MS5 and MS6.4 gb
Short Description
MAN EDC MS5 and EDC MS6.4...
Description
Installation directive
EDC for EURO 3 engines
Publication number: 51.99496.8145
Receipt of the Installation Directive EDC MS5 stage 5 EDC MS6.4 stage 2 Publication no. 51.99496.8145
First edition: September 2000
We confirm the complete receipt of _________ _________ copies of the above installation installation directive directive
______________________ (Company)
______________________ (Name, in letters)
_______________________ (Place, date)
______________________ (Signature)
Please return this this receipt receipt to: MAN Nutzfahrzeuge Aktiengesellschaft Abt. VEFT Postfach 50 06 20, D-80976 München (see overleaf)
Receipt of the Installation Directive EDC MS5 stage 5 EDC MS6.4 stage 2 Publication no. 51.99496.8145
First edition: September 2000
We confirm the complete receipt of _________ _________ copies of the above installation installation directive directive
______________________ (Company)
______________________ (Name, in letters)
_______________________ (Place, date)
______________________ (Signature)
Please return this this receipt receipt to: MAN Nutzfahrzeuge Aktiengesellschaft Abt. VEFT Postfach 50 06 20, D-80976 München (see overleaf)
MAN Nutzfahrzeuge Aktiengesellschaft Abt. VEFT Postfach 50 06 20
D-80976 Mü München
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
Publication number: 51.99496.8145
First edition September 2000
Page 1 of 27
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
Amendment status
------------------------------
First edition September 2000
Date
September 2000
Changes on pages First edition
Cleared by
Csoka / VEFT
Page 2 of 27
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
1. 1.1 1.2
General ................................................................................................................................... 5 Introduction.............................................................................................................................. 5 Warranty .................................................................................................................................. 5
2. 2.1 2.1.1 2.1.1.1 2.1.1.2 2.1.2 2.1.2.1 2.1.2.2 2.1.3 2.2 2.2.1 2.2.2
Installation manual ............................................................................................................... 7 Description............................................................................................................................... 7 EDC MS5 stage 5 ................................................................................................................... 7 Structure .................................................................................................................................. 7 Operating principle of the individual components.................................................................... 8 EDC MS6.4 stage 2 ............................................................................................................... 10 Structure ................................................................................................................................ 10 Operating principle of the individual components.................................................................. 10 Components on the vehicle ................................................................................................... 12 Diagnosis............................................................................................................................... 15 Diagnosis with flash code ...................................................................................................... 15 Diagnosis by means of the MAN-CATS diagnostic system................................................... 16
3.
Safety regulations ............................................................................................................... 17
4. 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11
Technical data on the electric components ..................................................................... 18 EDC control unit (A142)........................................................................................................ 18 Pedal value transmitter (B127) .............................................................................................. 18 Check lamp (H296)................................................................................................................ 19 Stalk switch for cruise control (S157) .................................................................................... 19 Proximity switch for brake pedal (S158) ................................................................................ 19 Proximity switch for clutch pedal (S159)................................................................................ 19 Relays (K170, K264, K321, K324, K173) .............................................................................. 19 EDC resistor group (R134) ................................................................................................... 20 Buttons (S281, S105) ............................................................................................................ 20 Switch (S284) ........................................................................................................................ 20 Solenoid valve (Y102)............................................................................................................ 20
5. 5.1 5.2 5.3 5.4 5.5 5.5.1 5.5.2 5.5.3 5.6 5.7 5.8 5.8.1 5.8.2 5.8.2.1 5.8.2.2 5.8.2.3 5.9 5.10 5.11 5.12
Installation variants............................................................................................................ 20 EDC with cruise control ......................................................................................................... 20 EDC with retarder .................................................................................................................. 21 EDC with engine brake.......................................................................................................... 21 Antigas................................................................................................................................... 22 PBM interface ........................................................................................................................ 22 EDC for automatic gearbox without ASR............................................................................... 22 EDC with ASR ....................................................................................................................... 22 ASR shutoff ........................................................................................................................... 23 CAN interface ........................................................................................................................ 23 PWG > Threshold .................................................................................................................. 23 Intermediate-speed control.................................................................................................... 23 Variable intermediate speeds................................................................................................ 23 Fixed intermediate speeds..................................................................................................... 24 ISG 1 ..................................................................................................................................... 24 ISG 2 ..................................................................................................................................... 24 ISG 3 ..................................................................................................................................... 24 Multi-stage switching input..................................................................................................... 24 Multi-stage switching input..................................................................................................... 24 External engine stop.............................................................................................................. 25 Engine-speed signal.............................................................................................................. 25
6.
Installation instructions ...................................................................................................... 26
First edition September 2000
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Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
7. 7.1 7.1.1 7.1.2 7.2 7.3
Installation inspection......................................................................................................... 26 Testing the EDC components (installation and functioning).................................................. 26 First-time installation.............................................................................................................. 26 Series production................................................................................................................... 26 EMC testing ........................................................................................................................... 27 End-of-Line programming (EOL) ........................................................................................... 27
8.
Appendices
First edition September 2000
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Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
1. 1.1
General Introduction
This present installation directive is a supplement to the general directive for the installation of MAN diesel engines in vehicles and automotive machinery to 51.99493-8283, describing specifically the installation of MAN engines with EDC (version MS5 stage 5 and MS6.4 stage 2) in vehicles from other manufacturers. To ensure purposeful operation and to prevent •
impairment of operating quality
•
functional risks
•
damage to or failure of the EDC
the EDC installation directive must be strictly observed. 1.2
Warranty
Warranty for the EDC is granted if: •
the genuine MAN parts contained in the extent of delivery are used
•
the installation directives and technical data are complied with,
•
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.
We reserve the right to make modifications in the course of further development. 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.
First edition September 2000
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Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
1.3
Abbreviations
The following abbreviations are used in this present installation directive:
AGR
Exhaust-gas recirculation
ASR
Anti-spin regulator
BAT
Battery voltage
CAN
Controller area network
DKR
Butterfly valve reduction
DKV
Load signal
EDC
Electronically controlled diesel injection (Electronic Diesel Control)
EMC
Electro-magnetic compatibility
EOL
End-of-line programming
EPP
Injection pump
ERL
Installation directive
FGB
Road speed limiter
FGR
Road speed control
HGB
Top speed limiter
LDA
Full load stop dependent on charge-air pressure
MAN-CATS
MAN computer-assisted testing and diagnostic system
NBF
Needle motion sensor
PBM
Pulse-width modulated signal (DKV, DKR)
PWG
Pedal value transmitter
SG
Control unit
Stv.
Plug connection
TKU
Technical document for customer
ZDR
Intermediate speed control
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Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
2. 2.1
Installation manual Description
2.1.1 EDC MS5 stage 5 2.1.1.1
Structure
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(30)
(8)
(28)
(9) (10)
EDC-Steuergerät
(11)
EDC control unit
(27)
(26)
(12) (13) (14)
(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: 1 Speed pickup
16
ISO interface
2 Auxiliary speed pickup
17
Terminal 15
3 Pedal value transmitter
18
Terminal 30
4 Needle motion sensor
19
PBM interface (ASR)
5 Charge-air pressure sensor
20
CAN interface
6 Fuel temperature sensor
21
Engine brake
7 Coolant temperature sensor
22
Engine brake
8 Stalk switch
23
Speed signal
9 FGB/FGR switch
24
Antigas
10 Check lamp, FGB set
25
Redundant shutoff
11 Proximity switch for brake pedal
26
Exhaust-gas recirculation cylinder
12 Proximity switch for clutch pedal
27
Air temperature sensor
13 Engine speed signal
28
ISG
14 PWG > threshold
29
Multi-stage input (moment & speed limiters)
15 Check lamp for EDC
30
Multi-stage input (for HGB)
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Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
2.1.1.2
Operating principle of the individual components
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 control 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 control rod travel transmitter
•
and an oil supply pump.
The fuel control rack works via a linear magnet whose armature acts directly on the fuel control rod, thus determining the injection quantity via the control rod travel. In the de-energised condition a spring keeps the control rod in or pushes it into zero delivery position. 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 cylinder as a function of the maps stored. In addition, the control unit assumes the monitoring and substitute functions. The control unit (A142) processes information received from: •
the control rod travel transmitter in the control rack (Y130)
•
the switching contact in the AGR cylinder (Y280)
•
the air temperature sensor (B123)
•
the pedal value transmitter (B127)
•
the charge-air pressure sensor (B125)
•
the coolant temperature sensor (B124)
•
the fuel temperature sensor (B197)
•
the speed transmitter (B7 signal from speedometer)
•
the operating unit for road speed control (S157)
•
the FGR/FGB switch (S284)
•
the proximity switch at the brake pedal (S158)
•
the proximity switch at the clutch pedal (S159)
•
the speed pickup and auxiliary speed pickup (B199 and B200)
•
the needle motion sensor (B198)
•
the PBM or CAN interface
•
the battery voltage (terminal 15)
•
the main relay (K170)
•
the resistor group (R134).
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Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
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 engine-speed pulse is triggered. The signals from the auxiliary speed pickup are used for redundant ascertainment 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 temperatures. 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 nitrogen. In addition, the temperature of the compressed intake air is recorded and processed by the EDC for triggering the lamp in the AGR cylinder.
First edition September 2000
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Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
2.1.2 EDC MS6.4 stage 2 2.1.2.1
Structure
EDC control unit
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
2.1.2.2
Operating principle of the individual components
The EDC system consists of a radial-piston distributor injection pump. The pump control unit is integrated into the injection pump; data are transferred between the pump control unit and the EDC control unit via a CAN data bus.
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Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
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 solenoid 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 control 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 control unit (A142) processes information received from: •
the control rack/pump control unit (Y130)
•
the pedal value transmitter (B127)
•
the charge-air pressure sensor (B125)
•
the coolant temperature sensor (B124)
•
the speed transmitter (B7 signal from speedometer)
•
the operating unit for road speed control (S157)
•
the FGR /FGB switch (S284)
•
the proximity switch at the brake pedal (S158)
•
the proximity switch at the clutch pedal (S159)
•
the speed pickup (B199)
•
the needle motion sensor (B198)
•
the PBM or CAN interface
•
the battery voltage (terminal 15)
•
the main relais (K170)
•
the resistor group (R134).
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 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.
First edition September 2000
Page 11 of 27
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
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. 2.1.3 Components on the vehicle The components on the vehicle are: •
pedal value transmitter
•
check lamp
•
stalk switch
•
proximity switch for brake pedal
•
proximity switch for clutch pedal
•
FGR/FGB switch
•
resistor group
•
relay for redundant shutoff
•
diagnostic sockets
•
main relais
• tachograph. 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:
First edition September 2000
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Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
Parameter Frequency
Min.
Type
0.5
2
Pulse duration Pulse duration fault Voltage UL Voltage UH Internal resistance
Max. 0,55 MS5 St.5 0,75 MS6.4 St. 2 5.45 ±1 2.5
5.5 2
Unit kHz ms % V V kΩ
Remark Synchronous to transmitter input frequency = 16000/k (k = pulses/km) * I = 1mA I = 1mA
* Standard setting : 2ms for k = 8000 pulses/km
Simulation values for the speedometer 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. 1.5 – 5 kΩ from sensor mass pin 13 for MS5 stage 5 and pin 35 for MS6.4 stage 2 to mass of engine/vehicle.
Note:
A simulation of the pedal value transmitter and speedometer is permissible only in vehicles not subject to the relevant statutory stipulations and regulations from the authority in charge.
First edition September 2000
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Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
Simulation values for the pedal value transmitter
Lower idle speed: Idle speed switch:
257 – 539 mV / Upper idle speed: 2944 – 4501 mV Switching point at 569 – 976 mV (typical: 800 mV)
(1)
(2)
(3) (4) (1) Upper idle speed; (2) Lower idle speed;
(3) entry of fault(s) (4) Idle-speed switch range (typical: 800 mV)
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 569 – 976 mV the idle speed switch must be simulated for reasons of plausibility monitoring by applying the signal mass via a 1kΩ resistor to the EDC control unit pin 39 for MS5 stage 5 and pin B16 MS6.4 stage 2.
Note: A simulation of the pedal value transmitter is permissible only if the simulation control includes the error monitoring with the required reactions.
First edition September 2000
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Installation directive EDC for EURO 3 engines MS5 stage 5 and 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 workshop.
•
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 emergency 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. 2.2.1 Diagnosis with flash code 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 doubles 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 .
Request button for EDC diagnosis
EDC electronics (code emission) EDC electronics (code request) Mass
The fault(s) stored is/are retrieved according to the following instruction: 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.
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Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
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.
NOTE: For the significance of flashing pulses see Repair Manual T 17-A1 for MS5 stage 5 and T 17-A2 for MS6.4 stage 2
Lamp in request button Ein= ON, Aus = OFF "Long flash 2, short flash 5" Dark phase before output: Duration of a long flash: Dark phase between two long flashes: Dark phase between a long and a short flash: Duration of a short flash: Dark phase between two short flashes:
3 sec. 2 sec. 1 sec. 5 sec. 0.5 sec. 0.5 sec.
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 button pressed. After the EDC has been switched on the button must be kept actuated for at least 2.5 seconds but not for more than 10 seconds. Once the button is released the fault memory will be deleted. 2.2.2 Diagnosis by means of the MAN-CATS diagnostic system To carry out diagnosis with MAN-CATS, the X200 test plug is absolutely necessary. The diagnostic system is available from MAN.
First edition September 2000
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Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
3.
Safety regulations
To prevent injury to persons and damage to the engine and the EDC system, the following rules are to be observed: •
In the event of unintended acceleration or of an unintended increase in engine speed immediately actuate the clutch and brake. If engine speed fails to drop, bring vehicle to an immediate stop, switch off ignition and, if necessary stall the engine.
•
When working on the vehicle electrics, always disconnect battery.
•
Never start engine unless the batteries are firmly connected up. The battery terminals must be tightened.
•
Do not disconnect the batteries while engine is running.
•
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, consequently, 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".
First edition September 2000
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Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
4. 4.1
Technical data on the electric components EDC control unit (A142)
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. Control unit:
Bosch control unit; system version: MS5 stage 5 Bosch control unit; system version: MS6.4 stage 2.
Characteristic data and installation instructions: Protective system: Contact protection and protection against foreign matter to DIN 40 050, Sheet 9: IP 54 A Protection against water with plugged-on plug to DIN 40 050, Sheet 9: IP 54 A The installation position and location must be chosen so that no water can penetrate via the cable harness into the plug connection leading to the control unit. The vehicle interior (dry environment) is recommended as the installation location. For EMC-related reasons the surface of the control-unit housing ought to be in full contact with the body mass.
Temperature range: Operating temperature, stationary air:-40 °C to +65 °C Operating temperature, air in motion: -40 °C to +70 °C Voltage supply: +UBAT ( 24V); -UBAT Permissible supply voltage: 7 – 3 2V for normal operation, but at least 16V for 50ms after the unit has been switched on.
NOTE: The complete characteristic and installation data can be learned from the relevant Bosch TKU document.
4.2
Pedal value transmitter (B127)
Characteristic data and notes on installation: Protective system:
IP 54 A
Temperature range:
-40 °C to +80 °C
Installation location:
Pedals (accelerator pedal). The vehicle interior (dry environment) is recommended as the installation location.
NOTE: The complete characteristic and installation data can be learned from the relevant Bosch TKU document.
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Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
4.3
Check lamp (H296)
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).
Colour of check lamp:
red
Output:
2.4 W / 24 V (typical), max. 1 A.
4.4
Stalk switch for cruise control (S157)
Installation location:
4.5
The switch should be within easy reach while the vehicle is in motion (e.g. attachment to steering column).
Proximity switch for brake pedal (S158)
Installation location:
Pedals (brake) Use the full MAN pedal unit.
The following is to be observed: •
The air gap between sensor and switching bar must be 2 – 0.2 mm.
•
The switch must be actuated at the start of the pressure triggering action for the service brake.
4.6
Proximity switch for clutch pedal (S159)
Installation location:
Pedals (clutch) Use the full MAN pedal unit.
The following is to be observed: •
The air gap between sensor and switching bar must be 2 – 0.2 mm.
•
The switch must be actuated before clutch separation.
4.7
Relays (K170, K264, K321, K324, K173)
K170
Relay for power supply to EDC (main relay)
K264
Relay for power supply to EDC
K324
Relay for EDC redundant shutoff
K321
Relay for moment limiter
K173
Relay for cruise control shutoff during retarder actuation
First edition September 2000
Page 19 of 27
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
4.8
EDC resistor group (R134)
Installation location:
vehicle interior Use of the MAN resistor group is recommended.
If the MAN resistor group is not used, the following is to be observed: Resistors R1, R5: 0.511 kΩ 1%, 0.6 W Resistors R2, R6: 1.37 kΩ 1%, 0.6 W Resistors R3, R7: 3.09 kΩ 1%, 0.6 W Resistors R4, R8: 8.20 kΩ 1%, 0.6 W 4.9 S281 S105
Buttons (S281, S105) Button for ASR shutoff Button for engine brake
4.10 Switch (S284) S284
Schalter FGR/FGB
4.11 Solenoid valve (Y102) Y102
Solenoid valve for engine brake
5.
Installation variants
5.1
EDC with cruise control
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). The following electric components are additionally required (incl. cabling): S157
Stalk switch for cruise control
S158
Proximity switch for brake pedal
S159
Proximity switch for clutch pedal
S284
Switch for FGR/FGB
First edition September 2000
Page 20 of 27
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
MS5 stage 5
The switch for FGR/FGB is not necessary for road-speed control alone. However, if the road-speed limitation 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 approximately 0 Volt (0 – 2.0 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 limitation 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 (0 – 2.0 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 (0 – 2.0 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. 5.2
EDC with retarder
If a retarder is used, cruise control may be switched off as soon as the retarder is activated. The following electric components are additionally required (incl. cabling): K173
Relay for cruise control shutoff with retarder actuation
The relay should be triggered according to the circuit diagram example (see Appendix). 5.3
EDC with engine brake
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 following electric components are additionally required (incl. cabling): S105
Button for engine brake
Y102
Solenoid valve for engine brake
The button and the solenoid valve should be triggered according to the circuit diagram example (see Appendix).
First edition September 2000
Page 21 of 27
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
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 measure 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 acceleration for approx. 1 second. 5.5
PBM interface
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 electronics through this signal. As a result, an engine control function (ASR) is feasible with the EDC system. 5.5.1 EDC for automatic gearbox without ASR 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). 5.5.2 EDC with ASR 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.
First edition September 2000
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Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
5.5.3 ASR shutoff 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.
•
Switching of the ASR electronics with a suitable switching signal. Application eg if ABS/ASR-SG CI12 (Bosch) is used.
5.6
CAN interface
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 (120Ω ) is integrated into the EDC control unit. The maximum data line length between 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 unshielded, 2-core twisted line with a cross-section of 1mm² and a lay number of approx. 30/m. 5.7
PWG > Threshold
When the accelerator pedal is actuated, the EDC control unit pin 6 emits +U BAT for MS5 stage 5 and pin A32 emits +U BAT for MS6.4 stage 2 (see circuit diagram example). This signal can be used eg for deleting the moving-off interlock function. 5.8
Intermediate-speed control
5.8.1 Variable intermediate speeds 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.
First edition September 2000
Page 23 of 27
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
If the signal from the EDC control unit pin 44 for MS5 stage 5 and pin B8 for MS6.4 stage 2 are supplied 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 Fixed intermediate speeds 5.8.2.1
ISG 1
If the EDC control unit pin 23 is supplied with +U BAT for MS5 stage 5 and pin B32 with +U BAT 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 +U BAT 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 +U BAT for MS5 stage 5 and pin B33 with +U BAT for MS6.4 stage 2, the engine speed will run up to the MAN-CATS-programmable "intermediate speed 2" and be controlled while +U BAT 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 +U BAT 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 "intermediate speed 3" and be controlled while +U BAT is present. When the supply of +U BAT is stopped, ISG 3 will be switched off and the engine will be controlled back to idle speed. 5.9
Multi-stage switching input
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. Switch position 0 1 2
Resistance R1 = 0.511 kΩ R2 = 1.37 kΩ R7 = 3.09 kΩ
3
R4 = 8.20 kΩ
Application Driving characteristic (see Appendix, circuit diagram) Moment limiter (see Appendix, circuit examples) Recognition of retarder operation for cruise-control shutoff (see Appendix, circuit examples) Engine-speed limitation for special applications (see Appendix, circuit examples)
5.10 Multi-stage switching input 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. Switch position 0 1
Resistance R1 = 0.511 k Ω R2 = 1.37 k Ω
2 3
First edition September 2000
Application Legal maximum speed limit (see Appendix, circuit diagram Maximum speed limit e.g. 30 km/h (~ 20 miles) (see Appendix, circuit examples) Without function Without function
Page 24 of 27
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
5.11 External engine stop 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. 5.12 Engine-speed signal 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 controlling the setting of a certain engine speed via "SET+" and "SET-". Square-wave pulses (1 x number of cylinders of engine/revolution) of the engine-speed signal prepared in the EDC control unit according to the following specification: 1. Output stage (switching mode) - open collector with pull-up (2.55 kΩ) to +UBat 2. Signal form
Signal at plug connection Voltage calculation
Pulse RL = Load resistance RPU = Pull-up resistance (2.55 k)
Example: a) Load resistance to earth point 2 kΩ 5 kΩ 10 kΩ 200 kΩ
Voltage Ux
Calculated with UBAT = 28 V
12.30 V 18.50 V 22.30 V 27.65 V
b) Load resistance to plus (pull-up) in the counter unit Max. 1.8 kΩ permissible, since the output stage is specified for I0 = 18 mA.
First edition September 2000
Page 25 of 27
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
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 150 – 200 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. 7.1
Installation inspection Testing the EDC components (installation and functioning)
7.1.1 First-time installation 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 support. MAN will then grant installation clearance on the basis of this list of checking procedures. 7.1.2 Series production Series production is •
to comply with the EDC installation directive
•
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 manufacturer by means of a list of checking procedures (see Appendix).
First edition September 2000
Page 26 of 27
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
Before the vehicle is handed over to the customer, the following measures are necessary in this sequence: •
Reading out the fault memory
•
Eliminating the faults which may have occurred
•
Deleting the fault memory
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.
NOTE:
7.2
Modifications deviating from the initial installation are to be cleared by MAN. The vehicle manufacturer is responsible for the installation quality.
EMC testing
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. 7.3
End-of-Line programming (EOL)
EDC control units are delivered with a basic setting. If changes are necessary, various vehicle data can be adapted with the MAN-CATS program via the interface X200.
First edition September 2000
Page 27 of 27
Installation directive EDC for EURO 3 engines MS5 stage 5 und MS6.4 stage 2
B
8.
Appendices
8.1 Overview of EURO 3 engines /Job instruction for cable routing 8.2 MS5 stage 5 Pin configuration Circuit diagram / switching examples Testing protocol for installation inspection
8.3 MS6.4 stage 2 Pin configuration Circuit diagram / switching examples Testing protocol for installation inspection
First editon September 2000
Appendix
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
Overview of EURO 3 engines
Engine model
Software stage MS5.5
MS6.4
D 0 834 LOH 01
x
D 0 834 LOH 02
x
D 0 834 LFL 02
x
D 0 834 LFL 03
x
D 0 836 LOH 02
x
D 0 836 LOH 03
x
D 0 836 LUH 01
x
D 0 836 LUH 02
x
D 0 836 LFL 02
x
D 0 836 LFL 03
x
D 0 836 LFL 05
x
D 0 836 LF 03
x
D 0 836 LF 04
x
D 0 836 LF 05
x
D 2866 LOH 27
x
D 2866 LOH 28
x
D 2866 LOH 29
x
D 2866 LUH 23
x
D 2866 LUH 24
x
D 2866 LUH 25
x
D 2866 LUH 30
x
D 2866 LF 23
x
D 2866 LF 24
x
D 2866 LF 25
x
D 2876 LOH 02
x
D 2876 LF 03
x
First edition September 2000
Appendix 1
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
Pin configuration MS 5 stage 5 Pin
Section (mm²)
Complete designation
Abbreviations
1
2.5
Quantity adjuster triggering
MES-0
2
2.5
Quantity adjuster triggering
MES-0
3
2.5
Initial stroke triggering
VHS-0
4
2.5
Initial stroke triggering
VHS-0
5
1.5
Engine brake adjuster
MBR-1
6
1.5
Pedal value transmitter > threshold
LEB-1
7
1.5
Exhaust gas return adjuster
ARS-1
8
1.5
Heavy-transport. high-speed limiter
9
1.0
Control rod travel pick-up, measuring coil
RWG-M
10
1.0
Control rod travel pick-up, reference coil
RWG-R
11
1.0
Control rod travel pick-up, central tap
RWG-Y
12
-----
13
1.0
Sensor mass
GND-A
14
1.5
Electrical cut-off
EAB-1
15
2.5
+UBAT via main relay
BAT+
16
2.5
+UBAT via main relay
BAT+
17
1.0
Needle movement sensor mass
18
2.5
-UBAT
BAT-
19
2.5
-UBAT
BAT-
20
1.0
Diagnosis lamp
DIA-B
21
1.0
Speed transmitter signal
DZG1
22
1.0
Auxiliary speed transmitter signal
HZG1
23
1.0
Intermediate speed control 1
ZDR1-E
24
1.0
Exhaust gas recirculation - end switch signal
ARS-E
25
1.0
Function mode switch FGR/FGB
FMS-E
26
1.0
Clutch switch signal
KUP-E
27
1.0
Pedal value transmitter signal
PWG1
28
1.0
Speed signal output
TDS-A
29
1.0
Multiplex signal output
MPS-A
First Edition September 2000
SHGB-1
-------------------------------------------
Appendix 2 a
NBFO/ HZGO
Page 1 of 2
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
Pin configuration MS 5 stage 5 Pin
Section (mm²)
30
1.0*
Controller area network (low)
CAN-L
31
1.0*
Controller area network (high)
CAN-H
32
1.0
Needle movement sensor signal
NBF1
33
1.0
Boost pressure sensor
LDF2
34
1.0
Fuel temperature sensor signal
KTF1
35
1.0
Multi-stage input (torque limiter)
MDB1
36
1.0
Boost pressure sensor signal
LDF1
37
1.0
Driving speed limit lamp
FGB1
38
-----
39
1.0
Idle switch signal
LGS-E
40
1.0
Engine stop external
MST-E
41
1.0
Intermediate speed control 2
ZDR2-E
42
1.0
Engine brake signal
MBR-E
43
1.0
Brake switch signal
BRE-E
44
1.0
Analog driving speed control
FGR1
45
1.0
Pedal value transmitter, supply
PWG2
46
1.0
Main relay output
HRL-0
47
1.0
Terminal 15, digit. info for control unit
K15-E
48
1.0
ISO-K line in accordance with ISO protocol
ISO-K
49
1.0
ISO-L line in accordance with ISO protocol
ISO-L
50
1.0
Antigas signal
TKS-E
51
1.0
Driving speed sensor signal
FGG1
52
1.0
Pulse duration modulation - input signal
PBM-E
53
1.0
Water temperature sensor signal
WTF1
54
1.0
Multi-stage input maximum speed limiter
HGB1
55
1.0
Air temperature sensor signal
LTF1
Complete designation
Abbreviations
-------------------------------------------
* CAN cable twisted (no. of twists: approx. 30/m)
First Edition September 2000
Appendix 2 a
Page 2 of 2
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
e
CHECKLIST EDC – MS5 STAGE 5 WITHOUT EHAB
✍
Service centre ....................................................
Checked by:
Customer:
First registration: .................................
....................................................
.................................
Vehicle model: ...................................................
Chassis no.:
................................
Engine model:
Engine no.:
.................................
Injection pump: ..................................................
Control unit no.:
................................
Kilometrage:
Date:
...................................................
...................................................
...............................
1. Checks while engine is stationary (ignition OFF, control unit not connected up)
Engine temperature » 20°C Do not connect up control unit, but connect up cable harness adapter
Measure resistance between Pin+ and Pin- using multi-range meter
Pin+ Control rod travel transmitter
Speed transmitter (DZG2 -0005) *
Pin-
Spe ci fie d va lue
11
9
18 – 25 Ohm
..........................
Ohm
11
10
18 – 25 Ohm
..........................
Ohm
18
9
..........................
Ohm
18
10
..........................
Ohm
21
13
0.5 – 0.7 kOhm
..........................
kOhm
0.8 – 1.0 kOhm
..........................
0.5 – 0.7 kOhM
..........................
kOhm
0.8 – 1.0 kOhm
..........................
kOhm
(DG6 -0008) Aux. speed transmitter
22
17
(HZG-0006)* (DG6 -0009)
>10 MOhm >10 MOhm
M ea sur ed value
15
3
1.2 – 2.0 Ohm
..........................
Ohm
18
3
>10 MOhm
..........................
MOhm
16
4
1.2 – 2.0 Ohm
..........................
Ohm
Needle movement sensor
32
17
90 – 130 Ohm
..........................
Ohm
Earthing
13
18
>10 MOhm
MOhm
17
19
>10 MOhm
.......................... ..........................
Safety relay
14
19
..........................
Ohm
EGR controlling (only Euro III)
7
18
39 – 47 Ohm
.........................
Ohm
EGR feedback (only Euro III)
15
24
< 1 Ohm
.........................
Ohm
Control rack
MOhm
* * 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.
First edition September 2000
Appendix 2 c Page 1 of 5
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
Checking fuel control rack: • • •
Pull off safety relay Connect up bridge between terminals 30 and 87 in the relay socket Measure resistance between Pin+ and Pin- using a multi-range meter
Fuel control rack
Pin+
Pin –
Sp ec ified val ue
Me as ur ed va lue
15
1
0.7 – 1.3 Ohm
..........................
Ohm
18
1
>10 MOhm
..........................
MOhm
16
2
0.7 – 1.3 Ohm
..........................
Ohm
• Remove bridge again and plug in safety relay.
2. Checks while engine is running and vehicle is stationary
Engine temperature > 30°C
Measure engine speed at the following operating points
Specified value
Value measured
Remarks
MAN-CATs
Speed transmitter (DZG)
lower idle upper idle
n=................1 rpm n=................1 rpm
PWG Min (l.i.) PWG Max (u.i.)
Engine speed (Monitoring 2)
Aux. speed transmitter *(HZG)
lower idle upper idle
n=................1 rpm n=................1 rpm
PWG Min (l.i.) PWG Max (u.i.)
Auxiliary engine speed (Monitoring 2)
* Short-circuit Pin 21 and 13 (speed transmitter defect is indicated).
First edition September 2000
Appendix 2 c Page 2 of 5
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
Measure voltage between Pin+ and Pin- using a multi-range meter. Pin+
Pin – Specified value [V]
Measured value [V]
Remarks
Speed
MAN-CATs (Monitoring)
Supply for control unit (U batt)
15 47
18 19
U-Bat U-Bat
....................... .......................
Idle Idle
Reference voltage (Uref)
45 33
13 13
4.75 – 5.25 4.75 – 5.25
....................... .......................
Idle Idle
Pedal value transmitter (PWG)
27
13
0.30 – 0.42 2.90 – 4.50
....................... .......................
PWG Min PWG Max
Idle Upper idle
0% 100%
Idle switch (LGS) (NO contact)
39
13
4.50 – 5.25 0 – 2.00 V
....................... .......................
PWG Min PWG Max
Idle Upper idle
Open Closed
Fuel temperature sensor (KTF)
34
13
4.17 – 2.62
.......................
10 °C -50 °C
Idle
10 °C - 50 °C
Water temp. sensor (WTF)
53
13
3.46 – 1.22
.......................
30 °C - 90 °C
Idle
30 °C - 90 °C
Charge-air pressure sensor (LDF)
36 36
13 13
0.94 – 1.20 1.10 – 1.40
....................... .......................
PWG Min PWG Max
Idle Upper idle
900-1050 mbar 1000-1400 mbar
FGR operating unit
44
13
....................... ....................... ....................... ....................... .......................
Not actuated Returnact. SET+act. SET-act. AUSact
Multi-stage switch (MSS)
35
13
0.75 – 1.25
.......................
Pos 0
(Moment limiter active)
1.75 – 2.25
.......................
Pos 1
(Truck retarder actuated)
2.75 – 3.25
.......................
Pos 2
(Speed limiter active)
3.75 – 4.25
.......................
Pos 3
0.75 – 1.25 1.75 – 2.25
....................... .......................
(2.75 – 3.25 3.75 – 4.25 0.0 – 2.0
Top-speed limiter switch (HGB)
54
13
3.15 – 3.55 1.41 – 1.80 0.65 – 0.97 2.30 – 2.75 3.72 – 4.33
Idle Return speed Speed increas, Speed drops Idle
Neutral Memory SET+ SETOFF
Id le
Drivin g ch arac teristics Multi-stageswitch, Pos 1 Multi-stageswitch, Pos 2 Multi-stageswitch, Pos 3
Pos 0 Pos 1
HGB1 HGB2
Speed 1 Speed 2
....................... .......................
Pos 2 Pos 3)
Not used
....................... .......................
Not actuated Actuated
Idle
UBat
Open Closed
Braking contact switch (NO contact) ∗
43
Clutch switch (NO contact)
26
19
0.0 – 2.0 U-Batt
....................... .......................
Not actuated Actuated
Idle
Open Closed
42
19
0.0 – 2.0
....................... .......................
Not actuated Actuated
Idle
Open Closedd
UBat
....................... .......................
Not actuated Actuated
Eng. speed > 850rpm
19
∗
Engine brake switch (MBR) (NO contact) Engine brake control
UBat 5
19
0.0 – 2.0
FGR/FGB switch
25
13
0.0 – 2.0 UBatt
....................... .......................
OFF ON
Antigas
50
13
0.0 – 2.0
....................... .......................
Not actuated Actuated
UBat Speedometer signal (FGR)
51
13
>0.6
.......................
Charge-air temperature sensor (LTF)
55
13
4.2 - 2.2
.......................
Idle 0 - 60 °C
0 km/h
Idle
*Contacts must be made before clutch or brake are effective (max. 20 mm pedal travel)
First edition September 2000
Appendix 2 c Page 3 of 5
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
ISG functional test
Check switch-off conditions (PWG intervention, brake, clutch) in every ISG mode 0..S, if necessary reprogramme them Pin 23 [V]
Pin 41 [V]
ISG Pos.
0
0
ISG speed S
0
24
0
ISG speed 1
1
0
24
ISG speed 2
2
24
24
ISG speed 3
3
Checking main relay
Main relay
∗
Pin+
Pin-
Specified value [V]
Measured value [V]
47
18
46 _
18 _
UBat0 V 0V UBat
...................... ...................... ...................... ......................
Remarks
Ignition ON Ignition OFF Ignition ON Ignition OFF
* With a delay of 0.5 to 5 secs. after the ignition has been switched off Pin 46 must switch over toU Bat.
Checking safety relay (PWG max., engine running at upper idle) •
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
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)
First edition September 2000
Appendix 2 c Page 4 of 5
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
Checking capacity reserve of resonant circuit of control rod travel transmitter: •
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
3. Checking while vehicle is in motion
Checking cruise control •
Drive at v > 40 km/h with cruise control
•
After change of gears and actuation of the MEMORY switch the last speed must be reset
Checking brake switch monitoring •
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
Erasing fault memory 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 ascertained and eliminated according to the troubleshooting plan.
First edition September 2000
Appendix 2 c Page 5 of 5
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
Pin configuration MS 6.4 /EDC MS6.4 stage 2 Pin A Section Pin
mm2
Complete designation
A01
1.0
A02
---------
-----------------------
A03
---------
-----------------------
A04
---------
-----------------------
A05
1.0
Water temperature sensor, sensor mass
WTFO
A06
1.0
Reserve analog sensor, sensor mass
AN010
A07
---------
-----------------------
A08
---------
-----------------------
A09
---------
-----------------------
A10
---------
-----------------------
A11
---------
-----------------------
A12
1.0
Boost pressure sensor signal
LDF1
A13
1.0
Speed transmitter, sensor mass
DZG0
A14
---------
A15
1.0
A16
---------
A17
1.0
Boost pressure sensor, sensor mass
A18
1.5
Engine brake adjuster
A19
---------
A20
1.0
A21
---------
A22
1.0
Water temperature sensor signal
WTF1
A23
1.0
Boost pressure sensor, supply
LDF2
A24
1.0*
Control area network 2, low
A25
---------
-----------------------
A26
---------
-----------------------
A27
1.0*
A28
---------
A29
1.0
First edition September 2000
Speed sensor signal
Abbreviation DZG1
----------------------Needle movement sensor, sensor mass
NBF0
----------------------LDF0 MBR-1
----------------------Quantity - solenoid valve cut-off
MAB-A
-----------------------
Controller area network 2, high
CAN2-L
CAN2-H
----------------------Needle movement sensor signal
Appendix 3 a
NBF1
Page 1 of 4
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
Pin configuration MS 6.4 /EDC MS6.4 stage 2 pin A Section Pin
mm2
Complete designation
Abbreviation
A30
---------
-----------------------
A31
---------
-----------------------
A32
1.5
Pedal value transmitter dependent ad juster ((PVT>threshold) brake control unit
PWG-1
A33
1.0
PVT idle switch output signal (PSG)
LGS-A
A34
---------
A35
1.0
----------------------Digitalised crankshaft speed output signal (PSG)
DZG-A
* CAN cable: Twisted cable 2 x 1.0. ( No. of twists approx. 30/m)
First edition September 2000
Appendix 3 a
Page 2 of 4
Installation Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
Pin configuration MS 6.4 /EDC MS6.4 stage 2 Pin B Section Pin
Complete designation
mm2
Abbreviation.
B 01
2.5
-UBAT BAT
BAT-
B 02
2.5
-UBAT BAT
BAT-
B 03
2.5
+UBAT BAT - via main relay
BAT+
B 04
2.5
+UBAT BAT - via main relay
BAT+
B05
1.0
Digitalised crankshaft speed output signal
TDS-A
B06
1.0
Diagnosis lamp
DIA-1
B07
1.0
Multiplex signal output
MPS-A
B08
1.0
Analog driving speed control element
FGR1
B09
1.0
CAN1-screen, mass for torque limiter signal, signal, driving speed control and idle switch signal
B10
1.0
Driving speed control element, control LED
B11
1.0*
Control area network 1 (low)
CAN1-L
B12
1.0*
Control area network 1 (high)
CAN1-H
B13
1.0
ISO-K line in accordance with ISO protocol
ISO-K
B14
1.0
Engine brake switch input signal
MBR-E
B15
1.0
Terminal 15, digit. info for control unit
K15-E
B16
1.0
Pedal value transmitter, supply
PWG2
B17
1.0
Idle switch input signal
LGS-E
B18
1.0
Solenoid valve cut-off relay
MAR-1
B19
1.0
Multi-stage input for maximum speed limiter
HBG1
B20
1.0
Clutch switch signal
KUP-E
B21
1.0
Idle request signal
LLA-E
B22
1.0
Function mode switch FGR/FGB
FMS-E
B23
1.0
Pedal value transmitter signal
PWG1
B24
1.0
ISO-L line in accordance with ISO protocol
B25
1.0
Idle switch output signal (gearbox con trol)
LGS-A
B26
1.0
Brake switch signal
BRE-E
First edition September 2000
Appendix 3 a
CAN10
FGB-1
ISO-l
Page 3 of 4
Installation Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
Pin configuration MS 6.4 /EDC MS6.4 stage 2 Pin B Section Pin
mm2
Complete designation
Abbreviation.
B27
1.0
Main relay, output
HR-0
B28
1.0
Torque limiter signal
MDB1
B29
1.0
Driving speed transmitter signal
FGG1
B30
1.0
Pulse duration modulation input signal
PBM-E
B31
---------
B32
1.0
Intermediate speed regulation 1
ZDR1-E
B33
1.0
Intermediate speed regulation 2
ZDR2-E
B34
1.0
Stop external signal (engine stop signal)
STP-E
B35
1.0
Pedal value transmitter, sensor mass
PWG0
-----------------------
* CAN cable: Twisted cable 2 x 1.0. ( No. of twists approx. 30/m)
First edition September 2000
Appendix 3 a
Page 4 of 4
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
CHECKLIST EDC – MS6.4 STAGE 2 WITHOUT EHAB
✍
Service centre
.....................................
Checked by:
..............................
Customer:
.....................................
First registration: ...........................
Vehicle model:
......................................
Chassis no.:
..............................
Engine model:
......................................
Engine no.:
...............................
Injection pump:
.....................................
Control unit no.: ..............................
Kilometrage:
......................................
Date:
...............................
1. Check while engine is stationary
Engine temperature > 20°C
Switch ignition OFF
Disconnect engine control unit
Connect cable harness adapter to engine control unit
Measure resistance between the following Pins
Pin
Pin
Specified value
CAN PSG
A 24
A 27
~ 120 Ohm
Speed transmitter (DZG)
A1
A 13
770 – 1000 Ohm
Needle movement sensor (NBF)
A 29
A 15
65 – 160 Ohm
Solenoid-valve switch-off relay MAN standard relay
B 18
B1
180 – 250 Ohm
CAN 1
B 11
B 12
~ 120 Ohm
Actual value
Connect to engine control unit Connect cable harness adapter to VP 44 between pump and cable harness Switch on ignition Measure voltage between Pins
First edition September 2000
Appendix 3 c Page 1 of 5
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
Pin
Pin
Specified
Actual value
valuet Voltage supply for pump control unit
Bat+
Bat –
U Bat
(from cable harness adapter for VP44)
2. Checks while engine is running and vehicle is stationary
Engine temperature > 30°C
Connect cable harness adapter to engine control unit
Measuring engine speed Specified value
Measured Value
Remarks
Speed transmitter (DZG)
Lower idle Upper idle
PWG Min (l.i.) PWG Max (u.i.)
Speed transmitter * in pump (IWZ)
Lower idle Upper idle
PWG Min (l.i.) PWG Max (u.i.)
MAN-Cats (Monitoring)
* Short-circuit PIN A1 and A13 (simulation DZG-defect -> diagnostic lamp is permanently ON). EDC continues to run with IWZ signal
Pin +
Pin – Specified value
Measured
Remarks
value [V]
Engine
MAN-CATS
speed
(Monitoring)
[V] Control unit supply MS 6.4
B15 B3 B15
B1 B2 B27
UBat
Pedal value transmitter (PWG)
B23
B35
0.30 – 0.42 2.90 – 4.50
PWG Min PWG Max
low. idle up. idle
0% 100%
Idle switch (LGS)
B17
B9
2.8 – 5 V 0 – 1.8 V
PWG Min PWG Max
low. idle up. idle
Open Closed
Water temperature sensor (WTF)
A22
A5
3.0 – 1.15
30 – 90 °C
low. idle
30 – 90 °C
Charge-air pressure sensor (LDF)
A12
A17
0.95 – 1.12 1.00 – 1.52
PWG Min PWG Max
low. idle up. idle
900 – 1050 mbar 1000 – 1400 mbar
FGR operating unit
B8
B9
3.35 – 3.74 1.6 – 2.0 0.83 – 1.21
Not actuated Return Set+
Neutral Memory Set+
2.53 – 2.97
Set-
4.18 – 4.53
OFF
low. idle Return Eng.speed increases Eng.speed drops Idle
First edition September 2000
Idle Idle Idle
UBat UBat
SetOFF
Appendix 3 c Page 2 of 5
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
Pin +
Multi-stage switch (MSS) *
B28
Pin –
B35
Specified
Measured-
value [V]
value [V]
R emarks
Engine
MAN –Cats
speed
(Monitoring)
Idle
Driving characteristics
0.75 – 1.25
Pos 0
1.75 – 2.25
Pos 1
Torque limiting
2.75 – 3.25
Pos 2
Retarder active
3.75 – 4.25
Pos 3
Function for reducing the k-value
Top-speed limiter switch *
Braking con-
B19
B26
B35
B2
tact switch ∗∗ Clutch switch **
B20
Engine brake switch
B14
Engine brake control
A18
B2
B2
B2
0.75 – 1.25
Pos 0
Idle
1.75 – 2.25
Pos 1
2.75 – 3.25
Pos 2
not
3.75 – 4.25
Pos 3
used
0 – 1 V
Not Actuated
Idle
UBat
Actuated
0 – 2 V
Not Actuated
UBat
Actuated
0 – 1 V
Not Actuated
UBat
Actuated
0 – 2 V
Not Actuated
Idle
UBat
Actuated
Eng.
Speed 1 Speed 2
Open Closed
Idle
Open Closed
Idle
Open Closed
speed > 800 rpm FGR-/FGBswitch
B22
B2
∗
Idle request
∗
B21
B2
0 – 2 V
FGR
UBat
FGB
0 – 2 V
Not Actuated
UBat
Actuated
Speedometer signal
B29
B2
> 0.6 V
Engine stop
B34
B2
0 – 2 V
Not Actuated
UBat
Actuated
u
PWG Min
UBat
PWG Max
< 1.4 V
PWG Min
UBat
PWG Max
switch
∗
PWG > threshold
A32
B2
∗
Idle switch output
B25
B2
Idle
Idle
Open Closed
Idle
Idle
Open Closed
Without load resistor < 17 V With load resistor 100 - 1.000 Ω ~ 0 V
∗
Check only if unit is fitted
∗∗
Contacts must be made before clutch or brake are effective (max 20 mm pedal travel) and have to be reopened before concealed position
First edition September 2000
Appendix 3 c Page 3 of 5
Installation directive EDC for EURO 3 engines MS5 stage 5 and MS6.4 stage 2
ISG functional test: Checking switch-off conditions (actuation of brake, clutch and PWG) PIN B32 vs B2
Set-point
Actual
PIN B33 vs B2
Set-point
Engine speed
ISG Pos
Actual
0
0
ISG speed S
0
UBat
0
ISG speed 1
1
0
UBat
ISG speed 2
2
UBat
UBat
ISG speedl 3
3
Measured
Remarks
Checking control of main relay, MAR and MAB:
Pin +
Pin –
Set value
value B15
B27
B18
B3
B2
UBat
Ignition ON
0V
Ignition OFF
0V
Ignition ON
UBat
Ignition OFF
0V
Ignition OFF
UBat
Ignition ON
UBat
Ignition ON
B2
B2
A20
Checking solenoid valve switch-off: •
Run engine at upper idle
•
Interrupt voltage supply to relay (pull off Pin B18)
•
Engine must stop after max. 10 secs
•
Switch off ignition, reconnect voltage supply
First edition September 2000
Appendix 3 c Page 4 of 5
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