MBE 900 4000 Troubleshooting - Section 2.2 Pld-Mr – Engine-Resident Control Unit

Section 2.2
Pld-Mr – Engine-Resident Control Unit

The PLD-MR monitors and determines all values which are required for the operation of the engine.‪

The PLD-MR control unit (see Figure "DDEC-ECU" ) is located on the left-hand side of the engine.‪

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Figure 1. PLD-MR Control Unit on Engine

The PLD-MR processes the data received from the DDEC-VCU for engine control management.‪

The data is then compared to the parameters stored in the PLD-MR.‪

From these data, quantity and timing of injection are calculated and the unit pumps are actuated accordingly through the solenoid valves.‪

The part numbers for the PLD-MR versions in production in NAFTA are listed in Table "PLD-MR Part Numbers and Software Versions" .‪

PLD-MR‪	Part Number‪	Software Version‪
D21‪	000 446 78 40‪	Rel. 53 (12/24 V), 4 cylinder‪
D21‪	000 446 74 40‪	Rel. 53 (12/24 V), 6 cylinder‪
D3‪	000 446 85 40‪	Rel. 56 (12/24 V), 4 cylinder‪
D3‪	000 446 84 40‪	Rel. 56 (12/24 V), 6 cylinder‪

Table 1. PLD-MR Part Numbers and Software Versions

Note: To obtain a replacement control unit, all the data given on the control unit data plate are required (see Figure "PLD-MR Control Unit Data Plate" ).

Figure 2. PLD-MR Control Unit Data Plate

Section 2.2.1
Environmental Conditions

Temperature, atmospheric conditions, and vibration must be considered. The PLD-MR is resistant to all fluids and toxic gases occurring in the engine compartment.‪

Section 2.2.1.1
Temperature

The ambient operating temperature range is -40 to 125°C (-40 to 257°F).‪

Section 2.2.1.2
Vibration

The vibration load for the PLD-MR is maximum 3 g at 10 Hz – 1000 Hz with damping elements.‪

Section 2.2.1.3
Water Intrusion

The PLD-MR can be exposed to steam cleaning and pressure washing. Care should be taken not to pressure spray the connectors.‪

Section 2.2.2
Engine Sensor Harness

The Engine Sensor Harness (ESH) is factory installed and delivered connected to the engine sensors and the PLD-MR. See Figure "Typical On-Highway MBE 900 Engine Harness — Non-EGR Engine" and Figure "Typical On-Highway MBE 900 Six-cylinder Engine Harness — EGR Engine" for the MBE 900 ESH for non-EGR and EGR engines. See Figure "Typical MBE 4000 Engine Harness — Non-EGR Engine" for the MBE 4000 ESH (non-EGR).‪

Figure 3. Typical On-Highway MBE 900 Engine Harness — Non-EGR Engine

Figure 4. Typical On-Highway MBE 900 Six-cylinder Engine Harness — EGR Engine

Figure 5. Typical MBE 4000 Engine Harness — Non-EGR Engine

The wiring for the 55-pin ESH connector to the PLD-MR is listed in Table "Engine Harness – Pins 0–27" , Table "Engine Harness – Pins 28–50" and Table "Engine Harness – Pins 51–54" . The side of the connector shown is looking into the pins.‪

Pin‪	Wire Color‪		Signal Type‪	Function‪	Connector‪
Pin‪	900‪	4000‪	Signal Type‪	Function‪	Connector‪
0‪	N/A‪	N/A‪	Digital Input‪	Oil Separator Diagnosis‪	Front‪ Looking into the Pins‪
1‪	Blk/Yel‪	Blk/Yel‪	Sensor Return‪	Camshaft Position (CMP) Sensor (-)‪
2‪	Blk/Vio‪	Blk/Vio‪	Sensor Return‪	Crankshaft Position (CKP) Sensor (-)‪
3‪	Wht/Yel‪	Wht/Yel‪	Sensor Return‪	Engine Coolant Temp Sensor‪
4‪	Brn/Grn‪	Brn/Grn‪	Sensor Return‪	Supply Fuel Temp Sensor‪
5‪	N/A‪	Grn/Wht‪	Sensor Return‪	Passive Engine Oil Press / Booster / Fan Speed Sensor‪
6‪	Brn/Gra‪	Wht/Blk‪	Sensor Supply‪	Active Engine Oil Press Sensor‪
7‪	Grn‪	Grn‪	Sensor Supply‪	Intake Manifold Press Sensor‪
8‪	N/A‪	N/A‪	Frequency Input‪	Turbo Speed No. 2 Sensor‪
9‪	Red/Blu‪	Red/Blu‪	Injector Return‪	Injector Valves Bank 2‪ (B - D - F - H)‪
10‪	Gra/Yel‪	N/A‪	Sensor Return‪	Active Engine Oil Press Sensor Alternative Oil Combination Sensor, each w/ Speed Sensor‪
11‪	N/A‪	Brn/Wht‪	Output Return‪	Proportional Valve - Ground‪
12‪	Red/Blk‪	Brn/Red‪	Output Supply‪	Proportional Valve Bank (PV 1 - 4)*‪
13‪	N/A‪	N/A‪	Sensor Supply‪	Optional Fuel Press / P3‪
14‪	N/A‪	N/A‪	Sensor Supply‪	Scavenging Gradient Sensor / Fan Speed Sensor‪
15‪	Brn/Wht‪	Gra/Yel‪	Sensor Return‪	Engine Oil Temp / Scavenging Gradient Sensor‪
16‪	Red/Grn‪	Red/Grn‪	Injector Return‪	Injector Valve Bank 1‪ (A - C - E - G)‪
17‪	N/A‪	N/A‪	Frequency Input‪	Fan Speed Sensor‪
18‪	N/A‪	N/A‪	High Side Control Output‪	Starter‪
19‪	Brn/Vio‪	Brn/Vio‪	Frequency Input‪	CKP Sensor (+)‪
20‪	Brn/Yel‪	Brn/Yel‪	Frequency Input‪	CMP Sensor (+)‪
21‪	Grn/Yel‪	N/A‪	Sensor Return‪	Intake Manifold Temp Sensor‪
22‪	N/A‪	N/A‪	Sensor Return‪	Optional Fuel Pressure‪
23‪	N/A‪	Blu‪	Sensor Return‪	Intake Manifold Press Sensor‪
24‪	N/A‪	Grn/Vio‪	Frequency Input‪	Turbo Speed No. 1 Sensor‪
25‪	N/A‪	N/A‪	Digital Input‪	Service Engine Switch - Start‪
26‪	‪	‪	Digital Input‪	Passive Engine Oil Press Sensor‪
27‪	N/A‪	N/A‪	High Side Control‪	Proportional Valve 5‪

Table 2. Engine Harness – Pins 0–27

Pin‪	Wire Color‪		Signal Type‪	Function‪	Connector‪
Pin‪	900‪	4000‪	Signal Type‪	Function‪	Connector‪
28‪	N/A‪	N/A‪	Analog Input‪	Optional Fuel Pressure‪	Front‪ Looking into the Pins‪
29‪	Vio‪	Vio‪	Analog Input‪	Intake Manifold Pressure Sensor‪
30‪	N/A‪	N/A‪	Sensor Supply‪	Service Engine Switch (Start/Stop)‪
31‪	N/A‪	N/A‪	Analog Input‪	Optional Press Gradient (Boost/Exhaust)‪
32‪	Grn/Blu‪	Brn/Gra‪	Analog Input‪	Active Engine Oil Press Sensor‪
33‪	Wht‪	Wht‪	Analog Input‪	Engine Oil Level (EOL) Sensor‪
34‪	Red/Yel‪	Red/Yel‪	Analog Input‪	Engine Coolant Temp Sensor‪
35‪	N/A‪	N/A‪	Digital Input‪	Service Engine Switch - Stop‪
36‪	Brn/Blu‪	Brn/Blu‪	Analog Input‪	Supply Fuel Temp Sensor‪
37‪	N/A‪	N/A‪	Injector Output – High Side‪	Injector/Solenoid Valve H‪
38‪	Wht/Blu‪	Wht/Blu‪	Injector Output – High Side‪	Injector/Solenoid Valve F‪
39‪	Gra/Brn‪	Gra/Brn‪	Analog Input‪	Engine Oil Temp Sensor‪
40‪	N/A‪	Brn/Blk‪	PWM/Digital Output – Low Side‪	Proportional Valve 6‪
41‪	Blu/Wht‪	Red‪	PWM/Digital Output – Low Side‪	Proportional Valve 3‪
42‪	N/A‪	Blu/Blk‪	Sensor Supply‪	Proportional Valve 6‪
43‪	Blu/Red‪	Blk/Wht‪	PWM/Digital Output – Low Side‪	Proportional Valve 4*‪
44‪	Gra/Yel‪	Wht/Blu‪	Injector Output – High Side‪	Injector/Solenoid Valve D‪
45‪	Gra/Vio‪	Gra/Grn‪	Injector Output – High Side‪	Injector/Solenoid Valve B‪
46‪	N/A‪	N/A‪	Injector Output – High Side‪	Injector/Solenoid Valve G‪
47‪	Gra/Blu‪	Gra/Vio‪	Injector Output – High Side‪	Injector/Solenoid Valve E‪
48‪	Brn‪	Brn‪	Analog Input‪	Intake Manifold Temp Sensor‪
49‪	Yel‪	Yel‪	Sensor Return‪	EOL Sensor‪
50‪	Grn/Wht‪	Gra/Vio‪	PWM/Digital Output – Low Side‪	Proportional Valve 2‪

Table 3. Engine Harness – Pins 28–50

Pin‪	Wire Color‪		Signal Type‪	Function‪	Connector‪
Pin‪	900‪	4000‪	Signal Type‪	Function‪	Connector‪
51‪	Red/Wht‪	Wht/Red‪	PWM/Digital Output – Low Side‪	Proportional Valve 1‪	Front‪ Looking into the Pins‪
52‪	Brn/Red‪	Gra/Vio‪	Output Supply‪	Proportional Valve 2‪
53‪	Gra/Grn‪	Gra/Blu‪	Injector Output – High Side‪	Injector/Solenoid Valve C‪
54‪	Gra/Blk‪	Gra/Blk‪	Injector Output – High Side‪	Injector/Solenoid Valve A‪

Table 4. Engine Harness – Pins 51–54

Section 2.2.3
Power Supply

‪

Note: The PLD-MR and DDEC-VCU must be powered from the same battery voltage source.

The voltage supply for the PLD-MR is listed in Table "PLD-MR Voltage Supply" .‪

Voltage Supply‪	Voltage Version‪
Voltage Supply‪	24 V‪	12 V‪
Nominal Voltage‪	22 V ≤ V≤ 30 V‪	11 V ≤ V≤ 16 V‪
Low Voltage‪	8 V ≤ V≤ 22 V‪ Limited Operating Range‪	6.5 V ≤ V≤ 11 V‪ Limited Operating Range‪
Overload Switch-off‪	V > 33 V‪	V > 33 V‪

Table 5. PLD-MR Voltage Supply

The polarity/overload protection for the PLD-MR is listed in Table "PLD-MR Polarity/Overload Protection" .‪

Polarity/Overload Protection‪	Voltage Version‪
Polarity/Overload Protection‪	24 V‪	12 V‪
Polarity Protection‪	Continuous polarity of battery (+) and battery (-) without damage of system‪	Continuous polarity of battery (+), battery (-) and ignition without damage of system‪
Overload Resistance‪	58 V‪	58 V‪
Overload Resistance‪	100 V (see SAE J1455)‪	100 V (see SAE J1455)‪

Table 6. PLD-MR Polarity/Overload Protection

The current consumption for the PLD-MR is listed in Table "PLD-MR Current Consumption" .‪

Current Consumption‪	Voltage Version‪
Current Consumption‪	24 V‪	12 V‪
Peak Power Consumption‪ (without solenoid drivers)‪	8.0 A cyclic, depending on engine rpm and series‪	12.5 A cyclic, depending on engine rpm and series‪
Standby Voltage Supply‪ (ignition off and after completion backup phase)‪	I < 1 mA‪	I < 1 mA‪

Table 7. PLD-MR Current Consumption

The short circuit recognition thresholds for the PLD-MR are listed in Table "PLD-MR Short Circuit Recognition Thresholds" .‪

Short Circuit Recognition Thresholds‪	Voltage Version‪
Short Circuit Recognition Thresholds‪	24 V‪	12 V‪
Ground Short‪	20 A‪	20 A‪
Starter to Ground‪	2.5 A‪	2.5 A‪
Solenoid Valve to Return Line‪	32 A‪	32 A‪
Proportional Valve Supply to Ground‪	14 A‪	14 A‪
Proportional Valve to Ground *‪	2 A‪	2 A‪

Table 8. PLD-MR Short Circuit Recognition Thresholds

* Open circuit fault greater than 40 kΩ resistance

Section 2.2.4
Fuses

‪

A Battery (+) fuse and an ignition circuit fuse must be provided by the vehicle wiring harness. Blade-type automotive fuses are normally utilized; however, manual or automatic reset circuit breakers which meet the following requirements are also acceptable. The fuse voltage rating must be compatible with the PLD-MR's maximum voltage of 32 volts. ‪

The ignition fuse current rating must be sized for the loads utilized in each application; however, a rating of between 5 and 10 amps is usually sufficient.‪

The Battery (+) fuse current rating must satisfy two criteria:‪

Must not open during normal operation
Must open before the PLD-MR is damaged during a reverse battery condition

Bussmann ATC-40 and Delphi Packard Electric Systems MaxiFuse 40 amp rated fuses or equivalent will satisfy these requirements. Acceptable blow times versus current and temperature derating characteristics are listed in listed in Table "Fuse Current and Blow Time" and listed in Table "Fuse Temperature and Current" .‪

% of Rated Fuse Current‪	Minimum Blow Time‪	Maximum Blow Time‪
100%‪	100 hours‪	-‪
135%‪	1 minute‪	30 minutes‪
200%‪	6 seconds‪	40 seconds‪

Table 9. Fuse Current and Blow Time

Temperature‪	% of Rated Fuse Current‪
-40°C (-40°F)‪	110% max‪
+25°C (+77°F)‪	100%‪
+120°C (+248°F)‪	80% min‪

Table 10. Fuse Temperature and Current

Section 2.2.5
Proportional Valve Control

The proportional valve control on the PLD-MR controls external setting and switching elements. The output function of the proportional valves is determined by the configuration. The outputs of the control unit can be configured as pulse width modulated (PWM) or digital outputs. The proportional valve control outputs can be enabled or disabled by minidiag2.‪

The output function of the proportional valves is listed in Table "Proportional Valves" .‪

Valve‪	Signal‪	Function MBE 900 Non-EGR Engine‪	Function MBE 900 EGR Engine‪	Function MBE 4000 EGR Engine‪	Low Side Control Pin‪	Power Supply Pin‪ (Switched V Bat)‪
PV1‪	PWM/Digital Output‪	Exhaust Flap or Wastegate‪	Exhaust Flap or Wastegate‪	Wastegate‪	55/51‪	55/12‪
PV2‪	PWM/Digital Output‪	Compression Brake‪	EGR Valve‪	EGR Valve‪	55/50‪	55/52‪
PV3‪	PWM/Digital Output‪	Fan 1‪	Fan 1‪	Fan 1‪	55/41‪	55/12‪
PV4‪	PWM/Digital Output‪	Fan 2‪	Fan 2‪	Fan 2‪	55/43‪	55/12‪
PV5‪	PWM/Digital Output‪	Unused‪	Compression Brake‪	Compression Brake‪	55/11 – Ground‪	55/27 — High Side Control‪
PV6‪	PWM/Digital Output‪	Unused‪	Grid Heater‪	Turbo Brake or Exhaust Flap‪	55/40‪	55/42‪

Table 11. Proportional Valves

Section 2.2.6
Connectors

See Figure "PLD-MR Connectors" for the connectors to the PLD-MR.‪

Figure 6. PLD-MR Connectors

MBE 900/4000 Troubleshooting Guide - 6SE422

Generated on 10-13-2008

MBE 900 4000 Troubleshooting – Section 2.2 Pld-Mr – Engine-Resident Control Unit