Electronic Diesel Control D2840 Man Marine Engines

Technical Information
Electronic Diesel Control

Repair Manual
EDC M(S) 5 − D28 V marine engines

Foreword
Dear Customer
These instructions are intended to help you to repair the electronic diesel control system
properly.
In writing these instructions, we have assumed that you have the necessary knowledge
of control systems for working on and with the electronic diesel control.
Best regards
MAN Nutzfahrzeuge Aktiengesellschaft
Nuremberg Plant
Since our products are in continuous development, we reserve the right to make technical modifications.
 1998 MAN Nutzfahrzeuge Aktiengesellschaft

Reprint, duplication or translation, as a whole or in part without the written approval of
MAN is prohibited. MAN reserves all rights accorded by the relevant laws on copyright.
MTDA Technical status: 03.1998 51.99493–8486
1
Contents
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electronic diesel control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Control unit plug connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electromagnetic fuel-delivery regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrohydraulic shut-off device EHAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pedal value transmitter (hand throttle signal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Temperature sensors for charge air, coolant and fuel . . . . . . . . . . . . . . . . . . . . . . . . . 17
Turbo pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
RPM sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
EDC operating element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Notes on operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Flash code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
List of checking procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Troubleshooting chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Troubleshooting program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Pedal value transmitter (PWG, hand throttle signal) . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Boost air temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Boost pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Control rod position transducer (Rack travel sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Coolant temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fuel-delivery regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Auxiliary rpm sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fuel temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Undervoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Request button (brake)
“Br” button on EDC operating element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Engine overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Multistage switch for engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
EDC operating element for idle speed setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Main relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Atmospheric pressure sensor (in control unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Electrohydraulic shut-off device EHAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Control unit EEPROM computer, 1 fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Control unit EEPROM computer, 2 faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
External stop switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Control unit (processor afterrunning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Control unit, after-running watchdog fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Control rod travel transmitter – loose contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Plug connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Engine terminal box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2
Contents
Arrangement of sensors for boost air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Arrangement of sensors for cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Arrangement of sensors for speed pickup and fuel system . . . . . . . . . . . . . . . . . . . . . . . 63
Arrangement of sensors for coolant level and oil pressure . . . . . . . . . . . . . . . . . . . . . . . 64
Arrangement of fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
EDC-diagnose-tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
MAN-Cats System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
MAN-Cats – Software Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Description of EDC-Check with pinadapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Terminal connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Terminal connection diagram – Brief overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3
Safety information
General
Important safety regulations are summarized in this quick-reference overview and ar-
ranged by topic to effectively convey the knowledge necessary to avoid accidents caus-
ing injury, damage or environmental hazard.
The engine operating manual contains further information.
Important:
Should an accident occur despite all precautionary measures, particularly one involving
contact with corrosive acid, penetration of fuel under the skin, scalding by hot oil, anti-
freeze splashing into the eyes etc. you must seek medical assistance immediately.
1. Instructions for avoiding accidents causing injury
Only authorized and qualified personnel are permitted to carry out inspection, ad-
justment and repair work
D Put gearbox of ship into neutral, if necessary unhinging gearshift lever

(disconnect via remote control)
D Firmly secure units and assemblies on disassembly

D Only authorized personnel are permitted to start and operate the en-
gine
D Do not stand too close to rotating parts while the engine is running
Wear close-fitting working clothes
D Do not touch hot engine with bare hands: Danger of injury by burning
ËË
D Keep area surrounding engine, ladders and stairways free of oil and
grease. Accidents caused by slipping can have serious consequences
D Only work with tools which are in good condition. Damaged or worn
spanners and wrenches can slip off: Danger of injury!
D Persons must not stand under an engine suspended on a crane hook.
Keep lifting gear in perfect condition
4
Safety instructions
D Only open coolant circuit once the engine has cooled down. Follow the
instructions given under “Care and Maintenance” in the Operating Man-
ual exactly if it is not possible to avoid opening the coolant circuit with
the engine at operating temperature.
D Do not tighten or undo pipes and hoses under pressure (lubricating oil
circuit, coolant circuit and any downstream hydraulic oil circuits).
Danger of injury caused by liquids escaping under pressure!
D Do not hold hands under the fuel jet when checking injection nozzles.
Do not inhale fuel mist
D Always disconnect battery when working on the electrical system
D Do not use rapid charger to start the engine. Rapid charging of bat-
teries is only permitted with the positive and negative leads discon-
nected!
D Disconnect batteries only with the “ignition” turned off

D Observe manufacturer’s instructions for handling batteries.
Caution:
Battery acid is toxic and corrosive. Battery gasses are explosive
D Only use suitable measuring instruments to measure voltages! The

minimum input resistance of a measuring instrument should be 10 MW
D Only disconnect or connect wiring harness connectors on electronic
control units only with the “ignition” turned off!
Disconnect batteries and connect the positive lead to the negative lead
such that they are electrically conductive before carrying out any electric
welding work. Earth the welding set as close to the weld as possible.
Do not route cable of welding apparatus parallel to electric lines on board
the ship.
Refer to the “Welders’ Code of Practice” for further accident prevention
measures.
D When carrying out repaint jobs, electronic components may be sub-
ject to high temperatures (max. 95°C) for only very short periods; a
period of up to approx. 2 hours is permissible at a max. temperature of
85°C, disconnect batteries
5
Safety information
Limitation of liability for parts and accessories
In your own interest, we strongly recommend you use only accessories and original MAN
parts expressly approved by MAN for your MAN engine. The reliability, safety and suit-
ability of these parts and accessories have been tested specially for MAN engines. Des-
pite us keeping a constant eye on the market, we cannot assess and be held responsible
for these properties in other products, even if they bear TÜV (German testing and in-
spection institute) approval or any other official approval in any particular case.
Laying-up or storage
Special measures must be implemented in accordance with MAN Company Standard

M 3069 Part 3 if engines are to be laid up or placed into storage for more than 3 months.
6
Electronic diesel control
Electronic diesel control EDC
General
The requirements set by customers and legislation in respect of fuel consumption, ex-
haust emission and noise characteristics etc. on diesel engines have grown over the
years and will be even more stringent in the future.
The fact that conventional mechanical injection systems have reached their capacity li-
mits has made electronically controlled fuel injection systems necessary.
Such systems increase engine efficiency, improve driving comfort and lessen the burden
on the environment.
The Electronic Diesel Control (EDC) fulfils all these requirements.
7
System description
System description EDC M(S) 5
Engine Engine Pedal value transmitter Charge-air Turbo Fuel Water

speed 1 speed 2 (hand throttle signal) temperature pressure temperature temperature
Control unit
Engine monitoring
EHAB (red. Stop)
Electrohydraulic
ISO diagnosis
Power supply
warning lamp
Terminal 15
terminal 30
Idle speed
MAN-Cats
Diagnosis
Diagnosis
request
system
setting
cutout
EDC operating element

51.11615-7141
The controller contains
– the linear solenoid

– the control rod position transducer
The linear solenoid is driven by the electronic control unit.

The control unit processes information which it receives via
– the control rod position transducer

– Pedal value transmitter (hand throttle signal)
– turbo pressure sensor
– coolant temperature sensor
– turbo air temperature sensor
– Pedal value transmitters
– Fuel temperature sensor (in injection pump)
The diagnosis request button and the EDC check lamp are used for indicating faults and
for the flashcode output device integrated in the terminal box as EDC operating element
51.11615-7141.
Communication with the MAN-Cats checking and diagnostic computer is possible via an
ISO interface also integrated in the terminal box.
8
System description
To ensure the vehicle can still be driven to the nearest workshop in the event of one or
several sensors failing, an emergency drive function is integrated in the control unit.
The idle speed is exactly maintained by means of the idle speed governor as long as the
engine output is sufficient for this. The regulated idle speed can be altered within certain
limits. The idle speed set ex works is 600 rpm. However, it can be varied via the EDC op-
erating element in the range from 600 to 750 rpm.
Starting-fuel delivery is output when either a lower start recognition speed is exceeded.
The starting-fuel delivery and cold idle speed are limited as a function of the coolant tem-
perature to avoid impermissible smoke emission and unnecessary revving of the engine
after starting.
9
Block Diagram M(S) 5
*
System description
10
* for M(S) 5 not connected, not in operation

Component description
Control unit plug connector

Pin arrangement
19 . . . . . . . . . . . . . . . . . . 1
37 . . . . . . . . . . . . . . . . . 20
55 . . . . . . . . . . . . . . . . . 38
Pin assignments of control unit plug connector

EDC Pin Connection to component (O=Output, I=Input)
1 Injection pump controller pin 8 O
Jumper to pin 2 (activation of fuel-delivery regulator) O
2 Jumper to pin 1 (activation of fuel-delivery regulator) O
3 Not used
4 Not used
5 Not used
6 Not used
7 Not used
8 Not used
9 Injection pump controller pin 5 (control rod position transducer, instrument coil)
10 Injection pump controller pin 1 (control rod position transducer, reference coil)
11 Injection pump controller pin 6 (control rod position transducer, centre pick-off)
12 Not used
13 Negative from control unit for (Sensor ground)
– Speed sensor
– boost pressure sensor
– pedal value transmitter (hand throttle signal)
– boost air temperature sensor
– coolant temperature sensor
– resistor bank (in the EDC operating element)
– Fuel temperature sensor
14 Electrohydraulic shut-off valve EHAB O
15 Control unit power supply batt. + (via main relay and fuse) I
16 Control unit power supply batt. + (via main relay and fuse) I
17 Ground for auxiliary rpm sensor
18 Power supply batt. –
19 Power supply batt. –
20 EDC indicator lamp and diagnostic lamp O
21 RPM sensor (twisted with cable pin 13) I
22 Auxiliary rpm sensor (twisted with cable pin 17) I
23 Not used
11
Pin assignments of control unit plug connector
EDC Pin Connection to component (O=Output, I=Input)

24 Not used
25 Not used
26 Not used
27 Pedal value transmitter (signal) – terminal 7 in the terminal box I
28 Engine speed signal output from control unit (square-wave pulses) O
29 Not used
30 Not used
31 Not used
32 Not used
33 Boost pressure sensor (supply) – Pin 2 on the charge-air pressure sensor O
34 Fuel temperature sensor
35 To the EDC operating element with resistors for reduction
in the event of external faults
36 Charge-air pressure sensor (Signal) –
pin 1 on the charge-air pressure sensor I
37 Not used
38 Not used
39 Pedal value transmitter (idle speed switch) – terminal 8 in the terminal box
40 Not used
41 Not used
42 Not used
43 Request button (brake) – Pin 7 in the EDC operating element I
44 Idle speed adjustment – pin 4 in the EDC operating element
45 Pedal value transmitter (supply) – terminal 6 in the terminal box
46 Relay for voltage supply (main relay) K1 coil O
47 Ignition system ”On”, terminal 15
48 Diagnostic connection (K line) for MAN-Cats
49 Diagnostic connection (L line) for MAN-Cats
50 Input for emergency stop
51 Not used
52 Assigned to batt.+ (to enable multiplex signal)
53 Coolant temperature sensor – Pin 3 on temperature sensor I
54 Not used
55 Boost air temperature sensor – Pin 1 on temperature sensor I
12
Injection pump
The EDC injection pump consists of a heavy-duty version of a conventional injection

stage of the well-known Bosch P-pumps and, instead of the mechanical regulator, a
flange-mounted electromagnetic fuel-delivery regulator with a control rod position trans-
ducer.
Electromagnetic fuel-delivery regulator
Description:
The fuel-delivery regulator operates in conjunction with the P-pump. The most important
component part of the fuel-delivery controller is a linear solenoid in which the armature
acts directly on the control rod thus determining the injection volume by means of the
control position. When no power is applied, the control rod is held in the stop position by
means of a spring.
The other important component in the controller is a control rod position transducer.
Injection pump Control rod Control rod position transducer
Fuel-delivery
regulator
(linear solenoid)
Fuel-delivery regulator
Control rod
position
4 transducer
3 5
8
2 6
1 7
Plug connection
13
Electrohydraulic shut-off device EHAB
The EHAB (electrohydraulic shut-off device) is a safety-relevant component.

The EHAB shuts off the fuel supply to the injection pump in the event of certain faults oc-
curring in the EDC system. The EHAB is connected in the fuel supply system between
the delivery pump and pump suction chamber. The EHAB reverses the delivery direction
of the delivery pump so that the pressure in the suction chamber is reduced rapidly thus
interrupting the filling procedure.
Power is always applied to the EHAB during operation. The power circuit is interrupted
by the EDC control unit in order to activate the EHAB (e.g. for emergency engine shut-
down).
For this reason, the “ignition” must be turned on when bleeding the fuel system by
means of the presupply pump.
2 1
T ÜV
Fi FP
4 3
5 6
2
5
3
4
Plug connection
14
Suction chamber
Injection pump
EHAB 6 5
1ÜV 3 FP 2 T 4 Fi
Overflow valve Double filter box
Prefilter
Presupply
pump
(hand Overflow valve
primer)
Fuel tank
Caution:
Presupply pump integration in the fuel circuit should be checked according to pump type.
15
Pedal value transmitter (hand throttle signal)
Function
The pedal value transmitter (hand throttle signal) transmits the driver’s requirement to
the control unit in the form of voltage inputs. Then control unit uses these inputs to calcu-
late the correct injection quantity.
Block diagram
Kick-down switch Terminal on plug Terminal in

(not connected) (if present) terminal box – top
yellow 3 Kl. 3
Idle speed switch Pin 13 in the EDC controller
grey 6 Kl. 8
Pin 39 in the EDC controller
brown 5 Kl. 3
white 2 Kl. 7
pink 4 Kl. 6
U = Reference voltage, approx. 5 V from the EDC control unit

u = Setpoint
16
Temperature sensors for charge air, coolant and fuel

Turbo air
Characteristic
Plug connection
Coolant temperature sensor, Fuel temperature sensor

Characteristic
2 3
Plug connection
Function
The temperature sensors for charge air, coolant and fuel are NTC resistors. The coolant
temperature sensor is located in the coolant circuit, the charge-air temperature sensor is
located in the charge-air circuit downstream of the charge-air cooler and the fuel tem-
perature sensor is located in the fuel circuit. They supply the control unit with information
on the coolant, fuel and charge-air temperatures.
17
Turbo pressure sensor
1
2 Output
+5V
5
3
–
4
Plug connection
Function
The pressure sensor element consists of an Si diaphragm which contains several piezo-
resistive (pressure-sensitive) semiconductor resistors. The pressure to be measured “de-
flects” the sprung diaphragms. As a result, extended or compressed zones are created
on the surface of the diaphragms. The action of these forces changes the electrical rat-
ings of semiconductor resistor arrays arranged in these zones. These values are a
measure for the pressure to be measured.
Circuit diagram
Output +5V
Pressure
connection
EDC Pin 13 36 33
18
RPM sensor
1 1
2 2
5 5
3 3
4 4
Plug connection Plug connection

RPM sensor (1) Auxiliary rpm sensor (2)
Function
The rpm sensor consists of a permanent magnet and a coil with a high number of wind-
ings. The magnet “touches” the rotaring component to be measured, normally a crown
gear or grooved ring gear, with its magnetic field.
If the EDC-M(S) 5 system is fitted, the marine engine is provided with 6 rivets on the fly-
wheel.
When a groove moves past the sensor, the magnetic flux increases and, conversely, de-
creases in the gaps between the grooves. This generates an induction voltage in the
sensor coil which is measured by the electronic control. The distance between the sensor
and the grooved ring gear is approx. 1 mm.
Two rpm sensors are required to ensure reliable operation of the EDC system.
Both rpm sensors are installed in the flywheel housing.
A distinction is made between the rpm sensor and the auxiliary rpm sensor.
The signals of the auxiliary rpm sensor are used only for redundant engine speed sens-
ing.
Caution:
Do not confuse installation locations of the rpm sensor (1) and the auxiliary
rpm sensor (2), nor the “+” and “–” wires of the sensors.
19
EDC operating element
Function
The EDC operating element is used for setting the idle speed and for requesting an EDC
fault diagnosis. It contains resistors and is the interface to the engine monitoring system.
Dia – Diagnosis request button

Aus – ”OFF”
Br – “Brake contact“
Sp – Memory
+ – Button for increasing idle speed
– – Button for reducing idle speed
20
Notes on operation
Start procedure
No pedal value transmitter input is necessary for starting.
Changing idle speed – EDC operating element
The idle speed is set to 600 rpm in the works. If necessary, the idle speed can be set
anywhere between 600 rpm and 750 rpm with the engine at operating temperature
(from approx. 30°C).
Batt.+ EDC Pin 13
680
200
680
62
Set+ Set – Memory

Request
(brake)
1K
Off
EDC Pin 43 EDC Pin 44
Engine running:
D Press and hold request button (Br=”brake”) during the entire following procedure
D Press and hold memory button (Sp) for at least 5 seconds
D Idle speed is dropping to 600 rpm
D Press SET+ button
D The idle speed increases by approx. 10 rpm every time the SET+ button is pressed
D Actuating SET+ six times sets a speed of 660 rpm
D Press and hold memory button (Sp) for 5 seconds once more
D Release Br button
The set idle speed is now retained even after turning off the ignition.
21
Notes on operation
Proceed as follows to reset the works idle speed of 600 rpm:

After pressing the request button (Br=”brake”), press and hold the memory button for
approx. 5 seconds.
The idle speed now drops back to 600 rpm.
Then press and hold the memory button for a further 5 seconds while still pressing the
request button (BR=”brake”). Release Br button.
The works idle speed of 600 rpm is now reset.
22
Self-diagnosis
General
The EDC system continuously checks itself by means of a signal-range check. During
this check, all signals are scanned for presence and plausibility within a certain time
frame (determined by the software).
The control unit itself is also checked during the entire program run. The first check is al-
ways carried out when the “ignition” is turned on.
The diagnostic check lamp on the EDC operating element will come on for about 2 sec-
onds.
Any faults occurring during operation are stored for the purpose of subsequent diagnosis.
A maximum of 5 faults can be stored simultaneously in the fault code memory. The faults
are stored in the same order in which they occurred. If more than 5 faults occur, the least
significant fault is deleted.
Fault storage includes
D allocation of fault priority,

D identification of the type of fault,
D recording of fault frequency.
Sporadic faults are recorded by a frequency counter the first time they occur. This means
that a certain frequency number is set which is decremented by one during every start
procedure. If the fault no longer occurs, it is deleted when the counter reaches zero.
The diagnostic lamp lights steadily or goes out depending on the fault significance for the
purpose of fault signalling. If several faults are stored, the steady light has priority over
OFF.
Only faults currently present are indicated. Faults which are stored but are not currently
present are not indicated.
There are two fault code memories:
D Fault code memory for diagnosis via ISO interface. This memory can be read and de-
leted with MAN-Cats
D Fault code memory for diagnosis via flash code. The flash code memory can be read
out and deleted with the aid of the diagnosis button
Faults are always entered in both fault code memories simultaneously and persist after
the ignition has been switched off and on again.
Indicator lamp check:

The EDC indicator lamp lights for approx. 2 seconds after turning on the ignition as a
lamp test.
23
Self-diagnosis
The following measures are implemented automatically depending on the signifi-

cance of the fault:
D Switching over to suitable replacement function for continued but restricted engine
operation, ie engine speed reduced to approx. 1,500 – 1,700 rpm
D Reduction of engine speed to idle speed
D Immediate shutdown of the engine if required for safety reasons. Depending on the
type of fault, engine shutdown takes place by reducing the fuel delivery volume to zero
or by way of emergency shutdown with EHAB.
Flash code
To read out fault code memory
D If engine is stationary or running and ”ignition system” is switched on, press diagnosis
request button (Dia button on the EDC operating element) for at least 2 seconds.
Diagnosis lamp does not come on
D The flash procedure starts after a pause of approx. 3 seconds. The flash code is di-
vided into long and short pulses
D The diagnostic system always outputs only one fault at a time. In order to check
whether several faults are stored, the fault scanning procedure must be repeated until
the fault last indicated reappears
Example of flash code outputs
On
Lamp
Off
0.5 sec
Fault 2x long, 5x short
OFF phase before output: 3 seconds

ON duration of a long pulse: 2 seconds
OFF phase between two long pulses: 1 second
OFF phase between long and short pulses: 5 seconds
ON duration of a short pulse: 0.5 seconds
OFF phase between two short pulses: 0.5 seconds
To delete fault code memory

1. Press and keep request button depressed
2. Turn on “ignition”
3. Keep request button depressed for another 3 seconds, but not longer than 10 seconds
Now only the fault memory of the flashcode diagnosis is deleted.

The second fault memory can be read and deleted only with MAN-Cats.
24
Self-diagnosis
Fault code output MAN M(S)5 EDC
Overview of flashcodes
Number Description Steady See
of flashes light Page
f lt
fault
Long Short
0 0 No fault stored
1 Pedal value transmitter (hand throttle signal) yes 33
3 Boost air temperature sensing no 34
4 Engine speed sensing (rpm sensor, DZG, 1) yes 35
5 Boost pressure sensing yes 36
6 Control rod position sensing yes 37
7 Coolant temperature sensing yes 38
10 Fuel-delivery regulator monitoring yes 39
14 Engine speed sensing (auxiliary rpm sensor, HZG, 2) yes 40
1 1 Fuel temperature reader no 41
1 3 Undervoltage no 42
1 4 Request button (brake) no 43
1 6 Control unit (Computer coupling) yes 44
1 7 Overrevving yes 45
1 12 Multistage switch for engine speed yes 46
1 13 EDC operating element for idle speed setting no 47
2 5 Main relay sticking no 48
2 8 Atmospheric pressure sensing yes 49
3 1 Redundant cutout device (EHAB) yes 50
3 2 Control unit EEPROM computer, 1 fault yes 51
3 3 Control unit EEPROM computer, 2 faults yes 52
3 4 Externer Stop-Schalter no 53
3 8 Afterrunning not completed yes 54
3 9 Control unit, after-running watchdog fault yes 55
3 10 Control rod travel transmitter – loose contact no 56
25
List of checking procedures
List of checking procedures for EDC M(S) 5 stage 3
1. Checks while engine is stationary

(Ignition off, control unit not connected)
– Engine temperature approx. 25°C

– Control unit not (!!!) connected, cable harness adapter connected
– Measure resistance between PIN+ and PIN– with multimeter
PIN+ PIN– Set-point value Measured value

Control rod position transducer1) 11 9 18 – 25 Ω ................ Ω
(Rack travel sensor) 11 10 18 – 25 Ω ................ Ω
18 9 >10 MΩ . . . . . . . . . . . . . . . . ΜΩ
18 10 >10 M Ω . . . . . . . . . . . . . . . . ΜΩ
RPM sensor (DZG) 3) -0005 21 13 0.5 – 0,7 kΩ . . . . . . . . . . . . . . . . kΩ
-0008 0.8 – 1,0 kΩ . . . . . . . . . . . . . . . . kΩ
Auxiliary rpm sensor 3) -0006 22 17 0.5 – 0,7 kΩ . . . . . . . . . . . . . . . . kΩ
(HZG) -0009 0.8 – 1,0 kΩ . . . . . . . . . . . . . . . . kΩ
Fuel-delivery regulator 15 1 0,7 – 1,3 Ω ................ Ω
18 1 >10MΩ . . . . . . . . . . . . . . . . ΜΩ
16 2 0,7 – 1,3 Ω ................ Ω
Ground 13 18 >10 MΩ . . . . . . . . . . . . . . . . ΜΩ
17 19 >10 MΩ . . . . . . . . . . . . . . . . ΜΩ
EHAB 14 19 30 – 70 Ω ................ Ω
The following checks may be carried out in addition to the voltage measurements (see below).
Coolant temperature sensor 53 13 1,3 – 3,6 kΩ 2) . . . . . . . . . . . . . . . . kΩ
Fuel temperature sensor 34 13 1,3 – 3,6 kΩ . . . . . . . . . . . . . . . . kΩ
Boost air temperature sensor 55 13 1,3 – 3,6 kΩ . . . . . . . . . . . . . . . . kΩ
Boost pressure sensor 33, 36 13 Resistance measurement not appropriate
Multistage switch 35 13
No reduction active 500 – 520 Ω ................ Ω
Operating element for idle speed 44 13
adjustment
Non-actuated 550 – 700 Ω ................ Ω
”Sp” button actuated 125 – 160 Ω ................ Ω
”SET+” button actuated 50 – 70 Ω ................ Ω
”SET–” button actuated 280 – 350 Ω ................ Ω
”OFF” button actuated 930 – 1940 Ω ................ Ω
1) Exact measurements are possible only at defined temperatures.

2) Resistance approx. 230 – 460 W with engine at operating temperature (approx. 80 °C)
3) Since August 97 new speed pick-ups DG6 (51.27120-0008/ -0009) have been in-
stalled. Their electrical resistance differs from that of the old speed pick-ups DG2
(51.27120-0005/-0006), but they are otherwise identical in function.
26
2. Checks while engine is running and ship is stationary (not coupled)
– Engine temperature approx. 30°C

– Cable harness adapter is connected up to control unit
– Measure speed at the following operating points
– Check with MAN-Cats Monitoring 2
Set-point value Measured value Remark MAN-Cats

RPM sensor (DZG) n lower idle speed n=................1/min PWG Min (u.LL) Engine speed
n top idle speed n=................1/min PWG Max (o.LL) (Monitoring 2)
Auxiliary rpm sensor n lower idle speed n=................1/min PWG Min (u.LL) Engine speed
(HZG) n top idle speed n=................1/min PWG Max (o.LL) (Monitoring 2)
– Measure voltage between PIN+ and PIN– with multimeter
PIN+ PIN– Set-point Measured Remark Engine MAN-Cats

value [V] value [V] speed (Monitoring)
Supply of control unit 15 18 UBAT ......... idle speed
(U-Batt) 47 19 UBAT .........
Reference voltage 45 13 4,75 - 5,25 ......... idle speed
(Uref) 33 13 4,75 - 5,25 .........
Pedal value transmitter 27 13 0,30 - 0,42 ......... PWG Min idle speed 0%
(PWG, hand throttle signal) 2,90 - 4,50 ......... PWG Max Top idle s. 100%
Idle speed switch (LGS, 39 13 4,75 - 5,25 ......... PWG Min idle speed open
normally open) 0 - 2,00 ......... PWG Max Top idle s. closed
Fuel temperature sensor 34 13 4,17 - 2,62 ......... 10 - 50°C idle speed 10 - 50°C
(KTF)
Water temperature sensor 53 13 3,46 - 1,22 ......... 30 - 90°C idle speed 30 - 90°C
(WTF)
Charge-air temperature 55 13 4,17 - 2,62 ......... 10 - 50°C idle speed 10 - 50°C
sensor (LTF)
Charge-air pressure 36 13 0,94 - 1,20 ......... PWG Min idle speed 0 - 100 mbar
sensor (LDF) 1,10 - 1,70 ......... PWG Max Top idle s. 300 - 600 mbar
Multistage switch (MSS) 35 13 0,75 - 1,25 ......... Pos 0 idle speed Cruising characteristic
No reduction active 1,75 - 2,25 ......... Pos 1 Multistage switch pos1
Speed reduction active 2,75 - 3,25 ......... Pos 2 Multistage switch pos2
Speed reduction active 3,75 - 4,25 ......... Pos 3 Multistage switch pos3
Brake contact switch 43 19 0,0 - 2,0 ......... non-act. idle speed open
(normally open) * U-Batt ......... actuated closed
Operating unit for setting 44 13 3,15 - 3,55 ......... non-act. idle speed Neutral
idle speed 1,41 - 1,80 ......... Sp act. Memory
0,65 - 0,97 ......... SET+ act. SET+
2,30 - 2,75 ......... SET– act. SET–
3,72 - 4,33 ......... Aus act. Off
Engine stop (keep stop 50 18 0,0 - 2,0 ......... non-act.
button depressed) U-Batt ......... actuated
* ”Br” button on EDC operating element for idle engine speed adjustment
27
– Check main relay
PIN+ PIN– Set-point Measured value [V] Remark

value [V]
Main relay * 47 18 U-Batt .............. Ignition sys. on
0V .............. Ignition sys. off
46 18 0V .............. Ignition sys. on
_ _ U-Batt .............. Ignition sys. off
* Pin 46 (main relay activation) must switch to Ubatt with a delay of 0.5 to 5 seconds
after “ignition” is switched off.
– EHAB check
S PWG max, engine running at upper idle speed
S Interrupt voltage supply to EHAB (EDC pin 14), engine stops (max. 10 secs.)
– Check flashcode diagnosis:

S Engine at idle speed; connect EDC pins 21 and 13 (short-circuit speed pickup)
S EDC check lamp must come on (permanently illuminated); engine continues to run
S Query flashcode (connect EDC pins 49 and 19 for at least 2 secs. or actuate diag-
nosis button for at least 2 secs. but not longer than 10 secs.)
S Flashcode for “pickup defective” must be indicated (4 x brief flashes) or
S Read out fault memory with MAN-Cats (defect in speed pickup momentarily pres-
ent)
S Disconnect pins 21 and 13 again
S Delete fault memory: switch off ignition system, actuate diagnosis button, switch on
ignition system, actuate button for at least 3 secs. but not longer than 10 secs
– Checking of capacity reserve of resonant circuit of control rod travel trans-

mitter: (Check only if the engine has general difficulties in starting)
S Connect decade capacitor between pins 11 and 13 (on cable harness adapter)
S Add auxiliary capacity until engine no longer starts and note down value
S The capacity reserve of the resonant circuit of the control rod travel transmitter is to
be at least 400 pF. If a Bosch cable harness adapter with approx. 100 pF is used,
the set-point value of the additional capacity is to be > 300 pF.
– Deleting of fault memory

After completion of the checks the fault memory must be deleted with MAN-Cats.
Once the ignition system has been switched on again there must be no fault stored;
otherwise the fault must be traced and eliminated according to the troubleshooting
plan.
28
Troubleshooting chart
1. EDC self-diagnosis or flash code output

2. Starter turns over engine only slowly or not at all
3. Starter turns, engine does not start, engine does not start/difficult to start when cold
4. Engine stalls (dies) during operation, no longer starts (starter turns),
engine does not start/starts with difficulty when hot
5. Sudden, temporary engine shutdown, engine does not reach full revs
6. Engine only runs at idle speed, no throttle response
7. Engine only runs at increased idle speed, no throttle response
8. Rated engine speed distinctly reduced (even under no load)
9. Reduced output in all ranges
10. Irregular engine operation, traction loss
11. Unstable idle speed, engine hunting, misfiring, knocking in engine
12. Engine judder
13. Unusual combustion noise
14. Excessive smoke emission: White smoke/blue smoke
15. Excessive smoke emission: Black smoke
16. Engine temperature too high (coolant loss)
17. Fuel consumption too high
18. Lubricating oil pressure too low
19. Lubricating oil pressure too high
20. Lubricating oil consumption too high
21. Engine too ”loud”/mechanical noise
22. Idle speed cannot be adjusted with idle speed operating unit
Possible causes
x x Batteries discharged, battery lead connections loose or corroded,
break in power circuit
x Crank gear blocked
x x Starter solenoid switch sticks (clicks)/defective, cable connection loose or dam-
aged
x x Starter/starter interlock relay defective (carbon brushes worked loose/worn,
winding defective, short to ground)
x x x x Engine oil viscosity unsuitable, not suitable for ambient temperature, lubricating
oil quality does not correspond to specifications
x x Oil level in sump too high
x Oil level in sump too low, oil in sump too thin (mixed with condensate or fuel)
x Engine temperature too high
x Oil filter clogged
x x Oil pressure gauge defective
x Safety valve in oil circuit defective (does not close, spring fatigued or broken)
x x Bearing wear
x Oil pump gears worn
x Crankshaft timing gears worn, tooth flank backlash too great
x x x Engine cold
x Lubricating oil entering combustion chamber (piston rings worn, piston rings
broken) – valve stem guide worn – overpressure in crankcase (crankcase vent
clogged)
x Relief valve in oil circuit defective (does not open), oil lines/oil galleries clogged
x Leaks in lubricating oil circuit, particularly at turbocharger and oil cooler
x x Piston rings heavily worn, broken
x x Piston pin or crankshaft bearing loose
x Valve stems worn, bent
x x x Valve clearance not correct
x x Valves jam
x x x x Compression deficient, or more than 3 – 4 bar pressure difference between indi-
vidual cylinders
x x x Valve seats leaking
o x x Increased power intake due to defective secondary consumers such as
hydraulic pumps, fan etc., power take-off engaged
x x x x x Air cleaner soiled or clogged, turbo air system leaking,
air inlet/exhaust line clogged/leaking
x x x x x x x x x Fuel low pressure system: Fuel tank, prefilter, water trap faulty/clogged/mould/
fungal attack, fuel unsuitable/contaminated (paraffin added)
x = Possible
o = Probable
29

12. Engine judder
Possible causes
x x x x x x x x Fuel low pressure system: Fuel lines leaking, broken, clogged
x x x x x x x Fuel low pressure system: Air in system (turn on ignition when bleeding system)
x x x x x x x x x Fuel low pressure system: Fuel pump, overflow valve, main filter
x x x x x o x x Fuel high pressure system: Jets defective/clogged/leaking/coked
x x x x o Fuel high pressure system: Pressure lines – constriction, cavitation, leaking
x x o x x x x o Fuel high pressure system: Injection pump worn/set incorrectly
o x o o Fuel high pressure system: Injection pump constant-pressure control
valve/return flow restrictor defective
x x x x o x EHAB defective, drive faulty
o o o x o x x x Injection pump-engine allocation: Start of delivery incorrect (basic installation),
start of delivery set incorrectly
x x x x o x o Injection pump – controller: Stiff movement – fuel delivery controller
(control deviation)
x x x x o Control rod position transducer in controller: Connection lines, break, short-circuit
o o o Control rod position transducer in controller: Set incorrectly
x x o Control rod position transducer in controller: Capacitance reserve of wiring har-
ness too low (e.g. water penetrated wiring harness)
x o x o o Injection pump: Delivery set incorrectly/uniform delivery, lower idle speed set too low
x o x x x Delivery actuating solenoid in controller: Connection lines, break, short-circuit
x x x x x o Pedal value transmitter (hand throttle signal) defective: Connection lines,
short-circuit, break
x x EDC rpm sensor defective, implausible with auxiliary rpm sensor, line defective
x x o EDC rpm sensor, polarity reversed
x x EDC auxiliary rpm sensor defective, implausible with rpm sensor, line defective
x x x x o o o o EDC detects incorrect engine speed (interference signal on rpm sensor line)
x x x x o Both rpm sensors defective, line defective
x x x EDC turbo pressure sensor: Defective, incorrect, implausible with atmospheric
pressure sensor, line defective
x x o x Exhaust turbocharger leaking or defective
x Turbine and compressor rotor in turbocharger dirty
(out-of-balance, irregular running)
x Intercooler leaking, defective
x x Charge-air preheater defective
x o x x o x EDC coolant temperature sensor: Defective, line defective
x x x EDC turbo air temperature sensor: Defective, line defective
o x x Radiator dirty or failure of cooling system (temperatures too high)
x Coolant level too low, air in coolant circuit
x = Possibleo
o = Probable
30

12. Engine judder
Possible causes
x V-belt for water pump drive not tensioned correctly
x x Incorrect V-belt tension
x Water pump leaking, defective/thermostat defective, does not open
x Coolant lines leaking, clogged or twisted
x Coolant entering combustion chamber (cylinder head/gasket leaking)
x x x o Resistor bank EDC control unit pin 35
x x x o o Power supply to EDC control unit interrupted or battery voltage too low
x x o o Line terminal 15 to EDC control unit pin 47 interrupted/loose contact
x x Operating unit for setting idle speed/resistor bank pin 44:
Voltage values incorrect/implausible, operating unit switched off
x o o o EDC control unit defective (internal fault)
x x x x o o o x Incorrect EDC control unit (check MAN part number)
x EOL programming terminated/voltage interrupt
x Afterrunning not completed
x EOL programming: Configuration incorrect
x x Thermostat defective
x Engine bearings worn
x = Possible
o = Probable
31
Troubleshooting program
The following troubleshooting program contains all faults which can be recognised by
EDC diagnosis.
The order corresponds to the numerical sequence of the flash code, irrespective of the
significance of the fault.
It is therefore not arranged on the basis of “fault is indicated by EDC indicator lamp” or
“fault is not indicated by EDC indicator lamp”.
The entire fault code memory should always be read out and all stored fault codes noted
down before starting the engine test.
This is important because lines or components need to be disconnected during
troubleshooting in the system this can cause the corresponding fault codes to be
set and stored.
For this reason, the fault code memory should always be deleted after intermedi-
ate checks.
The “check lines” test step must always be worked through as follows:
– Break or contact resistance

Setpoint: approx. 0 Ω
– Short to negative
Setpoint: ∞ Ω
– Short to positive
Setpoint: ∞ Ω
– Short to adjacent lines
Setpoint: ∞ Ω
– Loose contacts
After rectifying faults and checking, repeat test and delete fault code memory.
All checks which refer to the control unit plug connector are conducted with the aid of the
socket box. The pin designations at the control unit plug connector are identical to those
of the test sockets on the socket box.
Note:
The connection to the control unit must be disconnected at the socket box
when conducting resistance measurements.
32
Test
Pedal value transmitter (PWG, hand throttle signal)

Flash code: 1x short
Fault indication: Fault indicated by steady light at EDC indicator lamp
Fault path: Pedal value transmitter (PWG, hand throttle signal)
– Signal too high
– Signal too low
– Signal implausible with idle speed switch
(in pedal value transmitter)
Effect of fault: Engine assumes lower idle speed
Driving with idle speed switch:
– Hand throttle in idle speed position: idle speed
– Hand throttle in full-load position slow increase in engine speed
to approx. 1,500 – 1,700 rpm.
Possible cause: Line break, short-circuit, power supply interrupted, Pedal value
transmitter defective, control unit defective
Test precondition: EDC control unit connected
Socket box connected
“Ignition” switched on
Test Measurement Corrective measures

Power supply Measure voltage at socket box – Check lines
across pin 45 (+) and pin 13 (–) – Check plug connections
– If no fault found, replace
Setpoint: 4,75 – 5,25 V control unit
Potentiometer Measure voltage at socket box – Check lines
signal across pin 27 (+) and pin 13 (–) – Check plug connections
– Check mechanical connec-
tion between hand throttle
and pedal value transmitter
– Check idle-speed and full-
load stops of the pedal
Setpoints: value transmitters
PWG Min. 0 % Idle speed setting: 0,3 – 0,42 V – Exchange pedal value
PWG Max. 100 % Full load setting: 2,9 – 4,5 V transmitter
Idle speed switch Measure voltage at socket box – Check lines
– Check mechanical connec-
tion between hand throttle
and pedal value transmitter
– Check idle-speed and full-
load stops of the pedal
value transmitters
– Exchange pedal value
Setpoints: transmitter
PWG Min. 0 % Idle speed setting: 4,75 – 5,25 V Switch open
PWG Max. 100 % Full load setting: 0,0 – 2,0 V Switch closed
33
Test
Boost air temperature sensor

Fault path: Turbo air temperature sensor
Effect of fault: This fault has no direct effect.
The substitute value specified for such instances in the control unit
may lead to a slight reduction in output
Possible cause: Line break, short-circuit, turbo air temperature sensor defective,
control unit defective, failure or contamination of cooling system.
Test precondition: EDC control unit disconnected/connected

Sensor resistance Measure resistance at socket box – Check lines
across pin 55 and pin 13 – Check plug connections
– Replace temperature
Setpoint: sensor
3,8 – 0,8 kΩ at 10-50°C – If no fault found, replace
control
t l unitit
Sensor voltage Measure voltage at socket box
across pin 55 and pin 13
Setpoint:
4,17 – 2,62 V at 10-50°C
34
Test
Speed sensor
Fault path: RPM sensor
– Statically implausible
– Dynamically implausible
– Implausible with auxiliary rpm sensor
Effect of fault: Reduced full load delivery volume
Reduced final engine speed n = 2,000 ... 2,100 rpm
If the auxiliary rpm sensor also fails, the engine will be shut down
by EHAB
Possible cause: Line break, short to ground, rpm sensor defective,
control unit defective
Test precondition: Disconnect EDC control unit to ensure the engine cannot start up

Resistance Measure resistance at socket box – Check lines
Setpoint: 500 – 700 Ω rpm sensor
Engine speed sig- Check signal at socket box at start-
nal ing speed across pin 21 (+) and
pin 13 (–) with oscilloscope
Setpoint: See figure
U >2V
35
Test
Boost pressure sensor

Fault path: Turbo pressure sensor
– Signal too high
– Signal too low
– Signal implausible with atmospheric pressure sensor
(in control unit)
Effect of fault: Reduced full load delivery volume (engine runs only with intake de-
livery volume)
Possible cause: Line break, short-circuit, boost pressure sensor defective, control
unit defective

Power supply Measure voltage at socket box – Check lines
Setpoint: 4.95 – 5.05 V control unit
Signal voltage Measure voltage at socket box
across pin 36 (+) and pin 13 (–)
Setpoints:
Lower idle speed: 0.94 – 1.20 V
Upper idle speed: 1.10 – 1.40 V
If all values are OK, the atmos- – Replace control unit
pheric pressure sensor in the con-
trol unit may be defective
36
Test
Control rod position transducer

(Rack travel sensor)
Fault path: Control rod position transducer
– Signal too high
– Signal too low
Effect of fault: This fault results in the engine being shut down by setting the
control travel to 0. The engine cannot be started if this fault is cur-
rently present (EDC control lamp permanently on)
Possible cause: Line break, short-circuit, too little capacitance reserve (see page
28), control rod position transducer set incorrectly, injection pump
defective
Test precondition: EDC control unit disconnected

Test coil Measure resistance at socket box – Check lines
– If no fault found, repair in-
Setpoint: 18 – 25 Ω jection pump
Reference coil Measure resistance at socket box
Setpoint: 18 – 25 Ω
Measure resistance at socket box
Setpoint: > 10 MΩ
Setpoint: > 10 MΩ
In addition to the possibility of an – Remove injection pump
electrical fault, the fault described – Adjust control rod position
here may also be caused by incor- transducer
rect setting of the control rod posi-
tion transducer
37
Test
Coolant temperature sensor

Fault path: Coolant temperature sensor
Effect of fault: The substitute value provided in the control unit for such cases re-
sults in a reduction in power output
An increased quantity of white smoke may be discharged during
cold start
Possible cause: Line break, short-circuit, temperature sensor defective, control unit
defective, failure or contamination of cooling system

(control unit across pin 53 and pin 13 – Check plug connections
disconnected) – Replace temperature
Setpoints: sensor
1.3 – 3.6 KΩ at 15 – 30°C – If no fault found, replace
230 – 460 Ω at 75 – 80°C control unit
Sensor voltage Measure voltage at socket box
(control unit across pin 53 and pin 13
connected)
Setpoint:
3.46 – 1.22 V at 30 – 90°C
38
Test
Fuel-delivery regulator
Fault path: Fuel delivery controller control deviation
Effect of fault: The setpoint – actual value comparison for activating the fuel deliv-
ery regulator has resulted in a control deviation which has ex-
ceeded a specified time threshold. This fault results in the engine
being shut down. The engine can only be restarted when the fault
is no longer present and the “ignition” is switched off and on again
once
Possible cause: Line break, short-circuit, injection pump defective (internal fault in
control unit or stiff movement), capacitance reserve of line leading
to control rod position transducer too low (see page 28)

Actuating solenoid Measure resistance at socket box – Check lines
across pin 15 and pin 1 and pin 16 – Check plug connections
and pin 2 – If no fault found, replace
injection pump
Setpoints: 0.7 – 1.3 Ω

Setpoint: > 10 MΩ
39
Test
Auxiliary rpm sensor

Fault path: Auxiliary rpm sensor
– Statically implausible
– Dynamically implausible
– Implausible with rpm sensor
If the rpm sensor also fails, the engine will be shut down
Possible cause: Line break, short to ground, auxiliary rpm sensor defective, control
unit defective
Test precondition: Disconnect EDC control unit to ensure the engine cannot start up

Resistance Measure resistance at socket box – Check lines
across in 22 and pin 17 – Check plug connections
Setpoint: 500 – 700 Ω auxiliaryy rpm
p sensor
Engine speed Check signal at socket box at start-
signal ing speed across pin 22 (+) and
pin 17 (–) with oscilloscope
Setpoint: See figure
U >2V
40
Test
Fuel temperature sensor

Flash code: 1x long, 1x short
Fault indication: Fault is not indicated by EDC indicator lamp
Fault path: Fuel temperature sensor
Effect of fault: This fault has no direct effect.
The substitute value specified for such instances in the control unit
may lead to a slight reduction in output
Possible cause: Line break, short-circuit, Fuel temperature sensor defective, control
unit defective, failure or contamination of cooling system

(control unit across pin 34 and pin 13 – Check plug connections
disconnected) – Replace temperature
Setpoint: sensor
1.3 – 3.6 KΩ at 15 – 30°C – If no fault found, replace
Sensor voltage Measure voltage at socket box control unit
(control unit across pin 34 and pin 13
connected)
Setpoint:
4.17 – 2.62 V at 10 – 50°C
41
Test
Undervoltage
Fault path: Control unit power supply (battery voltage too low)
Effect of fault: The EDC system or the engine can behave in various ways de-
pending on the magnitude of the voltage drop:
– No power
– Highly irregular engine operation
– No engine operation
– Excessive smoke emission
– Contradictory fault code memory entries
Possible cause: Battery discharged or defective, alternator defective, line break,
short-circuit, main relay defective

Power supply To activate the main relay, connect – Check lines
jumper across pin 46 and pin 19 – Check plug connections
– Replace main relay
Measure voltage at socket box – Check battery, generator
across pin 15/16 (+) and pin and circuit breaker F1 on
18/19 (–) engine
Setpoint: 24 – 28 V
42
Test
Request button (brake)

“Br” button on EDC operating element
Fault path: Request button
Effect of fault: Idle speed adjustment cannot be activated
Possible cause: Line break, request button defective

Request button Measure voltage at socket box – Check lines
(brake) across pin 43 (+) and pin 19 (–) – Check plug connections
– Replace button
Button depressed: Ubatt
Button not depressed: 0
43
Test
Control unit
Fault path: Control unit defective (processor coupling)
Effect of fault: Engine is shut down by “no power applied to fuel delivery output
stage” and control position 0.
If this fault occurs only temporarily, the engine can be restarted by
switching the “ignition” off and on again
Possible cause: Undervoltage (loose contact), control unit defective

Control unit This fault signal can also occur in – Check lines
the event of extremely low power – Check plug connections
supply (loose contacts or undervol- – Replace control unit
tage)!
Internal fault in control unit
44
Test
Engine overspeed
Fault path: Engine overspeed
Effect of fault: Fuel delivery is interrupted. EHAB is deactivated.
If no other fault is applicable, fuel delivery is continued on exiting
engine overspeed
Possible cause: Control rod moves stiffly. Injection pump defective, control unit de-
fective, wiring harness defective

Injection pump If no other faults exist, no further – Delete fault code memory
action is necessary
If the fault occurs frequently, check – Replace lines
injection pump, control unit and – Replace control unit
lines – Replace injection pump
45
Test
Multistage switch for engine speed

Fault path: Multistage switch for engine speed reduction
– Voltage too high
– Voltage too low
– Wrong voltage
Effect of fault: No engine speed reduction possible
Function: Voltage signals are ascertained via the multistage input (control
unit pin 35); their values are determined by external resistor inter-
rupters in the EDC operating element
Possible cause: Line interruption, short circuit, resistor group in the EDC operating
element defective (eg cold junction)

Resistor bank Measure resistance at socket box – Check lines
– Exchange EDC operating
Setpoint: element
No engine speed reduction acti-
vated: 0,4 – 0,7 kΩ
Engine speed reduction activated:
6,2 – 11,6 kΩ
The fault occurs even if the resis-

tance is 0 Ω or ∞ Ω
46
Test
EDC operating element for idle speed setting

Fault path: Operating unit defective
– Voltage values incorrect or implausible
Effect of fault: Idle speed control can no longer be activated.
If the fault was only temporary (e.g. operating unit activated several
times) the system will be ready for operation after switching the
“ignition” off an on again.
The operating unit is resistor-coded, i.e. the control unit recognizes
each switching state according to the voltage level supplied. Faults
are detected when incorrect values are output over a certain period
of time; e.g. electrical fault or multiple operation (incorrect oper-
ation) of the operating unit
Possible cause: Line break, short-circuit, operating unit defective, incorrect oper-
ation

Operating unit Measure voltage at socket box – Check lines
– Replace operating unit
Switch through all settings of the – If no fault found, replace
operating unit and determine rel- control unit as a check
evant voltage value
Setpoints:
SET+: 0.65 – 0.97 V
SET–: 2.31 – 2.75 V
MEMORY: 1.41 – 1.81 V
OFF: 4.00 – 4.32 V
Not activated: 3.15 – 3.55 V
47
Test
Main relay
Fault path: Main relay
Contact sticks or jams (does not open)
Effect of fault: Under certain conditions this fault may not be detected
Function: The negative pole of the main relay is addressed by the EDC con-
trol unit through the control unit output pin 46. The main relay K1
switch off is delayed after the “ignition” is switched off (afterrun-
ning).
During the afterrunning phase, various processor functions are
checked and any faults stored in the fault code memory
Possible cause: Short to ground, main relay K1 defective

Main relay Measure voltage at socket box – Check lines
– If line OK, replace main K1
Setpoints: 0 V at “ignition” off relay
Ubatt at “ignition” on
Measure voltage at socket box

Setpoints: Ubatt at “ignition” off

0 V at “ignition” on
Note: Pin 46 must switch to Ubatt with a delay of up to 5 seconds after turning off
the “ignition” (processor afterrunning)
48
Test
Atmospheric pressure sensor (in control unit)

Fault path: Atmospheric pressure sensor in control unit defective
Effect of fault: No direct effect
In some cases, this may be accompanied by a turbo pressure
sensor fault being signalled
Possible cause: Control unit defective

Control unit If only this fault code is stored in – Replace control unit
the memory, testing is not possible
as the sensor is located in the con-
trol unit.
If, however, a faulty turbo pressure

sensor is also detected, it should
be checked first in accordance with
the turbo pressure sensor test
(page 36).
49
Test
Electrohydraulic shut-off device EHAB

Fault path: EHAB function
Effect of fault: Engine is shut down
Engine will not start
(In this case, it is assumed that the fuel supply is OK)
Function: The EHAB performs an important safety function in its capacity as
an independent, higher-ranking (redundant) engine shut-off device.
The EHAB is activated in certain emergency situations when the
engine can no longer be shut off by controlling fuel delivery to zero
– e.g. control rod jammed.
The EHAB reduces the pressure in the suction chamber of the in-
jection pump thus interrupting filling.
Possible cause: Line break, short-circuit, EHAB defective, faulty activation from
control unit (control unit defective)

Coil resistance “Ignition” switched off – Check line
Control unit disconnected – Check plug connection
Measure resistance at socket box – Replace EHAB
Power supply Turn on “ignition” – Check line
Measure voltage at socket box – Check plug connection
across pin 14 (+) and pin 19 (–) – Replace EHAB
If no fault is found:
Setpoint: Ubatt – Replace control unit
Note:
Power must be applied to the EHAB when bleeding the fuel system by means of presup-
ply pump, i.e. the fuel system cannot be bled without the “ignition” being switched
on!
See page 28 for function test.
50
Test
Control unit EEPROM computer, 1 fault

Fault path: Processor 1 in control unit defective
Possible cause: Control unit defective, EOL programming not completed (voltage
supply interrupted)

Power supply No further test necessary – Complete EOL pro-
g
gramming,g,
Control unit delete fault code
– Replace control unit
Important:
Do not change the control unit if the entries in the fault memory occurred in the following
way:
1. Entry made when ignition is switched off.
When the ignition is switched on again the fault which caused this entry to be made is
cancelled again and therefore has no effect on operation.
2. Entry after use of MAN-Cats (EOL programming)
If this entry in the fault memory was generated through use of MAN-Cats, the engine
can no longer be started. In this case do not change the control unit but repeat the
previous work with MAN-Cats.
Note:
If one of these entries in the fault memory occurs together with the entry
Main relay (flashcode: 2x long, 5x short)
the reason for this is to be sought not in the control unit but in the main relay (power sup-
ply to control unit).
51
Test
Control unit EEPROM computer, 2 faults

Fault indication: Fault indicated by steady light EDC indicator lamp
Fault path: Processor 2 in control unit defective
Possible cause: Control unit defective, EOL programming not completed (voltage
supply interrupted)

Power supply No further test necessary – Complete EOL pro-
gramming,
g g,
Control unit delete fault code
Important:
Do not change the control unit if the entries in the fault memory occurred in the following
way:
1. Entry made when ignition is switched off.
When the ignition is switched on again the fault which caused this entry to be made is
cancelled again and therefore has no effect on operation.
2. Entry after use of MAN-Cats (EOL programming)
If this entry in the fault memory was generated through use of MAN-Cats, the engine
can no longer be started. In this case do not change the control unit but repeat the
previous work with MAN-Cats.
Note:
If one of these entries in the fault memory occurs together with the entry
Main relay (flashcode: 2x long, 5x short)
the reason for this is to be sought not in the control unit but in the main relay (power sup-
ply to control unit).
52
Test
External stop switch

Fault path: External stop switch (control unit pin 50)
Possible cause: This fault is used only for recording stops using external switches
Effect of fault: The external stop switch switches the engine off
53
Test
Control unit (processor afterrunning)

Fault path: Control unit
– Processor afterrunning did not take place
Function Every time the engine is turned off, afterrunning takes place auto-
matically for the purpose of checking the various processor func-
tions
Possible cause: Control unit defective, main relay defective, battery voltage
switched off before “ignition” off

Control unit Test same as for undervoltage – Switch “ignition” on and
(page 42) and main relay (page 48) off again, delete fault
code
– Same as pages 42
and 48
Other possible causes

– Engine was shut down via battery + (e.g. by disconnecting the battery or removing the
fuse)
– Power supply fault (e.g. undervoltage, main relay K1 defective, loose contact)
54
Test
Control unit, after-running watchdog fault

Fault path: Control unit defective (watchdog test)

Control unit No further test necessary – Replace control unit
55
Test
Control rod travel transmitter – loose contact

Fault path: Control rod position transducer
– Signal too high
– Signal too low
Effect of fault: This check is designed to recognise a loose contact in the connec-
tion to the control rod travel transmitter
Possible cause: Line break, short-circuit, too little capacitance reserve (see page
28), control rod position transducer set incorrectly, injection pump
defective

Test coil Measure resistance at socket box – Check lines
– If no fault found, repair in-
Setpoint: 18 – 25 Ω jection pump
Reference coil Measure resistance at socket box
Setpoint: > 10 MΩ
Setpoint: > 10 MΩ
In addition to the possibility of an – Remove injection pump
electrical fault, the fault described – Adjust control rod position
here may also be caused by incor- transducer
rect setting of the control rod posi-
tion transducer
56
EDC Pin No. Abbreviation Description
1 MES O Activation for fuel-delivery actuator Output, fuel-delivery control circuit Imax 11 A temporarily, on average 4.5 A, against batt.+, pulsed
f=variable, pulse-width modulated
2 MES O Activation for fuel-delivery actuator Output, fuel-delivery control circuit
3 Not used
4 Not used
5 Not used
6 Not used
7 Not used
8 Not used
9 RWG M Control rod position
transducer measuring coil (RWG 2) Control rod position evaluator circuit
10 RWG R Control rod position
transducer reference coil (RWG O) Control rod position evaluator circuit
11 RWG Y Control rod position
transducer centre pick-off (RWG 1) Control rod position evaluator circuit
12 Not used
Plug connections
13 GND-A Sensor ground
14 EAB 1 Electrical shut-down Output (switch) Imax 1 A, Ubatt. against batt. –,
15 Batt + Batt.+ via main relay Input battery + I with engine stationary 0.9 A, idle speed 1.5 A, operation 4.5 A, temporarily 16 A
16 Batt + Batt.+ via main relay Input battery +
17 NBF Sensor ground HZG Reference ground
57
18 Batt.– Battery negative Input battery – Same as batt.+ (EDC Pin 15 and 16)
19 Batt.– Battery negative Input battery –
20 DIA-B Diagnosis lamp Output (switch) Imax 1 A, Ubatt. against batt. –,
21 DZG 1 RPM sensor signal Input, dynamic Alternating voltage Upp idle speed approx. 2 V, max. 80 V, f=6 x engine speed sec.–1
22 HZG 1 Auxiliary rpm sensor signal Input, dynamic Alternating voltage Upp idle speed approx. 2 V, max. 80 V, f=6 x engine speed sec.–1
23 Not used
24 Not used
25 Not used
26 Not used
27 PWG 1 Pedal position sensor signal Input, analog Direct voltage, U approx. 0.4 to 4 V
28 TDS-A Engine speed signal Output Ubatt. against batt. –, square-wave signal, f=6 x engine speed sec.–1
29 Not used
30 Not used
31 Not used
32 Not used
33 LDF 2 Turbo pressure sensor (supply) Output, supply Controlled direct voltage, U approx. 5 V
34 KTF 1 Fuel temperature sensor Input, analog
35 MDB 1 Multi-stage input (torque limitation) Input, analog Circuit of various resistors for external faults (integrated in EDC operating element)
36 LDF 1 Boost pressure sensor signal Input, analog
37 Not used
38 Not used
39 LGS-E Idle speed switch signal
(Pedal value transmitter) Input, static against GND-O (EDC-Pin 13)
EDC Pin No. Abbreviation Description
40 Not used
41 Not used
42 Not used
43 BRE-E Brake switch signal Input, static Batt. +, Br=button in the EDC operating element
44 FGR 1 Analog operating element
for idle speed adjustment Input Input by change in resistance
45 PWG 2 Pedal position sensor Output, supply Controlled direct voltage, U approx. 5 V
46 HRL O Main relay Output (switch) Imax 0.3 A, batt. – against batt.+
47 K15-E Terminal 15, digit. Data for control unit Input, static Batt. +
48 ISO-K ISO-K link to ISO protocol Interfaces Diagnostic connection for MAN-Cats
49 ISO-L ISO-L link to ISO protocol Interfaces Diagnostic connection for MAN-Cats
50 TKS-E STOP Input, static Batt. +, Input for engine stop
51 Not used
52 PB1-E Pulse-width modulated input signal 1 Interface Batt. +
53 WTF 1 Coolant temperature sensor Input, analog
54 Not used
55 LTF Turbo air temperature sensor Input, analog
Plug connections
58
Engine terminal box
Engine terminal box with connections

Fig. 1 4
À Connection plug for EDC from engine
Á Connection plug for alarm system to BE1 sta-
tion (main station)
Â Connection plug for engine room instrument
1
panel
Ã Pedal value sensor, item no. 81.25970-6072
Ä Connection plug for engine electric and alarm
2
system
3 5
1 4257
Engine terminal box with components

Fig. 2 4
À EDC operating element item no. 51.11615-7141
1
Á EDC-control unit
(ECU, ordering with engine no. only))
2 5
Â Starter interlock relais item no. 81.25902-0454 6
Ã EDC-relais (K1), item no. 51.25902-7008
Ä MAN-cats diagnose plug
Å Option: Glow plug timer control unit for electri-
cal boost air preheating system, 3
item no. 51.26802-0003
2 4258
Engine terminal box with clamps

Fig. 3
À Clamps for EDC 1
Á Clamps for instruments
Â Clamps for main power supply
2
3 4259
59
Arrangement of sensors for boost air system
Boost air pressure sensor for EDC-system

Fig. 1
Item no. 51.27421-0102
Location: right engine side,
heatexchanger / cylinder no. 1 area
1 4242
Boost air temperature sensor for EDC-system
Fig. 2
Item no. 51.27421-0077
Location: right engine side,
heatexchanger / cylinder no. 1 area
2 4240
Boost air temperature sensor for alarm system

Fig. 3
Item no. 51.27421-0103
Location: Intercooler elbow (after intercooler),
left engine side
3 4244
Boost air temperature sensor for alarm system
(Boost air preheating installed)
1
Fig. 4
À Glow plug box for electrical charge air preheat-
ing
Á Boost air temperature sensor
Item no. 51.27421-0103 2
4 4245
60
Arrangement of sensors for boost air system
Temperature switch for electrical boost air pre-

heating system
Fig. 5
Item no. 51.27420-0054
Location: engine front side below heatexchanger
opens above 45 deg. C
5 5254
61
Arrangement of sensors for cooling system
Coolant temperature sensor (WTF1) for EDC-

system (old position)
Fig. 1
Item no. 51.27421-0113
Location: left engine side,
front cover of watercooled exhaust manifold
1 4247
Coolant temperature sensor (WTF1) for EDC-
system (new position)
Fig. 2
Item no. 51.27421-0113
Location: engine front side below heatexchanger
2 4246
Coolant temperature sensors for instruments
and for alarm system (old)
Fig. 3
Location: left engine side, 2
À Coolant temperature sensor for instruments
Double sensor: Item no. 50.61344-1000
Single sensor: Item no. 50.27421-0034
1
Á Coolant temperature sensor for alarm system
(old)
Item no. 51.27421-0119
wrench size: 17 / 19 mm 3 4248
Coolant temperature sensors for alarm system

(new)
Fig. 4
Location: left engine side,
Item no. 51.27421-0138
wrench size: 24 mm
4 4249
62
Arrangement of sensors for speed pickup
and fuel system
Fuel temperature sensor for EDC-system

Fig. 1
Item no. 51.27421-0113
Location: injection pump
1 4251
Speed pickup sensors for EDC and alarm

system
Figs. 2 and 3
Location: right engine side, flywheel housing,
approx. 4 o’clock by view from engine back side
2 4252
À Engine speed sensor DZG1 for EDC-system
Item no. 51.27120-0008, Cable no. (1)
Á Engine auxiliary speed sensor HZG1 for EDC-
system
Item no. 51.27120-0009, Cable no. (2)
1
Â Engine speed sensor for alarm system,
Item no. 51.27120-0010
2
3
3 4253
Engine speed monitor for instruments

Fig. 4
Location: right engine side, underneath water-
cooled exhaust manifold
1
À engine speed monitor for instruments
Item no. 51.27120-7030
Á Connection for mechanical drive
(E2 - M 22 x 1.5)
2
4 4250
63
Arrangement of sensors for
coolant level and oil pressure
Coolant level sensor

Fig. 1
Item no. 51.27421-0116
Location: on both sides of the expansion tank
1 4255
Oil pressure sensors for instruments and

alarm system
Fig. 2
Location: left engine side between heatexchanger
and intercooler
À Oil pressure sensor (M10x1) for engine room 1 2
control panel
Item no. 51.76034-0007 3
Á Oil pressure sensor for instruments
Single (M10x1): Item no. 50.76034-0007
Double (M18x1.5): Item no. 50.27421-0033
2 4256
Â Oil pressure sensor for alarm system
Item no. 51.27421-0107
64
Arrangement of fuses
Main automatic fuse switch (F1) for engine ter-

minal box
Fig. 1
F1, automatic fuse device 16A (switch)
Item no. 51.25437-0002
Location: left engine side, starter motor area
1 4241
Main fuse switch for boost air preheating sys-

tem (option)
2
Fig. 2
Location: left engine side, starter motor
À Fuse box, see drawing 51.25431-6115
Á Automatic fuse switch, plus line 1
Â Automatic fuse switch, minus line
3
2 4243
65
EDC-diagnose-tools
Bosch pin adapterbox

Fig. 1
Connection between control unit and EDC cable to
control unit in terminal box for test purposes
Arrow: Control unit plug
1 4260
MAN-Cats diagnose system
Adapter cable
(Connection between diagnose plug in terminal
box and ISO-interface)
Fig. 2
À Connection plug for plug À in fig. 3
Á Connection plug for terminal box
2
1
2 4261
MAN-CATS interface
(Connection between adapter cable and note 2
book)
Fig. 3
À Connection plug for plug À in fig. 2
Á Connection plug for note book computer
3 4262
1
Note book computer

minimum equipment:
Fig. 4
S 386 processor
S 4 MB RAM
S RS 232 Com 1 interface
S MS-DOS 5.0
4 4263
66
MAN-Cats System
An engine electronic diagnostic system, which works with a laptop computer and is called
MAN-Cats.
The following functions are possible:
1. Reading EDC errors in text format
2 Deletion of stored errors
3. Monitoring the following operational parameters:

S Boost pressure
S Rack Travel
S Engine speed
S Coolant temperature
S Charge air intake temperature
S Fuel temperature
S Throttle position
S Battery voltage
S Additional EDC-parameters
However, the monitoring data cannot be stored or printed.
The following equipment is necessary to work with the laptop:

S Interface, white
MAN Item no. 93.09000-6015
S Adapter cable for Interface
(Connection between diagnostic plug in terminal box and interface)
MAN Item no. 51.25435-8002
S Software MAN-Cats
Operating System Disc D1 DM
MAN Item no. 81.99298-8130 German
81.99298-8071 French
81.99298-8082 English
81.99298-8033 Spanish
81.99298-8014 Italian
S Diagnostic software
EDC Bosch M (S) 5, Disc D 12
MAN Item no. 81.99298-8300 German
81.99298-8231 French
81.99298-8222 English
81.99298-8193 Spanish
81.99298-8134 Italian
67
MAN-Cats System
Please note!
An existing laptop should, as minimum, fulfil the following criteria for EDC:
S 386er processor
S 4 MB RAM memory
S Serial port
Operating the MAN-CATS software is only possible using MS-DOS 5.0 or higher.
With regard to the future diagnostic system, a suitable laptop must be acquired at the ap-
propriate time.
Laptop with the following features
Suitable for the proposed diagnostic system BE 3 for MAN marine engines:
S Processor Intel Pentium 133
S Memory 32 MB RAM
S Hard drive min. 1.0 G Byte
S Disc drive
S Lithium battery charger (without memory effect)
S Media Slot: Input alternatively for charger or CD ROM drive
S Track ball or touch pad
S Second serial port RS 232 for cable input (not infrared)
S TFT Display (active matrix), resolution 800 x 600 (width x height), min. 256 color
68
MAN-Cats – Software Description
To install the software DOS (version 5.0) or Windows can be used. As on independent
program the software will be on the harddrive “C:”. To get to it enter “C:man_cats diag-
nostics”.
On the screen you’ll see:
Use arrow key to go to “Diagnostics” and press “Enter”.
The following text you’ll find on your screen:
69
Use arrow key to go to “Mot” engine control.
You’ll see:
Use arrow key to go to “EDC Bosch MS5/M(S)5.
You will see:
70
71
72
First the contents of the fault memory will be shown (e.g. see list below).
Fault description:
↑ : too large ¢ measured value too high
↓ : too small ¢ measured value too low
– : no signal ¢ possible wire interruption, sensor fault
? : implausible ¢ unknown fault
J : saved ¢ fault is recorded
n : present ¢ fault is still existing
~ : sporadic ¢ momentary fault
Frequency: Depending on the channel the EDC ist recording the faults from 1 to 40 or 1
to 210. If alter a new start a fault doesn’t exist any more the incidence will be
set back I x.
Perripheral conditiong: Showing other, important channels to get more informations; e.g.
at what RPM a fault at what value existed.
After checking and recording the fault memory press “Enter” to come to a submenu
where you choose the function “Bus”.
73
74
Guided through the menu you come to the window “Instructions/Questions”.
Depending on the software version there are various submenus which are explained at
the following pages.
75
At “control unit identification” you find the engine number which must be checked. If en-
gine and control unit do not match it is very important to inform MAN. Further informa-
tions see below:
Next in the submenu you find “Fault memory content” which again shows the EDC’s ac-
tual fault memory (e.g. see picture below).
“Control rod test” contains on “EHAB” test which will not be explained here.
76
Monitoring 1 – 3” shows various engine parameter. The measured datas will not be re-
corded.
77
Depending on the software version you can also select “Monitoring 4” or “Definition Moni-
toring 4”. In the submenu item ”Definition Monitoring 4” up to six freely selectable measu-
ring channels can be selected with the ”Enter” key (see illustration below).
78
Selection of the measuring channels is completed with ”Complete the definition of moni-
tor window”.
After this you can view the measuring channels you have selected in ”Monitoring 4” (see
illustration below).
79
After diagnose and measuring of engine parameter select “End”.
Now you can use “Enter” to leave the main menu “Instructions/Questions”. The following
picture will be found on the screen.
80
Press “yes” to confirm. Using the “Enter” key you’ll be guided through the menu.
81
Following the instruction above you’ll come again to the beginning of the programm.
Via “Exit” you can now leave the “MAN_CATS” software.
82
Description of EDC-Check with pinadapter
see also list of checking procedures, page 26
EDC-check with engine stoped

Fig. 1
Ignition off, control unit not connected
Reason: Resistance measurement of EDC compo-
nents
1 4264
EDC-check with engine running, gearbox not

engaged
Fig. 2
Reason: Voltage measurement of EDC compo-
nents
2 4265
83
Notes
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84
Terminal connection diagram
Redundant
shut-down Actuator Fuel Engine Water Turbo air
device control rod Control rod temperature speed Auxiliary Turbo pressure temperature temperature
(EHAB) travel travel sensor sensor sensor rpm meter sensor sensor sensor
Connector on Motor
(on terminal box)
EDC controller
Kl. 4
Kl. 3
Kl. 2
Kl. 1
Kl. 6 Kl. 7 Kl. 8
Kl. 18
Pedal value transmitter Diagnostic plug
with idle speed switch
Operating element for EDC engine 51.11615-7141
(idle speed setting + flashcode request)
Kl. 5 C8 B6 B4 Kl. 15 Kl. 31 Kl. 30
Engine (Check lamp for Reducing (Stop) Ignition (–) (+)
speed electronics fault) Engine Engine
signal for engine monitoring monitoring monitoring Kl. = Terminal in the terminal box
85
Terminal connection diagram
86
Terminal connection diagram – Brief overview
EDC controller
Kl. 5
Engine speed signal 28 TDS A
C8
Check lamp for
electronics fault 2K2 Connector on Motor
for engine 1 20 DIA B (on terminal box)
monitoring 5K6
Dia 2 49 ISO L
a9 4
14 EAB 1 Reduntant shut-down
Kl.1 a3 1 device (EHAB)
680 3 18/19 BAT –
Sp Aus
Operating element +
200
1 MES 0
for EDC engine 4
680 1K 44 FRG 1
51.11615-7141 – Kl.4 b2 8
5 2 MES 0
(idle speed setting + 62
Actuator control rod travel
flashcode request) 6 13 GND 0 Kl.2 b1 7
15/16 BAT +
Br
3K08
7
511
43 BRE E a4 1
8 10 RWG R
a10 6 Control rod travel sensor
11 RWG Y
9 50 TKS E (Rack travel sensor)
a5 5
330 9 RWG M
5W 10
35 MDB 1
11
12 c4 3
34 KTF 1
Kl. 3 c10 2
Fuel temperature sensor
B6 Reducing 13 GND 0
Engine monitoring 18 BAT –
Kl. 18 19 BAT – a7 2
B4 (Stop) 21 DZG 1
Engine monitoring Engine speed sensor
a1 1
(DZG 1)
Kl.15 47 K15 E
Ignition
a8 3
22 HZG 1
52 PB1 E Auxiliary speed sensor
Kl. 31 (–) Kl. 1 a2 1
17 NBF 1 (HTG 1)
K1
A2 A1
46 HRL 0
11
Kl. 30 (+) 14 a11 2
21 Kl. 2 33 LDF 2
24
15 BAT + a6 1
36 LDF 1 Boost pressure sensor
a12 3
16 BAT +
1K
4 Kl. 6 45 PWG 2 c3 3
53 WTF 1
2 Kl. 7 Water temperature sensor
1K 27 PWG 1 c9 2
Pedal value transmitter 6 Kl. 8
with idle speed switch 39 LGS E
1K
3 Kl. 3 13 GND 0 c2 1
5
55 LTF 1
c8 2
Boost air temperature sensor
1
+
4
–
Diagnostic plug 2
ISO-L
3
ISO-K 48 ISO K
Kl. = Terminal in the terminal box
87
Terminal connection diagram – Brief overview
88
Notes
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89
Index
A M
Atmospheric pressure sensor (in control unit) . 49 Main relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Auxiliary rpm sensor . . . . . . . . . . . . . . . . . . . . . . . 40 MAN-Cats diagnose system . . . . . . . . . . . . . . . . 66
MAN-Cats Software Description . . . . . . . . . . 69–82
B MAN-Cats System . . . . . . . . . . . . . . . . . . . . . . . . . 67
Block Diagram M(S) 5 . . . . . . . . . . . . . . . . . . . . . . 10 Multistage switch for engine speed . . . . . . . . . . . 46
Boost air pressure sensor – EDC-system . . . . . 60
Boost air temperature sensor – Alarm system . 60 N
Boost air temperature sensor – EDC system . . 60 Notes on operation . . . . . . . . . . . . . . . . . . . . . 21–22
Bosch pin adapterbox . . . . . . . . . . . . . . . . . . . . . . 66
O
C Oil pressure sensors
Component description . . . . . . . . . . . . . . . . . . 11–19 for instruments and alarm system . . . . . . . . . . . . 64
Control rod position transducer . . . . . . . . . . . . 8, 37
Control rod travel transmitter – loose contact . . 56 P
Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Pedal value transmitter . . . . . . . . . . . . . . . . . . 16, 33
Control unit (processor afterrunning) . . . . . . . . . 54 Plug connections . . . . . . . . . . . . . . . . . . . . . . . 57–58
Control unit EEPROM computer, 1 fault . . . . . . 51
Control unit EEPROM computer, 2 faults . . . . . 52 R
Control unit plug connector – Request button (brake) . . . . . . . . . . . . . . . . . . . . . 43
pin arrangement . . . . . . . . . . . . . . . . . . . . . . . . 11–12 RPM sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 19, 35
Control unit, after-running watchdog fault . . . . . 55
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 S
Coolant level sensor . . . . . . . . . . . . . . . . . . . . . . . 64 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . 4–6
Coolant temperature sensor . . . . . . . . . . . . . 38, 62 Avoiding accidents likely to cause injury . . . . . . 4
Laying-up or storage . . . . . . . . . . . . . . . . . . . . . . 6
E Limitation of liability
EDC operating element . . . . . . . . . . . . . . . . . . . . 20 for parts and accessories . . . . . . . . . . . . . . . . . . 6
EDC operating element for idle speed setting . 47 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 23–25
EDC-Check with pinadapter . . . . . . . . . . . . . . . . . 83 Speed pickup sensor . . . . . . . . . . . . . . . . . . . . . . 63
EDC-diagnose-tools . . . . . . . . . . . . . . . . . . . . . . . 66 Start procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Electrohydraulic shut-off device EHAB . . . . 14, 50 System description EDC M(S) 5 . . . . . . . . . . . 8–10
Electromagnetic fuel-delivery regulator . . . . . . . 13
Electronic diesel control EDC – General . . . . . . . 7 T
Engine overspeed . . . . . . . . . . . . . . . . . . . . . . . . . 45 Temperature sensors for charge air,
coolant and fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine terminal box . . . . . . . . . . . . . . . . . . . . . . . 59
Temperature switch
External stop switch . . . . . . . . . . . . . . . . . . . . . . . 53 for electrical boost air preheating system . . . . . 61
Terminal connection diagram . . . . . . . . . . . . . 85–88
F Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–56
Flash code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Troubleshooting chart . . . . . . . . . . . . . . . . . . . 29–31
Fuel temperature sensor . . . . . . . . . . . . . . . . 41, 63 Troubleshooting program . . . . . . . . . . . . . . . . . . . 32
Fuel-delivery regulator . . . . . . . . . . . . . . . . . . . . . 39 Turbo air temperature sensor . . . . . . . . . . . . . . . 34
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Turbo pressure sensor . . . . . . . . . . . . . . . . . . 18, 36
I U
Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Undervoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
L
Linear solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
for EDC M(S) 5 stage 3 . . . . . . . . . . . . . . . . . 26–29
90
MAN Nutzfahrzeuge Aktiengesellschaft
Vogelweiherstraße 33
D–90441 Nürnberg
GB Printed in Germany 51.99493–8486

Electronic Diesel Control D2840 Man Marine Engines

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Technical Information

Electronic Diesel Control

EDC M(S) 5 − D28 V marine engines

 1998 MAN Nutzfahrzeuge Aktiengesellschaft

MTDA Technical status: 03.1998 51.99493–8486

Arrangement of sensors for boost air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

1. Instructions for avoiding accidents causing injury

D Put gearbox of ship into neutral, if necessary unhinging gearshift lever

D Firmly secure units and assemblies on disassembly

D Disconnect batteries only with the “ignition” turned off

D Only use suitable measuring instruments to measure voltages! The

Limitation of liability for parts and accessories

Special measures must be implemented in accordance with MAN Company Standard

Electronic diesel control EDC

The Electronic Diesel Control (EDC) fulfils all these requirements.

System description EDC M(S) 5

Engine Engine Pedal value transmitter Charge-air Turbo Fuel Water

EDC operating element

The controller contains

– the linear solenoid

The linear solenoid is driven by the electronic control unit.

– the control rod position transducer

* for M(S) 5 not connected, not in operation

Control unit plug connector

Pin assignments of control unit plug connector

Pin assignments of control unit plug connector

EDC Pin Connection to component (O=Output, I=Input)

The EDC injection pump consists of a heavy-duty version of a conventional injection

Electromagnetic fuel-delivery regulator

Injection pump Control rod Control rod position transducer

Electrohydraulic shut-off device EHAB

The EHAB (electrohydraulic shut-off device) is a safety-relevant component.

Overflow valve Double filter box

Pedal value transmitter (hand throttle signal)

Kick-down switch Terminal on plug Terminal in

U = Reference voltage, approx. 5 V from the EDC control unit

Temperature sensors for charge air, coolant and fuel

Coolant temperature sensor, Fuel temperature sensor

Turbo pressure sensor

Plug connection Plug connection

EDC operating element

Dia – Diagnosis request button

No pedal value transmitter input is necessary for starting.

Changing idle speed – EDC operating element

Set+ Set – Memory

EDC Pin 43 EDC Pin 44

Proceed as follows to reset the works idle speed of 600 rpm:

Fault storage includes

D allocation of fault priority,

There are two fault code memories:

Indicator lamp check:

The following measures are implemented automatically depending on the signifi-

Example of flash code outputs

Fault 2x long, 5x short

OFF phase before output: 3 seconds

To delete fault code memory

Now only the fault memory of the flashcode diagnosis is deleted.

Fault code output MAN M(S)5 EDC

List of checking procedures for EDC M(S) 5 stage 3

1. Checks while engine is stationary