MAN Injectie Electronica EDC M.S 6.4

T 17-A2 8.
40 - 1

DIAGNOSIS

Fault search programme

The following error search programme contains the errors that can be detected by the error memory.

The order of the tests corresponds to the numeric sequence of the flash codes, independent of the value of
the error.
So it is not arranged according to "Error is displayed by means of EDC indicator light" or "Error is not
displayed by means of EDC indicator light".
In addition to the flash code, the error location was recorded in hexadecimal figures, because this is
displayed by MAN-cats.

During the initial check on the vehicle, the entire error memory must always be read out and all the stored
errors documented.
A simple method of documentation is to make a screen copy (hardcopy) of the MAN-cats screen. This
contains all the information (environmental conditions, etc.).
This is important because during error search cables or components in the system have to be disconnected
and there should be the capability of setting and storing the corresponding error messages.
Because of this, the error memory should always be deleted again after intermediate tests.

The test procedure for checking cables ("Test lines") must always be followed:

Interruption or contact resistance (e.g. through stretched terminal sockets, plugs or terminal sockets
pushed back, or oxidised plug connections)
Short to minus
Short to plus
Short to adjacent wires
Loose contacts
Water or moisture in the wiring harness
Wiring harnesses can also be damaged although the corrugated tube appears undamaged externally!

All tests relating to the control device plugs are carried out with the aid of the diagnostic connector box (test
box). The pin assignment on the control unit plug is identical to the test sockets on the diagnostic connector
box.

Where resistances are being measured, the control unit must be disconnected at the diagnostic
connector box.

Before any exchange of pump or control units the error memory should always be deleted and the error
observed. If there are a number of error entries, the corresponding test instructions should generally only be
taken into account where they do not require a change of pump or control unit.

After removal of the error and checking, repeat the test and delete the error memory.
The error memory should always be deleted with MAN-cats.

Follow vehicle-related wiring diagrams!

In the case of bus chassis (HOC) 3-character wire numbers and deviating item descriptions are mainly
used.
On all other vehicles in the present series (trucks and buses) only 5-character wire numbers and identical
item descriptions are used.

T 17-A2 8.40 - 3

DIAGNOSIS

TEST 1
Pedal sensor

Flash code: 1x short
Error location (hex): 81

Error display: Yes (indicator light EDC on, or shown in display)

Error path: Pedal sensor
Signal too high
Signal too low

Effect of error: Torque reduced by 50 60%
Default 50%

Possible Interruption on line, short-circuit, interruption in power supply,
cause of error: Pedal sensor faulty, control unit faulty

Condition for testing: Diagnostics connector box (test box) connected
Ignition switched on


Test Measurement Remedy
Power supply Voltage measurement at diagnostics
connectors (test box) between Pin B16 (+)
and Pin B35 ()

Target value: 4.5 5.2 V
Test lines
Test plug connectors
If not fault found, try replacing the
control unit
Potentiometer signal Voltage measurement at diagnostics
and Pin B35 ()

Target values:
Idle speed: 0.3 0.6 V
Full-load: 4.0 4.5 V
Error limits: U < 0.3 V or U > 4.8 V
Test lines
Adjust linkage between
accelerator pedal and pedal
sensor
If adjustment is not possible,
replace pedal sensor

8.40 - 4 T 17-A2

DIAGNOSIS

TEST 2
Quantity solenoid valve for fuel injection pump (plausibility of actuation duration)

Flash code 2x short


Error path: Actuation duration of the solenoid valve, quantity transferred on the CAN-bus to the
pump

Effect of error: Engine is shut down
Engine does not start

Possible
cause of error: Power supply (U
bat
/earth), injection pump faulty

Note: Basically before replacing any pump or control unit the error memory should be
deleted and the error observed.
In practice, where there are several error entries, the corresponding test
instructions should first be followed where they do not necessitate the exchange of
a pump or control unit.


Injection pump

Voltage measurement between Pin 7 (+)
and Pin 6 () at injection pump plug

Target value: U
Bat

Test lines
Reprogram control unit to latest
status
If fault is still present, try replacing the
injection pump*

* Fitting and removing the injection pump and carrying out the associated adjustments is described in the
repair manual for the A 14!

T 17-A2 8.40 - 5

DIAGNOSIS

TEST 3
Engine speed sensor (flywheel)

Flash code 4x short


Error path: Engine speed sensor
Static: implausible
Dynamic: implausible

Effect of error: Full load quantity reduced by 25 40%
Final engine speed reduced to 1800 rpm
The system switches from injection start control to control mode with prescribed
injection start characteristic map; the engine is shut down if there are deviations
are found in comparison with the pump speed sensor

Possible Line interruption, short to earth, speed sensor faulty
cause of error: Sensor signal affected by metal filings, etc. at sensor's mounting position
Distance from speed sensor to flywheel is incorrect, wrong flywheel
Control unit faulty


Note: This error can simultaneously arise with error 5x long, 1x short (speed sensor
signal detection pump control unit)


Resistance Resistance measurement at diagnostics
connectors (test box) between Pin A1 (+)
and Pin A13 ()

Target value: 770 1000
Test lines
If no fault can be found,
replace engine speed
sensor
Engine speed signal Signal test at diagnostics connector box
(test box) with starting rpm between
Pin A1 (+) and Pin A13 () with
oscilloscope

Target value: see oscilloscope curves
Test lines
replace control unit
Gap between engine
sped sensor and
flywheel
Target value: 0.5 1.5 mm
Correct gap

8.40 - 6 T 17-A2

DIAGNOSIS

TEST 4
Charge air pressure sensor

Flash code 5x short


Error path: Charge air pressure sensor
Signal too high
Signal too low
Signal implausible in combination with atmospheric pressure sensor
(in control unit)

Effect of error: Full-load quantity reduced by 20 40%, default 1200 mbar
Black smoke during acceleration sequences

Possible interruption on line, short-circuit, intake manifold pressure sensor faulty,
cause of error: intake manifold connection leak, atmospheric pressure sensor (in control unit)
faulty, control unit faulty

Application of pressure by pressure sensor with ALDA test device or Mitywac Duo-
hand pump (absolute pressure gauge)


connectors (test box) between
Pin A23 (+) and Pin A17 ()

Target value: 4.75 5.25 V
Test lines
If no fault can be found, replace
control unit
Signal voltage Voltage measurement at diagnostics
connectors (test box) between Pin A12 (+)
and Pin A17 ()

Target values:
1.50 1.70 V at 1500 mbar
2.70 3.00 V at 2000 mbar
Test lines
intake manifold pressure sensor

Characteristic curve with 5 V supply

Note: Absolute pressures are used in the above diagram!

T 17-A2 8.40 - 7

DIAGNOSIS

TEST 5
Temperature sensor, coolant

Flash code 7x short


Error path: Temperature sensor, coolant

Effect of error: Full load quantity reduced by 50%
Formation of a default value (approx. 110 C)
Worse cold start performance

Possible
cause of error: Interruption on line, short-circuit, temperature sensor faulty, control unit faulty



Sensor resistance Resistance measurement at diagnostics
connector box (test box) between Pin A22
and Pin A5

Target values:
3.6 1.3 K at 15 30 C
460 230 at 75 80 C
Test lines
Replace temperature sensor
Sensor voltage Voltage measurement at diagnostics
connectors (test box) between Pin A22 and
Pin A5

Target value: 3.0 1.15 V at 30 90 C
Test lines
Replace temperature sensor

8.40 - 8 T 17-A2

DIAGNOSIS

TEST 6
Road speed signal

Flash code 8x short


Error path: Road speed transducer
Signal too high
Signal too low
No signal
Frequency too high

Effect of error: All speed functions such as cruise control ("Tempomat"), speed control and
maximum speed limiter are shut down
No idle speed comparison

Possible Interruption of line, plug connector in flexible steel-armoured cable is oxidising
cause of error: (ingress of water), short circuit, tachograph faulty



Signal line Resistance measurement at diagnostics
connector box (test box) between Pin B29
and tachograph Kl. B7

Target value: 0
Test lines
If no fault can be found, try
replacing tachograph
Voltage measurement at diagnostics
connectors (test box) between Pin B29 and
Pin B2

Target value: > 0.6 V

T 17-A2 8.40 - 9

DIAGNOSIS

TEST 7
Pump control unit self-test (pump characteristic map not present)

Flash code 9x short


Error path: Pump control unit (pump characteristic map not present)

Effect of error: Engine does not start

Possible
cause of error: Pump control unit (injection pump) faulty

Note: Basically before replacing any pump or control unit the error memory should be

Injection pump
Delete error memory
Read error memory again
If fault still present, try replacing injection pump*

* Fitting and removing the injection pump and carrying out the associated adjustments is described in the
repair manuals for the A 13 and A 14!

8.40 - 10 T 17-A2

DIAGNOSIS

TEST 8
Shutdown via quantity 0 (after-running test)

Flash code 1x long, 2x short


Error path: Engine control unit, vehicle speed signal, injection pump

Effect of error: Full-load quantity reduced by 25 40% because quantity can be inaccurate

Function: Quantity 0 is the default for after-running. If the expected fall in speed does not
come about, it is classified as an error.

Possible
cause of error: Engine control unit faulty, vehicle speed signal implausible, injection pump faulty

Note 1: Basically before replacing any pump or control unit the error memory should be
Note 2: In the event of errors in after-running, the road speed signal must also be checked.
Reason: If the road speed transducer already shows 0 km/h when the vehicle is
rolling and the ignition is then switched off, there is after-running.
The various shutdown paths in after-running can then be classified as defective
because the speed does not drop away fast enough (vehicle is rolling).


Engine control
unit

Vehicle remains standing, speed is 800 rpm,
multiple starting of engine (7 times) to delete
error
Minimal engine standstill period 5 s between
attempts at starting
Delete error memory
Read error memory once again
engine control unit
Injection pump
Delete error memory
injection pump*
Road speed
signal
See test 6
See test 6

* Fitting and removing the injection pump and carrying out the associated adjustments is described in repair
manuals A 13 and A 14!

T 17-A2 8.40 - 11

DIAGNOSIS

TEST 9
Undervoltage

Flash code: 1x long, 3x short

Error display: No (indicator light EDC off, or nothing shown in display)

Error path: Power supply for control unit (battery voltage too low < 9 V)

Effect of error: Depending on the amount of the drop in voltage, the EDC system or engine may
react in various ways:
engine does not start
engine runs very out of true
no output
high degree of smoke
contradictory error memory input

Possible Battery discharged or faulty, generator faulty, interruption in line, short circuit,
cause of error: main relay faulty


Follow vehicle-related wiring diagrams

Pin B15 (+) and Pin B1 ()

Target value: 20 28 V
Test lines
Replace main relay
control unit

8.40 - 12 T 17-A2

DIAGNOSIS

TEST 10
Proximity switch, brake



Error path: Proximity switch, brake signal

Effect of error: FGR and ZDR not functioning

Possible
cause of error: Interruption in line, proximity switch faulty or wrongly calibrated



Proximity switch
brake signal

Brake pedal actuated
Target value: U
Bat

Brake pedal not actuated
Target value: 0 2 V
Test lines
Adjust proximity switch
Replace proximity switch

T 17-A2 8.40 - 13

DIAGNOSIS

TEST 11
Proximity switch, clutch



Error path: Proximity switch, clutch signal

Effect of error: ZDR not functioning

Possible Interruption to line, proximity switch faulty
cause of error: The control unit also detects errors if a speed of 30 km/h
is exceeded and by then still no clutch signal has been detected



Proximity switch for
clutch signal
and Pin B2 ()

Clutch pedal actuated
Target value: U
Bat

Clutch pedal not actuated
Target value: 0 2 V
Test lines
Adjust proximity switch
Replace proximity switch

8.40 - 14 T 17-A2

DIAGNOSIS

TEST 12
Overspeed



Error path: Engine overspeed

Effect of error: Interruption in delivery of volume.
If there are not further errors, delivery will resume after quitting the overspeed.

Possible
cause of error: Incorrect operation, driver error (e.g. bad gearshift)

If not other error present no further
actions are necessary
Delete error memory

T 17-A2 8.40 - 15

DIADNOSE

TEST 13
Injection start deviation



Error path: Injection start actuator unit, deviation

Strong smoke development
The system switched from closed-loop control to open-loop control with a
predetermined injection start characteristic.

Possible Fault in fuel system (leak, clogged, air in system)
cause of error: Faulty or wrong overflow valve in pump's intake or return
Pre-delivery pump faulty
Empty tank
Tank ventilation faulty
Fuel filter defective (can result in pump contamination)
Speed transducer signals incorrect
Needle movement sensor signals incorrect (omitted from level 2 onwards)
Basic configuration of pump is false
Injection pump defective

Note: The function paths needle movement sensor (omitted from level 2 onwards) and
speed sensor (flywheel and injection pump) must always be checked in the case of
this fault, even if there is no relevant error entered in the memory.

Follow the wiring diagrams relating to the vehicle.

Injection pump Target value and actual value
Check injection start

Error condition:
+/ 3 degrees deviation, 2.5 s
monitoring only if engine speed
> 1000 rpm
Test fuel system
Test lines
Test pump installation*
Replace injection pump*
Needle movement
sensor
See test 14 See test 14
Engine speed sensor See test 3 See test 3

* Fitting and removing the injection pump and carrying out the associated adjustments is described in
repair manuals A 13 and A 14!

8.40 - 16 T 17-A2

DIAGNOSIS

TEST 14
Needle movement sensor

Error location (hex): 1A


Error path: Needle movement sensor
Signal not high enough
too few impulses
too many impulses
internal resistance wrong

Effect of error: The system switches from closed-loop control to controlling the start of delivery.
If the fault is no longer present, the system switches back to normal closed-loop
control.

Possible
cause of error: Interruption on line, short-circuit, needle movement sensor faulty

Note: The needle movement sensor becomes obsolete with the introduction of
EDC 6.4 level 2!



Internal
resistance
Resistance measurement at diagnostics
connector box (test box) between Pin A29
and Pin A15

Target values:
65 160
See oscilloscope curves
Test lines
Replace needle movement
sensor

Other possible causes of errors:

Faulty impulses from the speed sensor (even without error message)
Spurious pulses between the control unit and needle movement sensor (e.g. through relay switching)
Structure-borne noise effect on needle movement sensor through mechanical damage (e.g. valve train,
piston)
Jet needle sticking

Fault in fuel low-pressure system

Faulty or wrong overflow valve
Air or leaks in the system
Faulty fuel pump
Clogged filter
Clogged lines
Empty fuel tank
Faulty injection pump

T 17-A2 8.40 - 17

DIAGNOSIS

TEST 15
Plausibility of solenoid valve shutdown (MAB signal)

Error location (hex): 9B


Error path: Status of solenoid valve shutdown


Shutdown might not be possible via MAB

Function: Check whether MAB status is the same in the pump control unit and the engine
control unit

Possible Line interruption between engine control unit and injection pump
cause of error: (pump control unit), engine control unit faulty, injection pump (pump
control unit) faulty

Note: Before any exchange of pump or control units the error memory should always be
If there are a number of error entries, the corresponding test instructions should
generally only be taken into account where they do not require a change of pump or
control unit.


Engine control
unit
connectors (test box) between Pin B3 and
Pin A20

Target value: U
Bat
with ignition on
0 V with ignition off
Test lines
Delete error memory
If fault still present, try replacing the
engine control unit
Injection pump
Delete error memory
injection pump*


8.40 - 18 T 17-A2

DIAGNOSIS

TEST 16
Multi-level switch (resistor group) torque limiter

Error location (hex): 1C


Error path: Multi-level switch (resistor group) torque limiters
voltage too high
voltage too low
wrong voltage

Effect of error: No multilevel switch functions are possible

Function: Voltage signals are detected via the multilevel input (control unit pin B28), whose
values are determined by external resistance circuits.
The limits can be programmed with MAN-cats.

Possible
cause of error: Line interruption, short circuit, resistor group faulty (e.g. cold junction)



Resistor group Voltage measurement at diagnostics
connector box (test box) between
Pin B28 and Pin B35

Target values:
Handling characteristics:
0.75 1.25 V (resistance R 5 = 0.511 k)
Torque limiter:
1.75 2.25 V (resistance R 6 = 1.37 k)
Retarder active:
2.75 3.25 V (resistance R 7 = 3.09 k)
Speed limiter with special application:
3.75 4.25 V (resistance R 8 = 8.20 k)
Test lines
Replace resistor group
If no fault found, try replacing the
control unit

T 17-A2 8.40 - 19

DIAGNOSIS

TEST 17
Operating unit (combination switch on steering column)

Error location (hex): 1D


Error path: Operating unit (combination switch on steering column) faulty
Voltages false or implausible
EOL programming faulty

Effect of error: The cruise control is not functioning. Simultaneously all further functions of the
operating unit such as intermediate speed control or idle speed control are not
longer capable of activation.
If the fault was only temporary (e.g. through multiple activation of the operating unit)
the system will become operable again after switching the ignition off and then on
again.

Function: The operating unit is resistance-coded, in other words the control unit recognises
every switching state by reference to the voltage that has been read in. It
recognises an error if the wrong values are output over a certain period, e.g.
through electrical faults but also through multiple activation (incorrect operation!) of
the operating unit.

Possible
cause of error: Interruption on line, short-circuit, operating unit faulty, EOL programming wrong



Operating
unit
and Pin B9

Switch on all switch positions of opreating
unit determine the voltages

Target values:
SET+ 0.83 1.21 V
SET 2.53 2.97 V
MEMORY 1.60 2.00 V
AUS (OFF) 4.18 4.53 V
Not activated 3.35 3.74 V
Test lines
Test EOL programming
Replace operating unit
If no fault can be found, try replacing
control unit

8.40 - 20 T 17-A2

DIAGNOSIS

TEST 18
PBM interface (DKR/DKV)

Error location (hex): 1E


Error path: PWM = Pulse-width-modulated signal
Control unit input Pin B30 (DKR) and Pin B7 (DKV)
faulty
interrupted
EOL programming faulty

Effect of error: No intervention in quantity possible through PBM interface (e.g. ASR)
No load-dependent gear changes (automatic transmission) possible

Possible
cause of error: Short to minus, line interruption, EOL programming wrong

Note 1: If the DKR line is interrupted (e.g. faulty control switch for ASR shutdown) then no
DKV signal is emitted

Note 2: The PWM interface is only active with partner systems without CAN

Ignition switched off


Lines to the
partner system
and Pin B1/B2

Target value:
Test line (including partner
systems)
Test plug connector
Lines to the
partner system
and Pin B1/B2

Target value:
Test line (including partner
systems)
Test plug connector
If lines OK, continue fault search in
partner system

T 17-A2 8.40 - 21

DIAGNOSIS

TEST 19
CAN 1 interface (ASR, GS, FM)

Error location (hex): 1F


Error path: Engine control unit

Effect of error: Data exchange between the EDC system and the connected electronic systems is
interrupted

Possible Interface error
cause of error: EOL programming wrong
Control unit faulty

Note: The CAN databus is described in the repair manual T 51



Control unit Resistance measurement at diagnostics
connector box between Pin B11 and
Pin B12

Target value: 120
Error condition: 5 s no message
received
Test lines
At ca. 0 short-circuit from CAN-H to CAN-L
Try replacing control unit

8.40 - 22 T 17-A2

DIAGNOSIS

TEST 20
Timeout: CAN signal ASR



Error path: CAN signal from ABS/ASR control unit faulty

Effect of error: ASR not functioning

Possible
cause of error: Line interruption, short-circuit, wrong EOL programming of the ABS control unit




EDC control unit Resistance measurement at diagnostics
Pin B12

Target value: 120
Error condition: Timeout period 5 s
Test lines
At ca. 0 short-circuit from
CAN-H to CAN-L
Try replacing control unit
ABS/ASR control unit Resistance measurement between
Pin X1/3 and Pin X1/1

Target value: 60

Test lines
CAN-H to CAN-L
At ca. 120 the connection to
the terminator is broken

T 17-A2 8.40 - 23

DIAGNOSIS

TEST 21
Shutdown via relay redundant shutdown MAR (after-running test)

Error location (hex): A2


Error path: Relay, redundant shutdown (MAR), engine control unit


Engine shutdown via MAR (relay redundant shutdown) impossible

Function: The relay redundant shutdown (MAR = solenoid valve shutdown relay) is actuated
by the engine control unit (pin B18) and in the individual case interrupts the power
supply to the pump control unit.
This leads to shutdown of the engine.
In after-running the MAR is shut down (de-energised). If the expected fall in speed
does not come about, it is classified as an error.

Possible Line interruption, short-circuit, relay redundant shutdown (MAR) faulty, actuation
cause of error: from control unit faulty (engine control unit faulty), road speed signal implausible

Note: In the event of errors in after-running, the road speed signal must also be checked.



Pump relay (MAR)

Start engine and run at idling speed.
Pull bridge Pin B18 at diagnostics connector
box (test box). Engine must shut down within
3 s
Test lines
Replace relay
Power supply MAR Switch on ignition
and B2
Target value: U
Bat

Switch off ignition
and B2
Target value: 0 V
Test lines
If not fault can be found,
replace the control unit
Road speed signal See test 6
See test 6

8.40 - 24 T 17-A2

DIAGNOSIS

TEST 22
Timeout: CAN signal, transmission to EDC



Error path: CAN signal from transmission control unit faulty

Effect of error: Restriction of functioning of transmission control

Possible Interface error
cause of error: Line interruption, short-circuit
Control unit faulty
EOL programming wrong




EDC control unit Resistance measurement at diagnostics
Pin B12

Target value: 120
Error condition: Timeout period 5 s
Test lines
CAN-H to CAN-L
Try replacing the control unit

T 17-A2 8.40 - 25

DIAGNOSIS

TEST 23
Pedal sensor (plausibility with brake)



Error path: Idle speed switch in pedal sensor
implausible to the brake signal
Proximity switch, brake

Effect of error: Speed diminishes to idling

Function: This test is designed to check for a hanging or stuck accelerator pedal. In other
words, the accelerator pedal is not in or not completely in its idle position and
simultaneously a brake signal is detected.
This situation can also be induced by simultaneous actuation of the brake and of
the accelerator pedal.

Possible
cause of error: Interruption on line, short-circuit, setting wrong, pedal sensor faulty, operator error

Test 1 completed


Idle speed switch in pedal sensor See test 1 See test 1
Proximity switch, brake See test 10 See test 10

8.40 - 26 T 17-A2

DIAGNOSIS

TEST 24
Main relay



Error path: Main relay
Contact sticks or hangs (does not open)

Effect of error: This fault may not be noticed

Function: The minus-side actuation of the relay coil takes place through the control unit via
the control unit outlet pin B27. The main relay is de-energised with a time delay
after switching off the ignition (after-running).
During after-running, various computer functions are checked and any faults
detected are stored in the error memory.

Possible
cause of error: Short circuit, main relay faulty



Main relay Voltage measurement at diagnostics
connector box (test box)
between Pin B27 and Pin B2

Target values: U
Bat
with ignition off
0 V with ignition on
Test lines
If line is OK, replace main relay

T 17-A2 8.40 - 27

DIAGNOSIS

TEST 25
Shutdown via monitoring module (after-running test)



Error path: Engine control unit, pump control unit (injection pump), road speed signal

Shutdown via monitoring module impossible

Function: Microprocessor is tested for functioning through question/answer routine.
In after-running false responses are sent intentionally, so that they lead to the engine
shutting down.
If the expected fall in speed does not come about, it is classified as an error.

Possible Engine control unit faulty, pump control unit (injection pump) defective
cause of error: Road speed signal implausible

Note 1: Before any exchange of pump or control units the error memory should always be
control unit.



Engine control unit
Delete error memory
Read out error memory again
If fault still present, repalce engine
control unit
Pump control unit
(injection pump)

Delete error memory
Read out error memory again
If fault still present, repalce engine
injection pump*
See test 6


8.40 - 28 T 17-A2

DIAGNOSIS

TEST 26
Atmospheric pressure sensor



Error path: Atmospheric pressure sensor in control unit faulty

Effect of error: No direct effects
In individual case there may simultaneously be an error message from the intake
manifold pressure sensor
Possible
cause of error: Atmospheric pressure sensor (control unit) faulty

Control unit If only this error is stored, no test is
possible because the sensor is inside the
control unit.

However, if there is indication of a faulty
intake manifold pressure sensor, this must
first be put through test 4.
Replace control unit

T 17-A2 8.40 - 29

DIAGNOSIS

TEST 27
Solenoid valve for pump control unit



Error path: Fuel injection pump

Effect of error: Final engine speed reduced to 2000 rpm
Full load quantity reduced by 25 40%
Engine is shut down

Function: A failed output stage/short-circuit is diagnosed via measurement of voltage in pump
control unit

Possible
cause of error: Speed sensor on flywheel has a loose contact, injection pump defective

control unit.


Engine speed
sensor
See test 3
See test 3
Injection pump
Delete error memory
Read error memory again
If error still present, replace injection
pump*


8.40 - 30 T 17-A2

DIAGNOSIS

TEST 28
Timeout: CAN signal ASR to engine brake

Error location (hex): 2A


Error path: CAN signal from ABS/ASR control unit to engine brake

Effect of error: ASR does not actuate the engine brake

Possible
cause of error: Interruption on line, short-circuit, control unit faulty




EDC control unit See test 19
See test 19
ABS/ASR control unit See test 20
See test 20

T 17-A2 8.40 - 31

DIAGNOSIS

TEST 29
Timeout: CAN signal transmission to engine brake

Error location (hex): 2B


Error path: CAN signal from transmission control to engine brake

Effect of error: Transmission control does not actuate the engine brake

Possible




See test 19

8.40 - 32 T 17-A2

DIAGNOSIS

TEST 30
Timeout: CAN signal, vehicle management to engine brake

Error location (hex): 2C


Error path: CAN signal from vehicle management to engine brake

Effect of error: Vehicle management does not actuate the engine brake

Possible




See test 19

T 17-A2 8.40 - 33

DIAGNOSIS

TEST 31
Timeout: CAN signal, vehicle management to EDC

Error location (hex): 2D


Error path: CAN signal from vehicle management to EDC

Effect of error: No intervention in volume by vehicle management

Possible




See test 19

8.40 - 34 T 17-A2

DIAGNOSIS

TEST 32
Timeout: CAN signal transmission to EDC

Error location (hex): 2E


Error path: CAN signal from transmission to EDC

Effect of error: No intervention in volume by transmission

Possible




See test 19

T 17-A2 8.40 - 35

DIAGNOSIS

TEST 33
After-running control



Error path: Control unit for actuation output faulty
Computer after-running has not taken place


Function: After-running automatically takes place after each shutdown procedure

Possible Power supply for control unit for after-running is not secured
cause of error: EOL not completed



Power supply to control
unit
connector box (test box)
between Pin B3/B4 and Pin B1/B2

Target values:
U
Bat
with ignition off as long as after-running
takes place in control unit.
Main battery switch is held by the EDC control
unit (holding circuit)
Error condition: Relay must have responded
within 5 s
Test lines
Test after-running circuit
Test main relay

Oscilloscope measurement on switching ignition on and off

ON OFF

CH 1: Pin B1B3 CH 1: Pin B1B3
CH 2: Pin B15B1 CH 2: Pin B15B1

If Pin B1B3 is live for 5 s longer than Pin B15B1, there is a "main relay" fault classification

CH 2: 10.0 V
200 ms

CH 1: 10.0 V
200 ms
CH 2: 10.0 V
200 ms

CH 1: 10.0 V
200 ms

8.40 - 36 T 17-A2

DIAGNOSIS

TEST 34
Pump control unit self-test: Solenoid valve voltage measurement

Error location (hex): C1


Error path: Pump control unit (injection pump)

Effect of error: None known of

Function: Monitoring of voltage in self-test if solenoid valve is not actuated

Possible

control unit.

Injection pump
Delete error memory
injection pump*


T 17-A2 8.40 - 37

DIAGNOSIS

TEST 35
Pump temperature (pump control unit)



Error path: Injection pump (pump control unit) fuel temperature too high

Effect of error: If the values are implausible there is a switch to substitute value (75 C)

Possible
cause of error: Fuel temperature too high, sensor in pump defective, injection pump faulty

control unit.

Injection pump Error limits:
If implausible values t > 130 C or
t < 45 C the substitute value is set
Delete error memory
injection pump*


8.40 - 38 T 17-A2

DIAGNOSIS

TEST 36
Busoff: CAN 2 signal



Error path: CAN signal between pump control unit and engine control unit on switching on
(busoff)

Effect of error: Engine goes into fast idling (ca. 750 rpm), acceleration now impossible

Possible
cause of error: Interruption on line, short-circuit, control unit faulty, injection pump faulty

control unit.



Engine control
unit
control box between Pin A27 and A24

Target value: 120
Test lines
At ca. 0 short-ciruit from CAN-H to
CAN-L
If fault is still present, try replacing
the control unit
Injection pump
Delete error memory
the injection pump*


T 17-A2 8.40 - 39

DIAGNOSIS

TEST 37
CAN 2 signal (interface)



Error path: CAN signal to pump control unit on switching on

Effect of error: Engine goes into fast idling (ca. 750 rpm), acceleration now impossible

Possible
cause of error: Interface error
Injection pump (pump control unit) faulty

control unit.

Injection pump
Delete error memory
If fault still present, try replacing the injection pump*


8.40 - 40 T 17-A2

DIAGNOSIS

TEST 38
Shutdown via quantity solenoid valve (after-run test)



Error path: Status of solenoid valve shutdown (MAB) in after-running

Full load quantity reduced by 25 40%,
impossible to shutdown engine via MAR (high-pressure solenoid valve in injection
pump)

Possible Actuation of control unit is faulty (engine control unit defective)
cause of error: Injection pump (pump control unit) faulty
Road speed signal implausible

control unit.




Injection pump
Delete error memory
Read error memory once
again
If fault still present, try
replacing the injection
pump*
Engine control unit See test 15
See test 15
See test 6


T 17-A2 8.40 - 41

DIAGNOSIS

TEST 39
Busoff: CAN 1 signal



Error path: Vehicle CAN (busoff)

Possible

control unit.

Note 2: The CAN databus is described in the repair manual T 51



Engine control
unit
control box between Pin B11 and B12

Target value: 120
Test lines
CAN-H to CAN-L
Try replacing the control unit

8.40 - 42 T 17-A2

DIAGNOSIS

TEST 40
Pump speed sensor (IWZ signal)



Error path: Fuel system
Fuel injection pump

Effect of error: Engine shuts down

Function: Refer to page 3.02 - 14

Possible Fault in fuel system (leak, clogged, air in system)
cause of error: Injection pump defective (dynamic: implausible, static; increments per segment not
complete)

control unit.

Note 2: The fuel system layout (low pressure) is shown in the repair manuals A 13
and A 14.

Fuel system Fuel pressure
Vent (filter, then injector line at at least 3 injection nozzles)
After successful start, leave engine idling for at least 30 s
Fill the tank
Injection pump
Test pump installation*
Delete error memory
If fault still present, try replacing the injection pump*


T 17-A2 8.40 - 43

DIAGNOSIS

TEST 41
Residual quantity



Error path: CAN signal (quantity that is transferred to the pump on the CAN-bus)

Effect of error: Engine stops because calculation of quantities inaccurate

Function: If despite the quantity "quantity 0" being specified on the CAN the speed is
>700 rpm, the boost pressure >300 mbar and NBF signals (only with level 1) are
detected, there is classification as an error

Possible Line interruption, short-circuit, control unit defective, NBF (only in level 1) faulty,
cause of error: intake manifold pressure sensor faulty

Note: Before any replacement of pump or control units the error memory should always
be deleted and the error observed.
control unit.

Injection pump
Delete error memory
injection pump*
Intake manifold
pressure sensor
See test 4
See test 4
Needle movement
sensor
See test 14
See test 14


8.40 - 44 T 17-A2

DIAGNOSIS

TEST 42
Pump control unit self-test: solenoid valve output stage



Error path: Hardware error in solenoid valve output stage (pump control unit)


Function: Checking of output stage in PSG self-test

Possible

control unit.

Injection pump
Delete error memory
injection pump*


T 17-A2 8.40 - 45

DIAGNOSIS

TEST 43
Injection timing device (pump control unit)

Error location (hex): CA


Error path: Target-actual value exceeding/not reaching injection timing device


Possible Line interruption, short-circuit
cause of error: Fault in fuel low-pressure system
faulty or wrong overflow valve
air or leaks in the system
faulty pre-supply pump
blocked filters
clogged lines
empty fuel tank
faulty injection pump
faulty fuel filter

control unit.

Note 2: The fuel pipework layout (low pressure) is shown in the repair manuals A 13
and A 14.

Injection pump Error condition:
In case of deviation of target
from actual value for injection
start by more than
+/ 3 grad longer than 8 s
and speed > 1200 rpm
Delete error memory
injection pump*
Fuel system Fuel pressure
See above (possible cause of error)


8.40 - 46 T 17-A2

DIAGNOSIS

TEST 44
Timeout: CAN signal PSG 1

Error location (hex): CB


Error path: CAN signal from pump control unit to engine control unit (timeout)

Effect of error: Engine goes into increased idling speed

Possible
cause of error: Line interruption, short-circuit, control unit faulty, injection pump faulty

control unit.



Engine control
unit

Target value: 120
Test lines
At ca. 0 short-circuit from CAN-H
to CAN-L
the control unit
Injection pump
Delete error memory
injection pump*


T 17-A2 8.40 - 47

DIAGNOSIS

TEST 45
Shutdown via voltage monitoring (after-running test)



Error path: Status shutdown via voltage monitoring)

Torque reduced by 25 40%,
shutdown via voltage monitoring impossible

Function: In after-running, an error is consciously simulated (limit values). If the expected fall in
speed does not come about, it is classified as an error.

Possible Line interruption between engine control unit and injection pump (pump control unit),
cause of error: engine control unit faulty, injection pump (pump control unit) faulty
If additionally the error "Plausibility shutdown signal (MAB)" or "Shutdown via
monitoring module" occurs, check MAB line.

control unit.

rolling and the ignition is then switched off, there is after-running. The various
shutdown paths in after-running can then be classified as defective because the
speed does not drop away fast enough (vehicle is rolling).


Engine control unit

Delete error memory
If fault still present, try replacing the engine
control unit
Pump control unit
(injection pump)

Delete error memory
injection pump*
See test 6


8.40 - 48 T 17-A2

DIAGNOSIS

TEST 46
Timeout: CAN signal MSG 1

Error location (hex): B1


Error path: CAN signal from engine control unit to pump control unit (timeout)

Torque reduced by 25 40%
Possible
cause of error: Line interruption, short-circuit, control unit faulty, injection pump faulty

control unit.



Engine control
unit

Target value: 120
Test lines
to CAN-L
the control unit
Injection pump
Delete error memory
injection pump*


T 17-A2 8.40 - 49

DIAGNOSIS

TEST 47
Supply voltage, pump control unit



Error path: Power supply to pump control unit, relay, redundant shutdown (MAR)

Possible
cause of error: Line interruption, short-circuit

Condition for testing: See below


Power supply Voltage measurement at cable loom plug to
PSG between Pin 7 (+) and Pin 6 ()

Target value: U
Bat
Error limits: U < 7 V or U > 32 V
Test line
Test plug connection
Relay redundant
shutdown (MAR)

Switch on ignition
and Pin B1

Target value: U
Bat

Switch off ignition
Disconnect engine control unit
control box between Pin B18 and Pin B1

Target value: 180 250
Test line
Test plug
Replace relay (MAR)

Plug for pump control unit

1
2
3
4 5
7 8

8.40 - 50 T 17-A2

DIAGNOSIS

TEST 48
CAN signal, pump control unit (interface)



Error path: CAN signal to pump control unit (timeout value range violation)

Effect of error: Engine goes into increased idling speed
Engine shuts down

Possible Line interruption, short-circuit, control unit faulty, injection pump faulty,
cause of error: engine speed sensor flywheel faulty

control unit.



Engine control unit Resistance measurement at diagnostics

Target value: 120
Test lines
to CAN-L
If fault still present, try replacing
control unit
Injection pump
Delete error memory
injection pump*
Engine speed
sensor
See test 3
See test 3


T 17-A2 8.40 - 51

DIAGNOSIS

TEST 49
Speed sensor signal detection, pump control unit



Error path: Engine speed signal to the pump control unit


Function: Monitoring on negative flank in data collection window

Possible Speed sensor flywheel faulty, sensor distance false (target: 0.5 1.5 mm).
cause of error: Control unit faulty, injection pump installation wrong, injection pump faulty.
"Injection start deviation" is sometimes displayed when there is a loose contact.
The error "Speed sensor at flywheel" often appears at the same time

control unit.

Engine speed
sensor
See test 3
See test 3
Injection pump
Delete error memory
injection pump*
Cables Line between Pin A35
engine control unit and Pin 8
pump control unit
Test lines


8.40 - 52 T 17-A2

DIAGNOSIS

TEST 50
Pump control unit self-test: EEPROM checksum



Error path: Checksum test EEPROM

as injection timing device can go to advance stop

Function: Checksum test in self-test

Possible
cause of error: Control unit faulty, pump control unit (injection pump) defective

control unit.

Fuel injection
pump

Delete error memory
injection pump*


T 17-A2 8.40 - 53

DIAGNOSIS

TEST 51
Pump control unit self-test: EEPROM status



Error path: Status check EEPROM (hardware error)

as injection timing device can go to advance stop

Function: Hardware check in self-test

Possible
cause of error: Control unit faulty, pump control unit (injection pump) defective

control unit.

Fuel injection
pump

Delete error memory
injection pump*


8.40 - 54 T 17-A2

DIAGNOSIS

TEST 52
Pump control unit self-test: ADC status



Error path: Status analog-digital converter


Function: In the self-test checking earth potential of a channel of the AD converter there is no
quantity correction
Solenoid valve voltage is no longer acquired

Possible
cause of error: Control unit faulty, injection pump defective

control unit.

Fuel injection
pump

Delete error memory
injection pump*


T 17-A2 8.40 - 55

DIAGNOSIS

TEST 53
Pump control unit self-test: RAM



Error path: RAM in pump control unit

Effect of error: Engine does not start

Function: Checking RAM in self-test

Possible
cause of error: Control unit faulty, injection pump defective

control unit.

Fuel injection
pump

Delete error memory
injection pump*


8.40 - 56 T 17-A2

DIAGNOSIS

TEST 54
Polarity reversal, speed sensor on flywheel



Error path: Speed sensor on flywheel

Possible
cause of error: Cable plugged in wrongly, fault in speed sensor


Cables Plug connection X337
X337 Pin e: cable colour white/blue
X337 Pin F: cable colour blue
Engine control unit
Pin A1: cable colour white/blue
Pin A13: cable colour blue
Error condition:
Lower speed threshold: 500 rpm
Upper speed threshold: 1500 rpm
Cable should be assigned correctly
speed sensor

T 17-A2 8.40 - 57

DIAGNOSIS

TEST 55
Engine control unit monitoring module ( -controller)



Error path: -Controller in engine control unit


Possible
cause of error: Control unit faulty

control unit.

Control unit
Delete error memory
control unit

8.40 - 58 T 17-A2

DIAGNOSIS

TEST 56
Pump control unit initialisation

Error location (hex): CD


Error path: Exchange of messages between pump control unit and engine control unit takes
too long


Function: In the self-test the exchange of messages between the pump control unit and engine
control unit is monitored for duration. If the time interval is too long, there is an error
classification.

Possible Pump control unit (injection pump) faulty
cause of error: CAN bus between engine control unit and pump control unit is defective

control unit.

Fuel injection
pump

Delete error memory
injection pump*


T 17-A2 8.40 - 59

DIAGNOSIS

TEST 57
Multi-level switch (resistor group), maximum speed limiter

Error location (hex): DB


Error path: Multi-level switch (resistor group) for maximum speed limiters
voltage too high
voltage too low
wrong voltage

Effect of error: No multilevel switch functions are possible

Function: Voltage signals are detected via the multilevel inputs (control unit pin B19), whose
values are determined by external resistance circuits. The limits (HGB 1, 2 and 3)
can be programmed with MAN-cats.

Possible
cause of error: Line interruption, short circuit, resistor group faulty (e.g. cold junction)

Note 1: The maximum speed limiters via the multilevel switch (control unit pin B19) are only
implemented from level 2 onwards.
In level 1, HGB 2 is activated by wiring pin B21 with U
Bat
.
HGB 3 is not possible with level 1.

Note 2: Activation of another maximum speed limit (e.g. by a changeover switch) is only
possible at below a road speed of 10 km/h!



Resistor group Voltage measurement at diagnostics
connector box (test box) between Pin
B19 and Pin B35

Target values:
Maximum speed limit 1:
0.75 1.25 V (resistance R 1, 0.511 k)
1.75 2.25 V (resistance R 2, 1.37 k)
2.75 3.25 V (resistance R 3, 3.09 k)
Test lines
Test plug-in connections
Replace resistor group
If no fault is found, try replacing the
control unit

8.40 - 60 T 17-A2

DIAGNOSIS

TEST 58
Error when sending a CAN message

Error location (hex): E0


Error path: Engine control unit


Possible
cause of error: CAN from engine control unit faulty

Control unit See Test 19
See Test 19

T 17-A2 8.40 - 61

DIAGNOSIS

TEST 59
Test on shutdown paths

Error location (hex): E1


Error path: Road speed signal


Function: After-running automatically takes place after each shutdown
When the permissible number of shutdowns has been exceeded without after-
running, it is classified as an error

Possible
cause of error: Road speed signal faulty

Note: In the event of errors in after-running, the road speed signal must also be checked.
rolling and the ignition is then switched off, there is after-running. The various
shutdown paths in after-running can then be classified as defective because the
speed does not drop away fast enough (vehicle is rolling).


Road speed signal See Test 6 See Test 6

8.40 - 62 T 17-A2

DIAGNOSIS

TEST 57
Engine brake

Flash code: No data acquisition
Error location (hex): No data acquisition

Error display: No data acquisition

Error path: Engine brake, engine brake switch

Effect of error: No engine brake function

Function: The engine brake is actuated corresponding to the engine speed via Pin A18
(output) of the EDC control unit. Actuation takes place by supplying current to Pin
B14 (input) of the EDC control unit by actuation of the foot control switch for the
engine brake. Actuation can also take place from the transmission control or
vehicle management through a CAN message.
Possible
cause of error: Line interruption, short-circuit, engine brake switch faulty


Note 1: The engine brake function can also be switched off by other systems, e.g. by the
ABS control unit during a braking controlled under ABS. For this reasons the ABS
system should be included when fault finding.
A clutch signal coming from a faulty or incorrectly adjusted proximity switch can
also lead to failure of the engine brake.

Note 2: On part of the EDC control units 6.4 level 1 the engine braking activation functions
by the "flip-flop" principle, i.e. when the engine brake is actuated at a speed of >800
rpm, the engine brake stays active even though the control switch is no longer
actuated. Only when the foot control switch is activated again or the brake, clutch or
accelerator pedal are operated is the engine brake deactivated.
During EOL programming, the flip-flop switching is automatically deactivated
however and can also not be re-activated!


Power supply from
engine brake control
switch
Voltage measurement at diagnostics connector
box (test box) between Pin B14 (+) and
Pin B1/2 (-)

Target values:
Foot control switch, engine brake actuated: U
Bat

Test line
Test plug-in connection
Is bridge on ZE, position 61
plugged in?
Replace engine brake
control switch
Solenoid valve,
engine brake

Voltage measurement at diagnostics connector
box (test box) between Pin A18 (+) and
Pin B1/2 (-)

Start engine and run up to approx. 1100 rpm

Target values:
Foot control switch, engine brake actuated: U
bat
engine brake must function
Test line
Replace solenoid valve,
engine brake
If no fault is found, try
replacing the control unit

T 17-A2 8.40 - 63

DIAGNOSIS

TEST 58
FGB/FGR switch



Error path: FGB/FGR switch

Effect of error: No switchover to FGB is possible

Function: Refer to page 3.01 - 3

Possible
cause of error: Line interruption, short-circuit, FGR/FGB switch faulty



Supply voltage

Switch on ignition
Pin B22 (+) and Pin B1/2 (-)

Target values:
FGB/FGR switch activated: U
Bat

Test line
Test/replace FGB/FGR
switch

8.40 - 64 T 17-A2

DIAGNOSIS

TEST 59
Relay, redundant shutdown MAR (safety relay)



Error path: Relay, redundant shutdown (safety relay)


Function: The safety relay fulfils an important function as an independent, higher ranking
(redundant) shutdown facility of the engine. Actuation of the safety relay takes place
in certain emergency situations when shutting down the engine by control to zero is
no longer possible. The safety relay is actuated by the engine control unit Pin B18
and interrupts the power supply to the pump control unit (Pin 7). This leads to
immediate engine shutdown.

Possible
cause of error: Line interruption, short circuit, safety relay faulty, actuation by the control unit faulty
(control unit faulty)



Function safety relay

Start engine and run at upper idling speed
(control speed PWG max)
Interrupt Pin B18
Engine must shut down within approx.
10 seconds

Supply voltage Switch on ignition
Pin B18 (+) and Pin B1 (-)

Specified value: U
Bat

Test line
Replace safety relay
If no fault can be found:
Replace control unit
Coil resistance, safety
relay
Switch on ignition
Pin B18 (+) and Pin B1 (-)
Specified value: 180 250
Test line
Replace safety relay

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T 17-A2 8.

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