Sist Elect 906 4000

PLD - VCU
Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia
Marzo 2004
Control Module ( PLD ) Pump Line Nozzle
55 Pin Connection for Engine Harness Wiring Plug 16 Pin Connection for Cab Wiring Plug
Power Supply Grounds CAN Link Diagnostics
Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia Marzo 2004
Valve Clearance Adjustment
Valve Clearance Spec.

Intake Exhaust 0.40mm ( approx .016 inch ) 0.60mm ( approx. 024 inch )
Marzo 2004
Sistema de Control Electrnico Mercedes-Benz

Todos los Sistemas Electrnicos han sido Desarrollados por Mercedes-Benz en Cooperacin con VDO y Temic Introducido en 1995 Minimo 2 sistemas de cajas
Marzo 2004
Modulos de Control
PLD (Engine Control Module)
VCU (Vehicle Control Unit)
Marzo 2004
Sistema Mercedes-Benz
Menor Cantidad de Circuitos de la Cabina al Motor. Menor longitud de Circuitos en el Vehiculo. Programacin del Vehiculo en base a las Necesidades del Cliente. Parametrizacin Simplificada. Responsabilidades Definidas por unidades de Control. Diagnstico Simplificado y Solucin de Problemas.
Marzo 2004
Electronic Engine Advantages

Engine Protection
Engine Diagnostics
Reduced Maintenance Improved Engine Governing Fuel Economy Optimization Enhanced Cold Starting Smoke Control Reduced Emission Levels
Marzo 2004
Localizacin de Sensores MBE4000
Presin/Temperatura
Presion/Temp. del Turbo
de Aceite
Temperatura de Refrigerante
Sensor de Arbol
Temperatura de Combustible
de Levas
Sensor de Cigeal
Presin Atmosferica
Bombas Unitarias
PLD
Marzo 2004
Seguridad y precauciones Preliminares
Nunca arrancar el motor a menos que las baterias esten correctamente conectadas. Nunca desconecte las Baterias cuando el motor esta trabajando. Nunca invierta las terminales. Esta accin puede daar a las ECUs. Nunca conecte desconecte el conector del PLD VCU a menos que la llave este apagada. Nunca desconecte los cables CAN a menos que la llave este en la posicin de apagado. Cuando desconecte las terminales de las baterias mantega los cables + y - de la bateria juntos. Tambien desconecte los conectores electricos del PLD y VCU. Cuando realice reparaciones electrnicas simpre utilice el equipo correcto (Multimetro).
Marzo 2004
Rango de Operacin de Trabajo de los sensores

Operates on 5 Volts for All D.C. Sensors
0 .25
4.75
Rango de Operacin Normal
Marzo 2004
10
Modulo de Control Electrnico (PLD)
Conector de 55 Terminales Harnes del Motor Conector # N3
Conector de Cabina 16 Terminales Conector # EC 1
Alimentacin de Bateria Seal de Ignicion Tierra Cables CAN
Marzo 2004
11
PLD
Procesador Montado en el Motor Funciones Strategia Entradas de Sensores Salidas El Corazn del (PLD) SIEMENS C167CR chip Procesador Automotriz de Alta Velocidad 16 Bit Micro controller 34 MHZ Clock Speed OBD II (On Board Diagnostic II) (Engine Performance Codes)
Marzo 2004
12
Informacin (PLD)
8 BIT = 256 SEGMENTS
.01953125 VOLTS 65,536 Possible Codes .0000762939453125 VOLTS
Up to 34 MILLION Decisions Per Second
256 Possible Codes
16 BIT = 65,536 SEGMENT
8 BITS
256 Segments
Ejemplo:
16 BITS
13
Harnes del Motor
Marzo 2004
14
Conector de 55 Terminales ( Harnes del Motor )
Pin 1
Pin 18
Pin 0
Pin 36
Pin 37
Pin 19
Pin 54
Marzo 2004
15
Diagrama Esquematico de un Sistema MBE Crank Angle TDC Sensor Engine Control Module (PLD)
Marzo 2004
16
Crank Angle and TDC Sensors
Marzo 2004
17
Sensor de Cigeal y Arbol de Levas

Crank Angle / TDC
Magnetic pickup sensors generate alternating current (A.C.). The frequency will change dependent on the speed of the Cam Gear and Flywheel
Flywheel has 37 Drilled Holes

36 holes spaced 10 degrees apart 1 hole 65 degrees before TDC
Cam Gear has 13 Drilled Holes

1 hole 55 degrees before TDC 12 holes spaced 30 degrees apart
Marzo 2004
18
Volante
Series - 900 Series - 4000
Marzo 2004
19
Sensores de Posicin Sincronizacin

Operating Temperature
- 40 to 250 F
Resistance Range
1000 - 1385 ohms
1) Electric Cable 2) Housing 3) Clamping Bushing 4) Permanent Magnet 5) Permanent Magnet 6) Coil Core 7) Drilling
Marzo 2004
20
Sensor de Cigeal
Marzo 2004
21
Sensor de Arbol de Levas TDC
Marzo 2004
22
55 Grados Antes del PMS
Camshaft Signal
Crankshaft Signal
Marzo 2004
23
Seal de Velocidad del Motor
Marzo 2004
24
Seal de Arbol de Levas TDC
Marzo 2004
25
Inicio de Inyeccin
Marzo 2004
26
Seal de Cigeal TDC
Marzo 2004
27
Seal de Velocidad del Motor en el Arbol de Levas
Marzo 2004
28
Inico de la Inyeccion en el Arbol de Levas en Ausencia de la seal del Cigeal
Marzo 2004
29
Schematic Diagram MBE System
Crank Angle TDC Sensor Turbo Boost Air Temp Engine Control Module (PLD)
Marzo 2004
30
Turbo Boost / Air Temp Sensor

Operating Temperature - 40 to 266 degrees F Resistances 14 F 7980 to 10560 ohms 68 F 2280 to 2750 ohms 176 F 290 to 365 ohms Values 0.5 volts = 0.5 bar 4.5 volts = 3.5 bar 1 Bar = 14.5 PSI
Marzo 2004
31
Marzo 2004
32
Marzo 2004
33
Intake Air Sensor
Marzo 2004
34
Intake Air Pressure / Temp Sensor Curve
-22 -4
32
68 104 140 176 212 248 284 *F
Marzo 2004
35
Sistema Esqumatico MBE

Crank Angle
TDC Sensor Turbo Boost Air Temp Coolant Temp Engine Control Module (PLD)
Marzo 2004
36
Sensores de Temperatura
Thermistor As the Temperature increases the resistance decreases Operating Temperature - 40 to 266 F
The Temperature Sensors are the Same Part Number for

Coolant Temp Fuel Temp Oil Temp
New Type
37
Coolant Temperature Sensor

The Coolant Temperature Sensor is the Base Line Sensor for Engine Performance. The Coolant Temperature should Be Between 80 and 95 Degrees C ( 176 to 203 Degrees F ) Before requesting Full Engine Potential. Coolant Temperature Outside Normal Operating Range can Result in a Reduction in Power.
Marzo 2004
38
Coolant Temperature Sensor
Marzo 2004
39
Crank Angle TDC Sensor Turbo Boost Air Temp Coolant Temp Fuel Temp Engine Control Module (PLD)
Marzo 2004
40
Fuel Temperature Sensor
Marzo 2004
41
Fuel Temperature Sensor
Marzo 2004
42
Temperature Sensor Graph
Marzo 2004
43

Crank Angle TDC Sensor Turbo Boost Engine Control Module (PLD)
Air Temp
Coolant Temp Fuel Temp Oil Pressure
Marzo 2004
44
Oil Pressure Sensor

Piezoelectric Sensor
As The Pressure Increases The Resistance also Increases Operating Range 0 to 5 bar 1 Bar = 14.5 PSI
Marzo 2004
45
Oil Pressure Sensor
Marzo 2004
46

Air Temp
Coolant Temp Fuel Temp Oil Pressure Oil Temp
Marzo 2004
47
Oil Temperature Sensor
Marzo 2004
48
Oil Pressure / Temp Sensor
Marzo 2004
49
Oil Pressure / Temperature Sensor
Marzo 2004
50
Oil Pressure / Temp Sensor curve
Marzo 2004
51

Air Temp
CAN Oil Temp

52
CAN Connection
The Term CAN (Controller area Network) Means that the control units in the vehicle are interlinked (Bus System) Can Wires are Twisted to reduce Electromagnetic Interference
CAN HIGH CAN LOW
PLD
VCU
Marzo 2004
53
CAN - Proprietary Data Link
CAN - LOW
CAN - HIGH
Marzo 2004
54

Air Temp
Battery / Ignition CAN
Battery
Oil Temp
55
Power Supply
12 Volt System
Battery 12 Volts
Marzo 2004
56
PLD Power Supply
Battery Supply (KL 30) (T 30) CAN LOW CAN High

Battery Ground KL31
Ignition (KL 15) (T 15)
Battery Grounds (KL 31) (T 31)
Marzo 2004
57

Air Temp
Atmospheric Pressure
Battery / Ignition CAN
Battery
Oil Temp
58
Atmospheric Pressure Sensor
Marzo 2004
59

Crank Angle TDC Sensor Turbo Boost Engine Control Module (PLD) Diagnostics Coolant Temp Fuel Temp Oil Pressure CAN Oil Temp
Air Temp
Atmospheric Pressur Battery / Ignition

Battery
60
Diagnostics
Hand Held Readers
Minidiag 2 Pro-Link 9000 (DDR)
Diagnostic Software (Case Point)

Case Base Diagnostics
Marzo 2004
61
Diagnostic Socket
Pin-outs for On-highway Cable
6 Pin Deutsche Connector

C E A B 12V Ground Data Link + Data Link -
Marzo 2004
62
Diagnostic Socket
Pin-outs for On-highway Cable
9 Pin Deutsche Connector
A B C D E F G H I Ground 12 Volts J1939 + J1939 J1939 Shield J1587 + J1587 Plug Plug
Marzo 2004
63

Crank Angle TDC Sensor Turbo Boost Engine Control Module (PLD) Oil Level Diagnostics Coolant Temp Fuel Temp Oil Pressure CAN Oil Temp
Air Temp

Battery
64
Oil Level Sensor
Marzo 2004
65
Oil Level Sensor
Marzo 2004
66

Crank Angle TDC Sensor Turbo Boost Engine Control Module (PLD) Unit Pumps Oil Level Diagnostics Coolant Temp Fuel Temp Oil Pressure CAN Oil Temp
Air Temp

Battery
67
Unit Pumps
Series 900 Engine
1 Part # All Power Ranges No cal Codes
Series 4000 Engine

1 Part # All Power Ranges No cal Codes
Marzo 2004
68
Injection Terminology
IRT Impact Response Time - Length of Time in (ms) required to close the Control Valve
Normally 1.2 to 2.1 milliseconds (ms) (1200 to 2100 microseconds (us)
PW Pulse Width - Degrees of Crankshaft Rotation when Fuel is Injected
Injection Pressure
(S-900) 1600 Bar / 23,200 PSI (S-4000) 1800 Bar / 26,300 PSI
Marzo 2004
69
Impact Response Time
Marzo 2004
70
Delivery Phases of Unit Pump
Suction Stroke
PreStroke
Marzo 2004
71
Delivery Phases of Unit Pump
Delivery Stroke
Residual Stroke
Marzo 2004
72
Injector Wiring
5 1 2 3 4
Marzo 2004
73

Crank Angle TDC Sensor Turbo Boost Engine Control Module (PLD) Unit Pumps Oil Level Diagnostics Coolant Temp Fuel Temp Oil Pressure Oil Temp
Air Temp
Atmospheric Pressur Battery / Ignition CAN

Marzo 2004
Battery
74
MBE Engine Control System

CAN
Start of Delivery
Quantity
Oil Pressure & Oil Temp
Coolant Temp Oil Pressure Oil Temp
Turbo Boost & Inlet Temp

75
Fuel Temp
Crankshaft Sensor
TDC Cam Sensor

Marzo 2004
(VCU) Vehicle Control Unit

CAN
Vehicle Control Unit (VCU)
Marzo 2004
76

All Switches On the Chassis or in the Cab Will be Wired to the (VCU)
Marzo 2004
77

Foot Pedal Speedometer Air Filter Sensor PTO Tachometer Vehicle Control Unit (VCU) CAN Cruise Control Grid Heater Ignition Switch Neutral Switch ABS
Engine Shutdown override
Air Conditioning
Oil pressure Coolant Level Sensor
Ambient Air Temp Battery Voltage Clutch Pedal Sensor Brake Switch Diagnostics
Marzo 2004
Coolant Temp
Engine Brake Switch
78
(PLD) Pump Line Nozzle

Wiring / Pin Assignments
Marzo 2004
79
(PLD) Pump Line Nozzle

55 Pin Connection for Engine Harness Wiring Plug # N3
16 Pin Connection for Cab Wiring Plug # EC 1

Power Supply Ignition Ground CAN Link
80
(EC 1) 16 Pin Connector

Pin 1 CAN High Pin 2 CAN Low Pin 3 CAN Ground Pin 4 CAN Ground Pin 5 Battery Voltage Pin 6 Battery Voltage Pin 7 N/A Pin 8 Starter Control Signal Pin 9 Battery Ground Pin 10 Proportional Valve 1-4 Pin 11 Battery Ground Pin 12 Starter Pin 13 Diagnostic Line Pin 14 Proportional Valve 3 Pin 15 Ignition Pin 16 Proportional Valve 4
1. Input / Output 2. Input / Output 3. Input 4. Input 5. Input 6. Input 7. N/A 8. Input 9. Input 10. Output 11. Input 12. Output 13. Input / Output 14. Output 15. Input 16. Output
Marzo 2004
81
(N 3) 55 Pin Connector
Marzo 2004
82
(N 3) 55 Pin Connector
Marzo 2004
83
Engine Sensor Harness

Marzo 2004
84
Sist. Electrnico MBE 4000
Marzo 2004
85
Marzo 2004
86
Marzo 2004
Fig. 2
87
Fig. 3
88
Marzo 2004
Fig. 4
89
Marzo 2004
Fig. 5
90

Marzo 2004
91
15 Pin
18 Pin
21 Pin
VC-4
VC-3
VC-1
Marzo 2004
92
(VCU) Vehicle Control Unit Connectors
1= 21 pin (VC-1) 2= 18 pin (VC-3) 3= 15 pin (VC-4) 4= VCU Module

93
VCU/Columbia/Century
Marzo 2004
94
(VCU 1) 21 Pin Connector

Pin 1 Battery Voltage Pin 2 Ignition Pin 3 Ground Pin 4 Oil Level Lamp Pin 5 Stop Engine Lamp Pin 6 Check Engine Lamp Pin 7 Flame Start Lamp Pin 8 Air Filter Lamp Pin 9 Throttle Supply (Pedal Analog) Pin 10 Boot Mode Pin 11 Throttle Signal Pin 12 Idle Validation 2 Pin 13 Idle Validation 1 Pin 14 Throttle Ground (Pedal & Remote) Pin 15 Service Brake Pin 16 Park Brake Pin 17 J1708 + Pin 18 J1708 Pin 19 CAN High (J1939) Pin 20 CAN Ground (J1939) Pin 21 CAN Low (J1939) 1. Input 2. Input 3. Input 4. Output 5. Output 6. Output 7. Output 8. Output 9. Output 10. Input 11. Input 13. Input 14. Output 15. Input 16. Input 17. Input / Output 18. Input / Output 19. Input / Output 20. Input / Output 21. Input / Output
Marzo 2004
95

Pin 1 Accessory Bus Shutdown Pin 2 Clutch Switch 1 Pin 3 Ground for Idle Validation Switch Pin 4 Cruise Control (Set) Pin 5 Cruise Control (Resume) Pin 6 Cruise Control( on/off) Pin 7 Throttle Select Pin 8 Engine Brake (Low) Pin 9 Engine Brake (High) Pin 10 Limiter 1 (Remote PTO) Pin 11 Limiter 2 (Engine Rating) Pin 12 Dual Road Speed Limit Pin 13 Engine Shutdown Override Pin 14 Air Conditioning (Fast Idle.Fan) Pin 15 Fan Override Pin 16 Throttle Inhibit Pin 17 5 Volts Supply Remote (PTO) Pin 18 Remote Signal (PTO)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Output Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Output
Marzo 2004
96

Pin 1 Transmission Neutral Pin 2 Dual Speed Axle Pin 3 Vehicle Speed Sensor Pin 4 Vehicle Speed Sensor GRD Pin 5 Gear Out 1 Pin 6 Gear Out 2 Pin 7 Coolant Level Pin 8 Air Filter Sensor Pin 9 Flame Start Valve Pin 10 Flame Start Gate (Grid Heater) Pin 11 Oil Level Lamp Pin 12 Starter Lock Out Pin 13 High Speed CAN (MB) Pin 14 CAN Ground (MB) Pin 15 Low Speed Can (MB) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Input Input Input Input Input Input Input Input Output Output Output Output Input / Output Input / Output Input / Output
Marzo 2004
97
( VCU )
Control Unit
15 Pin 18 Pin 21 Pin
Marzo 2004
Marzo 2004
Marzo 2004
Diagnostic Tools or Other Controllers

SAE J1939 ( 9 Pin Connector ) ( CAN High )
ICU
SAE J1587 ( 6 Pin Connector ) ( Serial )
Inputs
VCU
Outputs
Proprietary Data Link ( CAN Low )
Inputs
PLD
Outputs
Marzo 2004
Proteccin del Motor

La lampara se iluminar cuando el motor se encuentre trabajando mientras se esta conduciendo cuando una falla es detectada en el sistema de PLD or VCU.
Lampara de Check Engine
Lampara de Stop Engine
Marzo 2004
Proteccin de Motor (Disminucin)
Lampara de Check Engine ( On )
El motor disminuir a 1300 rpm por las siguientes fallas.

High Oil Level Low Oil Level Low Oil Pressure Coolant Temperature High High Oil Temperature
Marzo 2004
Engine Protection (Shutdown)
Check Engine Light ( On ) Stop Engine Light ( On ) Engine will Shut Down for the Following Faults.
Very High Coolant Temperature Low Coolant Level Very Low Oil Pressure
Marzo 2004
Fault Codes
All Fault Codes are Eight Digits

Example of Fault Code
128 021 03
128 = Message Identifier ( MID ) 021 = Parameter ID ( PID ) 03 = Failure Mode ID ( FMI ) 128 021 03 = Crankshaft Position Sensor Open Circuit
Marzo 2004
Performance Fault Codes
What is a Performance Code?

A Mechanical Failure ( Non Electrical )
A Performance Fault Code will be Logged when the Engine Electronics sees a Value 25 Percent above the Normal Engine Operational Values Calculated in the PLD.
Marzo 2004
Communication and Diagnostics
SAE J 1587 Message Format

Message Identifier ( MID ) Parameters ID ( PID ) Failure Mode ID ( FMI )
PLD & VCU ( One Common MID = 128 )

PLD - Assigned SID = 233 VCU - Assigned SID = 254
Marzo 2004
Diagnostic Trouble Code( s )

MID ( Message Identifier ) PID / SID for J 1587
( PID ) Parameter ID ( SID ) System ID
FMI ( Failure Mode Identifier )

0 - Parameter High 1 - Parameter Low 3 - Circuit High Voltage 4 - Circuit Low Voltage
Marzo 2004


Marzo 2004


Marzo 2004


Marzo 2004


Marzo 2004

Sist Elect 906 4000

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PLD - VCU

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Control Module ( PLD ) Pump Line Nozzle

Valve Clearance Adjustment

Valve Clearance Spec.

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Sistema de Control Electrnico Mercedes-Benz

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

PLD (Engine Control Module)

VCU (Vehicle Control Unit)

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Electronic Engine Advantages

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Localizacin de Sensores MBE4000

Presion/Temp. del Turbo

Seguridad y precauciones Preliminares

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Rango de Operacin de Trabajo de los sensores

Rango de Operacin Normal

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Modulo de Control Electrnico (PLD)

Conector de 55 Terminales Harnes del Motor Conector # N3

Conector de Cabina 16 Terminales Conector # EC 1

Alimentacin de Bateria Seal de Ignicion Tierra Cables CAN

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

256 Possible Codes

16 BIT = 65,536 SEGMENT

Harnes del Motor

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Conector de 55 Terminales ( Harnes del Motor )

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Crank Angle and TDC Sensors

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Sensor de Cigeal y Arbol de Levas

Flywheel has 37 Drilled Holes

Cam Gear has 13 Drilled Holes

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Sensores de Posicin Sincronizacin

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Sensor de Arbol de Levas TDC

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

55 Grados Antes del PMS

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Seal de Velocidad del Motor

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Seal de Arbol de Levas TDC

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Seal de Cigeal TDC

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Seal de Velocidad del Motor en el Arbol de Levas

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Inico de la Inyeccion en el Arbol de Levas en Ausencia de la seal del Cigeal

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Schematic Diagram MBE System

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Turbo Boost / Air Temp Sensor

Capacitacin Comercial Sistema Elctrico y Electrnico Century Class/Columbia

Turbo Boost / Air Temp Sensor