Documente Academic
Documente Profesional
Documente Cultură
As at 04/03
This document is provided for training purposes only and is not subject to the normal updates.
Printed in Germany
2003 Copyright DaimlerChrysler AG
Issued by: Global Training
This documentation and all its constituent parts are subject to copyright. Any reproduction or re-use requires written
permission from DaimlerChrysler AG in advance. This especially applies to any form of duplication, dissemination,
editing, translating, microfilming, or storage and/or processing of this documentation on electronic systems,
databases or online services.
1511
1210
02
st
edition
04.03
72
Note:
The term "employee" always refers to both male
and female staff.
As at
04/03
Contant
07.05.2003
Title
Side
Welcome ..................................................................................................................................................................................................................................................1
Course targets .........................................................................................................................................................................................................................................2
Structure and principle of operation of the engine control (MR).............................................................................................................................................................3
MR/PLD engine control ...........................................................................................................................................................................................................................4
MR components - BR 500 ........................................................................................................................................................................................................................8
MR components - BR 900 ......................................................................................................................................................................................................................10
Telligent engine control..........................................................................................................................................................................................................................12
Rotational speed, crank angle and TDC detection.................................................................................................................................................................................17
Evaluation of crankshaft and camshaft angles ......................................................................................................................................................................................19
Temperature detection ..........................................................................................................................................................................................................................20
Oil pressure sensor, oil temperature sensor .........................................................................................................................................................................................22
Oil level detection ..................................................................................................................................................................................................................................23
MR control loop......................................................................................................................................................................................................................................24
Engine control parameterization............................................................................................................................................................................................................25
Starter actuation through the MR..........................................................................................................................................................................................................26
Direct starter actuation..........................................................................................................................................................................................................................28
Telligent engine system .........................................................................................................................................................................................................................30
ADM - FR ................................................................................................................................................................................................................................................32
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Contant
ADM - 2 ..................................................................................................................................................................................................................................................34
ADM - AR and FR....................................................................................................................................................................................................................................36
Pedal communication functions of the Mercedes-Benz foot throttle actuator......................................................................................................................................40
Alternators .............................................................................................................................................................................................................................................42
Engine brakes ........................................................................................................................................................................................................................................48
Turbobrake.............................................................................................................................................................................................................................................50
Flame starting system............................................................................................................................................................................................................................60
Heater flange in Mercedes-Benz engines ..............................................................................................................................................................................................62
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Contant
Welcome
Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Welcome
07.05.2003
GT07_15_0001_00
Course targets
07.05.2003
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Course targets
07.05.2003
Protection/redundancy:
The PLD/MR is configured as a 2-computer system, which means that if the host CPU fails, the back-up computer takes over the control of the solenoid valves at
the unit pumps. In this case, the engine speed remains constant (about 1300 rpm). The redundant operation (i.e. if one functional component fails, at least one
other functional component is available to take its place) applies also to solenoid valves (unit pumps), rpm sensors, starter actuation and the engine CAN bus
(single-wire mode capability). The electronic system also has a watchdog circuit, extensive self-tests are performed continuously, and mutual monitoring is
performed with the ADM electronics.
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Structure and principle of operation of the engine control (MR)
07.05.2003
The MR (PLD) engine control system receives guideline values from the drive
control (FR) or ADM in the form of 'desired torque' factors.
Using these values, the fuel delivery and start of injection at the unit pumps is
controlled in relation to a series of performance maps and characteristics
stored in the control module, and the actual operating conditions of the
engine.
BR 500
A3
A4
A6
B9
B10
B11
B13
B12
B14
B15
B16
B65
M1
S10
S11
N15.00-2067-12
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
MR/PLD engine control
BR 900
A3
A4
A6
B10
B14
B15
B16
B65
B110
B111
Y2
Y6-Y11
S10
S11
N01.00-2124-06
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
MR/PLD engine control
m Now assign the components to the correct functions. Not all components are linked into the
conventional engine management system! In the "Engine management" column, identify the
components required for engine running.
Task
Component
Unit pump (Y...)
Engine
management
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
MR/PLD engine control
W07.15-1117-06
A6
W07.15-1116-06
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
MR/PLD engine control
MR components - BR 500
07.05.2003
W07.15-0005-09
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
MR components - BR 500
W07.15-0006-09
05/03
Starter (M1)
Starter relay
Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
MR components - BR 500
MR components - BR 900
07.05.2003
W07.15-1019-09
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MR components - BR 900
10
W07.15-1020-09
05/03
sensor (B110)
Starter (M1)
Starter relay
Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
MR components - BR 900
11
07.05.2003
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Telligent engine control
12
N07.02-2018-06
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Telligent engine control
13
PLD components
Camshaft
Roller tappet
High-pressure cylinder
Injection nozzle
Pressure line
Valve body
High-pressure chamber
10 Pump plunger
11 Pressure pipe
12 Suction gallery
N07.15-2031-06.
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Telligent engine control
14
N07.15-2024-01
Intake stroke
05/03
Initial stroke
Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Telligent engine control
N07.15-2025-01
Delivery stroke
Residual stroke
15
The beginning of fuel injection (start of injection) must take place at a certain crank position
determined by the rotary sensor and by the control module.
Chronologically, start of delivery comes before the actual start of injection.
Before the actual start of delivery, the control module places a voltage at the unit pump concerned.
This creates a magnetic field in the coil, which causes the anchor plate to be drawn along with the
screwed-on valve body through channel A into the valve seat, where it is held. The time required to
do this is called the response time.
When actuated, the current at first rises to about 16 A, and as the gap (clearance) between the
anchor plate and the magnetic core decreases, the current drops to around 10 A. If the falling
current goes below a set value, this is detected by a detector circuit in the control module and
identified as a reference mark or hit detection.
In this way, the hit detection is set as the bottoming point of the valve body.
The pressure build-up just before start of delivery by the pump plunger causes the injection nozzle
needle to lift, and injection to begin.
The control module sets the end of delivery by breaking the voltage supply to the coil, and this
causes the magnetic field in the unit pump solenoid to collapse.
This allows the return spring to push the valve body out of the valve seat and against the valve stop
in the suction chamber.
N07.15-2026-12
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Telligent engine control
16
07.05.2003
N07.15-2028-73
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Rotational speed, crank angle and TDC detection
17
Rotary sensor
Induction-type pulse generators are used for detecting instantaneous crank angle and rotational speed.
These pulse generators have a coil around a soft iron core with permanent magnets connected to them,
so that the field lines from the magnets penetrate the core.
The end of the soft iron core is set at a minimum distance from the rotating flywheel or camshaft
sprocket. As the 'marks' (grooves, pins, or holes) rotate, a voltage is induced in the coil (in the same way
as the ABS rotary sensor) by the variation of the magnetic flux lines.
Crankshaft angle position sensor
The sensor placed at the flywheel detects the rotational speed and crankshaft angle by
means of 36 symmetrically arranged grooves or holes (1).
From the received signal, the electronics also determine variations in crankshaft rotational
speed between the individual working cycles and regulates cylinder uniform speed at idle.
An additional 37th groove (65 before TDC), depending on the signal synchronization (see
below), sends the trigger point for calculating the start of delivery.
Cylinder 1 TDC sensor (camshaft angle position sensor)
In case of requirement, the sensor placed at the camshaft sprocket sends the rotational
speed by means of 12 symmetrically arranged pins.
An additional 13th pin (13th hole) (55 before TDC) is needed for signal synchronization, as the
trigger point for calculating the start of delivery.
Resistance = 1000 - 1385 W
N07.15-2032-03
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Rotational speed, crank angle and TDC detection
18
07.05.2003
At engine start, a matching (synchronization) of the two signals from the crankshaft angle position sensor and cylinder 1 TDC sensor is performed in the
electronics.
If both signals are present, all actions are coupled to the crankshaft. The crankshaft signal has priority.
The camshaft signal is only used to check that both signals match.
m The signal function should be easy to understand, but what is the effect if a signal is missing?
Identify the possible effects in the table below, and indicate whether a fault code is displayed.
Task
Double
Limited power actuation of unit Engine does not
output / torque
pump per
start
working cycle
Engine stops
automatically
Fault code
indication
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Evaluation of crankshaft and camshaft angles
19
Temperature detection
07.05.2003
Various temperature values have to be detected in the engine, for optimal control of start of delivery in all engine operating conditions, for the engine protection
system, and for actuation of the electromagnetic fan clutch.
From start of production of the BR457, BR 500, and BR 900, the coolant, fuel, and charge air
temperatures were detected by three temperature sensors. Since then, the fuel temperature sensor has
been removed from the BR 500. Nevertheless, fuel temperature is taken into account along with coolant
temperature for calculating fuel quantity.
The structure and principle of operation on these temperature sensors are the same:
The temperature sensor housing contains a temperature-sensitive resistor (1) with negative temperature
coefficient (NTC thermistor). Since its electrical resistance falls as temperature increases, this component
is referred to as a thermal resistor.
If connected to the battery voltage, these temperature sensors are destroyed by overheating.
W07.15-0022-02
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Temperature detection
20
7980 W
2280 W
290 W
to
to
to
10560 W
2750 W
365 W
W07.15-0023-02
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Temperature detection
21
07.05.2003
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Oil pressure sensor, oil temperature sensor
W07.15-0029-11
22
07.05.2003
The MR control module detects the oil level in the engine through the oil level sensor. The detected value
is placed on the CAN bus.
If the value differs from normal level, the ADM sends a warning indication.
W07.15-0030-01
Function:
A sensor probe of about 210 mm in length is screwed into the engine oil pan. The probe is designed so that the measured level is detected from about 100mm.
Level measurement is started on terminal 15 when the ignition is switched on. A constant current pulse then passes through the probe for 1.5 seconds and
heats a hot wire, thus raising the resistance.
At the start of the current pulse, and just before the end, the voltage over the hot wire is measured and the voltage difference compared with a pre-set threshold
value.
If the temperature increase, and consequently the voltage difference, goes over the pre-set threshold value, then the oil level is too low and the warning lamp is
lit on the instrument cluster.
The sensor probe is linked with the MR/PLD control module, and over the CAN data bus with the ADM control module, which controls the indicator lamp on the
instrument cluster.
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Oil level detection
23
MR control loop
07.05.2003
ADM
N07.15-2027-75
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MR control loop
24
07.05.2003
For ordering a new engine control electronic system, the required parameters are found on the model
plate.
Legend:
1
2
3
4
=
=
=
=
N07.15-2017-20
For ordering a new MR control module, the required data can be read out of the old MR with Minidiag 2.
MR
Parameter
Value
Explanation
01
Engine number
XXXXXX-XX-XXXXXXX
02
03
Certification number
04
Device code 1
XXXX.XXXX.XXXX XXXX.XXXX
Power correction code. The EOL data. These can be determined on the bench dynamometer by the end of
production (End of Line).
05
Device code 2
XXXXX
Parameters should only be changed after obtaining the approval of the engine installer!
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Engine control parameterization
25
07.05.2003
Function description
After the ignition (tml.15) is switched on and the ignition key is turned to the start position (tml. 50), the
FR sends the engine start request over the CAN Bus to the MR control module.
The MR control module then starts the engine start relay at the starter, which in turn energizes the starter
solenoid switch.
During the start request (tml. 50 over the CAN), the engine start relay is only energized till a certain
engine speed is reached.
When an engine start request from the start button has been identified, the MR sends the request over
the CAN bus to the ADM. The ADM sends the engine start request back to the MR as described above.
The engine speed can be raised to rated rpm by operating the start button while the engine is running.
When the start button is released, engine speed returns to idle speed.
By simultaneously operating the engine start and stop button, the engine can be cranked on the starter
without starting the engine.
Note:
If the starter has been operated using the start button on the engine, for safety reasons, the engine can
only be started with the drive switch after the ignition has been switched off then on again.
05/03
In order to ensure engine starting when there is a fault in the drive switch/ADM connection (tml. 50), or
an ADM control module failure, or discontinuity in the CAN Bus data line, the engine start signal (tml.50)
is also connected directly to the MR control module.
In this way, the engine start relay is actuated directly by the MR control module.
Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Starter actuation through the MR
26
ADM
30
15
50
MR
PPT
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Starter actuation through the MR
27
07.05.2003
Disadvantages:
30
15
50
PPT
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Direct starter actuation
28
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Direct starter actuation
29
07.05.2003
The engine control (or engine management) system is divided into two subsystems, each with its own control module. The control module of the ADM subsystem
is installed on the vehicle side, and the engine control (MR) subsystem is installed at the engine.
Daimler-Chrysler engines of the 457, 500 and 900 model series are equipped with an MR electronic engine control. All engine specific data are stored in the MR
control module. The MR monitors and defines all the values required for engine operation (for example, start of injection, load condition, ambient conditions,
sensor evaluation, etc.).
Connection to the ADM is over a single-wire enabled CAN bus, which carries the specified values (required torque, required engine speed, etc.) and actual values
(engine speed, coolant, temperature, etc.) in digital form.
The ADM control module contains vehicle-related data (among other things), determines the vehicle operating conditions, and allows driver requirements to be
transferred to the engine side. These requirements may consist of an accelerator pedal action, application of the engine or service brake, or the working speed
control (ADR).
From these, the ADM control module determines the required engine torque or engine speed, and sends it as an engine specified torque or specified engine
speed by the ADR control to the MR. The ADM monitors and defines certain values required for vehicle operation (legally required speed limitation, maximum
working speed, engine brake, etc.). It also provides fault detection, emergency mode functions, and diagnoses.
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Telligent engine system
30
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Telligent engine system
31
ADM - FR
07.05.2003
ADM-FR function
Mercedes-Benz engines of the 500, 900 and 450 model series are equipped with an MR electronic engine control. The MR monitors and defines all the values
required for engine operation (for example, start of injection, load condition, ambient conditions, sensor evaluation, etc.).
Connection to the vehicle is through a CAN interface, which carries the specified values (required torque, required engine speed, etc.) and actual values (engine
speed, oil pressure, etc.) in digital form.
The adaptation module as vehicle control (ADM-FR) possesses the CAN interface required for the MR, and allows driver requirements to be transferred to the
engine side. The ADM-FR allows the use of conventional display devices, while also providing the conventional interface for special functions.
Switch signals allow the selection of operating statuses pre-defined in the engine control, for example torque and engine speed limits, or the specifying of predefined rpm values.
By parameterization, the routines stored in the control module can be adapted optimally to the type of application. A diagnostic interface is provided for
connecting external diagnostic equipment.
IMPORTANT!
ADM-FR parameters should only be changed after obtaining the approval of the engine installer!
Note:
There is an operator's manual for the ADM-FR, which gives a description of the possible functions, inputs/outputs, required parameter settings, and fault codes.
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
ADM - FR
32
ABS
ADR
BGR
FFG
N30.14-2023-00
Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
ADM - FR
33
ADM - 2
07.05.2003
ADM-2 function
Mercedes-Benz engines of the 500, 900 and 450 model series are equipped with an MR electronic engine control. The MR monitors and defines all the values
required for engine operation (for example, start of injection, load condition, ambient conditions, sensor evaluation, etc.).
Connection to the vehicle is through a CAN interface, which carries the specified values (required torque, required engine speed, etc.) and actual values (engine
speed, oil pressure, etc.) in digital form.
The adaptation module as vehicle control (ADM-2) possesses the CAN interface required for the MR, and allows driver requirements to be transferred to the
engine side. The ADM-2 allows the use of conventional display devices, while also providing the conventional interface for special functions.
Switch signals allow the selection of operating statuses pre-defined in the engine control, for example torque and engine speed limits, or the specifying of predefined rpm values.
By parameterization, the routines stored in the control module can be adapted optimally to the type of application. A diagnostic interface is provided for
connecting external diagnostic equipment.
The ADM-2 is connected to an SAE J 1939 CAN bus (high-speed CAN bus) and an additional diagnosis CAN bus.
The ADM-2 is a new development of the ADM-FR.
IMPORTANT!
The ADM-2 parameters should only be changed after obtaining the approval of the engine installer!
Note:
There is an operator's manual for the ADM-2, which gives a description of the possible functions, inputs/outputs, required parameter settings, and fault codes.
05/03
Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
ADM - 2
34
ABS
ADR
ABS/ASR
BGR
FFG
FLA
Transmission
ISO
IWA
MBR
MR
Retarder
SAE J 1939
GT_30_14_0001
Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
ADM - 2
35
ADM - AR and FR
07.05.2003
If the engine installer is also installing other MB assemblies, for example if a crane vehicle manufacturer is also installing an MB transmission with EPS (electronic
power shift), the transmission electronics must be able to communicate with the drive control, or must have engine-specific data.
A CAN bus is required for this purpose. In this case, we have the MB commercial vehicle CAN bus, with the related components (excluding instrument cluster),
to fall back on.
However, the MB commercial vehicle FR does not have its own display functions, since it sends all the information required by the driver over the CAN bus to the
electronics system in the instrument cluster.
FR function
The connection between the MR and FR is over a single-wire enabled CAN bus, which carries the specified values (required torque, required engine speed, etc.)
and actual values (engine speed, coolant, temperature, etc.) in digital form.
The FR control module contains vehicle-related data (among other things), determines the vehicle operating conditions, and allows driver requirements to be
transferred over to the engine side.
These requirements may consist of an accelerator pedal action, application of the engine or service brake, or the power take-off control.
From these, the FR control module determines the required engine torque or engine speed, and sends it as the engine specified torque or specified engine speed
by the ADR control to the MR.
The FR monitors and defines certain values required for vehicle operation (for example, legally required speed limitation, maximum working speed, engine brake,
etc.).
The FR does not have its own display functions, and requires information about the current drive status. This is provided over an HS CAN bus, which links the FR
with the other on-board electronic systems (transmission, retarder, etc.).
The FR control module also provides fault detection, emergency mode functions, and diagnoses.
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
ADM - AR and FR
36
ADM-AR function
The ADM-AR has the task of transferring all important data to conventional display devices for the operator, and also provides the conventional interface for
special functions.
Switch signals allow the selection of operating statuses pre-defined in the engine control, for example torque and engine speed limits, or the specifying of predefined rpm values.
By parameterization, the routines stored in the control module can be adapted optimally to the type of application. A diagnostic interface is provided for
connecting external diagnostic equipment.
Important!
The FR or ADM-AR parameters should only be changed after obtaining the approval of the engine installer!
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
ADM - AR and FR
37
GT_15_40_0004
Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
ADM - AR and FR
38
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
ADM - AR and FR
39
07.05.2003
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Pedal communication functions of the Mercedes-Benz foot throttle actuator
40
0% 10%
Lower
pedal stop
90% 100%
Duty cycle
2. 0 % indicates no voltage.
100 % indicates continuous voltage.
The percentage values can be read as actual values on
the Minidiag2.
30% 40%
0%
Upper
pedal stop
100%
Pedal range
Closed
Throttle position
Kickdown-ON position
Kickdown-OFF position
Wide-open position
Note:
A teach-in process is required for the foot throttle
actuator, using the test equipment.
N.B.: The kickdown only provides one more item of information, which is evaluated by certain functions such as the cruise control, or limiter.
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Pedal communication functions of the Mercedes-Benz foot throttle actuator
41
Alternators
07.05.2003
N15.40-2034-11
1
2
3
4
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Alternators
5 Multifunction controller
6 External slip rings
7 External rectifier
42
Information unit
The greatest differences between a compact alternator and the bowltype alternator are ...
... internal fan
... modified connections
... multifunction controller.
... exciter diodes no longer necessary.
N15.40-2032-11
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Alternators
43
10 A
GT00_19_0015
05/03
N15.40-2033-06
Starter
Positive terminal point
Ground terminal point
Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Alternators
44
>
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Alternators
45
BS connection
The actual value of the control voltage is detected over the BS connection (Battery Sensor).
Preferably, this is connected to the battery in order to compensate for a voltage drop on the charge line.
At present, on our vehicles, this terminal is connected to starter B+.
Voltage drop on the charge line
If the BS line is connected, the controller can compensate for a voltage drop of DU = 2.5 V.
If there is a voltage difference of DU = 3.5 V 1 V, a fault indication is generated in the ADM.
For reasons of safety, the control voltage is limited to Umax = 31 V 1 V.
DFM connection (not used)
The DFM connection supplies the duty cycle of the excitation current, i.e. the capacity utilization of the alternator, in the form of a PWM signal.
The pulse width depends on the operating point of the alternator. The connection must be activated for this purpose.
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Alternators
46
Task 1
Legend:
A3
FR control module
A6
G2
Alternator
M1
Starter
X8
X9
GT00_19_0015
What possible fault sources do you find when you examine the voltage supply on terminal 15 at the alternator?
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Alternators
47
Engine brakes
07.05.2003
Constant throttle
A constant throttle valve is located in each cylinder head, as a 'fifth valve'.
It is actuated pneumatically or hydraulically through the screw-on connection.
The pressure chamber is sealed at the top by an O-ring in the cap.
The cap is fixed to the cylinder head housing by a retaining clip.
Hydraulic actuation (by engine oil pressure) is used only on the OM 906 and
OM 457; but in this case, actuation is by connection to the Turbobrake.
The MR takes over control of the solenoid valve (connected to engine oil
pressure) when a request is sent by the ADM electronics (over the CAN bus).
N01.50-2001-50
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Engine brakes
48
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Engine brakes
49
Turbobrake
07.05.2003
N14.15-2053-50
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Turbobrake
50
N14.15-2052-52
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Turbobrake
51
N14.15-2062-72
Turbobrake disengaged
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Turbobrake
N14.15-2063-72
Turbobrake engaged
52
The better the cylinder charge, the higher the compression pressure.
The stronger the pressure release after TDC, the lower the acceleration of the piston due
to release of the pressure in the previously compressed air (constant throttle function).
The higher the head pressure, the more power is required for gas exchange. The head pressure
in the exhaust pipe must be limited in order to prevent undesired opening of the valves.
The larger the air volume that is moved under pressure, the more power is absorbed.
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Powersystems Industrial Engines Electronical Engine Control Series 457, 500 and 900 Advanced Training
Turbobrake
53
With the exhaust valve brake, the supercharger runs on idle during brake operation. The cylinder charge corresponds to that of a naturally
aspirated engine, or is even poorer, because in this case the supercharger impedes the intake process.
With the Turbobrake, the supercharger ensures good cylinder charging. The sliding sleeve has molded slits on the turbine side and
narrows the cross-section at the inlets for the turbine, and guides the air stream directly towards the outer area of the turbine blades.
The delivered volume of air is the same as or greater than in fuel combustion operation, thus achieving optimal cylinder charge, or a
very high compression pressure. This is why the charge air pressure or turbocharger rotational speed must be controlled in engine
brake operation. The rate of air flow in engine brake operation is raised, and the engine is under lower thermal load than with the valve brake.
A controlled bypass connects the twin-pipe turbine with the turbine outlet (for the wastegate function), and the head pressure or
turbine rotational speed can be controlled.
The Turbobrake is also used by the brake speed control.
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Turbobrake
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Turbobrake:
When starting, the MR (proportioning valve 1) energizes the EPW solenoid valve (with a PWM signal), at which the pneumatic
reservoir pressure from the ancillary consumer circuit is present.
This valve allows pneumatic pressure through (about 5 bar) and the rod in the vacuum cell at the Turbobrake is extended.
The rotary valve in the Turbobrake is rotated and the bypass between the turbine and turbine outlet is closed (there is no wastegate function).
At engine speeds over 900 rpm, the Turbobrake can be engaged.
The FR energizes the engine brake solenoid valve. The pneumatic cylinder extends and the sliding sleeve is pushed into the Turbobrake by
the actuating arm.
The turbo speed increases.
On the shaft linking the turbine wheel to the compressor turbine wheel is an rpm sensor (induction-type pulse generator), which indicates
the turbine speed to the MR.
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Turbobrake
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If the speed reaches 85,000 - 90,000 rpm, the solenoid valve (EPW) vents the vacuum cell. The spring in the vacuum cell pushes the
rod back, and the rotary valve turns in the blow-off direction (part of the exhaust gases now bypass the turbine).
The speed is maintained at 85,000 - 90,000 rpm.
The vacuum cell can be vented down to 0 bar with the solenoid valve (EPW).
There is an electronic circuit in the solenoid valve (EPW), which measures pressure and atmospheric pressure.
If the engine is stopped, the vacuum cell is vented down to 0 bar with the solenoid valve (safety circuit, bypass fully open).
The turbocharger rotational speed can be read off in the MR actual values.
The proportioning valve 1 parameter in the MR must be set to "active".
In the "Actuations" menu in Star Diagnosis, the solenoid valve for the sliding sleeve cylinder or the EPW solenoid valve can be
actuated in the FR or MR.
Turbobrake MR wiring diagram
Rotary
valve
B104
MV
(EPW)
Y 87
N3
24
N3
5
N3
11
N3
51
N3
12
N3
4
MR
N3=55-pin plug
at the MR
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Turbobrake
Turbobrake PPT
56
Note:
The flame starting system does not operate if the engine is started before the "Flame starting system" indicator lamp goes off.
If the coolant temperature goes above -4C approximately, the "Flame starting system" indicator lamp goes off after about 2 seconds (function check).
If the coolant temperature goes under -4C approximately, the "Flame starting system" indicator lamp goes off after about 20 seconds.
Faults in the flame starting system are indicated on the display by means of a warning light and a fault code. Have the flame starting system inspected at a
Mercedes-Benz service station.
If the engine coolant temperature sensor fails, the flame starting system electronics use the engine oil temperature instead.
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Flame starting system
61
The Turbobrake is switched on and off by the FR. Non-operation of the Turbobrake may also be caused
by another vehicle system, for example the ASR or ABS.
Clutch pedal teach-in error in the FR or GC, or teach-in not performed.
The accelerator pedal is actuated.
Faulty engine brake solenoid.
Where necessary, the FR calculates engine brake power and sends it to the MR.
The MR controls the wastegate function. Non-operation may be due to causes in the engine components.
Faulty boost pressure sensor (substantial loss of engine brake power).
Faulty boost pressure rpm sensor (substantial loss of engine brake power).
Faulty EPW valve (sporadic or no engine power, low engine brake power)
Wiring fault
Hardware fault
Turbobrake function is also affected by the pneumatic system.
Pressure in the ancillary consumer circuit.
Leaktightness of pneumatic lines
Easy movement of the engine brake cylinder, vacuum cell, and Turbobrake mechanical system
Checking the function (not power output) of the Turbobrake without test equipment.
Always perform the check with the engine at operating temperature.
Switch on the ignition. Engage the highest stage of the engine brake.
An assistant starts the engine using the starter button on the engine. During the starting procedure, the rod in
the vacuum cell is reset (no wastegate function).
The assistant accelerates the engine using the starter button on the engine. The engine begins to 'hunt'.
Check visually whether the sliding sleeve fork moves and whether the rod in the vacuum cell is reset.
When the engine is switched off, the rod in the vacuum cell must be reset again (wastegate in full operation).
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Turbobrake
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Turbobrake
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07.05.2003
The flame starting system consists of a diagnostics-enabled electronics system (which is linked over a Low-Speed CAN bus in the ADM with the engine CAN bus,
or joined with the engine CAN bus through the plug in the ADM), a solenoid valve, a glow plug, and a fuel nozzle.
The fuel is supplied over a line (with throttle) from the fuel filter to the solenoid valve, and then to the fuel nozzle. The fuel nozzle atomizes the fuel, which is then
ignited at the glow plug and thus heats the intake air.
Flame starting system:
The flame starting system is a cold-starting aid, for when outside temperatures are low.
At coolant temperatures below -4C approximately, the flame starting system reduces pollutant
emissions (after the engine is started). This also spares the starter and battery and shortens the
starting time. Therefore, the engine should only be started after the "Flame starting system"
indicator lamp goes off.
Turn the ignition switch to Ignition "On". The "Flame starting system" indicator lamp must light up.
Start the engine within 30 seconds after the "Flame starting system" indicator lamp goes off.
1 Flame starting system indicator lamp
N54.30-4365-20
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Flame starting system
60
Note:
The flame starting system does not operate if the engine is started before the "Flame starting system" indicator lamp goes off.
If the coolant temperature goes above -4C approximately, the "Flame starting system" indicator lamp goes off after about 2 seconds (function check).
If the coolant temperature goes under -4C approximately, the "Flame starting system" indicator lamp goes off after about 20 seconds.
Faults in the flame starting system are indicated on the display by means of a warning light and a fault code. Have the flame starting system inspected at a
Mercedes-Benz service station.
If the engine coolant temperature sensor fails, the flame starting system electronics use the engine oil temperature instead.
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Flame starting system
61
07.05.2003
Since the flame starting system cannot be used at high altitudes (due to lack of oxygen), a heater flange is installed in the engine intake manifold.
Version 1: Installed with FR and ADM-FR
The preheating unit is switched on separately using the switch .
The indicator lamp lights up = start of preheating.
The heater flange is then actuated by the control module and supplied with current through the power relay .
Preheating time depends on voltage and lasts for about 30 seconds at 21 V.
When the preheating time is ended, the indicator lamp flashes, indicating ready-to-start (this lasts about 30 s).
When the starting time has ended, and terminal 50 is 'Off'; the post-heating time begins. This depends on temperature, and lasts about 120 seconds at -4C to 10C, 150 seconds at about -10C, and 180 seconds at -20C and under.
After starting, the indicator lamp is no longer lit.
The relay cuts off the current to the heater flange while the starter is engaged.
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Heater flange in Mercedes-Benz engines
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GT_15_45_0002
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Heater flange in Mercedes-Benz engines
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GT_15_45_0001
Resistor 7 is used as the load detection for heater flange 5. If the heater flange fails, indicator lamp 2 indicates the fault with a flash code.
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Heater flange in Mercedes-Benz engines
64
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Heater flange in Mercedes-Benz engines
65
21/7
GT_15_45_0003
The indicator lamp flashes if the Make contact in the relay remains stuck.
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Heater flange in Mercedes-Benz engines
66
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