be sent to the EDC control
unit pin 50 for MS5 stage 5 and pin B21 for MS6.4 stage 2 (see circuit diagram example). This mea-
sure protects the clutches which can be charged with the full engine moment only after approx. 1 second.
In the event of "Antigas" the injection pump is forcibly set to idle-speed quantity, which prevents any ac-
celeration for approx. 1 second.
The PBM interface is on the EDC control unit, on pin 29 for MS5 stage 5 and pin B7 for MS6.4
stage 2 (DKV) and pin 52 for MS5 stage 5 and pin B30 for MS6.4 stage 2 (DKR).
Description of interface:
The EDC's quantity specification is transmitted via the DKV signal. If necessary, the ASR electronics
emits the reduction request via the DKR signal. The engine output is then reduced via the EDC electro-
nics through this signal. As a result, an engine control function (ASR) is feasible with the EDC system.
If an automatic gearbox (e.g.: ZF-HP) is installed, the gearbox control unit must be given a load signal
(PBM signal: DKV) by the EDC. To ensure that the automatic gearbox functions faultlessly, the gearbox
electronics must receive information on the engine's load condition from the EDC control unit. To make
the load signal (DKV) available +24 V (pin 15/16 for MS5 stage 5 and pin B3/B4 for MS6.4 stage 2)
have to be connected to the DKR input (pin 52 for MS5 stage 5 and pin B 30 for MS6.4 stage 2).
The realisation of this variant can be learned from the circuit diagram example (see Appendix).
If ASR (without CAN interface) is installed, the PBM interface must be connected with the ASR control
unit as shown in the above diagram.
If ASR is installed together with an automatic gearbox (without CAN interface), the engine load signal
(DKV) must be additionally wired from the EDC control unit pin 29 for MS5 stage 5 and pin B7 for
MS6.4 stage 2 to the gearbox electronics.
On request, the ASR can be shut off. ASR shutoff is possible in 2 ways which must be realised differently,
depending on the ASR control unit fitted:
Interruption of the DKR line by means of a button, as shown in the circuit diagram example (see
Appendix)
Application eg if ABS/ASR-SG 2E (Bosch) is used.
The control unit is CAN-capable, i.e. a connection for communication via CAN data bus with other control
units is possible. The CAN interface is on the EDC control unit, on pin 30 (CAN-L) for MS5 stage 5 and
pin B11 for MS6.4 stage 2 plus pin 31 (CAN-H) for MS5 stage 5 and pin B12 for MS6.4 stage 2.
The CAN data bus conforms to the latest SAE J1939 and ISO/DIS 11898 - 24V standards. One of the
terminating resistors (120 ) is integrated into the EDC control unit. The maximum data line length be-
tween the 2 terminating resistors must not exceed 40 m. If spur lines are used, these must not be longer
than 1 metre. If several spur lines are used the distance between the individual nodes must be at least
10 cm. The nodes of the spur line ought to be ultrasonically welded; plug connections should under all
circumstances be avoided because of the transition resistances. The data line ought to be an unshield-
ed, 2-core twisted line with a cross-section of 1mm and a lay number of approx. 30/m.
When the accelerator pedal is actuated, the EDC control unit pin 6 emits +UBAT for MS5 stage 5 and
pin A32 emits +UBAT for MS6.4 stage 2 (see circuit diagram example).
This signal can be used eg for deleting the moving-off interlock function.
Function: Increasing the engine speed "SET+"/lowering the engine speed "SET-"; this is possible only if
cruise control is installed (see circuit diagram examples).
If the signal from the EDC control unit pin 44 for MS5 stage 5 and pin B8 for MS6.4 stage 2 is supplied
to the cruise-control operating unit/pin 1/2 ("SET+ external") or if the "SET+" button of the cruise-control
operating unit is actuated, the engine speed will infinitely run up to a programmable upper engine-speed
limit; if this activation is interrupted, the EDC will set the current engine speed.
If the signal from the EDC control unit pin 44 for MS5 stage 5 and pin B8 for MS6.4 stage 2 is supplied
to the cruise control operating unit/pin 1/3 ("SET- external") or if the "SET-" button of the cruise-control
operating unit is actuated, engine speed will infinitely run down to a programmable lower engine-speed
limit; if this activation is interrupted, the EDC will set the current engine speed.
The engine speed set will be switched off, i.e. the engine will run down to a programmable lower engine
speed by interruption, by actuating the "external OFF button", the external bridge at the cruise control
operating unit between pin 1/1 and 1/5.
If the signal from the EDC control unit pin 44 for MS5 stage 5 and pin B8 for MS6.4 stage 2 are sup-
plied to the cruise-control operating unit/pin 1/4 ("MEM external") or if the "MEM" button of the cruise
control operating unit is actuated, the engine will run up to the intermediate engine speed last run up to.
5.8.2.1 ISG 1
If the EDC control unit pin 23 is supplied with +UBAT for MS5 stage 5 and pin B32 with +UBAT for
MS6.4 stage 2 (see circuit diagram examples),(see circuit diagram examples), the engine speed will run
up to the MAN-CATS-programmable "intermediate speed 1" and be controlled while +UBAT is present.
When the supply of +UBAT is stopped, ISG 1 will be switched off and the engine will be controlled back
to idle speed.
5.8.2.2 ISG 2
If the EDC control unit pin 41 is supplied with +UBAT for MS5 stage 5 and pin B33 with +UBAT for
MS6.4 stage 2, the engine speed will run up to the MAN-CATS-programmable "intermediate speed 2"
and be controlled while +UBAT is present. When the supply of +UBAT is stopped, ISG 2 will be switched
off and the engine will be controlled back to idle speed.
5.8.2.3 ISG 3
If the EDC control unit pins 23 and 41 are supplied with +UBAT for MS5 stage 5 and pins B32 and
B33 with +UBAT for MS6.4 stage 2, the engine speed will run up to the MAN-CATS-programmable "in-
termediate speed 3" and be controlled while +UBAT is present. When the supply of +UBAT is stopped,
ISG 3 will be switched off and the engine will be controlled back to idle speed.
The multi-stage switching input can be supplied with four different voltage levels through the use of the
resistor group. This makes it possible to limit the engine speed or moment. For standard reasons the
driving characteristic has to be wired.
The multi-stage switching input can be supplied with two different voltage levels through the use of the
resistor group. This makes it possible to switch to a second maximum speed limit. For standard reasons
HGB1 (0) must be wired.
If +24 V (pin 15/16 for MS5 stage 5 and pin B3/B4 for MS6.4 stage 2) are supplied to pin 40 for MS5
stage 5 and pin B34 for MS6.4 stage 2 of the EDC control and (progammable) by means of "external
engine stop button", the engine is stopped. The EDC control unit, however, is still supplied with electricity
so that the interfaces to other control units are maintained.
An engine-speed signal in the form of square-wave pulses can be picked up from the EDC control unit
pin 28 for MS5 stage 5 and pin B5 for MS6.4 stage 2. This signal may be used e.g. for externally con-
trolling the setting of a certain engine speed via "SET+" and "SET-".
1. Output stage (switching mode) - open collector with pull-up (2.55 k) to +UBat
2. Signal form
Example:
a) Load resistance to earth point Voltage Ux Calculated with UBAT = 28 V
2 k 12.30 V
5 k 18.50 V
10 k 22.30 V
200 k 27.65 V
b) Load resistance to plus (pull-up) in the counter unit
Max. 1.8 k permissible, since the output stage is specified for I0 = 18 mA.
6. Installation instructions
Notes on cabling
The entire engine cabling up to the 35-pole engine interface X337 is contained in the MAN extent of
delivery.
NOTE: Engine and MAN cabling are checked up to the 35-pole plug
connection (X337). For the cabling on the vehicle the use of
MAN cable harnesses is recommended. These are available in
different lengths.
.
If you are providing the vehicle cabling from interface X337 onwards yourself, proceed as shown in the
relevant circuit diagram (see Appendix). For EMC reasons 2 ferrite rings have to be included in any
case for MS6.4 stage 2. The overall cable length from the control rack (Y130) of the injection pump to
the control unit (A142) must not be more than 6 metres, as otherwise the required capacity reserve of
approx. 300 pF can no longer be guaranteed.
The engine interface is to be attached to the vehicle, and the cable harness is to be additionally fastened
in brackets at a distance of 150200 mm from and on both sides of the plug connection.
The relevant cable routing (kinks, moisture etc.) is to be learned from the job instruction (see Appendix).
.
7. Installation inspection
The EDC engine is to be installed by the vehicle manufacturer according to the EDC installation directive
and be checked with the aid of a list of checking procedures (see Appendix), if necessary with MAN sup-
port. MAN will then grant installation clearance on the basis of this list of checking procedures.
Series production is
to be performed according to the first-time installation including the modifications made during the
commissioning of the first engine installed.
Prior to delivery each and every installation of an EDC engine ought to be examined by the vehicle ma-
nufacturer by means of a list of checking procedures (see Appendix).
Before the vehicle is handed over to the customer, the following measures are necessary in this se-
quence:
This procedure ensures that faults which occurred during commissioning at the manufacturer's are no
longer stored in the fault memory after delivery of the vehicle to the customer.
The vehicle manufacturer is to carry out on his own authority an EMC measurement of the entire vehicle
configuration to ensure that the electric and electronic systems function faultlessly.
8. Appendices
1. Checks while engine is stationary (ignition OFF, control unit not connected up)
* * Since August 97 new DG6 (51.27120-0008 /-0009) speed pickups have been fitted which differ in their electrical
resistance from the old DG2 (51.27120-0005 /-0006) speed pickups but are otherwise identical in their function.
Speed transmitter lower idle n=................1 rpm PWG Min (l.i.) Engine speed
(DZG) upper idle n=................1 rpm PWG Max (u.i.) (Monitoring 2)
Aux. speed transmit- lower idle n=................1 rpm PWG Min (l.i.) Auxiliary engine
ter *(HZG) upper idle n=................1 rpm PWG Max (u.i.) speed
(Monitoring 2)
Idle switch (LGS) 39 13 4.50 5.25 ....................... PWG Min Idle Open
(NO contact) 0 2.00 V ....................... PWG Max Upper idle Closed
Charge-air pressure sensor 36 13 0.94 1.20 ....................... PWG Min Idle 900-1050 mbar
(LDF) 36 13 1.10 1.40 ....................... PWG Max Upper idle 1000-1400 mbar
FGR operating unit 44 13 3.15 3.55 ....................... Not actuated Idle Neutral
1.41 1.80 ....................... Returnact. Return speed Memory
0.65 0.97 ....................... SET+act. Speed increas, SET+
2.30 2.75 ....................... SET-act. Speed drops SET-
3.72 4.33 ....................... AUSact Idle OFF
Multi-stage switch (MSS) 35 13 0.75 1.25 ....................... Pos 0 Idle Driving character-
istics
(Moment limiter active) 1.75 2.25 ....................... Pos 1 Multi-stage switch,
Pos 1
(Truck retarder actuated) 2.75 3.25 ....................... Pos 2 Multi-stage switch,
Pos 2
(Speed limiter active) 3.75 4.25 ....................... Pos 3 Multi-stage switch,
Pos 3
Braking contact switch 43 19 0.0 2.0 ....................... Not actuated Idle Open
(NO contact) ....................... Actuated Closed
UBat
Engine brake switch (MBR) 42 19 0.0 2.0 ....................... Not actuated Idle Open
(NO contact) UBat ....................... Actuated Closedd
Engine brake control 5 19 0.0 2.0 ....................... Not actuated Eng. speed
UBat ....................... Actuated > 850rpm
Check switch-off conditions (PWG intervention, brake, clutch) in every ISG mode 0..S, if necessary re-
programme them
0 0 ISG speed S 0
24 0 ISG speed 1 1
0 24 ISG speed 2 2
24 24 ISG speed 3 3
* With a delay of 0.5 to 5 secs. after the ignition has been switched off Pin 46 must switch over toUBat.
Interrupt voltage supply to safety relay (Pin 14), engine switches off
(max. 10 secs.)
This may prompt the message "fuel control rack monitoring" to be entered in the faulty memory
(10 x brief flash codes)
Switch off ignition, reconnect voltage supply up to safety relay and erase fault memory
K Checking flash code diagnosis: connect up Pins 21 and 13 (short-circuit speed transmitter)
The EDC check lamp must be ON (permanently lit); END speed is reduced
Request flash code (connect Pins 49 and 19 for at least 2 secs or actuate diagnosis switch for at
least 2 seconds but not for more than 10 seconds)
The flash code for speed transmitter defect must be emitted (4 x brief flash codes) or
Read out fault memory (current speed transmitter defect) with the aid of MAN-CATs
Disconnect Pin 21 from 13
Erase fault memory (via switch MAN-CATs)
Connect up decade capacitor between Pins 11 and 13 (to cable harness adapter)
Add auxiliary capacity until engine stops starting
Ascertain value:
set-point value > 300 pF without cable harness adapter
the capacity of the RB cable harness adapter: approx. 100 pF
Interrupt Pin 43
Drastically decelerate vehicle in cruise control operation
Cruise control must switch off (brake switch is classified as being defective)
It must be possible to reactivate cruise control only after the ignition has been switched off
Reconnect Pin 43
After completion of the checks the fault memory must be erased via the switch. After the ignition has
been switched on again no fault must be stored in the memory; otherwise the fault must be ascer-
tained and eliminated according to the troubleshooting plan.
Section
Pin Complete designation Abbre-
mm2 viation
Section
Pin Complete designation Abbre-
mm2 viation
Section
Pin Complete designation Abbre-
mm2 viation.
* Short-circuit PIN A1 and A13 (simulation DZG-defect -> diagnostic lamp is permanently ON).
EDC continues to run with IWZ signal
Pedal value trans- B23 B35 0.30 0.42 PWG Min low. idle 0%
mitter (PWG) 2.90 4.50 PWG Max up. idle 100%
Charge-air pres- A12 A17 0.95 1.12 PWG Min low. idle 900 1050 mbar
sure sensor (LDF) 1.00 1.52 PWG Max up. idle 1000 1400 mbar
FGR operating unit B8 B9 3.35 3.74 Not actuated low. idle Neutral
1.6 2.0 Return Return Memory
0.83 1.21 Set+ Eng. speed Set+
increases
2.53 2.97 Set- Eng. speed Set-
drops
4.18 4.53 OFF Idle OFF
Contacts must be made before clutch or brake are effective (max 20 mm pedal travel) and have to be reopened before concealed position
0 0 ISG speed S 0
0V Ignition OFF
B27 B2 0V Ignition ON
UBat Ignition ON
u Checking flash code diagnosis: connect up Pins A1 and A13 (short-circuit speed transmitter)
The EDC check lamp must be ON (permanently lit); END speed is reduced
Request flash code (connect Pins B24 and B2 for at least 2 seconds, do not actuate for more
than 10 seconds)
The flash code for speed transmitter defect must be emitted (4 x brief flash codes) or read out
fault memory (current speed transmitter defect) with the aid of MAN-Cats
Disconnect Pin B24 from Pin B2
Erase fault memory
Switch:
While pressing switch start ignition; release after 2 - 10 seconds and switch off ignition
MAN-CATS
After completion of the checks the fault memory must be erased via switch. After the ignition
has been switched on again no fault must be stored in the memory; otherwise the fault must be
ascertained and eliminated according to the troubleshooting plan.