Mercedes-Benz

Electronic Controls

Series 500

Series 457 Series 900

 Class Agenda
• OM900 / OM500 / OM457 Electronic Controls for
Off Highway Applications
– Engine Control Electronics
– Vehicle Control Electronics
• PLD - FRE Operation
– System Parameters
• Diagnostics and Troubleshooting
– Diagnostics Tools
– Parameterization
– Wiring Schematics
– Fault Codes
 Training Center Operation

• 8:00 AM Class Start

• 9:30-9:45 AM Morning Break
• 11:00 AM Lunch or as Scheduled
• 12:00 PM Resume Class
• 2:00-2:15 PM Break
• 4:30 PM End of Class (Monday - Thursday)
• 3:30 PM End of Class on Friday
 Product Support

• Technical Service
– Daniel Snook (313) 592-7136
– Ronald Broekman (313) 592-5712

• Parts
– DDC Call Center (313) 592-5800
Off Highway OEM’s
Grove Mobile Cranes
Tadano Faun Cranes
 Mannesmann Demag
Crawler and Mobile cranes
Liebherr Loaders, Dozers, Cranes
Noell Straddle Carriers
Wirtgen Planer and Recycler
CLAAS Forage Harvesters
Kaessbohrer Pisten Bully
Hitachi Articulated Trucks
Ponsse Harvesters
Gradall Excavators
 Telligent
Telligent
Telligent
Telligent
Mercedes Benz.
Electronic Controls
 Telligent System
• The Entire Electronics System has been
Developed by Mercedes-Benz in Cooperation
with VDO and Temic

• Introduced 1995

• Minimum 2 box system

 Telligent System

• What are the Advantages of a Multi-box System?

 Minimal Wiring from Cab to Engine.

 Vehicle Wiring Lengths Reduced.
 Customer specific Vehicle programming.
 Simplistic Parameterization.
 Defined Responsibility of control units.
 Simplified Diagnostics and Troubleshooting.
• PLD (MR) (Engine Computer) Control Boxes
• FMR (Vehicle Engine Control)
• ADM (Adaption Module)
• ADM-FR (Vehicle Engine Control/Adaption Module)
• ADM-2 (Vehicle Engine Control/Adaption Module)
• EPB (BS) (Electronic Power Brake)
• MKR (KS) (Engine Clutch Control)
• EPS (GS) (Electronic Power Shift)
• EMK (KB) (Power Clutch Control)
• AGE (AG) (Automatic Gear Detection)
• ABS Mercedes (Brakes)
• ABS Wabco (Brakes)
• CAN Bus (Star Point )
• FLA (Flame Start System)
 Electronic Engine Advantages
• Engine Protection
• Engine Diagnostics
• Reduced Maintenance
• Improved Engine Governing
• Fuel Economy Optimization
• Enhanced Cold Starting
• Smoke Control
• Reduced Emission Levels
 Series 900 Sensor Location
Oil Pressure Boost Pressure
Oil Temp Air Temp

Unit Pumps

Cam Sensor
Coolant Temp
Crank Sensor

Start/Stop
Buttons
Fuel Temp
Oil Level
Atmospheric PLD
Pressure
 Series 500 Sensor Location

Fuel Temp Turbo Boost

Air Temp
Cam Sensor
Oil Pressure
Start/Stop
Buttons
Oil Temp

Crank Sensor
Coolant Temp
PLD Atmospheric
Pressure
Oil Level
Unit Pumps
 Safety And Precautionary Measures
• Never start engine unless batteries are properly connected.
• Never disconnect batteries when engine is running.
• Never reverse battery terminals, This will damage the ECUs.
• Never use a quick charger to jump start engine.
• Never unplug or plug in a connector at the PLD or any other
ECUs unless the Ignition is OFF.
• Never disconnect CAN Link unless Ignition is OFF.
• When Welding disconnect + and - battery cables and connect
together.
• Always use proper test leads when probing electrical connectors.
• Telephones and 2 way radios which are not connected to an
external aerial can cause malfunctions in vehicle electronics.
 Sensor Operations

Operates on 5 Volts for All D.C. Sensors

0 .25 4.75 5

Normal
Operating
Range
Schematic Diagram Telligent System

Engine
Control
Module
(PLD)
 (PLD) Information
• Engine Mounted Processor
– SIEMENS C167CR chip
• 16 Bit Micro controller
– Up to 34 Million decisions / sec
– 65,536 Code capacity
• OBD II compliant
– Engine Performance Codes
• Controls:
– Fueling Strategy
– Supply Voltage 12 / 24 Volts
Functions
– Sensor Inputs
– Outputs
 Electronic Control Module (PLD)
• 55 Pin
Connection for
Engine Harness
Wiring Plug # N3

• 16 Pin
Connection for Cab
Wiring Plug # X1
Power Supply
Ignition
Ground
CAN Link
Engine Harness
 N3 (Engine Harness 55 Pin Plug)
Pin 1 Pin 18

Pin 0 Pin 36

Pin 37 Pin 19 Pin 54

 Schematic Diagram Telligent System
Crank Angle

TDC Sensor
Engine
Control
Module
(PLD)
Crank Angle and TDC Sensors
 Crank Angle / TDC Sensor
• 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 or Slots

– 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
 Crank Angel / TDC Sensors

• These sensors provide redundant signals

• The engine can start and run on one sensor

• The Flywheel sensor (CKP) is normally used to

determine RPM, and for piston position in relation
to TDC

• The Cam sensor (CMP) is normally used to identify

number 1 cylinder in the firing order
 Flywheel

Series - 900 Series - 457 / 500

36 holes/slots, 10 degrees apart

The “odd” hole/slot is 65 degrees BTDC
 TDC/Cam Signal
MBE - 4000
12 holes are
spaced 30
degrees apart.
The “odd” hole
is 55 degrees
BTDC
 Timing Sensors
• 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
 Timing Sensor Signals
55 Degrees
BTDC

Camshaft
Signal

Crankshaft
Signal
 Normal Sensor Operation

• The signal from the “odd” spaced hole in the Cam

gear is generated once per two crank revolutions
• This identifies number one cylinder in the firing
order at 55 degrees BTDC at compression

• The 36 signals from the evenly spaced holes in the

flywheel are for speed and piston position in
relation to TDC
• These signal are generated every 10 degrees
 Failed Sensor Operation
• With a failed Crank sensor, the 12 evenly spaced
holes in the Cam gear provide speed and piston
position information to the PLD.
• This provides a low resolution of 6 signals per rev.
• With a failed Cam sensor, the “odd” hole in the
flywheel provides number 1 or 6 info to the PLD at
65 degrees BTDC.
• The PLD activates the number 1 and 6 solenoids in
turn and waits for a speed increase to identify the
number one cylinder at compression
 Schematic Diagram Telligent System
Crank Angle

TDC Sensor
Engine
Turbo Boost Control
Module
Air Temp (PLD)
 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
Intake Air Sensor
 Intake Air Pressure / Temp Sensor Curve
5.0

4.5

4.0

3.5
Voltage ( V )

3.0

2.5
3.0
2.0

1.5

1.0

0.5

0.5 1.0 1.5 2.0 2.5 3 0 3.5 4.0 4.5 5.0

Boost pressure indicated by the ECU ( bar )

-22 -4 32 68 104 140 176 212 248 284 *F

 Schematic Diagram Telligent System
Crank Angle

TDC Sensor
Engine
Turbo Boost Control
Module
Air Temp (PLD)

Coolant Temp

Fuel Temp

• Thermistor
– As the Temperature
increases the resistance
decreases
Temperature Sensors
• Operating Temperature
– - 40 to 266 F
Coolant Temperature Sensor
Fuel Temperature Sensor
 Temperature Sensor Graph

-22 -4 32 68 104 140 176 212 248 284 *F

 Schematic Diagram Telligent System
Crank Angle

TDC Sensor
Engine
Turbo Boost Control
Module
Air Temp (PLD)

Coolant Temp

Fuel Temp

Oil Pressure
 Oil Pressure Sensor
• Operating Range 0 to 5 bar
• Resistances
– 0 bar 5 to 13 ohms
– 1 bar 44 to 52 ohms
– 2 bar 78 to 86 ohms
– 3 bar 111 to 121 ohms
– 5 bar 154 to 214 ohms

• 1 Bar = 14.5 PSI

Oil Pressure / Temp Sensor
Oil Pressure / Temperature Sensor
 Oil Pressure / Temp Sensor curve

pressure indicated by the ECU ( bar )

-22 -4 32 68 104 140 176 212 248 284 *F
 Schematic Diagram Telligent System
Crank Angle

TDC Sensor
Engine
Turbo Boost Control
Module
Air Temp (PLD)

Coolant Temp

Fuel Temp

Oil Pressure
CAN
 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
• Minimum 10 turns per foot
CAN HIGH

CAN LOW
PLD FRE

CAN Grounds
CAN - Proprietary Data Link

Ground
Ground
CAN - LOW
CAN - HIGH
 Schematic Diagram Telligent System
Crank Angle

TDC Sensor
Engine
Turbo Boost Control
Module
Air Temp (PLD)

Coolant Temp

Fuel Temp

Oil Pressure Battery / Ignition - +

Battery
CAN
 Power Supply

+ -

Battery
12/24 Volts

12 Volt System 24 Volt System

Nominal Voltage 11-16 V Nominal Voltage 22-30 V
Low Voltage Code < 11 V Low Voltage Code < 22 V
High Voltage Code > 16 V High Voltage Code > 30 V
PLD Power Down < 6.5 V PLD Power Down <8V
 PLD Power Supply

Ignition
(KL 15)
Battery Supply (T 15)
(KL 30)
(T 30)

Battery Grounds
(KL 31)
(T 31)

Battery Ground – KL31

 Schematic Diagram Telligent System
Crank Angle

TDC Sensor
Engine
Turbo Boost Control
Module
Air Temp (PLD)

Coolant Temp

Fuel Temp Atmospheric Pressure

Oil Pressure Battery / Ignition - +

Battery
CAN
Atmospheric Pressure Sensor
 Schematic Diagram Telligent System
Crank Angle

TDC Sensor
Engine
Turbo Boost Control
Module
Air Temp (PLD)

Coolant Temp Start/Stop Buttons

Fuel Temp Atmospheric Pressure

Oil Pressure Battery / Ignition - +

Battery
CAN
 Start and Stop Buttons

• Two Pushbuttons are located on engine for ease of

operation when servicing engine
• Ignition must be on
• Transmission in neutral
• Push both buttons at same time to crank engine
only (No Start) Stop

Stop Start
Start

S-900 S-500
Engine Start / Stop Buttons
 Schematic Diagram Telligent System
Crank Angle

TDC Sensor
Engine
Turbo Boost Control
Module
Air Temp (PLD) Diagnostics

Coolant Temp Start/Stop Buttons

Fuel Temp Atmospheric Pressure

Oil Pressure Battery / Ignition - +

Battery
CAN
 Diagnostic Socket

• Diagnostic Readers
– HHT (Hand Held Tester)
– Minidiag 1
– Minidiag 2
» Version A (Read Only)
» Version B (Programming)
– Star Diagnostics
(P.C. Software)
14 Pin
 Schematic Diagram Telligent System
Crank Angle

TDC Sensor
Engine
Turbo Boost Control Starter Relay
Module
Air Temp (PLD) Diagnostics

Coolant Temp Start/Stop Buttons

Fuel Temp Atmospheric Pressure

Oil Pressure Battery / Ignition - +

Battery
CAN
 Starter Relay
• The starter circuit must receive a signal from the
PLD to activate the starter motor.
• There is a starter safety relay wired in series.
– Limit starting time ( 90 seconds) starter safeguard
– Deactivate starter while engine is running
– Transmission safe guard

Starter Relay
 Schematic Diagram Telligent System
Crank Angle

TDC Sensor
Engine Oil Level
Turbo Boost Control Starter Relay
Module
Air Temp (PLD) Diagnostics

Coolant Temp Start/Stop Buttons

Fuel Temp Atmospheric Pressure

Oil Pressure Battery / Ignition - +

Battery
CAN
Oil Level Sensor
 Oil Level Sensor
• The Oil Level sensor consists of a Hot wire, Whose measured resistance
is temperature dependent. During the measurement the sensor is heated
up for 0.6 seconds with 200 ma direct current. The change in voltage is
measured on the sensor during the (switch-on duration). The change in
voltage is a correlation of engine oil level.
• The measurement is repeated every 6 seconds.

• Resistance value is 22 ohms (Oil Level Full at Room Temperature)

Oil Level Sensor
 Schematic Diagram Telligent System
Crank Angle
Unit Pumps
TDC Sensor
Engine Oil Level
Turbo Boost Control Starter Relay
Module
Air Temp (PLD) Diagnostics

Coolant Temp Start/Stop Buttons

Fuel Temp Atmospheric Pressure

Oil Pressure Battery / Ignition - +

Battery
CAN
Electronic Unit Pumps / Calibration Codes

Calibration
Code

Series 900

Series 457/ 500

 Injection Terminology
• IRT Impact Response Time - Length of Time in (us)
required to close the Control Valve
 (Normally 1200 to 2100 microseconds (us)

• PW Pulse Width - Degrees of Crankshaft Rotation when

Fuel is Injected
Impact Response Time
Delivery Phases of Unit Pump

Suction Stroke PreStroke

 Delivery Phases of Unit Pump

Delivery Stroke Residual Stroke

Fuel Delivery
 Firing Order and Numbering
• 4 Cylinder: 1 - 3 - 4 - 2
• 6 Cylinder: 1 - 5 - 3 - 6 - 2 – 4

• Solenoid Driver Designation:

– A first cylinder in the firing order:
– B second
– C third
– D fourth
– E fifth
– F sixth

A E C F B D
 PLD
55 Pin Four Cylinder EUP Wiring
54
1-A
16 Bank 1 Return (ground)

2-D
47

45
3-B
9 Bank 2 Return (ground)

4-C
38
 PLD
55 Pin
Six Cylinder EUP Wiring
54
1-A
47
Bank 1 Return (ground) 2-E
16
53
3-C

38
4-F
45
Bank 2 Return (ground) 5-B
9
44
6-D
 Schematic Diagram Telligent System
Crank Angle
Unit Pumps
TDC Sensor
Engine Oil Level
Turbo Boost Control Starter Relay
Module
Air Temp (PLD) Diagnostics

Coolant Temp Start/Stop Buttons

Fuel Temp Atmospheric Pressure

Oil Pressure Battery / Ignition - +

Battery
CAN
 Engine Control System
Oil CAN
Level

Start of
Quantity
Start & Stop Delivery
Buttons

Oil Pressure Coolant Turbo Boost Fuel Crankshaft TDC Cam

Oil Pressure Oil Temp
& Oil Temp Temp & Inlet Temp Temp Sensor Sensor
 (FRE) Vehicle Electronics

All Switches
On the Chassis or in the Cab
Will be Wired to the (FRE)
 (ADM-FR) Vehicle Electronics
Foot Pedal Cruise Control
CAN Flame Start
Speedometer
Air Filter Sensor Ignition Switch

PTO Neutral Switch

Vehicle
Tachometer Motor Transponder Code
Regulator (optional)
Alternator Speed (ADM-FR) Ambient Air Temp
Oil pressure Stop Lamp
Coolant Level Sensor Clutch Pedal Sensor
Coolant Temp Park Brake Switch
Engine Brake Switch (PLD)(FRE)
Fault Lamp Diagnostics
 (ADM-2) Vehicle Electronics
Foot Pedal Cruise Control
CAN Grid Heater
Speedometer
Air Filter Sensor Ignition Switch

PTO Neutral Switch

Vehicle
Tachometer Control ABS
Unit Engine Shutdown override
Air Conditioning
(ADM-2) Ambient Air Temp
Oil pressure Battery Voltage
Coolant Level Sensor Clutch Pedal Sensor
Coolant Temp Park Brake Switch
Engine Brake Switch
Diagnostics
 Electronic Foot Pedal
• The Electronic Foot Pedal
Transmits Two PWM (Pulse
Width Modulated) Signals.
• Supply Voltage 12/24 Volts
– 1) Potentiometer
– 2) Potentiometer
– 3) Electronic Module 1
– 4) Electronic Module 2

• Note: Mercedes Benz. Foot

Pedal Assembly has a
teach in Process.
 Electronic Foot Pedal
• A- Idle
– Output 1 5% on/off ratio
– Output 2 95% on/off ratio
• B- Half Throttle
– Output 1 50% on/off ratio
– Output 2 50% on/off ratio
• C- Full Throttle
– Output 1 95% on/off ratio
– Output 2 5% on/off ratio Full
 Electronic Foot Pedal
• William’s Controls Assembly
– Analog Potentiometer
– Idle Validation Switch
• ADM-2
– Monitors Pedal Signal
– Monitors Idle Validation Switch
– Logs Fault Codes and Sets CEL
– Performs Limp Home Functions
• Pedal “Limp Home” Function
– Low Engine Idle
– Limp Home Speed
» Acceleration to 1300 RPM
 Constant Throttle (Engine Brake)
• Controlled by Driver Activated Switch or Automatically by
ADM-2 Programming.
• Activation Speed (Engine RPM)
– Minimum 1100 RPM 906 Engine
• 904/457/501/502 Engines are Pneumatically operated.
• 906 Engines are hydraulically operated.
• The Constant Throttle Valves and Exhaust Brake Flap can be
operated together or separately.
– Low Braking = Constant Throttle
– High Braking = Constant Throttle & Exhaust Flap
 Hydraulic Constant Throttle
(906 Engine Brake)
• When the solenoid valve
is activated engine oil is
supplied to the
individual constant
throttle valves in the
Cylinder head.
– 1) Valve
– 1.1) Piston
– 1.2) Cover
– 2) Oil Gallery
– 3) Oil line
– 4) Solenoid Valve
– 5) 3 / 2-way Valve
– 6) Pressure Holding Valve (0.2 bar)
 Brake Performance
215

188

160

134

107

80

54

26

HP
Constant Throttle
Constant Throttle+ Flap
 Cold Weather Start

• Start to +5 F
• Grid Heater Start down to -13 F
• Coolant Block Heater Below -13 F
• Grid Heater Computer Controlled
• No Ether Start System Allowed!
 Grid Heater (Option)
• Needed to Improve Start ability of Engine in
Temperatures that are below 23 degrees F
• An Electric Grid Heater is located in the intake Pipe
to Warm Intake Air.

• Benefits
– Reduce white smoke.
– Reduce load on batteries and starter motor.
– Improve Start ability at low ambient temperatures.
No Ether Start Systems Allowed ! ! !
Grid Heater (Option)
 Flame Start (Option)

• A flame start glow plug is located in the intake

manifold to ignite the fuel.
• The fuel is supplied to the flame glow plug via a
solenoid valve with a metering nozzle.
– Glow time (Max 20 seconds)

• Benefits
– Reduce white smoke.
– Reduce load on batteries and starter motor.
– Improve Start ability at low ambient temperatures.
 Engine Protection

• Fault Lamp will illuminate when engine is running or

while driving when a fault is detected in the PLD or
FRE system.
• The PLD - FRE System is designed to enable the
vehicle to continue to be driven even in the event of
a failure. (Possibly with reduced output)
– Dual PWM Foot Pedal
– Dual CAN Connection
– Triple Detection Engine Speed (Cam , Crank , Alternator)
– Emergency Run Logic in PLD
 Emergency Run Mode

• Constant Engine Speed Idle or 1300 RPM

Regardless of Engine Load.
• The following Faults will activate emergency run
mode.
– Total Failure of FMR control unit
– Total Failure of both CAN Lines
– Total Failure of Foot Pedal
– Excess Turbo boost
– Engine Overheat (Coolant Temp Above 266 F)
 (ADM-FR) Engine Protection
• Fault Lamp will illuminate when the engine is running or while
driving when a fault is detected in the PLD or ADM-FR system.

Check Engine Light

– Note:
The ADM-FR (Vehicle Motor Regulator) Control Module has
No engine shutdown Features.
 (ADM-2) Engine Protection

• Fault Lamp will illuminate when the engine is

running or while driving when a fault is detected in
the PLD or ADM-2 system.

Check Engine Light

Stop Engine Light

 Engine Protection (Derate)

• Check Engine Light (On)

• Engine will Derate for the Following Faults.

– High Oil Level
– Low Oil Level
– Low Oil Pressure
– Coolant Temperature High
 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
– Oil Level Very Low

• Note: Shutdown Feature only available with ADM-2

Vehicle Control Modules
(FMR) Vehicle Motor Regulator
(ADM) Adaptation Module
(ADM-FR)
(ADM- 2)
 (ADM-FR)
Construction
1 assembly. spring
2 housing
3 data plate
4 connectors

1 support plug
2 connector 1 (15-pin)
3 connector 2 (18-pin)
4 connector 3 (12-pin)
5 connector 4 ( 9-pin)
The Telligent System
(PLD - FRE)
Diagnostic Tools

K-Line
Diagnostic Tools

Inputs or Other Controllers

FRE Outputs

Proprietary Data Link

(CAN)

Inputs PLD Outputs

(PLD) Pump Line Nozzle
Wiring / Pin Assignments
 (PLD) Pump Line Nozzle
• 55 Pin
Connection for
Engine Harness
Wiring Plug # N3

• 16 Pin
Connection for Cab
Wiring Plug # X1
Power Supply
Ignition
Ground
CAN Link
 (X1) 16 Pin Connector
• Pin 1 CAN High 1. Input / Output
• Pin 2 CAN Low 2. Input / Output
• Pin 3 CAN Ground 3. Input
• Pin 4 CAN Ground 4. Input
• Pin 5 Battery Voltage 5. Input
• Pin 6 Battery Voltage 6. Input
• Pin 7 N/A 7. N/A
• Pin 8 Starter Control Signal 8. Input
• Pin 9 Battery Ground 9. Input
• Pin 10 Proportional Valve 1-4 10. Output
• Pin 11 Battery Ground 11. Input
• Pin 12 Starter 12. Output
• Pin 13 Diagnostic Line 13. Input / Output
• Pin 14 Proportional Valve 3 14. Output
• Pin 15 Ignition 15. Input
• Pin 16 Proportional Valve 4 16. Output
 (X1) 16 Pin PLD Wiring Schematic

CAN High
1 16
CAN Low Ignition Batt.
2 15
CAN Shield
3 14
CAN Shield Diagnostic K-Line
4 13
Battery Pos. To Starter
+ 5 12
Battery Pos. Battery Neg.
Bat. 6 11
_
W

7 10
Starter Signal Battery Neg.
8 9
 (N3) Engine Harness 55 Pin Plug
Pin 1 Pin 18

Pin 0 Pin 36

Pin 37 Pin 19 Pin 54

(N3) 55 Pin Connector
(N3) 55 Pin Connector
Diagnostic Tools
(HHT) Hand Held Tester
 Minidiag 1

• Diagnostics of
Engine and
Vehicle
Electronics
Only
Minidiag 2
Minidiag 2 – Connectors

1. Power supply connector

(12 V – 24 V)

2. 25 pin connector
(diagnostic connector or PC)
Minidiag 2 - Key Pad Description
help enter/ ok

cursor up clear value

cursor reserved
down
escape reserved

page right reserved

page left change to alpha

page up reserved

page down decimal point

ok minus
 Minidiag 2 Capabilities

• Minidiag 2 is the latest Diagnostic Tool from Daimler

Chrysler
• Version A (Read Only)
• Version B Capabilities
– Automatic detection of all ECUs built into the Vehicle
– Display Actual Values
– Readout and Clear Fault Codes
– Execution of Routines
– Setting of ECU Parameters
 Fault Codes

• All Fault Codes are Five Digits

– Example of fault code

10605
– 1 = Fault Priority
– 06 = Fault Path
– 05 = Fault Type

• 10605= Accelerator pedal signal 1 not present

 Fault Codes (ADM-FR)
• In the five digit fault code,The first digit (0,1 or 2) indicates
the fault priority.
• 0 = Fault can be corrected at next maintenance service.
– No Check Engine light
• 1 = Fault must be corrected as soon as possible.
– Check Engine light illuminated
– ( It can be expected that the running characteristics of the engine will
be affected.)
• 2 = Fault must be corrected immediately!
– Check Engine light illuminated
– ( Engine in emergency run mode, Constant 1300 RPM )
 Fault Codes (ADM-2)
• In the five digit fault code,The first digit (0,1 or 2) indicates the
fault priority.
• 0 = Fault can be corrected at next maintenance service.
– Check Engine light illuminated

• 1 = Fault must be corrected as soon as possible.

Check Engine light illuminated
( It can be expected that the running characteristics of the engine will
be affected.)
• 2 = Fault must be corrected immediately!
Check / Stop Engine lights illuminated
Engine in emergency run mode, ( Idle-1300 RPM )
Engine Shut down (ADM-2)
 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.
Reading Fault Codes
 Minidiag 2 - Assistant
Minidiag 2 Assistant is
a software package
that interacts with the
reader.
• Upload parameter
sets to the PC from the
PLD-FMR
• Edit parameter sets
on the PC
• Download parameters
back to the PLD-FMR
• Update the Minidiag 2
reader
 Minidiag 2 - Assistant

Selection Screen
from the Logistic
Assistant
 Minidiag 2 - Assistant

Selection
screen from
the
Parameter
Assistant
 Minidiag 2 - Assistant

Select the
parameters
you want to
modify from
the group
listing
 Minidiag 2 - Assistant
Sample screen
of the Engine
Brake group of
parameters

Print
Parameters
Option
Setting Parameter Block
Troubleshooting Tools
Digital Multi-meter
 Wire Repair Kit
• Tool # 950 589 00 99/00
 Engine Harness Repair Kits

J- 46252- 900 J- 46252- 4000

(FRE) Connector Secondary Lock
Wire Sizes
Basic Electricity
 DDEC Three-Wire Sensors
ECM +5V Supply Sensor

Signal

Return

Open Supply = Lo Volt

Open Signal = Lo Volt
Open Return = Hi Volt
Supply short to Signal = Hi Volt
Supply short to Return = Lo Volt
Signal short to Return = Lo Volt
 MBE Three-Wire Sensors
PLD +5V Supply Sensor

Signal

Return

A combination of an open supply along with Signal

shorted to Return will cause a Lo Volt code.

All other external wiring faults will cause a High Volt code
 MBE Two-Wire Sensors
PLD

+5V Supply

Sensor
Signal

Return

Open = Hi Volt
Short = Lo Volt
 MBE Four-Wire Sensors
PLD Sensor

Pressure Signal

+5V Supply
Common Return

Temperature Signal

Faults are the same as for separate sensors

 Basic Electrical Circuits

Shorted Closed Open

Has Continuity Has Continuity No Continuity
Lower or no Resistance Has Resistance Infinite Resistance

0.0  XX.X  OL
 Basic Circuit Tests
• Voltage
– Power on circuit
– VOM set on DC Voltage
– Red to +
– Black to -
– Read voltage
 Basic Circuit Tests
• Total Circuit Resistance
– Power off circuit
– Disconnect circuit at source
– VOM set on resistance ()
– One VOM lead to each wire
– Read resistance
 Basic Circuit Tests
• Shorts
– Power off circuit
– Disconnect circuit at both ends
– VOM set on resistance ()
– One VOM lead to each wire
– Check continuity

– Continuity = Short
– No continuity (OL) = No short
 Basic Circuit Tests
• Opens
– Power off circuit
– Disconnect circuit at both ends
– Jumper one end
– VOM set on resistance ()
– One VOM lead to each wire
– Check continuity

– No continuity (OL) = Open

– Continuity = No Open
 Basic Circuit Tests
• Shorts to Ground
– Power off circuit
– Disconnect circuit at both ends
– VOM set on resistance ()
– One VOM lead to chassis ground
– One VOM lead to each wire
– Check continuity

– Continuity = Short to ground

– No continuity (OL) = No short to ground
5100 (120 Ton Crane)
 Grove GMK 5100
• PLD
Engine ECU
• FMR
Vehicle ECU
• CAN
Star Point
• ADM
Gages
• EPS
Power Shift
• MKR
Clutch
• AG
Gear Detection
• ABS
Brakes
 GROVE (GMK 5100)
6
• 1) FMR
• 2) MKR
1
• 3) ADM 7
2
• 4) EPS
3
• 5) AGE 8
• 6) CAN-BUS 4
• 7) ABS Merc.
• 8) ABC Wabco 5
Diagnostic Socket
Daimler Chrysler G240-16 Gearbox (EAS)
Electronic Automatic Shift
The Driver only has to select the starting gear.
No Manual clutch actuation necessary.
System backup, an emergency program.
Electronic gear selection,which can be influenced
by the driver at any time.