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Powertrain; Electrical

Chassis, Running Gear

Technical Notes

Diagnostic Engine Analyzer/Tester (Traditional/Standard)

NOTES, REQUIREMENTS, INFORMATION, ETC.

Engine analyzers/testers provide digital scope technology with storage memory capability (to allow identification of intermittent faults in the ignition system), compression testing by measurement of the starter current (starter current consumption per cylinder), as well as direct lambda test signal measurement, etc. The start-of-delivery measurement via RI adapter is possible using MB Special Tools.

User training is required for utilization of the test possibilities. Due to developments in diagnostic options and in the relative significance of specific malfunctions, the engine idle quality (or engine smooth-running test) has continued to gain in importance.

HHT
The HHT (Hand-Held Tester) and engine analyzer unit are mutually complementary in the field of troubleshooting work.
For intermittent misfires (combustion faults) in particular, workshops will have to continue resorting to the capabilities of the on-board diagnostic system and/or the engine analyzer (with digital memory storage) in the foreseeable future. However, it is also conceivable that the continuing development of on-board diagnostics (e.g. analysis of engine roughness) will permit the reduction in the complexity of the future diagnostic devices.

Engines M 111, M 104:
The Hand-Held Tester (HHT) and Star Diagnosis System (SDS) can monitor and store in its memory malfunction information on rpm, coolant temperature, ignition angle, lambda oxygen number, voltage at 02 probe, and injection time as values. It can also provide real time data on electrical faults at the injector and in the ignition (not intermittent faults). It is also possible to read out stored faults using the pulse counter. Engine specific adapters is required in order to fully utilize the testing intensity of the engine analyzer.

Engine M 119 and M 120 without 9-pin engine diagnostic socket (as of 07.93):
A further adapter (two for the 12-cylinder engine) is required in addition to the adapter (CD1216, via Hermann/Pierburg).
With the exception of the firing-angle measurement via the TDC sensor, the functions remain the same.

Engines with ME1.0, e.g. M 119/120 (as of 09.95):
The HHT and SDS can be used to perform a cylinder-related analysis of the engine roughness. More detailed tests using engine analyzer are only possible on the conspicuous cylinder identified in by HTT (or SDS) regarding engine roughness analysis (single cylinder display on oscilloscope). The secondary adapters can be attached directly on the ignition coil. The primary voltage can be tapped via an adapter cable or socket box.

D960S (shown w/o boom) on mobile cabinet MG 820

Features: Diagnostic Engine Analyzer/Tester (Pierburg/Hermann Electronic)

Type of measurement, equipment, etc.
x = standard scope of supply --- = not available ++ = accessory	Datatest D 960 S
Rpm (including diesel with TDC sensor)	X
Lambda	X
Voltage	X
Resistance (Ohm, kOhm)	--
DC Current with clip-on probe (A)	X
Engine oil temperature (°C)	X
Pressure (bar)	++
Vacuum (mbar)	++
Connection / display, exhaust gas (CO/CO²/HC/O², rpm)	X
Digital storage memory scope	X
Scope display of sensor signals, etc.	X
Data / cylinder display. From the ignition voltage curve (kV, ms)	X
Engine Idle Quality display (graphic display of roughness)	X
Dynamic compression test via starter current	X
Rpm drop per cyl. under ignition suppression	--
Graphics printer connection	X
Cabinet, mobile	X
Testing of distributor less ignition systems (via supplied adapters)	X
External data media for non-MB vehicles	Accessory

Adapters for D960S


Adapter CD 1216 A (for M119, M120)		Adapter CD 1222 MB (for M111, M104)

Adapter CD 1223 A (for M119 (cyl. 1-8) / M120 cyl. 7-12 )		Adapter CD 1225 (for M120 cyl. 1-6 )

Primary Adapter Cable (for engines with ME 1.0)		kV Pickup ( for engines with ME 1.0; e.g. M119/120 as of 09.95 )

034 = Adapter cable (ECD 52) for vehicles without 9-pin engine diagnostic socket. The test cables (green, yellow, black) have 4mm multiple-spring wire plugs for connection to the usual signal pickup clips or for direct contacting to appropriate jacks, e.g. MB socket box, injection valve adapter CA 1217, MB electrical connection set, etc.

Typical Wave Form Patterns are shown below


Compression graph (good pattern M 102) The device displays the Vss values per cylinder.		Faulty pattern

Digital memory oscilloscope Faulty patterns ==> secondary (parade)		Faulty pattern

ENGINE TESTER - DEVELOPMENT HISTORY

NOTES, REQUIREMENTS, INFORMATION, ETC.

	The first engine testers consisted of autarkic standalone devices or special housing units collected on a common equipment cabinet. The heart of the system was an analog scope surrounded by the various dial instruments.
	The next stage of development was the transition to a uniform front panel and digital displays or a non-graphics-capable monitor screen. Digital data processing and the ability to connect a printer became increasingly common features. Connection to the vehicle was simplified by the introduction of diagnostic sockets on the vehicle side and the widespread use of electronically controlled systems. Advances in semiconductor and PC technology produced the migration to computer-based engine testers.
	The increase in sporadic, intermittent faults and developments in measurement technology resulted in computer-aided diagnostic testers. These allowed the implementation of new, cylinder-related test methods (dynamic compression test, dynamic idle-quality measurement). The analog scope was replaced by a digital storage unit with a graphics screen. A continual memory allowed intermittent faults to be detected, recorded, stored and replayed (as well as printed). External devices (e.g. exhaust gas testers, chassis dynamometers) could be connected via computer interfaces and the measured data displayed and printed.
	Optimization of system self-diagnosis (on-board) with intermittent fault detection, the HHT and Star Diagnosis System (SDS), the complexity of adapters, and the ability to display actual values with the HHT and SDS (e.g. °C, rpm, lambda), meant that the testing intensity of engine testers was no longer fully utilized. Specific cylinder assignment of intermittent engine malfunctions by vehicle on-board diagnostics resulted in single-cylinder use of the digital scope. The new generation of engine testers (HMS 990 via Hermann Electronic) was first employed in the equipment of the SDS with MT. This signal and data processor is accommodated in a compact housing and outputs the conditioned input signals to an IBM ThinkPad.
	SDS Compact was developed for mobile use. An IBM ThinkPad is housed in a plastic casing, to which the peripheral hardware is connected, e.g. "Caesar" multiplexer, the external power supply, the cables and also the HMS 990 if required. Further, with the introduction of the SDS Basic, this additional platform was introduced to provide a lower cost unit for workshops requiring multi-SDS capabilities.
	In addition to the standard engine analyzers, the modular and PC (computer-based) units provide the highest testing intensity in conjunction with comprehensive diagnosis tools. Use these at engine test bays for performing test, adjustment, troubleshooting and diagnosis work using familiar test procedures and special digital oscilloscope with signal storage of ignition voltage and speed curve (engine idle quality test per cylinder) with possibility of identifying even intermittent faults in the ignition system or the combustion process. The start-of-delivery measurement via RI adapter (MB special tool) is also possible. Graphs can also be printed out for fault documentation. Intensive user training is required for complete utilization.

STAR DIAGNOSIS Station MT and Compact

Retroactively replaces the HHT (HHT.WIN) for all vehicles model series and control modules. The new Diagnostic Assistance System (DAS) provides guided diagnosis based on decision trees for vehicles as of the W220 and beyond. Further assistance can be obtained by using the workshop Information system (WIS). In vehicles as of the W220, on-board diagnosis with the HHT is no longer possible. The IBM ThinkPad's display offers improved display capabilities over the HHT (e.g. graphics, color). In conjunction with the HMS990 test module (via Hermann Electronic), it is possible to use multimeter and engine analyzer/test functions with the Star Diagnosis System (with MT capability) and to display the results on the display of the Thinkpad. Note that to utilize the engine analyzer/test functions fully, it will be necessary to procure the additional accessory cables.

The combination of a ThinkPad with a test module to acquire, condition and transfer the test results is also possible with the SDS Compact.

With the launch of the new V6/V8 engines (M112/113) the descriptions of the diagnostic procedure, specifications, etc. were tailored/adapted specifically to suit the SDS with MT. The traditional Hermann Electronic Engine Analyzer is no longer used. The SDS with MT (Hermann Electronics HMS 990) and the additional accessory cables, may also be used on older and non-MB vehicles. However, the MB diagnostic literature is designed for the Hermann Electronics standard engine analyzer. It may therefore be advisable to continue using the standard engine analyzer for older vehicles.

The Star Diagnosis System (SDS) family (with the HMS 990 module) is absolutely essential in the workshop.


SDS Station with MT	Compact	HMS 990

Quality Assurance and Utility Value Retention

Engine analyzers feature a wide variety of measurement and test modes, functions, controls and connection parts. The complexity of the instruments requires assembly of the devices and specialized training. Training programs offered by MB are absolutely essential to gain for full testing capabilities. The advise and experience of MB field representatives should be sought.

Checklist for Diagnostic Engine Analyzer

Careful handling of all components is a must. Replace any cables, trigger and kV clips etc. that are visibly damaged.
Use MB test documentation and specifications (e.g. diagnostic manuals, WIS).
Keep jaw surfaces of trigger, kV and current clips clean and ensure they close fully with sufficient force.
Prevent cables, adapters, clips, etc,. from coming into contact with hot engine parts or rotating parts.
Correct zero settings for all measurement modes when disconnected, pressure sensor e.g. 0.1bar.
Roughly compare the rpm reading with the vehicle rpm counter.
The values from the ignition voltage curve (kV and ms) can be compared with the oscilloscope readings.
For a rough function check of cylinder-related measurements (e.g. engine concentricity, ignition voltage curve, etc.), intermittent disturbances can be generated at one cylinder (intruding air, misfiring, etc.), for vehicles with Lambda control do not exceed 5 seconds. The graphic display and the tabular figures should then permit comparable fault interpretations.
Rough function check of the compression test by removing a spark plug and comparing with normal measurements (graphic and tabular). Before starting the engine, ground the removed spark plug in the spark plug connector.

Accessory Cables Available for SDS with MT

Description	Part No.
Scope cable "A" 4.0 m with 4 mm banana plug for 12-channel oscilloscope. Note: 12-channel oscilloscope, channels A1 to A6	HKR 047 (Ref: 162 03 002)
Pickup cable Trigger cable for external trigger in universal scope	HKR 033 (Ref: 162 03 004)
Current clip Direct current measurement up to 500 A. For multimeters and various engine test modes.	HKR 015 (Ref: 162 03 005)
Sensor connecting cable For simultaneous connection of current clip, pickup and pressure sensor.	HKR 035 (Ref: 162 03 006)
Pressure sensor - 1 to 7.0 bar	HDS 02 (Ref: 162 03 018)
kV clip 1 For tapping the secondary voltage on ignition cables.	HKR 043 (Ref: 162 03 007)
kV clip 2 For tapping on other ignition circuits.	HKR 044 (Ref: 162 03 008)
Connecting cable, kV clip 1 to 2 (400 mm) Connecting cable, kV clip 1 to 2 (1200 mm)	HKR 045 (Ref: 162 03 009) HKR 046 (Ref: 162 03 010)
Adapter, BNC to 2x banana jacks For secondary sensor to May & Christe and Bosch ignition coils.	HKR 027 (Ref: 162 03 011)
Adapter cable, 6.3 mm flat connector to banana jack For kV pickup 1620 1040 (ME 1.0)	HKR 028 (Ref: 162 03 012)
Adapter cable to 9-pin engine diagnosis	HKAB 028 (Ref:162 03 020)
Primary adapter cable ME 1.0 For measuring the primary ignition voltage on M 112/113. Also available as accessory for engine tester.	HPAL 029(Ref: 162 03 038)
Set (2) secondary adapters M 111/104 HFM For tapping secondary signals on May & Christe and Bosch ignition coils. Also included with the CD 1222 adapter.	HSLT 005 (Ref: 162 03 039)
kV pickup (ME 1.0) (Also available as accessory for engine tester as MB Special Tool: 909 589 12 21 00)	HSLT 010 / 5 (Ref: 162 03 040)
Connecting cable for kV pickup Length 400 mm Length 1200 mm	162 03 001 162 03 010
Adapter cable For alternative rpm measurement or auxiliary trigger on vehicles with multipoint injection without terminal 1 or TN measurement capability.	HCA 218 (Ref: 162 03 041)