Trucks • Engine

Telligent® Engine systems

Series 457, 500, 900

Advanced Training

As at 08/03

Trucks • Engine Telligent® Engine

systems Series 457, 500, 900
Ad dT i i
This document is intended solely for use in training and is not subject to regular updating.

Printed in Germany Note:

ã 2003 Copyright DaimlerChrysler AG The term »employees« does not imply any
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Publisher: Global Training refers to maler and female employees alike.
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1511 1009 02 - 1st edition 05.03 98 As at 08/03

2nd edition 08.03 100
 Inhaltsverzeichnis 04.09.2003

Titel Seite

Description of Training Course Code NMMS - MM262 ...........................................................................................................................................................................1

Overview of subsequent NMMS course sequence ..................................................................................................................................................................................2
KontAct network, ACTROS Type 930-934 ...............................................................................................................................................................................................3
Data-transfer modalities within the network ...........................................................................................................................................................................................5
KontAct network configuration, ACTROS Type 930-934 .........................................................................................................................................................................6
KontAct network configuration, ACTROS Type 930-934; Exercise..........................................................................................................................................................8
Informations and settings in control unit; Exercise .................................................................................................................................................................................9
Powertrain network control units, ACTROS Type 930-934; Exercise ....................................................................................................................................................10
Telligent engine system, ACTROS Type 930-934 ..................................................................................................................................................................................11
Telligent engine system assignments; Exercise.....................................................................................................................................................................................12
Telligent engine system closed-loop control circuit; Exercise ...............................................................................................................................................................13
Drive- and working speed control ..........................................................................................................................................................................................................14
Components Telligent engine system, ACTROS with GS; Exercise .......................................................................................................................................................16
Powertrain network engine management, ACTROS Type 930-934; Exercise........................................................................................................................................18
Fuel injection with the unit pump; Exercise...........................................................................................................................................................................................20
Classification of unit pumps ..................................................................................................................................................................................................................21
Engine tests; Exercise ............................................................................................................................................................................................................................23
Information exchange Telligent engine system, ACTROS with GS; Exercise .........................................................................................................................................25

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Inhaltsverzeichnis I 1
Information exchange Telligent engine system, ACTROS with HPS, A/C and Linnig; Exercise ............................................................................................................28
Information exchange Telligent engine system, comparison between ACTROS and ATEGO<15t; Exercise .........................................................................................30
Powertrain network engine management and HPS, ACTROS Type 930-934; Exercise........................................................................................................................32
Correlating components and their functions HPS, ACTROS Type 930-934; Exercise.........................................................................................................................34
Functions of FR Drive Control ECU, ACTROS Type 930-934; Exercise ...............................................................................................................................................35
Accelerator pedal operation with engine torque, actual values, ACTROS Type 930-934; Exercises ....................................................................................................37
Accelerator pedal sensor, fuel flow control; Exercise............................................................................................................................................................................39
Onboard initialization of accelerator pedal, ACTROS Type 930-934 ...................................................................................................................................................40
Engine start function, actual values, ACTROS Type 930-934; Exercise ................................................................................................................................................41
On-board error code displays and their interpretation ..........................................................................................................................................................................43
Engine control / continuous brake lever operating status options .......................................................................................................................................................44
Operational modes: FR Drive Control functions; Exercise.....................................................................................................................................................................46
New features in driving systems control concept, ACTROS Type 930-934...........................................................................................................................................47
Control concept for drive control systems, ACTROS Type 930-934; Exercise......................................................................................................................................48
Powertrain network HPS and RS, ACTROS Type 930-934; Exercise .....................................................................................................................................................50
Continuous brake function with RS, actual values, ACTROS Type 930-934; Exercise ..........................................................................................................................52
Powertrain network with HPS and retrofitting Linnig, ACTROS Type 930-934; Exercise....................................................................................................................55
Electromagnetic fan clutch (Code MZ5), wireing and parameterization; Exercise ................................................................................................................................57
Electromagnetic fan clutch (Code MZ5), actual values and ext. control; Exercise................................................................................................................................58
Assignments of MR proportional valves; Exercise .................................................................................................................................................................................61
Parameter MR; Exercise.........................................................................................................................................................................................................................62
Engine start/stop; Exercise ...................................................................................................................................................................................................................63

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Inhaltsverzeichnis I 2
Control of rpm for auxiliary equipment / PTO operation ACTROS, AXOR and ATEGO > 18t ................................................................................................................65
Control of rpm for auxiliary equipment / PTO operation ATEGO <15 t .................................................................................................................................................66
Drive- / Stationary PTO functions..........................................................................................................................................................................................................67
Logical relationships in the base module ..............................................................................................................................................................................................69
Function pins in the base module..........................................................................................................................................................................................................70
PTO control with GM, ACTROS Type 930-934 .......................................................................................................................................................................................71
Self holding function with PTO engaged ................................................................................................................................................................................................72
PTO function in base module, ACTROS Type 930-934 ..........................................................................................................................................................................73
Alteration with function pin - engine speed, ACTROS Typ 930-934 ......................................................................................................................................................75
Central data storage in base module.....................................................................................................................................................................................................76
Exercises <> Central data memory ........................................................................................................................................................................................................77
Immobilizer (WSP)..................................................................................................................................................................................................................................79
Immobilizer (WSP), innovation - improved immobilizer..........................................................................................................................................................................82
Starter actuation system; Exercise ........................................................................................................................................................................................................83
Symbolical fuel circuit Engine Series 457; Exercise ..............................................................................................................................................................................85
Real fuel circuit engine series 457; Exercise .........................................................................................................................................................................................87
Fuel pressure test locations series 500; Exercise .................................................................................................................................................................................88
TIPS, general ..........................................................................................................................................................................................................................................90
Powertrain network, Legend ..................................................................................................................................................................................................................92

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Inhaltsverzeichnis I 3
09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Inhaltsverzeichnis I 4
 Description of Training Course Code NMMS - MM262 15.05.03

Training course title: Telligent engine system – Series 457, 500, 900 - Advanced Training
Target group: Mechanics, electricians
Requirements: Participants have successfully completed the final examination for the NMMG and NMGG courses, or have
worked through the pretraining course and passed the entry exam. (Among the resources available to assist
in acquiring this knowledge are the "Unit Injector, Parts 1 and 2" and "Electrical Wiring Diagrams Parts 1-3"
CBTs).
Performance rating: 2
Ratio of practice to theory: 50% / 50%
Duration/venue: 2 days, Esslingen-Brühl, mobile
Course objective: The participant can:
- describe the general design and basic operating features of the TelligentÒ engine-management system
(supplementary control functions for cooling, engine-brake management, turbocharger control, flame start
system).
- describe the shared features and differences of the various engine-management systems used with the
Series 457, 500 and 900 powerplants.
- carry out diagnosis without assistance.
- perform test, adjustment and repair operations.
Content: - Design and operation:
- of electronic vehicle data networks
- of Telligent closed-loop engine control systems with similarities and differences of various systems in
ACTROS, ATEGO, AXOR und ECONIC.
- Testing, adjustment, parameter entry, diagnosis with current diagnostic systems along with repairs on
installed component assemblies.
- Problem diagnosis based on sample cases.

Notice: The check on learning success is the final element in the training course.

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Description of Training Course Code NMMS - MM262 1
 Overview of subsequent NMMS course sequence 15.05.03

The subsequent course sequence is defined by the following main subjects. You will become familiar with this material studying in work groups.

Powertrain network Telligent engine system Engine control Powertrain network drive Options
control Immobilizer
è è è è
Fuel circuit

KontAct network System seperation Fuel injection, Engine management and GS Engine start / stop
Signal course

Network IES Closed-loop control circuit Classification of unit pumps Engine management and Working speed control
HPS wireing, parameters

Informations Drive- and working speed MR control Accelerator pedal Immobilizer

control

Components Telligent MR parametrization Engine start Testing fuel circuit

engine system

Operation modes Database "TIPS"

FR drive functions

Engine management HPS

and RS

Engine management HPS

and Linnig

Optional: Turbobrake construction, function and troubleshooting

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Overview of subsequent NMMS course sequence 2
 KontAct network, ACTROS Type 930-934 13.05.03

The network in the current ACTROS has been expanded substantially beyond earlier versions. The earlier network (IES) has been expanded to embrace new
functionality and operations.
While the earlier system serves as the basis for KontAct, it has now been enlarged to include new CAN bus systems.

Distinguishing the earlier CAN bus systems was simple, with the IES being divided into high-speed and low-speed CAN buses. The expanded KontAct network
incorporates 11 different CAN bus systems. The designations for these systems reflect the sectors in which they function, such as frame CAN, interior CAN, etc.

N00.19-2054-05 W00.19-1011-79

IES (Integrated Electronic System) KontAct (Concept for electronic network linkage in the Actros)

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
KontAct network, ACTROS Type 930-934 3
Major new features in the expanded network environment

· network componentry is distributed throughout the entire vehicle

· only a relatively limited number of components are still installed at a central location in the E module
· installed components are linked by the data wires
· new CAN bus systems have been integrated
· significant network tasks have been reassigned to different components
· functionality once residing in electronic control units has been reassigned to new components
· electronic control units have been fully integrated in other components, and are now present as software instead of physical hardware
· diagnosis capabilities have been expanded to support greater in-depth analysis

Notice
Earlier systems such as PSM, the retarder and BS have been adopted from the earlier ACTROS in essentially unmodified form.

Objectives of advanced development

· further reductions in numbers of connecting wires

· reduction in number of plug-in connections
· more modest space requirements for wiring harnesses
· integration of all electronic components in network environment
· all electronic components include self-diagnosis capabilities
· reduced length for power and signal paths
· more detailed problem diagnosis

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
KontAct network, ACTROS Type 930-934 4
 Data-transfer modalities within the network 13.05.03

Exercise

The diagram illustrates the network structures of

significance for engine-management operations.

The familiar C wire bus is used in addition to the

CAN bus versions.

Correlate each connecting wire with a specific

type of data transfer as indicated!

Type of data transfer:

A ð HS CAN bus
B ð LS CAN bus
C ð C wire bus
D ð Conventional signals

X13 Diagnostic interface socket

N54.00-2116-76

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Data-transfer modalities within the network 5
 KontAct network configuration, ACTROS Type 930-934 13.05.03

W00.19-1011-79

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
KontAct network configuration, ACTROS Type 930-934 6
1 Powertrain components A22 PSM Parameter-controlled Special Module K2 Battery kill switch
2 Brake system components A64 Front module (FM) K Diag C wire diagnosis
3 Trailer and superstructure components A65 Rear-end module (HM) K C wire emrgency switch
4 Vehicle components CAN 1 Vehicle CAN P2 Instrument (INS)
5 Cab components CAN 2 Interior CAN P3 Modular tachograph (MTCO)
6 Frame components CAN 3 Frame CAN X11 15-pin trailer socket
7 Telematics/ diagnosis CAN 4 Engine CAN X12 7-pin trailer ABS socket
22 Superstructure electronics CAN 5 Transmission CAN X13 Diagnostic interface socket
CAN 6 Brake system CAN X126 Telematics platform (FleetBord)
A3 FR Drive Control ECU (FR) CAN 7 Trailer CAN (PSM) Z2 CAN node in cab waistrail, special equipment
A7 Base module (GM) CAN 8 Superstructure CAN Z3 Supplementary CAN node
A11 Brake control ECU (BS) CAN 9 Telematics CAN
A16 Gear selection ECU (GS) CAN 10 Speedo CAN
A20 Retarder control ECU (RS) CAN 11 Trailer CAN (BS)

Notice: Refer to GF 00.19-W-0002 MP, "KontAct functionality within opverall network environment" for additional information

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
KontAct network configuration, ACTROS Type 930-934 7
 KontAct network configuration, ACTROS Type 930-934; Exercise 13.05.03

We now proceed to the revised network configuration found in the new ACTROS. Refer to the diagram for the new network in responding to the following!

Exercise m Provide the correct CAN bus designation!

Frame CAN bus Speedo CAN bus

Vehicle CAN bus Trailer CAN (BS)
Transmission CAN bus Trailer CAN (PSM)
Brake system CAN bus Telematics CAN bus
Engine CAN bus Superstructure CAN
Interior CAN bus

Exercise m Which electronic control units are incorporated in the vehicle CAN bus?

-
-

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
KontAct network configuration, ACTROS Type 930-934; Exercise 8
 Informations and settings in control unit; Exercise 18.07.03

Task m The information types are displayed and described.

Name a few examples!

Information type Description Display/change Examples

Actual value Refers to the currently determined value within a defined area Display, OFF-board
in a system that describes a current state. The value can
continually change.

Measured value Refers to the currently determined value within a defined area Display, ON-board
in a system that describes a current state. The value can
continually change.

Binary value Refers to the currently determined value in a system that Display, ON-board
describes a “switching state” and that only recognizes “ON”
and “OFF” positions. The value can continually change.

Parameter Refers to a basic setting with a defined value or state stored in Display and changes, in
the control unit, thus allowing the same control unit to be used general OFF-board
for different vehicle models, variants and operating conditions. (exception: ON-board)
Travel value Refers to the currently determined value in the GS system for a Display, OFF-board
position or placement of a sensor on the transmission, which
describes a state and which can constantly alter – a travel
value is to be regarded as an actual value.
Learning value Refers to the currently determined value in the GS system for a Display, OFF-board,
“minor” or “major” teach-in process, for the position or change by means of
placement of a sensor on the transmission, which is filed in the teach-in process
control unit. The learning value may be of assistance during
diagnosis.

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Informations and settings in control unit; Exercise 9
 Powertrain network control units, ACTROS Type 930-934; Exercise 13.05.03

Exercise
ASIC HM
A68 A82
The diagram illustrates a typical vehicle with gear A65
selection control, retarder and parameter-entry
special module. MTCO INS GM
P3 P2 A7
Provide the designations for the bus systems in
the diagram! CAN 1

CAN 1 Vehicle CAN bus

RS PSM BS
CAN 2 Interior CAN bus
CAN 3 Frame CAN bus A20 A22 A11
CAN 4 Engine CAN bus
CAN 5 Transmission CAN bus
CAN 10 Speedo CAN bus FR GS
ASIC ASIC data CAN bus A3 A16

A3 FR Drive control ECU

A4 Flame start ECU (FLA)
A6 Engine-management ECU (MR)
A7 Base module (GM)
A11 Brake system control ECU (BS) MR FLA
A16 Gear-selection control ECU (GS) A6 A4
A20 Retarder control ECU (RS)
A22 Parameter-controlled Special Module ECU (PSM)
A65 Rear end module (HM)
A68 Switch module 4, master
A82 Switch module 6, lock switch
P2 Instrument (INS)
P3 Modular tachograph (MTCO)
TM Powertrain 1_D

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Powertrain network control units, ACTROS Type 930-934; Exercise 10
 Telligent engine system, ACTROS Type 930-934 13.05.03

Engine-management functionality is separated into two difrerent subsystems, each with its own electronic control module. The control module for the FR Drive
Control subsystem (FR/FMR) is assigned to the vehicle, while the module for the engine-management (MR/PLD) is assigned to the engine.

All data specifically related to the engine are stored in the MR Engine Control ECU, which registers data on the engine's operating conditions relayed by a range
of sensors. Within the module these data are evaluated as the basis for adjusting the fuel injection to the coordinates for FR Drive Control demand (specified
engine output) stored for the instantaneous status in the program map.

The FR Drive Control ECU contains data of relevance to the vehicle. It registers the vehicle's operating conditions and responds to the driver's command inputs.
This latter category can include demand transmitted through the accelerator pedal, service and engine brake activation, clutch actuation and control of PTOs.
The FR Drive Control ECU employs these data as the basis for calculating a specific engine output for relay to the MR.
Additional software modules may be integrated in the FR in some vehicle configurations.

Bilateral data communications between FR and MR are expedited through CAN 4, traffic to the GS gear-selection module runs through CAN 5, and data transfer
to other, vehicle-side control modules is through CAN 1.

You may ask "What is the point of having separate systems?"

Let's talk about the reasoning behind this concept and the advantages it provides.

· Modulalr design offers flexibility that makes it possible to adapt and expand systems to reflect individual requirements.
· Drive Control embraces functions outside the engine, and can be structured for individual versions.
· Data for the specific vehicle (idle, working rpm, etc.) remain with the vehicle in the event of engine replacement.
· The engine control module and the data for the specific engine remain with the engine, forming a logical unit.
· Excahnge engines always have the most recent engine data.
· Exchange diagnosis is facilitated because processes can be assessed in isolation.

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Telligent engine system, ACTROS Type 930-934 11
 Telligent engine system assignments; Exercise 19.05.03

Exercise m While the reasons behind the decision to use separate subsystems may be clear, there remains the
question of how individual functions are assigned. To give you a clearer understanding of how the
strategy works, below we have compiled a list of operational assignments along with the subsystems
in which they reside.

Task assignments
Engine brake plate control solenoid E
D Constant throttle control solenoid N
R Oil level monitor ð G
I Injection timing and flow volume assignment I
V Registration and processing of driver demand N
E RPM governor E
ï Relay engine start signal ð
Cruise control and set control C
Start D+ alternator trigger current O
Relay coolant temperature N
System monitor, error assessment and error code generation T
C Assess current engine operating conditions R
O ï Control excess rpm warning O
N Activate emergency default program L
T Activate engine protection functions, overheating guard, etc.
R Check coolant level
O Activate engine start/stop function (MSS)(ATEGO only)
L Process transponder code
Control of transmission splitter group with HPS/MPS

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Telligent engine system assignments; Exercise 12
 Telligent engine system closed-loop control circuit; Exercise 13.05.03

Exercise

¦ The text provides the basic information flow from the time pressure is exerted against the Z1
accelerator pedal until active engine control sets in. Correlate the information flow with
the symbols in the diagram. Use the numbers indicated in the text.

Description of operation

The electronic accelerator pedal transmits two PWM pulse-width-modulated signals. Their pulse-duty 1 FR
factor reflects the position of the pedal to mirror driver demand. When the accelerator pedal is
depressed, the pulse-duty factor (1) changes and the FR Drive Control ECU recognizes that the pedal is
no longer at idle. It responds by dialing in the requested engine output (2).

The engine's maximum available torque (3) is defined by the MR Engine Control, and can be
permanently transmitted to the FR Drive Control through the CAN bus.
The primary limit on output level is imposed by the data set in the MR electronics, and is thus defined
by the engine series. The system can also limit instantaneous operating conditions as monitored by the MR
sensors.

The operation control can limit the issued specified engine torque (2) with actuator commands of a
higher hierarchical level. This could result from external governor intervention (4) associated with
closed-loop operation of the ASR or ABS, as received through the HS CAN. Activated programmed
parameters (such as vmax) can also produce a limitation with a high priority in rthe FR Drive Control's
hierarchical structure.
The MR transmits the current actual torque (5) (calculated) to the HS CAN through the FR Drive
Control.

PPT

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Telligent engine system closed-loop control circuit; Exercise 13
 Drive- and working speed control 18.07.03

The FR (drive control) determines the operating mode of the MR (engine control) via the rpm regulator
selection.
Implemented are regulator structures for neutral (type 15) and working speed control
(type 0 - type 5). The MR notifies the FR as to its current operating mode via the CAN bus.

If the FR does not request working speed control, this signifies normal driving operation. The engine is
controlled via the accelerator pedal input or a cruise control input. Due to a torque setting input, the MR Torque FR ADR
regulates in torque mode by the FR. Neutral and maximum governed speed are adjusted by the neutral or mode A3 mode
maxi speed controller in the MR.
If a target speed is specified in torque mode via the FR, the regulated rotational speed is above the
requested speed when the engine is not under load. RQ RQV
regulator regulator
characteristic MR characteristic
If the FR requests a valid working speed controller and provides a plausible rpm target value for this, the
MR switches over to the working speed control mode. The regulating torque is restricted by the output A6
limit (“corrected limit torque”). The rpm target value is limited by the current neutral and the current
maximum governed speed.

The FR can increase the idle speed above the idle speed target value set in the MR by specifying the “idle
speed”.
The maximum governed speed set in the MR also can be decreased by the FR by specifying a valid
“maximum speed”. The rotational speed determined as a result is sent back to the FR as the “current
breakaway speed”. The maxi speed control limits the MR to the current maximum value, independent of
the operating mode. TM Antriebsstrang 1_D.ppt

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Drive- and working speed control 14
Rpm regulator selection

Type Application
0 Rpm adaptation when shifting by EAS
1 Working speed control (ADR), standard ADR regulator
2 Working speed control for highly dynamic applications, e.g. concrete pumping
3 Working speed control, no application/approval from DCAG
4 Working speed control, no application/approval from DCAG
5 Working speed control, no application/approval from DCAG
15 Idle speed control

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Drive- and working speed control 15
 Components Telligent engine system, ACTROS with GS; Exercise 13.05.03

The illustration shows the information flow WS

INS
between the individual components and P2 A30
electronic circuits.
GS
Z1 BS
The illustration uses an ACTROS with the systems A16 A11
MR, FR, INS, BS and GS as an example.

Notice: A7 S2
Components and electronic circuits can vary S1
when other systems such as RS, AGE, etc., are A42 Y1
installed. Y2
G2
P3
FR B5
B1
S4
B7
B6
B4

B14 B110
B15 B111
B16 Y6-Y11
B10 MR S10
B65 S11
S1 M1
A42

TM FR 2_D.ppt

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Components Telligent engine system, ACTROS with GS; Exercise 16
Exercise m Here is another list of the installed components.
Complete the table by adding the missing component designations.

A7 G2 Alternator
A 11 M1 Starter
A 16 GS/EPS control module P2
A 30 P3
A 42 S1
B1 S2
B4 Outside temperature sensor S4 Brake light switch
B5 Parking brake switch S 10 Push-button engine start switch
B6 Coolant level switch S 11
B7 Air filter monitor switch, sensor Y1
B 10 Y2 Engine brake solenoid valve
B 14 Y 6 - Y 11 Pump insert cylinder
B 15
B 16
B 46
B 65
B 110
B 111

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Components Telligent engine system, ACTROS with GS; Exercise 17
 Powertrain network engine management, ACTROS Type 930-934; Exercise 19.05.03

ASIC HM
X13 B28 A68 A82
A65
CAN 10 CAN 2 CAN 3
MTCO INS GM
P3 P2 A7
CAN 1

RS PSM BS
A20 A22 A11

FR
A3

CAN 4

MR FLA Y1 Y2
A6 A4

Y6-13

TM Antriebsstrang 1_D.ppt

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Powertrain network engine management, ACTROS Type 930-934; Exercise 18
Exercise m Identify the components missing from the diagram! Refer to the MR and FR wireing diagrams.

The following questions may assist you in finding the answers.

· Have you remembered all of the sensors and switches installed on the engine?
· Which ECU triggers the starter?
· Is the alternator integrated within the engine-management system?
· Where is the foot throttle actuator connected?
· How are the ignition switch and the electronic processing circuitry integrated?
· Where does the command for engine braking originate, and how is the engine brake activated?
· Where does the vehicle speed signal enter the system?
· Is the parking brake switch connected?
· Can you read out informations, shown on the display?

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Powertrain network engine management, ACTROS Type 930-934; Exercise 19
 Fuel injection with the unit pump; Exercise 13.05.03

Exercise m The illustration is a simplified rendition of the injection process.

Place the terms below in their correct locations in the sequence!

1 The is a solenoid trigger signal calculated in the electronic control unit

(output amplifier circuit). It contains information on start and
duration of fuel delivery.

2 The in the solenoid coil is caused by the shift in the magnetic field
within the windings and the reverse induction that it causes.

3 The idenitifies the negative pulse as the reference point for starting
injection (within the control unit).

4 The shows the travel of the valve body in the pump insert.

5 The is identified by F and shows the electrical start of injection along

with G for the actual start of main injection.

6 The indicates the travel of the needle in the injection nozzle.

7 The is registered at the crankshaft (angular shift) and provides the basis
for calculating the duration of delivery as a function of time.

N07.15-0046-03
A Initial stroke, B Delivery stroke, C Residual stroke, Contact recognition, injection pressure, rpm signal, control signal,
D Response lag, E Pulse width valve body travel, needle lift, current flow

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Fuel injection with the unit pump; Exercise 20
 Classification of unit pumps 17.10.2002

The unit pumps of series 500, 900 and series 457 are classified during
production. AXOR MR
The classification class of each individual pump is recorded when it is installed
in the engine on the assembly line at Mannheim and stored in the MR Steckpumpe austauschen
electronics.
Zylinder Code
This information is taken into account when metering the fuel quantity 1 Zylinder 1 X-XXX-XXX-XX-XXXXX
(injection times) in order to assure smooth engine running. 2 Zylinder 2 X-XXX-XXX-XX-XXXXX
3 Zylinder 3 X-XXX-XXX-XX-XXXXX
After a unit pump is replaced or has been removed for diagnostic purposes, the
classification of the unit pump should be assigned to the cylinder in order to 4 Zylinder 4 X-XXX-XXX-XX-XXXXX
ensure smooth engine running. 5 Zylinder 5 X-XXX-XXX-XX-XXXXX
6 Zylinder 6 X-XXX-XXX-XX-XXXXX

A wrong input can cause an engine run out of round and overloading of Hinweis:
individual cylinders! Der Benutzer muß die Steckpumpennummer auf der
Steckpumpe ablesen und für den entsprechenden
Zylinder eingeben. Nur von Steckpumpen, die
erneuert werden, die Steckpumpennummer
eingeben.
Zur Eingabe Taste F3 drücken.

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Classification of unit pumps 21
The classification class is indicated on the type plate of the unit pump in the form of a 14-digit number
(C). This code is entered with DAS in the menu "Replacing unit pump".

A= MB number
B= Certification number
C= Unit pump number
D= Barcode
E, G, H = Manufacturer information
F= Manufacturer barcode

N07.02-2028-01

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Classification of unit pumps 22
 Engine tests; Exercise 15.05.03

Exercise m Engine test with Star Diagnosis. Is that possible at all? Of course! But what test should be used for
each particular problem?
A number of important engine tests are listed. Discuss in the groups the possible complaints and
problems which can be detected and verified using these engine tests. Assign the tests to the
problems found.

Engine test Application, possible complaint and problems

Deactivation of single cylinder

Compression test

Check of idle consistency control

Test of impact times

Reversed polarity check

Test of single cylinder calibration

Test of proportional control solenoid

Test of Linnig fan

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Engine tests; Exercise 23
Exercise m Carry out the requested test at the vehicle and transfer the results..

Compression test: Check of idle consistency control:

Cylinder 1 % Cylinder 1 %
Cylinder 2 % Cylinder 2 %
Cylinder 3 % Cylinder 3 %
Cylinder 4 % Cylinder 4 %
Cylinder 5 % Cylinder 5 %
Cylinder 6 % Cylinder 6 %
Cylinder 7 % Cylinder 7 %
Cylinder 8 % Cylinder 8 %

Test of impact times:

Cylinder 1 ms
Cylinder 2 ms
Cylinder 3 ms
Cylinder 4 ms
Cylinder 5 ms
Cylinder 6 ms
Cylinder 7 ms
Cylinder 8 ms

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Engine tests; Exercise 24
 Information exchange Telligent engine system, ACTROS with GS; Exercise 13.05.03

Exercise
Z1
The illustration shows the FR Drive Control and
directly connected components along with the
directions in which data flows.

The object is to identify the type of information S2

A7
being transferred.
Insert the terms from the list in the diagram on
the right!
Y1
S1 Y2
A42 Transponder code
B5
A3
G2 S4

P3
Terminal 30 TERMINAL 15
TERMINAL 31 D+ B1
Demand: Backup lamp Demand: Brake light
TERMINAL 50 Transponder code
D+ n signal TERMINAL W
v signal C3 PWM signal GAS1 B7
PWM signal GAS2 A/C pressure
Filter contamination Coolant level B6
Outside air temperature Brake pedal position B4
Parking brake status MB2 control
MB1 control Limiter demand
Limiter/cruise control OFF MB2 demand A6
Cruise control demand MB1 demand
TM FR 2_0.ppt

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Information exchange Telligent engine system, ACTROS with GS; Exercise 25
Exercise
. Coolant temperature
The illustration shows the FR Drive Control and Coolant temperature
other relevant systems. Indicated are the Engine oil temperature WS
direction and flow of information in a sample
n-engine n-engine A30
vehicle.
Engine oil pressure Air filter. soiling
The object is to identify the type of information INS Engine oil level
being transferred. P2
Enter the correct terms from the following list in
the chart on the right! Z1
Activ. Stop light
Activ. warning buzzer
Service brake status

Neutral position Engine actual torque BS

GS Clutch status A11
A16 n-transmission input Min. input torque
Max. input torque

Outside air temperature Coolant level FR

Parking brake lamp v-signal C3
Continuous brake lamp Status of reverse gear
Current engine torque Vehicle V
Parking brake status Vehicle V MR

TM FR 2_0.ppt

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Information exchange Telligent engine system, ACTROS with GS; Exercise 26
Exercise
Z1
The diagram illustrates the FR Drive Control and
the MR Engine Control.
It shows the information flow and directions in a
sample vehicle.
FR
Fill in the boxes with the missing information.

Engine oil temperature

Specified rpm

Tml. W rpm signal

Governor type Engine start (p/button)
n-max
n-min
Engine status
Momentary max. torque

Spec. engine torque TERMINAL50 MR

Transponder code n-engine
Engine oil level Engine oil pressure
Coolant temperature Warning buzzer active
Brake light active Current engine torque
TM FR 2_0.ppt

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Information exchange Telligent engine system, ACTROS with GS; Exercise 27
 Information exchange Telligent engine system, ACTROS with HPS, A/C and Linnig; Exercise 13.05.03

Exercise Z1
An ACTROS is equipped with Hydro-Pneumatic
Shift (HPS), an air conditioner, and Terminal 30 Demand MB1
electromagnetic clutch and various other Terminal 15 Demand MB2
components. Terminal 31 Demand Limiter S2
A7
D+ Demand Tempomat
What is the resulting supplementary data flow?
Demand reversing light Limiter/Tempomat OFF
Enter the answers in the diagram on the right! Demand brake light Y1
Actuation MB1
S1 Terminal 50 Y2
Actuation MB2
A42 Transponder code
Service brake status B5
D+ A3
G2 Brake pedal status S4
n-signal Tml. W
P3 v-signal C3 Y30
Y29
PWM signal GAS1
B1
PWM signal GAS2 S3
B46 S9
B7 Air filter soiling S7
B6 Coolant level
B2
B4 Ambient air temper. B3
Y70
A6
Y71
TM FR 2_D.ppt

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Information exchange Telligent engine system, ACTROS with HPS, A/C and Linnig; Exercise 28
Exercise Ambient air temperature Coolant temperature
Coolant temperature Engine actual torque
Which components are deleted on an ACTROS
with Hydro-Pneumatic Shift, air conditioning and Coolant level Engine oil temperature WS
electromagnetic fan when compared to an n-engine n-engine A30
ACTROS with GS? Engine oil pressure Air filter. soiling
INS Engine oil level
Draw a line through the deleted items! P2 v-vehicle
Activ. parking brake light
Activ. service brake light
Z1
Activ. stop light
Activ. warning buzzer
Service brake status
v-signal C3
Parking brake status
Neutral position Engine actual torque BS
GS Clutch status v- vehicle A11
A16 n-transmission input Min. input torque
Reverse gear status Max. input torque

FR

MR
TM FR 2_D.ppt

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Information exchange Telligent engine system, ACTROS with HPS, A/C and Linnig; Exercise 29
 Information exchange Telligent engine system, comparison between ACTROS and ATEGO<15t; 13.05.03
Exercise

Exercise Z1
Which components are not installed on the
ATEGO<15t with the OM 906LA engine and G 85 Terminal 30 Demand MB1
transmission? Terminal 15 Demand MB2
Terminal 31 Demand Limiter S2
The object of the comparison is an ACTROS with A7
D+ Demand Tempomat
Hydro-Pneumatic Shift (HPS), air conditioning and
an electromagnetic fan clutch. Demand reversing light Limiter/Tempomat OFF
Demand brake light Actuation MB1 Y1
Cross out the components that are not installed S1 Terminal 50
on the ATEGO! Actuation MB2 Y2
A42 Transponder code
Service brake status B5
D+ A3
G2 Brake pedal status S4
n-signal Tml. W
P3 v-signal C3 Actuation Splitter 1 Y30
Actuation Splitter 2 Y29
PWM signal GAS1
B1
PWM signal GAS2 Demand Splitter S3
B46 Pressure air condition Neutral position status S9
B7 Air filter soiling Reverse gear status S7
B6 Coolant level
Clutch status B2
B4 Ambient air temper. B3
n-transmission input
Y70 Fan step 1
A6
Y71 Fan step 2
TM FR 2_D.ppt

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Information exchange Telligent engine system, comparison between ACTROS and ATEGO<15t; Exercise 30
Exercise Z1
What new components have been added?
Terminal 30 Demand MB1
What additional information transfers are being Terminal 15
expedited? Terminal 31 Demand Limiter S2
A7
D+ Demand Tempomat
Enter these in the diagram at the right?
Limiter/Tempomat OFF
Remember the constant throttle and the clutch Demand reversing light Y1
Actuation MB1
travel! S1 Terminal 50
A42 Transponder code
Service brake status B5
D+ A3
G2 Brake pedal status S4
n-signal Tml. W
P1 v-signal C3
PWM signal GAS1
B1
PWM signal GAS2
Neutral position status S9
B7 Air filter soiling Reverse gear status S7
B6 Coolant level
B4 Ambient air temperature

A6

TM FR 2_D.ppt

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Information exchange Telligent engine system, comparison between ACTROS and ATEGO<15t; Exercise 31
 Powertrain network engine management and HPS, ACTROS Type 930-934; Exercise 13.05.03

ASIC HM
X13 B28 A68 A82 B5
A65
CAN 10 CAN 2 CAN 3
MTCO INS GM
B17 S144 S145
P3 P2 A7
CAN 1

RS PSM BS
A20 A22 A11
G2 S2 B1
FR
A3
A42 S1
CAN 4

MR FLA Y1 Y2
A6 A4

TM Antriebstrang 1_D.ppt

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Powertrain network engine management and HPS, ACTROS Type 930-934; Exercise 32
Exercise m Identify the components missing from the diagram!

Several questions to assist you in seeking a solution:

· Have you considered the clutch sensor?
· How is gear position registered?
· Which components are significant for the engine overspeed warning?
· Have you considered the components for splitter control?

Notice: For additional information refer to GF 30.35-W-0002 MP "FR Drive control operation" and current flow diagram.

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Powertrain network engine management and HPS, ACTROS Type 930-934; Exercise 33
 Correlating components and their functions HPS, ACTROS Type 930-934; Exercise 13.05.03

Exercise m The listed components have an effect on the operations described.

Correlate components and functions! Discuss the functions performed by the individual operations in
your group!

B2 S3 S7 S9 B3 Function
Clutch travel Splitter switch Reverse gear Neutral switch Countershaft
sensor switch rpm sensor
Releases engine brake activation

Splitter group activation request

Releases limiter activation

Backup light activation request

Activation release for Tempomat cruise control

Releases engine acceleration limiter with transmission in

neutral
Release for engine start with engine starter switch

Monitors layshaft rpm for activation of engine overspeed

warning
Splitter group activation release

Registers redundant engine speed

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Correlating components and their functions HPS, ACTROS Type 930-934; Exercise 34
 Functions of FR Drive Control ECU, ACTROS Type 930-934; Exercise 13.05.03

The FR Drive Control ECU discharges a range of functions. These vary according to the FR status, defined by factors such as ignition on/ignition off, engine start,
diagnosis and parameter entry mode, and also reflect differences in the equipment levels of individual vehicles.

Describe the essential functions in GF30.35-W-4103-02MP "FR Drive Control ECU Exercise."
Extend your understanding by working through the following exercises!

Exercise m When the ignition is off the functions discharged by the FR Drive Control ECU are:

a To store data applicable to the individual vehicle such as parameters, protection functions and special
equipment
b Storing data relevant to the engine
c To respond to system malfunction by storing the corresponding error codes along with indication of
time and frequency
d To store maximum engine torque to obtain evidence of manipulation of power

Exercise m Which supplementary functions are incorporated in the FR Drive Control ECU with equipment version
code MD9, Tempomat cruise control?
a Standby function for cruise control (entered speed remains stored when clutch is released for less
than 5 seconds)
b Tempomat and Temposet-cruise control
c Tempomat cruise control monitoring function (deactivation in response to control stalk malfunction or
deceleration rate of > 2m/s2 without brake light signal)
d RPM limit function

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Functions of FR Drive Control ECU, ACTROS Type 930-934; Exercise 35
Exercise m The following list includes special equipment with the corresponding sales codes.
Which equipment is directly related to the FR Drive Control?
Discuss the connections in the group!
a MD9 Tempomat cruise control
b MT7 Electronic speed governor set to 80 kph
c MZ5 Electromagnetic fan drive
d BA9 Voith secondary retarder, R 115, high-speed
e ET5 Telligent proximity control
f FZ7 Immobilizer transponder
g GS7 Telligent shift control II
h GE2 Telligent automatic gear selection II
i MB1 Engine brake with constant throttle
j ED5 Special module with parameter entry
k ML3 High fan with belt drive

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Functions of FR Drive Control ECU, ACTROS Type 930-934; Exercise 36
 Accelerator pedal operation with engine torque, actual values, ACTROS Type 930-934; Exercises 13.05.03

Exercise Actual Value IW A B C D

m Use DAS to access the monitored data readings for the FFG, first branch 01
MR Engine Control and FR Drive Control. FFG, second branch 99
FFG 1st branch feedback 93
a) Enter the data obtained with ignition on in column A.
A3 FFG 2nd branch feedback 94
b) Enter the data obtained with accelerator pedal fully
depressed in column B. Accelerator pedal torque 03
c) Enter the data with the accelerator in its kickdown FR Idle 69
position in column C. Kickdown 70
d) Enter the data indicated with engine at idle in column D.
Specified engine torque 14
Actual engine torque 15

×
Notice:
Actual engine torque 001
Assess the results in a group discussion. The trainer will be
available to answer any questions. A6 Specified engine torque 002
MR Max. engine torque 003

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Accelerator pedal operation with engine torque, actual values, ACTROS Type 930-934; Exercises 37
Exercise You can present your group results to the entire class later.
Discuss the following questions in the group!

m What is the relationship between the first and second accelerator pedal branches?
-
m What is the significance of the monitored FR Drive Control figure 14 with the pedal depressed to "full
throttle?"
-
m What is the relationship between monitored FR Drive Control figure 03 and FR Drive Control figure 14?
-
m When and why do you check the monitored FR Drive Control figure 69?
-
m What is the relationship between the monitored FR Drive Control figure 14 and the MR Engine Control
reading 02, and between FR Drive Control reading 15 and MR Engine Control reading 01?
-
m What is the significance of the MR Engine Control reading 03?
-
m Why are the FR Drive Control reading 14 and MR Engine Control reading 02 negative at idle?
-

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Accelerator pedal operation with engine torque, actual values, ACTROS Type 930-934; Exercises 38
 Accelerator pedal sensor, fuel flow control; Exercise 03.09.03

Exercise

The example in the diagram illustrates an

effective pedal travel range.
Idle adjustment range Full throttle adjustment range
Indicate the minimum and maximum injection
flow quantities that the driver can initiate at the 0% 10% 30% 40% 90% 100%
pedal in the "accelerator pedal demand for On-Off-Ratio
injection flow quantity" bar

Lower Upper
The group should discuss why the accelerator
travel stop travel stop
pedal sensor has to be initialized!
0% Effective travel range 100%

Pedal range

Idle Kickdown-Position ON
position
Kickdown- Position OFF

Full throttle position

Foot throttle actuator

Quantitiy demand

TM FFG 1_D.ppt

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Accelerator pedal sensor, fuel flow control; Exercise 39
 Onboard initialization of accelerator pedal, ACTROS Type 930-934 13.05.03

Requirement:
Release diagnosis menu in settings menu (see operator's manual).

Initializing accelerator pedal:

· Select diagnosis menu
· Select service information submenu

Display
FR LEARN
Reset with reset key to start initialization"
____

A___

+___
Hold accelerator pedal in full-throttle position
+__A

+__+
Exit initialization routine by again activating reset key
FR OK

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Onboard initialization of accelerator pedal, ACTROS Type 930-934 40
 Engine start function, actual values, ACTROS Type 930-934; Exercise 13.05.03

Exercise Readings IW A B C D

m Access the menu for current data readings in the MR Engine speed at Terminal W 08
Engine Control and FR Drive Control using the DAS. MR engine speed 09
Engine start 61
a) Enter the figures obtained with "ignition on" in column A.
A3 Engine running 62
b) Enter the figures displayed for "engine at idle" in column
B.. Engine shutdown 63
c) Enter the data shown for "starting process" in column C. FR Starter lockout 64
d) While starting the engine attempt to simulate the problem Engine signal, Terminal 50 26
associated with turning the key all the way through at once
Transponder recognized 55
and enter the figures in column D.
Controller type 11

×
Engine speed 004
Delivery angle 006
Controller type 032
A6 Terminal 50 status in FR 021
Notice: Terminal 50 status in MR 023
Discuss and assess the results in the group.The trainer will be MR Engine status 033
available to assist you with any questions. MR starter activation 042
Starter lockout 043

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Engine start function, actual values, ACTROS Type 930-934; Exercise 41
Exercise You can present your group's solution to the entire class later on.
Discuss the following questions in the group!

m Which functions can you check with MR Engine Control reading 006?
-
m What is the significance of reading 55 "Transponder recognized" in the FR Drive Control?
-
m Under what conditions do the MR Engine Control readings 021 and 023 switch to "active" status?
-
m When and why do you check MR Engine Control reading 32 for "controller type?"
-
m Describe the current path represented by MR Engine Control reading 42.
-
m Which components are the data source for FR readings 08 and 09?
-

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Engine start function, actual values, ACTROS Type 930-934; Exercise 42
 On-board error code displays and their interpretation 13.05.03

Exercise m What options are available for interpreting displayed error codes with on-board means, without
connecting Star diagnosis to the vehicle?
a Error code lists in the DAS simulation
b Error code lists in WIS
c Error code lists in the vehicle's operator's manual

Exercise m Use key terms to describe the diagnosis procedure using WIS!

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
On-board error code displays and their interpretation 43
 Engine control / continuous brake lever operating status options 13.05.03

The engine control / continuous brake control lever governs the following operating modes:

§ Tempomat cruise control

§ Limiter
§ Continuous brake in graduated mode
§ Continuous brake with cruise control
§ Combined powertrain and brake cruise control
§ TelligentÒ proximity control (ART)
§ Engine fast idle
§ Fast idle for operating auxiliary equipment

W54.25-1035-11

The operating modes for Tempomat cruise control and continous brake cruise control are not included on the ACTROS, Type 930-934. The combination cruise
control for powertrain and brakes is offered as factory equipment.The literature (operator's manual) continues to refer to the combination powertrain and brake
regulation system as Tempomat cruise control. The TelligentÒ proximity control (ART) is available as an option to supplement this feature as desired.

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Engine control / continuous brake lever operating status options 44
Vehicle response to activation of the various features

Tempomat: Maintains constant speeds by placing a floor below the truck's velocity without any need for the driver to depress the accelerator pedal (an
"automatic" pedal). The Tempomat cruise control does NOT prevent the vehicle from accelerating beyond the preset speed when coasting downhill.

Limiter: Adjustable top speed. Limits the top speed available with engine under power. Beyond a specified point the vehicle will discontinue acceleration in
response to pressure on the accelerator pedal (unless kickdown is activated). On the ACTROS Type 930-934 the limiter function is also active when the
vehicle is not under power, with the brake cruise control intervening during coasting.

Continuous brake in graduated mode: Decelerates the truck. Engine-based and rpm-sensitive systems such as the engine brake valve, constant throttle, turbo
brake (option) and a speed-sensitive retarder (option) brake the vehicle. The effectiveness of engine-based braking systems climbs as a function of engine
speed.

Continuous brake cruise control: Within the realm of its performance potential, this device uses the continuous brake to place a ceiling on the vehicle's speed.

Combination cruise control for powertrain and brakes: Unifies Tempomat cruise control and continuous brake cruise control in a single system. This system
provides automatic acceleration as well as automatic deceleration when the actual vehicle speed varies from the selected velocity. The continuous brake
cruise control's intervention speed is slightly above the level set by the driver (roughly 4 kph) to prevent it from responding immediately each time the
vehicle accelerates to a speed that is only minimally above the programmed speed. By the same principle, the standard cruise control does not become
immediately active each time the vehicle decelerates to just slightly below the preset velocity.

TelligentÒ proximity control (ART): This is an expanded version of the combination cruise control for powertrain and brakes. It not only automatically
maintains the selected speed, but also prevents the truck from closing on the preceding vehicle beyond the preset minimum distance. If the truck gets too
close, it starts to decelerate automatically without the need for driver intervention. It then accelerates to the preselected speed again as soon as following
distance is again adequate.

Fast idle control: Can be used to raise the idle speed while the vehicle is stationary, for instance, to charge the pneumtaic circuit for the air brakes.

ADR Fast idle for operating auxiliary equipment: Dials in a permanent or variable engine speed without the driver having to apply continuous pressure to the
pedal. This feature is used to operate PTOs while the vehicle is stationary.

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Engine control / continuous brake lever operating status options 45
 Operational modes: FR Drive Control functions; Exercise 13.05.03

Exercise m The engine control / continuous brake control lever can be used to select various operating modes.
Enter these is the table in the correct positions!
Use the following questions as an orientation aid:
- Which control system is activated by each specific operational mode?
– What is the operational mode's effect on vehicle operation?
– What control parameters are activated by the operational mode?

Function Control to ... Effect on the vehicle: Control parameters:

n v s Acceleration Deceleration Deceleration v- v- n-
from continuous from service constant maximum constant
brake brakes
Limiter

Tempomat cruise control

Continuous brake (graduated mode)

Continuous brake with cruise control

Combination powertrain / brake
cruise control
TelligentÒ proximity control (ART)

Fast idle

Fast idle for auxiliary equipment

n-control Control of engine speed

v-control Control of vehicle speed
s-control Control of distance to preceding vehicle

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Operational modes: FR Drive Control functions; Exercise 46
 New features in driving systems control concept, ACTROS Type 930-934 13.05.03

Over the course of time the features controlled by the multifunction lever have changed a number of times.
Control of the multifunction lever has now been simplified in response to the following considerations.

· No single unified system was used in the earlier controls for limiter and cruise control, operational clarity was less than optimally intuitive
· Combination powertrain and continuous brake cruise control is not standard
· Excessive number of overlapping functions on the steering-column stalk
· Restricted limiter functionality

Revised operating concept:

· Reduction to two operating modes
- Combination powertrain / brake cruise control (standard), ART proximity control as available option
- Limiter with supplementary incorporation of brake-based cruise control

· Unified user-control concept

- Acceleration and deceleration available in 0.5 kph increments in limiter and ART modes
- Acceleration and deceleration in 0.5 kph increments and with ramp in the combination Tempomat cruise control mode
- Single concept for returning to speed in all modes

· Single unified pressure over-ride concept

- Over-ride induced by accelerator pedal in the combination cruise control and ART mode
- Over-ride via kickdown in the limiter operating mode
- Deceleration with continuous brake (does not trigger deactivation)
- Deceleration with service brakes (does not trigger deactivation during coasting)

· Unified acoustic acknowledgement

- when system is deactivated through service brakes
- when vehicle speed falls below deactivation threshhold (10 kph)
- when system is deactivated in response to malfunction

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
New features in driving systems control concept, ACTROS Type 930-934 47
 Control concept for drive control systems, ACTROS Type 930-934; Exercise 13.05.03

Alternating between limiter, Tempomat cruise

control and ART functions

Selection and entry of speed settings are possible

both while the vehicle is parked and when it is
underway.

TM FR Fahrsysteme 1_D.PPT

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Control concept for drive control systems, ACTROS Type 930-934; Exercise 48
Exercise Limiter Tempomat

m Enter the control modalities for the Speed selection/switching function

multifunction lever in the table!
Activate function at current speed

Activate function with stored speed

Deactivate function (at lever)

Reduce speed

Increase speed

Exercise m What conditions need to be satisfied?

Complete the table!

Limiter Tempomat ART

Condition for active operation · · · v > 15 kph
· Clutch not released
· Service brakes not on
Condition for automatic deactivation · · v < 10 kph
· Engine/powertrain + service
brakes
· Clutch > 5s release time
· Gear "R" or "N"
· NR not at standard height

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Control concept for drive control systems, ACTROS Type 930-934; Exercise 49
 Powertrain network HPS and RS, ACTROS Type 930-934; Exercise 13.05.03

ASIC HM
X13 B28 A68 A82 B5
A65
CAN 10 CAN 2 CAN 3
MTCO INS GM
B17 S144 S145
P3 P2 A7
CAN 1
Y44 B65 B66
RS PSM BS B2 B3
A20 A22 A11
G2 S2 B1 S3 S7 S9
FR
A3
A42 S1
Y101 Y102
CAN 4

MR FLA Y1 Y2
A6 A4

B10 B15 B16 B65 B111

B11 B12 B14 S10 S11 S166 Y6-13 M1

TM Antriebsstrang 1_D.ppt

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Powertrain network HPS and RS, ACTROS Type 930-934; Exercise 50
Exercise m The diagram corresponds to a vehicle with retarder control (RS) and HPS. The electrical components
in the retarder control are A20, B65, B66 and Y44.
What network connections link these components,and what is the data flow direction?
Connect the components and supply the direction in which the information flows!

m Describe the information flow following activation of engine brake switch (S2).

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Powertrain network HPS and RS, ACTROS Type 930-934; Exercise 51
 Continuous brake function with RS, actual values, ACTROS Type 930-934; Exercise 19.05.03

Part A B IW Information Information IW B A Part

B65 Coolant temperature Proportional valve control Y44
B66 002 A20 --- --- --- --- ---
003 è --- --- --- --- ---
--- 162 ê RS Transmission output rpm 165 ---
--- Max. retarder torque é Spec. retarder torque ---
×
--- 87 20 ---
--- 21 Current retarder torque é Transmission output rpm 12 ---
82 Clutch engaged A3 Y1
B1 Idle position Engine brake output ground 43 Y1/Y2
--- --- --- --- --- FR è MB2 control signal -- Y2
--- --- --- --- --- Engine speed 09 ---
--- Spec. engine torque é 15 ---
×
--- 002 Spec.engine torque A6 Current engine torque 001 ---
004 Engine speed è Y6-13
--- --- --- --- --- MR --- --- --- --- ---

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Continuous brake function with RS, actual values, ACTROS Type 930-934; Exercise 52
Exercise m Complete the following exercises with DAS simulation or by using DAS on the vehicle.

a) Supply the missing components (component column)!

b) Supply the numbers for monitored data readings (readings column)!

c) Define the exchanged information (information column)!

d) Indicate the direction in which the information flows (arrows)!

m DAS must be used on the vehicle for the following exercises.

a) Enter the current data readings from the vehicle at "ignition on" in column A!

b) Column B has been provided for readings with continuous brake activated.

Notice:
Do not make entries in the fields marked by line!

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Continuous brake function with RS, actual values, ACTROS Type 930-934; Exercise 53
Exercise You can present the solution from your group to the entire class later on.
Discuss the following questions in your group!

m What are the effects of an FR actual value of 82 on

a) retarder braking?
-
b)engine braking (brake valve, constant throttle)?
-
m What are the effects of a monitored FR Drive Control data reading of 69 on
a) retarder braking
-
b) engine braking (brake valve, constant throttle)?
-
m Does a actual value of 01 in the RS retarder control have any effect on retarder performance?
If yes, when and what effect?
-

m Define the FR actual values 41 and 43!

-

m What is the effect of RS actual value 164 on retarder performance?

-

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Continuous brake function with RS, actual values, ACTROS Type 930-934; Exercise 54
 Powertrain network with HPS and retrofitting Linnig, ACTROS Type 930-934; Exercise 13.05.03

ASIC HM
X13 B28 A68 A82 B5
A65
CAN 10 CAN 2 CAN 3
MTCO INS GM
B17 S144 S145
P3 P2 A7
CAN 1

RS PSM BS B2 B3
A20 A22 A11
G2 S2 B1 S3 S7 S9
FR
A3
A42 S1
Y101 Y102
CAN 4

MR FLA Y1 Y2
A6 A4

B10 B15 B16 B65 B111

B11 B12 B14 S10 S11 S166 Y6-13 M1

TM Antriebsstrang 1_D.ppt

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Powertrain network with HPS and retrofitting Linnig, ACTROS Type 930-934; Exercise 55
Exercise m Assume that you are going to install an electromagnetic fan clutch (Linnig) in the field.
What supplementary electrical components will be required?
Name the supplementary components in the illustration, transfer them to the table and describe their
functions!

Supplementary components Functions

B46
Y70
Y71

Exercise m Which of the components already installed are required for open and closed-loop control?
Enter these in the table and describe their functions along with how they operate!

Available standard components Functions

A3 FR Drive Control ECU Monitors air conditioner status
Monitors v vehicle
Activates fan speed 1 (a/c on)
A6 MR Engine Control ECU Temperature-sensitive control
Regulates activation of proportional-control valve
Proportional-control valves govern fan speeds
B65
B11

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Powertrain network with HPS and retrofitting Linnig, ACTROS Type 930-934; Exercise 56
 Electromagnetic fan clutch (Code MZ5), wireing and parameterization; Exercise 19.05.03

Exercise m The assignment is to examine a vehicle with a Linnig fan and air conditioning to verify the electrical
circuit.
Complete the table by entering the correct information. Refer to the current flow diagram.

Electronic system Pin designation Pin assignment Function

FR GSE A/C refrigerant status from high-pressure switch
FR GSV3 Switch power supply output signal
MR N3 55/41 Control of fan clutch speed 1
MR N3 55/43 Control of fan clutch speed 2
MR PROP RÜCK N3 55/12

Exercise m The next task on this vehicle is to ensure that the correct parameters are entered.
Use DAS to complete the table.

Electronic Parameter Parameter text Entered figure /

system number entered text
FR 73 Fan control
FR 61 GSE input in use
FR 74 Retarder coolant temperature
MR 8 Proportional-control solenoid 3
MR 9 Proportional-control solenoid 4
MR 17 Fan type

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Electromagnetic fan clutch (Code MZ5), wireing and parameterization; Exercise 57
 Electromagnetic fan clutch (Code MZ5), actual values and ext. control; Exercise 21.07.03

Exercise m The assignment is to check a vehicle with Linnig fan clutch and air conditioning using the relevant
instantaneous data readings.
Fill in the missing squares in the table. Use DAS.

Electronic Reading Reading text Numeric entry /

system number text entry
FR 88 Fan activation request
MR 11
MR Status of proportional-control valve 3
MR Status of proportional-control valve 4
RET Coolant temperature

Exercise m The objective is to use DAS for a manual check of the fan clutch control on a vehicle equipped with a
Linnig fan clutch and air conditioning. Provide a concise description of the required procedure.

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Electromagnetic fan clutch (Code MZ5), actual values and ext. control; Exercise 58
Exercise m The object is to perform a manual check of the activation temperatures for controlling the Linnig fan
clutch using an ohmmeter.
Enter the missing figures to complete the table.
Refer to WIS document AR20.40-W0003A.

W20.40-1012-11

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Electromagnetic fan clutch (Code MZ5), actual values and ext. control; Exercise 59
 Resistance setting Simulated Triggered proportional-
temperature control valves
25°C 0
230 Ohm
220 Ohm
97°C 3 und 4

W07.15-0023-02

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Electromagnetic fan clutch (Code MZ5), actual values and ext. control; Exercise 60
 Assignments of MR proportional valves; Exercise 16.06.03

Exercise
Proportionalventil
The functions assumed by the proportional-
control valves used for MR Engine Control vary
according to individual vehicle and equipment 1 2 3 4 5 6
level.

Enter the correct valve designations in the chart ACTROS with electromagnetic fan Y70 --- ---
on the right! clutch

Use the current flow diagrams as required.

AXOR with electromagnetic fan clutch --- ---
Notice: Some valves discharge multiple functions. and turbo brake

ATEGO with OM 906 LA --- ---

Y70 Fan speed 1 solenoid valve

Y71 Fan speed 2 solenoid valve
Y49 Solenoid for hydraulic constant throttle ECONIC --- ---
Y66 Proportional valve for hydraulic fan
Y87 Electropneumatic transducer (EPW)

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Assignments of MR proportional valves; Exercise 61
 Parameter MR; Exercise 18.07.03

Task m A list of the parameters currently available has been provided to you as accompanying lecture
material.
You will find a description of the parameters in DAS or DAS Simulation.
Are you sure that you have understood all of the parameters and that you can correctly set them?

Please check your knowledge and understanding by answering the guiding questions below.
· You have received a new MR control unit to be installed. Can you check to see if the parameters
set at the factory coincide with the vehicle version?
· Can you describe the parameterizations for possible conversions (e.g. converting a series oil pan to
an oil pan for a Frigoblock refrigeration unit)?
· Can you describe the parameterizations for possible fan conversions?
· Can you correctly set the parameterization for oil level sensing?

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Parameter MR; Exercise 62
 Engine start/stop; Exercise 19.05.03

N54.25-2003-20 N54.302027-20

Exercise m When the automatic engine start/stop feature is active the engine is shut down automatically. What
conditions must be present for at least 3 seconds to provoke this response?
Identify the required conditions.

a Engine speed below 660 rpm f Coolant temperature > 60°C

b Engine speed below 550 rpm g Coolant temperature < 96°C
c Transmission in neutral h Coolant temperature > 5°C
d No pressure on clutch pedal i Outside temperature > 0°C
e Clutch pedal depressed j No pressure on accelerator

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Engine start/stop; Exercise 63
Exercise m If the indicator lamp for the start/stop switch is flashing ...

a a system malfunction is present

b a condition has not been satisfied
c the stop/start system is not on

Exercise m When the automatic start/stop feature is on, the engine will start automatically if ...

a the engine was previously automatically shut down by the start / stop system
b the key in the steering lock is switched to normal operating position
c the clutch pedal is depressed
d the vehicle is rolling

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Engine start/stop; Exercise 64
 Control of rpm for auxiliary equipment / PTO operation ACTROS, AXOR and ATEGO > 18t 13.05.03

While four circuit-control pins are available Kl.15

on the FR Drive Control ECU on the ACTROS, only
two are actually used.
Pulsed power voltage is supplied at outputs GSV2 INS
and GSV3 to facilitate improved monitoring for P2
errors at the corresponding inputs. S 64 Z1
Various parameters with their corresponding
functions can be activated through the CAN bus
(ADR 1) and the FSBE input circuit (ADR2); the
actual process varies according to circuit S 23
Y 46
sequence.

ADR 2 ADR 1
GSV2 FSBE
A3 (FR) R GSV3

X3 X3 X4 X4
15/5 15/9 18/18 18/12
A3 FR Drive Control ECU
B5 Parking brake switch
P2 Instrument
S 23 PTO 1 control switch
S 64 PTO1 switch B5
Y 46 PTO1 solenoid valve
Z1 Node

Circuit concept

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Control of rpm for auxiliary equipment / PTO operation ACTROS, AXOR and ATEGO > 18t 65
 Control of rpm for auxiliary equipment / PTO operation ATEGO <15 t 13.05.03

The FR Drive Control ECU has four pins for the

control circuit. ADR 2 ADR 1
Pulsed power voltage is supplied at outputs GSV2 GSV2 FSBE
A3 (FR) R GSV3
and GSV3 is available to faciliate improved
monitoring for errors at the corresponding inputs. X3 X3 X4 X4
Various parameters with their corresponding 15/5 15/9 18/18 18/12
functions can be activated through R and FSBE
inputs; the actual process varies according to
circuit sequence. B5

Y46 S23

A3 FR Drive Control ECU

B5 Parking brake switch S64
K 37 Working speed control relay
S 23 PTO 1 control switch
K37
S 64 PTO 1 switch 1
Y 46 PTO 1 solenoid

Circuit concept

Kl. 15 Kl. 15

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Control of rpm for auxiliary equipment / PTO operation ATEGO <15 t 66
 Drive- / Stationary PTO functions 13.05.03

Generally a distinction is made between driving functions with RQ controller characteristics and stationary functions of working speed control in accordance with
RQV governor characteristics.

Driving functions

The parameters 05, 08, 09 and 10 are activated with the actuation of ADR1.
ADR-Fest
The driver can control the engine in the range limited by the parameters via NEIN INS JA
the accelerator pedal (FFG).
39 06 nNA max 08
JA NEIN

ADR-Variabel
nNA min 09
vNA max 05
MNA max 10
FFG

ppt

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Drive- / Stationary PTO functions 67
Stationary functions

The working speed control (ADR) with RQV control characteristics takes place after receiving the inputs at FSBE and ADR1.
The adherence to the connection sequence FSBE first, ADR2 before ADR1 is important.

The parameter 06 determines whether a fixed working speed is to be approached or whether the speed control should be variable
ADR-Fest
JA
NEIN INS

FSBE 39 06 nNA Fest 07

JA NEIN nNA max 08 nNA max 08
ADR-Variabel
nNA min 09 vNA max 05
vNA max 05 MNA max 10
ADR-Fest
MNA max 10 NEIN INS JA
Reglertyp 11
Reglertyp 11 FSBE 39 06
JA NEIN
FFG ADR-Variabel

ADR-Tempomat

ppt ppt
Variable ADR working speed control ADR working speed control according to a fixed speed requirement

The working speed requirement can be adjusted variably by means of the In vehicle operation the stationary ADR working speed control can also be
accelerator pedal (FFG) or ADR-Tempomat (cruise control lever). combined with the driving function in order to extend the application
potential.
The working speed adjusted via the ADR-Tempomat is held as a fixed speed
and can be increased or decreased in steps.

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Drive- / Stationary PTO functions 68
 Logical relationships in the base module 13.05.03

AND gate OR gate

All input conditions must be true (satisfied) simultaneously to Only a minimum of one input condition must be true to activate
trigger an output from the AND gate switch. the output function of the OR gate.

Input condition 1 Input condition 1

O
A Output function Output function
R
N
Input condition 2 D Input condition 2

Combination logic gates

In this example two logical gate functions are combined. Input condition 1
The result of the logical AND gate is empoyed as the input
signal for the OR gate. Output function
The output function is activated when input condition 1 or Input condition 2 2 O
the input from the AND gate is valid, or true. R
A
Input condition 3 N
D

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Logical relationships in the base module 69
 Function pins in the base module 13.05.03

Three outputs are provided as function pins on plug X12 on the base Input condition 1
module.
These pins are furnished to accomodate special functions and
Output function
equipment installed after the vehicle leaves the factory. Parameters
can be enterd to govern their operation. The outputs can handle
currents of up to 0.5 amperes. Input condition 2

Parameters can be entered for the required AND/OR gate functions. Gate function
AND / OR

These output terminals are monitored for shorts to UBatt and ground as well as open circuits.

Default assignments of function pins in base module:

X12 21/15 Input condition 1: High beam on

Input condition 2: Auxiliary equipment switch 1 on
Gate function: AND

X12 21/18 Input condition 1: Parking lights on

Input condition 2: Auxiliary equipment switch 1 on
Gate function: AND

X12 21/21 Input condition 1: Auxiliary equipment switch 2 on

Notice: Other samples illustrating correct use of function and potential pins are provided in WIS document SN54.21-W-0006-03MP.

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Function pins in the base module 70
 PTO control with GM, ACTROS Type 930-934 14.05.03

Notes:

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
PTO control with GM, ACTROS Type 930-934 71
 Self holding function with PTO engaged 18.07.03

O
Power take-off request O Solenoid valve
N
Y
R Þ U
T actuated
A Þ P
N U
Neutral N T Power take-
A D
Y
O off is engaged
Parking brake N
N Þ R
Þ
Y D

Power take-off N
Y
Switch
feedback actuated

m Note the functional principle!

N00.00-2179-03

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Self holding function with PTO engaged 72
 PTO function in base module, ACTROS Type 930-934 13.05.03

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09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
PTO function in base module, ACTROS Type 930-934 73
 ......................................................................................................................
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Notice: The base module's PTO function is active only provided that no PSM is installed in the vehicle.

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
PTO function in base module, ACTROS Type 930-934 74
 Alteration with function pin - engine speed, ACTROS Typ 930-934 13.05.03

Exercise m Power supply to an electric motor connected through relay is to be activated via current supply when
the engine runs at above 700 rpm and the auxiliary equipment switch is on.

a) Use a function pin on the base module to respond to this customer request!
b) Record your procedure in key phrases!
c) Complete the current flow diagram!

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Alteration with function pin - engine speed, ACTROS Typ 930-934 75
 Central data storage in base module 13.05.03

The base module is equipped with a central data memory where all of the parameters for the vehicle's electrical equipment are stored. The
memory's storage capacity is 2048 kB.

The central data memory continuously maintains data for the use of the electronic control modules. parameters from the central data
memory can be written into new control modules when needed, for instance, in the event of replacement.

The central data memory contains the following data for each control module:
· MB serial number
· Hardware and software version
· Diagnosis version
· Diagnostic data
· Date of most recent diagnosis session
· Parameter data
· Life history data for WS only

Each time the power to Terminal 15 is switched on the date of the most recent parameter change is checked in the control modules. This
information is then compared with the data stored in the central data memory. It will be necessary to update the central memory with the
diagnosis tester in response to changes in parameters or control module versions.

Within the instrument, the data from the central memory are written to a mirror memory (128 kB) for extra security. This makes it possible
to restore all data even when the base module is replaced.

Notice The data for the MR, FLA, TCO and ART-control modules are not backed up in the central data memory.

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Central data storage in base module 76
 Exercises <> Central data memory 13.05.03

Exercise m Use the DAS simulation to enter the central data memory for an overview of the system.
What options are available in the "special functions" menu?

Exercise m The front module needs replacement for accident repairs.

What steps will be required? Indicate the correct work sequence!

AR54.21-W-1245-01MP Download from central data memory to front module after repairs

Install new front module

Calibrate central data memory prior to repair if possible.

Remove damaged front module

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Exercises <> Central data memory 77
Exercise m Why is it necessary to update the central data memory before and after module replacement?

a The current data from the control unit should be stored in the central data memory prior to the repair.
b The data for the control module should be deleted from the central data memory before the repair.
c Following repairs the data set stored in the central data memory should be transfered to the new
electronic device.
d The central data memory in the base module updates itself every 5 seconds. Thus no additional work
is required.

Exercise m What conditions can be detected by the compatibility check for new electronic devices?
What is the significance for service technicians performing a control module replacement?
AR54.21-W-1245-02MP a Control module is fully compatible, no additional parameter entries required.
b Control module is partially compatible, all stored parameters are transfered automatically,
supplementary parameters must be entered in the new ECU manually.
c Control module is beyond repair, all stored parameters are automatically deleted.
d Control module is compatible, meaning that DAS cannot be used to enter parameters.
e Control module is not compatible, DAS attempts to enter some parameters, all others must be
entered manually.

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Exercises <> Central data memory 78
 Immobilizer (WSP) 14.05.03

Function of the system

The immobilizer (WSP) consists of

¨ MR/PLD control module

¨ Transponder key (each key has a different transponder code)
¨ Electronic readout circuit
¨ FR/FMR control module

The electronic readout circuit is located directly on the steering lock and
reads the code out of the transponder key without contact. The transponder
(miniature electronic receiver/transmitter circuit in key) is supplied with
power by induction by the electronic readout circuit when the ignition, circuit
(15 on) is switched on. The transponder sends a weak signal to the electronic
readout circuit containing the transponder code. A signal amplifier installed in
the electronic readout circuit amplifies the transponder code signal level.

The FR/FMR and MR/PLD control modules are connected to the electronic
readout circuit via the c. 50-wire. The transponder code (TP code) is
permanently transmitted to the engine electronic circuitry through this wire.

N54.00-1185-14
5 Drive switch
7 Engine CAN-Bus
8 Starter
9 SPump unit

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Immobilizer (WSP) 79
In the MR/PLD control module the transponder code is compared with a stored code (up to 8 codes are possible).

If the TP code corresponds to the code learned in (stored) the starter is actuated with the next c. 50-signal (4) and simultaneously the MR/PLD engine control
"unlocked" electronically.
If a transponder key is used with a code not learned in the starter turns but the solenoid valves (9) in the in-line pumps are not actuated.

Even when c. 30 and c. 50 are directly connected to the starter the engine does not start, because there
is no injection. If the transponder key is turned very fast without delay from the "Steering unlocked" (2)
position to the "Start position" (4) the MR/PLD control module cannot check the transponder code. The
immobilizer is not deactivated and in this case the display "Code!" appears on the green display. In
addition DTC 1 99 63 or 1 99 65 may be stored in the MR/PLD control module and displayed on the red
field.

When an attempt is made to start the vehicle with an invalid transponder key the MR/PLD control module
stops TP code evaluation for a certain time. The time limitation doubles with each additional attempt.

The FR/FMR control module checks the transponder signal and stores it until the ignition is switched off.
When requested by the MR/PLD control module the transponder code is sent together with the WSP
parameterizing via the engine CAN bus. This allows the engine to be started in spite of an error on c. 50
from the MR/PLD control module as well as allowing recognition of the error. The electronic readout
circuit can be replaced easily in the event of a defect (does not contain transponder codes, only transmits
them on).

1 Transponderkey
2 Transponder
3 Transponderholder

W82.57-002-02

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Immobilizer (WSP) 80
Replacing the FR/FMR control module is also easy since it is only necessary
to set the parameters for operation with an immobilizer. The WSP parameter
settings cannot be reset.
If it is necessary to replace the MR/PLD control module or transponder keys,
the new transponder codes can be learned in with the HHT (only in
combination with FDOC).

Up to a billion different codes are possible for the transponders used. Only
transponder keys programmed in the electronic immobilizer can be used to
start the vehicle. This makes a maximum of 8 keys per vehicle.

1 Steering lock
2 Reader electronics (A42)
3 Transponder
4 Transponderkey

A Electromagnetic alternating field

B Transponder code modulates alternating electro-magnetic
field

W82.57-003-12

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Immobilizer (WSP) 81
 Immobilizer (WSP), innovation - improved immobilizer 18.07.03

Introduction:
· Since July 1, 2002 for production 2002
· Later, retroactive to production 2000

Authorization code via FDOK (screen 1801) for

· Teaching in vehicle key
· Engine control (MR) download

The system checks the following prior to outputting an authorization code:

· That the “A” basic number or ID code of the MR control unit coincides with the
· the engine and chassis numbers of the vehicle specified in the FDOK documentation.

For emergency service:

· Authorization code via FDOK (screen 1801) only possible for vehicle transfer control units as per STIN07.15W027

If data are not correct in the FDOK:

· Engine replacement by workshop not documented in the FDOK as per SI07.15-W-0012A
· Vehicles improperly documented in the FDOK at the factory (EDP error)
· Control units not delivered through the GLC are not documented

Assistance:
· FDOK hotline

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Immobilizer (WSP), innovation - improved immobilizer 82
 Starter actuation system; Exercise 18.07.03

Ecercise

¦ Complete now the starter actuation system in

the diagram by drawing the connections.
Use the workshop manual and the follow
function description of starter actuation.
30 50
15

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Starter actuation system; Exercise 83
Function description

Engine start via ignitation lock When the ignition is switched on (term. 15) and the key is turned to the starting position (term. 50), the
FR sends the engine starts request via the CAN bus to the PLD control unit. The PLD control unit then
actuates the starting relay on the starter which in turn energizes the solenoid swith of the starter.

The engine starting relay is ernergized during the start request (term. 50 via CAN) until the engine
reaches a given starting speed.

Engine start via start button After recognition of the engine start requirement through the start buttom the MR control unit leads the
requirement via CAN bus to the FR control unit. That engine start requirement will be send back to MR
control unit in consideration of the transmission neutral position like the description above.

Cranking of engine during service work The engine can be cranked without starting by actuating the engine start and stop buttons
simultaneously.

Note:
If the starter is actuated via the start button on the engine, then for safety reasons the engine can only be
started from the ignitation lock after the ignitation has been switched off and back again.

Engine start with CAN bus failure In order to ensure that the engine will start in the event of failure of the FR control unit or an open circuit
in the data line, the engine start signal (term. 50) is also stored directly at the PLD control unit. The
engine starting relay can then be actuated directly via the PLD control unit.

Since no data message is transmitted in the case, the engine run at emergency speed after starting.

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Starter actuation system; Exercise 84
 Symbolical fuel circuit Engine Series 457; Exercise 15.05.03

Exercise m Trace the fuel stream and mark the flow direction with arrows!

N07.00-2082-09

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Symbolical fuel circuit Engine Series 457; Exercise 85
1 Fuel tank 10. Overflow valve (2,0 bar)
1.1 Fuel strainer (800 mm) 10.1 Restrictor in overflow valve
1.2 Ventilation valve 12 Restrictor in flame starting system fuel line
2 Fuel hand pump
2.1 Fuel prefilter "Racor" (SA) R3 Flame glow plug
3.1 Assembly valve in fuel feed (opened by pressure) Y5 Flame starting system solenoid valve
3.2 Assembly valve in fuel return flow(opened by pressure)
4. Fuel heat exchanger A Fuel feed/suction- underpressure side
5. Fuel pump B Fuel feed/pressure side
5.1 Pressure relief valve (7.0 – 8.0 bar) C Fuel high pressure side (injection line) downstream of PLD unit pumps
6. Fuel filter (KF 3 mm) D Fuel return flow downstream of unit pump/ leak fuel
6.1 Fuel filter drain valve E Fuel scavenging quantity (fuel bypass)
6.2 Continuous relieving bore F Fuel return flow/
7. Nozzle holder combination
8. PLD unit pumps (Y6 bis Y11)

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Symbolical fuel circuit Engine Series 457; Exercise 86
 Real fuel circuit engine series 457; Exercise 15.05.03

Example m Complete with the aid of WIS-dokumentes SN47.00-W-0003-02A real fuel circuit the missing therms
in the legend!

Hint: Name of components

Hand fuel delivery pump

Fuel cooler
Fuel delivery pump
IV Fuel filter
Unit pump
VI Injection valve
Pressure holding valve
Bypass line

1 from tank over hand fuel delivery pump

to fuel cooler
2 to fuel delivery pump
3 to fuel filter
4 to unit pumps
5 from unit pumps
6 to injection valves
7 Leak fuel line
from pressure holding valve to fuel delivery pump
Fuel filter reliefing line
(by filter changeing)
10 to tank

A Fuel suction line

B Fuel return line
C Fuel low-pressure line
D Fuel high-pressure line

N07.00-2083-09

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Real fuel circuit engine series 457; Exercise 87
 Fuel pressure test locations series 500; Exercise 13.05.03

W07.15-1080-09

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Fuel pressure test locations series 500; Exercise 88
Components
1 Fuel tank B10 Fuel temperature sensor
1.1 Fuel strainer (800 mm) R3 Flame glow plug
2 Fuel prefilter (300 mm) with fuel priming pump Y5 Flame starting system solenoid valve
3.1 Assembly valve in fuel feed (opened by pressure)
3.2 Assembly valve in fuel return flow(opened by pressure) Fuel circult
4. Fuel heat exchanger A Fuel feed/suction side
5. Fuel pump B Fuel feed/pressure side
5.1 Pressure relief valve (9.0 – 12.0 bar) C Fuel high pressure side (injection line) downstream
6. Fuel filter (1,5 mm) of PLD unit pumps
6.1 Fuel filter drain valve D Fuel return flow downstream of unit pump
6.2 Continuous ventilation in fuel filter (0.7 mm) E Fuel scavenging quantity (fuel bypass)
7. Nozzle holder combination F Fuel return flow/leak fuel
8. PLD unit pumps (Y6 bis Y13)
9. Ring piece with countinuous ventilation (0.7 mm)
10. Overflow valve (2.0 bar) Test points, tost data
(till engine-Nr. 092407 2,0 bar G Pressure gauge test
from engine-Nr. 092408 2,65 bar) H Fuel return flow quantity test
10.1 Restrictor (3.1 mm) in overflow valve
11.1 Fuel feed connector (in frame) - -- - Fuel-channels in ZKG
11.2 Fuel return flow connector (in frame) ------ Fuel-lines
12 Restrictor (0.5 mm) in flame starting system fuel line

Exercise m Assign the check point to the rigt fuel pressure test.

Check point Fuel pressure test

Fuel pressure downstream
Fuel return flow quantity to the fuel tank
Low-pressure fuel circuit leaktightness
Fuel intake pressure upstream of fuel pump
saving of air bubbles at the fuel intake pipe
Fuel return flow quantity to nozzle-and-holder assemblies

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Fuel pressure test locations series 500; Exercise 89
 TIPS, general 18.07.03

What is TIPS?

TIPS is an integrated DP system for the global exchange of technical information, knowledge and solutions covering all service levels (workshop, CAC Maastricht,
MPC/GV, GSP/T as well as plant customer services) based on Internet technology for the purpose of assisting in warranty & goodwill cases.

TIPS supports the following four business processes: product service, product reliability, technical service in the workshop and in Service 24 h.

Goals of TIPS

· Increase in aftersales competency in workshops, markets and CAC Maastricht (with the outcome being higher customer satisfaction).

· Increase in the efficiency of the processes to be supported by

- reducing diagnosis and repair times,
- improving the data quality for field information,
- more efficiently using resources in the MPC/GV workshop support process, in product service at GSP and in plant customer services,
- reducing warranty/goodwill costs as a result of early detection of key damage topics and their remedies in the product reliability process,
- reducing unnecessary removals/multiple repairs in the workshop.

· Improvement in product quality to boost brand image.

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TIPS, general 90
Users of TIPS

Headquarters (GSP/T, plant customer services) MPC/GV

· Product service advisors · Technical product service
· Product reliability advisors · Technical field service
· Diagnosis and telematics employees
· Categories

CAC Maastricht Workshop

· Call center agents (CSR) · Acceptors
· CAC 2nd level support · Foremen
· Technical coordination team · Mechanics
· Service 24h mechanics

How do I reach TIPS?

http://tips-reader.daimlerchrysler.com

User name: Universal name published by MPC or plant

Password: Universal password from MPC or personally assigned password

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 Powertrain network, Legend 13.05.03

A3 Drive Control ECU (FR) B6 Coolant level switch S1 Ignition switch

A4 Flame-start system ECU (FLA) B7 Air filter monitor sensor S2 Engine control/continuous brake lever
A6 Engine Control ECU (MR) B10 Fuel temperature sensor S3 Splitter switch
A7 Base module (GM) B11 Engine oil temperature sensor S7 Reverse gear switch
A11 Brake control ECU (BS) B12 Oil pressure sensor S9 Neutral switch
A15 Gear selection controller (GS) B14 Oil level sensor S10 Start button
A16 Gear selection ECU (GS) B15 Crankshaft position sensor S11 Stop button
A20 Retarder control ECU (RS) B16 Camshaft position sensor S144 Multifunction steering wheel button group, left
A22 ECU for Parameter-controlled Special Module (PSM) B17 Speed sensor S145 Multifunction steering wheel button group, right
A42 WSP readout electronics B28 Speaker at center of headliner S166 Oil pressure switch
A63 Distance-sensitive cruise control ECU (ART) B46 High/low pressure switch
A64 Front Module (FM) B57 Transmission output rpm sensor X13 Diagnostic interface socket
A65 Rear module (HM) B60 Gear sensor (SGG)
A68 Switch module 4, master B61 Gate sensor (SGE) Y1 Engine brake solenoid 1
A82 Switch module 6, lock switch B62 Splitter sensor (SSP) Y2 Engine brake solenoid 2
B63 Range sensor (SRA) Y6-13 Pump insert cylinders 1-8
B65 Coolant temperature sensor Y29 Splitter solenoid 1 (MS1)
B66 Retarder fluid temperature Y30 Splitter solenoid 2 (MS2)
B99 Transmission output speed sensor Y31 Range selection solenoid 1 (MR1)
B111 Combination boost air pressure and temperature Y32 Range selection solenoid 2 (MR2)
sensor
Y33 Gate solenoid 1 (MG1)
CAN 1 Vehicle CAN Y34 Gate solenoid 2 (MG2)
CAN 2 Interior CAN Y35 Odd gear air supply solenoid (MUB)
CAN 3 Frame CAN Y36 Even gear air supply solenoid (MGB)
CAN 4 Engine CAN Y37 Odd gear air discharge solenoid (MUE)
CAN 5 Transmission CAN Y38 Even gerar air discharge solenoid (MGE)
CAN 10 Speedo CAN Y39.1 Clutch air supply solenoid 1
Y39.2 Clutch air supply solenoid 2
G2 Alternator Y39.3 Clutch air discharge solenoid 1
Y39.4 Clutch air discharge solenoid 2
M1 Starter Y44 Proportional-control valve for retarder
B1 Accelerator pedal Y49 Constant throttle solenoid
B2 Clutch travel sensor P2 Instrument (INS) Y70 Fan speed 1 solenoid
B3 Idler shaft rpm sensor P3 Modular tachograph (MTCO) Y71 Fan speed 2 solenoid
B4 Outside temperature sensor Y101 Splitter solenoid 1 (MS1)
B5 Parking brake switch Y102 Splitter solenoid 2 (MS2)

09/03 Trucks • Engine Telligent® Engine systems Series 457, 500, 900 Advanced Training
Powertrain network, Legend 92
» ... Die Mitarbeiter werden zukünftig in die Rolle persönlicher Wissensmanager hineinwachsen
müssen, die aktiv die Verantwortung für ihre Qualifizierung übernehmen ... « Jürgen E. Schrempp

» ... Staff must in future assume the role of personal knowledge managers, who actively take
responsibility for their own qualification ... « Jürgen E. Schrempp

Global Training.
The finest automotive learning

DaimlerChrysler AG
Global Training
HPC T301
D-70546 Stuttgart

Intranet: http://intra-gt.daimlerchrysler.com

1511 1009 02 1st edition 05.03 98

2nd edition 08.03 100