Trucks • Diagnostics Technician <>

Powertrain • Specialist Training <<>>

Evaluation Actual Values

Trucks
Diagnostics Technician
Powertrain • Specialist Training
Evaluation Actual Values

As at 01/04
This document is intended solely for use in training and is not subject to regular updating.

Printed in Germany Note:

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1511 1372 02 - 1st edition 01.04 22 As at 01/04

Content 14.10.2004

Title Page

Welcome ..................................................................................................................................................................................................................................................1
FR, Evaluation of Actual Values ...............................................................................................................................................................................................................2
GS II (Code GS7), Evaluation of Actual Values GS II / FR; Exercise ........................................................................................................................................................9

01/04 Trucks • Diagnostics Technician <> Powertrain • Specialist Training <<>> Evaluation Actual Values
Content I 1
01/04 Trucks • Diagnostics Technician <> Powertrain • Specialist Training <<>> Evaluation Actual Values
Content I 2
Welcome 14.10.2004

With the introduction of the ACTROS Type 950-

954, the first step was made towards linking the
individual systems in a network.
The introduction of the ACTROS Type 930-934
represents a further development.
The individual systems are linked more strongly
than before.

The technology as well as the individual

components are becoming more and more
complex.

You have certainly felt this in your everyday work

in the past.

This means for you that replacing components on

a "trial and error" basis is very time and cost
intensive.
It is all the more important, therefore, to correctly
understand the actual values available and
identify relationships and wrong conclusions.

This is what the exercises included in this training

document are meant to achieve.

We hope you enjoy them!

N26.00-2025-06

01/04 Trucks • Diagnostics Technician <> Powertrain • Specialist Training <<>> Evaluation Actual Values
Welcome 1
FR, Evaluation of Actual Values 14.10.2004

A Information On the basis of these FR actual values from the DAS report, evaluate the existing situation!

Actual Values FR
No. Name Actual Unit No. Name Actual Unit
001 Foot Drive Sensor, first branch 20 % 064 Start Lock No
002 Foot Drive Sensor, second branch 18 % 069 Idle Yes
003 Drive Pedal Torque 0 Nm 070 Kickdown No
004 Vehicle Speed 0 km/h 073 Status ADR No
009 Engine Speed - MR Engine Control 564 1/min 074 Status Cruise Control No
014 Target Engine Torque 0 Nm 075 Status Speed Set No
015 Actual Engine Torque (MR Engine Control) 600 Nm 082 Clutch Closed Yes
016 Clutch Travel Sensor - Actual 1 % 083 Clutch Open No
017 Transmission Input Speed 564 1/min 087 Pos. Operation Lever "Engine Control/Permanent Brake" 0
018 Transmission Output Speed 0 1/min 095 Maximum Current Engine Torque 600
020 Target Retarder Torque FR Drive Control > RS Retarder St. 0 Nm 105 Selection "Shift Up" at Main Lever of Transmitter Unit No
021 Actual Retarder Torque 0 Nm 106 Selection "Shift Down" at Main Lever of Transmitter Unit No
025 Pin 15 Yes 107 Sel. "Shift Up" at Half-Gear Rocker Switch of Transm. Unit Yes
026 Engine Start Signal Pin 50 No 108 Sel. "Shift Down" at Half-Gear Rocker Sw. of Transm. Unit No
032 Activation Speed Set No 109 Position of Automatic Switch at Transmitter Unit GS No
033 Cruise Control Switch "Set and Accelerate " No 110 Signal "Neutral" of Transmitter Unit GS Gear Control No
034 Cruise Control Switch "Set and Decelerate " No 111 Quit Signal of Transmitter Unit GS Gear Control Yes
055 Transponder Identified Yes 112 Function Button on Transm. Unit GS Gear Control Pressed No
056 Control Module FR Drive Control With Immobilizer Yes 119 Emergency Drive Menu in Instrument Not Active

01/04 Trucks • Diagnostics Technician <> Powertrain • Specialist Training <<>> Evaluation Actual Values
FR, Evaluation of Actual Values 2
 Exercise / Question m Which is the operating condition of the vehicle based on the DAS report above?
Name the operating conditions that can be determined!

01/04 Trucks • Diagnostics Technician <> Powertrain • Specialist Training <<>> Evaluation Actual Values
FR, Evaluation of Actual Values 3
B Information On the basis of these FR actual values from the DAS report, evaluate the existing situation!

Actual Values FR
No. Name Actual Unit Nr. Name Actual Unit
001 Foot Drive Sensor, first branch 20 % 064 Start Lock No
002 Foot Drive Sensor, second branch 18 % 069 Idle Yes
003 Drive Pedal Torque 0 Nm 070 Kickdown No
004 Vehicle Speed 85 km/h 073 Status ADR No
009 Engine Speed - MR Engine Control 2152 1/min 074 Status Cruise Control Yes
014 Target Engine Torque 600 Nm 075 Status Speed Set No
015 Actual Engine Torque (MR Engine Control) 600 Nm 082 Clutch Closed Yes
016 Clutch Travel Sensor - Actual 0 % 083 Clutch Open No
017 Transmission Input Speed 2152 1/min 087 Pos. Operation Lever "Engine Control/Permanent Brake" 3
018 Transmission Output Speed 2152 1/min 095 Maximum Current Engine Torque 1800
020 Target Retarder Torque FR Drive Control > RS Retarder St. 950 Nm 105 Selection "Shift Up" at Main Lever of Transmitter Unit No
021 Actual Retarder Torque 948 Nm 106 Selection "Shift Down" at Main Lever of Transmitter Unit No
025 Pin 15 Yes 107 Sel. "Shift Up" at Half-Gear Rocker Switch of Transm. Unit No
026 Engine Start Signal Pin 50 No 108 Sel. "Shift Down" at Half-Gear Rocker Sw. of Transm. Unit No
032 Activation Speed Set No 109 Position of Automatic Switch at Transmitter Unit GS No
033 Cruise Control Switch "Set and Accelerate " No 110 Signal "Neutral" of Transmitter Unit GS Gear Control No
034 Cruise Control Switch "Set and Decelerate " No 111 Quit Signal of Transmitter Unit GS Gear Control No
055 Transponder Identified Yes 112 Function Button on Transm. Unit GS Gear Control Pressed No
056 Control Module FR Drive Control With Immobilizer Yes 119 Emergency Drive Menu in Instrument Not Active

01/04 Trucks • Diagnostics Technician <> Powertrain • Specialist Training <<>> Evaluation Actual Values
FR, Evaluation of Actual Values 4
 Exercise / Question m Which is the operating condition of the vehicle based on the DAS report above?
Name the operating conditions that can be determined!

-"

01/04 Trucks • Diagnostics Technician <> Powertrain • Specialist Training <<>> Evaluation Actual Values
FR, Evaluation of Actual Values 5
 Exercise / Question m On the basis of the vehicle operating condition as indicated, complete the corresponding FR actual
values in the DAS report!

C Vehicle Data ACTROS 2544, Type 930-934 with Telligent Shift II, Transmission G231 and Voith Retarder 115H.
6. Gear Split Low engaged, Engine Speed 2048 1/min, Foot Drive Sensor Not Activated, OM 501 LA with
2200 Nm, Vehicle Speed 63 km/h, Clutch Closed, Operating Lever of Permanent Brake in Level 3
Actual Values FR Actual Values MR
No. Name Actual Unit No. Name Actual Unit
001 Foot Drive Sensor, first branch % 001 Actual Engine Torque 600 Nm
002 Foot Drive Sensor, second branch % 002 Target Engine Torque 0 Nm
003 Drive Pedal Torque Nm 003 Maximum Current Engine Torque 1800 Nm
-1
004 Vehicle Speed km/h 004 Engine Speed min
009 Engine Speed - MR Engine Control 1/min 011 Coolant Temperature 86 °C
014 Target Engine Torque Nm 012 Fuel Temperature 58 °C
015 Actual Engine Torque (MR Engine Control) Nm 014 Boost Pressure 1004 bar
016 Clutch Travel Sensor - Actual % 015 Atmospheric Pressure 996 bar
017 Transmission Input Speed 1/min 028 Engine Start Sensor Not Actuated
018 Transmission Output Speed 1792 1/min 029 Engine Stop Sensor Not Actuated
020 Target Retarder Torque FR Drive Control > RS Retarder St. 696 Nm 021 Status Pin 50 at Control Module FR Drive Control Not Active
021 Actual Retarder Torque Nm 023 Status Pin 50 at Control Module MR Engine Control Not Active
025 Pin 15 Yes 042 Starter Operation Not Active
026 Engine Start Signal Pin 50 No 043 Start Lock Not Active
032 Activation Speed Set No 017 Battery Voltage 24,23 V
033 Cruise Control Switch "Set and Accelerate " 020 Status Pin 15 at Control Module FR Drive Control
034 Cruise Control Switch "Set and Decelerate " 022 Status Pin 15 at Control Module MR Engine Control
069 Idle 006 Feed Angle °
070 Kickdown 019 Vehicle Speed
087 Operating Lever "Engine Brake/Permanent Brake" 034 Engine Brake Flap

01/04 Trucks • Diagnostics Technician <> Powertrain • Specialist Training <<>> Evaluation Actual Values
FR, Evaluation of Actual Values 6
 Exercise / Question m On the basis of these FR actual values from the DAS report, evaluate the existing situation!

D Customer Complaint The customer complains about bad performance of an ACTROS 2546 L.
VIN no. WDB 930 205 .......Engine 501 948 .....Transmission 715 513 .....(G231)

Actual Values FR Actual Values MR

No. Name Actual Unit No. Name Actual Unit
001 Foot Drive Sensor, first branch 59 % 001 Actual Engine Torque 1504 Nm
002 Foot Drive Sensor, second branch 58 % 002 Target Engine Torque 2100 Nm
003 Drive Pedal Torque 2100 Nm 003 Maximum Current Engine Torque 1518 Nm
-1
004 Vehicle Speed 63 km/h 004 Engine Speed 1824 min
009 Engine Speed - MR Engine Control 1824 1/min 011 Coolant Temperature 87 °C
014 Target Engine Torque 2100 Nm 012 Fuel Temperature 61 °C
015 Actual Engine Torque (MR Engine Control) 1504 Nm 014 Boost Pressure 1236 bar
016 Clutch Travel Sensor - Actual 0 % 015 Atmospheric Pressure 992 bar
017 Transmission Input Speed 1824 1/min 028 Engine Start Sensor Not Activated
018 Transmission Output Speed 1478 1/min 029 Engine Stop Sensor Not Activated
020 Target Retarder Torque FR Drive Control > RS Retarder St. 0 Nm 021 Status Pin 50 at Control Module FR Drive Control Not Active
021 Actual Retarder Torque 0 Nm 023 Status Pin 50 at Control Module MR Engine Control Not Active
025 Pin 15 Yes 042 Starter Operation Not Active
026 Engine Start Signal Pin 50 No 043 Start Lock Not Active
032 Activation Speed Set No 017 Battery Voltage 24,23 V
033 Cruise Control Switch "Set and Accelerate " No 020 Status Pin 15 at Control Module FR Drive Control Active
034 Cruise Control Switch "Set and Decelerate " No 022 Status Pin 15 at Control Module MR Engine Control Active
055 Transponder Identified Yes 006 Feed Angle 118 °
056 Control Module FR Drive Control With Immobilizer Yes 019 Vehicle Speed Not Active
069 Idle No 034 Engine Brake Flap Active
070 Kickdown Yes 040 Warning Buzzer No

01/04 Trucks • Diagnostics Technician <> Powertrain • Specialist Training <<>> Evaluation Actual Values
FR, Evaluation of Actual Values 7
 Exercise / Question m On the basis of the actual values in the report, what could be the cause for the bad performance of
the ACTROS! If possible, name more than one failure source!

Exercise / Question m Explain the relationship between possible failure sources and the customer complaint!

01/04 Trucks • Diagnostics Technician <> Powertrain • Specialist Training <<>> Evaluation Actual Values
FR, Evaluation of Actual Values 8
GS II (Code GS7), Evaluation of Actual Values GS II / FR; Exercise 14.10.2004

E Information On the basis of these GS actual values in the DAS report, evaluate the existing situation!

Actual Values GS II
No. Name Actual Unit No. Name Actual Unit
030 Travel Percentage Value "Split" 0 % 021 Countershaft Speed B3 0 1/min
031 Travel Percentage Value "Gear" 1 % 022 Transmission Output Speed D3 0 1/min
032 Travel Percentage Value "Gate" 100 % 055 Counter "Gear Cancell. When Switching into Neutral Pos." 12
033 Travel Percentage Value "Range" 1 % 056 Counter "Gear Cancellations When Sw. intoTarget Gear" 12
034 Travel Percentage Value "Clutch" 1 % 130 Counter Gate Cancellations 7
035 Travel Value Split 999 counts 131 Counter Range Cancellations 1
036 Travel Value Gear 167 counts 132 Counter Split Cancellations 1
037 Travel Value Gate 2012 counts 134 Counter Clutch Cancellations 0
038 Travel Value Range 1042 counts 135 Counter Clutch Cancellations (Gear "slips" in) 5
039 Travel Value Clutch 969 counts 136 Counter Gear Cancell. Due to Mechanical or Sensor Error 34
040 Learning Value "Split, Position Slow " 998 counts 156 Actual Gear 3. Gear, Split L

041 Learning Value "Split, Position Fast " 1272 counts 157 Target Gear 2. Gear, Split L

042 Learning Value "Gear Cylinder, Gear Odd " 157 counts 220 Engine Speed 0 1/min
043 Learning Value Gear Cylinder, Position Neutral 913 counts 221 Transmission Input Speed 0 1/min
044 Learning Value "Gear Cylinder, Position Gear Even " 1558 counts 223 Clutch Status Closed
045 Learning Value Gate Cylinder Position Reverse Gear 1030 counts 226 Maximum Current Engine Torque 2160 Nm
047 Learning Value Gate Cylinder Position Gate 1./2. Gear 1488 counts 228 Voltage Supply Pin 15 2425 mV
048 Learning Value Gate Cylinder Position Gate 3./4. Gear 2007 Counts 283 Construction Site Function Active
049 Learning Value Range Slow 1040 Counts 299 Engine Status Running
050 Learning Value Range Fast 2599 Counts 303 Retarder Not Active
051 Learning Value "Clutch Open " 475 counts 305 Switch "Differential Lock" Active
28 Learning Value "Clutch Closed " 967 counts 308 GS Substitute Operation Not Active

01/04 Trucks • Diagnostics Technician <> Powertrain • Specialist Training <<>> Evaluation Actual Values
GS II (Code GS7), Evaluation of Actual Values GS II / FR; Exercise 9
 Exercise / Question m Based on the DAS report above, which vehicle operating condition exists?
Name the operating conditions that can be determined!

01/04 Trucks • Diagnostics Technician <> Powertrain • Specialist Training <<>> Evaluation Actual Values
GS II (Code GS7), Evaluation of Actual Values GS II / FR; Exercise 10
F Information On the basis of these GS actual values in the DAS report, evaluate the existing situation!

Actual Values FR Actual Values GS II

No. Name Actual Unit No. Name Actual Unit
001 Foot Drive Sensor, first branch 45 % 021 Countershaft Speed B3 1089 1/min
002 Foot Drive Sensor, second branch 43 % 022 Transmission Output Speed D3 1152 1/min
003 Drive Pedal Torque 1456 Nm 055 Counter "Gear Cancell. When Switching into Neutral Pos." 12
004 Vehicle Speed 64 km/h 056 Counter "Gear Cancellations When Sw. intoTarget Gear" 12
009 Engine Speed - MR Engine Control 1264 1/min 130 Counter Gate Cancellations 7
014 Target Engine Torque 1456 Nm 131 Counter Range Cancellations 1
015 Actual Engine Torque (MR Engine Control) 1448 Nm 132 Counter Split Cancellations 1
016 Clutch Travel Sensor - Actual 1 % 134 Counter Clutch Cancellations 0
020 Target Retarder Torque FR Drive Control > RS Retarder St. 0 Nm 135 Counter Clutch Cancellations (Gear "slips" in) 5
025 Pin 15 Yes 136 Counter Gear Cancell. Due to Mechanical or Sensor Error 34
026 Engine Start Signal Pin 50 No 156 Actual Gear 7. Gear, Split L

055 Transponder Identified Yes 157 Target Gear 8. Gear, Split L

056 Control Module FR Drive Control With Immobilizer Yes 220 Engine Speed 1264 1/min
095 Maximum Current Engine Torque 1800 Nm 221 Transmission Input Speed 1264 1/min
105 Selection "Shift Up" at Main Lever of Transmitter Unit Yes 223 Clutch Status Closed
106 Selection "Shift Down" at Main Lever of Transmitter Unit No 226 Maximum Current Engine Torque 2160 Nm
107 Sel. "Shift Up" at Half-Gear Rocker Switch of Transm. Unit No 228 Voltage Supply Pin 15 2425 mV
108 Sel. "Shift Up" at Half-Gear Rocker Switch of Transm. Unit No 283 Construction Site Function Not Active
109 Position of Automatic Switch at Transmitter Unit GS No 299 Engine Status Running
110 Signal "Neutral" of Transmitter Unit GS Gear Control No 303 Retarder Not Active
111 Quit Signal of Transmitter Unit GS Gear Control Yes 305 Switch "Differential Lock" Not Active
112 Function Button on Transm. Unit GS Gear Control Pressed Yes 308 GS Substitute Operation Not Active

01/04 Trucks • Diagnostics Technician <> Powertrain • Specialist Training <<>> Evaluation Actual Values
GS II (Code GS7), Evaluation of Actual Values GS II / FR; Exercise 11
 Exercise / Question m Based on the DAS report above, which vehicle operating condition exists?
Name the operating conditions that can be determined!

01/04 Trucks • Diagnostics Technician <> Powertrain • Specialist Training <<>> Evaluation Actual Values
GS II (Code GS7), Evaluation of Actual Values GS II / FR; Exercise 12
 Exercise / Question m On the basis of the vehicle operating condition indicated, complete the corresponding GS actual
values in the DAS report!

G Vehicle Data ACTROS 2544, Type 930-934 with Telligent Shift II, Transmission G231 and Voith Retarder 115H.
6. Gear Split Low engaged, Engine Speed 1456 1/min, Foot Drive Sensor activated appr. 50%, slight
uphill slope; Vehicle Speed 63 km/h, OM 501 LA with 2200 Nm, Clutch Closed, Vehicle Unloaded

No. Name Actual Unit No. Name Actual Unit

001 Foot Drive Sensor, first branch % 156 Actual Gear
002 Foot Drive Sensor, second branch % 221 Transmission Input Speed 1/min
003 Drive Pedal Torque Nm 223 Clutch Status
004 Vehicle Speed km/h 226 Maximum Current Engine Torque 2160 Nm
009 Engine Speed - MR Engine Control 1/min 283 Construction Site Function Not Active
014 Target Engine Torque Nm 035 Travel Value Split counts
015 Actual Engine Torque (MR Engine Control) Nm 036 Travel Value Gear counts
016 Clutch Travel Sensor - Actual % 037 Travel Value Gate counts
017 Transmission Input Speed 1178 1/min 038 Travel Value Range counts
018 Transmission Output Speed 1036 1/min 039 Travel Value Clutch counts
020 Target Retarder Torque FR Drive Control > RS Retarder St. 0 Nm 040 Learning Value "Split, Position Slow " 998 counts
021 Actual Retarder Torque 0 Nm 041 Learning Value "Split, Position Fast " 1272 counts
025 Pin 15 Yes 042 Learning Value "Gear Cylinder, Gear Odd " 157 counts
026 Engine Start Signal Pin 50 No 043 Learning Value Gear Cylinder, Position Neutral 913 counts
032 Activation Speed Set No 044 Learning Value "Gear Cylinder, Position Gear Even " 1558 counts
033 Cruise Control Switch "Set and Accelerate " No 045 Learning Value Gate Cylinder Position Reverse Gear 1030 counts
034 Cruise Control Switch "Set and Decelerate " No 047 Learning Value Gate Cylinder Position Gate 1./2. Gear 1488 counts
055 Transponder Identified Yes 048 Learning Value Gate Cylinder Position Gate 3./4. Gear 2007 Counts
056 Control Module FR Drive Control With Immobilizer Yes 049 Learning Value Range Slow 1040 Counts
069 Idle 050 Learning Value Range Fast 2599 Counts
070 Kickdown 051 Learning Value "Clutch Open " 475 counts
087 Pos. Operating Lever "Engine Control/Permanent Brake" 0 28 Learning Value "Clutch Closed " 967 counts

01/04 Trucks • Diagnostics Technician <> Powertrain • Specialist Training <<>> Evaluation Actual Values
GS II (Code GS7), Evaluation of Actual Values GS II / FR; Exercise 13
 Exercise / Question m On the basis of these GS actual values in the DAS report, evaluate the existing situation!

H Customer Complaint The customer complains about problems with shifting on an ACTROS 2546 L.
VIN no. WDB 930 205 .......Engine 501 948 .....Transmission 715 513 .....(G231)

No. Name Actual Unit No. Name Actual Unit

030 Travel Percentage Value "Split" 100 counts 021 Countershaft Speed B3 486 1/min
031 Travel Percentage Value "Gear" 55 counts 022 Transmission Output Speed D3 0 1/min
032 Travel Percentage Value "Gate" 49 counts 024 Shifting Time Split 95 ms
033 Travel Percentage Value "Range" 100 counts 025 Shifting Time Engage Gear 475 ms
034 Travel Percentage Value "Clutch" 1 counts 026 Shifting Time Disengage Gear 0 ms
035 Travel Value Split 1274 counts 027 Shifting Time Gate 105 ms
036 Travel Value Gear 925 counts 229 Synchronization Time Gear 78 ms
037 Travel Value Gate 1488 counts 055 Counter "Gear Cancell. When Switching into Neutral Pos." 50
038 Travel Value Range 1040 counts 056 Counter "Gear Cancellations When Sw. intoTarget Gear" 64
039 Travel Value Clutch 970 counts 130 Counter Gate Cancellations 7
040 Learning Value "Split, Position Slow " 998 counts 131 Counter Range Cancellations 1
041 Learning Value "Split, Position Fast " 1272 counts 132 Counter Split Cancellations 1
042 Learning Value "Gear Cylinder, Gear Odd " 157 counts 134 Counter Clutch Cancellations 0
043 Learning Value Gear Cylinder, Position Neutral 913 counts 135 Counter Clutch Cancellations (Gear "slips" in) 5
044 Learning Value "Gear Cylinder, Position Gear Even " 1558 counts 136 Counter Gear Cancell. Due to Mechanical or Sensor Error 128
045 Learning Value Gate Cylinder Position Reverse Gear 1030 counts 156 Actual Gear Neutral
047 Learning Value Gate Cylinder Position Gate 1./2. Gear 1488 counts 220 Engine Speed 564 1/min
048 Learning Value Gate Cylinder Position Gate 3./4. Gear 2007 Counts 221 Transmission Input Speed 564 1/min
049 Learning Value Range Slow 1040 Counts 223 Clutch Status Closed
050 Learning Value Range Fast 2599 Counts 226 Maximum Current Engine Torque 2160 Nm
051 Learning Value "Clutch Open " 475 counts 228 Voltage Supply Pin 15 2425 mV
28 Learning Value "Clutch Closed " 967 counts 308 GS Substitute Operation Not Active

01/04 Trucks • Diagnostics Technician <> Powertrain • Specialist Training <<>> Evaluation Actual Values
GS II (Code GS7), Evaluation of Actual Values GS II / FR; Exercise 14
 Exercise / Question m Based on the actual values present, what could be the cause for the shifting difficulties on the
ACTROS! If possible, name more than one reason!

Exercise / Question m Explain the relationship between the possible causes of the problem and the customer complaint!

01/04 Trucks • Diagnostics Technician <> Powertrain • Specialist Training <<>> Evaluation Actual Values
GS II (Code GS7), Evaluation of Actual Values GS II / FR; Exercise 15
» ... 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

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1511 1372 02 1st edition 01.04 22