Текст документа
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. 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. 2002 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: 04.2002 51.99598–8063 1
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Contents
Contents Foreword 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety information 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Diesel Control 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System description 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component description 8 . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control unit plug connector 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MS 5 injection pump 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MS 5 Electromagnetic fuel volume regulator 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control-slider adjusting mechanism 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . Resistor bank 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Redundant cut-out device Safety relay 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive stage selection 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charge-air, coolant and fuel temperature sensors 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charge-air pressure sensor (51.27421–0181) 16 . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . RPM sensor 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector and needle movement sensor 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notes on operation 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-diagnosis 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check-list 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting chart 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting program 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug connections 62 . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EDC diagnostic tools 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAN-Cats Diagnostics System 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAN-Cats – Software Description 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rating data sheet 83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection diagram 91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Diesel Control Description of inputs and outputs 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Diesel Control Guidelines for Preparing Wiring Harnesses 119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable cross-section 134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. Index 136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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Safety information
Safety information General Important safety regulations are summarized in this quick-reference overview and arranged by topic to ef- fectively convey the knowledge necessary to avoid accidents causing injury, damage or environmental haz- ard. The engine operating manual contains further information. Important: Should an accident occur despite all precautionary measures, particularly one involving contact with corros- ive 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 re- pair 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 ЛЛ 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: 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
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Safety information
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 M Ω 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 TЬV (German test- ing 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 en- gines are to be laid up or placed into storage for more than 3 months. 4
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