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1. Safety .............................................................................................................. 11
1.1. Symbols ............................................................................................................................................11
1.2. General information ........................................................................................................................11
1.3. Use for the indended purpose .......................................................................................................12
1.4. Personnel requirements .................................................................................................................12
1.5. Conversions and modifications to the MR-PLD..........................................................................12
1.6. Installation .......................................................................................................................................12
1.7. Organizational measures................................................................................................................12
1.8. Safety precautions for engines with electronic control units ..................................................13
1.9. DaimlerChrysler original parts .....................................................................................................14
1.10. Safety and backup running programm......................................................................................14
2. General governor architecture...................................................................... 15
2.1. Standard model of engine control (MR-PLD) and vehicle electronics (FRE) .........................15
2.2. Features of the governor and interface module .........................................................................16
2.2.1. VCU (ADM2) as FRE (vehicle electronics)...................................................................................... 16
2.2.2. ADM as FRE (vehicle electronics).................................................................................................... 17
3. MR-PLD engine control (pump-line-nozzle) ................................................. 18
3.1. Brief description of the Diesel engine control unit PLD-MR ....................................................18
3.2. Control unit - operating principle .................................................................................................18
3.2.1. Overview of the telligent engine system BR 500 .......................................................................... 19
3.2.2. Overview of the telligent engine system BR 900 .......................................................................... 20
3.2.3. Control unit block diagram............................................................................................................... 21
3.2.4. PLD control unit as engine control (MR-PLD) .............................................................................. 22
3.3. Functional description .....................................................................................................................23
3.3.1. Configuration...................................................................................................................................... 23
3.3.2. Flexibility of the concept................................................................................................................... 23
3.3.3. Control unit description of engine electronics MR-PLD .............................................................. 24
3.3.3.1. Safeguard /redundancy...................................................................................................... 24
3.3.3.2. Description of the inputs ................................................................................................... 24
3.3.3.3. Description of the outputs ................................................................................................. 24
3.3.4. Compound network between MR-PLD <=> FRE ............................................................................ 25
3.3.4.1. Communication ................................................................................................................... 25
3.3.5. MR-PLD <=> FRE interface functions .......................................................................................... 26
3.3.5.1. Idle-speed control / speed control / maximum engine speed limitation .................. 26
3.3.6. Shutoff or throttling of the engine through the FRE (vehicle electronics)............................. 27
3.3.7. Engine start and stop........................................................................................................................ 28
3.3.7.1. Starter control (conditions)................................................................................................ 28
3.3.7.2. Starter protection................................................................................................................. 29
3.3.7.3. Start by the driver ............................................................................................................... 29
3.3.7.4. CAN start .............................................................................................................................. 30
3.3.7.5. Starter reset bridge ............................................................................................................. 30
3.3.7.6. Starter driver........................................................................................................................ 31
3.3.7.7. Start through the FRE (vehicle control electronics) via CAN...................................... 32
3.3.7.8. Starting procedure .............................................................................................................. 32
3.3.7.9. Service start button at the engine block ......................................................................... 32
3.3.7.10. Service stop button at the engine block........................................................................ 32
3.3.7.11. Engine cranking via the service start and stop button .............................................. 33
3.3.7.12. Rev up to maximum speed via service start button.................................................... 33
6
Index
3.3.7.13. Engine stop......................................................................................................................... 33
3.3.8. Plausibility check terminal 50 ........................................................................................................ 34
3.3.9. Calculation of injection delivery angle and start of injection.................................................... 35
3.3.10. Controls (PID governor) ................................................................................................................. 36
3.3.11. Operating modes ............................................................................................................................. 37
3.3.11.1. PTO speed control ............................................................................................................. 37
3.3.11.2. Controlled operation (normal operation)..................................................................... 37
3.3.11.3. Immobilizer ........................................................................................................................ 37
3.3.12. Tow starting of the engine............................................................................................................. 37
3.3.13. Emergency syndrome..................................................................................................................... 37
3.4. Mechanical description...................................................................................................................38
3.4.1. Mechanical layout of PLD engine electronics ................................................................................ 38
3.4.2. Complete version PLD engine electronics ...................................................................................... 38
3.4.2.1 Fuel cooling ........................................................................................................................... 39
3.4.2.2 MR-PLD Control Unit ........................................................................................................... 39
3.4.2.2.1.MR-PLD - version assignment table................................................................. 41
3.4.3. Technical data ................................................................................................................................... 41
3.4.4. General testing conditions ............................................................................................................... 41
3.5. Electrical description .......................................................................................................................42
3.5.1. System interface diagram ................................................................................................................ 42
3.5.1.1. Interface diagram................................................................................................................ 42
3.5.1.2. Socket pin designation MR-PLD control unit (D2.1)/according to pin assignment . 43
3.5.1.3. Pin assignment of MR-PLD control unit (D2.1); function oriented/alphabetical ..... 46
3.5.1.4. Voltage supply of control unit MR-PLD (D2.1) ............................................................... 50
3.5.2. xx
3.5.2.1. ............................................................................................................................................... xx
3.5.2.2. ............................................................................................................................................... xx
3.5.2.3. ............................................................................................................................................... xx
3.5.3. Sensor system of the PLD engine control unit (MR-PLD)........................................................... 51
3.5.3.1. Control unit internal sensors ............................................................................................ 51
3.5.3.2. Control unit external sensors............................................................................................ 51
3.5.3.3. Active sensors ...................................................................................................................... 51
3.5.3.4. Passive sensors.................................................................................................................... 52
3.5.3.5. Temperature sensors .......................................................................................................... 52
3.5.3.6. Passive oil pressure ............................................................................................................ 53
3.5.3.7. Oil level ................................................................................................................................ 54
3.5.3.8. Camshaft / crankshaft position (inductive).................................................................... 55
3.5.3.9. Booster speed 1 / 2.............................................................................................................. 55
3.5.3.10. Fan speed........................................................................................................................... 56
3.5.4. Digital inputs..................................................................................................................................... 57
3.5.4.1. Ignition (Terminal 15)......................................................................................................... 57
3.5.4.2. Terminal 50 .......................................................................................................................... 57
3.5.4.3. Service button start/stop ................................................................................................... 58
3.5.4.4. Oil separator........................................................................................................................ 59
3.5.5. Proportional valve control................................................................................................................ 60
3.5.5.1. Functional assignment of proportional valves/hardware status D2.1 ....................... 61
3.5.5.2. Principle block diagram proportional valve control /hardware status D2.1............. 62
3.5.5.3. Functional assignment of the proportional valves/hardware status C3..C6 ........... 63
3.5.5.4. Principle block diagram proportional valve control/hardware status C3..C6.......... 64
3.5.6. Starter control through the MR-PLD .............................................................................................. 65
3.5.6.1. Main path (self-locking) ..................................................................................................... 65
3.5.6.2. Auxiliary path (self conducting)....................................................................................... 65
3.5.6.3. Principle block diagram starter control .......................................................................... 66
3.5.6.4. Starter relay.......................................................................................................................... 66
3.5.6.5. Principle block diagram of safety concept of JE-starter ............................................. 67
3.5.7. Serial communication interfaces .................................................................................................... 68
7
Index
3.5.7.1. CAN data bus (2-wire-interface, standard: ISO 11992) ................................................ 68
3.5.7.2. Diagnostic line (standard: ISO 9141)............................................................................... 69
3.5.7.3. Classification of the injector valves ................................................................................. 69
3.6. Configuration possibilities of the MR-PLD..................................................................................70
3.6.1. Fan type.............................................................................................................................................. 70
3.6.1.1. General connection ............................................................................................................. 70
3.6.1.2. Pin assignment of the proportional valve-power stages (PV/Prop) for fan control. 70
3.6.1.2.1. Type 0/Linning-clutch (on highway/two-stage) ........................................... 70
3.6.1.2.2. Type 1/Linning-clutch (off highway/two-stage)........................................... 70
3.6.1.2.2.1.Configuration / fan switch-on threshold (type 1).................... 70
3.6.1.2.3. Type 2 /electrically controlled Viscous-fan................................................... 72
3.6.1.2.4. Type 3 /Hydrostatic Fan ................................................................................... 73
3.6.1.2.5. Type 4/Horton-clutch ........................................................................................ 74
3.6.1.2.6. Type 5/one Hydrostatic-fan.............................................................................. 75
3.6.1.2.7. Type 6/two Hydrostatic-fans............................................................................ 76
3.6.2. Starter control ................................................................................................................................... 77
3.6.2.1. JE-starter ............................................................................................................................... 77
3.6.2.2. KB-starter............................................................................................................................. 78
3.6.2.2.1. KB-starter with starter solenoid relay (2 A) .................................................. 78
3.6.2.2.2. KB-starter without Starter Solenoid Relay (2 A) ......................................... 79
3.6.3. Oil pans .............................................................................................................................................. 80
4. Diagnosis ........................................................................................................ 81
4.1. Measured values ..............................................................................................................................81
4.1.1. Analogue measured values.............................................................................................................. 81
4.1.2. Binary measured values................................................................................................................... 83
4.2. Serial diagnosis interfaces .............................................................................................................86
4.2.1. Diagnostic line .................................................................................................................................. 86
4.2.1.1. Fault memory....................................................................................................................... 86
4.2.1.2. Operating modes ................................................................................................................. 86
4.2.2. CAN data bus systems...................................................................................................................... 87
4.2.2.1. Engine-CAN (ISO 11992) ................................................................................................... 87
4.2.2.2. Vehicle CAN......................................................................................................................... 87
4.2.3. SAE J1587/SAE J1708 (USA- and partly NAFTA-market).......................................................... 88
4.2.4. Configuration of diagnostic interface............................................................................................. 88
4.2.4.1. MB-truck / Brazil................................................................................................................. 89
4.2.4.2. Europe (ADM / not MB-trucks)......................................................................................... 90
4.2.4.3. Europe (ADM2 / not MB-Trucks)...................................................................................... 91
4.2.4.4. USA- and partly NAFTA-market ....................................................................................... 92
4.2.5. Diagnosis interface/software description ..................................................................................... 93
4.2.5.1. Fault memory structure ..................................................................................................... 93
4.2.5.2. Ground switching................................................................................................................ 93
4.3. Diagnosis unit & application..........................................................................................................94
4.3.1. minidiag2........................................................................................................................................... 94
4.3.1.1. Display/delete fault code memory ................................................................................... 94
4.3.1.2. Testing routines................................................................................................................... 97
4.3.1.2.1.Voltmeter function.............................................................................................. 97
4.3.1.2.2.Cylinder cutoff..................................................................................................... 98
4.3.1.2.3.Compression check............................................................................................. 99
4.3.1.2.4.Idle speed balance (hot engine!)..................................................................... 100
4.3.1.2.5.Impact delay time ............................................................................................. 101
4.3.1.2.6................................................................................................................................ xx
4.3.1.2.7................................................................................................................................ xx
4.3.1.3. Calibration .......................................................................................................................... 102
8
Index
4.3.1.3.1.Single parameters ............................................................................................. 102
4.3.1.3.2.Data set calibration........................................................................................... 104
4.3.1.3.3.Save modified parameter set........................................................................... 105
4.3.1.3.4.Convert modified parameter set..................................................................... 106
4.3.1.4. Program protection ........................................................................................................... 107
4.3.2. Stardiagnose.................................................................................................................................... 107
4.3.3. ServiceLink...................................................................................................................................... 108
4.4. Diagnosis routines........................................................................................................................109
4.4.1. Detailed testing routines ................................................................................................................ 109
4.5. Backup............................................................................................................................................110
4.5.1. System backup capability .............................................................................................................. 110
4.5.1.1. Microprocessor 1-backup................................................................................................. 110
4.5.1.1.1.Crankshaft backup............................................................................................ 110
4.5.1.1.2.Camshaft backup .............................................................................................. 110
4.5.1.1.3.CAN-backup (definition).................................................................................. 110
4.5.1.1.4.CAN-backup, mode 0 (standard-backup) ...................................................... 111
4.5.1.1.5.CAN-backup, mode 1........................................................................................ 112
4.5.1.1.6.CAN-backup, mode 2........................................................................................ 112
4.5.1.1.7.CAN data-area check ........................................................................................ 112
4.5.1.1.8.Nominal engine speed CAN-backup .............................................................. 112
4.5.1.1.8.1.Nominal engine speed CAN-backup mode 0.......................... 112
4.5.1.1.8.2.Nominal engine speed CAN-backup mode 1.......................... 113
4.5.1.2. Microprocessor 2-backup................................................................................................. 113
4.5.2. Backup functions............................................................................................................................ 114
4.5.2.1. Ambient pressure sensor................................................................................................. 114
4.5.2.2. Boost pressure control...................................................................................................... 114
4.5.3. Sensor-replacement values............................................................................................................ 114
4.5.3.1. Plausibility limits and sensor replacement values ..................................................... 114
4.5.4. Diagnosis of sensor and backup functions ................................................................................. 115
4.5.4.1. Temperature and presure sensors.................................................................................. 115
4.5.4.2. Crankshaft sensor ............................................................................................................. 115
4.5.4.3. Camshaft sensor (cylinder 1 recognition)..................................................................... 116
4.5.5. Diagnosis of actuators ................................................................................................................... 117
4.5.5.1. MR-PLD injector-/magnetic valves (MV)....................................................................... 117
4.5.5.2. MR-PLD proportional valves............................................................................................ 118
4.5.5.3. Starter control .................................................................................................................... 118
4.6. Fault codes & repair instructions............................................................................................... 119
4.6.1. Fault codes ...................................................................................................................................... 119
4.6.1.1. Fault priority 0 ................................................................................................................... 119
4.6.1.2. Fault priority 1 ................................................................................................................... 119
4.6.1.3. Fault priority 2 ................................................................................................................... 119
4.6.2. Fault path ........................................................................................................................................ 120
4.6.3. Fault type ........................................................................................................................................ 122
4.6.4. Fault codes und repair instructions, high priority ................................................................... 124
4.6.5. Fault codes und repair instructions, mean priority.................................................................. 125
4.6.6. Fault codes und repair instructions, minor priority................................................................. 134
4.6.7. ............................................................................................................................................................ xx
4.6.8. ............................................................................................................................................................ xx
4.7. Special measurements..................................................................................................................138
4.7.1. General information ....................................................................................................................... 138
4.7.2. Actuators ..........................................................................................................................................138
4.7.2.1. Solenoid valves: Current modulation curve of the injector valve control/type 1.. 138
4.7.2.2. Solenoid valves: Current modulation curve of the injector valve control/ type 2.. 140
4.7.2.3. ................................................................................................................................................ xx
4.7.3. ............................................................................................................................................................ xx
9
Index
5. Parameters (minidiag2)............................................................................... 142
5.1. MR-PLD Diagnosis version 3 to 5 (up-/download)...................................................................142
5.2. MR-PLD Diagnosis from version 6 (single parameters)..........................................................146

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