RA-EDC-51-99493-8486-GB (EN)

Foreword

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. Best regards MAN Nutzfahrzeuge Aktiengesellschaft Nuremberg Plant Since our products are in continuous development, we reserve the right to make technical modifications. 1998 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:

03.1998 51.99493–8486 1

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Contents

Contents Safety information 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic diesel control 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System description 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component description 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control unit plug connector 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection pump 13 . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electromagnetic fuel-delivery regulator 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrohydraulic shut-off device EHAB 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pedal value transmitter (hand throttle signal) 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature sensors for charge air, coolant and fuel 17 . . . . . . . . . . . . . . . . . . . . . . . . . Turbo pressure sensor 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RPM sensor 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EDC operating element 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notes on operation 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-diagnosis 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flash code 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of checking procedures 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting chart 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting program 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pedal value transmitter (PWG, hand throttle signal) 33 . . . . . . . . . . . . . . . . . . . . . . . . . . Boost air temperature sensor 34 . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed sensor 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boost pressure sensor 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control rod position transducer (Rack travel sensor) 37 . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant temperature sensor 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel-delivery regulator 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. Auxiliary rpm sensor 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel temperature sensor 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Undervoltage 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Request button (brake) “Br” button on EDC operating element 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control unit 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine overspeed 45 . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multistage switch for engine speed 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EDC operating element for idle speed setting 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main relay 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Atmospheric pressure sensor (in control unit) 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrohydraulic shut-off device EHAB 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. Control unit EEPROM computer, 1 fault 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control unit EEPROM computer, 2 faults 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External stop switch 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control unit (processor afterrunning) 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control unit, after-running watchdog fault 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control rod travel transmitter – loose contact 56 . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . Plug connections 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine terminal box 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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Contents

Contents Arrangement of sensors for boost air system 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arrangement of sensors for cooling system 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arrangement of sensors for speed pickup and fuel system 63 . . . . . . . . . . . . . . . . . . . . . . . Arrangement of sensors for coolant level and oil pressure 64 . . . . . . . . . . . . . . . . . . . . . . . Arrangement of fuses 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EDC-diagnose-tools 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . MAN-Cats System 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAN-Cats – Software Description 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of EDC-Check with pinadapter 83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminal connection diagram 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminal connection diagram – Brief overview 87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Safety information

Safety information General Important safety regulations are summarized in this quick-reference overview and ar- ranged by topic to effectively convey the knowledge necessary to avoid accidents caus- ing 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, anti- freeze splashing into the eyes etc. you must seek medical assistance immediately. 1.

Instructions for avoiding accidents causing injury Only authorized and qualified personnel are permitted to carry out inspection, ad- justment and repair work D Put gearbox of ship into neutral, if necessary unhinging gearshift lever (disconnect via remote control) D Firmly secure units and assemblies on disassembly D Only authorized personnel are permitted to start and operate the en- gine D Do not stand too close to rotating parts while the engine is running Wear close-fitting working clothes D Do not touch hot engine with bare hands: Danger of injury by burning ЛЛ 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: Danger of injury! D Persons must not stand under an engine suspended on a crane hook. Keep lifting gear in perfect condition 4

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