DIAGNOSIS

Check step list EDC MS 6.4 level 2

Service operation: Tester:

Customer: Initial registration:

Type of vehicle: Chassis no.:

Engine type: Engine no.:

Fuel injection pump: Control unit no.:

Mileage: Date:

1. Testing with engine at a standstill

Engine temperature ≈ 20 °C

Ignition off

Engine control unit closed down

Wiring loom adapter for engine control unit connection

Measure resistance between the following PINs

PIN PIN Target value Actual value

CAN–PSG A 24 A 27 ∼ 120 Ohm

Engine speed sensor (DZG) A1 A 13 770 – 1000 Ohm

Relay, redundant shutdown (MAR) B 18 B1 180 – 250 Ohm

CAN 1 B 11 B 12 ∼ 120 Ohm

Note: The needle movement sensor is omitted in level 2

Connect engine control unit

Connect wiring harness adapter for VP 44 between pump and wiring harness

Switch on ignition

Measure voltage between the PINs

PIN PIN Target value Actual value

Power supply, pump control unit

Bat+ Bat– UBat
(from wiring loom adapter for VP44)

T 17-A2 8.21 - 1
 DIAGNOSIS

2. Testing with running engine and stationary vehicle

Engine temperature > 30 °C
Connect wiring harness adapter for engine control unit

Speed measurement

Target value Measured value Remark MAN–cats

Engine speed sensor Lower idling PWG MIN (lower idling)
(DZG) Upper idling PWG MAX (upper idling)
Engine speed sensor* Lower idling PWG MIN (lower idling)
in pump (IWZ) Upper idling PWG MAX (upper idling)

* Short-circuit PIN A1 and A13 (simulation DZG–defective diagnosis lamp is on constantly).

Target Measured
PIN + PIN– Remark Rpm MAN–cats
value [V] value [V]
Control unit supply B15 B1 U Bat Idling
MS 6.4 level 2 B3 B2 U Bat Idling
B15 B27 U Bat Idling
Pedal sensor B23 B35 0.30 – 0.42 V PWG MIN lower idling 0%
(PWG) 2.90 – 4.50 V PWG MAX upper idling 100%
Idle speed switch B17 B9 2.8 – 5 V PWG MIN lower idling open
(LGS) 0 – 1.8 V PWG MAX upper idling closed
Temperature sensor A22 A5 3.0 – 1.15 V 30 – 90 °C lower idling 30 – 90 °C
coolant (WTF)
Intake manifold A12 A17 0.95 – 1.12 V PWG MIN lower idling 900 – 1050 mbar
pressure sensor (LDF) 1.00 – 1.52 V PWG MAX upper idling 1000 – 1400 mbar
FGR operating unit B8 B9 3.35 – 3.74 V not actuated lower idling Neutral
1.6 – 2.0 V WA WA speed Memory
0.83 – 1.21 V Set+ speed Set+
increases
2.53 – 2.97 V Set– Set–
speed drops
4.18 – 4.53 V Aus (Off) Off
Idling
Multilevel switch B28 B35 0.75 – 1.25 V Pos 0 Idling Handling
(resistor group) characteristics
torque limiter 1.75 – 2.25 V Pos 1 Torque limiter
2.75 – 3.25 V Pos 2 Retarder active
3.75 – 4.25 V Pos 3 Function for k–value
reduction
Multilevel switch B19 B35 0.75 – 1.25 V Pos 0 Idling Speed 1
(resistor group) 1.75 – 2.25 V Pos 1 Speed 2
Max. speed limiter 2.75 – 3.25 V Pos 2 Speed 3
(HGB) *
3.75 – 4.25 V Pos 3 not used
Brake contact switch B26 B2 0–1V not actuated Idling open
U Bat actuated closed

* Activation of another maximum speed limit is only possible at below a road speed of 10 km/h!

8.21 - 2 T 17-A2
 DIAGNOSIS

Target Measured
PIN + PIN– Remark Rpm MAN–cats
value [V] value [V]
Clutch switch B20 B2 0–2V not actuated Idling open
U Bat actuated closed
Engine brake switch B14 B2 0–1V not actuated Idling open
U Bat actuated closed
Engine brake actuation A18 B2 0–2V not actuated Idle
U Bat actuated speed >
800 rpm
FGR/FGB switch B22 B2 0–2V FGR Idling
U Bat FGB
Idle speed request B21 B2 0–2V not actuated Idling open
U Bat actuated closed
Tacho signal B29 B2 > 0.6 V Idling

Engine stop switch B34 B2 0–2V not actuated Idling open

UBat actuated closed
PWG high threshold A32 B2 PWG MIN
UBat PWG MAX

Idle speed switch output B25 B2 < 1.4 V PWG MIN

UBat PWG MAX

without load resistor < 17 V

with load resistor 100 – 1.000 Ω ~ 0 V

Proximity switch clutch and brake must activate before the clutch disengages or the brake responds
(max. after 20 mm pedal travel) and open again before normal position

ZDR function test:

Shutdown conditions (check actuation of brake, clutch, PWG)

PIN B32 PIN B33

against against Rpm ZDR–Pos
B2 B2
Target Actual Target Actual
0 0 ZDR speed S 0
U Bat 0 ZDR speed 1 1
0 U Bat ZDR speed 2 2
U Bat U Bat ZDR speed 3 3

Test main relay, MAR and MAB actuation:

PIN + PIN – Target value Measured value Remark

B15 B2 U Bat Ignition on
0V Ignition off
B27 B2 0V Ignition on
U Bat Ignition off
B18 B2 0V Ignition off
U Bat Ignition on
B3 A20 U Bat Ignition on

T 17-A2 8.21 - 3
DIAGNOSIS

Test solenoid valve shutdown:

Operate engine at upper idling speed

Interrupt power supply to relay (draw PIN B18)

Engine must remain still after max. 10s

Switch off ignition and restore power supply

Test flash code diagnosis: Connect PIN A1 and A13 (short-circuit DZG)

EDC indicator lamp has to be on (continuous light); final speed is reduced.

Request flash code (connect PIN B24 and B2 for at least 2 sec., but do not actuate for longer
than 10 sec.)

Flash code for DZG defect must be emitted (4x short) or read out with MAN–cats error memory
(DZG defect momentarily present)

Release connection between PIN B24 and B2 again

Delete error memory

• Momentary contact control switch:

With pushbutton depressed, switch on ignition and release again after 2 – 10 sec. and
switch off ignition

• MAN–cats

3. Test with running vehicle

Test cruise control

Drive at v > 25 km/h in cruise control mode

After change of gear and actuation of Memory key, the last speed must be re-actuated

Test brake switch monitoring

Interrupt PIN B26

In cruise control mode brake vehicle sharply

Cruise control must shut down

(brake switch is classified as defective)

Cruise control must only be capable of reactivation after switching off ignition.

Connect PIN B26 again

Delete error memory

After completing the tests, the error memory should be deleted using MAN-cats. No errors should be
shown after turning on the ignition again, otherwise they must be identified and rectified.

8.21 - 4 T 17-A2