X

RailSystem
Common
r\ EDC7

2003 l1 l2ls l7l8le l10 11 1| 1 2

' o$u

Systemdescription
81.99598.5892 2ndedition
T 18

MAN NutzfahzeugeAktiongesollschaft EleKrische Anlage

DachauerStr. 667 oder Postlach50 06 20 Systembeschroibung T 18
8o99sMUNoHEN 80976MUNCHEN - englisch-
Prir ed in G€many -
 system
Electrical A
@

CommonRailSystem
EDC7
System T 18 (2.)
description

81.99598-s892
ELECTRICAL
SYSTE

The rightto maketechnicalchangesin linewithdev€lopments

is rcsetued

O 2003 ilAN NutzfahrzeugeAktiengesellachatt

Reprinting, reproduction includingin part,is notpermittedwithoutthe writtenpermission

ortranslation, ot
MANNutzfaheeuge AG.
All rightsundercopyrightlawremainthe expresspropertyof lllAN NuttahrzeugeAG.
lf changesare madewithoulthe wilten permission of [,lANNutzlaheeuge, all guaranteesor warranty
obligalionsby MANNutzlahrzeuge AG tor damageor deficiencies dueto unauthorized changesare void.
Furthermore, [4ANNutzfahrzeuge AG acceptsno rosponsibility for damagecausedas a resultof changes
madewithoutpermission.

vswY-s/Ts.05.2003 Satz: emesGmbH

Friedrichshafen

0.01- 2 T 18
 ELECTRICAL
SYSTEM

Contentslist

Electricalsystem........ ...,........''....''...'....'...'..'..
0

T 18 0 . 1 1- 1
 ELECTRICAL
SYSTEM

o . 1 1- 2 T 18
 ELECTRICAL
SYSTEI',

ABBREVIATIONS Dato:11.02

a Acceleration
ABE Generaloperating permission
ABS Anti-lockbrakesystem
ABV Anti-locksystem
AC (climatesystem)
Air conditioning
ACC AdaptiveCruiseControl
ACK Autocheck
ADC AnalogueDigitalConverter
ADR IntemationalAgreement on the Transpodol Dangerous
Goodsby Road
AGB Aulomaticspeedlimiter
AGND Analogueearlh
AGR Exhaustgas recirculation
AHK Towinghitch
AHV Trailerbrakevalve
ALB Automaticload-dependent brakingtorcecontrol
AlilA Antennamaslsystem
ANH Trailer/semitrailer
AS Automaticlransmission
ASD Trailersocket
ASM Trailercontrolmodule
ASR Tractionand slipcontrol
ASV T.ailerconlrolvalve
ATC AutomaticTerhperatureControl
ATF AulomaticTransmission Fluid
AU Exhaustemissionanalysis
AV Exhaustvalve
AVS Automaticsystem

BA Operatinginslructions
BBA Seryicebrakesyslem
BBV Servicebrakevalve
BKR Brakelorceconlroller
BUGH Front-endheating
BV Backupvalve
BVA Brakewearindicator
BVS Brakewearsensor
BW Brakewearsensorsupply
BW GermanArmedForces
BWG Brakingvaluelransmitter
SZ Brakecylinder

CAN AreaNelwoft(databussystemwithbit-serial
Controller transmission)
CAN-H Dataline,CAN-high
CAN-L Dataline,CAN-low
CATS Testinganddiagnosing
Computer-Assisted Syslem
CCU Diagnosticcomputer
CCVS CruiseControlVehicle
Speed
CKD CompleteKnockedDown
CNG CompressedNalulalGas
CPU CenkalProcessingUnit
CRT Continuously Trap(exhaustgassibncer,oxidationcatalyser,
Regenerating dieselparticlefilter)
CS ComlortShift

DAHL Roofventilator
DBR Constantbrakingrelay
DECKE Cover({ordoors)
DF.. Speedsensor
DFU Remotedatatransmission

T 18 0 . 1 3- 1
 ELECTRICAL
SYSTEM

ABBREVIATIONS

DIA Diagnosis and inlomationdisplay

DIAK Diagnosis, K line(dataline)
DIAL Diagnosis, L line(excitation)
DIAR Diagnosis,furtherexcitation
DIN DeutscheInduslrieNorm(Geman IndustalStandard)
DKE Throttlevalvelift{anti-slip
control)
DKH Roofchannelheating
DKL Roolvalves
DKR Throttlevalvereduction(reduction demandfromtheASR to the EDC/EMS)
DKV Throttlevalvepreset(loadtransmittersignalfrompedaltransmitter
(EDC/EMS)
DLB Pneumatic brakesystem
DM Diagnostic message
DNR DriveNeutralReverso(seleclorleverlorautomatic kansmission)
DPF Dieseloarticleftlter
ORM Pressureregulating module
DS Pressuresensor
DSV Pressurecontrolvalve
DV Throttlevalve
DWA Theftwarningsystem
OZG Speedsensor
DZM Speedmeter

EBS Eleckonicbrakesystem
ECAM ElectronicallyConlrolledAirl\ranagement
ECAS ElectronicallyControlledAirSuspension
ECE Emergency shutdownaccording
to ECE36
ECU Eleclronic ControlUnit
EOC EleckonicDieselControl
EDM Eleckonicdieselconsumplion measuring syslem
EDR l\/aximumspeedcontrol
EEC Eleclronic enginecontroller
EEPROMRead/write (programmable)non-volatile
readonlymemory
EFB Electronic chassisconlrol
EFS Electricdriverseat
EHAB Electrohydraulic shutdown
ELAB Electricshutdown
ELF Elecironic air suspension
Elils Electronic enginepowercontrol
EMV Electromagneticcompatibility
EOL Endol line(endof lineprogramming)
EP Injectionpump
ER Engineretarder(enginebrake)
ESAC Electronic ShockAbsoberControl
ESP Electronic StabilityProgram
ESR Electricalrollerblind
EST Electroniccontrolunit
EV lnletvalve
EVB ExhaustValveBrake

FAP Diveaworkstation
FAQ FrequenllyAskedQuestions
FBA Parkingbrakesystem
FBAS Videosignal
FDR Roadhandlingcontrol
FFR D ver computer
FGB Ddvingspeedlimiter
FGR Ddvingspeedcontroller
FHS Driver'scab
FIN number(chassisnumber)
Vehicleidentification

0 . 13 - 2 T t8
 ELECTRICAL
SYSTEII

ABBREVIATIONS

FM Vehiclemanagement
FMI FailureModeldentification
FMR Vehicleenginecontrol
FOC Bearenginebuschassis
FSCH Windscreenheating
FSG Furowedroaddevice
FSH Window-mirrorheating
FTW Driverpartition
FUNK Radiosystem
FZA Routesyslem

GDK Controlleddieselcatalyticconverler
GEN Generator
GET Transmission
GGVS DangerousGoodsOrderforRoads
GNO Earth
GP planetarygeargroup(rear-mounted
Transmission, group)
GS Transmissioncontrol
GV Transmission,
tront-mountedgroup(splittergroup)

HA Rearaxle
HBA Auxiliarybrakesystem
HGB l\raximum speedlimiter
HGS Hydraulic geaEhitl
HLUE Hydrostaticlan
HOC Rear-engine buschassis
HSS Highsideswitch
HST Mainswitchpanel
HU Generalinspection
Hz Hertz(change/period persecond)
HZA Stop sign system
HZG Auxiliaryspeedsensor

IBEL Intemallighting
IBIS Integratedon-boardinformationsystem
lC Integratedcircuit
lO ldentification
IMR lntegratedmechanical relay(stadcontrol)
INA Informationdisplay(e.9.Indicatorlights)
lR Individualconirol(ABS)
IRM Individualcontrol,modified(ABS)
ISO lnternational
Systemol Standardization
IWZ Incremental angle-timemeasudng system

KBZ Combi-brakecylinder
KFH Fuellilterheating
KITAS Kienzleintelligent
tachog€phsensor
KLI Air-conditioningsystem
KNEEL Kneeling
KSM Customizedcontrolmodule
KSW Customerspecialrequirements
KWP KeyWordProtocol(protocolfor diagnosisusingMAN'cats)

LBH Air reseNok

LCD LiquidCrystalDisplay
LDA Booslpressuredevelopmentlull loadstop
LDF Booslpressuresensor
LOS Air suspensiondampersystem
LED Lightemittingdiode

T 18 0. 1 3- 3
 ELECTRICAL
SYSTEM

ABBREVIATIONS

LF Airsuspension
LGS LaneGuardSystem
LL ldlingspeed
LLA ldlingspeedincrease
LLR ldlingspeedcontrol
LNA Steeredtrailingaxle
LNG LiquiliedNaturalcas
LOE Powersleeringoil levelmonitor
LPG LiquefiedPetroleumGas
LWR Headlightrangeadiustrnent
LSVA Power-relatedheavy-lraflictax

llr-TCO EUtachograph module

i,lAB Solenoidvalveshutdown(engineshutdownusinghigh-pressure solenoidvalvein the injection
pump)
lilAN.cats|VIAN-computorassistedtestinganddiagnosingsystem
!,!4! Solenoidvalve shutdown relay(relay-redundant
engineshutdown)
MDB Enginespeedrange
MES Fuelllowactualor
ML Midline
lrMl Man"machineinterface
irOTB Enginebrake
lrP Enginepowerbox{cableducton engineblock)
irR Enginecontroller(anti-slip
controt)
tilsc Enginecontrolunit(EDC)
MV Solenoidvalve
)lZ Diaphragm cylinder
n Speed
NA Powertakeotf
NBF Needlemovementsensor
NES Neweleclronicstructure
NFZ Commercial vehicle
NLA Trailingaxle
NSL Rearfog light
NSW Foglight

OBOU On boarddiagnosticunit
OC O@urrence Count
OEAB Oilseparator
OENF Oil replenishment
p Pressure
PBM PulseBreadthModulation
(seealsoPWM)
PLM Programmablelogicmodule
PSG Pumpcontrolunit(EDC)
PTO PowerTakeOft
PWM PulseWidthModulation
(seealsoPB[,/)

RA Repairmanual
RAH Spacerheater
RAM RandomAccesslllemory
RAS RearAxleSteedng
RAS-EC RearAxleSteering-Electronic
Controlled
RBL Computeroperatingsystem
RDRA Tyrepressurecontrolsystem
RDS RadioDataSystem
RET Retarder
RGB Red-creen-Blue

0 . 13 - 4 T18
 ELECTRICAL
SYSTEM

ABBREVIATIONS

RKL Roiatingidentification
light
RLV Relayvalve
RME Ester(Biodiesel)
Rapstulethyl
ROM ReadOnlyMemory

SA Sourceaddress
SAE Societyof AulomotiveEngineers
SAMT SemiAutomaticlllechanicTransmission
SB Serviceoperation
sec Seconds
SER Se es
SG Controlunit
SH Select-highcontrol(ABS)
SKD SemiKnockedDown
SL Select-lowcontrol(ABS)
SML Sidemarkerlighl
SPN SuspectParameter Number
STA Enginestart/stop
SWR Headlightcleaningsystem

t Time
TC T€ction Control
TCl, TrailerControlN4odule
TCO Tachograph
TKU Technicalcustomerdocumentation
TitC TratficMessageChannel
TRS TechnicalGuidelines
lor Roads
TSC TorqueSpeedControl
TUER Doorconlrol

Usd Batteryvoltage
UOS Accidenldatamemory

v Speed
VA Frontaxl€
VG Ditferential
assembly
VLA Leadingaxle

Maintenance instructions
WAB Water separator
WaPu Waterpump
WLE Altemating-chargeunit
WR Warningrelay
WS Travelsensor
WSK Converlerandclutchunit

z Braking
z.SR Centralvehiclecomputer
ZBRO Centralvehiclecomputer,bus
ZDR Intermediatespeedconlrot
ZE Centralelectrics
ZR Centralcomputer
ZS Centrallubrication
ZUSH Nightheater
ZWS ScheduledMaintenance System

7, Slip
F Coetficient
of ldction
FC (microprocesso4
lricrocontroller

T !8 0. 1 3- 5
 GENERAL

Safety regulations

Thisquick-reference summarycontainsimportant rulespresentedaccordingto theirmainemphasis,in

orderto pass on the necessaryknowledge to persons,and damagelo property
so as to avoidaccidents
andthe environment.
Addilionalindicationsare includedin the vehicle'sOperatingl\ranual.

lmportant:
Shouldan accidenloccurdespiteall precautionary measures, particularly
dueto contactwithcausticacids,
lhe penetration liquidin the €yesetc.,you must see a
ol fuelinlothe skin,scaldingwithhotoil, anti-lreeze
doctor immediately.

Buleslor the preventionol accidentsinvolvinginjury to pelsons!

Only authorized,skilled personnelmay cary out tesling,adiusimentsand repairs.

. Securevehicleto preventit rollingaway.

. Supportthe chassiswhenworkingon the airsuspension
or suspension
system.
. Secureassemblies
whentheyareto be temoved,
. personnel
Onlyauthorized maystartandoperatethe engine.
. Whenan engineis runningdo notgetloo closeto rotatingpartsandwear
close-litting
workclothes.

. Do nottouchaxleswhichhaverunhotwithbarehands.Thereis a danoerof
burnino!

Keepthe areaof lhe axle,laddersand stepsfreeof oil and grease.Accidents

dueto slippingcan haveseriousconsequences.
Useonlythe propertools.Wornspannersslipand posea dangerolinjury!
Nobodymayslandundercomponents suspended
tromthe hookof a crane.
- Keeplittinggearin goodcondition.
-

Collectleakingbrakelluid-Brakelluidis classiliedas specialwaste!

Obseruesafetyrulesfor prevention of environmental pollution.
Brakefluidis toxiclDo notallowit to comeintoconlactwithloodor oDen
wounds.

Onlyopenthe coolantcircuitwhenthe enginehascooleddown.lf it becomes

necessarytoopenit whenthe engineis hot,lollowlhe instructions
in the chapter
"Maintenanceand repail'in the Operating
Manual.
Do notattemplto lightenor undopipesand hoses(lubricating oil circuits,cooling
oil ckcuils)underpressure.
circuilsand hydraulic Thereis a riskof injuryfrom
escapingfluidsl
Whencheckingthe injectols,do notpositionthe handsin lhe wayof the stream
of luel.Do not inhalefuelvapours.

T r8 1 . 2 0- 1
 GENERAL

. The batterymuslalwaysbe disconnected

whenworkingon the electricalsystem
ol lhe vehicle.
Warning!Therecanbe a build-upof orygenand hydrogenin closedbatteryboxes.
Whendisconnecting a battery,any continuous consumers, tachographsetc.that
cannotbe switchedoft can causesparkswhichwill ignitethe gas.Blowout the
batteryboxwithcompressed air beloredisconnecting
the battery!
. Tow vehiclesonlywiththe batteriesconnected{minimum charge40ol")lDo not
usequickchargerslor slarting!Batteriesshouldonlybe rapidlychargedwiththe
positiveand negativeleadsdisconnected!
. Disconnect the batterieson parkedvehiclesand chargeevery4 weeks.
Caution!Batteryacidis loxicand caustic.Batlerygasesareexplosive.
. Followthe manufacture/s
instruclions
whenhandlingbatteries.
. Measurevoltagesonlywithappropdate equipmentl
The inputresistance
of a voltagemeasu ng deviceshouldbe at leastlO lrohm.
. You mustonlyremoveor connectwiringharnessplugsol eleckonicconlrolunits
whenthe ignition is ofl.
Wheneleciro-weldingonlyconnectthe proteclive'ANTIZAP-SERV|CE-
WACHTER"(N4AN partnumber80.78010.0001) orthe improveddesignSES-j
{MAN part number 80.79010.0002)accordingto the instructionssupptiedwilhthe
oevrce.
ll thisdeviceis notavailable,
disconnect
the batteriesat theterminalsand makean
electricallyconductiveconnectionbetweenthe negaiiveand positiveleads.
The earthof theweldingdevicemustalwaysbe attachedas closeto lhe welding
pointas possible.Theweldingdevice'scableshouldnotbe laidparalleltoelectrical
wires/cables in thevehicle.
Forlurthermeasures to preventaccidentspleasereferto the "information
sheellor
welders"-
Thechassisis nol designedas an earlhreturn!
. Whenadd-onsare retrofitted,e.g.a tail lift,extraearth leadsol adequate
diametershouldbe incorporated becauselhe eadhconnection will otherwisego
via winchcables,wire harnesses,gearlever,gearwheels, etc.Thiswillcause
senousdamage.

. When painiing,electaoniccomponents mustonlybe exposedto high

tor a shorltime (max.95 'C); up to abouttwo hoursis permissible
lemperatures
al a maximumof 85 'C. Disconnectbatteriesand removethem.

Plaslictubing
Warning!- Riskottire and damage!
. The adiacentwarningnoticeis situaledon the diesellueland heatingoil tank
llaps.lt warnsagainstweldingor d l{ingjn the vicinityof plastictubing.

1 . 2 0- 2 T 18
 GENERAL

Limilationot liabilityfor parts and acces3ories

It is in yourown interestthatwe recommend onlyusingaccessories specilicallyapprovedby l\4ANand
originalI\,ANpartson yourIIAN vehicle.The reliability, safetyandsuitabilityof theseaccessories and
partshasbeendetermined lor IIAN vehiclesin particular.
In the caseot otherproducts- evenif theyhave
TUVapprovalor are licensedby an otficialauthorily-we cannolassessthemorvouchlor themdespite
continuous scrutinyo, the market.

Bodywork
In the caseof standardor customized the safetyruleso{ the particular
bodywork, manufacturer
mustbe
observedwithoutfail.

Laying up or aiorage
Whenlayingup or storingbusesortrucksfor periodsol longerthanthreemonths,particular
measuresare
requiredin compliancewiththe factoryslandardMAN"M3069Part3.

SPECIALRULESTO BE FOLLOWEDWHENWORKINGONTHECOi/|i'ONRAILSYSTEM

CAUTION

Dangerot iniury!
Fucl spray can p€netralethe skin.
Thele is a dangerot fire ftom fuel mist.
. Neverundothe threadedunionson lhe fuel high-pressure side(iniectionlinefromthe high-
pressurepumpto the rail,on the railand on the cylinderheadto the injeclor)on lhe common
railsystemwiththe enginerunning.
. Avoidremaining closeto a runningengine.

cAUTtOl'l

Dangerot injury!
Whenthe engineis running,the lines are alwaysundera fuel pressureof up to
1,600bar.
. Beforethethreadedunionsare undone,waital leastone minuteuntilthe pressurehas
dissipated.
. lf necessary,usethe MAN-catsto checkthe pressuredropin the rail.

CAUTION

Dangerof injury!
wilha heartpacemaker
Persons mustnotapproach
closerthan
to wilh20 cmof lherunning
engine.
Do not touch live parts on the electricalconnectionof the injeclorswith the enginerunning.

T 18 1 . 2 0- 3
 GENERAL

Cleanliness
I\rodemcomponents ol dieselinjectionsystemsconsistol high-precision
partsexposedlo extreme
stresses.Becauseof thishighprecision, absolutecleanlinessmostbe observeddudnganyworkon the
luel system.
Evenparticlesof dirtgreaterthan0.2 mm in sizecanleadto failureof components.
Therefore,the measuresdescribedin thefollowingmusl be compliedwithbeforestartingwork.

WARNING

Dangelof damagedue to ihe ingressof dirtl

. Belorewo*ing on the cleansideot theluel system,cleanthe engineand enginecompartment
(steamjet), makingsurethatthe fuelsystemis blankedotf whendoingso.
. Carryout a visualinspectionlor leaksor damagelo thefuel system.
. Do notaimthe steamiet directlyontoelectricalcomponents, or lit covels.
. lvlovethe vehicleintoa cleanareaof lhe workshopin whichno wolk is beingcarriedoutthat
couldcausedustto be agitated(grinding, welding,brakerepairs,brakingand perloftnance
testsetc.).
. Avoidair movement(possibledustagitationwhenstartingthe engine,the workshop
ventilation/healing,
by draughtsetc.).
. Withthe fuelsystemstillblankedoff,cleanthe areaof the systemusingcompr€ssed air.
. Removeloosedirl parliclessuchas paintllakesand insulatingmateialusinga suilable
vacuumdevice(industrial vacuumcleaner).
. Shieldareasol the enginecompartment fromwhichdirtparticlescan be becomedetached, e.g.
tiltedcab,enginecompartment ol buses,usingnew,cleancoversheets.
. Beforestartingdismantling,washhandsand puton newworkingoveralls.

Therefore,
the measuresdescribedabovemu6t be comoliedwith beforestartinowork.

WARNING

Dangerol damagedue to the ingiets ot dirt!

. The useof compressed ak for cleaningis not permitted
afterthe cleansideof lhe fuelsystem
hasbeenopened.
. Removeloosedirtduringmaintenance workby usinga suitablevacuumdevice(industrial
vacuumcteaner),
. Useon lint-lreecleaningclothson the fuelsysterh.
. Cleanloolsandworkingmaterialsbelorestarlingwork-
. Useonlytoolsthat are undamaged (crackedchromeplating).
. No materialssuchas clolhs,cartonsor woodmay be usedfor the removalandlittingof
corhponents, becausethesecan shedparliclesandfibres.
. lf paintllakes(dueto any excesspainting)are producedwhenundoingconnections, carefully
removethesepaintflakesbelorefinallydisconnecting the unions.
. Blankofl the connectionopeningsof all removedcomponents ol the clean-sidefuelsyslem
immediately usingsuitableblankingcaps.
. Blankmaterialsmustbe k€ptpackedin a dustprootmannerusedonceonlyandthendisposed
OTI.
. All componentsare thento be carefullykeptin a clean,closedcontainer.
. Neveruseusedcleaningor testfluidsfor thesecomponents.
. Newcomponents are notto be removedfromtheiroriginalpackaginguntilimmediately before
use.
. Workmaybe carriedoul on removedcomponents onlyat a workstation
equippedfor the
oulDose.
. lf removedcornponentsarelo be shipped,the originalpackagingof the newcomponentmust
alwaysbe usedtorthispurpose.

1 . 20 - 4 T18
 GENERAL

Whenwo*ing on the engineaof busea,the measures

describedabovemust additionally
be complied
withbeforestartinowork.

WARNING

Dangerof damagedue to the ingressof dirtl

Beforeopeningthe clean-side of the luel syslem:
. Cleanthe enginepartsaroundpressureconneclions, injectionlines,railandvalvecoverusing
compressed arr.
. Removethe valvecoverlollowedby againcleaningthe enginepartsaroundlhe pressure
connections, inlectionlinesand rail.
. Initially,onlyslackenthe pressurepipeconnections.
. Slackenthe unionnutsol the pressurepipeconnections and unscrewtourtums.
. Liltthe pressurepipeconnections usinga specialtool.
. Reason:The pressurepipeconnections are onlyto be completely removedwhenlhe injectors
havealreadybeenremoved, so thatno dirtcanJallfromaboveintothe injectors.
. Removeinjectors:
. Afterremoval,llushthe iniectorswithcleaningfluidmakingsurethalthe high-pressure
connection boreis ditecteddownwards.
. Removethe pressurepipeconnections:
. Unscrewlhe unionnutof the pressureplpeconneclion and r€movethe pressurepipes.
. Cleanthe injectorborein the cylinderhead.
. Installin preciselythereveEeorderof removal.

T 18 1.20- 5
 SYSTEMOESCRIPTION

General

The requirementson diesel enginesimposedby law and the

concernsoI the customerin respectof environmental compatibility,
tuel consumption,exhausl gas and noise characterislics,
conltancy ot speed lor po$,ertake-offs,etc. have been increasing
andwilldoubtless becomeevermoreslringentin lhe future.

The Common Rail diesel injector system meets all the

rcouirementsthat are olacedon a modem internalcombustion
engine.

This systemcombinedwith elodronicallycontrolledgear shift6,

anti-lockbrakingsystems,ASR hactionconhol,shock absorber
control,brakingsyslemcontrol,etc- increas€svehicleeconomy,
improvesdrivingcomlortand takesthe pressureotf the ddveras
wellas the environment.

T 18 2.01- 1
 SYSTEMDESCRIPTION

Structurcand tunctioning

Efficienlcombustion dep€ndson havinga goodmixture.The Injectionsystemplaysa centralrole.Thefuel

hasto be iniectedin the correctquantity,at the righttimeand underhighpressure.
TheCommonRailSyslemis a promisinghigh-pressure injectionsystem.Pressuregeneration and iniection
are separaie.Thefuellor the individual cylinders comeskon a sharedrail,whichis keptconstantly under
highpressure. The pressurein lhe railis suppliedby a high-pressure pumpandcan be modifieddepending
on the operatingconditions.
Eachcylinderis equippedwithan injector,whichis controlled via a solenoidvalve.
Thequantityto be iniectedis deteminedby theoutletdiamelerof the injeclor,the periodthatthe solenoid
is openandthe railpressure. Thesystemreachesa pressureof up to 1400bar.In future,systemswill
functionat 1600bar.Systemsof as muchas 18OO bar are currentlybeingdeveloped.
Thefunctional sepaEtionol pressuregeneration and injectionpermitsa betterdesignof the injeclion
processand so of combuslion. The injectionpr€ssurecan be selecledfreelywithinthe characteristic map.
are possible,i.e.pre-andpost-iniections.
Multipleinjections Thefuelquantity,startof injectionand pre-
andposl-injectionsare controlledby exkemelyrapidsolenoidvalves.
Oneadvantageof CommonRailSystemsis thattheycan be littedto existingengines,withoutlhe needto
changethe cylinderhead.

wlx
-l I
,t-
.+'.g+ -a s A
.YT

Schematic
construction
of a CommonRailSyslem
Thesystemessentiallyconsistsof lhe lollowingcomponenls:
. Volume-controlledhigh-pressure pumpO
. High-pressureaccumulalor(commonrail)@
. Pressurelimitingvalve@
. Bailpressuresensor@
. Injectors
@
. Eleclroniccontrolunit@
. Addilionalsensorsandolherunits@

T 18 2.O2- 1
 FUNCTIONAL
DESCRIPTION

EDCcontrol unit (A435,A570)

The primetaskot the EDCconholunitis to controlthe quantityinjected,the timeot injectionandthe

tdggeringof the starter.
The panicularoptimalinjectionquantityandtimeare calculatedfor oplimalcombustion in everyoperaling
stateof the engine.

Thecontrolunilanalyzeslhe sensorsignalsandcalcuiates
the triggeringsignalsfor the inlectors-

Thecontrolunit(software/hardware)
can be usedlora maximumof six cylinders.
A secondcontrolunitis
thereforeneededto operatea Vl0 engine.Thetlvoconlrolunilscommunicatevia CANandfunclionin
whatis termedthe master^lavemode.

Theconlrolunitsotlwareincludesthe followinggroupsol functions:

Settingvolumes,luel proportioning
Fuelpressurecontrolwithhigh-pressurepump
Fuel pressureshutdoh/n(limp-home function)
ldlingspeedcontrol
Finalspeedconlrol,smok6andtorquelimitation
Adaptivecylinderbalancingconlro!(smoolhrunning)
Cylindershutdown
Exhaustgas recirculation
Wastegale control
Diagnosisand monitoring funclions

The conlrolunitis {ittedwilhthreewkinghamessplugs:

A Engine plug 89-pole

B Vehicleplug 36-pole
C Injectorplug 16-pole

T 18 3.01- 1
FUNCTIONAL
DESCRIPTION

Controlunit EDC7 (A435)

Pin assignmentoI engine plug A

E E O E @O
oG000
o0EoE0

401 U U BAT+1 60034 Battery+

402 Notassigned(resetuedfor gatecontrolacluator)
A03 I\,I M BAT_1 31000 Earth
A04 Nol assigned(reserved
tor wastegateacluatorearth)
A05 Notassigned
A06 Notassigned
AO7 U U_BAT+2 60035 Battery+
A08 ATZME 60373 ZIIE input
A09 M M BAT_2 31000 Earth
A10 I\,IR ZME 60374 ZMEearth
A11 M_R_AGR 60340 EGRaclualorearth
412 U U_BAT+3 60036 Battery+
A13 U_U_BAT+4 60033 Battery+
414 I\,I_M_BAT_3 31000 Eanh
A15 I\,,IM_BAT-4 31000 Eadh
416 A S_ANRH 60314 SlarterIMRinpul
A.17 ATAGR 60367 EGRactuatorinput
A18 Not assigned
419 A S ANRL 31330 Siarlerl[4Rearth
420 EAKND 60137 Fuellow oressuresensorinoul
Ml E_A PI\,!OEL 60134 Oil pressuresensorinpul
M2 E_A-AGR 60153 EGRactuatorsensorfeedback
M3 A-U_sVAGR 60031 EGR actuatorsensorsupply
M4 U U_SVPIVIOEL 60156 Oilpressure
sensorsupply
M5 U_U-sVLDF 60'159 Chargepressuresensorsupply
A26 Notassigned
M7 Notassigned
MA Notassigned
M9 Not assigned
430 Notassigned
A3.I Notassigned
A.32 Notassigned

3.01- 2 T18
 FUNCTIONAL
DESCRIPTION

Controlunit EDC7 (A435)

Pin assignmenlol engine plug A

A33 Not assigned

A34 Notassigned
A35 Notassigned
A36 Notassigned
437 I./ R KND 60158 Fuellowpressuresensorearlh
438 M R PI\4OEL 60135 Oil pressuresensorearth
A39 Notassigned
A40 U_U_5VKND 60155 Fuelpressure
sensorsupply
441 Notassigned
A.42 Notassigned
A43 U U sVRDS 60161 Railpressuresensorsupply
Notassigned(signaloutputcamshaflspeec,
A45 Notassigned
A46 Notassigned
Notassigned
448 Nol assigned
A49 Notassigned
A50 Nolassigned
A51 Nolassigned
A.52 Notassigned
A53 Nol assigned
454 M R NWDG Grey/brown Camshaftspeedsensorearth
455 I\4 R KWDG Grey/white Crankshaft
speedsensorearlh
A56 Notassigned
p.57 I!I-R_TANS 60100 Charge-air
temperaturesensorearth
A58 M_R_TMOT 6010 1 CoolanltemDeralure
sensoreanh
A59 Notassigned
A60 Notassigned
A61 I\,tR_LDF 60160 Railpressuresensorearth
462 IVIR LDF 6014 1 pressuresensorearth
Charge-air
A63 Nolassigned
A64 Notassigned
A65 Nol assigned
A66 Nolassigned
A.67 Noiassigned
A68 Notassigned
469 Notassigned
470 Notassigned
471 Notassigned
472 E F NWDG Grey Camshattspeedsensorinput
473 E F KWDG Grey/green Crank"shaft
soeedsensorinDut

T 18 3.01- 3
 FUNCTIONAL
OESCRIPTION

Conlrol unit EDC7 (A$5)

Pin assignmentof engine plug A

474 Notassigned(signaloutputcrankshaft
speed)
475 Notassigned
476 E_A_TANS 60'151 Charge-air
lemperaturesensorinput
E A TI\4OT 60131 Coolantlemoerature
sensorinout
A7A Notassigned
A79 Notassigned
A80 E.A RDS 60162 Railpressuresensorinpul
A81 E_A_LDF 60102 pressuresensorinput
Charge-air
AA2 Notassigned
A83 Notassigned
A84 Notassigned
A85 Notassigned
486 Notassigned
487 Notassigned
488 Notassigned
A89 Nolassigned

3 . 0t- 4 T18
 FUNCTIONAL
DESCRIPIION

Controlunit EDC7 (A435)

Pin assignmentot vehicleplug B

Ll_rr_l_l
L!.1 t7.l L6.t

801 Nolassigned
BO2 Nolassigned
803 Notassigned
804 Notassigned
805 Not assigned
806 Notassigned
807 Notassigned
808 Notassigned
809 Notassigned
810 Notassigned
811 Not assigned
812 Notassigned
812 Nol assigned
813 Nolassigned
814 Nolassigned
815 Nol assigned
816 Not assigned
817 Notassigned
818 Notassigned
819 Notassigned
820 Notassigned
B21 B_D_CANL1 Green/black lvl-CANLow
822 B D CANH1 Black/green M-CAN High
823 Nol assigned
824 Nol assigned
825 Nolassigned
826 Nol assigned
827 Nolassigned
B2A Notassigned
829 Notassigned
830 Notassigned
831 Notassigned
832 Notassigned

T 18 3.01- 5
FUNCTIONAL
DESCRIPTION

Controlunit EDC7 (A435)

Pin assignmentof vehicleplug B

Pin assignmentof iniector plug C

i&\
fffitt1
i l i oo:rasoi l
itf
H#:J]i
E O O t rO
o g80Do
GEEGG

c01 A P I\,IVH21 Black lnjectorcylinder5 high-signal

co2 A P MVH22 Red Injectorcylinder6 high-signal
c03 A_P_t\,/lVH23 Red Injectorcylinder4 high-signal
c04 Black Injectorcylindert high-signal
c05 A-P I\,{VH12 Black Injectorcylinder3 high-signal
c06 White/red Injectorcylinder2
co7 Nol assigned
c08 Nol assigned
c09 Not assigned
c10 Notassigned
c11 A P MV H13 Red In,ectorcylinder2 high-signal
cl2 White/black Injeclorcylinder3
c13 White/black Injeclorcylinder1
c14 A P-t\,4V23 White/red Injeclor
cylinder4
A_P_t\,4V22 White/red Injeclorcylinder6
c16 A_P_tvlV21 White/black Injeclorcylinder5

3.01- 6 T 18
 FUNCTIONAL
DESCRIPTION

Control unit EDC7I'IASTER(A435)

Pin assignmentot engineplug A

r- .;l T;'rT;l T;l aJ

A01 U U BAT+1 60034 Battery+

AO2 Not assigned
A03 M_I\,I_BAT_1 31000 Earth
A04 Nol assigned
A05 Nolassigned
A06 Nol assigned
AO7 U,BAT+2 60035 Battery+
A08 A_T_ZME 60373 ZMEinput
A09 t\.,t_t\4_BAT-2 31000 Earth
A 10 t\,t_R_zl\4E 60374 ZMEearth
411 lil R AGR 60340 EGRactuatorearth
412 U_U_BAT+3 60036 Battery+
A'13 U-U-BAT+4 60033 Battery+
M-M-BAT-3 31000
A15 lrl_M_BAT-4 31000
A t6 A_S_ANRH 60314 SlarterIMBinput
A17 A TA GR 60367 EGRactuatorinpul
A 18 Notassigned
419 A S ANRL 31330 StarterIMRearth
MO E A K ND 60137 FuellowDressure sensorinout
4.P1 E_A-PMOEL 60134 Oil pressuresensorinput
M2 E_A_AGR 60153 EGBactuatorsensorfeedback
M3 A-U-5VAGR 60031 EGRactualorsensorsupply
A.24 U U 5VPI\4OEL 60156 Oilpressure
sensorsupply
M5 U-U_sVLDF 60159 Chargepressuresensorsupply
M6 Notassigned
M7 B D CANH2 Brown/black CANHighMaster/Slave
MA Notassigned
A29 Not assigned
A30 Notassigned
A31 Not assigned
432 Not assigned

T 18 3.02- |
FUNCTIONAL
DESCRIPTION

Control unit EDC7 MASTER(A€51

Pin assignmentof engine plug A

A33 Notassigned
A34 Notassgned
Notassgned
Notassgned
437 I\,I-R KND 60158 Fuellowpressuresensoreadh
A38 M R PMOEL 60135 Oilpressure
sensoreanh
A39 Notassigned
A40 U_U_sVKND 60155 Fuellow pressuresensorsupply
441 Notassigned
442 Notassigned
A,r3 U U 5VRDS 60161 Bailpressure
sensorsupply
O P ENGN2 60546 Speedsignal2 output
A45 B_D-CANL2 BlacUbiue CANLowMaster/Slave
A,16 Notassigned
447 Notassigned
A48 Notassigned
A49 Notassigned
A50 Notassigned
A5l Notassigned
Nolassigned
A53 Notassigned
454 I\,I_R_NWDG Grey/brown Camshatlspeedsensor€arth
M_B_KWDG Grey/white Crankshaftspeedsensorearth
Notassigned
A57 M R TANS 60100 Charge-air
temperaturesensorearth
A58 M_R,TMOT 60101 Coolanttemperature
sensorearth
A59 Notassigned
A60 Notassigned
A61 I!I_R LDF 60160 RailDressuresensorearlh
A.62 |\,|_R-LDF 60141 Chatgepressuresensorearth
A63 Notassigned
A64 Notassigned
Notassigned
A66 Notassigned
467 Notassigned
468 Notassigned
A69 Nol assigned
A70 Notassigned
471 Notassigned
472 E F NWDG Grey Camshaftspeedsensorinput
473 E_F_KWDG Grey/green Crankshattsoeedsensorinout

3.02- 2 T 18
 FUNCTIONALDESCRIPTION

Conlrol unit EDC 7 MASTER(Ai*]5)

Pin assignment ot engine plug A

O_P-ENGN1 60545 Speedsignal1 outpui

Nol assigned
A76 E A TANS 60151 Charge-air sensorinput
temperature
A.77 E_A_TI\,,IOT 60 1 3 1 CoolanltemDeralure
sensorinDut
A7A Nol assigned
A79 Nol assigned
A80 E A RDS 60162 Railpressure
sensorinpul
A81 E_A_LDF 60102 pressuresensorinpul
Charge-air
AA2 Not assigned
A83 Not assigned
A84 Notassigned
A85 Notassigned
A86 Notassigned
A87 Not assigned
A88 Not assigned
A89 Nol assigned

T 18 3.02- 3
 FUNCTIONAL
DESCRIPTION

Controlunit EDC7 MASTER(A435)

Pin assignmentol vehicleplug B

rj.rL'Jt'.t
I,l_l t_t_l
r-!-rL7.lL6l

801 Nolassigned
BO2 Nolassigned
803 Nolassigned
804 Notassigned
805 Notassigned
806 Not assigned
807 Notassigned
808 Notassigned
809 Notassigned
B1 0 Notassigned
811 Nolassigned
812 Nolassigned
812 Nolassigned
813 Notassigned
814 Notassigned
B't5 Nolassigned
816 Notassgned
817 Notassgned
818 Notassgned
819 Notassgned
820 Notassgned
821 B D CANL'1 160 lvl-CANLow
822 B D CANH1 159 lvl-CANHigh
823 Notassigned
B24 Notassigned
Notassgneo
826 Notassgned
827 Notassgned
B2A Notassgneo
829 Notassigned
830 Noiassigned
831 Nolassigned
832 Noiassigned

3.O2- 4 T 18
 FUNCTIONAL
DESCRIPTION

Controlunit EDc 7 MASTER(Airi's)

Pin assignmentof vehicleplug B

Teminal15

Pin assignmentof injeclor plug C

a€l*T\
fiffillt
l l l ooooool l
Nt[
N

WPJ-Ji
EO Bt rO
O@EEOE
@G G t rG

c01 A P IuVH21 Black Injectorcylinder5 high-signal

A P IuVH12 Black Iniectorcylinder3 high-signal
c03 Notassigned
c04 A_P_I\,!VH11 Black Injectorcylindert high-signal
c05 A P-MV13 White/red Injectorcylinder2
c06 A_P_tVlVH23 Red Injectorcylinder4 high-signal
c07 Not assigned
c08 Not assigned
c09 60561 Encodinglvlaster/Slave
c10 60561 Encodinglraster/Slave
c 11 A P I'V23 White/red lnjectorcylinder4
c12 A_P_MVH13 Red Injectorcylinder2 high-signal
c 13 White/black Injectorcylinder1
cl4 Notassigned
c 15 White/black Injectorcylinder3
c t6 A_P_tVlV21 White/black Injectorcylinder5

T 18 3.02- 5
FUNCTIONAL
DESCRIPTION

Control unit EDC7 SLAVE(A570)

Pin assignmentol engineplug A

l7l. l rl r nl

r,! Ljl t! L_.,r

r_,,r
L,J

A01 U_U_BAT+1 60039 Battery+

A02 Notassigned
A03 I\,I M_BAT_1 310 0 0 Eann
A04 Notassigned
A05 Notassigned
A06 Notassigned
AO7 U_U_BAT+2 60038 Battery+
A08 A_T_ZME 60375 ZMEinput
A09 t\4 t\,t_BAT-2 31000 Earth
A10 t _R_zt\,tE 60376 ZME eadh
A11 Notassigned
412 U_U_BAT+3 60037 Batlery+
A13 U-U BAT+4 60040 Battery+
A14 t!l-t\,t BAT-3 31000 Earth
At5 lll_|\,1_BAT-4 31000 Earth
A16 Notassgned
417 Notassgned
418 Not ass gned
At9 Notassigned
MO Notassigned
Ml Not ass gned
M2 Notassgned
M3 Not ass gned
424 Notassgned
425 Notassigned
A26 Notassigned
427 B_D-CANH2 Browrvblack CANHighlraste/Slave
A2A Notassigned
429 Notassigned
A30 Notassgned
A31 Notassgned
432 Notassgned

3.02- 6 T 18
 FUNCTIONAL
DESCRIPTION

Controlunit EDC7 SLAVE(A570)

Pin assignmentof engineplug A

A33 Notassigned
A34 Notassigned
A35 Notassigned
A36 Notassigned
437 Notassigned
438 Notassigned
A39 Notassigned
A40 Not assigned
Not assigned
A.42 Nol assigned
A43 U U sVRDS 60165 Railpressure
sensorsupply
Nolassigned
A45 B_D_CANL2 Blacldblue CAN Low lvlasler/Slave
A46 Notassigned
Notassigned
A48 Notassigned
A49 Notassigned
A50 Notassigned
A51 Not assigned
A52 Notassigned
453 Notassigned
A54 Notassigned
A55 Notassigned
A56 Nolassigned
p.57 Not assigned
A58 Notassigned
A59 Notassigned
A60 Notassigned
A61 MRLDF 60164 Railpressuresensorearth
A.62 Notassigned
A63 Nol assigned
A64 Nol assigned
A65 Notassigned
A66 Not assigned
A67 Not assigned
A68 Notassigned
A69 Notassigned
470 Notassigned
A71 Notassigned
A.72 60545 Speedsensorsignal1 input
A.73 60546 Speedsensorsignal2 input

T 18 3.O2- 7
FUNCTIONAL
DESCRIPTION

Conirol unit EDC7 SLAVE(A570)

Pin assignmentof engineplug A

474 Notassigned
A75 Notassigned
A76 Notassigned
477 Notassigned
A78 Nol assigned
A79 Nolassigned
480 E_A_RDS 60163 Railpressuresensorinpul
A81 Nolassigned
A82 Notassigned
A83 Nolassigned
A84 Nolassigned
A85 Notassigned
486 Notassigned
A87 Nolassigned
488 Nolassigned
A89 Notassigned

3.02- I T 18
 FUNCTIONAL
DESCRIPTION

Controlunil EDC7 SLAVE(A570)

Pin assignmentot vehicleplug B

801 Nol assigned

BO2 Not assigned
803 Notassigned
804 Notassigned
Notassigned
806 Not assign6d
807 Notassigned
808 Notassigned
809 Notassigned
810 Notassigned
811 Notassigned
812 Nol assigned
812 Nolassigned
Bt3 Notassigned
814 Notassigned
815 Notassigned
816 Notassigned
817 Not assigned
818 Notassigned
B19 Notassigned
920 Notassigned
821 B D CANLI 't60 M-CANLow
822 B D CANH1 159 Nl'CANHigh
823 Notassigned
824 Notassigned
Notassigned
826 Notassigned
827 Notassigned
B2A Not assigned
829 Notassigned
830 Not assigned
831 Notassigned
832 Nolassigned

T 18 3.02- 9
FUNCTIONAL
OESCRIFNON

Controlunit EOC7 SLAVE(A570)

Pin assignmentof vehicleplug B

Terminal
15

Pin assignmentot iniectorplug C

at=Jcrr\'
fffiilIlt[
WHUJJI
Bfi G trO
N@ EGtrO

c01 A_P-MVH21 Black lnjectorcylinder10 high-signal

co2 A_P_MVH22 Black Injectorcylinder8 high-signal
c03 Notassigned
c04 A_P_MVH11 Black Injectorcylnder6 high-signal
c05 A_P_MVH'12 Red Injectorcylnder7 high-signal
c06 A_P_t!tv13 White/red Injectorcy nder9
co7 G R CPUSS 60561 Encoding slave
c08 ts_cPuss 60561 Encoding slave
c09 Notassigned
c1 0 Notassigned
c11 A P I\4VH13 Red InjectorcylinderI high-signal
c12 A-P_MV12 Injectorcylinder7
c13 Whiteiblack Injectorcylinder6
c14 Notassigned
c15 A_P_MV22 White,/black Injectorcylinder8
c16 A_P_MV21 White/black Injectorcylinder10

3.02- 10 T18
 FUNCTIONAL
OESCRIPTION

High.pressurepump

The high-pressure pumphasthejob ol providingthe highpressurethat is requiredtor injeclionandto

transporla suflicientquantityof {uelduringalloperatingstates.
The high-pressure pumpis drivenby the engineand is installedin the sameplaceas a conventional
injectionpump.The pumpis oil-lubricated. Thetuel is deliveredby a pre-leedpumpthroughluel linesto
the fuellifter(KSC)and subsequently deliveredvia the ZMEintothe "suctionchambel'of the high-pressure
oumo.
The pre-feedpumpis flange-mounted ontothe high-pressure pump.
On the suclionsideol the high-pressure pumpis the proportioning unitZ[rE (MProp).Theproportioning
unitis an actuatorfor regulatingthe fuel pressurein the rail.

pumpin usewhosedesignsdiflerin the

At the momentlherearetwovarianlsof the high-pressure
lollowingrespecls:
- Radialplunger pumpCP3.4
- Inline plungerpumpCPZ4
The radialplungerpumpCP3.4is usedon seriesD08,D20and D28(iniine)engines.
The inline plungerpumpCPZ4 is usedwiththe D2840engine(Vl0 engine).

The pictureaboveshowsa radialplunger

pumpCP3.4.

T 18 3.03- 1
FUNCTIONAL
OESCRIPTION

High-prcssuJcpump CP3.4

pumpCP3.4is a radialplungerpumpwiththreecylinders.
Thehigh-pressure This pumpis usedon series
D08,D20and D28(inline)engines.

Thistransportol thiscrankshaft
lor lhe engineseriesD081:'1.33and enginesof seriesD20and D28
pumpwitha tastcrankshatt.
1:1.67,i.e. high-pressure

lmooftantcomDonents
are
pump
O High-pressure
unitZME(MProp)
@ Proportioning
O Feedpump

3.03- 2 T 18
 FUNCTIONAL
DESCRIPTION

High-pressurepump CPZ4

Sideview

Frontview

pumpCP 2/4 is an inline plungerpumpwithfourcylinders,

The high-pressure whicharearrangedin a
V-shape.
Thispumpis usedon seriesD2840engines{V 10engines).

Thetransmission ratiolor the crankshaflis 2:1,i.e.thispumprunsat the speedof the camshaft,i.e.halfas

fastas the crankshafl.

lmportantcomponenls
are

O High-pressurepump
unitZLlE(2 items,one for eachrowol cylinders)
@ Proportioning
@ Speedsensor{torrecording the camshaflspeed)
@ Feedpump

T 18 3.03- 3
FUNCTIONAL
DESCRIPTION

Proportioningunit ZME(proportionalvalvefuel MProp)(Y332,Y355)

Theproportioning unitZNIE(MProp)is an actuatorfor€gulatingthe fuelpressurein the rail.

The proportioning pumpand is boltedintothe
unitis locatedon the suctionsideof the high-pressure
housingol the high-pressure pumpCPs.
Thehigh-pressure pumpCP2l4for the V 10engineis fittedwilhtwo proportioningunitsbecauseherelwo
railsare controlled(onerailperbankof cylinders).

The proportioning
unitZtulEis regulaledwitha PWMoutput(pulse-width-modulated
signal):
Pulsecontrolfactor100% unitclosed(zeroquantitydelivery)
Proportioning
Pulsecontrolfactor 0% unitopen(maximumdelivery)
Proportioning

Theclosedloopconsistsol the railpressuresensor,controlunitand proportioning

unil.
Theproportioning
Noteon definitions: unitcanalsobe calledthe 'l,lProp".Bothtermsare permissible-
MPropstandsfor (fuel)volumeproportional
valve.

Tableshowing pin assignmenl

InputsignalPWM

Pin aaaignmeni

3.03- 4 T18
 FUNCTIONAL
DESCRIPTION

Commonrail

The name'CommonRail' is dedvedlromthe designandfunctionof the high"pressure accumulator.

Thefuel is injectedintothe lndividual whichfunclionsas a distributor
cylindersvia thisaccumulator, railat
the sametime.
Thefuel is pemanentlysubjectedto highpressureandjust needsto be removedat ihe ight moment.

Thejob of the commonrailis:

. Storingluel
. Prevenling pressuretluctuations

Thecommonrailis a tubemadekom lorgedsteel.lt hasditfercntdiametersand lengthsdepending on the

engine.
To prevontfluctuations as largea volumeas possiblemustbe used,i.e.as longandas largea
in pressure,
diameteras Dossible.
However,a smallvolumelavoursrapidstartingol the engine.
Thereloreas accuralea designof thevolumeto tit ihe engineis needed.
Theillustrationabovethereloreshowsonlyoneexampleof thedesign.
On the raillhereare mountedin additionto a pressurelimitingvalve@ and a pressuresensor,lhe rail

pumpthrougha lineintothe rail.Eachcylinderhasa connection

Fuel,is deliveredby lhe high-pressure to
the commonrail.Fuelreachesthe injectorvia thisconneclion
and an associatedline.

T 18 3.03- 5
 FUNCTIONAL
DESCRIPTION

Pressurelimitingvalve DBV,lwo-stage

Thetwo stagepressurelimitingvalveis mountedon the railandhasthejob of an overpressure valve.

The pressurelimitingvalvelilnitspressurein the rail.ll pressureis too high,il uncoversa drainaperture.At
normaloperalingpressurea springpressesa pisloncloseintothe valveseat,so thatthe railstaysclosed.
Onlyon exceeding the maximumsystempressureis a pistonpressedontoa springbythe pressurein the
tilrl.

The pressurelimitingvalveconsistsof two pislons.lf the railpressureis too high(at 1800bao the tirst
pistonmovesandpermanently exposesa partialcross-section, via whichfuelcanflowout ol the rail.The
railpressureis lhenmainlained constantat about700to 800bar.Th€ enginecontinues to run andlhe
vehiclecan be drivenat reducedspeedas lar as the nearestMANservicepoint.
Thelwo-slagepressurelimitingvalveonlyclosesagainwhenthe enginefailsand railpressureis under
50 bar,i.e.oncethe DBVhasbeenopened,the secondstageremainsopenas longas the engineis
running.
lf the pressurelimitingvalvedoesnotopenquicklyenoughwhenrailpressureis excessive, the prsssure
limitingvalveis "pushedopen , i.e.a forcedopening.
To lorceopenthe pressurelirnitingvalve,the fuel proportioningunit,is openedandthe flowol fuelvia lhe
iniectorsis blocked.The railpressureincreasesshaDlyuntiltheopeningpressureol the pressurelimiting
valveis reached.
lf lorcingopendoesnot succeed,lor examplethrougha mechanically jammedDBV,the engineis
neve{helessshutdown.

T 18
 FUNCTIONAL
DESCRIPTION

Rail pressurcsensor(8487,8514)

The railoressuresensormonilorsthe luel oressurein the rail.

Theaim is to guaranteea specifiedpressurein the raildepending
on the operatingpoint.
The railpressuresensoris mountedon the rail.

The sensormeasures
a rangeof 0 - 1800bar.

On enginesof seriesD2840(1o-cylinder therearetwo rails(oneperbankof cylinders).

V-engines) There
arethereforetwo railpressuresensors.

Sensorcharacierislic

Vollagein V 5.00

4.00

3.00

2.00

1.00

0.00
Pressurein bar (x 100) ' 1 0 t 1 1 21 3 t 4 1 5 1 6 1 7 1 A 1 9 2 0 2 1

Tableshowing pin assignment

60160/60164
60162/60163 Outputsignal
60161/60165 Supplyvoltage5 V

Pin assionment

T 18 3.03- 7
 FUNCTIONAL
DESCRIPTION

Injecrol(Y341- Y350)

Fuelis injectedintothe combustionchamberby the injector.ThecontrolunitEDC7 speciliesthe injection

duration(triggeng periodol injectorcoillor pre-iniection,
mainand possiblyatsopost-iniection) andthe
pointof injection,
and energizesan extremely fastsolenoidvalvein the injector.Theoulletvalveofthe
conlrolchamberis openedor closedby the amatureof lhe solenoidvalve.Whenthe outletvaiveis open,
the pressureinthe controlchamberfallsandthe valveneedleopens.Whenlhe outletvalveis closed,the
pressurein thecontrolchamberdsosandthe valveneedleis closed.Theopeningcharacterislics of the
iniectorneedle,(openingandclosingspeeds)are theretoredetermined by the inletand outletvalvein the
iniector'sconlrolchamber.
Leakagelromth€ injectoris retumedvia the returnlineto the tank.
Theexactquantityto be injectedis determaned by the nozzle'soutlet,the timethe solenoidvalveis opened
andthe pressurein the rail.

3.03- I T 18
 FUNCTIONAL
DESCRIPTION

Crankshaftspeedsensor(speedincrementsensoi)(8488)

Thesensormeasures(calculates) the crankangleol the crankshaflat the llywheel.

Thisinformalion is criticalfordetermining the correctpointal whichlo triggerlheiniectorsof the individual
cylinders.
Thepickupwheelis designedas an increment wheel.Thereforethisspeedsensoris termedthe speed
tncremenl sensor.
The increment wheelis a component ol the flywheeland has60 - 2 = 58 holes(6 x 5 mm)whichare
arrangedat antervals ol 6'. Two holesare missing,creatinga gap.Thisgap is designedin orderto
determine the angularposilion360"KW (crankshaft) ot the engine(onerotationof the crankshaft)and is
associated witha delined posilionot the crankshaft for cylinder1.
The enginecan alsostartwrtheithera crankshaft sensorora camshaftsensor.Dudngoperationwithonly
the crankshaft sensorlestinjections at (gasexchange) TDCand ignitionTDC are madein the starl-up
process,becausethe EDCfirsthasto seekthe correclignitionTDCwithouta camshaftsensor.Whenlhe
controlunilrecognizes a speedreaction(ignition), il hastoundthe correctTDCandthe enginestartsand
runsas il bothsensorswereworking.
Thespeedincremenlsensorconsistsof a permanenlmagnetanda coilwitha largenumberof windings.
The magnetic lield"touches" the rotatingpartof the machineto be recorded,herethe increment wheel,
whichis mountedon the crankshafl.
Whena holemovespastthe sensor,lhe flowof currentis amplified, or elseweakenedin the gapsbetween
them.Thisproducesan inducedvoltagein the sensorcoil,whichis analyzedby the controlelectronics. In a
sinussignalfromthe sensor,the positivehalf-wave mustbe first.Thesensordistancelromthe increhent
wheelis aoorox.1 mm.

Tableshowing pin assignment

Yellow(grey/green)
Black(grey^vhite)

Pin aaaignmenl Diagram

l* 3
Lls
2

T 18 3.04- '1
FUNCTIONAL
DESCRIPTION

Camshaftspeedsensor (apeedsegmentsensor)(8489)

Thecamshaftcontrolsthe engine'sinlelandoutletvalves.lt rotatesat halfthe speedof the crankshaft. lts

positiondetermines whethera pistonis in the compression or exhauststrokewhilstit asmovingtowardstop
deadcentre.This information cannotbe obtainedlromthe positionof the crankshaft duringstan-up.By
conlrast,the intormation generatedby the speedincrehentsensoral the crankshaft duringrunningis
sufficienlto enablethe positionol the engineto be determined. This meansthal il the speedsensorfailsat
the camshattwhilethe engineis running,the controlunitis stillawareof the engine'sposition.
Thepickupwheelis designedas a segmented wheeland is drivenby the camshaft. Thereforethisspeed
sensoris termedthe speedsegmentsensor.
Thesegmenlwheelis alsotermeda phasewheel.ll hasa phasema* (e.9.six markson 6-cylinder
engines,lour markson 4-cylinderengines)and a sync-mark tor eachcylinder.The phasemarkis a tooth
on the phasewheel.The phasemarksare positioned at regularinlervalson the phasewheel.The sync-
markis a supplementary markon the phasewheel,whichliesclosebehindoneof the phasemarks_lt
servesto determine the angularpositionof the enginewithin720"KW.
Theenginecanalsostanwitheithera camshaflsensoror a crankshaft sensor.Duringoperation withonly
the crankshaft sensortest injectionsal (gasexchange) TDCand ignitionTDCare madein the start-up
process,becausethe EDCfirsthasto seekthecorrectignitionTDCwithouta camshaflsensor.Whenthe
controlunitrecognizes a speedreaction(ignition),it hasfoundthe correctTDCandthe enginestarlsand
runsas if bolhsensorswereworking.
Dudngoperationwithjustthe camshaftsensor,angleconections are storedin the controlunitso lhal the
injectionpoinlcan be correctlydetermined evenwithoutexactcalculation of thecamangleusingthe
inctementsensor.
In lermsof conslruction andfunclions,the speedsegmentsensormalchesthe speedincremenlsensorlor
determining crankshatlspeed.

Note:On V 10 enginesthe sensoris mountedin the housingof the high-pressure

pumpCP2.

Tableshowing pin assignment

Pin assignment Oiagram

!'s fi
3.O4- 2 T 18
 FUNCTIONAL
DESCRIPTION

Charge-airsensor(8125)

Thecharge-air sensoris usedto measurelhe absolutecharge-air pressure.

The piezo-resislive sensorelementand electronics lor signalamplification
andtemperalure compensation
are integrated on a siliconchip.The activesurfaceol lhe chipis exposedto a referencevacuum.The
suctionpipepressureis ledto the rearof the diaphlagmvia a pressurized connectoron lhe reverseof the
diaphragm, the diaphragm beingresistant to the mediumto be measured.
Thecharge-air sensoris mountedon the suctionpipe.
ll thereis a defectclassification
lor the charge-airsensor(SPN102),a substitute valveis sent,i.e.an intact
sensoris simulated. Operation is thereforenot limited.

S€naor charac{eristic

Voltagein V 5.00

4.00

3.00

2.OO

1.00

0.00
Pressure
in bar -1 -0,5 0

Tableahowingpin assignment

Supplyvoltage5 V

Pin assionmenl

T 18 3.05- '1
 FUNCTIONAL
DESCRIPTION

Oil pressuresensor(8104)

"r'/3

Theoil pressuresensoris the€ to protectthe engine.It monitorsthe oil pressure.

The pressuremeasuring
rangeextendsfrom0 bar (0.5V to 6 bar (4.5V).

Sensorcharacteiislic

Voltage 5,00

4,00
,,.1
7
3,00 I ,

2,O0 *

1,00
'),/
I t 7

0,00
Pressurein bar -1 0 'f 2 3 4 5 6 7 8 I 10 11

Nominalvalue l\raximumvalue Minimumvalue

Tableshowing pin aasignment

Supplyvoltage5 V

Outputsignal

Pin assignment

3.05- 2 T18
 FUNCTIONALDESCRIPTION

Fuelpressuresensor(8377)

"r'/a

Thefuelpressuresensormonitorsthe fuelpressurein the pumpinlet(onthe low-pressure

side).
Thepressuremeasuring rangeextendsfrom0 bar (0.5V) to 15 bar (4.5V).
Thesensoris not currentlyfitted
on se es D08engines.

Sensorcharacteristic

Voltage 5,00

4,00 4
vv
3,00

2,00

1,00
2
x
t
0,00
Pressurein bar -1 012 34 567 I 10 ,111213 14 15 16 17 18

Nominalvalue lvlaximumvalue Minimumvalue

Tableshowing pin assignment

Supplyvoitage5 V

Outputsignal

Pin assignment

T 18 3.05- 3
FUNCTIONAL
DESCRIPTION

Cooleniiemperaluresensor(8124)

Thecoolantlempe€turesensoris a NTCthermistor.lt is locatedin the coolingcircuitand providesthe

controlunitwithinfornationaboutthe lemDerature
of lhe coolant.
Variouscharacteristic
mapsfor engineoperationare calledup by the controlunitas a functionof the
coolantlemperature.

Measuremenlvaluetablc

Tableshowing pin assignment

S€nsorearlh

Pin assignment

3.05- 4 T 18
 FUNCTIONAL
DESCRIPTION

Charge-airtemperalu.esensor(81231

The charge-air
temperalure sensoris a NTCthemistor.lt monitorsthe recirculation ol exhaustgas.
Exhaustgasrecirculation
is shutdownundercerlaintemperature condilions,in orderon the one handto
preventsulphurous
acidstromcondensing undercoldcharge-air lemperatu€sandon the othertoprotect
the enginetromexcessivelyhot intakeair in the eventof faulisin lhe exhaustgas reckculation.

Measurementvaluetablc

Tableshoi'vingpin assignment

Outputsignal

Pin aasignment Diagram

IT
ft Ll
L

T 18 3.06- 1
 FUNCTIONAL
DESCRIPTION

Exhausigas recirculationactuatorAGR(Y280)

Recirculation ol exhaustgas lowersthe proportion

of nitrogenoxide(NO) in exhaustgasby reducingthe
excessorygenand loweringpeaktemperatures and pressures.
TheAGRactuatoris triggeredby the EDCcontrolunit.The inlormation on the lemperature ol the charge
aid is providedby the charge-air
lemperaturesensor.
TheAGRis shutdownundercerlaintemperature conditions,in orderon lhe one handto prevent
sulphurous acidskom condensing undercoldcharge-air lemperaturesandon the otherto preventlhe
charge-air fromheatingexcessively throughthe returningexhauslgases-
A reedcontactis installedwithinthe AGRactuatorto delectwhetheran AGRvalveis openorclosed.

Theexhaustgasrecirculation actuator(AGRactuatoDessentially consislsof lhe followingcomponents.

- Compressed air cylinderlo activatetheexhaustgas recirculation
valve
- Solenoidvalvefor controlling
lhe cylinder
Reedcontactlor reporting the positionof the piston

Note: The reedcontactis closedin its restingposition(pistonret€cted).Pleasenotethe devialing

presentation
in the circuitdiagramsfromCh.6.00onwards!

TableshowinEpin assignmenl

Pin assignment

1 (4)

2 (3t
4 (1 )

3 (2)

3.06- 2 T 18
 DESCRIPTION
OF COI/|PONENT

Conirol unit EDC(A435,A570)

DescriDtion

The maintaskof the EDCcontrolunitis to control

fuel injectionand adjustil to the differentoperating
conditions, so controllingengineoutputand
emrss|ons,
Theconlrolunit(software/hardware) can be usedfor
a maximumof six cylinders. A secondconlrolunitis
thereloreneededlo operatea Vl0 engine.Thetwo
controlunitscommunicate via CANandfunctionin
whataslermedthe master/slave mode.

ll/lountingposition

D08enoine

Thecontrolunitis littedon the sideof the engine

block.

D28enoine

D28enoine{V101

Theconkolunitsare positioned
on a rackbehindthe
cab.
Thispholoshowsthe mountingpositionswhenthe
cab is tilted.

o Maslerconkolunit
@ Slaveconkolunit
 t

This pagg is intentionallyl€lt blank

4.O1- 2 T 18
 DESCRIPTION
OF COMPONENT

High-pressurepump CP3

Description

TheCP3high-pressurepumpis a radialplunger
Thispumpis usedon
pumpwilhthreecylinders.
seies D08,D20and D28engines(in-lineengines).

Mountingposilion

D08enoine

The high-pressure pumpis drivenby the engineand

is installedin the sameplaceas a conventional
injectionpump.

D28enoine

T 18 4.O2 |
DESCRIPTION
OF COMPONENT

High-pressurepump CPZ4

Description
pumpis an iniine plunger
The CP2l4high-pressure
pumpwithfourcylinders.
This pumpis usedon
seies D2840engines(V 10 engines).

Mountingposition

The high-pressure pumpis drivenbythe engineand

is installedin thesameplaceas a conventional
injectionpump.

4.O2- 2 T 18
 DESCRIPTION
OF COMPONENT

Proportioningunit ZME(MProp)(Y332,Y356)

Description

Theproportioning unitZl\4E(MProp)is an actuator

lhe luel pressurein the rail.
lor regulating

irounting position

Hioh-oressure
oumoCP3

Theproportioning unitis locatedon the suctionside

pumpand is boltedontothe
of the high-pressure
high-pressurepumphousing.

Hioh-pressure
oumoCP 2/4

The high-pressure pumpCPZ4 for the V 10engine

is fittedwithtwo proportioning
unitsbecausehere
two railsare controlled(onerailper bankol
rylinders).

T 18 4.O2- 3
DESCRIPTION
OF COi'PONENT

Injecror (Y341- Y350)

DescriDlion

Fuelis injectedintothe combustion chamberby lhe

iniector.ThecontrolunitEDC7 prescribes the
iniectionvolumeand lime andtdggersan extremely
lastsolenoidvalvein the injeclor.Thesolenoid
opensthe valveandthe fuelis iniectedintothe
combuslion chambgral the pressureprevailing
insidethe rail.

Itounting position

D08enoine

Theinjectorsare arrangedin the sameposilionon

lhe cylinderheadas conventional iniectors.

D28enoine

4.02- 4 T'!8
 DESCRIPTION
OF COMPONENT

Commonruil

Descdption

Thename'CommonRail"is derivedtromthe design

andtunctionol the high-pressure accumulator.
Thetuelis iniectedintothe individualcylindersvia
lhisaccumulator,whichtunctionsas a distributor lail
at the samelime,
Theluel is pemanentlysubjected to highpressure
andiustneedsto be removedat the rightmoment.

1'rountingposition

D08and D28in-lineenoine
pumpon the
The railis fittednearthe high-prcssure
sideof th6 engineblock.
Thispholoshowsa sampl€installation on a D08
engine.

D28V10enoine

SeriesD2840(lGcylinderV engines)havetwo rails

(on€per bankol cylinders).

T 18 4.03- 1
DESCRIPTION
OF COMPONENT

Pressurclimiting valve

Description

The pressurelimitingvalvelimitspressurein lhe rail.

ll pressureis too high,it uncoversa drainaperture.
The pressurelimitingvalvehastheiob o{ an
overpressure valve.

Mountingposilion

Thepressurelimitingvalveis mountedon the

commonrcul,
Thisphotoshowsa sampleinstallalionon a D08
engine.

4.O3- 2 T 18
 DESCRIPTION
OF COIIJPONENT

Rail pressulesensor(8487,B514)

Description

The railpressuresensormonitorsthe fuelpressure

in the rail.
On enginesoJseriesD2840(1o-cylinder V-engines)
thereare hvorails(oneper bankof cylinders).
There
aretherelotetwo railpressuresensors.

Mountingposition

The railpressuresensoris mountedon the rail,

Thispholoshowsa sampleinstallationon a D08
engine.

T 18 4.03- 3
DESCRIPTION
OF COMPONENT

Charge,airsensor(B125)

Description

The charge-air
sensoris usedto measurethe
pressure.
absolutecharge-air

Mouniingposition

D08enoine

The charge-air
sensoris mountedon lhe suction
pipe.

D28 inline enoine

D28V10enoine
 DESCRIPTION
OF COMPONENT

Oil pressuresensor(8104)

Description

Theoil pressuresensoris lhereto prolectthe

engine,it monitors
theoilpressure.

Mounlingposition

Theoil pressuresensoris mountedon the oilfilter.

Thisphotoshowsa sampleinstallation
on a D08
engrne.

D28V10enoine

T 18 4.O4
DESCRIPTION
OF COMPONENT

Fuel pressuresenaor(8377)

Description

Thetuelpressuresensormonitorsthefuelpressure
in the pumpinlet(on the low-pressure
side).
Thesensoris notfitledon seriesD08engines.

Mounlingposition

D28inline enoine

Thefuel pressuresensoris fittedon oneot lhe

KSCs.

D28V10enoine

Thefuelpressuresensoris fittedon oneof the

KSCS.
The KSCSare mountedon the rackbehindlhe
dive/s cab.

4.O4- 2 T 18
 DESCRIPTION
OF COi/|PONENT

Speed incrcment aenaor (8488)

DeacdDiion

Thespeedincrement sensorrecordsthe engine

crankshaftsoeedand oasseson the inlomationto
the controlunitin the tormof an inducedvoltaoe.

Mounlingposition

The speedincrementsensoris mounledon the

flywheelcasing.
This photoshowsa sampleinstallation
on a D08
engine.
DESCRIPTION
OF COMPONENT

Speedsegmentsensor (8489)

Description

The speedsegmentsensorrecordsthe engine

camshattspeedand passeson lhe inlormation to the
controlunitin thelormol an inducedvollage.

Mountingposilion

D08enoine

The speedsegmentsensoris mountedat the endof

the engineon thecamshaftdrive.

D28inline enoine

The speedsegmentsensoris locatedabovethe

pump.
high-pressure
This photoshowsa parliallydismantled
enginewith
pumpremoved.
the high-pressure

D28V10enoine

Thespeedsegmentsensoris mounledin the

pump.
housingof the high-pressure
 DESCRIPTION
OF COMPONENT

Coolanttemperatu.esensor(8124)

Description

Thecoolantlemperature sensoris a NTCthermistor.

It providesthe controlunitwilh inlormation
on the
temperature of the coolant,
Various,characteristic mapsfor engineoperationare
calledup bythe controlunilas a functionof the
coolanltemperature.

Mountingposition

D08enoine

Thecoolanttemperature sensoris locatedin lhe

coolantcircuilon the D08withoutexhaustgas
(EGR).
recirculation
Thisphotoshowsa sampleinstallation on a D08
engine.Thetemperature sensoris bolledlo the AGR
modulewhichalsodist.ibutes lhe water.

D28in-lineenoine

sensoris locatedin the

Thecoolanttemperature
coolanlcircuit.

D28V10enoine
OESCRIPTION
OF COMPONENT

Charge.airlemperaturesensor(8123)

Description

Thecharge-air temperaturesensoris a NTC

thermistor.lt monators
the recirculation
ol exhaust
gas.

Mountingposition

D08enoine

Thecharge-airtemperature
sensoris mountedon
thesuctionpipe.

D28in-line
enoine

028 V 10enoine
 DESCRIPTION
OF COMPONENT

st gas rcciiculationactuarorAGR (Y280)

ption

rlationof exhaustgas lowerslhe proporlion

of
n oxide(NOJin exhaustgas by reducingthe
oxygenand loweringpeaklemperatures and
res.

ing position

lotoshowsa sampleinstallation
on a D08

T 18 4.O7 |
 CIRCUITDIAGRAMS

Conienb list

Circuitdiagrams Circuit Chapter/page

diagramno.

Instructionstor using circuit diagrems 6.01

Ouickreferencesummadea
summaryEDC7
Quick-reference 6.02- 3
summary- EDC7 master/slave
Ouick-reference 6.02- 5

Circuitdiagrams- commonrail
TG truckwithengineD0836LF (fieldtdals) 81.99192.2692 6.03- 1
TG truckwithengineD0836LF 81.99192.1557 6.04- 1
(whhoutexternalEGR)
TG truckwithengineD0836LF 81.99192.2923 6.05- 1
(withext€malEGR)
TG lruckwithengineD2876LF 81.99192.2834 6.06- 1
TG truckengineD2840LF (master/slave) 82.99192.47
42 6.07- 1
NUNUbuswithengineD0836LUH 88.99289.5564 6.08- 1
NL buswithengineD0836LOH(cradle) 88.99289.6087 6.09- 1

T 18 6.00- 1
 CIRCUITDIAGRAMS

Instructionsfor using circuit diagrams

|(7 @ /-1
vr 006- t

rl+i

x46/5
@
@lrrm
Y
*J
I.t

x238/R-7

50520

'I Component designation(inthiscase:DiodeV'100on the centralelectrics,posilion53)

2 Mountingpositionon the frontendof the centralelectics(inthiscaserStampedpositionnumber53)
3 Connector on the backol the cenlralelectfics(inthiscase:Plug78,terminal8)
4 Cablenumber;prinledon the cableat shortinteNals(delailsot cross-section onlyil greaterthan1')
5 Sheet number (not page numbe4 and current pathnumber
of whichsheetand in whichcurrentpaththe cableis routed
ldentification
(inthiscase:Roulingof cable31002on sheet2 in currentpath4)
6 Connector(inthiscase:Single-pole connector X'104in centralelectricarea)
7 positionot componenl(inthiscase:21-poleconnectorX238pin R
ltJlounting
- Cabto enginecablehamess- in cenlresection)
8 Currentpathnumber(pleasenote: Eachsheetis seially numberedagainfrom 1 to 55)

lmportantnote legardingthe use ol circuit board Keys:A lhree-digitnumberin bracketsis placedatler

someitemnumbe6.This numberis a codedpartnumbero{thiscomponent. Thesepartnumbersaregiven
in Eouioment
ListT60.

T 18 6.01- 1
CIRCUITDIAGRAMS

Mountingposilionslor LHDtrucks

6)
{

6.01- 2 T18
 CIRCUITDIAGRAMS

Designation Mountingposition

@ Rear
@ Engine
@ Gealbox
@ Fronlend
@ Bumper
@ Entrance,RH
@ Entrance,
LH
r€9 Centralelectrics(ZE)area
@ lgnitioncontrolunit
@ Rearwallof cab
(a panel
lnstrumenl
@ Middlesection
@ Steedngcolumnl,vheel
@ Footpedals
G' Frontpanel,insideleft
@ Frontpanel,insiderighl
@ Drive/scab
@ Passeng€rseat
@ Switchconsole
€, Batterybox
@ B-pillar,driverside
@ A-pillar,driverside
@ B-plllar,passenger side
@ A-pillar,passenger side
(9 Ceiling/roof
@ Frontaxle
(9 Bearaxle
@ Frontsectiono{frame
@ Rearseclionol frame
@ Door,LH
@ Door,BH

T 18 6.01- 3
CIRCUTT
DIAGRAMS

l/lounling positionsfor RHDirucks

6.01- 4 T 18
 CIRCUITDIAGRAI'S

Designation Mountingposition

@ Rear
@ Engine
@ Gearbox
@ Frontend
@ Bumper
@ Entrance,
RH
@ Entrance,
LH
@ Centralelectrics(ZE)area
@ lgnitioncontrolunit
@ Rearwallofcab
o Instrumentpanel
rt Middlesection
@ Steeringcolumn^rheel
t9 Foot pedals
Frontpanel,insideleft
Frontpanel,insiderighl
Drive/scab
Passengerseat
Switchconsole
Batterybox
B-pillar,driverside
A-pillar,driverside
B-pillar,passengerside
A-pillar,passengerside
Ceiling/rool
Frontaxle
Rearaxle
Frontsectionol frame
Bearseclionof lrame
Door,LH
Door,RH

T 18 6.01- 5
CIRCUITOIAGRAMS

Mounlingpositionstor buses

lllc| J-
tt t---J

E
t-
tNt 1 le l
tttl
:l lo:'l tH :
tH I lE5|

Locationdesignalion lltountingposiiion

@ Bear

@ Engine,gearbox
Frontend

Mainswitchpanel

@ Devicelocker(batterybox)

@ Deviceboard1 (auxiliaryswitchpanel)

@ Deviceboard2 (transverse
duct)

€9 Deviceboard3 (centralcomputer)

@ Deviceboard4 (EDC)
\7 panel
lnstrument

@ Controlpanel

Batterybox

LH sideol vehicle
a) RHsideof vehicle

Centreof vehicle

Ceiling/root

Frontaxle

Rearaxle

6.0'1- 6 T18
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 HYDRAULIC
TESTPROCEDURE

General

The prcssureshould not be measureduniil all othel possibilitiesot detectingthe tault havebeen
exhaustedand the lault could still not be located.

This meansthatthe pressuremeasuring

pointsare to be regardedas a verylasttest resortduring
as parlo{ servicing.
koubleshooling

Measuringpoint I at the glowplugconnection is alsoa measuringpointbelorehigh-pressurepump

cP3.4.
The likelihood ofthe ingressof dirlat the cleanend is however,clearlylesshere.
This measuring pointcandetecta faultin the pressuremainlaining valvein the CP3.4(pressure at approx.
5-6barrelative).
However,it is lirst necessarytocheckthatthe hollowscrewis correctwitha 0.5 fim restrictorborelo the
llamestartoutputandthatthe correclBS seaiingringis fittedat thispoint.
Thisfaultalwaysresullsin faultsin the controlunitthatatfectthe railpressureregulation
and in the evenlof
a powerdemandcan leadto a collapsein the railpressureandto inadequate peformance.Whenthe
powerdemandis removed, the railpressurecan"recovefbul wouldagainreassertitselfon the nexlpower
oemano.

Measuringpoinl 2 on the returnsideof the injectorchecksonlythatthe pressuremaintaining valvehasa

relativepressureot approx.0.3 barandthatthereis no blockagein this relumbranch.lf lhereare leakage
returnpressures of morethan4 bar absolute,the enginereaclsby increasing the amountandthuswilha
powerincrease,
A laull at thispointdoesnol resultin a faultbeingregistered
in the controlunit.
Two othermethodsof checkingthe powerunitand injectionsystemare the compression test(referredto in
the followinga TCOlvl(referred
lo as TestCoMpression)
andthe run-uplest {referredto in thefollowingas
TRUP(calledTesi RunUP)
Thesetestscan be slartedusingl\4AN-cats.

lmponad: Bothtestsmustalwaysbe cardedout in orderlo obtaina conclusive

resultfromthe test.
See nolesat the endot thischapter.

T 18 7.O1- 1
HYDRAULIC
TESTPROCEDURE

Fueldiagram,general

Key

O Overllowvalve(Ap= 10.4- 13bar)

@ Coolingplate(optional)
@ "Permanent ventilation"
reslrictorbore,0.7 rnmdia. (max.10 l/h at Ap = 5 bar)
@ Filterwithwaterseparation (burstingpressure> 15 bar)
@ Glowplugconnection
@ Restrictor bore,0.5mm dia.
@ Proportioning unitZtulE(proporlional valve,fuel lllProp)
@ Iniectorreturn(leakageoil line)
@ Commonrailwith iniectorconnection
@ Pressurelimitingvalve,two-stage
@ Pressuremainlaining valve,injectorreturn(Ap=0.3bar)measuringpoint 2
@ Zerodeliveryrestrictor
@ Pressuremaintaining valve(dp = 5.5 bar)
@ Pressuremaintaining valve(Ap= 1.3bar)measudngpoint 1
@ Bypassvalve(Ap= 0.15bar)
@ Inletfilter(<=300 pm)
@ Handpump
@ High-pressure line
@ Low-pressure line

7.O1- 2 T 18
 HYDRAULIC
TESTPROCEDURE

Fueldiagram,D 2876LF 12/13engine

Key
O Quantity-controlledhigh-pressurepumpCP3.4
@ Cornmonrail
@ Pressurelimitingvalve
@ Railpressuresensor
@ Injectors
@ Injectorreturn{leakageoil line)
@ Collectorretumwithpressuremaintaining
valve,approx.0.3 bar
@ FuelSarviceCentre{FSC)
(l) MeasurinEpoint 1: Glowplugconnection to retumsealed
(ll) Measuringpoint 2: Iniectorreturnal cylinder2

T 18 7.01- 3
HYDRAULIC
TESTPROCEDURE

Fueldiagram,D 2066engine

Key
high-pressurepumpCP3.4
O Quantity-controlled
@ Commonrail
@ Pressurelimilingvalve
@ Railpressuresensor
@ Injectors
@ Injectorretum(leakageoilline)
@ Overflow valve,'1.2...1.3bar
@ Centre(FSC)
FuelService

7.O1- 4 T 18
 HYDRAULIC
TESTPROCEDURE

Fueldiagram,D 0836engine

Key
O Ouantity-controlledhigh-pressurepumpCP3.4
@ Commonrail
@ Pressurelimitingvalve
@ Railpressure sensor
@ Injectors
@ Injectorreturn(leakageoil line)
O FuelServiceCenke(FSC)

T l8 7.0t - 5
 HYDRAULIC
TESTPROCEDURE

Fuel pressure test

Whenmust the luel pressurcafter the filter be checked?

Egqllsytrp!9![ Rail pressuretoo low or absent.

checkbelorelilter(l\,lAN-cats
Pressure Moniloring)
Targetvalue:6-9bar

MeasuredDressure 1 - 2 bar:Fault!!
Thecausein thiscasecan be an incorrecthollowscrewin the supplyto ihe glowplugconneclion(without
additional0.5mmbore).LeakingBS sealingringsor incorrectsealingrings(copperdngs).
Thisleakcausesa largeamountof fuelto flowdirecllyto retum.
- Thiscausesa highluelllowthroughthe liller.Thismaycausea highpressuredropso thatlhe pressure
at the filterinputappearsnomal.

Pressurecheckatler filter.
Measudngpoint 1: Glowplugconnection outputlo returnsealed
To do this,the pressuremaintainingvalve,approx.1.3bar (refertopage7.01- 2, item14),mustbe
unscrewed and replacedby the pressuremeasuring lineandfuel pressuresensor.
1- I\reasured pressure0 - 1 bar:Faultll
In thiscase,the pressuremaintaining valve(5 - 6 bar)in the high-pressure
pumpis permanently open
(delective), because:
- Whenthe pressuremaintaining valveis openthe completefuelamountflowsdirectlyto return(inlet
filte0
- Thiscalses a highfueltlowthroughthe lilter.Thismaycausea highpressu.edropso lhal lhe pressure
at the lilterinputappearsnormal.

2. Pressurech€ckafter filler.
Measuredpressure5 - 6 bar:O.K.

Finefilterscreenin inlelconnection pumpblockod?

to high-pressure
lf not,the high-pressurepumpis defective(low-pressure/high-pressure pump
valvesof the individual
elements).

In the eventof lault 1, the pressurebeforethefiltercanalsoalreadybe too low.

In thiscasethe measurement providedby the fuelpressuresensor(on FSC)in the MAN-catsMonitoring
is
sufticienland it is not necessaryto takea measurement downstream o, the filter.

Messuringpoint 2 on lhe retumsideof the injectorchecksonlythatthe pressuremaintaining valvehasa

relativepressureof appoximately0.3 barandlhal thereis no blockagein thisreturnbranch.lf thereare
highleakagereturnpressures of morethan4 barabsolute,the enginereactsby increasingthe amountand
thuswilh a powerincrease.
A taultat thispointdoesnot resultin a faultbeingregislered
in the conkolunil.

How is lhe measurementcarriedout?

Themeasuring points,lestvaluesand pressuremeasuinglinesdescribedhereapplyinitiallyonlyforthe

D28seriesof inline engines.Thevaluesand methodsfor the D08,D20and D28V engineserieshavenot
yet beenspecitiedbutwill be addedas soonas possible.

Formeasuremenls on the D28inline engine,twopressuremeasuringlinesareavailablethatare provided

withthe sameluel sensorsas are screwedin to the FSC.
Thisenablesthe resullof lhe measurement to be displayedin the l\4AN-cals
l\4onitoring
by unplugging
the
electrical
connectionon theluel pressuresensorFSC(8377)and pluggingit intolhe padicularsensorsin
the measuringlines.lt alsomeansthat no additionalgaugesor adaptorsare necessary.

Al timeof printing,
the srppliertor lhe pressuremeasu ng lineshasstillnotbeendecidedbutwill be
noliliedthroughthe "Speciallools/Testequipment'nolices.

7 . 01- 6 T1A
 HYDRAULICTEST
PROCEDURE

Mountingpositions

D28enoine

Measuringpoint'1:Glowplugconnection
outputto
relurnsealed

point2: Injectorretumend (leakoil line)

l\reasuring
cylinder2

Generalview
point1
O l\/easuring
@ l\4easuingpoint2

Pressure
measuring
lines

O In,ector
retum
@ Glowplugconnection
output

T 18 7.O1- 7
HYDRAULIC
TESTPROCEOURE

Compiessiontest Iesl ggUpression OCOM)

Thecompression test is startedfromIIAN-cals,i.e.withthe engineshutdownlhe slartermustbe operated

lor a few secondsafterthestadof thetestby usingthe ignitionkey.
lnjectionis shutotf by the EDCduringthe tests,so lhatthe enginecannotslart.

As a resuh,the operatorobtainslwo rotaryspeedsfor all cylinders,

as follows.
Lowerspeed: This is the lowerof the twospeedsthatwasmeasuredby lhe EDCwiththe compression
at
TDC.

Upperspeed: This is the higherof thetwo speedsthatwasmeasuredby the EDClar beforeTDCand

wastherelorebarelyinlluencedby the compression
andwasthushigherthanthe 1ower
speed".

Onlythe lowerspeedcan be usedto assesslhe compression.

l{ a cylinderis ma*edly higherat the lowerspeedthanat the other,a compression
probtemcan be
assumed,
Thetollowingexampleshowsthe influence of changesin compression overthemeasuredspeeds.

Theadiacentillustration
showsthe resufts 21o
of the TCOMon a serviceable
engine.
230

220

210

E 2oo
X t.o
180

170

160

t50
36
Cy lin d e rNo . r[ -]
2txt
A compression reductionof approx.5 bar in cylindeB 6 rnd 2: 30 ba., lll otherc appmx. 35 b.r
wasgeneraledby the valvetiminggearon 2g
cylinder6 andcylinder2. Thiswasdetected
by the compressiontest by an increasein ZN
the "lowerspeed".
21{J

2tn

't90

1E{l

17l,

160 g spcsd,approl 66"bcfoErDc.

3*l;TS!""* "'*n
15{)

7.01- 8 T 18
 HYDRAULICTEST
PROCEDURE

Iest EunUPfiRUP)
The run-uptesl is startedlrom lllAN-cals.
In the run-uptesta sequenceof sevenrun-upsarecarriedoul in succession (onewithoutthe iniector
switchedoff,six withone injector(1,2, 3, 5, 6) switchedotl in eachcase.The resultshowsthe speed
accelerations lor the sevenrun-ups.

The{ollowingis an exampleot a testresultwherecylinder3 hasan iregularity.

0 (nocylinderswitchedoff)

The speedacceleraiion levelitsetfprovidesno indication,

butonlyprovidesa compa son relativeto lhe
otherswitchedoff cylindersandforlhe run-upwithouta cylinderswitchedotf indicateslaultsin the
injection.

TheTRUPcan indicateperlormance conversion

weaknesses in a cylinderbut providesno indication as to
whelherthe problemin the cylinderis causedby the mechanicalsideor injectionside(injector,blade
connection etc.).
TheTCOMcan indicatewhetherit is on the mechanical side.A faultin the injectionequipmenttorthis
cylindercanbe assumedonlyil the compression testshowsthatlhe engineis mechanically OK andthe
TRUPhasdetecteda cylindertobe defective.
lf the enginehasa compression problemon onecylinderonlyon the mechanical side,the resultsof bolh
testsmuslindicalea defectivecylinder.

T 18 7.01- 9
 DIAGNOSIS

Faultmemory

The EDCsystemconslantly A SignalRangeCheckis carriedout lor thispurpose.

carriesout self-checks.
Duringthischeck,all lhe signalswithina certaintimegrid(determined
by the soltware)are scannedfor
presenceand plausibility.
Thecontrolunititselfis alsocontinuouslycheckedduringthe entireruntimeof the program.Thefirstcheck
alwayslakesplacewhenswitchingon the ignition(checksum test).
lheseare sloredin lhe laultmemoryand a messageappearson lhe
ll faultsoccurduringoperalion,
driver'sdisplay.

Duringtault siorage,the tollowing lakes place

. ldentilicationol the errorcode(SPN)
. ldentilicationol the typeof fault(FMl)
. Allocationol taultpriodty
. Recording ot fault{requency
. Recording ol background (lwoenvironmental
conditions conditions)
at thelime of faultclassification

Sporadicfaultsare recordedby a lsell-healing

counte/ whentheylirsl disappear.Thismeansthata
certainoccurrencecountis setwhichreducesby oneat everystart.lf the laultdoesnotoccuragainand
lhe counlerreacheszero,lhe corresponding faultblockwillbe deletedand the countwillbe incremented
on anyolherfaultblockspresenl.

Dependingon the evaluationol a fault that has occurred,the following actionsare automaiically
triggered:
. Switching to a suitablesubstitutefunclionfor continued,
bul limiteddiving operation,in orderto enable
the vehicleto be drivento the neareslMANServicesite.
. lmmediate shutdownof lhe engineif saletydictatesthis.

As soonas a lault occurs,a faultblockis set up in the faultmemory,or a laultthatalreadyexistsis

updated.ln addition,thisfaultblockis sentoverthe CAN-busto lhe vehiclemanagement computer(FFR).
The messagecontainsthefollowinginformation:

. Faultidentification SPN(SuspectParameter Number)

. Environmental condition1 SPN1withassociated measured value
. Environmental condition
2 SPN2withassociated measured value
. Typeol fauft(cause) F[rl (FailureNlodeldentification)
. Faultp ority PRIO(Priorily)

Eachsinglefar.rltmustbe allotteda prioritybecausethe faultsdiagnosed

andstoredby the controlunitcan
involvedifferentrisks.

Cenkalwarning
lampflashesred while Vehicle'sroadworthiness
and/orsafetyare al dsk.
drivinoand when at a standstill Stopimmediatel
Centralwaminglampstays illuminated Go to workshopimmediately.
r€d while drivinoand when at a standstill
Centralwarninglampsiays illuminaied Actionsare necessary beforedriving.
llow whenal a standstill Drivingsafetyis not at risk.
Faultwhichdoesnotatlectdivi
Centralwarninglampstays illuminated lmmediaterepahis not necessary. Havethe faull
yellow whiledrivingandwhenat a reclifiedduringnextvisitto wo shop.
standstill

Onlyonefaultis displayed at a time.

. A faultwithhighprioritytakesprioritylor displaypurposes.
. lf thefaultis of lowerpriority,the ddveris not shownanymessageandthe currentinlormalion
displayed
remains.

T 18 8.01- 1
DIAGNOSIS

MAN-catstault memory

AllJaultsand the memorystalus,faullstatus,faulthequency,priorityandthe twoenvironmental

conditions
(SPNl and SPN2)are displayedby l\4AN-cats whenthe laultmemoryis read.

F.hl.iib.Eicht EDC7 AosCX

a*
KEf rerondruckr.n$r lRridru.kl a,,
AGRbl.ib.nd. R.g.lrb*.lchung as,
Kiihlm.int mp.EtuE.Nor t&
as
w.gf.hEp.n:x.in.M.ng. og
959 iMF:TDATE: s.kund.n unr!.nh oa
os
ow
IMBDAIE: Trg. ungu.|tig o*

StatusdisplayedFMI(FailureModeldentification)

0 Faultnolspecified
1 Too high
2
) 3 lmplausible
4 No signalpresent
5 Short-circuit
to earth
6 Shorl-crrcuit
lo +UBat
7 Shorl-circuit
Signalfaulty
9 Deviceerror
4 10 lnlerruption

Memorystatus

No faull

lntermitlenl
fault
Faulthasbeenfoundstored

8.01- 2 T 18
 DIAGNOSIS

SPN list - EOC7

94 Fuelsupplypressure Monitoring whetherfuelsupply Problemsin fuelinlake,engine

pressureis in normalrange can shutdown
(blockedfihers,excessive
underpressurein lhe intake
pipe,faultypresupplypump)
10 0 Oil pressure lllonitoring
for looseconlactor None
plausibility
of changespeed
fromP611
102 pressure
Charge-air l,loniloringfor loosecontactor None
plausibility
ol changespeed
kom PL
'|05 Charge-air
temperature Monitoring
lor loosecontactor None
plausibility
of changespeed
fromTLL
108 ptessure
Atmospheric Monitoingfor loosecontactor None
plausibility
of changespeed

11 0 CoolantwatertemperatureNroniloringfor looseconlactor Torquereduction

plausibility
ol changespeed

168 voltage
Battery lvlonitoring
of voltagelimils None
174 Fuellemperature Sensoris currentlynot{itted Sensoris currentlynol fitted
190 Enginespeed Defectin camshattor None
crankshaft speedpath
518 FFR2:Bit error,torque FFR2requestsinvalidlorque No torquerestictionthroughFFR
limitation value
609 CAN module l Bus-oltstateof CANmodule1 Stard-aloneoperation(= idling)
Bank1 solenoidvalve1 Testingthe solenoidvalvelinal No injectionon cylinder1
cylinder1 stagefor shoningto eadhor
+Ubat,lossof powerand
plausibility
652 Bank2 solenoidvalve1 Teslingthe solenoidvalvefinal No iniectionon rylinder5
cylinder5 stagetor shortingto earthor
+Ubat,lossol powerand
plausibility
653 Bank1 solenoidvalve2 Testingthe solenoidvalvelinal No injectionon cylinder3
cylinder3 stageJorshoningto earthor
+Ubat,lossof powerand
plausibility
654 Bank2 solenoidvalve2 Testingthe solenoidvalvefinal No injeclionon rylindero
cylinder6 stage{or shortingto earthor
+Ubat,lossol powerand
plausibility

T 18 8 . 1 0- 1
DIAGNOSIS

655 Bank 1 solenoidvalve 3 Testingthe solenoidvalve linal No injectionon cylinder2

cylinder2 slage lor shortingto earth or
+lJbat,loss of power and
plausibility
Bank2 solenoidvalve3 Testingthe solenoidvalvelinal No in,eclionon cylinder4
cylinder
4 stagelor shortingto eadhor
+lJbat,lossof powerand
plausibility
959 Tll\4E/DATE:
Seconds FFRsendsinvalidnumeical Timein secondsnol available
invalid value
960 TIME/DATE:Minutes FFRsendsinvalidnuherical Timein minutesnotavailable
invalid value
961 TIME/DATE: FFRsendsinvalidnumeical
Hoursinvalid Timein hoursnot available
value
962 TIME/DATE: Daysinvalid FFRsendsinvalidnumerical Timein daysnotavailable
value
963 TIME/DATE: Nlonths FFRsendsinvalidnumerical Timein monthsnotavailable
invalid value
964 TIME/DATE: Yearsinvalid FFRsendsinvalidnumerical Timein yearsnotavailable
value
't079 Supply lor railpressure Testingfor shortto earthor DBVopens,enginecontinues
sensor +Ubatand powerloss runningat 800bar railpressure.
Torquereductionon D08and D28
engines.
'1080 Supplyfor fuel low Testingfor shortto earthor Possiblythe sensorprovidesfalse
pressure,charge-airand +lJbatand powerloss valuesor none
oll pressuresensor
2039 FFRl:Timeout No receptionof FFR1message Stand-alone operation(= idling)
3004 AGR:Lastingcontol Targetand actualpositionsof BPM reduction/speedreduction to
deviation valveare notthe same 2200lpm on D08engines
3005 Timeoutmessagepoint13 TimeoutwhensendingDM4 Readoutol faultmemorynot
message(faultmemory)to FFB possible
3007 DI\r4requestinvalid InvalidrequeslfromFFRto Readoulof faullmemorynot
senda Dl\44message(fault possible
memory)
3009 Engineoverspeed Testingfor overstepping
the lnjectionis blockeduntiiengine
lirnilRPM speedis reducedthreshold
D08:3100lpm
D28:2800rpm
3 014 Mainrelay Faultif the controlunitis still None
(controlunit,internal) liveaftera certainperiodfrom The batteryis slowlydischarged
switchingotfterminal15 wilhstickingmainrelay
3016 FFR1:Biterror,o-quantity FFRI sendsinvalidnumerical Enoinebrakedoesnotlunction
becauseof enginebrake value
3017 FFBl:Biterror, FFBl sendsinvalidnumerical Enginegoesto idling
targettorque value
3018 FFRl:Bitenor,finalspeedFFR1 sends invalidnume cal Conlrolparameter set "0"
limitation
{EDR) parametervalue activaled
set

8 . 10 - 2 T18
 DIAGNOSIS

3019 FFR1:EDRmin.target FFRl doesnot requesta final Enginegoesto smallest

valuenot reached speed(EDR) permissible
EDR
3020 FFRl:Biterror, FFR1 sends invalidnumerical EDR reductionis cancelled
EDRtargetvalue value
3022 FFRl:ZDFtargetvalue FFRl sendsinvalidnumerical ZDB targelvalueis setto 0 rpm
) enginedoesnot go intoZDR
operation
3023 FFRI:Biterror,request FFR1sendsinvalidnumeical Requestmeosis cancelled
"momentary
engine value
overspeed"(rheos)
3024 FFRl: Biteror, rampsoff FFR1sendsinvalidnumerical IntemalEDCrampsarere-
request value actvated
3025 FFR1:Reservedbitsand FFR1doesnotsend'1"in the None
bytes(testingcontrolbits, reserveomessagepornts
target= 1)
3028 FFR2:Torquetargetvalue FFR2requeststoo smallan Engine goes to idling
iniectionvolume
3029 FFR2:Biteror, idling FFR2sendsinvalidnumerical Enginegoesto EDC-intemal idling
largetvalue value speeo
3030 FFB2:Bit error,idling FFR2 sends invalidnumerical LLRparameter set '0" is activated
controlparameter (LLR) value
3031 FFR2:LLRtargelvalue FFR2requestsidlingspeed l\4aximumpossibleidlingspeed
too high higherthan800 rpm (800rpm)is operated
FFM: Bitefior,requestlor FFB2sendsinvalidnumerical EDCgoeslo stand-alone
stand-alone operation(idling)
3033 FFR2:Bil error,requestlor FFR2sendsinvalidnumedcal No triggeringol starter
triggering
staner
3034 FFR2:Bil error,requestlor FFR2sendsinvalidnumerical Engineis notshutdownvia FFR
enginestop value
3035 FFR2:Reserued bilsand FFR2doesnotsend"1" in the None
bytes(testingcontrolbit6, reserueomessagepornls
larget= 1)
3036 FFR2:Timeout No receplionol FFR2message FFR2defaultsare notexeculed
3037 FFR3:Bit error,pedal FFR3 sends invalidnumerical Engineoperalionwithoul
sensorposilion restriction;
reporledaccelerator
posation0%
3038 FFB3:Standstill FFR3sendsinvalidnumerical Despitemotionless vehicle
intormation value sotwarereports"movingvehicle"
) conlrolunilprogramming only
possiblewithCANinterrupted
3039 FFRS:Reserued bitsand FFR3doesnotsend'f inthe None
bytes(testingcontrolbits, reserveomessageporms
target= 1)
3040 FFR3:Timeout No receptionof FFB3message Startnol possible(immobilizeD

T 18 8 . 1 0- 3
DIAGNOSIS

3045 Slaneractuationdeleciive Voltagedropin batteryat start Eror in starterpalh.Enginecan

too low possiblynot be started(starter
motorfaulty,IMRrelaylaulty,
cablesfaulty)
pressure
3046 Atmospheric Monitoring
for voltagelimitsand Whencharge-airpressuresensor
sensor AD blocking faulty:Detaultvalue1000mbar,
otheMisethe sameas charge-air
Pressure duringidling
3052 Timeoulmessagepoint5 EDCl messagetransmission EDC1messageinformation in
error(possiblybecauseCAN FFB notavailable, i.e.EDCstatus,
bus loadtoo high) EDCoperatingmode,EDCmode,
leminal 15,AGR,startrequest
3053 Timeoutmessagepoint6 EDC2messagetransrnission EDC2messageinformation in
error(possiblybecauseCAN FFRnotavailable, i.e.injection
bus loadtoo high) quantilies,ZDRspeed
3054 Timeoutmessagepoint7 SendingerrorEDC3message EDC3messageinformation in
(possiblebecauseCANbus FFRnotavailable, i.e.LLR,EDR,
loadtoo high) ZDRparameter sets,engine
toques
3063 Afterrun nol ended The lastlwo afterrunswerenot None

3064 Stand-alone
operation Faultyrequeslfroh stand-aloneStand-alone operation(= idling)
operalon
3076 lmnobilizer(WSP) FalselD fromFFR Starterengages,EDCdoesnot
releaseanyquantaty, enginedoes
notstart
3077 lmmobilizer (WSP) F AKC IU IIOM FFH Starterengages,EDCdoesnot
releaseanyquantity,enginedoes
notstart
308'1 Wastegatecontroller Charge-air pressure target RPMreduction/speed reductionto
shuldown valuecannotbe achieved 1800lpm andtorquereduction on
D08engines
3082 of oil pressure Sensorshowsat stateoil
Plausibility None
sensor Pressure> 500 mbarorwith
enginerunning thesameoil
Pressure at ditferentspeeds
3086 AGRactuatorposition,end l\,lonitoring of voltagelimits ActiveAGRis providedas a
position (supplyvoltageand sensor substitute
value
voltage)andAD blocking
3087 Oilpressure sensor lronitoringof voltagelimits Outpulof substitute
value:1 bar
(supplyvohageand sensor
voltage)andAD blocking
3088 Charge-air pressure I\,4onitoring
of voltagelimits Outpulof a simulatedcharge-air
sensor (supplyvoltageand sensor pressureas a substitulevalue
voltage)andAD blocking
3089 Charge-airtemperature Ivlonitoring of voltagelimits Outpulof substitule
value:40"C
sensor (sensorvoltage)and AD
blocking

8.10-4 T18
 DIAGNOSIS

3091 Coolantwatertemperaturel\4onitong of voltagelimits Outputol substitute value:

sensor (sensorvoltage)andAD D0 8 :1 1 0 ' C
blocking D28:100,4'C
Torquereduction10%
3092 TIME/DATE: Timeout lronitoringlor timeoutol daie Variables are kozenat valuesprior
information(daylmonlh/year, to timeout
etc.)
3093 TIME/DATE: Reservedbits TIME/DATEmessagedoesnot None
and bytes(teslingconlrol send"1" in lhe reserved
bits,target= 1) messagepornls
3094 Timeoutmessagepoint8 Errorsendingthe No None
Acknowledge message(is sent
as responseto a message
requestfromFFR,whichwas
treatedas invalidby the EDC)
3099 Railpressuresensor lronitoringof vohagelimits Outputof substitute valuer800bar
(supplyvoltageandsensor DBVopens,enginecontinues
voltage)andAD blocking runningat 800 bar railpressure.
Speedreduction to 2000rpmon
D08
Torquereductionon D08and D28
3100 Fuellowpressure sensor lvlonitoringof voltagelimits None
(supply pressure) (sensorvoltage)andAD
blocking
3671 Eror whenreadingfrom Checksum testol EEPROM None
the EEPBOM laultybecauseEEPROMis
laultyor storagewas
interrupted duringthe last
atterrun
3673 CANmodule2 Bus-otfstateof CANmodule2 Slavecontrolunil blocksinjection
volume,engineconlinuesto run
withonecylinderbank(haltpower)
3674 FFRl: Bankshutdown FFRsendsinvalidvalue No shutdownof cylinderbankon
byte,&it5-8 master/slave V-engines
3676 Faullyredundanl Testinglinalslageshutdownof None
shutdowndeviceafterrun injectoEin atterrun
Iest
3687 Pressure reduction valve Monitoring whetherpressure Engineshulsdown
does not open limitingvalveopens
3693 Boostervoltage Voltagetoo lowlor injector Problems withpre-injection, main
acluation injeclionand post-iniection
3694 Timeout message poinl4 Sendingeror EDCSmessage EDCsmessageinlomationin FFR
(possiblebecauseCANbus not sent,i.e.temperaiure,
loadtoo high) almospheric pressure
3732 Defect classificationfor Testequipment for overuoltage None
(overvoltage lesl nol in order
initialization
test)
3735 Iemperaturein EDC Monitoring ol vollagelimitsand Outputol substitute value:60'C
controiunil AD blocking

T 18 8. 1 0- 5
DIAGNOSIS

3736 Finalstageshutdown Errorin watchdog Engineshutsdown

by EDC communicalion or overvollage
lnitializationin I\ronitong masler/slave
with None,enginerunsnormally
master/slaveoperation ignitionON
Highsidefinalstage lvonito ng for voltagelimilsand Shutdownof finalstage(reversible)
wastegateconlrol powerloss Speedreduction 1o1800lpm on D08
lorquereduclionon D08
Drehmomentreduzierung bei D08
3746 Highsidefinalstage Monitoringfor voltagelimitsand Shutdowno, finalstage(reversible)
exhaustgas reduclion powerloss Speedreduction to 2200lpm on D08
torquereduction on D08
3744 Highsidefinalstage Monitoringfor voltagelimitsand Shutdownol finalstage(reversible)
Proportioningunithigh- powerloss DBVopens,enginecontinuesrunning
pressurepump at 800 bar railpressure.
Speedreduction to 2000rpmon D08
Torquereduction on D08and D28
3751 Highsidefinalstage Monitoringfor vollagelimitsand Shuldownol finalstage(reversible)
stanerrelay powerloss
3752 Camshaflspeedsensor No signalorfalsepulse Enginecontinues lo runwith
(seghentsensor) sequence, sensorwilhPolarity increment sensor,Longerstarting
timeneededuntilignitionTDC is
delerminedby controlunit
3753 Crankshafl speed Nosignalorfalsepulse Enginecontinues lo runwithsegment
sensor(rncrement sequence,sensorwilhpolarity sensor
senso0 teversed
3754 Watchdogerrorsystem Watchdoglestfailed Enginedoesnotstad
$an
SupplyvoltageAGR Testingfor shortto earthor Thesensordoesnotsupplyvaluesor
leedback +Ubatand powerloss suPpliesfalseones
3758 Sending errormessageMasler-slave communicalion Slavecontrolunitblocksinjeclion
point2 to partner {V-engine) disrupted. volumeuntilcommunication is in
controlunit Possiblybecausebusloadtoo orderagain.Enginecontinuesto run
great withmastercontrolunit,i.e.one
cylinderbank(halfpower)
3759 Sendingerrormessage lllaster-slave communication Slavecontrolunitblocksiniection
point3 to partner (V-engine) djsrupted. volumeuntilcommunication is in
controlunit Possiblybecausebusloadtoo orderagain.Enginecontinuesto run
great withmastercontrolunil,i.e.one
cylinderbank(hallpower)
3760 Sendingerrormessage lilaster-slave communication Slavecontrolunitblocksiniection
point3 to partner (V-engine) disrupted. volumeuntilcommunication is in
conlrolunit Possiblybecausebus loadtoo orderagain.Engineconlinueslo run
grear wilh mastercontrolunit,i.e.one
cylinderbank(hallpower)
3761 Sendingerrormessage Master-slave communication Slavecontrolunitblocksinjection
point5 to partner (V-engine) disrupted. volumeuntilcommunication is in
conlrolunit Possiblybecausebu6loadtoo orderagain.Engineconlinueslo run
great withmastercontrolunit,i.e.one
cylinderbank(halfpower)

8 . 10 - 6 T18
 DIAGNOSIS

3762 CAMD-ANA message l,lasler-slave

communication Slavecontrolunitblocksinjection
pointtimeout (V-engine) disrupted. volumeunlilcommunication is in order
Beceivingerror again.Enginecontinues to runwith
CANmaster/slave decoder mastercontrolunit,i.e.onecylinder
bank(halfpower)
3763 CAI\/D-ClroLmessage Master-slave
communication Slavecontrolunitblocksinjection
pointtimeout disrupted.
{V-engine) volumeuntilcomhunication is in order
Receiving
error again.Engineconlinuesto runwith
CANmasler/slavedecoder mastercontrolunil,i.e.one cylinder
bank(hallpower)
3764 CAI\4D-CONTROL MasteFslave communicalion Slavecontrolunitblocksinjection
messagepoinllimeout (V-engine) disrupled. volumeuntilcommunication is in order
Receiving error again.Enginecontinues to runwith
CANmaste/slavedecoder masterconkolunit.i.e.one cylinder
bank(halfpower)
CAi.ilD-FFRI timeoul l/laster-slavecommunication Engineconlinuesto runnormally,no
(V-engine) disrupted. reactrcn
Receiving error
CANmaster/slave decoder
3766 CAMD-FFR2 timeout lrasler-slave communication Enginecontinuesto run normally, no
(V-engine) disrupted. reaction
Beceivingerror
CANmaster/slave decoder
CA[4D-FFR3 timeout Master-slave communication Enginecontinuesto run normally,no
(V-engine) disrupted. reaction
Receiving error
CAN masler/slavedecoder
3768 CA[,lDinitialization Master-slave communicalion Enginecontinuesto run normally,no
(V-engine) disrupted. reactron
Receiving error
CANmaster/slave decoder
3769 CAMD-LlMlT message [raster-slave communicationSlavecontrolunitblocksinjection
pointtimeout (V-engine) disrupted. volumeuntilcommunication is in order
Receivingeffor again.Engineconlinueslo runwith
CAN master/slavedecoder mastercontrolunil,i.e.onecylinder
bank(halfpower)
3771 Master/slave CANerror Mastetor slaveerroran Padnerconkolunitsendsmessages
in partnercontrolunit receivinglrom FFR-CAN via master/slave
CAN
3772 Monitodng terminal15 Monitodng whethermaster Enginecontinuesto run normally
masler/slave andslaved€tectignitionON
3773 Operatingmode lvlonitoring
of operalingmode Engineconlinuesto run normally
masler/slave betweenmaslerand slave
changeovererror
3775 Railpressure tvlonitoring
fortoo highO or O Pressure limitvalveis forcedopen
monitoring too low@ railpressure @ Engine shuts
downbecause of lack
of railpressure
3776 Positivecontrol Lowrailpressurecannotbe Problemsin regulaling
tuelsupply,
ditference achieved enginecan shutdown
3777 Negativecontrol Excessiverailpressure Problems withfuelretum,pressure
ditference cannotbe achieved limiling
valvecanopen

T 18 8 . 1 0- 7
 DIAGNOSIS

Railpressure: lronitoringfor leakagein high- High-pressure sideleaking,engine

Leakunder Pressure hydraulics during shutsdown,dropin power,riskof
deceleration
conditions deceleralion fire
Railpressure: Monitoring for leakagein high- High-pressure sideleaking,engine
Leakbecauseol Pressure hydraulics shutsdown, drop in power,riskof
volumeadjustment lire
Railpressure: MoniloringrailpressurecontrollerEnginecanshutdownowingto low
Highregulatoroutput whenidling rarlpressure
whenidling
Ptessutereduclion Moniloring roropenpressure Railpressure700- 800 bar
valveopen(excessive limiting valve Reduction of rpmon D08and D28
pressure) Reduction of rpmlo 2000lpm on
D08
Fuelpressure Monitoring lor fluctuating
supply Possiblvthereis air in the svstem
oynamrcs pressure

8 . 1 0- 8 T 18
 DIAGNOSIS

Test orocedurcEDC7

SN: Tesler:
Cuslomer: Initialiegisilation:
Typeof vehicle: Chassisno.:
Enginetype: Enginenumber:
CR high-pressurepump: Controlunil no.:
.......,....,...,....,....,..........
Mileage: Date:

A taultmemoryextractof lhe FFRand EDCcontrolunil is to be generatedusingMAN-catsand is lo be

withthe compleledtesl procedure-
usedin coniunction

1. Tesls with motionlessengineaignitionOFF.control unit nol connected)

+ Enginetemperature = 20 "C
i Conlrolunitnot(ll!)connected,
wiringharnessadaplerconnected
+ lleasureresistance betweenPIN+and PIN-usinga multimeter
+ NEVERMEASUREAT THE PLUGCOI.ITACTS THET'SELVES WITHOUTSUITABLETEST
PROBES!(Riskof spreadingconlact6)

PIN PIN Target value

Sp€ed increment sen8or (cranbhaft) 473 0.75- 1.1kohm kohm
Ea.th connection A55 A03 >'t0 Mohm t\,40hm
Speedsegment sensor (c€mshrft) A-72 A54 0.75- i.1 kohm kOhm
Earth connection A03 >10 t\,40hm MOhm
charge-air temp6ratur. sensor 6arth 457 A03 > 10l\,tohm MOhm
{onlvon enoineswilhextemalEGR)
Wat6rt€mDeralurus6nsor 6arlh A58 AO3 >10t\,tohm MOhm
pr€ssuresensorearth
Charg€-aia 462 A03 >10MOhm MOhn
Oil DEssure s€nsor eadh A38 A03 >3 MOhm MOhm
Fuel oi€saule s€nsor 6arlh 437 A03 >3 MOhm MOhm
(Nottitledto D08engines)
Rail oressule sensor earth A03 > 10 MOhm MOhm
AGRt€€dback signal earth M2 A03 > 10 MOhm lllOhm
Proponioningunit (ZME)eanh A10 403 >10 MOhm MOhm
CAN connection to FFR 822 821 115- 125Ohm Ohm
AGRtriqqerinq 80- 110Ohm Ohm
AGR leedback te3 M2 < 1Ohm Ohm
Proportioningunit ZME(MProp) A0a 410 2.5- 4.5Ohm Ohm
CylinderI c04 c13 Ohm
Cylinder5 c01 c l6 Ohm
lniectors Cylinder 3 c05 cl2 < 2Ohm Ohm
Cylinder6 co2 c15 Ohm
cylinder2 c11 c06 Ohm
Cylind€r4 c03 cl4 Ohm
Cylinder1 c13 MOhm
Cflind6r5 c16 [IOhm
Inj€ctors earth Cylinder 3 c12 A03 >10MOhm MOhm
Cylinder6 MOhm
Cylinder2 c06 MOhm
Cylind€r4 c14 MOhm

T 18 8.20- 1
 DIAGNOSIS

lri,lRrelay (starter actuation) A16 A 19 15- 30 Ohn .........................

Ohm
Charge-airpressure acluator (if fitled) AO2 55- 85 Ohm ..........................
Ohm

2. Test on motionlessor runningengineand motionlessvehicle

=t Enginetemperature > 30 'C
= Wiringhamessadapterconnecledto controlunil
= Readoul faultmemory,no ,aultspresent?
ireasurcvoltagebetweenPIN+and PlN. using a multimetei
PIN+ PIN- Target Measured Remarks Rpm MAN€ts
value M vatuelvl (monitorinq)
Signalrail pressuresensor 480 A61 0.2- 0.8 approx.0 bar
Supply to control unit (lJ-Batt) A01 A03 U-Ban ldling
AO7 A09 U-Balt ldling
A.12 At4 U.BaT ldling
A13 A15 U-Batt ldling
lgnition 836 A03 U'Bat! ldling
Waler temDeraluresensol 477 A.5A3.46- 1.22 3 0 -9 0 " c ldling 30- 90.c
Refsranc! vollas€ LDF (urct) M5 A.624.75- 5.24 ldling
Chargeairsensor(LDR A81 A62 0.94- i.2C ldling
Supplyto oil pr$sure sensor A24 A38 4.75- 5.24 ldling
Oil pressure6€nsorsignal 1.5- 5.4bar
421 A38 1.96-4.81 ldling
Supplyto fuel pressuresensor 4.75- 5.21 ldling
Fuel prussure sensor signal PCO A.37 2.33-3.4I 5.0- 6.0 bar ldling
(Notfitledto DO8enoines)
Supply to rail pressure sensor A4:l A61 4.75- 5.25 ldling
500bar
RailDr€ssulEsensorsianal A80 A61 1.01- 1.6C ldlinq
Charg€-airlemperalure sonsor 476 A.57 4.2- 2.2 0 -6 0 " c ldling
(onlvon enoineswilh sxternalEGR)

3. Test mein relav

PIN+ PIN. Target valu6 Bemarks

IVJ tv]
Mainrelay * 836 A03 lJBatl lgnationON
lgnilionOFF
A03 4.75- 5.25V lgnitionON
lqnilionOFF
* Pin 1.40 mustswitchto 0 V wilh a delayol 0.5 to 5 s atterswitchingofl iqnition.

4. Deletefault memoN
Allercompleling
thetests,lhe faull memorymustbe deletedwithMAN,cats. Whenthe ignitionis
switchedon againno moreraultsmuslbe sloredtif thereare,theyneedto be foundand rectified.

4.20- 2 T 18
 DIAGNOSIS

Teal procedure- EDC7 maste/slave

SN: Tester:
Customer: Initialregistration:
Type of vehicle: Chassisno.:
Engine typ€: Enginenumber:
CR high-pressurepump: .............................,...,...
Controlunit no.:
Mileage: Date:

A laultmemoryexlractof the FFRand EDCcontrolunitis to be generatedusingIvIAN-cats

and is lo be
usedin conjunction
withlhe completedtestprocedure.

1. Testswith motionlessenoine(ignilion OFF.control unit not connected)

+ Enginetemperature = 20'C
+ Controlunitnot(ll!) connected,
wiringharnessadapterconnected
+ I\reasureresislance betweenPIN+and PIN-usinga multimeter
= NEVERiIEASUREAT THE PLUGCONTACTS THEMSELVES WITHOUTSUITABLETEST
PROBES!(Riskot spreadingcontacts)

1.1 Masterconlrol unit

PIN PIN Targ€tvalue
Speed increment sen3or (crankshaft) A73 A55 0.75- 1.1kohm
Eanhconneciion A55 A03 >10MOhm
specdsegmenrsensor(camshaft) 472 A54 0.75- 1.1kohm kohm
Earlhconneclion A03 >10MOhm [4Ohm
Chrroa.ir t.hdrttur. *nsdr 6rth 457 A03 >10MOhm lllOhm
{onlvon enoineswithextenalEGR)
Water temDeraturesensor earth 458 A03 > 10 MOhm MOhm
Charge-airpressure sensor earth 462 403 > 10 MOhm MOhm
Oil or6ssur€
sonsoreanh A38 A03 >3 MOhm MOhm
Fuel Drq*3uresensor earth A.37 A03 >3 MOhm MOhm
Rail Dr€$ure sensor earth A61 A03 > 10 MOhm MOhm
AGR t edback signal ealth 422 A03 >10MOhm MOhm
Proportioningunit (ZME).arth A10 A03 >10MOhm ..................__.......
t{ohm
CAN connection to FFR E22 B21 110- 130Ohm Ohm
AGF triggoring 80- 110Ohm Ohm
AGR fe€dback ra3 P22 < l Ohm Ohm
Propo.tioningunit ZME(MProp) A08 2.5 - 4.5 Ohm Ohm
v8 v10 v12
Cyl2 Cyl. 5 Cyl.5 c01 c16 Ohm
Cyl. 4 Cyl. 3 Cyl. 6 co2 c15 Ohm
Iniectors Cyl. 4 c03 c14 < 2Ohm Ohm
Cyl.1 Cyl.1 Cyl. 1 c04 c13 Ohm
Cyl.3 Cyl.2 Cyl. 3 c05 c12
Cyl.4 Cyl. 2 c06 c l1

T 18 8.20- 3
DIAGNOSIS

v8 v10 v12
Cyl.2 Cyl. 5 Cyl.5 c16 MOhm
IniecloF, Cyl.4 Cyl. 3 Cyl.6 c15 MOhm
6aJth Cyl.4 ct4 A03 >10MOhm MOhm
cyl. 'l Cyl.1 Cyl. 1 c13 MOhm
Cyl.3 Cyl.2 Cyl.3 cl2 MOhm
Cvl.4 Cyl- 2 c11 MOhm
IMR rel.y (slaner actuation) A16 A 19 15 - 30 Ohm Ohm
Charge-air pressure actuator (if fitl€d) 402 AO4 55 - 85 Ohm Ohm

1.2Slavecontrol unit
PIN PIN Target value
Rail pressurc sonsor earth 461 A03 >10t\rohm MOhm
Proportioningunit (ZME)earth A10 A03 > 10 MOhm MOhm
CAN connectionto FFR B22 821 110- 1s0Ohm Ohm
Proportioningunit ZME(MProp) 408 A10 2.5- 4.5Ohm Ohm
v8 v10 v12
CylT Cyl.10 Cyl. 8 c01 c16 Ohm
Cyl.8 Cyl.8 Cyl. 7 coz c 1 5 Ohm
Iniecrors Cyl. 9 c03 c14 < 2Ohm Ohm
Cyl.5 Cyl.6 Cyl- 12 co4 c13 Ohm
Cyl.6 Cyl-7 Cyl.10 c05 c12 Ohm
Cyl.9 Cvl.11 c06 c11 Ohm
Cyl.7 Cyl.10 Cyl. 8 c01 t Ohm
Cyl.8 Cyl.8 Cyl. 7 co2 l,rohm
Inlectors, Cyl. I co3 403 >10 l\,tohm MOhm
earth Cyl.5 Cyl.6 C y l .1 2 c04 MOhm
Cyl.6 Cyt.7 C y l .1 0 c05 MOhm
Cyl.I Cyl. 11 c06 MOhm

1.3CAN and RPll,speedconnectionfrom masterto slave contlol unil

Mastercontrol Slave conkol Targot value
UNitPIN U N TP IN
CAN 2 high 427 i27 < 2Ohm ...........................
Ohm
CAN 2 lorv < 2Ohm ..................-........
Ohm
Speed 1 <2Ohm Ohm
Speed 2 472 <2Ohm ...........................
Ohm

2. Tesl on motionlessor runningengineand motionlessvehicle

2.1 Mastercontrol unit

3 Enginetemperature
> 30 "C
= Wiringhamessadapterconnected
to conlrolunit
= Readouifaultmemory,no laultspresent?
MeasurevoltagebetweenPIN+and PIN-usinga multimeter

8.20-4 T18
 DIAGNOSIS

PIN + P IN - Target RemaJks RPm MAN-cats

valueM (monitorinql
Siqnalrail Fressuresensor A80 A61 0.2-0.8 approx.0 bar Slandstill
Supplyto control unit (U-Batt) AO1 AM lJ-Batt ldling
407 409 U-Batt ldhng
at2 at4 U-Batt ldling
A13 A15 U-Batt ldling
lgnition m6 Am U-Batt ldlino
Watet lemDeratut€gensor ATl A5A 3-46- 1.22 30- 90'c ldling 30-9 0"c
Referencevoltage LDF (Ureo M5 462 4.75 5.25 ldling
Charge-airp.e$ure sensor(LDF) A81 A62 0.94- 1.20 ldling
Supplyto oil pre€sure3en3or A24 A38 4.75- 5.25 1.5- 5.4 baf ldling
Oil pr$sure €€n6orsignal A21 A38 1.96-4.81 ldling
Supplyto fuel pressure6en6or ..40 ,.37 4.75- 5.25 ldling
5.0- 6.0 bar
Fuelpre63urtsensorsignal 420 p.37 2.33-3.43 ldling
Supplyto rail pressuresensor A4il 461 4.75- 5.25 ldling
500bar
Oil rail s€nsorsignal A80 461 1.01- 1.60 ldling
Charge-airtemperslure 3eBor 476 457 0 -6 0 " c ldling
(onlyon engineswitheltemalEGB)

2.2 Slavecontrol unit

+ Enginetemperature
> 30 "C
Wiringhamessadapterconnected
to controlunit
-
+ Readoul faultmemory,nolaullspresent?
MeasurevoltagebelweenPIN+and PIN-usinga multimeter

PIN+ PIN- Target Remarks Bpm IItAN-cats

value lvj tvl (nonitorins)
Signal rail pr6ssur6 sensot A80 A61 0.2- 0.8 apDrox,
0 bar Standslill
Supply lo control unit (U-Balt) A01 AO3 U-Batt ldling
407 A09 U-Batt ldling
412 A14 U-Batt ldling
A13 A15 U-Ban ldling
lgnition 836 A03 U-Batl ldling
Supplylo rail pressure sensor A43 A61 4.75- 5.25 ldling
Signalrail pressue sensor A80 A61 l.o1- 1.60 500bar ldling

T 18 8.20- 5
 DIAGNOSIS

3. Test main relav

3.1 Mastercontrol unit

Pl + PIN. Target ileasulbd Remarks

value M valu. M
Mainrclay 836 403 UBatt lgnitionON
'
lgnitionOFF
440 A03 4.75 - 5.25V lgnilionON
lgnitionOFF
* Pin 1.40 musrswilch!o OV wiih a d€tayof 0,5 to 5 s afts swiichangofi ignilion.

3.2 Slave Conlrolunii

PIl{+ PIN. Targ.t Meagured Remark3

valuo M value M
ilain relay* 836 A03 UBatt lgnilionON
lgnitionOFF

A40 A03 4.75- 5.25V lgnilionON

lgnilionOFF
t Pin 1.4Omustswiichto OV with a d€tayot 0.5 105 s attorswilchingotf ignilion.

4. Delete fault m€moru

Attercompleting
lhe tests,the faultmemorymustbe detetedwithMAN-cats. Whenthe ignitionis
switchedon againno morefaultsmustbe stored;il thereare,theyneodto be foundand rectified.

8 . 20 - 6 T18
 DIAGNOSIS

Troubleshootino schedule

'1.Stanerdoesnot engage
2. Slarterdisengages againafterone second
3. Startertltrns,enginedoesnot start
4. Engineslartswithdifficulty
5. Englnedoesnot move.stalls
6. Engineonlyrunsal idlingspeed,doesnotaccelerale
7. Unusualco
8. Unusualcombustion noises
Possible Possibleerror
causes displays
No poweris beingsuppliedlo EDC7
Terminal50 is nol on FFR
x x EngineCANfrom FFR10EDCinterrupted 2039/ 3064
CablesbetweenEDC7 andstarterinterrupted
{power 37s1/ 3045
supplyto starter,IMRrelay)
Recordingof enginespeed:Crankshaftand camshatt 190/ 3082
sensorsnot connected
Camshattspeedsensornotconnected, polesreversed, 190/ 3752
signals,camshallpickupwheeldamaged
interlerence
o x ..f ': o CamshaftsoeedsensoroolesreveEed 190/ 3752
Camshaltspeed sensor not connecled,poles reversed, 190/ 3753
interlerencesignals,{lylvheeldamaged
Crankshatl sDeedsensoroolesteversed '190 / 3753
x EDC-FFRpairingnotOK (assignparameters againkom 3076/ 3077
vehicledalafile)
Controlunitlaully,wrongparl number
. lix x Air in the syslem,fuel railpressure
doesnotbuildup 94213755t3733
ox x Fuelpumpinlelpressuretoo low(linelromlank closed),rail g42t9755t37ao
oressuredoesnotbuilduo
xx xo Injectorstaysopen,railpressure doesnot buildup 3733/3774/3775
oo oo Injectordamage
xx to injectors
Connection leaking.railpressLrre
doesnotburldup 37338774/3775
unitZME([IProp)sticks,DBVsiaysopen
Proportioning 3775/3776t3777/
3780
Fuelleedpump(gearpump)faulty 942/3775t97761
3780
ox x High-pressure pumpfaully.lail pressuredoesnot buildup 37751377
6137AO
xo x Retumpressureai high-pressure pumptoo high,resultof 377513777
137A1
excessiverailpressure(duringidlingand decelerationin
oarlicularl
Fuelfilterblocked,dirty 942
oo ,( Cables1orailpressuresensoror sensoritseltfaulty 3099

x ls morelikely
o- Mightbe likely
x' Currenllyonlyon D08engines
..' Fuellowpressuresensoris cufientlyonlyfittedto the {illeron D28engines

Conlinuedon nexl page

T 18 8.30- 1
 DIAGNOSIS

Troubleshootingschedule(continued)

1. Starterdoesnotengage
2. Starterdisengages againaflerone second
3. Stafiertums,enginodoesnotstart
4. Enginestartswithdilficulty
5. Enginedoeellot move,stalls
6. Engineonlyrunsat idlingspe
7. Un
8. Unusualcombustion noises

lPossible Possibleerror
I causes displays
Pressurelimitingvalve(DBV)on railis open/stuck 368713741
Cablesto injectors 651..656
Air filterdrrty,clogged.enginereceivesno arr
x xo Batteryvollagetoo low (lessthanI V) 168/3780
x Cablesbetweenbatteryandstarterinlerrupled, starterfaulty 3045
x Cablesto proporlioning unitZME(N4Prop) interrupted 374413741
x Enginebrakingswitchactuated

9.NimimlenginespeedobliE ili,"dr,caai::
10.Reduced powerinall units
11.lregularrunnrnoiF
12.ldlingspeedirregular,
characteistic
enginenoise
13.Thicks , ,,,
14.Thicksmoke:White/blue
15-rh*Si&*: Attu power
Possible Possibleeror
causes displays
Recording ot enginespeed:Crankshalt and camshaftsensors '190 / 3082
notconneclect
Camshaftspeedsensornol connected! polesreversed, 190/ 3752
t interference signals,camshaftpickupwheeldamaged
{, x' q. o, o, Camshaftsoeedsensoroolesreversed 190/ 3752
{r Camshaftspeedsensornol connected,
interlerence signals,flywheeldamaged
polesreversed, 190/ 3753

Crankshatt soeedsensoroolesreversed 190/ 3753

o i:oo Controlunillaulty,wrongpartnumber
xx Air in the system,fuel railpressuredoesnoi buildup 942,3755t3776
xxo Iniectorslaysopen,railpressuredoesnot buildup 3733137751377A
Inieclordamage

x ls morelikely
o. lilightbe |kely
x' Currently onlyon D08engines
..' Fuellowpressuresensoris currentlyonlyfittedto the tilteron D28engines

on nextpage
Continued

8 . 30 - 2 T18
 DIAGNOSIS

Troubleshoolingschedule(continued)

L Nominale.ginespeedobviouslyreduced
10.Beduced powerin all units
! 1. lrregula.running
12. ldlingspeedirregular.
characteristic
engine
13- Thick smoke on accelerating
14.Thicksnoke:White,/blue
'15.Thick6moke:
Al lullPower
Possible Possibleerror
causes displays
xl Connection lo injeclorsleaking,railpressuredoesnotbuildup 3733t3775t3778
r i? x o ,t,' Proporlioning unitZlllE (MProp)slicks,DBVstaysopen 3775/3776/3777/
3780
High-pressure pumpfaulty,railpressuredoesnol buildup 377513776137AO
o Fuelfilterblocked,diny 942
o Cableslo rail pressu'e sensoro. sensor ilselffau'ty 3099
Pressurelimitingvalve(DBV)on railis open/stuck 3647/3741
xxo Cables to injector 651..656
x Airfilterdiny.clogged.enginereceivesno arr
x Charge-air coolertoohigha pressureloss(drain 102
condensation),lrozen
o Exhaustgas recirculationhasconslantsystemdeviation,
AGR 3004/3746
valvestitf,cableslo comoressedaircvlinder
Overvollagein controlunil 3637
Cablesto proportioningunilZ[,4E(N,4Prop)
interrupted 3744/3741
x Cablesto charge-airpressuresensor 1080/3088
x Cableslo coolanitemperature sensor 3091
Cablesto air temperaturesensor 3089
Glowplugconnection leaking
EEPRO[,4 error 3671
of orlpressuresensor
Plausibility 30a2BOA7
Atlenunincoffect(teminal30lo controlunitinlerrupted) 3063

x ls morelikely
o- Mightbe likely
x' Cuffentlyonlyon D08engines
..' Fuellowpressuresensoris curentlyonlyfittedto the filteron D28engines

T 18 8.30- 3
 DIAGNOSIS

PROGRAM
TROUBLESHOOTING
programcoverstaultsdetectable
Thetollowingtroubleshooting lromthe faultmemory.

Theseies of testscorespondsto the numericalsequenceof the faultcode(SPN'S)regardless

of the
of lhe faull.
significance
Thecomplotefaultmemoryis to be readand all storedfaultsdocumented on the inilialinspeclion
of a
vehicle(MAN-cats keycombinationSTRG+ F11).
Thisis ihportantbecausecablesor components haveto be disconnected tortroubleshooting andlhe
corresponding {aultmessagescan alsobe setor storedduringthis process.
Forthis reason,thefaultmemoryshouldalwaysbe deletedafterinlermediate tests.
lf partsare replaced,a MAN-catspdntoutrecordingthe fault(extracttromthetaultmemory,seeabove)is
lo be includedlor reimbursement
o, costs.

fromthisare permissible
Deviations wdhMunichService.
onlyin consultation

Controlunitsthatare stillunderwa antymayalsoonlybe replacedin consultation

withMunichService.

andchecking,repeatthe testanddeletethe faultmemory.

Afterfaultrectification

Thefaultmemoryshouldalwaysbe deleledusingMAN-cats.

In principlc,the fault memoryshould be deletedand the faull obseivedbelote each ieplacementof

a componeni01contlol unit. Wherethete are severalfault entries,ihe correspondingiest
instructionthat does not requirea replacemenlol a componentor cont.ol unit should first be
Iollowed,

cables"teststeomustalwavsbe carriedout as follows.

The'Tesvinsoecl

'/ Interruption (e.9.due lo expandedsocketsleeves,pushedbackpinsor pin

or contaclresistance
sleevesor oxidizedplugsockets)
r' Short-circuit
to negative
/ Short-circuit
to posilive
/ Short-circuit
to adjacentcables
'/ Loosecontacls
r' Wateror moislurein the cableharness
Cableharnesses
can alsobe defectiveeventhoughthe corrugated
sleeveappearsoutwardlyundamaged.

whencarryingout resblance measunemenls.

Theconnectionto the control unil mustbe disconnected

Notevehicle-related
circuitdiagrams.

All testsconcemingthe conltolunilconnectorarecarriedout usinga lestboxand an adaptorcableset.The

pinassignment on the controlunitconnectoris identicaltothe test socketson the testbox.

cablesare obtainable
Theteslboxand associated from
15, 85053Ingolstadt
Cartool,StrauPenlettenstrape
Testboxpartnumber: 97 0 010
Testcablepartnumber: 97 0 120

lllustration
on reverse

T 18 8.40- 1
 OIAGNOSIS

Testbox with test cable

Connection
10vehiclecableharness Earthterminals

8 . 4 0- 2 T18
 DIAGNOSIS

FORWARDFUELPRESSURE

Indicationot tault: Centralwarninglampstays illuminatedyellowwhiledrivingandwhenat a standstill

Effeciive faull: Enginecanshutdown

Possiblelossof power

Causeof fault: Fueltilterblocked,tankventblocked,inlettilterblocked,air in syslem,

fuelpressurein supplylo high-pressure
pump(low-pressure side)too low,
looseconlacton lhe signalline

Faull inoutsto othej control units:

Note 1: The'Rail pressuretoo loM/'faull(SPN3Zl5) canalsooccur.

Note 2: Thefuel pressuresensoris nol currentlylittedon seriesD08engines.

Notevehrcle-related
circuitdiagrams

Fuelpressure Pressuretest usinggaugeset - Checkthe levelin lhe tank(thetank retlrn

(specialtool)
in accordance
with mustbe belowlhe levelof lhe luel
testprocedure
hydraulic othelwiselhe syslemrunsdry)
Checkthe luelfilterlorblockage
- Checkthe pipesbetweenthetanl?spur-
gearpumpand spur-gearpump/high-
pressurepumplor blockage
- Leakson the suctionsidebetweenthe
tankand presupplypump(noexlernalluel
leak)
Leakson the low-pressure sidebetween
the presupplypumpand high-pressure
pump(external fuel leak)
- Presupply pumpdefective(replace)
Powersupply Measurement of voltagebelween Checkplausibility
ol signalusingl\rAN-cats
pin A40(+)and pinA37 (-) Monilodng
Checkcables
Talget value:4.75- 5.25V
Checkconnectors
Signalvoltage ol voltagebetween
I\reasurement Replacefuel pressuresensor
pinA20 (+)and pinA37 (-)
lf no faultis lound,replaceconlrolunit
Targetvalue:2.33- 3.43V
v 3.5
3.0
2.5
2.O

bar

T 18 8.40- 3
DIAGNOSIS

Phy3icalOIL PRESSURE

Indic.tion of t uh: C€ntralvi,aminglampcontinually tla.h!. ]rd while ddvingand wh6nat a standstill

E fcciivG t ult Dangerof enginedamag6

Cauaoof tauh: Oil pressuretoo lou loosecontacton signal line

Faull inputr lo other control unlta:

Not6vehicle-aelated
circuitdiagrams

Oilpressure Talgcl v.lu!: 1,5- 5.4 bar Checkoil level

Checkoilsupply
Checkfor oildilution
Powersupply Measuremontof voltage Checkplausibilityol signalusing
belweenpinA24(+)andpin MAN-calsMonitoring
A38H
Checkcables
Targrt valu.: 4.75- 5.25V Checkconneclors
Signalvohage Measurement of vohage Replaceoit pressures€nsor
belweenpin A21 (+) and pin
A38 (-) ll nofaultis tound,replace
conlrolunil
Targ.t valuc: 1.96- 4.81V

,-

8.40- 4 T 18
 DIAGNOSIS

PhysicalCHARGE-AlR
PRESSURE

lamp6taysilluminatedred whiledrivingandwhenat a standstill

lndicationot tault: Centralwarning

Effective faull: Outputof a simulatedcharge-airpressureas a substitute

value
Enginehastoo littleair,powerloss

Causeot tault: pressures€nsorsticking{{rozen),looseconlactin the signalline

Charge-air
Charge-air
coolerblocked,charge-airpipesleaking

Faultinputs to othei conuol units: Yes,FFR:SPN3117(CANcharge-air

pressuresensornol available)

Note: A changeoverto charge-akpressurevalueusuallytakesplace.Thedriver

a simulated
receivesa faultmessagebutcandetectno limitationunlessthe completecooleris,for
exampre,rozen.
Furthermore,the SPN102is notalwaysin pdorily2 (redlaultlight).
A physicaldefec!classification
thatdoesnot reactto an iced-upsensor(or alsoa
charge-aircoole4is storedas piority 4 (no indication).

Notevehicle-relaled
circuildiagrams

pressure
Charge-air ol pressureto pressuresensor
Application Checksensorandcharge-air
usingALDAtestsetor MitywacDuo coolerfor icing
handpump(absolutepressuremeter)
- Checkair lilter
Measurement usingMAN-cats withengine
and ignitionswitchedon
stalionary - Checkcharge-air pressure
connection lor leaks
Targelvalue:0 mbar
Powersupply Measurement of voltagebetweenpin Checkplausibility of signalusing
A25 (+)and pinA62 (-) MAN-catsl\4onitoring duringidling,
usingatmospheric pressuresensor
Targetvalue:4.75- 5.25V Checkcables
Checkconnectors
Signalvoltage I\reasu
remenlol voltagebetween Replacecharge-air pressure
pinA81 (+)and pinA62(-) sensor
lf no faull is lound,replacecontrol
Targeivalues: unit
0.94- 1.20V al0 bar
1.10- 1.40V at 0.2bar

Refeiencevalues:
- 0.5bar.0.50V
0 bar.......
1.07V
0.5bar....1.64V
1 bat.......2.21V
1.5bat....2.78V
2 bar.......3.35
V
2.5bar....3.93V
3 bar.......4.50
V

T 18 8.40- 5
DIAGNOSIS

TEI{PERATURE
CHARGE-AIR

Indic.llon ot fauh: Centralwaming lamp .tays illuminrt d ]!d while ddvingand when at a standstill

Eftlcliva lault None

Caulc ot tauhi Maximumpormissibl€

tempo€tureund6rchol,
loos€conlactin the signal

Faull inpub lo olher contaol unita:

Nole vehiclerelatedcircuil diagrams

Resislorsensor Measuromontol rosistamo - Checkplausibility of signalusing

b€twegnpin A76 and pin A57 MAN{ats Monhoring
- Checkcables
TargGtvaluc:
2.05 Ko t 3% at 25 'C - Checkconnectors
- R€placetempeEturesonsor
S€nsorvoltage Measurememof voltaqebetwe€n - lf no laull is found, replacecontrol
pin476 and pinA57 unit

Targal valuc:
4.2-2.2V at0-60" C
- EGRvalveopen (SPN3004)

Targal valu€ tabla lolerancei3%

8.,rO
-6 T18
 DIAGNOSIS

KKI Physlc.l ATMOSPHERIC

PRESSURE

Indication ol faullr Centralwaminglamprtays illuminatcd rcd while drivingand whenal a standstill

Efflctivc tauft: None

Caure of tault: Prgssurecoftpgnsating€lemgnlon contrcl unit damagedor blocked(paintedover)

Fauh inouts lo olhcr control unita:

Notevehicle-related
circuitdiagaanE

Contrclunil Checkplausibility
of signalusing - lf no lauft is iound, rsplace
MAN-catsMonitoring dudngidling, conlrol unit
usinga chaQ€-airpressur€
sensor

T 18 4.40 - 7
DIAGNOSIS

PhysicalCOOLINGWATERTEMPERATURE

Indicationol fault: Centralwarninglampstays illuminatedred whiledrivingand whenal a standstill

Effeclivefault: None

Causeof fault: Problemsin coolantcircuit(maximum

permissible
temperature
overshol),
loose
contactin the signalline
Faull inputs io other conlrol unils:

Notevehicle-related
circuitdiagrams

- Referto EngineRepairManual
Sensorr6sistanceI\reasurement
of resistance
between - Checkplausibility
of signalusing
pin A77and pinA58 NIAN-catslvlonitoring
- Checkcables
Tajget value:
2.05 K() I 3ol"at 25 "C - Checkconneclots
- Replacetemperature sensor
Sensorvoltage Measurement of voltagebetween - lf no faull is found,replacecontrol
pin A77and pinA58 unit

Targel value:
3.46- 1.22V at 30 - 90 "C

Targetvaluetable tolerancet3olo

8.40- I T 18
 DIAGNOSIS

BATTERYVOLTAGE

Indicationol tault Cenlralwaminglampstays illuminatedyellowwhenal a standstill

EfleciivefauR: lf the batteryvollagedropsbelowI V, the EDCcontrolunitswitchoff

Cduseof fault: Batleryvoltagetoo high(> 32 V) or too low (< 16 V)

Faultinpuls to other contol units: Yes,FFRand ZBR

Notevehicle-related
circuitdiagrams

unitpower
Control Measuremenl of vollagebetweenpins - Checkplausibility of signalusing
suPPly A01,A07,A12andA13(+)andpins l\.,lAN-catsMonitoring
A03,A09,A14andAls (-)
- Checkcables
Targetvalue:20 - 28 V Checkconnectots
- ll no faultis found,replace
controlunit
Voltage,outputaccordingto datasheet Repairor replacethe generaloris
foundto be detective
Chargestateaccording to datasheet - Replacebatteryif defective

T 18 8.40 - I
DIAGNOSIS

ENGINE
SPEED

Indicalionot fault: Centra'warninglampstays illuminatedred whiledrivingand whenat a standslill

Effeclivefault: Enginemay notslartor remainsshutdown

Causeot taull: Problehsin deiectingthe camshaflor crankshaltspeedsignal

Faultinputs to other conlrol units:

Note: Thisfaultcan alsooccurtogetherwithlaultsSPN3752and/orSPN3753

Notevehicle-related
circuildiagrams

Crankshait
speedsensor Nreasuremenl
of resistance
between Checkplausibilily of signalusing
pinA73and pinA55 MAN-catslvlonilodng andthe
statusol the speeddelection
Targetvalue:750- 1100Q Checkcables
Checkconnectors
Checkconnector for coffecl
Polarity
Camshaflspeedsensor Measurementol resistance
between Replacespeedsensor
pinA72and pinA54
lf no faultis found,replace
controlunit
Targetvalue:750- 1100O
Speedsignal Checksignalusingoscilloscope

Targetvalue: Reterto oscilloscope

Clearancebetweenspeed Targetvalue:0.5- 1.5mm Correctclearance

sensorandll)ryheel

Camshaftspeedsensorsignal
measuredat 600 rpm
betweenpinsA72and A54

Crankshalt
speedsensorsignal
measuredat 600 rpm
betweenpinsA73and A55

8.40- 10 T 18
 DIAGNOSIS

TOROUELII/|ITBIT ERROR

Indicationof taull: Centralwahing lampstays illurninatedyellowwhiledrivingandwhenat a standstill

Etieclivefault No torquerest ctionthough FFR(vehiclemanagemenl

computer)

Cau3eof fault: FFR2requeslsinvalidtorquevalue

Fauhinputs to othei control units: Yes,FFR

Notev€hicle-related
circuildiagrams

Unknowncontrolunit Checkremaining control

in vehiclo unitsin the electronic
link

T 18 8.40- 11
DIAGNOSIS

CAN MOOULE.I

lndicationof fault: Centralwarninglampstays illuminatedred whileddvingandwhenat a standstill

Eflectivefaull: EDCconlrolunitgoesto "Standalonemode"(i.e.enginerunsin idlingand doesnol

accelerate)

Causeof fault: Bus-offstateol CANmodule1

Faullinpuls to other control units: Yes.FFR

Nolevehicle-related
circuitdiaorams

EDCcontrolunit Ivleasurement
of resistance Checkcables
betweenpin 821 (CAN-L)and 822
(cAN-H) - Checkconnectors
- ShortcircuitfromCAN-Hto
Targatvalue: -120 O CAN-Lat approx.0 Ohm
Vehiclemanagemenl Measurement of resistance - lf no faultit found,replace
compurer(FFR) betweenpinX1/12(CAN-L)and controlunitor FFR
x1/10(CAN-H)

Targetvalue: -120 Q
Targetvalue:
Re{erto oscilloscope
curve

E
1n
ui)

ate!3iqlal CAIiI Hign EE,1eI rr

CrU{ L,rra (arn] !

4.40- 12 T 18
 DIAGNOSIS

BANK1; SOLENOID
VALVE1, CYLINDER
1

Indicationof fault: Centralwarninglampstays illuminatedred whiled vingandwhenat a standstill

Effectivefault: Powerdrop,nofuel is injectedintothe relevanlcylinder

Causeot tault: atlerbreakin Ubd(batleryvoltage)cable

Solenoidvalveend stagehasa shorl-circuit

Fault inputs to other conlrol units:

Notevehicle-related
circuitdiagrams

Injectoraclivaiion Checksignalpattern - CheckinjectorplausibilityusingMAN-cats

usinga clip-onammeter Monitoring
- Checkcylinderassignment
- Checkcables(alsoundervalvecover)
Checkplug-in/screwed conneclions (also
undervalvecover)
- lf no faullis found,replacecontrolunit
TRUPrun-up
lest - RefertoTRUPdescription

Iniectorsignal
Caution!Theinjectorvoltagewasmeasuredhere

T 18 8.40- 13
DIAGNOSIS

BANK2; SOLENOID
VALVE1, CYLINDER
5

Indicationof faull: Centralwarninglampsiays illuminatedrcd whiledrivingandwhenat a standstill

Eltectivefault: Powerdrop,nofuel is injectedintothe relevantcylinder

Causeot tault: Solenoidvalveendstagehasa short-circuit

afterbreakin Ub"i(batteryvoltage)cable
Fauli inputs to other conlrol units:

Notevehicle-related
circuitdiaorams

Injecloractivation Check signalpattem - Checkinjectorplausibility usinglllAN-cats

using a clip-onammeter I\ronitoring
Checkcylinderassignment
- Checkcables(alsoundervalvecover)
- Checkplug-rn/screwed connections (also
undervalvecover)
- lf no faultis found,replacecontrolunil
TRUPrun-uplest - Relerto TBUPdescription

Injectorsignal
Caulion!Theinjectorvoltagewas measuredhere

4.40- 14 T 18
 DIAGNOSIS

BANK1; SOLENOID
VALVE 2, CYLINOER
3

Indicationol lault: Centralwarninglampstayailluminatedred whiledrivingandwhenat a standstill

Effeciivefault: Powerdrop,nofuel i6 injecledinlothe relevanlcylinder

CauseoI tault: Solenoidvalveend stagehasa short-circuit (batteryvoltage)cable

alterbreakin Ubar

Fauli inputs to olher conlrol unilsi

Notevehicle-related
circuitdiagrams

Injectoractivation Checksignalpattern - Checkinjectorplausibility usinglvtAN-cats

usinga clip-onammeter llonitoring
- Checkcylinderassignment
Checkcables(alsoundervalvecover)
- Checkplug.in/screwed connectons(also
undervalvecover)
ll no faultis lound,replacecontrolunit
TBUPrun-uptest - RelertoTRUPdescription

lniectol signal
Caution!The injectorvoltagewas measuredhere

T 18 8.40- 15
DIAGNOSIS

BANK2 SOLENOIDVALVE2 CYLINDER

6

Indicationof Iault: Centralwarninglampstays illuminatedred whiled vingandwhenat a standstill

Etfectivetault: Powerdrop,nofuel is injectedintothe relevantcylinder

Causeof faull: Solenoidvalveend stagehasa short-circuit (batteryvoltage)cable

afterbreakin Ubar
Faultinputs to other control unils:

Notevehicle-related
circuitdiagrams

Injectoractivalion Checksignalpattern - Checkinjectorplausibility usinglllAN-cats

usinga clip-onammeler Monitoring
- Checkcylinderassignment
- Checkcables(alsoundervalvecover)
- Checkplug-in/screwed conneclions (also
undervalvecover)
- lf no faultis lound,replacecontrolunit
TRUPrun-uptest - Referto TRUPdescription

Injeclorsignal
Caution!The injectorvoliagewasmeasuredhere

8.40- 16 T 18
 DIAGNOSIS

BANK1 SOLENOIDVALVE3 CYLINDER2

Indicationof lauli: Centralwaminglampslays illuminatedred whiledrivingandwhenat a standsiill

Effeclivefault: Powerdrop,nofuel is injectedinlothe relevantcylinder

Causeof fault: afterbreakin Ub (batteryvoltage)cable

Solenoidvalveend stagehasa shoft-circuit

Faultinputs to other conirol unils:

Nolevehicle-related
circuitdiagrams

Injectoractivation Checksignalpattern - CheckiniectorplausibilityusingMAN-cats

usinga clip-onammeler Monitoring
- Checkrylinderassignment
Checkcables(alsoundervalvecover)
- Checkplug-in/screwed connections(also
undervalvecove4
- lf nofaultis tound,replacecontrolunit
TBUPrun-uptesl RelerloTRUPdescription

Iniectorsignal
Caution!The injectorvoltagewas measuredhere

T 18 8.40- t7
 DIAGNOSIS

VALVEg, CYL|NOER
BANK2; SOLENOTD 4

Indicationof lault: Centralwarninglampstays illuminatedred whiledriving

andwhenat a standstitl
Effectivelaulti Powerdrop,nofuel is injectedintolhe relevantcylinder
Causeof tault: Solenoidvalveendstagehasa short_circuit
afterbreakin Ubd(baneryvottage)cable
Faultinputs to other control units:

Notevehicle-relaled
circuiidiagrams

Iniectoractivation Checksignalpattern Checkinjectorptausibitity usrngMAN-cats

usinga clip-onammeter Monrtoring
- Checkcylinderassignment
- Checkcables(alsoundervalvecover)
Checkplug-irvscrewed connections(also
unoervaue cover)
- lf no faultis lound,replacecontrolunit
TRUPrun-uplest - Referto TRUPdescription

Injectoj signal
Caution! The injectorvoltage was measureonere

8.40- 18 T 18
DIAGNOSIS

TI E/DATE:SECONDSltWALlD

Indlc.lion of laohr Cant€l warninghmp.Lys illuminaLd r.d while drivingand whenat a standstill

Eficctlvc f.ult: No date or timg inlormationavailablelor the faults

Cauaaof faulti computer(FFR)transmitsinvalidnum€icalvalue

Vehiclemanagoment

Fault inpub lo othor conlrol unllrr: Yes, FFRand lachograph(tdTCO)

Notevehicle-relaled
circuitdiagrams

- lf no fault if found, r€placsFFR

T 18 8.40- 19
DIAGNOSIS

TIME/DATE:
MINUTESINVALID

Indicaiionot faufti Centralwaminglampstays illuminatedred whiledrivingandwhenat a standstill

E fectivefault: No dateor timeinformation

availabletor thefaults

Causeof tault: computer(FFB)transmitsinvalidnumerical

Vehiclemanagement value
(|!ITCO)
Fault inputs to other control units: Yes,FFRandtachograph

Nolevehicle-related
circuildiagrams

Vehiclemanagemenl Checkparametering - lf no faultis found,replaceFFR

computer
- lf no faultis found,replace
tachograph

8.40- 20 T 18
 otaGNosts

TIME/DATE:HOURSINVALID

Indicationol faull: Centralwaminglampstays illuminatedred whiledrivingandwhenat a standstill

Effeciivetault: No dateor timeinformation

availablelor the laulls

Causeof fault compuler(FFR)transmitsinvalidnumeicalvalue

Vehiclemanagement
(MTCO)
Faultinputs to other control uniis: Yes,FFRandtachograph

Notevehicle-related
circuitdiaorams

Checkparametedng - lf nofaultis lound,replaceFFR

Checktunction ll no faullis found,replace

tachograph

T 18 8.40- 21
DIAGNOSIS

TI E/DATE:DAYSINVALID

Indlc.tion ol Centralwarninglamprlay. illuminat d r€d while drivingand whsn at a standstill

'|ull:
Efilctlv. t uh: No date or tim€ inlormationavailablelor the faults

C6u!! ol fault Vehiclemanagementcompuler (FFR)transmit€irwalid nurn€.icalvalue

Faglt inpuE lo olhlr co rol unil.: Yes, FFR and lachograph(MTCO)

Notevehicle relatedcircuitdiagrams

- lf no fault is lound. reDlaceFFR

8.40- 22 T 18
 DIAGNOSIS

TI EItATE: IO'{THS |I{VALIO

Indkdi,on ot f.|.rlt Csni€lwaming lamp.tayr ilturnindad rld while drivingand whenai a standstill

Efi.c-tiv. f.ult: No date or lim6 inlormationavailabl€for th€ faults

Caula ol fault: Vehiclemanagementcompder (FFF) transmitsinvalidnumaricalvalue

Fault Inputa to othcr control unltai Y€s, FFRand tachograph(MTCO)

Nole v€hicl€-rslatodcircuitdiagrams

- lf no lault is tound.reolaceFFR

T 18 a.& -n
DIAGNOSIS

TlilE/ttATE: YEAHSIIVALID

Indicdlon ol hult C€ntralwaminglamp!t y! lllurnlnat d rtd while drivingand when at a standstill

Efisctiw trult No date orlime informationavailablofor th€ faults

Cru.G ot fauh: VehiclgnEnagementcompuler(FFB)transmil5invalidnum€dcalvalus

Faglt inpu|! lo oth.r comrol unitr: Yss, FFR and tachograph(MTCO)

Notevehicle-relatedcircuitdiagrams

- lf no taul i5 lound, r€plac€FFR

8.40- 24 T 18
 DIAGNOSIS

RAILPRESSURE
SENSOR
SUPPLY

lndicationof fauli: Centralwarninglampsiays illuminatedred whib drivingandwhenai a standstill

Effeclivefault: Speedreduction to 2000rpm(D08engine)

Torquereduction(D08and D28engine)
Pressurelimitingvalve(DBV)is activeopen

Causeof fault: Supplylinecablebreak,short-circuit

Faultinpuls io other control unils:

Notevehicle-related
circuitdiagrams

Railpressuresensor Measurenent of voftagebetlveen - Checkcables

powersupply pinA4:]and pinA61
- Checkconnectors
Targetvalue:4.75- 5.25V Replacerailpressuresensor
- lf nofaultis found,replacecontrol
unit

T 18 8.40- 25
DIAGNOSIS

SUPPLYTO FUELPRESSURE, PRESSURE

CHARGE-AIR ANOOIL PRESSURE
SENSORS

Indicationof lault: Centralwarninglampstays illuminatedred whiledrivingandwhenat a standstill

E fective lault: Senso6supplynovaluesor inconectvalues

Causeof fault: Supplylinecablebreak,short-circuit

Faultinputs to other control units: Yes,FFR,ZBR

Notevehicle-related
circuitdiagrams

Fuelpressure
sensor Measurement of voltage - Checkcables
powersupply betweenpin A40and pinA37
- Checkconnectors
Targetvalue: 4.75- 5.25V - Replacesensor
- lf nofaull is found,replace
conlrolunit
Charge-airpressure I\reasurement
o{ voltage
sensorpowersupply betweenpinA25 and pinA62

Targetv6lue:4.75- 5.25V

Oil pregsuresensor Measurement of voltage

powersupply betweenpin A24and pinA38

Targetvalue: 4.75- 5.25V

4.40- 26 T 18
 DIAGNOSIS

FFR1: TIMEOUT

Indicationot tault Centralwarninglampslays illuminatedred whiledrivingandwhenat a slandslill

Eflectivefauli: EDCcontrolunitgoesto "Standalonemode"(i.e.enginerunsin idlingand doesnot

accelerale)

Causeot lault: Timeoutstale,no receptionof FFB1message

Fauli inpuls to other control units: Yes,FFR

Notevehicle-related
circuitdiagrams

EDCcontrolunit Measurement of resistance - Checkcables

betweenpin 821 (CAN-L)and 822
(cAN-H) - Checkconnectors
- ShortcircuitfromCAN-Hto
Targetvalue: -120 Q CAN-Lat approx.0 Ohm
Vehiclemanagemenl I\reasurement
of resistance - lf no laultif found,replace
computer(FFR) betweenpinX1/12(CAN-L)and controlunitor FFR
xln0 (cAN-H)

Targetvalue:-120f,)
M-CANdatabus Targetvalue:
Relerto oscilloscope
curve

fl3jt4* F?5t,*
i"ll it , i*i"', 'l!e'*,

CAII HigL Xnnal A

t$I lr1, Xnnal E

T 18 4.40- 27
otaGNosrs

EGRACTUATORPERSISTANT
CONTROLDEVIATION

Indicationof lault: Centralwarninglampstays illuminatedred whiledrivingandwhenat a standstill

Effectivefaull: Speedincreaseat 2200lpm (D08engine)

Torqueredlction(D08engine)
EGRdoesnotfunction
Enginebrakedoesnolfunclion

Causeof tault: Targetandactualpositionsol the EGRvalveare notthe same

Faull inputs to other control units: Yes,FFR: Enginebrakedoesnotlunction

Indication
in display:Enginebrakefailure

Notevehicle-related
circuitdiagrams

Feedbackswitch(reed Measurement ol resislance - Perlofinactuatortesl usingMAN-cats

contact) betweenpinA23 andA22
- Checkcables
Targetvalue:< 1O - Checkconnectors
Solenoidvalvecontroller Ivleasu
remenlol resistance ReplaceEGBactuator
between pinAl7 andA11
- lf no iaultis found,replacecontrolunit
Targelvaluei 80 - 110O
Freedomof movementol Repairor replaceEGRvalve
valveactuation
Compressed
air supply - Checkcompressed
airsupply

8.40 - 28 T 18
 DIAGNOSIS

TIMEOUTMESSAGEPOINT13

Indicationof lault None

Effeciivetaull: Cannolreadfaultmemoryin display

Causeof fault: TimeoutwhensendingDM4message(faullmemory)to the display(viaFFR)

Faultinputs io other conlrol unita: Yes,FFR

Notevehicle-related
circuitdiagrams

Measuremenl ol resistance - Checkcables

betweenpin B21(CAN-L)and822
(cAN-H) Checkconnectors
- ShortcircuitfromCAN-Hto
Targetvalue:-120 f) CAN-Lat approx.0 Ohm
Vehiclemanagement [reasurementof resistance - lf no laultil found,replace
computer(FFR) betweenpin X1/12(CAN-L)and controlunilor FFB
x1l10(cAN-H)

Targetvalue:-120 Q
M-CANdatabus Targetvalue:
Relertooscilloscope
curve

$3jl4u' ?lSEu*
..?.!.!.!q . ....r'thrua.
..r'1,!.9.
up..
::::,tt:

aienslqral aAN ltugh XsaI A

CAI t !!r R@aI E

T 18 8.40- 29
DIAGNOSIS

DM4REOUESTINVALID

Indicationot lault: None

Etfectivefault: Cannotreadfaultmemoryin displayvia menu

Causeot taull: lnvalidrequestfromdisplay(viaFFR)to senda DM4message

Faultinputs to other conllol units: Yes,FFR

Notevehicle-related
circuitdiagrams

Vehicledatafile - Checkcontrolunilpa€metering
EDCcontrolunit I\reasurement
of resistance Checkcables
betweenpin821 (CAN-L)and 822
(cAN-H) - Checkconneclors
- ShortcircuitfromCAN-Hto CAN-L
Targetvalue:- 120O at approx.0 Ohm
Vehiclemanagement Measurement
of resistance - It nofaultil found,replacecontrol
computer(FFR) pinX1/12(CAN-L)
between and unilor FFR
x1n0(cAN-H)
Targetvalue:-120 O
M-CAN data bus Targetvalue:
Referlo oscilloscope
curve

Eu*
'l!9..!,.q.

dter61,]r1al IA1[ High iG.'ral ,{

l*$ lo! [aa] !

8.40- 30 T 18
 Draol{oor3

I E {iINE OVENSPEED

lndlcdo|| ol laltt Contralwrrntnglamp.t yr lllurninai.d rtd whilediving a|d whsnat a sleridEtill

Efilcdv! fruh: Dangerof enginedam.g€
Cauaaot Luh: opcralion,ddvgr6nor(e.9.incongclg€archang€)
InconEc,t
F.rft Inpub lo oirar coflrol unhr:

T16 8.,10- 31
DIAGNOSIS

MAINRELAYSTICKING

Indicationot fault: Centralwarninglampslays illuminaledred whiledrivingandwhenat a standstill

Ettectivefault: Batterycandischargeduringlongshutdown

Causeol lault: I\rainrelayintegrated

intothe controlunilis delective

Faultinputs to other control unils:

Notevehicle-related
circuitdiagrams

of voltagebelweenpins
[,lainrelayin EDC I\,4easuremenl Checkcables
controlunit 836 and A03with ignitionON
Checkconnectors
lgnitionon lf no laull is found,replace
Targetvalue: UMr controlunit
lgnitionotf
Targetvalue: 0 V

Ivleasuremenl
of mainrelayvoltage
betweenpinsA40and A03
lgnilionon
Targeivalue: 4.74- 5.25V
lgnilionotf
Targetvalue: 0 V

Note:Withthe engineshutdown,pinA40 mustswitchto 0 V wilhin0.5 to 5 s aftertheignitionis switched

o{f.

lgnitionON lgnitionOFF

n_

:
srel

4.40- 32 T18
 DIAGNOSIS

BECAUSEOF ENGINEBRAKEBIT ERROR

G,OUANTITY

Indicationof fault: Cenlralwarninglampstays illuminatedyellowwhiled vingandwhenat a standslill

Elieciivefault: None,messageis ignored

Causeotfault: FFRsendsinvalidnumedcalvalue

Fault inpuls io olher control unit6:Yes,FFR

Notevehicle-related
circuitdiagrams

- Checkconlrolunitparameteng
Measurementol resistance - Checkcables
betweenpin821 (CAN-L)and
822 (CAN-H) Checkconneclors
- ShortcircuitfromCAN-Hto CAN-L
Targetvalue:-120 O at approx.0 Ohm
Vehiclemanagehenl Measuremenl of resistance - lf nofaultif lound,replacecontrol
(FFB)
computer betweenpinX1/12(CAN-L) unitor FFR
andx1/10(CAN-H)
Ta.getvalue:-120 Q
Targetvalue:
Relerto oscilloscope
curve

4un PEEBu^
...rlnqfl,...:1,!.9.uit..

i; lu, 20!5/r I! T.i .:at 3; ,u*

ffi**IMTlffiq'T-Fsl
atEr3iqnal aAt 11i41 (mar A
CA$ l.tr !i&al E

T 18 8.40- 33
 otAGNOStS

SETTORQUEBIT ERROR

Indicationof fault: Centralwarninglampstays illuminatedred whiledrivingand whenat a slandstill

Effectivetault: Enginegoesto idling

Causeof fault: FFRsendsinvalidnumericalvalue

Faultinpuis to other control unitsl Yes,FFR

Notevehicle-related
circuildiagrams

Vehicledatafile - Checkcontrolunilparametering
EDCcontrolunit Measurementof resistance - Checkcables
betweenpin821 (CAN-L)and
822 (CAN-H) Checkconnectors
- ShortcircuitfromCAN-Hto CAN-Lat
Targetvalue:-120 O approx.0 ohm
Vehiclemanagement l/leasurement
ol resislance - lf no taultif found,replacecontrolunil
compuler(FFR) betweenpin X1/12(CAN'L)and OTFFR
xln0 {CAN-H)
Targetvalue:-120 O
M-CANdatabus Targel value:
Referto oscilloscope
curve

HSII{u'
rs
FilSBu*
rlntunr,. rl,!! .ul1
-:B1.1
-l l i i .,.:

n- | U,rr eils/r f! Trrs:AJ B- | U,/.

o|m{l#FTlrq"*-r
lf'"-*
iL.nsiwal f,qt fi1q! Rma] A
tr,l l.! Hmal !

8.40- 34 T 18
 DIAGNOSIS

MAX.SPEEDREGULATION
PARA IETERBIT ERROR

Indicationot lault: Centralwarninglampstays illuminatedyellow whiledrivingandwhenal a standslill

Elfectivefauli: Conlrolparamelerset'0' is active,possiblepoorenginerunningup to currenispeed

regulalion

Causeof tauli: FFRsendsinvalidnumerical

value

FaultinDutsio other conllol units: Yes.FFR

Nolevehicle-relaled
circuitdiaorams

Vehicledatalile - Checkcontrolunitparametering
EDCcontrolunit Ivleasurement
ol resistance - Checkcables
betweenpin821(CAN-L) and
822 (CAN-H) - Checkconnectoas
- ShortcircuitlromCAN-Hlo CAN-Lat
Targetvalue: -120 Q approx.0 ohm
Vehiclemanagement Measuremenlol resislance - ll no laultif found,replacecontrolunit
computer(FFR) betweenpinX1/12{CAN-L)and OTFFR
x1/10(cAN-H)
Targetvalue: -120 O
lVl-CANdata bus Targetvalue:
Reterto oscilloscope
curve

fl3jl4u'
re,l l. uq
fl?5Eu*
irAltui!
::,::i

a ':
::ii:t: ::
;.... ... i.. .i.... . . ; | .. .. .1....1..
A* I U, 20L3, 5l lrig:hj B; I U/!

[H"*.M{lFFEI"u;:-Fsf
alrnsiqnaL t*II 6iq1: ::ansl li
lAn r.r, Sena: E

T 18 8.40- 35
DIAGNOSIS

EDRliIIN.TARGETVALUENOTREACHED

Indicationol fault: Centralwarninglampstays illuminatedyellow whiled vingandwhenat a slandstill

Efiectivefault: Enginegoeslo lowestpermitted

maximumspeed(D08/D28:1000rpm)
Causeot taull: FFRrequestsa maximumspeedthat is too low(EDR)

Faultinputs to other contjol units: Yes,FFR

Notevehicle-related
circuitdiagrams

Vehiclemanagement Checkcontrolunitparametedng
comp'iter(FFR) (vehicledatafile)
Customized
control - Checkconfolunit parametedng
module{KSM)

8.40- 36 T 18
 oraGNosts

EDRTARGETVALUEBIT ERROR

Indicationot fault: Centralwarninglampstays illuminatedyellowwhiledrivingandwhenal a standstill

Effectivefauh: EDRreductionin maximumspeedis withdrawn,

enginecan run up slowly

Causeottaull: FFRsendsinvalidnumericalvalue

Fault inDutsto other control units: Yes.FFR

Notevehicle-related
circuitdiagrams

- Checkcontrolunitparametedng
EDCcontrolunit lreasuremontot resistance - Checkcables
betweenpin 821 {CAN-L)and
822 (CAN-H) - Checkconneclors
ShortcircuitlromCAN-Hto CAN-Lat
Tar96ivalue:-120 Q approx.0 ohm
Vehiclemanagement Measuremenlof resislance - ll no faultif tound,replaceconlrolunit
computer(FFR) betweenpinX1/12(CAN-L)and OTFFR
x1n0(cAN-H)
Targelvalue: -120 O

di lu/r 20F5/i S T.is:aI 3; I u,/r

|fi*. ,:' liE {[i"ffF:lc'{rt.srI
ater13iqna.:. gAI,l E -sh l:nea A
a$I tr$ liaie! E

T 18 8.40- 37
DIAGNOSIS

ZDRTARGETVALUEBIT ERROR

Indicationol lault Centralwaminglampstays illuminatedyellow whiledrivingandwhenat a standstill

Efteclivefault Enginedoesnot run in permissible

speed(ZDR)mode
Causeol lault FFRsendsinvalidnumerical
value
Faull inputs to other control units: Yes,FFR

Notevehicle-related
circuitdiagrams

Checkcontrolunitparamelering
EUU COnrOtUn|I Measutemenlof resistance - Checkcables
betweenpin821 (CAN-L)and
822 {CAN-H) - Checkconnectors
- ShortcircuitfromCAN-Hto CAN-Lat
Targetvalue:,120 O approx.0 Ohm
V6hiclemanagemenl lreasurement
o{ resistance - lf no lauhit found,replacecontrolunit
computer(FFR) betweenpinX1/12(CAN-L)and OTFFR
x1110(oAN-H)
Targetvalue:,120 Q
lvl-CANdatabus

H3jl4u^ EISEu'
vc.. ranrr r'1.03
-r4t.l.
' ltlll
tt t t;
'a llll ll ll

i : iiP it H t
..:l :::

tu lt/r 1[Es7r Trigtqj B; llrlJ

A*n'M{l$FryfmTmf -!

atenelqnal CIl[ High X€n.1

CAil hn liar1al B

8.40- 38 T 18
 DIAGNOSIS

MEOSREOUESTBIT ERROR

Indicationof fault: Centralwarninglampstays illuminaledyellowwhiledrivingandwhenat a standstill

Effectivetaulii I\IEOS(momentary
engineoverspeed)
requestis wilhdrawn

Causeot Iault: FFRsendsinvalidnumerical

value

Faultinpuls to oiher conlrol uniis: Yes,FFR

Notevehicle-related
circuitdiagrams

vehicledatalile - Checkcontrolunitparameteing
Measuremenl of resislance - Checkcables
betweenpin 821 (CAN-L)and
822 (CAN-H) - Checkconnectors
- Shortcircuit{romCAN-Hto CAN-Lat
Taigetvdlue: - 120 O approx.0 ohm
Vehiclemanagemenl Measurement of resistance - ,t no laultil found,replacecontrolunit
computer(FFR) betlveenpinX1/12(CAN-L)and OTFFR
x1/10(cAN-H)
Targetvalue:-120 O
Taoet value:
Relerto oscilloscope
curve

?3j14,,B?5Bu^
u*,
."ll i* . lonlo',
'l'e

,-
l

lrEnsllna.l ll]I Eigl' ?ara1 A

flt lor !ide] E

T 18 8.40- 39
 DIAGNOSIS

REQUESTTO SHUTDOWN
EDCINTERNALRAMPBIT ERROR

Indicationof fault: Centralwaminglampstays illuminatedyellowwhiled vingandwhenat a standstill

Ettective fault: Rampsare re-activaled

Causeot fauh: FFRsendsinvalidnumerical

value,transmission
controlunitsendsinvalidvalue
Faull inputs to other control unils: Yes,FFR

Notevehicle-related
chcuitdiagrams

Vehicledata file - Checkcontrolunitparametedng

EUU COnrOtUnlI Measurementof resistance - Checkcables
betweenpinB2'1(CAN-L)and
822 (CAN-H) - Checkconnectors
ShortcircuittromCAN-Hto CAN-Lat
Targetvalue:-120 O approx.0 Ohm
Vehiclemanagemenl llleasurement
of resistance - lf no laultif lound,replacecontrolunit
computer(FFR) betweenpinX1/12(CAN-L)and OTFFR
xl/10 (CAN-H)
Targei valuel -120 O
Targei value:
Referto oscilloscopecurue

93fl4u, H?53*
I up lenrar...r!,oglrs.
-r?l

Hrqn 6nr'ta1 A
ctr B

8.40- 40 T 18
 otAGNOStS

CHECKOF CONTROLBIT(FFR1MESSAGE)

IndicationoI lault: Centralwaminglampslays illuminaiedyellowwhiledrivingandwhenat a standslill

Ellectivefault: None

Causeof fault: FFBsendsno "1" in the controlbits

Fault inDutsto other control units: Yes.FFR

Nolevehicle-related
circuitdiagrams

Vehicledatafile - Checkcontrolunitparametering
EDCcontrolunit Measurement of resistance Checkcables
betweenpin 821 (CAN-L)and
822 (CAN-H) - Checkconnectors
- ShorlcircuitfromCAN-Hto CAN-Lat
Targetvalue:-120 f,) approx.0 ohm
Vehiclemanagement Measurementof resistance - lf no faultif lound,replacecontrolunit
computer(FFB) betweenpinX1/12(CAN-L)and OTFFR
x1/10(oAN-H)
Targetvalue:-120 O
lvl-CANdala bus Targelvalue:
Referto oscilloscope
cuwe

P3:l
4u* ??5fl,'
_:el.t..
*.,. ltn"o*.,..tlot'."t'..
.

$i I U/:

arP1'13tg::et 1ll{ iii-sh X€ndt !

l1l'l lo$ lien*l t

T 18 8.40- 41
DIAGNOSIS

TOROUETARGETVALUETOO LOW

lndicationof fault: None

Efiectivefault: Enginegoesto idling

Causeof tault: FFRrequestsa torquethat is too low

Faultinputs to other control units: Yes,FFB

Notevehicle-related
circuitdiagrams

Vehicledata lile - Checkcontrolunitparametering

EDCcontrolunit Measurement ol resislance - Checkcables
betweenpin 821 (CAN-L)and
822 (CAN-H) - Checkconnectots
- ShortcircuitfromCAN-Hto CAN-Lal
Targetvalue: -120 Q approx.0Ohm
Vehiclemanagement Measurementol resislance - lf no faultif found,replacecontrolunit
computer(FFR) betweenpinX1112(CAN-L)and OTFFR
x1/10(oAN-H)
Targetvalue: -120 O
l\4-CAN
databus Targetvalue:
Referto oscilloscope
curve

.'i |'.:,:.:,.1 rl
: :i I I : .

20!s/J f! Irrq:AJ B: I u,,r

TNIGGEB:YIOl|TBisT
5L0P E .r :
aterdtgnal [AIl ali!'h X8nar I
c.{t lo0 I(daI E

4.40- 42 T 18
 DIAGNOSIS

IDLINGTARGETVALUEBIT ERROR

Indicationof fault: Centralwarninglampstays illuminatedyellowwhilediving andwhenat a standstill

E fective fauli: Enginegoesat EDo-intemal

idlingspeed(D08:600 rpm)

Causeot tault: FFRsendsinvalidnumerical

value

Fault inputs to other control units: Ye6.FFR

Notevehicle-related
circuildiaorams

Vehicle data file Checkcontrolunitparametering

EDCcontrolunit Ivleasurement
of resislance Checkcables
betweenpin821 (CAN-L)and
822 (CAN-H) - Checkconnectors
- ShortcircuittromCAN-Hto CAN-Lat
Targetvalue:-120 O approx.0 ohm
Vehiclemanagement Measurementol resistance lf no taultit found,replacecontrolunit
computer(FFR) betweenpinXll12 {CAN-L)and OTFFR
x1n0 (oAN-H)
Targetvaluei-120 O
Targetvalue:
Referto oscilloscope
curve

P?8u^
l[9 uc
p..r.:AL
-:?l'l ug
:'.':.'':'
,l l ::l :::

! |J p lr LrFFr l.J
'a

i; I Ul3 20!s/: E' lriqrA.l Ei I U4

ffiFHEIImFEI'q-*-l
at€niiqnal CAI liiqil KanEl A
CAlr L.r lltrra] t

T 18 8.40- 43
DIAGNOSIS

IDLING.SPEED
CONTROLLER
PARAMETER
BIT ERROR

Indicationot fault: Centralwarninglampstays illuminatedyellowwhileddvingandwhenat a slandstill

Effectivetault: ldling-speed parameterset"0' is activated

controller

Causeol fault: FFRsendsinvalidnumedcal

value

Fault inputs to other cont.ol units: Yes.FFR

Notevehicle-relaled
circuitdiaorams

Vehicledatatile - Checkcontrolunilparametering
EDCcontrolunit Measurementot resistance - Checkcables
betweenpin821 (CAN-L)and
822 (CAN-H) Checkconneclors
- ShortcircuitlromCAN-Hto CAN-Lat
Targetvalue:-120 f,) approx.0 ohm
Vehiclemanagement lleasutementof resistance - lf no lault if lound,replacecontrolunit
computer(FFR) betlveenpinX1/12(CAN-L)and OI FFH
x1l10(CAN-H)
Taiget value:-120 O
Targetvalue:
Beferlo oscilloscope
curve

T3jl4u* flfl53u0

tu I Ut: aars, 3 T.ig:nl [i l ar/r

ffi;M:IFFTI"q'*T
atens1lral alll ltiqh Ranal
CAiI Lor XeaI !

4.40- 44 T 18
 DIAGNOSIS

REOUESTED
TARGETIDLINGSPEEDTOOHIGH

Indicationof faull: Cenlralwarninglampstays illuminatedyellowwhiledrivingand whenat a standslill

Effeclivelault: possibleidlingspeed(800rpm)is operated

l\4aximum

Causeot fault: FFRrequestsidlingspeedhigherthan800 rpm

FaultinDutsto other control units: Yes.FFR

Notevehicle-related
circuitdiagrams

Vehicledata file - Checkconlrolunil pa€metering

I\reasurement
of resistance - Checkcables
betweenpin 821 (CAN-L)and
822 (CAN-H) Checkconnectors
- ShortcircuitfromCAN-Hto CAN-Lat
Targetvalue:-120 o approx.0 ohm
Vehiclemanagement lvleasurement
o{ resistance - lf no taullil found,replacecontrolunil
cornpuler(FFR) betweenpinX1/12(CAN-L)and OTFFR
xl110(oAN-H)
Targetvalue: -120 O
M-CANdalabus Targetvalue:
Beferto oscilloscope
curue

P3-94*??5Bu^
tlot u*,.
,t*!.1..*
.,...9ntot
,.

i ,,;t)tl
Ai I U,,r l0rs/i t! T.is:it Ei , u/.
A*.+MItPCET-ry*'l
CAI.IHiarhtnn6l
ttt !

T 18 8.40- 45
DIAGNOSIS

STANDALONEREOUESTBIT ERROR

Indicationot tauR: Centralwarninglampstays illuminatedyellow whiledrivingandwhenat a standstill

Eftectivefault: EDCgoesintosland-alone (idling)

operation

Causeol lault: FFRsendsinvalidnumedcalvalue

Fault inpuls to other contiol units: Yes,FFR

Nolevehicle-related
circuitdiaorams

Vehicledatalile - Checkcontrolunitparamelering
EDCcontrolunit lreasuremenlof resislance - Checkcables
betweenpin 821 (CAN-L)and
822 (CAN-H) - Checkconnectors
ShodcircuilfromCAN-Hto CAN-Lat
Targetvalue:-120 O approx.0 ohm
Vehiclemanagement Ivleasuremenl
of resistance - lf nofaull il found,replacecontrolunit
comPuter(FFR) betweenpinX1112(CAN-L)and OTFFB
x1/10(CAN-H)
Targeivalue:-120 O
Targetvalue:
Reterto oscilloscope
curve

$3Il4u*8fl58"0
,r3l l ue
mXUi!....r':,Bg
u!
:i:l::

A; I U,rr 20}s/r E l.rq:AJ Bi t U/r

tE"*o|ffi'lfFFql.q.*r
tll{ !

8.40- 46 T 18
 DIAGNOSIS

STARTREOUESTBIT ERROR

Indicalionot lault: Centralwaning lampstays illuminatedyellowwhiledrivingandwhenat a standstill

Etfeclivefault: No startercontrol

Causeof faull: FFRsendsinvalidnumedcalvalue

Faultinputs to other contlol units: Yes,FFR

Nolevehicle-related
circuitdiagrams

Vehicledata file - Checkconlrolunitparamelering

EDCcontrolunit lvleasuremenl
of resistance - Checkcables
betweenpin B21(CAN-L)and
822 (CAN-H) - Checkconneclors
ShortcircuitfromCAN-Hto CAN-Lat
Targetvalue:-1 20 Q approx.0 ohm
Vehiclemanagement Measurementof resislance - lf no taultil found,replacecontrolunit
computer(FFR) belweenpinX1/12(CAN-L)and OIFFR
x1n0 (cAN-H)
Targelvalue:-120 Q
L/.CANdalabus Targetvalue:
Referto oscilloscope
curve

P3jl4u^H?58,,
,rfltl..ec....m$n"...rlJS.!a
..
_:...
::'

:llllllllllLLllll
: f,r ts t' f-, |JiJFr tr
'E

:-: : : : : :-
:: ...' l l
Ai I urr ?ous/: I! T.is:at 3i t rrrr
ffi*c'M$FFEI'-ET€I
liellsrqt}al CAI'IHl{L (anr A
L_}l'l Lu lituial B

T 18 4.40- 47
DIAGNOSIS

ENGINE
STOPREOUEST
BITERROR

Indicationol fault: Centralwarninglampstays illuminatedyellow whiledrivingandwhenal a standstill

Eftectivefault: Engineis notshutdownvia FFR

Causeof fault: FFRsendsinvalidnumedcalvalue

Faultinputs to other control units: Yes,FFR

Nolevehicle-related
circuitdiagrams

Vehicledatafile - Checkcontrolunitparametering
EDCcontrolunit Measurement ol tesistance - Checkcables
betweenpin 821 (CAN-L)and
822 (CAN-H) - Checkconneclors
- ShortcircuitfromCAN-Hlo CAN-Lat
Targetvalue:-120 s) approx.0 ohm
Vehiclemanagement Measurementof tesistance - lf no laultiJlound,replacecontrolunit
compuler(FFR) betweenpinX'l/12(CAN-L)and OTFFR
x1110(oAN-H)
Ta.getvalue:-120 O
Targetvalue:
Referto oscilloscope
curue

I 'a

rNrGcEBaTc0iirinST
5L0PE o a
Elgh tra-:la.L
ctl{ !

8.40- 48 T 18
 DIAGNOSIS

CHECKOF CONTROLBIT (FFR2MESSAGE)

Indicaiionol tault: Centralwarninglampstays illuminatedyellowwhiledrivingandwhenat a standstill

Ellectivefault: None

Causeof fault: FFRsendsno "1" in the controlbits

Faull inputs to other control units: Yes,FFR

Notevehicle-related
circuitdiagrams

vehicledatafile - Checkcontrolunitparametering
EDCcontrolunit Measurement ol resistance - Checkcables
betweenpin 821 (CAN-L)and
822 (CAN-H) Checkconnectors
- ShortcircuilfromCAN-Hto CAN-Lat
Targetvalue:-120 O approx.0Ohm
Vehiclemanagemenl Ivleasurement
of resistance - lf no taull if found,replacecontrolunit
computer(FFR) betweenpinX1/12(CAN-L)and OI FFR
x1/10(cAN"H)
Targelvaluei-120 O
databus
|\,|-CAN Targetvalue:
Flefer
to oscilloscope
curue

F3T4,*??50u'
,rel ':.. ! 9 . . . 1 1 4 r y * . 1 , 0 9u *

:...,. ..i .. .i ....i ...t. .. . . ....t.. .;

6i t lrli 2085./! E T.is:6J 3; lU/r
m;EM::Frq'*T"5r
atrlsrqna] CAI iiigil l{€nal ,1
cAx 1o{ !i&q.l B

T 18 8.40- 49
DIAGNOSIS

TIMEOUTFFR2MESSAGE

lndicationof lault: Centralwaminglampstaya illuminatedyellowwhiledrivingandwhenai a standstill

Effeclivefault: Instructions
ol FFR2messagesnotimplemented

Causeof lault: No reception

of FFR2messages

Fault inputs lo olher control unils: Yes,FFR

Notevehicle-relaled
circuitdiagrams

T&r :
Vehicle data file - Checkcontrolunitparameteng
EDCcontrolunit Measuremenl of resistance - Checkcables
betweenpin 821 (CAN-L)and
822 (CAN-H) - Checkconneclors
ShortcircuitfromCAN-Hlo CAN-Lat
Targetvalue:-120 O approx.0 ohm
Vehicle management Measurementof resistance lf no taultif lound,replaceconlrolunit
computer (FFR) betweenpinX1l12(CAN-L)and OTFFR
x1/10(CAN-H)
Targetvalue:-120 Q
M-CANdatabus Targel value:
Relerto oscilloscope
cuNe

E3Il4u,
t *,
T?58,*
tl o ' .u *
..n t" o * .,

l.Fl...:!.rL]..

20!s, ft lris:Aj
TflIGGEE'
SL0PE !l

aL.nsiqnal CAII Hlgh

llt[ ],r!

8 . 4 0 ,50 1 18
 DIAGNOSIS

ACCELERATOR
PEDALPOSITION
SENSORBIT ERROR

Indicationot fault: Centralwarninglampsiays illuminatedyellow whiled vingandwhenat a slandstill

Effectivefault: No tunctional
limitation
pedalposition{MAN-catslilonitoring)
outputaccelerator 0%
Causeoftault: FFRsendsinvalidnume calvalue

Faultinputs to olher conkol unit6: Yes,FFR

Nolevehicle-related
circuitdiagrams

Vehicledata file - Checkcontrolunilparametering

EDCcontrolunit Ivleas!rement
ol resistance - Checkcables
betweenpin 821 (CAN-L)and
822 (CAN-H) Checkconnectors
- ShortcircuittromCAN-Hto CAN-Lat
Targelvalue: -1 20 Q approx.0 ohm
Vehicle management lreasurement
ot resistance - lf no laultif found,replacecontrolunit
compuler(FFR) betweenpinX1/12(CAN-L) and OTFFR
x1/10(CAN-H)
Targetvalue:-120Q
M-CANdalabus Targelvalue:
Referto oscilloscope
cuwe

PSjl Ug
-r?.1.1
??5ru^
4r*t"nitt tut, *,
l
,

I I
:
iiii:l:..
.; t lr, l0!s/! B TristA"l Bi I U,
lil*aMll$Fsl-ry*f
L_,{tiIHig! }i*il A
Cili L0!r Xanal E

T r8 8.40- 51
DIAGNOSIS

VEHICLESTANDSTILL
DETECTION
BIT ERROR

Indicationof lault: Centralwarninglampsiays illuminatedyellow whiledrivingand whenat a standstill

Eftectivefault: Despitethevehiclebeingal a standstill"movingvehicles"is detected

Controlunitprogrammingpossibleonlywithinterrupted CAN
Run-uplesl andcompression test notavailable
Cauaeot fault: FFRsendsinvalidnumerical
value
Faultinputs to other control units: Yes.FFR

Nolevehicle-related
circuitdiagrams

Vehicledatafile - Checkcontrolunitparametering
EUU COmrOtUn|I Measuremenl of resislance - Checkcables
betweenpin 821 (CAN-L)and
822 (CAN-H) - Checkconneclors
- ShortcircuitfromCAN-Hto CAN-Lat
Targelvalue:-120 O approx.0 Ohm
Vehiclemanagement Measuremenl of resistance - ll no faultif found,replacecontrolunit
computer(FFR) betweenpin Xl/12 (CAN-L)and OI FFH
x1/10(oAN-H)
Targetvalue:-120 O
- Applypaftingbrake
Instrumentalion - Checklachographand Kitassensor

[,]-CANdalabus

fl334u^?Es
E u*
l!3 !rg.
:l i

ateniiqnal l&,1 flrgh R&ar A

IAS l,rr Rdar E

4.40- 52 T 18
 DIAGNOSIS

CHECKOF CONTROLBIT (FFR3MESSAGE}

Indicationot fauli: Centralwarninglampstays illuminatedyellowwhiledrivingandwhenat a standstill

E fectivefaull: None

CauseoI fault: FFRsendsno "1" in the controlbits

Fault inputs lo olher control units: Yes,FFR

Notevehicle-related
circuitdiagrams

Vehicledatalile - Checkcontrolunitparamelering
Measurement ol resistance - Checkcables
betweenpin 821 (CAN-L)and
822 (CAN-H) - Checkconnectors
- ShortcircuitfromCAN-Hto CAN-Lat
Targetvalue:-120 O approx.0ohm
Vehiclemanagement I\reasurementol resistance - lf nofaultif lound,replacecontrolunit
computer(FFR) betlveenpin Xl/12 (CAN-L)and
x1/10(CAN-H)
Targetvalue: -120 Q
tul-CAN
databus Targetvalue:
Referto oscilloscope
curve

?3T4,,
*
P|SBu*ir e
11"09
.ral l , . . t - , t lt t q a ! . .

I B

:
!i ;i ;i :i l
e i tu , 20!s,.r s Tri s:A .i .; ,u/:
lil**M;:Rql'*T*l
aien3iqnal CAI Eigir fimal A
CANLod l:ma] B

T 18 8.40- 53
oTAGNOSTS

TIMEOUTFFR3MESSAGE

Indicationot fault: Cenlralwarninglampstays illuminatedyellow whiledrivingandwhenat a standstill

Effectivetault: Stannotpossible(immobilizer)

Causeof fault: No receptionof FFR3messages

Fault inputs to other contrcl units: Yes,FFR

Notevehicle-related
circuildiaorams

EDCcontrolunit l/leasuremenl
of resislance - Checkcables
betweenpin 821 (CAN-L)and
822 (CAN-H) - Checkconneclors
- ShodcircuitfromCAN-Hto CAN-Lat
Targetvalue:-120 O approx.0 Ohm
Vehiclemanagement Measutemenlof resistance - ll nofaultif found,replacecontrolunit
comPuter(FFR) betweenpinXl112(CAN-L)and OT FFH
x1n 0 (CAN-H)
Targetvaluei -120 O
M-CANdatabus Targei value:
Reterto oscilloscope
curve

fl354urinrnun
+qt I U?'
PISHu^
. rt!9 .ug.
.i

Hiqh X:rnal
t&$ F

8.40- 54 T 18
 D|AGI{OS|S

F TIMEOI'TTIESSAGE
PONT10

hdbnbn ol Irult None

Ellccdvctault Engin€startnolpossiblebecauseot abs€r*immobilizsr
lD
Cauaaof Lull: €ror du€lo gxcasSiwCANbusbad
Transmission
Frult Inpnt lo othcr conlrol unit : Yes,FFR
Notev€hiclerelaledcircuitdiagramg

CAN ir erconnoclion - Removeintod6rgnco

\roltage

T 18 8.40- ss
DIAGNOSIS

STARTERCONTFOLFAULT

Indlcation of flult Centralwaminglamp aby. illuminat d red while drivingand when at a standstitl

ElHiv. trult: Fault in stan€r path, it may not be possiblelo start the €ngin6

Cau.c ot t ult Voltagedrcp in banerytoo low on strarting

Flull inpuL to othcr cantrol uniL:

Nole vehicle-rBlal€dcircuitdiagrams

IMB.elay Measurememof rosistanc€ - Checkcables

belweenpinA16and pinA19
- Ch€ck connectors
Targal valuc: - Replaco|MRrehy
15-30f,r - Replacestarter
- ll no fauh is found, replace
contrclunit

8.40- s6 T 18
 D|AGitosts

,K ATiIOSPHERICPRESSURE
SENSOR

Indicalion of fauh: Centralwaminglamp3toy3 illuminat d y.llow while drivingand when at a slandstill

E lGcliv. fEult: None

Causa ol feull: Monhoringfor voltagelimits

Fauh inputa to other conlrol unila:

Not : Ref€rto SPN t08

Nole vehicle-relatedcircuitdiagrams

Contolunit Ch€ckplausibility
of signalusing - lf no tauhis tound,replace
MAN{ats Monitoring dudngidling, conlrolunit
usinga charg€-air
Pressurc
s€nsor

T 18 8.40- 57
DIGNOSE

TI!/|EOUTMESSAGEPOINT5

Indicationot tault: None

Efiectivelault: EDCI message(EDCstatus,EDCmode,EGRelc.)notavaitabte

in the FFR
Causeot faull: EDCI messagetransmission
efior dueto excessiveCANbus load
Fault inputs to othe. conlrol units: Yes,FFR

Notevehicle-relaled
circuitdiagrams

EDCcontrolunit Measurement of resislance - Checkcables

betweenpin 821 (CAN-L)and
822 (CAN-H) - Checkconnectors
- ShoncircuitfromCAN-Hto CAN-Lat
Tdrgetvalue: -120 O approx.0 Ohm
Vehiclemanagement Measurementol resistance - ll nofaultif tound,replacecontrolunit
computer(FFR) betweenpinX1/12(CAN-L)and OT FFH
x1n0 (CAN-H)
Targetvalue: -120 O
M-CANdatabus Targetvalue:
Beferto oscilloscope
curve

P354
,ret.t ulj
- . . , '. 'j ''. '

. . l l J i l l. l J

Ai lU/ r 20!3 / i E! T.rq:AJ B; lU/i

|E*nsMIlFFTIrml'Esf
erensigla1 aArt :liqh (aa] a
:itt ls (Enal I

8.40- 58 T 18
 DIAGNOSIS

TIMEOUTMESSAGEPOINT6

lndicationoI fault: None

Effectivefault: EDC2message(injectors,
ZDRspeed)notfiftedin FFR

Causeof fault: EDC2messagetransmission

eror dueto excessive
CANbus load

Fault inputs lo other control units: Yes,FFR

Notevehicle-related
circuitdiagrams

EDCcontrolunit lvleasuremenl
of resistance - Checkcables
betweenpin 821 (CAN-L)and
822 (CAN-H) - Checkconnectors
- ShortcircuitlromCAN-Hto CAN-Lat
Targetvalue:-120 O approx.0 ohm
Vehiclemanagemenl Measurement of resislance - lf nofauli if lound,replacecontrolunit
computer(FFR) betweenpin X1/12(CAN-L)and OTFFR
x1/10(cAN-H)
Targeivalue:-120 f,)
Targetvalue:
Relerto oscilloscope
curve

Pljl4u* Ft58,'
rnrvo tt09 w
,t4l.l.ug

:; -: : L l. . l. . . , . . 1 . I :
& t U, ?0!s4 E! l}asrA, Bi I t/i
IilFM;IFFTI"-F*I
s:er::riglnl [Il{ High gusl I
|lII l.!r Xmal !

T 18 8.40- 59
DIAGNOSIS

TIMEOUT!/|ESSAGEPOINT7

Indicalionot fault: None

Effectivefault: EDC3message(idling,maximumspeed,inlermediate
speedparamelersets)not
availablein the FFR

Causeot leult: EDC3messagelransmission

errordueto excessive
CANbusload
Fault inputs io olher contiol units: Yes,FFR

Nolevehicle-related
circuitdiaorams

EDCcontrolunit l,leasurement
of resislance - Checkcables
betweenpin 821 (CAN-L)and
822 (CAN-H) - Checkconnectors
- ShortcircuilfromCAN-Hto CAN-Lat
Targetvalue: -120 O approx.0 ohm
Vehiclemanagement ldeasurement
of resistance - lf no lauftil found,replacecontrolunit
computer(FFR) betweenpinX1112(CAN-L)and OTFFR
xlno (CAN-H)
Targetvalue: -120 O
M-CANdatabus Targetvalue:
Referto oscilloscope
curue

fl3j14,' Efl58uo

drrensl$ra.L flll High fidal I

CAll l0o l<{al E

8.40- 60 T 18
 DIAGNOSIS

AFTERRUNNOTENDED

lndicationof tault Centralwarninglampstays illuminatedrod whiledrivingandwhenat a slandstill

Elfectivetault: None,laultstoragepossiblein EDC

Causeoftault: Thelasltwo afterrunswerenotcorrectlvended

FaultinDutsto other control unils:

Note: lf the vehicleis shutdowntoo ottenby using"EMEBGENCY

OFF"(fittedin dangerous
goodstransporters) thislaultalsooccurs.

Notevehicle-related
circuildiao.ams

Controlunitpower lreasurementol voltagebetweenpins - Checkplausibility ol signalusing

supply A01,A07,412andA13(+)andpins MAN-calslronitoing
A03,A09,A14 andA15 (-)
- Checkcables
Targetvalue:20 -28 V - Checkconnectors
- lf no faullis found,replace
conlrolunit

T 18 8.40- 61
DIAGNOSIS

SIAND ALONEMODEOF EOC

IndicationoI fault: Cenlralwarninglampstays illuminatedred whiledrivingandwhenat a standslill

Etfectivefault: EDCcontrolunitgoesto "Standalonemode"(i.e.enginerunsin idlingand doesnot

accelerate)

Causeof tauli: FFRrequestsstandaloneoperalion,

engineCANinlerrupted
Faull inputs to other contrcl units: Yes,FFR

Nolevehicle-related
circuildiagrams

EDCcontrolunit ldeasurement
of resistance - Checkcables
betweenpinB21 (CAN-L)and
822 (CAN-H) - Checkconnectors
- ShortcircuitfromCAN-Hto CAN-Lat
Targelvalue:- 120O approx.0 Ohm
Vehicle managemenl I\reasurement
of resistance - lf no faullil found,replacecontrolunit
computer(FFB) between pinX1/12(CAN-L) and OTFFR
x1/10(CAN-H)
Targeivalue:-120O
lvl-CANdatabus Targetvalue:
Rererto oscilloscope
curve

fl3jl4un
:?'l I us
E?58"
rrury 11,0.9.
vg..

arensigral lAlt Hilh Xarat A

t$l llri KirBI B

8.40- 62 T 18
 DIAGNOSIS

IMMOBILIZEF

Indicationol fault: Cenlralwaminglampstays illuminatedred whilediving andwhenat a standstill

E iective fault: Slarlerturns,enginedoesnotstart

C6useof fault: lmmobilizer

lD in the FFRand EDCcontrolunitdoesnol match

Fault inpuls to olher conllol unils: Yes,FFR

Notevehicle-relaled
circuitdiagrams

l\4AN-cats
diagnosis ol paifng
- Correction
Vehicledatatile parametering - Checkcontrolunitparameledng
l\,lAN-cats

T 18 8.40- 63
DI,AGNOSIS

rri oBtLtzER

Indlc.tlon of fault Cer ral waming lamp rtlya illumin.t d rrd while drivingand when at a standstill

Eltcctlva lault Starterlums, onginedo€s not atarl

C6u.. ot t ult lmmobilizerlD in lhe FFB and EDCcontrolunit does noi match

F.uh inpuls to olhcr control unitr: Yes, FFR

Nole vehicle-relaledcirtuil diagrams

- Checkconlrol unit Daramelerin

8.,t0- 64 T 18
 DIAGNOSIS

CHARGE-AIR
PRESSURE
@NTROL

Indication of f.uh: Centralwaminglamp .tay8 illumi'|.Ld tld while drivingand whenat a standstill

Efi.ctivc taulti Sp€edroductionto1800 lpm and torque reduction

Crua. of laulk Charge-airprossur€largel value cannol bo achieved

FaultInpul3lo othar control unila:

Nolc: Thistaultoccursonlyon D084-cylinderenoines

Notevehicle-relatedcircuitdiagrarns

pressure Measurement
Charg€-air ol resistance - Ch6ckcableG
aqualot b€twsenpinAm andpinA04
- Checkconn€ctors
Targclvaluc: - Checktimingvalve (ac{uator
5 5 -8 5 (} t€s0
- lf rE faull is tound,replace
conllol unit
Compressed
airsupply - CheckchaEe-airsupplyline

- Referto EngineRopairManual

Relerto SPN 102 and 3088 - RetertoSPN 102and3088

T 18 8.40 - a5
 DIAGNOSIS

OIL PRESSURE
SENSORPLAUSIBILITY

IndicalionoI lault: Centralwarninglampstays illuminatedred whiledrivingandwhenat a standstill

Effectivetault: None

Causeot tault: Faultclassification

if engineis at standstillandthe oil pressureis > O.Sbar or if lhe oil
pressureremainsthe samewilhthe enginerunning

Faultinputs to other control units:

Notevohicle-related
circuildiagrams

Oilpressure Targetvalue: 1.5- 5.4bar Checkoil level

Checkoilsupply
Checkfor oil dilution
Powersupply Measurementof voltage Checkplausibility of signalusing
betweenpinA24 (+)and ptn MAN-calsMonitodng
A38 (-)
Checkcables
Targetvalue:4.75- 5.25V Checkconnectors
Signalvoltage l/leasurement
of voltage Replaceoil pressuresensor
betweenpinA21 (+)and pin
A38 (-) lf no faultis lound,replace
controlunit
Targetvalue: 1.96- 4.81V

0
oar

8.40-66 T18
 DIAGNOSIS

EGRACTUATORENDPOSITION

IndicationoI fault: Centralwarninglampstays illuminaledyellow whenal a standstill

E tectivefault: EGRopenis outpulas equivalent

value

Causeof tault: lorvoltagelimits(supplyandsensorvoltage)

Monitoring

FaultinDutsto other contlol units:

Notevehicle-related
circuitdiagrarns

Feedback switch(reed lvleasurement

of resislance - PedormactuatorlestusingMAN-cats
contacl) betweenpinA23andA22
Checkcables
Targetval u e : < 1 O - Checkconnectors
Solenoidvalvecontroller lreasurementof resistance - ReplaceEGBactuator
between pin417 and411
- lf no taultis found,replaceconlrolunit
Targetvalue:80 - 110O
Freedomof movement of Repairor replaceEGRvalve
valveactualion

T 18 4.40- 67
DIAGNOSIS

OIL PRESSURE
SENSOR

lndicationof lault: Centralwaminglampstays illuminatedred whiledrivingandwhenat a standstjll

E fectivefault: Outoutof 1 baras eouivalent

value
Causeot taull: forvoltagelimits(supplyand sensorvoltage)
Monitoring

Faultinputs to other contrcl units:

Nolevehicle-related
circuitdiagrams

Powersupply Measurementof voltage Checkcables

betweenpinA24 (+) and pin
A38 (-) Checkconnectors
Replaceoil pressuresensor
Targetvalue:4.75- 5.25V
Signalvollage Measurement of voltage lf no taultis lound,replace
betweenpinA21 (+) and pin controlunit
A38 (-)

Targetvalue: 1.96- 4.81V

I
#

8.40 - 68 T 18
 DIAGNOSIS

PRESSURE
CHARGE-AIR SENSOR

Indicationol lault Centralwaminglampsiays illuminatedred whiledrivingandwhenat a standstill

Effectivefault: Oulputol a simulatedchargeair pressureas equivalenl

value

Causeollault: lorvoltagelimits(supplyand sensorvoltage)

Monitoring

Faull inputs lo olhel control units:

Notevehicle-related
circuitdiagrams

Powersupply Ivleasurement
of voltagebetween Checkcables
pinA25(+)and pin462 (-)
Checkconnectors
Targelvalue: 4.75- 5.25V Replacecharge-airpressure
sensor
Signalvoltage Vollagemeasuremenl between lf no lault is found,replacecontrol
pinA81(+) and pin462 (-) unit

Targetvalues:
0.94-1.20V at0b a r
1.10- 1.40V a10 . 2b a r
Referencevalues:
- 0.5bar.0.50V
0 bar.......
1.07V
0.5bar....1.64 V
1 bat.......2.21V
'1.5bar....2.78V
2 bar.......3.35
V
2.5bar....3.93 V
3 bar.......4.50
V

T 18 8.40 - 69
DIAGNOSIS

CHARGE-AIR
TEMPERATURE
SENSOR

Indic.tlon ot fault: CentElwaminglamp5tay5illuminat d icd whib drivingandwhenat a standstitl

E iEctiv. fault Outplt ot 40 'C as eouival€nlvalue

C.u!c ot tuult Monitoringtor vohagGlimits (supplyand sensorvottage)

Faull inputs to othcr control unita:

Notevehicle-relal€dcircuitdiagrams

Sensorvoltage Measurement
of voltageb€twe€n - Checkcables
pinA76andpinA57
- Checkconn€clors
Targotvaluo: - R€placetemperaturesensor
4.2-2.2Vato -ffi"C - It no laulti6 lound,rgplac€control
unit

Tlrgat valua tablc tolerancc13%

8.40- 70 T 18
 DIAGNOSIS

COOLINGWATERTEMPERATURE
SENSOR

IndicationoI tault Centralwarninglampstays illuminaledJedwhilediving andwhenal a standstill

Effectivefault: Outputof 100"C as equivalent

value
Torquereduclion

Causeof taull: forvoltagelimits(supplyandsensorvollage)

Monitoring

Fault inoutsto other conlrol unils:

Notevehicle-related
circuitdiagrams

Sensorvoltage lreasurement
of voltagebelween - Checkcables
pinA77and pinA58
- Checkconnectors
Targetvalue: - Replacetemperature sensor
3.46- 1.22V at 30 - 90 "C - It no laultis found,replacecontrol
unit

Talget valueiable tolerance

13olo

T 18 8.40- 71
DIAGNOSIS

TIMEOUTOF OATEINFORMATION

Indicalionof fault: Centralwarninglampstays illuminatedred whiledrivingandwhenat a standstill

Elieciivetault: No dateortime information

availableforthe faults

Causeof fault: (year,monthetc.)

Timeoutof dateinlormation

Fault inpuls to other control units: Yes,FFRandtachograph

(MTCO)

Notevehicle-related
circuitdiagrams

Vehicledata filo - Checkcontrolunil parametering

EUU COnIrOtUnl Measurement of tesistance - Checkcables
betweenpin 821 (CAN-L)and
822 (CAN-H) - Checkconnectors
- ShortcircuitfrornCAN-Hto CAN-L
Targelvalue:-120 o at approx.0 Ohm
Vehiclemanagement Measurement of resistance - lf no faullil lound,replacecontrol
computer(FFR) betweenpinX1/12(CAN-L) unitor FFR
andx1/10(CAN-H)
Targetvalue:-120 ct
M-CANdatabus Targetvalue:
T-CANdatabus Referto oscilloscope
curve
l-CANdatabus
Checkfunclion

PJ94,^
*
P?5t,^
u*,
. luniot,
"!t
''tll

ii I U/{ 2l!i/d S! Triq:AJ B; I U,/,

ffi*n"ffill[BFT]-oqE"sf
ie&:itlal C$I ituqh
fA$ L!!r

4.40- 72 T 18
 DIAGNOSIS

CHECKOF CONTROLBIT OIME/DATEMESSAGE)

Indicationof fault Centralwarninglampstays illuminatedred whiledrivingand whenat a standstill

E iective fault: None

Causeof lault: Time/dalemessagedoesnotsend"l" to the reservedmessagepoints

Fault inputs to other control units: Yes,FFR

Nolevehicle-related
circuitdiagrams

Vehicledata file - Checkcontrolunitparametering

EDCcontrolunit Measuremenl of resislance - Checkcables
betweenpin 821 (CAN-L)and
822 (CAN-H) Checkconnectors
- ShortcircuitfromCAN-Hto CAN-L
Targetvalue:-120 Q at approx.0 ohm
Vehiclemanagement Ivleasurement
of resistance - lt no lauhil found,replacecontrol
computer(FFR) betweenpin X1/12(CAN-L) unitor FFR
andx1110(oAN-H)
Targetvalu6:-120 Q
M-CANdalabus Targeivalue:
T-CANdatabus Relerto oscilloscope
curve
I-CANdatabus

EISE,^
i-*ll" i l"
un. . . . r ] ! w.
. 9.. .
t::

l ll,l!lllllllllll
f,J I'J I F.r t-]f.r |J t-r

i. , , , .. i :." .
i; : lr, !0rs/, t! Trig:AJ 3i a U,
|H"*,)M#FFEI'$Y-]
aiensisnal f.Ul High !i a.t A
CAI lor &8ial E

T 18 4.40-73
DIAGNOSIS

TIMEOUTMESSAGEPOINT8

lndicalionot fault: None

Eftectivcfauh: None

Causeof lault: Errorwhentransmitting message(is sentin responseto a

the no-acknowledge
messagerequestfromthe FFRthatwas regardedas invalidby the EDC),maybedue
lo excessiveCANbus load

Faultinputs to other control units: Yes,FFR

Notevehicle-relaled
circuitdiagrams

CANinterconnection - Removeinterference
voltage
M-CANdatabus T6rgetvalue:
T-CANdatabus Reterto
oscilloscope
curve
I-CANdatabus

4.40- 74 T 18
 otAGNOStS

RAIL PRESSURE
SENSOR

Indicationot lault: Centralwarninglampstays illuminatedred whiled vingandwhenal a standstill

E ieciive tauh: Targetvalueoutput700- 90Obar

Speedreduction to 2000rpm(D08engine)
Torquereduclion(D08and D28engine)
Pressurelimitingvalve(DBV)is activateopen

Causeof fault: l4onitoring

forvoltagelimiis{supplyand sensorvoltage)

Fault inputs to other control units:

Notevehicle-relaled
circuitdiagrams

Powersupply l,leasurement
of voltagebetween - Checkcables
pinA43and pin 461
- Checkconnectors
Targeivalue: 4.75- 5.25V Beplacerailpressuresensor
Signalvoltage Measurement ol voltagebelween - ll no faultis found,replacecontrol
pinA80and pin A61 unit
Talgel value: '1.01- 1.60V

Sensol characle!istic

Voltage 5.00

4.00

3.00

2.OO

1.00

0.00
Pressurein bar (x 100) 1 0 1 1 1 2 1 3 1 41 5 1 6 1 7 1 A1 9 2 0 2 1

T 18 8.40- 75
DIAGNOSIS

SENSOR(LOWPRESSURE)
FUELPRESSURE

Indicationof fault: Centralwarninglampsiays illuminatedyellow whenat a standstill

Etfectivefault: None

Causeof faull: l,tonitoring

lor voltagelimits(supplyandsensorvoltage)

Fault inputs to other conlrol units:

Nolevehicle-relaled
circuitdiaorams

Powersupply Measurementof voltagebetween Checkcables

pinA40(+)and pin A37 (-)
Checkconnectors
Taiget value:4.75- 5.25V Beplacefuelpressuresensor
Signalvoltage Measurement of voltagebelween ll no faullis found,replacecontrolunil
pinA20 (+)and pin A37 (-)

Targetvalue:2.33- 3.43V

3.0

2.O

bar 5 6 7 I I 10

8.40- 76 T 18
 DIAGNOSIS

ERRORWHENNEADINGFFOMTHE EEPROiI

lndication of tlult Centralwaminghmp aray8 lllunin.Ld ycllou wh6n at a standstill

E trcliv. t!uh: Fauhmemoryand loamsd dala of EDCcannotbe storedin the controluntil the
afterrun

Caurc ol |.ult Checksumtest of EEPROMfautly, b€causestoEg€ (faull storage€tc.) was

inteduptedduringthe hst afterrun,or EEPROMdof€ctjve

F.uh InpuL to olh.r control u.it!:

Notevehicle-relatedcircuil diagrams

T 18 B.q - T7
DIAGNOSIS

FAULTYREDUNDANT
SHUTDOWN
DEVICEOEST IN OVERRUN)

Indicationof tuult: Centralwaminglampstays illuminatedJcdwhiledrivingand whenat a standstill

Eftectivefault None

Cauaeol fault: protecliondef€ctive

Overvoltage

Feultinouts lo other control units:

Notevehicle-related
circuitdiagrams

EDCcontrolunit - Replaceconlrolunil
(onlyin consuftation
withMunichService)

8.40- 78 T 18
 DIAGNOSIS

!K PRESSURE
LIIIITINGVALVEDOESNOTOPEN

Indicltion ot Luhi CEntralwaming hmp contlnu.lly fla.h.. rcd whiledrivingand when at a standstill
Stop shown in display

E f.c-tivc Engineshuts down

'.uft:
Crtrr! ot tlult: Pressurelimitingvalve is mechanicatlyblock€d

Fluh Inputa io odrar conbol unllr:

Not€vehicle-r€latedcircuitdiagram6

Prossur€limftingvalve - Ch€ckretumlin6is clear

- Redace pressurelimitingvalve

Not : The fauhoccursonly in conjunctionwith SPN 3099. D€terhine reasonfor obstruclion.

T 18 8.40- 79
DIAGNOSIS

BOOSTERVOLTAGE

Indicationof tauh: Centralwarninglampstaya illuminaiedrcd whiledrivingandwhenat a standstill

E fectivc fauh: Possibleproblemsin pre,mainor postinjection(enginenoise,runningbehaviouo

Causeot fault: Monitoring

currentandvoltagelimits

Faull inpuls to olher control unib:

Nolevehicle-related
circuitdiagrams

EDCcontrolunil - Reterto batteryvoltagetest {SPN168)

powersupply

8.40- 80 T18
 DIAGNOSIS

TIMEOUTMESSAGEPOINT4

lndicationof lault: None

Effectivefault: EDCsmessage(temperatures, pressure)notfittedin FFR

atmospheric

Causeol faull: EDCsmessagetransmission

errorduelo excessive
CANbusload

Fault inouts to other control units: Yes.FFR

Nolevehicle-related
circuitdiagrams

EDCcontrolunit Ivleasurement
of resislance - Checkcables
betweenpin 821 (CAN-L)and
822 (CAN-H) - Checkconnectors
- ShortcircuitfromCAN-Hto CAN-Lat
Targetvalue:-120 O approx.0 ohm
Vehiclemanagement ot resistance
I\,leasurement - lf no laultif lound,replaceconlrolunit
compurer(FFR) between pinX1/12(CAN-L) and OTFFR
x1/10(oAN-H)
Targeivalue:-120Cl
M-CANdatabus Targetvalue:
Referlo oscilloscope
curve

fl3jl4u' $15ffu'
, t 1 t . l ..p e. ..
..r ln flu n.tt,0
r 9 .vq.
: :
:
rl L fll..

i i !F if ll Ll
ti i :::::t:
A: t U/, E0trs;, t| fris:A,a 8. I U4
1ffiFMT:mq1"'F*l
nsillrsl f,L]I Eigl !:ana.L .},
CAl{ !o$ Knnd] !

T 18 8.40- 81
 DIAGNOSIS

DEFECTCLASSIFICATION
FORINITIALIZATION
Indicationof faulti Centralwarninglampstay3 illuminatedy.[ow whenat a standsti

Elfeclive tauh: None

Causeol fault: lntemaltesldevicefor ovorvollage
testin the EDCcontrolunitis delective
Fault inputs lo olhel control units:

Notevehicle-related
circuildiagrams

EUU COnUOtUnrl - Replacecontrolunil

8.40- a2 T 18
 Dtact{ttgE

EI'C NIEN AL TEMENAruBE

tdlcrdon ot i!||h: t{om
Efibcdy. trulk OutDutot 60 "c as €olival6ntvalue.
C.u.a ol fr : t\,lonhotug
for \oltagglimits
Flult InpsL to ofiar coitol unlL:
Nd€ \,€hiclo-Elal€d
circlit dhgramg

16

T1E 8.40 - 83
l
a: I
DIAGNOSIS

FINALSTAGESHUTDOWN
BY EDC

lndicationof iaulti Centralwaminglampslays illuminatcdred whiledrivingandwhenat a standstitl

Elfective tuult: Enginsshutsdown

Cause of fauli: Error in watchdogcommunicationor overvohage

Fault inDuta to othor control unils:

Notevehicle-related
circuitdiagrams

EDCcontrolunit - Beplacecontrolunil

8.,!0- 84 T18
 DIAGNOSIS

HIGHSIDEFINALSTAGECHARGE-AIR
PRESSURE
CONTROL

Indication of fautl: Centralwarninglamp atay. illuminaled ]!d rvhiloddvingand when at a standstill

E tcctiv. tault: Speedreduclionto 1800rpm and toque reduclion

Causool lault: Moniloring

for voltagelimitsandcablebreak

Fauh inputs to othcl conrol unlB:

Nolr: Thislaultoccursonlyon D08engines

Notevehicle-relatedcircuitdiagrams

pressure
Charge-air Measurementof resis'tance - Checkcables
actualor betweendn A02 and pin A04
- Checkconnectors
Targct valuc: - Checkiimingvalve(actuator
tes0
- lt nofaultis found,replac€
conlrolunit

T 18 8.40 - 85
DIAGNOSIS

HIGHSIDEFINALSTAGEEXHAUSTGASRECIRCULATION

Indication ot tault Centralwaminglamp .t!y. illuminalcd ]!d while drivingand when at a standstill

Eff.cliv! fauft: Sp€edreduc'tionto 2200 rpm and toque r€duction

Cauac ot tauh: Monitodngfor volt6g6limils and cabl6br6ak

Fluh inDuta to othar control unlL:

Not l Thistauhoccursonlyon DoBenginos

Notevehicle-relatedcircuit diagrams

Solenoidvafue contrcller Measuremenlol r€sistance - Perlormac{ualorte6t usingMAN-cats

betweenpinAl7 andA11
- Checkcables
T.rgpt valuc: 80 - 110 O - Checkconnectors
- ReplaceEGRactualor
- lf no fault is lound, replacecontrol unh

8.,r0- 86 T18
 DIAGNOSIS

HIGHSIDEFINALSTAGEPROPORTIONING
UNTTCP3

Indicaiionof fault: Centralwarninglampstays illuminatedred whiledrivingandwhenal a standstill

Effectivefault: Speedreduction to 2000lpm (D08only)andtorquereduction(D08and D28)

Pressurelimitingvalveopens(railpressure700- 900ba4
Enginemaysmokeheavily

Causeol fault: l,lonitoring

forvoltagelimils{supplyandsensorvoltage)

Fault inouts to other control units:

Notevehicle-related
circuitdiagrams

unit(N,lProp)lvleasurement
Proporlioning of resistance - Checkcables
betweenpinA08and A10
- Checkconnectors
Targetvalue:2.5- 4.5 O - ReplaceMProp
- lf no faultis lound,replacecontrolunit

Nole:Afterfaultrectificalion as passive
the enginemustagainrunkeelybelorethefaullcan be classified
and deleted.

T 18 8.40- 87
DIAGNOSIS

HIGHSIDEF1NALSTAGESTARTERRELAY(IMR)

lndicationot tsuh: Contralwaming

lampst ys illuminat d ]!d whib drivingandwhenat a standstill

Effective fauh: Enginemay fail to staft

Causs ot leult Monitoringtor voltagelimits and cablebreak

Foull Inputs to othrr control unitr:

Nol6v€hicle-relaled
circuitdiagrams

IMRrelay Measurcmentof rgsistance - Checkcables

betweenpinA16 and pinA19
- Chsck connectors
Targd value: - ReplaceIMRrelay
15-30() - Replacestaner
- lf no faullia found,replace
conttolunit

8.40 - 88 T 18
 DIAGNOSIS

CAMSHAFTSPEEDSENSOR(SEGMENT
SENSOR)

lndicalionol tault: Centralwarninglampstays illuminaiedred whilediving and whenal a standstill

Effectivefaull: Enginestanswithditficuhy

Causeol taull: No signalsor incorrecipulsesequence(interference

inputs)
Sensorpolarityreversed

Fault inouts to other control unils:

Note: Relerto SPN190

Notevehicle-related
circuitdiagrams

Camshattspeedsensor lreasurement
of resistance
belween Checkplausibility ol signalusing
pinA72and pinA54 ldAN-catsMonitoring andthe
statusof the speeddetection
Targetvalue:750- 1100Q - Checkcables
Checkconnectors
- Checkconnector lor correcl
Polarity
Checkof signalusingoscilloscope - Replacespeedsensor
- lf no laultis found,replace
Targetvalue: controlunat
Re{erto oscilloscope
curve
Clearance
behveenspeed Taroelvalue:0.5- 1.5mln
sensorandflywheel

betweenpinsA72andA54
Camshaftspeedsensorsignalat 600 lpm measured

T 18 8.40 - 89
oraGNosts

SPEEOSENSOR(INCREMENT
CBANKSHAFT SENSOR)

Indicationol fault: Cent€l waminglampstays illuminatodred whiledrivingand whenat a standstill

Elfectivelault: None

Causeof fault: No signalsor incorreclpulsesequence(interference

inputs)
Sensoroolaritvreversed
Fault inputaio other conkol unib:

Note: RefertoSPN190
Notevehicle-related
circuitdiagrams

Crankshaft
speedsensor I\reasurement
of resistance
between - Checkplausibilityol signalusing
pinA73 and pinA55 MAN-catslllonitoring andlhe
statusof the sp6eddeteclion
Targetvalue: 750- 1100 Cl Checkcables
- Checkconnectors
Checkconnector tor correct
polarity
Checkof signalusingoscilloscope - Replacespeedsensor
- lf no laultis lound,replace
Targetvalue: controlUnit
Referlo oscilloscope
curve
Clearancebetweenspeed Targetvalue: 0.5- 1.5mm
sensorand flywheel

speedsensorsignalal 600 lr|m measuredbetweenpinsA73 andA55

Crankshaft

8.40 - 90 T18
 DIAGNOSIS

INJECTORFINALSTAGEMONITORING,/WATCHDOG
I/|ONITORING

Indicationot tault Centralwarninglampcontinuallyflashesrod whileddvingandwhenat a standstill

Elteclivefaull: Engineshutsdownor enginestartnotpossible

Causeof fault: Al leastone injectorfinalstagecannotbe shutdownby the monitoring

routine

Faultinputs to oiher cor rolunits:

Notevehicie-related
circuitdiagrams

- Replacecontrolunit

T t8 8.40 - 91
DIAGNOSIS

EGRFEEDBACK,
SUPPLYVOLTAGE

Indicaiionot fault: Centralwarninglampstays illuminatedyellow whenat a standstill

Effectivetautt: None

Causeof fault: Checkingthe supplyvollagefor shon-circuit

to earthor Ubdandcablebreak

Fault inputs to other control units:

Notevehicle-related
cjrcuitdiagrams

Feedbackswitch(reed Ivleasurement
of resisiance - PerformactuatortestusingMAN-cats
conlacl) bet$/eenpinA23andA22
- Checkcables
Targetvalue:< 1 O Checkconneclors
Solenoidvalveconlroller I\,leasurement
of resislance - ReplaceEGRactuator
between pinA17andA11
- lf no faultis found,replacecontrolunit
Targetvalue: 80 - 110Q
Freedom of movement of - Repakor replaceEGRvalve
valve actuation

8.40- 92 T18
 DIAGNOSIS

RAILPRESSURE
MONITORING

Indicationot fault: CenkalwarninglampcontinuallyIlashesred whileddvingandwhenat a standslill

Stopshownin display

Effeclivefault: powerreduction
30o/o

Causeof tault: Railpressuretoo haghortoo low

Fault inouts to other control units:

Note: 1 Checkvehiclevoltage:Voltagepeaksor voltagedipscan crealeimpermissible

in the railpressure
tluctuations

Note:2 Referto SPN94

Nolevehicle-related
circuitdiaorams

Fuelsystem Pressuretesl usinggaugeset FuelfilterKSCblocked

(specialtool)
- lnletlilterblocked
- Leakson the suclionsidebetweenthetank
Targel value: andpresupplypump(noextemalluel leak)
Reterto hydraulic test procedure
- Leakson the low-pressuresidebelweenthe
presupplypumpand high-pressure pump
(external fuel leak)
Pressurelest in inlelat limiting Replacepresupplypump2P18.5dueto
Targetvaluei=5bar defectiveoverllowvalva
Proportioning
unit lreasurement of resislance Checkcables
(NlProp) betweenpinA08andA10
Checkconnectors
Taig€t value:2.5- 4.5 O Replacel\.,lProp

T 18 8.40- 93
DIAGNOSIS

POSITIVECONTROLDIFFERENTIAL
OF RAILPRESSURE

Indicationof fault: Centralwaminglampstays illuminated.ed whiledrivingandwhenat a slandstill

Stopshownin display

E iec{ive tault: Railpressurelimitingto 700- 900 bar,30ol"powerreduction

Causeof fault: Rajlpressureactualvaluelessthantargetvalue

Fault inpuls to other control units:

Notevehicle-related
circuitdiaorams

Fuelsystem Pressuretest usinggaugeset - Checkfor externalleaks

(specialtool)
- Checkfor leakbetweenbladeand injector
- Tankempty
Targetvalue:
Referlo hydraulic testprocedure Checkthe fuellines/lilterlor
blockage
Checktor leakor malfunction - Replacepressurelimitingvalve
(openstoo ea y)
pump Pressuretest in inletat limiting - Presupply
High-pressure pump2P18.5or itsddve
cP3 Targeivalue:=5bar delective
High-pressurepumpCP3or its drive
delective
Proportioning
unit lreasurement of resistance Checkcables
(MProp) betweenpinA08and A10
Checkconnectors
Ta.get value: 2.5- 4.5 O ReplaceMProp

8.40- 94 T18
 DIAGNOSIS

NEGATIVE
CONTROLDIFFERENTIAL
OF RAILPRESSUBE

Indicationot fault: Cenlralwarninglampconlinuallyflashesred whiled vingandwhenat a standstill

Slopshownin display

Effectivefault: Pressurelimilingvalvecan open(railpressurelimilingto 700- 900 bar)

(< -10 'C)
at lowlemperatures
Startingdifficulties

Causeol lault: Railpressureactualvaluegreaterthantargetvalue

Fault inouis to othe. conlrol units:

Note: Checkvehiclevoltage:Voltagepeaksor voltagedipscan crealeimpermissible

in the €il pressure
lluctuations

Notevehicle-related
circuitdiaorams

Fuelsystem Pressurelest usinggaugesel FuelfilterKSCblocked

(specialtool)
- lnlelfilterblocked
Leakon the suctionsidebetweenthetank
Targetvalue: and presupply pump(no externalfuel leak)
Reterto hydraulictest procedure
- Leakon the low-pressure sidebetlveenthe
presupply pumpand high-pressurepump
(exlernalfuel leak)
High-pressure Pressure test in inletat limiting Replacepresupply pump2P18.5dueto
pumpcP3 Targetvalue:=5bar detective overf
low valve
Proportioning
unit Measurement of resistance Checkcables
(MProp) belweenpinA08 andA10
Checkconnectors
Targetvalue:2.5 - 4.5 f,) ReplacelvlProp

T r8 8.40- 95
oraGNosrs

RAIL PRESSURE:
LEAKAGEUNDERDECELERATION
CONDITIONS

Indicationof fault: Centralwarninglampcontinuallytlashesred whiledrivingandwhenat a standstill

Stopshownin display

E fectivelault: Railpressurelimitingto 700- 900 bar,30% powerreduction

Causeof fault: lmpemissibleleakin iniectorsystem

- Raieof reductionin €il pressureduringdecelerationis too greal
conlrolfor puarl= const.duringdeceleralion
- IvlProp loo great
Fault inputs to other control units:

Notevehicle-related
circuitdiagrams

Fuelsystem Pressuretest usinggaugeset - Checktor efemal leaks

(specialtool)
- Checklor leakbetweenbladeand injector
- Ptessurereliefvalveon railopentoo early
Targetvalue: (replace)
Refertohydraulictest procedure
High-pressure Pressuretest in inletat limiting - Tankemply
pumpcP3
Targetvalue:=5bar - Checkthe fuellines,{ilter
for blockage
- RepiacepresupplypumpZPl8.5 (check
drivefirsl)
- Replacehigh-pressure pump(checkdrive
tirsO
Proporiioning
unit I\reasurement of resislance Checkcables
{MProp) betweenpinA08 andA10
Checkconnectors
Targetvalue: 2.5- 4.5 O ReplaceN4Prop

8.40 - 96 T 18
 DIAGNOSIS

FAIL PRESSURE:
LEAKAGEOUETO VOLUMEADJUSTMENT

Indicationof tauli: Centralwarninglampcontinuallyflashesred whiledrivingandwhenat a standstill

Stopshownin display

Effectivefault: Bailpressurelimitingto 700- 900 bar,30o/"powerreduction

Causeof lault: MPropcontrollor settingtargelrailpressurein operationis loo great

FauftinDutsio olher conlrol unita:

Notevehicle-related
circuitdiagrams

Fuelsystem Pressure tesl usinggaugeset - Checklor externalleaks

(specialiool)
Checklor leakbetweenbladeand injector
- Pressurereliefvalveon railis leakingor
Targelvalue: openstoo eady(replace)
Beferlo hydraulic test procedure
High-pressure Pressure testin inletat limiting - Tankempty
pumpcP3 Targetvalue:=5 bar - Checkthe luel lineMillerfor blockage
- Replacepresupplypump2P18.5(check
drivefirst)
- Beplacehigh-pressure pump(checkdive
li|st)
Proportioning
unit I\reasuremenl ol resistance Checkcables
(MProp) betweenpinA08andA10
Checkconneclors
Targetvalue:2.5- 4.5 O ReplaceMProp

T 18 8.40- 97
DIAGNOSIS

RAILPRESSURE:
HIGHCONTROLLER
OUTPUTDURINGIDLING

Indicationol faull: Centralwarninglampcontinuallyflashesred whiled vingandwhenal a standstill

Stopshownin display

Ellectivetault: Railpressurelimilingto 700- 900 bar,30%powerreduction

Causeof lault: of idlingrailpressureis too greal

MPropcontrollor mainlenance

Faull inDutsto other control unils:

Notevehicle-related
circuitdiagrams

Fuelsystem Pressuretest usinggaugeset - Checkfor elftemalleaks

(specialtool)
- Checktor leakbetweenbiadeand injector
- Pressurereliefvalveon railis leakingor
Targelvalue: openstoo early(replace)
Referto hydraulic test procedure
High-pressure Pressuretest in inletat limiting Tankempty
pumpcP3
Targetvalue:=5bar - Checkthe luel Iines/filter
tor blockage
- Replacepresupply pump2P18.5(check
ddvelirst)
- Replacehigh-pressure pump(checkdrive
lirst)
Proportioning
unit Measurement ol resistance Checkcables
(N,lProp) betweenpinA08and A10
Checkconnectors
Targetvalue:2.5- 4.5 O Replacel\,,lProp

8.40 - 98 T 18
 DIAGNOSIS

PRESSURE
LIMITINGVALVEOPEN

Indicationol lault: Centralwarninglampcontinuallyllashes red whiledrivingandwhenal a standstill

Slopshownin display

Elfectivelault: Railpressurelimitingto 700- 900 bar,30o/.powerreduction

Causeol fault: Railpressurebrieflyabove1750bar (D08)or '16540bar (D28)

Fauli inputs to other control units:

Notevehicle-related
circuitdiagrams

Fuelsyslem Pressuretestusinggaugesel - FuelfilterKSCblocked

(specialtool)
- lnletfilterblocked
- Leak"s on the suctionsidebetweenthetank
Targetvaluci and presupply pump(no externalluelleak)
testprocedure
Referto hydraulic
- Leakson the low-pressure sidebetweenlhe
presupplypumpand high-pressure pump
(external fuelleak)
High-pressure Pressuretestin inletat limiting Replacepresupplypump2P18.5dueto
pumpcPs Taigetvalue:=5bar delectiveoverflowvalve
Proportioning
unit Measurement of tesistance Checkcables
(MProp) betweenpinA08and410
Checkconnectors
Targetvalue:2.5- 4.5 o ReplaceMProp

T 18 8.40 - 99
DIAGNOSIS

FUELSUPPLYPRESSURE:
DYNAMIC

Indicationof lault: Centralwarninglampslays illuminatedyellowwhenat a standstill

Etfectivefaull: Possiblelossof power

Causeof fault: fuelsupplyp.essure

Fluctuating

Fault inputs lo oiher contJolunils:

Notevehicle-related
circuitdiagrams

Fuelpressure Pressurelesl usinggaugesel Checkthe levelin the tank(thetankreturn

(specialtool)in accordance
with mustbe belowthe levelof lhe fuel
hydraulictesl procedure otherwisethe systemrunsdry)
Checkthetuelfiherfor blockage
Checkthe pipesbetweenthe tank/spur
gearpumpand spur-gearpump/high-
pressurepumpfor blockage
Leakson lhe suctionsidebetweenthe
tankand presupplypump(noexternalfuel
leak)
Leakson lhe low-pressure sidebetween
the presupplypumpand high-pressure
pump(external fuei leak)
Presupply pump defective(replace)
Pressurerelietvalvein high-pressure
pumpdeiectiveGeplacehigh-pressure
pump)
Fuelpressuresensor Measurement of voltagebelween Checkplausibility of signalusingMAN-cats
powersupply pinA40 (+)and pin A37{-) lronitoring
- Checkcables
Targetvalue: 4.75- 5.25V
- Checkconneclors
- Replacefuelpressuresensor
Fuelpressuresensor Measurement of voltagebetlveen lf no laultis found,replacecontrolunil
signalvoltage pinA20 (+) and pinA37 (-)

Targeivalue: 2.33- 3.43V

8.40- 100 T 18