Manual modulo EDC7UC311

EMR3 System description

Systembeschreibung EMR3 by DEUTZ AG

Das elektronische Motorregelsystem EMR3 löst die Systeme EMR1,2 und MVS ab. Für die DEUTZ-Motor-Baureihe 2011/12 bleibt das EMR2-System vorläufig erhalten. Dieses Dokument beschreibt die Neuerungen, den Aufbau und die Funktionsweise des EMR3 und gibt Hinweise zur Fehlersuche und zur Problembehebung. Das elektronische Motorregelsystem EMR3-OnRoad wird in einer eigenen Systembeschreibung behandelt.

The electronic engine control system EMR3 replaces the EMR and MVS systems. For the DEUTZ-Series 2011/12 EMR2 will remain. This document describes the new features, the structure and the functional principle of the EMR3 and gives hints for troubleshooting and elimination of problems. The electronic engine control system EMR3-On-Road is dealt within its own system description.

EMR3 System description © 2007 DEUTZ AG All rights reserved. No parts of this work may be reproduced in any form or by any means - graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without the written permission of the publisher. Products that are referred to in this document may be either trademarks and/or registered trademarks of the respective owners. The publisher and the author make no claim to these trademarks. While every precaution has been taken in the preparation of this document, the publisher and the author assume no responsibility for errors or omissions, or for damages resulting from the use of information contained in this document or from the use of programs and source code that may accompany it. In no event shall the publisher and the author be liable for any loss of profit or any other commercial damage caused or alleged to have been caused directly or indirectly by this document. Copyright © 2007 DEUTZ AG Version 1.2.2 Compiled 11.09.2007

Special thanks to: Publisher DEUTZ AG Managing Editor Service Information Systems Technical Editors Fi Ad Cover Designer . Team Coordinator . Production .

All collegues of DEUTZ AG

Inhalt 1

EMR3

1 Foreword ................................................................................................................................... 1 2 Important ................................................................................................................................... notes 1 3 System components ................................................................................................................................... 3 4 System functions ................................................................................................................................... 13 Control/regulation ......................................................................................................................................................... functions 14 Monitoring functions ......................................................................................................................................................... 14 Diagnosis functions ......................................................................................................................................................... 16

5 Interfaces ................................................................................................................................... 16 Protocols

......................................................................................................................................................... 18

Wiring

......................................................................................................................................................... 22

Diagnostic plug .................................................................................................................................................. 23 Main relay .................................................................................................................................................. 25 Control unit .................................................................................................................................................. EMR3-S (EDC 16 UC 40) 28 Control unit .................................................................................................................................................. EMR3-E (EDC 7 UC 31) 35 Circuit diagrams .................................................................................................................................................. 50

6 Service tasks ................................................................................................................................... 59 Calibrating foot ......................................................................................................................................................... pedal and hand throttle 60 Setting idle speed ......................................................................................................................................................... 62 Setting Droop ......................................................................................................................................................... 1 63 Setting Droop ......................................................................................................................................................... 2 64 Setting fixed......................................................................................................................................................... speed 65 Setting emergency ......................................................................................................................................................... speed 66 Setting pulse ......................................................................................................................................................... rate for vehicle speed 67 Setting vehicle ......................................................................................................................................................... maximum speed 68 Initialize the......................................................................................................................................................... EEPROM 69 Updating operating ......................................................................................................................................................... software 70 IO-Testing ......................................................................................................................................................... 74

7 Diagnostics ................................................................................................................................... 75 Diagnostics......................................................................................................................................................... with diagnostic key and error lamp 75 Diagnosis with ......................................................................................................................................................... SERDIA 77 Table of system ......................................................................................................................................................... errors 80

8 Technical................................................................................................................................... data 82 9 Glossary................................................................................................................................... 88

89

Index

© 2007 DEUTZ AG

Vorwort

Es ist unser Bestreben, den Inhalt dieses Dokuments kontinuierlich zu optimieren, wobei praktische Erfahrungen aus dem Kreis der SERDIA-Anwender eine besonders wertvolle Hilfe darstellen. Sollten Sie daher Änderungen, Erweiterungen oder Verbesserungen wünschen, bitten wir um eine entsprechende Nachricht (E-Mail: Herr Finken, [email protected]). Wir bewerten jede Meldung sorgfältig und veröffentlichen Neuauflagen dieses Dokumentes, sobald sein Inhalt verändert wurde. Im Voraus bedanken wir uns für Ihre Unterstützung.

Our aim is to continuously optimise the contents of this document, whereby practical experience from the circle of SERDIA users is very valuable. So, if you want any changes, extensions or improvements made, please notify us accordingly (E-mail: Mr. Finken, [email protected]). We will examine all messages carefully and publish new editions of this document as soon as its content is changed. Thank you in advance for your kind support.

© 2007 DEUTZ AG

1


1

EMR3

1.1

Foreword

1.2

Important notes Binding documentation This document serves for a detailed explanation and illustration of the structure and functional principle of engine components. The data contained herein only correspond to the state of the art at the time of the setting and are not subject to an immediate revision service. The data of the published and respectively valid technical documents such as operating instructions, circuit diagrams, workshop manuals, repair and setting instructions, technical bulletins, service bulletins etc. are exclusively binding for the operation, maintenance and repair. We refer especially to the valid edition of the "Installation Guideline for Electronic Systems on DEUTZ Diesel Engines" which are available from the Installation Consulting Dept. (E-mail: Mr. Benke, [email protected]).

Safety The fuel systems described in this document operate under very high pressures. The appropriate work guidelines from the workshop manual must be observed for all work on the fuel system because otherwise there is a danger to life

Customer wiring In order to attain the required protection class (IP 66) at the control unit, the individual wire seals, plugs and sealing rings provided must be used. The connection between pins and individual wires must only be carried out with the proper crimp tools. The voltage supply on inputs and outputs for connected switches, sensors and loads must be switched off via the ignition switch (terminal 15) and not via battery positive pole (terminal 30).

© 2007 DEUTZ AG

EMR3

2

Work on the electrical system The power supply (ignition, terminal 15) must be switched off before all work on the electrical system. Sensors and actuators must not be connected to external voltage sources for test purposes. They must be connected to EMR3-ECU only. The components could otherwise be permanently damaged. Regardless of the reverse polarity protection integrated in the EMR3, all wrong polarity should be avoided to rule out any risk of damaging the control unit. The control unit plug may not be pulled out when the control unit is in operation (i.e. when the power supply is switched on at terminal 15). Correct procedure: Switch off the power supply (normally with the ignition key), wait for the main relay to switch off (delayed by up to 15 s, listen for clicking noise), pull out control unit plug. The connecting plugs of the EMR3 are only protected against dust and splash water when the mating plugs are plugged in. If the mating plugs are removed, make sure that the control unit is not exposed to moisture.

Electrical welding All plugs must be removed from the control unit during electrical welding on the vehicle or machine to avoid damage.

© 2007 DEUTZ AG

3

1.3


System components The engine control system EMR3 requires the following components as a minimum equipment for operating the engine:  Engine control unit (EMR3-S or EMR3-E)*  Power supply (battery)*  Foot pedal, hand throttle or switch for nominal value preset*  Ignition start switch*  External main relay (only in EMR3-S)*  Function switch*  Speed sensors  Pressure and temperature sensors  Cable harness, engine side / vehicle side*  Error lamp*  Diagnostic button*  Diagnostic socket*  installation and wiring by customer The system can be extended by additional components depending on the application-specific engine configuration. Please contact DEUTZ AG for further information.

Engine control unit The central component of the EMR3 system is the engine control unit. This has the job of ensuring optimum running of the engine with aims  good exhaust behaviour,  low consumption,  quiet engine running,  long engine life,  efficient service For this purpose, the engine control unit makes a number of calculations with the measured values and the parameters saved in the data memory which form the basis for all the functions provided. The most important functions include:  exact control of the injection process (including number, start and duration of injections),  governoring of the idle speed,  governoring of the exhaust return volume,  optimisation of the balanced running (by correction of injection volume),  engine monitoring,  system diagnosis.

© 2007 DEUTZ AG

EMR3

DEUTZ ROAD-MAP for EMR3-Systems

© 2007 DEUTZ AG

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5


Description of functions The hardware of the EMR3 contains (roughly described): o one CPU (MOTOROLA central processing unit) o memory  flash-memory (for software and parameters)  eeprom-memory (for special parameters and counters)  RAM (for working memory) Inputs and outputs o digital (means ON-OFF signals and PDM signals) o analogue (continous signals, inputs only) communication ports o ISO 9141 (Keyword protocol) o CAN-Bus (SAE J 1939 protocol) Power regulator A EMR3-ECU contains several parts of data in general: o main software ( it´s like the BIOS in a PC - DEUTZ calling: "BSW") o application data ( it´s like an office-program on a PC - DEUTZ calling: "dataset") o manufacturing data (it´s like the CMOS-RAM in a PC - DEUTZ calling: "logistic data") The EMR3 could be programmed via the ISO 9141 interface (Programmimg via CAN-Bus is in pipeline). There are different possibilities of programming an EMR3: o complete dataset + BSW (needed for main software exchange) o complete dataset (needed for e.g. spare parts) o partitial dataset (needed for e.g. special adjustment in small series production) o calibration (needed for adjustment in field e.g. footpedal calibration) Many engine functions of the EMR3-Software are available via switches (digital or analog inputs) and CAN-Bus. These functions are choosen from a DEUTZ-configurator called ELTAB. The output of the configurator is the customerspecific dataset for serial production. In factory every EMR3 is programmed with a customerspecific complete dataset + BSW. After power calibration on the DEUTZ-testbench the EMR3 enters the status "engine specific" and receives a barcode label with the engine number printed on.

It´s forbidden to exchange EMR3-ECU´s (with or without barcode label), that don´t match with the DEUTZ-engine-number.

© 2007 DEUTZ AG

EMR3

6

The sensors attached to the engine provide the electronics in the control unit with all the relevant physical parameters. In accordance with the information of the current condition of the engine and the preconditions (accelerator pedal etc.) the EMR 3 controls the injectors and thus doses the fuel quantity in accordance with the performance requirements. The EMR 3 is equipped with safety devices and measures in the hardware and software in order to ensure emergency running (Limp home and/or shut off) functions. In order to switch the engine off, the user needs to turn the ignition switch into Stop-position (terminal 15) only. The ECU shuts off the fuel ignition and enters a data-saving mode for about 15s (max). Within this time the terminal 30 (constant battery voltage) must not be disconnected from EMR3. When the ECU leaves this mode the internal/external Main-Relay is shut off and terminal 30 is disconnected from EMR3 permanently.

Base System functions The following list gives an overview of the implemented EMR3-Functions. Nearly all functions described in EMR2-System are available in EMR3. o Speed control o All speed governor, fuel governor (Min/Max-Governor), switchable governor mode during operation, freezing the current speed, fixed speed for synchronization or load distribution, overdrive speed o Set point input o Footpedal and/or hand throttle o External voltage signal (0 - 5 V) o CAN Bus (remote electronics) o Fixed speed signal (genset operation) o Pulse width modulation (PWM) o Touch control operation Up/Down (digital) o Optimal adaptation to different applications o Torque limitation o Up to three top curves can be set independently o Droop o Constant, variable or switchable droop o Engine Start/Stop o Monitoring and signal output functions o Coolant temperature and level, oil pressure, charge air temperature, fuel temperature, o fault display and/or power reduction or switch-off-engine o Boostpressure (LDA) function o Smoke limitation o Temperature-dependent start control o Improving the starting ability, gentle cold start without smoke ejection o Altitude correction o Engine and turbo charger protection o Fuel volume correction o Compensation for fuel heating o Emergency running (limp home mode) o Emergency running after failure of set point signal (e.g. using accelerator pedal), the charge air sensor or the vehicle speed signal o Selection of cold start aid

© 2007 DEUTZ AG

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EMR3 System description o o o o o

ECU controls a heating flange or the glow plugs or the flame heating Data communication Interfaces, diagnostics and programming Output of fault fault blink codes Simplified fault diagnosis

© 2007 DEUTZ AG

EMR3

DEUTZ-Labeling Label of manufacturer engine types

injection system

EMR3-E

EMR3-S

ED 7 UC 31

ED 16 UC 40

TCD 2015

TCD 2012 2V TCD 2013 2V TCD 2013 4V

DCR® = DEUTZ Common Rail / DMV = DEUTZ Magnetic valve

supply voltage operating temperature mounting methods main relay Max. number of cylinders electrical plugs environment protection category data interface / protocol

8

12 und 24 V -40 °C bis +80 °C, cooling with air convection chassis, cabin

chassis, cabin

internal

external

6 / 8 Zyl. @ (DMV),

4 / 6 Zyl. @ (DCR®)

89 + 36 + 16 Pins

94 + 60 Pins

IP 6K, IP 9K

IP 6K, IP 9K

CAN / SAE J1939, ISO 9141 / KWP 2000

See the "DEUTZ Engine Control Units, An Overview" brochure for further details. The Deutz Common Rail System is a high pressure injection system for diesel-engines. The rail is the a memory for high compressed fuel for all injectors. This memory is charged by two high pressure pumps. The system is controlled by the EMR3 via fuel control unit. Advantages:  mostly free chooseable injection pressure  injection pressure up to 1600 bar  flexible injection processes  As shown in the picture the system contains 4 different fuel-pressure zones. Several pressure sensors give the EMR3 some status information of the system and via MPROP the EMR3 is able to control the pressure. The processes is controlled in a closed loop governor. Three different types of injection could be used:  pre injection (e.g. to reduce noise emission)  main injection (working)

© 2007 DEUTZ AG

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EMR3 System description  post injection (e.g. to higher the exhaust gas temperature for urea-injection)

© 2007 DEUTZ AG

EMR3

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Example for an electrical activation of injector and the resulting fuel-injection:

The following schematic diagrams show the EMR3 system in connection with the injection system.

© 2007 DEUTZ AG

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1 = fuel tank

7 = ECU

15 = Diagnosis-, 12 = engine main plug button, -plug, (X17) -lamp.

21 = indicating instrument

2 = prefilter

8 = high pressure reservoir, Rail

12a = connection harness ECU <-> engine

22 = Battery (clamp 31, 30)

3 = fuel pump

8a = DBV = high pressure limiting valve 12b = customer (closed: Pmax = specific harness 1800bar, opened: Pmax ~ 700bar)

17 = switchable function (eg. fixed speed 1-2, droop 1-2 etc.)

9 = injectors

12c = engine harness

18 = clutch switch

5 = fuel high pressure pump

10 = Railpressure sensor

13 = EGR exhaust gas 19 = e.g. footpedal, recirculation (external) setpoint setting

6 = FCU = ZME = MPROP = fuel control unit

11 = exhaust turbo charger

14 = engine sensors ( e.g. speed, coolant temp., oil pressure)

4 = fuel filter

16 = ignition key (clamp 15)

20 = Signal light, -lamp

© 2007 DEUTZ AG

EMR3

Engine with DMV 1,2,3,6,7,8,9,0,11,12,13 = MotorSensoren

24 = Diagnosis plug

16 = Signal light, -lamp

4 = engine main plug (X17

21 = ignition key (clamp 15)

15 = indicating instrument

5 = ECU

20 = switchable function (eg. fixed speed 1-2, droop 1-2 etc.)

14 = Battery (clamp 31, 30)

22 = Diagnosis button

19 = clutch switch

23 = Diagnosis lamp

18 = e.g. footpedal, setpoint setting

© 2007 DEUTZ AG

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13

1.4


System functions The EMR3 system functions vary slightly according to the used hardware (HW), operating software (MSW = main software (BSW = German)) and engine equipment.

Four software combinations can be named at the moment:

Injection system DCR

Injection system DMV

Control unit ED 7 (0421 4432)

MSW project name:

MSW project name:

P_490_aaa

P_513_bbb

Control unit ED 16 (0421 4367)

MSW project name:

MSW project name:

P_491_ccc

P_492_ddd

The consecutive designation aaa ... ddd indicates the development state of the software and the connected system functions. The partnumbers (PN) refer to the date of writing this document. Changes in PN are possible.

The following DEUTZ part numbers (PN) were defined at the time this document was written:

TN ASAP

TN BSW

Name BSW

TN EStG

Name EStG

0421 4633

0421 4632

P_491_220

0421 4367

EMR3-S (ED 16UC40)

0421 5113

0421 5112

P_491_302

0421 4367

EMR3-S (ED 16UC40)

0421 5436

0421 5435

P_491_310

0421 4367

EMR3-S (ED 16UC40)

0421 5546

0421 5545

P_491_400

0421 4367

EMR3-S (ED 16UC40)

0421 4689

0421 4688

P_492_213

0421 4367

EMR3-S (ED 16UC40)

0421 4680

0421 4679

P_513_214

0421 4432

EMR3-E (ED 7UC31)

0421 5330

0421 5329

P_513_300

0421 4432

EMR3-E (ED 7UC31)

© 2007 DEUTZ AG

EMR3

1.4.1

14

Control/regulation functions

Regulation of the engine torque The basic task of an engine regulator is to call the respective engine torque necessary in every operating state from the engine to set a constant speed, for example, or to match the nominal value specified by the driver. The EMR3 engine control unit determines the torque in the following way: Starting from the position of the setpoint transmitter (foot pedal, hand throttle or switch) it first determines the necessary drive torque and calculates the necessary coupling toque from this. By adding the power requirements of engine components, you get the nominal value for the torque to be emitted by the engine (external torque). Under consideration of friction losses and the operating point-dependent engine efficiency, the internal engine torque is obtained and finally, from this, the nominal value for the fuel volume.

1.4.2

Monitoring functions The monitoring functions serve to avoid operating states which could damage the engine. The following hardware and signals can be monitored. Sensors Coolant temperature Coolant level (optional*) Oil pressure Charge air temperature Water in fuelAir filter differential pressure (optional*)

Actuators Battery voltage Heating flange (only installed in 4V engines) There are other monitoring functions (e.g. for rail pressure ), which are activated automatically in the event of an error. All monitored values can be displayed (additionally to the diagnostic lamp). early detection of errors: intention: early recognizing of malfunctions in EMR3-Systems, to avoid environmental pollution or subsequent damage. Three strategies are possible: Warning Warning / power reduction with or without delay Warning / power reduction / shut off with or without delay Example Coolant temperature: The shut off limit at high temp has been increased by DEUTZ AG. But this was only possible, because now a power reduction comes first. Therefore a strategy warning and shutoff without powerreduction is not allowed anymore! User defined combinations of warning strategies are not possible any more (look functional description of sales department) and the user has to use the tested DEUTZ-combinations. Activated power reduction starts with after warning (diagnosis lamp is activated). The warning- and shut off - limits are engine type or ECU - type dependant. (see ELTAB chapter 8) The shut off condition leads to a blinking lamp (override is possible, that means shut off could be bypassed by user, if configurated. Warranty claims will get lost in this case) Warning strategy is dependant from the monitoring functions, that means, something

© 2007 DEUTZ AG

15

EMR3 System description that is not monitored could not be evaluated.

© 2007 DEUTZ AG

EMR3

1.4.3

16

Diagnosis functions The EMR3-Ecu´s offer a diagnosis via

 Blink-Code  CAN-Bus  K-Line The blink-code is described in Table of diagnostic errors. With this feature it is possible to readout an active system error without a connected diagnosis-tool. Activating this mode is described in Diagnosis with diagnosis button an error lamp The CAN-Bus protocol contains the standard messages from SAE J 1939. Not all telegrams have been implemented. Therefore ask your DEUTZ-Dealer or salesman. Via K-Line the ECU uses the KWP2000-protocol with crypted datastream. The DEUTZ-diagnosistool SerDia2000 is able to read out and/or write the errormemory, measurements and parameters. The access to the ECU and the SerDia-Menu is controlled by competence classes, which are implemented in the SerDia-Hardware-Interface. The levels are password-protected. For each competence class the user needs an extra interface. Further information see diagnostics.

1.5

Interfaces Interfaces refer generally to data transfer points. In the EMR3 system, the transferred data are electrical signals which transport either information about engine application or engine diagnosis. The interfaces of the EMR3 system can be divided accordingly into application interfaces and a diagnostic interface.

Application interface engine - control unit All the sensors installed in the engine (e.g. for oil pressure and coolant temperature) and actuators (solenoid valves, heating flange etc.) are usually wired at the factory by laying the individual cables in an engine cable harness at the engine adapter plug. The connecting cable from the engine adapter plug to the engine control unit is installed by the customer. The connecting cable can be ordered in a specified length from DEUTZ or can be assembled by the customer himself. There are no special demands on the wiring between the engine transfer plug and the control unit but you should make sure that the power cables of the injectors are not laid directly next to the sensor cables. Shielding the cables for these signal types is definitely an advantage. Please observe the DEUTZ wiring instructions.

Application interface vehicle - control unit This can be understood as the cable harness which connects the display and control elements in the instrument panel to the engine control unit. Here too, there are no special demands on the wiring but it is an advantage to use shielded cables for individual signal types (CAN-bus, diagnosis, foot pedal, hand throttle, etc.).

© 2007 DEUTZ AG

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EMR3 System description Please, mind the DEUTZ-wiring-plans, which are available for every ordered engine. Wire the communication-wires like in DEUTZ-installation-instructions described. Handle the ECU-communication-ports as networks and install them accurate in your application.

© 2007 DEUTZ AG

EMR3

18

Diagnostic interface The engine control units EMR3-S and EMR3-E have three interfaces via which the control unit data hardware can access the appropriate communication hardware (e.g. SERDIA USB interface) and diagnosis software (e.g. SERDIA). These are  the ISO-9141 bus (with KWP-2000 protocol, only K-line),  the CAN-bus 1 (with SAE-J-1939 protocol),  the CAN-bus 2 (not used at the moment). The wiring between the diagnosis socket and the engine control unit is done by the customer and is usually integrated in the cable harness of the application interface vehicle - control unit. The DEUTZ wiring instructions for CAN-bus cables must be observed. The ISO-9141 bus wiring between the control unit and the communication hardware should not exceed a total length of 15 m to achieve good signal quality. ´The KWP2000 protocol cannot be viewed and can only be used by the DEUTZ diagnosis software SERDIA. The SAE-J-1939 protocol on the other hand is internationally standardised and can be used with any CAN diagnosis hardware and software. For this, standard messages are selected from the set of the SAE-J-1939 protocol by DEUTZ via control unit parameterization which are sent regularly to the bus by the control unit. The configuration of the CAN messages is determined in predefined CAN function scopes from which the customer selects a suitable one for the engine application when ordering the engine. An adaptation of the CAN messages to individual conditions is only possible in agreement with the DEUTZ head office. The control unit also provides the possibility of outputting a blink code according to the currently available errors in the event of an error. The error lamp and the diagnostic key must be connected for a diagnosis in this case. The diagnostic button is connected to the K-line of the ISO-9141 bus. Accidental actuation of the button during ISO communication leads to the connection being broken and the diagnostic program must be restarted. see also Diagnostics

1.5.1

Protocols Protocols specify the process of data transmission between intelligent devices. Two protocols are used in the EMR3 system for external communication:  KWP 2000 Via the K-line, for diagnostic purposes  SAE J 1939 Via the lines CAN-High and CAN-Low, for diagnostic purposes and communication between the control units.

© 2007 DEUTZ AG

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CAN-Bus interface o Baud-Rate: 250 kBit/s o Several scopes of CAN-functionalities available o All source adresses and priorities are fixed for every single message like SAE J1939-protocol. o After Power up of he ECU the diagnosis starts with a delay of 10 seconds. o Dignosis interrupts for 30s if battery-voltage drops under 9 Volt. o Data FFh tells: not defined o Data FEh tells: not valid

Example for a CAN-Standard-Function 3100 CAN Code No. 3100Engine Type:

Don't care

CAN – Function

Transmit Messages, Engine Stop Request, Request

For ECU`s:

EMR3-s CR, EMR3-e CR, EMR3-e PLD

Data Sets:

CAN_3100

The CAN - BUS has got the following adjustment: The node address of EMR3 is 0. The rate of transmission is 250 kBaud CAN Function without Time Out detection. The node address for the received messages is 3. Only the engine stop request messages can be received from any node on the BUS.  The PDUS Byte of Multi package Transport Protocol got the Value FF by automatically send. Otherwise it will include the identifier of the request Node.  The priority, resolution, repetition rate and all other information is outlined in the CAN Specification for EMR3 and this Documentation.    

Receive Messages: Po Name s.

DLC

J1939

Repetitio Identifier n

Identifier

Data Reserve Page Priority d Byte 1 Bit 3 Bit 1 Bit (P+R+D P)

PDU F 1 Byte

PDU S 1 Byte

Sourc e rate Addre (msec) ss 1 Byte

Hex

1

Request

3

6

0

0 (18)

EA

00

3

0

18 EA 00 03

2

Engine Stop request

1

2

0

0 (08)

FF

16

Ignorie 0 rt

08 FF 16 xx

3

Delete active Error (DM11)

0

6

0

0 (18)

FE

D3

3

0

18 FE D3 03

4

Delete Passive Error (DM3)

0

6

0

0 (18)

FE

CC

3

0

18 FE CC 03

© 2007 DEUTZ AG

EMR3

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Transmit Messages: Pos Name .

DLC

Repetitio Identifier n

J1939 Identifier

Data PDU Priorit Reser PDUF S Page y ved Byte 1 Byte 1 1 Bit 3 Bit 1 Bit (P+R+DP) Byte

SrcA ddr. RATE (msec) 1 Byte

Hex

1

EEC1

8

3

0

0 (0C)

F0

04

0

20

0C F0 04 00

2

EEC2

8

3

0

0 (0C)

F0

03

0

50

0C F0 03 00

3

EEC3

8

6

0

0 (18)

FE

DF

0

250

18 FE DF 00

4

Fuel economy

8

6

0

0 (18)

FE

F2

0

100

18 FE F2 00

5

Cruise Control

8

6

0

0 (18)

FE

F1

0

100

18 FE F1 00

6

Engine Temperature

8

6

0

0 (18)

FE

EE

0

1000

18 FE EE 00

7

Inlet/Exhaust Conditions

8

6

0

0 (18)

FE

F6

0

500

18 FE F6 00

8

Engine Fluid Level/Pressure

8

6

0

0 (18)

FE

EF

0

500

18 FE EF 00

9

Measure 1

8

6

0

0 (18)

FF

04

0

200

18 FF 04 00

10

Measure 2

8

6

0

0 (18)

FF

12

0

100

18 FF 12 00

11

Measure 3

8

6

0

0 (18)

FF

13

0

100

18 FF 13 00

12

Measure 4

8

6

0

0 (18)

FF

14

0

100

18 FF 14 00

13

Measure 5

8

6

0

0 (18)

FF

1A

0

100

18 FF 1A 00

14

Measure 8

8

6

0

0 (18)

FF

1D

0

100

18 FF 1D 00

15

Measure 9

8

6

0

0 (18)

FF

19

0

100

18 FF 19 00

16

Limitation

8

3

0

0 (0C)

FF

15

0

100

0C FF 15 00

17

Vehicle Electrical Power

8

6

0

0 (18)

FE

F7

0

1000

18 FE F7 00

18

Ambient Conditions 8

6

0

0 (18)

FE

F5

0

1000

18 FE F5 00

19

State of Input 1

8

6

0

0 (18)

FF

0A

0

1000

18 FF 0A 00

20

State of Output 1

8

6

0

0 (18)

FF

0B

0

1000

18 FF 0B 00

21

Engine Configuration

8

6

0

0 (18)

FE

E3

0

5000

18 FE E3 00

22

Engine Hours

8

6

0

0 (18)

FE

E5

0

Request

18 FE E5 00

23

Controller Configuration

8

6

0

0 (18)

FF

0C

0

Request

18 FF 0C 00

24

Software Identification

8

6

0

0 (18)

FE

DA

0

Request

18 FE DA 00

25

Active Error (DM1)

8

6

0

0 (18)

FE

CA

0

1000 (by 18 FE CA 00 active Error)

26

Error Number (DM5)

3

6

0

0 (18)

FE

CE

0

Request

18 FE CE 00

27

Frese Frame Parameter (DM4)

8

6

0

0 (18)

FE

CD

0

Request

18 FE CD 00

© 2007 DEUTZ AG

21

EMR3 System description 28

Passive Error (DM2)

8

6

0

0 (18)

FE

CB

0

29

Multi package Transport

8

6

0

0 (18)

EC

FF

0

18 EC FF 00

30

Multi package Transport Protocol

8

6

0

0 (18)

EB

FFÚ 0 03

18 EB xx 00

31

Acknowledgment

8

6

0

0 (18)

E8

FF

18 E8 FF 00

0

Request

18 FE CB 00

© 2007 DEUTZ AG

EMR3

1.5.2

22

Wiring For a lot of work on the EMR3 system such as the device/vehicle side wiring, testing or replacing components, system extensions, an exact knowledge of the assignment of the connecting plugs and sockets of the system components and their correct connection with each other is necessary. The plug assignment sketches and circuit diagrams illustrated below serve as a reference for this.

manufacturing of the wiring Please refer to the DEUTZ instruction manuals ! In particular the pin contacts must be crimped with the designated crimp-tools. If necessary remove inserted pin-contacts only with the designated ejection-tool. Further specifications for crimp-connections see DIN EN 60352-2.

© 2007 DEUTZ AG

23 1.5.2.1

EMR3 System description Diagnostic plug In order to be able to access the EMR3 control unit with the SERDIA 2000 diagnosis software, a connection must be made between the SERDIA-PC and the diagnostic interface of the EMR3 system. The connection is made with the interface cable HS-Light/HS-Light II from the USB port of the PC to the DEUTZ diagnostic socket which must be mounted easily accessible on the vehicle or device (e.g. in the instrument panel). A diagnostic socket is the prerequisite for the possibility of using SERDIA for error diagnosis and changing the engine configuration. The diagnosis plug has got a connection to the CAN-Bus via PIN G and H. This connection is not used with ED 7 and ED 16 and will be used in the future. The complete diagnosis an programming is done via K-Line of the interface. The pins M and F of the diagnostic plug may be connected like in DEUTZ-wiring-plan described and are connected with the customer CAN-Bus. At this pins the user may connect a DEUTZ-CAN-Display to watch the standard messages. See also DEUTZ technical product information 0199 – 99 – 0340.

Circuit diagram (excerpt from the engine wiring diagram)

© 2007 DEUTZ AG

EMR3

pin assignment A B K L M F D E

© 2007 DEUTZ AG

Battery minus (-) Battery plus (+) ISO 9141 K-Line Diagnosis ISO 9141 L-Line Diagnosis CAN 2 High (SAE J 1939) CAN 2 Low (SAE J 1939) A-Line (SAE J 1708/1587) Diagnosis B-Line (SAE J 1708/1587) Diagnosis

24

25

1.5.2.2


Main relay The main relay serves to release the energy supply of the vehicle/device for the EMR3 system.  The engine control unit EMR3-S requires an external relay (see circuit diagram below).  The engine control unit EMR3-E has an internal electronic relay. For both control units applies: as soon as terminal 15 is not carrying battery + (i.e. the ignition is switched off), the main relay is switched off by the control unit after approx. 10 s. The main relay therefore separates the control unit from terminal 30 (battery +) which disconnects the power. The switching state of the main relay can be observed in the EMR3-S directly at the relay contact and in the EMR3-E at pin 1.13. technical requests for the main relay  min. current via switching contacts: 25A  coil response time and fall time: < 50 ms

Connection of alternator pin D+ If the clamp D+ of the alternator is connected to clamp 15 of the electrical system (and the ECU), then install a diode with a lamp like shown in the following pictures in the harness. Without this diode you run the risk, that after ignition off the ECU may not shut off. The diode has to be adjusted to the maximum current on this wire.

Circuit diagram The marking of the relay-pins is not compatible to the DEUTZ wiring diagrams.

© 2007 DEUTZ AG

EMR3

© 2007 DEUTZ AG

26

27


EXAMPLE:

© 2007 DEUTZ AG

EMR3

1.5.2.3

28

Control unit EMR3-S (EDC 16 UC 40) The engine control unit EMR3-S has two connecting sockets arranged on the top of the housing:  socket D2.1 for connecting the engine cable harness,  socket D2.2 for connecting the vehicle/device side cable harness.

Pin assignment

Max. cable cross section: 2.5 mm², 1.5mm², 0.75 mm²

Pinout for the ECU EMR3-S (EDC 16 UC 40)

© 2007 DEUTZ AG

29

EMR3 System description Pin

Signal type

D2.2.1

power supply (+)

D2.2.3

power supply (+)

D2.2.5

power supply (+)

D2.2.2

power supply (–)

D2.2.4

power supply (–)

D2.2.6

power supply (–)

Function / Component

remark / Technical data

power supply ECUs

UBat (clamp 30)

power supply ECU

UGnd (clamp 31) UBat geschaltet (clamp

D2.2.28 Signalinput, digital

Betriebssignal für ECU

D2.2.72 power supply (–), geschaltet

main relay

15) U > 4,79 V: ECU eingeschaltet U < 3,63 V: ECU ausgeschaltet 12V: 140 mA, 120 mH bei 1 kHz 24V: 80 mA, 350 mH bei 1 kHz

footpedal (setpoint)1

Uin= 0...5 V, Rdown =

D2.2.22 power supply (+)

footpedal (setpoint) 1

Uout = 5 V

D2.2.30 power supply (–)

footpedal (setpoint) 1

Intern mit UGnd

D2.2.9

Signalinput, analog, mit PulldownWiderstand

100 kW

verbunden Externer Schalter zu U Gnd,

D2.2.58 Signalinput, digital, mit Pullup-Widerstand

idle switch footpedal 1

D2.2.31 Signalinput, analog, mit PulldownWiderstand

handthrottle (setpoint) 2

Uin = 0...5 V, Rdown =


handthrottle (setpoint) 2

Uout = 5 V

Positionsgeber Fahrpedal 2:

Intern mit UGnd

D2.2.8

power supply (–)

Rup = 100 kW, Ulow = 2,1 V, Uhigh = 3,9 V 100 kW

verbunden Externer Schalter zu U Gnd,

D2.2.81 Signalinput, digital, mit Pullup-Widerstand

idle switch footpedal 2


Temperature sensor 2 (optional)

Intern mit UGnd

Temperature sensor 2 (optional)

Uin = 0...5 V, Rup = 1,3 k

D2.2.11

Signalinput, analog, mit PullupWiderstand

D2.2.12 power supply (–) D2.2.13


Rup = 100 kW, Ulow = 2,1 V, Uhigh = 3,9 V connected W

oil level sensor

Intern mit UGnd

oil level sensor

Uin = 0...5 V, Rup = 1,28

connected kW

© 2007 DEUTZ AG

EMR3 Pin

Signal type



D2.2.15



D2.2.89


Signalinput, digital, mit PulldownD2.2.17 Widerstand




30

Function / Component

remark / Technical data

oil level sensor

Uout = 5 V

multiple state switch for speed

Intern mit UGnd connected


Uin = 0...5 V, Rup = 2,3 kW

multiple state switch for droop


multiple state switch for droop

Uin = 0...5 V, Rup = 2,3 kW Externer Schalter zu UBat,

break switch

Rdown = 6,8 kW, Ulow = 2,2 V, Uhigh = 3,7 V Externer Schalter zu UBat,

break switch


clutch switch


exhaust break switch



engine start switch


intake air differential pressure switch

Rdown = 6,8 kW, Ulow = 2,2 V, Uhigh = 3,7 V Externer Schalter zu UBat, Rdown = 6,8 kW, Ulow = 2,2 V, Uhigh = 3,7 V Externer Schalter zu UGnd

D2.2.52

Signalinput, digital, mit PullupWiderstand

switch customerspecific

, Rup = 5 kW, Ulow = 2,2 V, Uhigh = 3,7 V

Signalinput, digital, mit PullupD2.2.19 Widerstand

© 2007 DEUTZ AG

Externer Schalter zu UGnd Overrideswitch

, Rup = 5 kW, Ulow = 2,3 V,

31





Uhigh = 3,7 V Externer Schalter zu UGnd D2.2.79


coolant temp switch

, Rup = 6,8 kW, Ulow = 2,2 V, Uhigh = 3,7 V Externer Schalter zu UGnd

D2.2.87


governor mode switch

, Rup = 6,8 kW, Ulow = 2,2 V, Uhigh = 3,7 V Externer Schalter zu UGnd

D2.2.57


droop switch


D2.2.55 power supply (+), switched

diagnosis lamp

D2.2.71 power supply (–), switched

Oil signal lamp


Oil signal lamp

0,3 A bei 12 V, 4 W bei 24 V Einschaltstrom 0,9 A 0,3 A bei 12 V, 4 W bei 24 V Einschaltstrom 0,9 A

power supply (+), switched

engine running or boost temp lamp


engine running or boost temp lamp


lamp (customerspecific)

Uout = UBat, Imax = 6 A


coolant temp warn lamp

0,3 A bei 12 V, 4 W bei 24 V Einschaltstrom 0,9 A


heater lamp



fuel filter water level sensor


fuel filter water level sensor

Uin = 0...5 V, Rup = 120 k

oil temp sensor


D2.2.7

D2.2.64




W

D2.2.66


oil temp sensor

Uin = 0...5 V, Rup = 1,28 k

D2.2.75


velocity sensor

Externer Schalter zu UBat,

W

© 2007 DEUTZ AG

EMR3

32

Rup = 6,8 kW, Ulow = 2,2 V, Uhigh = 3,7 V D2.2.53 power supply (–)

D2.2.48

Signalausgang, digital (PWM), mit Pullup-Widerstand, minus-schaltend

velocity sensorr

engine speed sensor

Intern mit UGnd connected Imax = 50 mA, fmax 5kHz, Standard: 60 Impulse/ Umdrehung

Fan speed sensor

UOut = 5 V

Fan speed sensor

Imax = 20 mA, fmax = 1


Fan speed sensor



fan control


fan control

D2.2.23 power supply (+) D2.2.84


kHz

R > 30 W bei 24 V R > 10,6 W bei 12 V L = 15...80 mH Einschaltstrom 1,9 A bei 16 V (15 Minuten) fmax = 300Hz fmin = 15Hz Externer Schalter zu UGnd

D2.2.83


PDM-setpoint






PDM-setpoint


Temperaturesensor (customerspecific)

Uin = 0...5 V, Rup = 1,3 kW

Temperaturesensor (customerspecific)


exhaustgas temp sensor

Uin = 0...5 V, Rup = 11,05 kW




D2.2.26 signal output, digital

PDM-output (customerspecific)

Imax = 50 mA, fmax = 1 KHz


PDM-output (customerspecific)


D2.2.27 signal output, digital

PDM-output torque (customerspecific)

Imax = 50 mA, fmax = 300 Hz


switch (customerspecific)


sensor (customerspecific)

© 2007 DEUTZ AG

Externer Schalter zu UBat, Rdown = 6,8 kW, Ulow = 2,2 V, Uhigh = 3,7 V UOut = 5 V

33

EMR3 System description D2.2.35 power supply (–) D2.2.36


D2.2.37 power supply (–) D2.2.61 Kommunikation, CAN low D2.2.62 Kommunikation, CAN high D2.2.60 Kommunikation, CAN low




Uin = 0...5 V, Rup = 680 kW


Intern mit UGnd connected.

CAN-Bus 2, customer

D2.2.82 Kommunikation, CAN high

CAN-Bus 1, für Diagnosis

D2.2.25 Kommunikation, K-Leitung

ISO-9141-Bus


boost pressure sensor



Uin = 0...5 V, Rup = 680 kW


UOut = 5 V

boost temp sensor

Uin = 0...5 V, Rup = 1,28 kW

cam shaft sensor


D2.1.40


D2.1.14 power supply (+) D2.1.53


D2.1.20 Shield D2.1.10

Signalinput (+), digital, mit Schmitt- Cam shaft speed Trigger mit Schwellwert-Anpassung sensor

inductive sensor, Uin = 0,2...80

Signalinput (–), digital, mit Schmitt- Cam shaft speed D2.1.50 Trigger mit Schwellwert-Anpassung sensor

V~


coolant temp sensor


D2.1.58


coolant temp sensor

Uin = 0...5 V, Rup = 1,28 kW

D2.1.7

Schirm

crank shaft speed sensor


D2.1.12

Signalinput (–), digital, mit Schmitt- crank shaft speed Trigger mit Schwellwert-Anpassung sensor

D2.1.27

Signalinput (+), digital, mit Schmitt- crank shaft speed Trigger mit Schwellwert-Anpassung sensor

power supply (–), switched, mit D2.1.45 recovery diode zu U Bat

exhaust gas break valve control


exhaust gas break valve control

inductive sensor, Uin = 0,2...80 V~ R > 42 W bei 24 V R > 14 W bei 12 V L < 480 mH bei 12 V

für 12-V-Anwendungen: IOut = 1,7 A bei Vbat = 14,4 V,


internal exhaust gas break or EGR

L = 160 mH, f = 300 Hz, IOut = 3,1 A bei Vbat = 14,4 V, L = 10 mH, f = 1 Hz, für 24-V-Anwendungen: IOut = 0,9 A bei Vbat = 28,8 V, L = 600 mH, f = 300 Hz, IOut = 1,7 A bei Vbat = 28,8 V,

© 2007 DEUTZ AG

EMR3 D2.2.35 power supply (–)


34

Intern mit UGnd connected L = 44 mH, f = 1 Hz


fuel control unit (FCU, MPROP)




fuel temp sensor or crankshafthousing pressure sensor

UOut = UBat, Imax = 5 A


D2.1.52


fuel temp sensor or crankshafthousing pressure sensor

UIn = 0...5 V, Rup = 1,28 k

D2.1.59

power supply (–), switched oder PWMSignal

fuel valve flame starting or external EGR

INenn = 1,3 A bei 24 V

W

L = 0...15 mH bei 24 V


fuel valve flame starting or external EGR


fuel low pressure sensor



UIn = 0...5 V, Rup = 680 k



UOut = 5 V


heater relay

max. 130 mH 2A bei 12 V, 1,5A bei 24V


heater relay

D2.1.57

D2.1.21



sense for heater relay

W

Externer Schalter nach Masse, Rup = 6,8 kW, Ulow = 2,2 V, Uhigh = 3,7 V


oil pressure sensor



oil pressure sensor

UOut = 5 V

D2.1.56


oil pressure sensor

UIn = 0...5 V, Rup = 6,81 k

D2.1.8

power supply (–)

rail pressure sensor


D2.1.43



UIn = 0...5 V, Rup = 4,6 kW



UOut = 5 V


Starterrelay

Lmax = 130 mH, Imax = 6 A


Starterrelay

D2.1.35

© 2007 DEUTZ AG


engine stop switch (optional)

W

Rup = 6,8 kW, Ulow = 2,2 V, Uhigh = 3,7 V

35

EMR3 System description D2.1.49 power supply (–), switched


UOut = UBat, Imax = 5 A


external EGR (optional)



crankshafthousing pressure sensor (optional)

UOut = 5 V


Injektoren 1 (Y15.1), 3 (Y15.3) und 5 (Y15.5) = Bank 1

Y15. DCR, 4 und 6 Zylinder 1/3/5

power supply (+)

Injektoren 2 (Y15.2), 4 (Y15.4) und 6 (Y15.6) = Bank 2

Y15. DCR, 4 und 6 Zylinderer 2/4/6

D2.1.1


Injektor 1

Y15. DCR, 4 und 6 Zylinder 1


Injektor 2



Injektor 3



Injektor 4



Injektor 5

Y15. DCR, 6 Zylinder 5


Injektor 6

Y15. DCR, 6 Zylinder 6

The table above illustrates the maximum assignment of the control unit pins. However, in practice, not all the named pins are actually assigned. Pins which are not listed are generally not used by the EMR3 system. 1.5.2.4

Control unit EMR3-E (EDC 7 UC 31) The engine control unit EMR3-E has three connecting sockets arranged on the top of the housing:  socket D2.1 for connecting the vehicle/device side cable harness,  socket D2.2 for connecting the engine cable harness for sensors and actuators,  socket D2.3 for connecting the engine cable harness for the fuel measuring unit and fuel injectors.

Pin assignment

© 2007 DEUTZ AG

EMR3

36

Max. cable cross section: 2.5 mm², 0.75 mm²

Pinout for ECU EMR3-E (EDC 7 UC 31) Pin

Pintype / Signaltype

D2.1. 02

Function / component

remark / technical data

Supply of the ECU with positiv battery voltage

UBat clamp 30

Supply of the ECU with negative battery voltage

UGND clamp 31

D2.1. 03 D2.1. 08 D2.1. 09 D2.1. 05 D2.1. 06 D2.1. 10 D2.1. 11 D2.1. 40

Digital input terminal 15

D2.1. 77

Sensor supply

© 2007 DEUTZ AG

Terminal 15 (switched UBAT+)

Accelerator pedal position sensor 1 supply

ECU in on state > 3,35V < 2,81 off state clamp 15 VOUT = 5V

37

EMR3 System description D2.1. 78

GND reference for sensors and actuators.

Accelerator pedal position sensor 1 ground

D2.1. 79

Analog input (with pulldown resistor)

Accelerator pedal position sensor 1 signal

D2.1. 48

Digtal input (with pullup resistor)

D2.1. 60

Sensor supply

D2.1. 59



D2.1. 61



D2.1. 80

Digital input (with pullup resistor)

Low idle switch, throttle 2

Digital input external switch to GND, Rup = 100 kOhm, Ulow = 2,4V, Uhigh = 3,6V

D2.1. 50


Multiple state or digital switch ( speed setpoint) ground

D2.1. 43

Analog input (with pullup resistor)

Connected to UGND inside of ECU. Analog input, UIN = 0 ... 5 V, Rup = 3,4 kOhm

D2.1. 65


Multiple state or digital switch (Torque/ droop switch) ground

D2.1. 62


Multiple state or digital switch (Torque/ droop switch) signal

D2.1. 76


Multiple state or digital switch (controller mode, power boost) ground

D2.1. 44


Multiple state or digital switch (controller mode, power boost) signal

D2.1. 29


D2.1. 32

Digital input (with pullup Resistor)

Override switch

D2.1. 55


Coolant level switch


D2.1. 86


Droop choice switch


D2.1. 21

Power output high

Supply digital swiches

D2.1. 41

Digtal input (with pulldown resistor)

Engine Stop-switch



Multiple state or digital switch (speed setpoint) signal

Digital switch input ground

Connected to UGND inside of ECU. Analog input, UIN = 0 ... 5 V, Rdown = 100 kOhm Digital input external switch to GND, Rup = 100 kOhm, Ulow = 2,4V, Uhigh = 3,6V VOUT = 5V Connected to UGND inside of ECU. Analog input, UIN = 0 ... 5 V, Rdown = 100 kOhm

Connected to UGND inside of ECU. Analog input, UIN = 0 ... 5 V, Rup = 1,4 kOhm Connected to UGND inside of ECU. Analog input, UIN = 0 ... 5 V, Rup = 3,4 kOhm Connected to UGND inside of ECU. Digital input external switch to GND, Rup = 4,1 kOhm, Ulow = 2,2V, Uhigh = 3,8V

VOUT = UBAT, IMAX = 10 A Digital input external switch to UBAT,

© 2007 DEUTZ AG

EMR3

38

Rdown = 4,1 kOhm, Ulow = 2,2V, Uhigh = 3,8V D2.1. 49


Parking brake optional redundant brake switch

Digital input external switch to UBAT, Rdown = 4,1 kOhm, Ulow = 2,2V, Uhigh = 3,8V

D2.1. 66

Digital input (with pulldown Resistor)

Gear switch


D2.1. 42


Air filter differential pressure switch

Digital input external switch to UBAT, Rdown = 4,1 kOhm, Ulow < 0,28xUBAT, Uhigh > 0,68xUBAT

D2.1. 47

Digital input (with pulldown resistor)

Engine brake switch


D2.1. 74


Engine start switch


D2.1. 85


Oil-Level switch


D2.1. 21

Power output high

Supply digital switches

VOUT = UBAT, IMAX = 10 A

D2.1. 31


Speed switch (+)


D2.1. 64


Speed switch (-)


D2.1. 46


Speed switch (hold/resume)


D2.1. 70


Vehicle speed sensor ground

D2.1. 71

Digital input with comparator

Connected to UGND inside of ECU. Ri = 3,1 kOhm, Ulow = 1,0 V, Uhigh = 5,42 V

© 2007 DEUTZ AG

Vehicle speed sensor signal

39

EMR3 System description fmax= 5 kHz D2.1. 33

Digital output with pullup resistor(small signal), switch to GND, PDM Output

Engine speed output signal

D2.1. 22

Power output UBat+

Diagnostic lamp supply HS

D2.1. 30

Power switching output low side to GND

D2.1. 13

Power output UBat+

D2.1. 20


Warning oil pressure/level lamp LS

D2.1. 38


Warning fuel-/airfilter/fuelpress. lamp LS

D2.1. 39


Warning coolant temp/level lamp LS

D2.1. 54


Preheat lamp LS

D2.1. 56


Engine running/warning boost air temp lamp LS

D2.1. 17


Starter relay LS

D2.1. 37

Power switching output high-side to Vbat+

Starter relay HS

D2.1. 68

Sensor supply

Fan speed sensor supply

VOUT = 5V

D2.1. 67


Fan speed sensor ground

D2.1. 69

Digital input

Fan speed sensor signal

Connected to UGND inside of ECU. fmax=1kHz

D2.1. 14

Power output high

Fan control actuator HS

D2.1. 15


Fan control actuator LS

D2.1. 24


Exhaust gas or cylinder head temperature sensor ground

50mA fmax 5kHz Standard: 60 pulse per rev. 0,3A@12V; 4W@24V nominal 0,3A inrush current 0,9A

Diagnostic lamp LS Battery plus output for warning lamps

VOUT = UBAT, IMAX = 10 A 0,3A@12V; 4W@24V nominal 0,3A inrush current 0,9A 0,3A@12V; 4W@24V nominal 0,3A inrush current 0,9A 0,3A@12V; 4W@24V nominal 0,3A Inrush current 0,9A 0,3A@12V; 4W@24V nominal 0,3A inrush current 0,9A 0,3A@12V; 4W@24V nominal 0,3A inrush current 0,9A Lmax=130mH Imax=2A

Rmin >30Ohm @24V Rmin >10,6Ohm @12V L=15...80mH inrush current 1,9A@16V (15 minutes) fmax=300Hz fmin=15Hz

Connected to UGND inside of ECU.

© 2007 DEUTZ AG

EMR3

40

D2.1. 25


D2.1. 28


D2.1. 27


D2.1. 26

Oil level sensor

D2.1. 72


Oil level sensor ground

D2.1. 23


Torque PDM output signal

D2.1. 51


Reserve 2 (LS), PDM

D2.1. 57

Power output UBat+

Reserve 1, Actuator HS

D2.1. 16


Reserve 1, Actuator LS

D2.1. 81


Crank case pressure or engine speed precontroller sensor signal

Analog input, UIN = 0 ... 5 V, Rup = 100 kOhm

D2.1. 82

Sensor supply

Crank case pressure or engine speed precontroller sensor supply

VOUT = 5V

D2.1. 83


Crank case pressure or engine speed precontroller sensor ground

D2.1. 34

CAN driver

Connected to UGND inside of ECU CAN low

D2.1. 35

CAN driver

D2.1. 52

CAN driver

D2.1. 53

CAN driver

D2.1. 89

ISO-K Interface

D2.2. 03

Digital output HS (UBAT via internal main relay)

Battery supply output (HS)

D2.2. 07

Power switching output low-side to GND

Preheat relay actuator or glow plug for flame start LS

D2.2. 08


D2.2. 04

Analog output (UBAT via internal main relay)

© 2007 DEUTZ AG

Exhaust gas temperature sensor signal

Analog input, UIN = 0 ... 5 V, Rup = 1,4 kOhm

Oil temperature sensor ground

Connected to UGND inside of ECU. Analog input, UIN = 0 ... 5 V, Rup = 1,35 kOhm

Oil temperature sensor signal Oil level sensor

Customer - Controller area network CAN

Signal evaluation with constant current source 247mA Connected to UGND inside of ECU IMAX = 50 mA, fMAX = 300Hz IMAX = 50 mA, fMAX = 1kHz VOUT = UBAT, IMAX = 2,4 A, LMAX = 130 mH

CAN high Diagnostic - Controller area network CAN

CAN low CAN high

K-Line communication

Preheat sense switch

Fuel valve for flame start actuator HS

Diagnostic, programming UBat max. 130mH Rmin > 6 Ohm @ 12V Rmin > 16 Ohm @ 24V Digital input external switch to GND, Rup = 5 kOhm, Ulow = ?, Uhigh = ? 0,75ANenn@24V 14,5-15mH@24V 12V: no fuel valve for

41

EMR3 System description flame start available Connected to UGND inside of ECU. UBat

D2.2. 05

GND reference for sensors actuators.

D2.2. 03



D2.2. 06


Engine brake flap actuator LS

D2.2. 10


D2.2. 09

Schmitt-trigger input with threshold adaption for engine speed sensor signal.

D2.2. 19


D2.2. 23


D2.2. 12


Rail fuel pressure or crank case pressure sensor ground

D2.2. 13

Sensor supply

Rail fuel pressure or crank case pressure sensor supply (G3)

D2.2. 14


Rail fuel pressure or crank case pressure sensor signal


D2.2. 15


Coolant temperature sensor signal


D2.2. 26


Coolant temperature sensor ground

D2.2. 16

Analog output / sensor supply

D2.2. 18


Low fuel pressure sensor ground

D2.2. 22


Low fuel pressure sensor signal

D2.2. 18


Fuel temperature sensor ground

D2.2. 35


Fuel temperature sensor signal

D2.2. 17


Customer temp. 1 (gear box oil) ground

D2.2. 29


Customer temp. 1 (gear box oil) sensor signal

D2.2. 32

Sensor supply

D2.2. 27


Oil pressure sensor signal


D2.2.

GND reference for

Oil pressure sensor ground

Connected to UGND

External EGR or Fuel valve for flame start actuator ground

Camshaft speed sensor ground Camshaft speed sensor signal

Crankshaft speed sensor ground Crankshaft speed sensor signal

Low fuel pressure sensor supply (G2)

Oil pressure sensor supply (G2)

Rmin > 42 Ohm@24V Rmin >14 Ohm@12V Lmax < 480mH @12V Connected to UGND inside of ECU. Induktivsensor, Uin=0,2 ... 80V AC, fin= ? Connected to UGND inside of ECU. Induktivsensor, Uin=0,2 ... 80V AC Connected to UGND inside of ECU. VOUT = 5V, max 50mA

Connected to UGND inside of ECU. VOUT = 5V Connected to UGND inside of ECU. Analog input, UIN = 0 ... 5 V, Rup = 6,81 kOhm Connected to UGND inside of ECU. Analog input, UIN = 0 ... 5 V, Rup = 1,3 kOhm Connected to UGND inside of ECU. Analog input, UIN = 0 ... 5 V, Rup = 1,3 kOhm VOUT = 5V

© 2007 DEUTZ AG

EMR3 24

sensors actuators.

D2.2. 24


Water in fuel sensor ground

D2.2. 28


Water in fuel sensor signal

D2.2. 33

Sensor supply

D2.2. 25


Boost air pressure/temp. sensor ground

D2.2. 34


Boost air pressure sensor signal

D2.2. 36


Boost air temperature sensor signal

D2.2. 03


D2.2. 05


D2.2. 11

Digital output / PWM (small signal), switch to GND

D2.2. 02


Engine stop and reserve switch ground

D2.2. 21


Engine stop or reserve switch

D2.2. 20


Reserve pulse input ground

D2.2. 30


Reserve pulse input signal

D2.2. 01


Engine brake internal or IEGR actuator LS

D2.3. 04

Injector output high-side

Injektoren 1 (Y15.1), 3 (Y15.3), 5 (Y15.5) und 7 (Y15.7) = Bank 1

D2.3. 03

Injector output high-side

Injektoren 2 (Y15.2), 4 (Y15.4) 6 (Y15.6) und 8 (Y15.8) = Bank 2

© 2007 DEUTZ AG

42

inside of ECU. Connected to UGND inside of ECU. Analog input, UIN = 0 ... 5 V, Rup = 120 kOhm

Boost air pressure/temp. sensor supply (G1)

Battery supply output (HS) External EGR or Fuel valve for flame start actuator ground External EGR actuator LS

VOUT = 5V Connected to UGND inside of ECU. Analog input, UIN = 0 ... 5 V, Rup = 680 kOhm Analog input, UIN = 0 ... 5 V, Rup = 1,3 kOhm UBat Connected to UGND inside of ECU. max. 50mA, 200Hz Connected to UGND inside of ECU. Analog input, UIN = 0 ... 5 V, Rup = 1,1 kOhm Connected to UGND inside of ECU. Induktivsensor, Uin=0,2 ... 50V AC

DEUTZ 12V application: I_Out=1.7A @ Vbat=14.4V, L=160mH, frequency=300Hz, I_Out=3.1A @ Vbat=14.4V, L=10mH, frequency=1Hz, DEUTZ 24V application: I_Out=0.9A @ Vbat=28.8V, L=600mH, frequency=300Hz, I_Out=1.7A @ Vbat=28.8V, L=44mH, frequency=1Hz Y15.1/ CR 4 und 6 Zylinder / PLD 6 und 8 Zylinder 3/5/7 Y15.2/ CR 4 und 6 Zylinder / PLD 6 und 8 Zylinder 4/6/8

43

EMR3 System description D2.3. 13

Injector output low-side

Injector 1 "low", Bank 1 (Y15.1)

Y15.1

CR 4 und 6 Zylinder / PLD 6 und 8 Zylinder

D2.3. 15



Y15.2


D2.3. 06



Y15.3


D2.3. 14



Y15.4


D2.3. 12



Y15.5

CR 6 Zylinder / PLD 6 und 8 Zylinder

D2.3. 16



Y15.6


D2.3. 07



Y15.7

PLD 8 Zylinder

D2.3. 08



Y15.8

PLD 8 Zylinder

D2.3. 09

Power switching output high-side

Fuel metering unit (MPROP) supply HS

D2.3. 10


Fuel metering unit (MPROP) LS

Pin



VOUT = UBAT, IMAX = 1,3 A

remark / technical data UBat clamp 30

D2.1.02 D2.1.03

Supply of the ECU with positiv battery voltage

D2.1.08 D2.1.09 UGND clamp 31

D2.1.05 D2.1.06

Supply of the ECU with negative battery voltage

D2.1.10 D2.1.11 D2.1.40

Digital input terminal 15 Terminal 15 (switched UBAT+)

ECU in on state > 3,35V < 2,81 off state clamp 15

D2.1.77

Sensor supply


VOUT = 5V

D2.1.78




D2.1.79


D2.1.48



Analog input, UIN = 0 ... 5 V, R down = 100 kOhm



D2.1.60

Sensor supply


VOUT = 5V

D2.1.59




D2.1.61



Analog input, UIN = 0 ... 5 V, R down = 100 kOhm

© 2007 DEUTZ AG

EMR3

Pin


D2.1.80


D2.1.50



Low idle switch, throttle 2 Multiple state or digital switch (speed setpoint) ground

D2.1.43 Analog input (with pullup Multiple state or digital switch (speed setpoint) resistor) signal D2.1.65


Multiple state or digital switch (Torque/droop switch) ground

D2.1.62 Analog input (with pullup Multiple state or digital switch (Torque/droop resistor) switch) signal D2.1.76


Multiple state or digital switch (controller mode, power boost) ground

D2.1.44 Analog input (with pullup Multiple state or digital switch (controller mode, resistor) power boost) signal D2.1.29


D2.1.32

Digital input (with pullup Resistor)

D2.1.55

D2.1.86



D2.1.21

Power output high

D2.1.41


D2.1.49

D2.1.66

D2.1.42

D2.1.47

D2.1.74

© 2007 DEUTZ AG



Digital switch input ground

remark / technical data Digital input external switch to GND, Rup = 100 kOhm, Ulow = 2,4V, Uhigh = 3,6V Connected to UGND inside of ECU. Analog input, UIN = 0 ... 5 V, R up = 3,4 kOhm Connected to UGND inside of ECU. Analog input, UIN = 0 ... 5 V, R up = 1,4 kOhm Connected to UGND inside of ECU. Analog input, UIN = 0 ... 5 V, R up = 3,4 kOhm Connected to UGND inside of ECU.

Override switch

Digital input external switch to GND, Rup = 4,1 kOhm, Ulow = 2,2V, Uhigh = 3,8V

Coolant level switch


Droop choice switch

Digital input external switch to GND, Rup = 5 kOhm, Ulow = 4,6V, U high = 8,7V

Supply digital swiches


Engine Stop-switch


Parking brake optional redundant brake switch


Gear switch


Air filter differential pressure switch


Engine brake switch


Engine start switch




44


45


Pin


D2.1.85



Oil-Level switch

D2.1.21

Power output high

D2.1.31


D2.1.64

D2.1.46

Supply digital switches

D2.1.71

Digital input with comparator

Speed switch (-)


Speed switch (hold/resume)


Vehicle speed sensor ground


Vehicle speed sensor signal

Ri = 3,1 kOhm, Ulow = 1,0 V, Uhigh = 5,42 V fmax= 5 kHz

D2.1.33 Digital output with pullup resistor(small signal), Engine speed output signal switch to GND, PDM Output D2.1.22


Speed switch (+)






D2.1.70


Power output UBat+ Diagnostic lamp supply HS

50mA fmax 5kHz Standard: 60 pulse per rev. 0,3A@12V; 4W@24V nominal 0,3A inrush current 0,9A

D2.1.30


D2.1.13

Power output UBat+

D2.1.20


Warning oil pressure/level lamp LS

0,3A@12V; 4W@24V nominal 0,3A inrush current 0,9A


Warning fuel-/airfilter/fuelpress. lamp LS



Warning coolant temp/level lamp LS

0,3A@12V; 4W@24V nominal 0,3A Inrush current 0,9A


Preheat lamp LS



Engine running/warning boost air temp lamp LS


D2.1.38

D2.1.39

D2.1.54

D2.1.56

Diagnostic lamp LS Battery plus output for warning lamps


D2.1.17


Starter relay LS

Lmax=130mH Imax=2A

D2.1.37

Power switching output high-side to Vbat+

Starter relay HS

D2.1.68

Sensor supply

Fan speed sensor supply

VOUT = 5V

D2.1.67


Fan speed sensor ground


© 2007 DEUTZ AG

EMR3

Pin


D2.1.69

Digital input

D2.1.14

Power output high


fmax=1kHz

Fan control actuator HS

Rmin >30Ohm @24V Rmin >10,6Ohm @12V L=15...80mH inrush current 1,9A@16V (15 minutes) fmax=300Hz fmin=15Hz


Fan control actuator LS

D2.1.24


Exhaust gas or cylinder head temperature sensor ground

D2.1.25 Analog input (with pullup Exhaust gas temperature sensor signal resistor) GND reference for sensors and actuators.

Oil temperature sensor ground

D2.1.27 Analog input (with pullup Oil temperature sensor signal resistor) D2.1.26


Fan speed sensor signal

D2.1.15

D2.1.28

46

Oil level sensor Oil level sensor

D2.1.72


Oil level sensor ground

D2.1.23


Torque PDM output signal

D2.1.51


Reserve 2 (LS), PDM

D2.1.57

Power output UBat+

D2.1.16


Reserve 1, Actuator HS

Connected to UGND inside of ECU. Analog input, UIN = 0 ... 5 V, R up = 1,4 kOhm Connected to UGND inside of ECU. Analog input, UIN = 0 ... 5 V, R up = 1,35 kOhm Signal evaluation with constant current source 247mA Connected to UGND inside of ECU IMAX = 50 mA, fMAX = 300Hz IMAX = 50 mA, fMAX = 1kHz VOUT = UBAT, IMAX = 2,4 A, LMAX = 130 mH

Reserve 1, Actuator LS

D2.1.81 Analog input (with pullup Crank case pressure or engine speed resistor) precontroller sensor signal

Analog input, UIN = 0 ... 5 V, R up = 100 kOhm

D2.1.82

Sensor supply

Crank case pressure or engine speed precontroller sensor supply

VOUT = 5V

D2.1.83


Crank case pressure or engine speed precontroller sensor ground

Connected to UGND inside of ECU

D2.1.34

CAN driver

D2.1.35

CAN driver

D2.1.52

CAN driver

Customer - Controller area network CAN

CAN low CAN high

Diagnostic - Controller area network CAN

CAN low

D2.1.53

CAN driver

CAN high

D2.1.89

ISO-K Interface

Diagnostic, programming

D2.2.03


D2.2.07


D2.2.08


D2.2.04

© 2007 DEUTZ AG

K-Line communication

Battery supply output (HS) Preheat relay actuator or glow plug for flame start LS

Preheat sense switch

Analog output (UBAT via Fuel valve for flame start actuator HS internal main relay)

UBat max. 130mH Rmin > 6 Ohm @ 12V Rmin > 16 Ohm @ 24V Digital input external switch to GND, Rup = 5 kOhm, Ulow = ?, Uhigh = ? 0,75ANenn@24V 14,5-15mH@24V

47


Pin



remark / technical data 12V: no fuel valve for flame start available

D2.2.05


D2.2.03


D2.2.06


D2.2.10


External EGR or Fuel valve for flame start actuator ground Battery supply output (HS) Engine brake flap actuator LS Camshaft speed sensor ground

D2.2.09 Schmitt-trigger input with threshold adaption for Camshaft speed sensor signal engine speed sensor signal. D2.2.19


Crankshaft speed sensor ground

D2.2.23 Schmitt-trigger input with threshold adaption for Crankshaft speed sensor signal engine speed sensor signal.

Connected to UGND inside of ECU. UBat Rmin > 42 Ohm@24V Rmin >14 Ohm@12V Lmax < 480mH @12V Connected to UGND inside of ECU. Induktivsensor, Uin=0,2 ... 80V AC, fin= ?

Connected to UGND inside of ECU. Induktivsensor, Uin=0,2 ... 80V AC

D2.2.12


Rail fuel pressure or crank case pressure sensor ground


D2.2.13

Sensor supply

Rail fuel pressure or crank case pressure sensor supply (G3)

VOUT = 5V, max 50mA

D2.2.14 Analog input (with pullup Rail fuel pressure or crank case pressure sensor resistor) signal

Analog input, UIN = 0 ... 5 V, R up = 5,6 kOhm

D2.2.15 Analog input (with pullup Coolant temperature sensor signal resistor)


D2.2.26


D2.2.16

Analog output / sensor supply

D2.2.18


Coolant temperature sensor ground Low fuel pressure sensor supply (G2) Low fuel pressure sensor ground

D2.2.22 Analog input (with pullup Low fuel pressure sensor signal resistor) D2.2.18


Fuel temperature sensor ground

D2.2.35 Analog input (with pullup Fuel temperature sensor signal resistor) D2.2.17


Customer temp. 1 (gear box oil) ground

D2.2.29 Analog input (with pullup Customer temp. 1 (gear box oil) sensor signal resistor) D2.2.32

Sensor supply

Oil pressure sensor supply (G2)

D2.2.27 Analog input (with pullup Oil pressure sensor signal resistor)

Connected to UGND inside of ECU. VOUT = 5V Connected to UGND inside of ECU. Analog input, UIN = 0 ... 5 V, R up = 6,81 kOhm Connected to UGND inside of ECU. Analog input, UIN = 0 ... 5 V, R up = 1,3 kOhm Connected to UGND inside of ECU. Analog input, UIN = 0 ... 5 V, R up = 1,3 kOhm VOUT = 5V Analog input, UIN = 0 ... 5 V, R up = 6,81 kOhm

D2.2.24


Oil pressure sensor ground


D2.2.24


Water in fuel sensor ground


D2.2.28 Analog input (with pullup Water in fuel sensor signal resistor) D2.2.33

Sensor supply

Boost air pressure/temp. sensor supply (G1)

Analog input, UIN = 0 ... 5 V, R up = 120 kOhm VOUT = 5V

© 2007 DEUTZ AG

EMR3

Pin


D2.2.25



48

remark / technical data Connected to UGND inside of ECU.

Boost air pressure/temp. sensor ground

D2.2.34 Analog input (with pullup Boost air pressure sensor signal resistor)

Analog input, UIN = 0 ... 5 V, R up = 680 kOhm

D2.2.36 Analog input (with pullup Boost air temperature sensor signal resistor)


D2.2.03


D2.2.05


D2.2.11

D2.2.02

UBat



External EGR or Fuel valve for flame start actuator ground

Digital output / PWM (small signal), switch to External EGR actuator LS GND GND reference for sensors actuators.

max. 50mA, 200Hz


Engine stop and reserve switch ground

D2.2.21 Analog input (with pullup Engine stop or reserve switch resistor) D2.2.20


Analog input, UIN = 0 ... 5 V, R up = 1,1 kOhm Connected to UGND inside of ECU.

Reserve pulse input ground

D2.2.30 Schmitt-trigger input with threshold adaption for Reserve pulse input signal engine speed sensor signal.

D2.2.01


Induktivsensor, Uin=0,2 ... 50V AC

DEUTZ 12V application: I_Out=1.7A @ Vbat=14.4V, L=160mH, frequency=300Hz, I_Out=3.1A @ Vbat=14.4V, L=10mH, frequency=1Hz, DEUTZ 24V application: I_Out=0.9A @ Vbat=28.8V, L=600mH, frequency=300Hz, I_Out=1.7A @ Vbat=28.8V, L=44mH, frequency=1Hz

Engine brake internal or IEGR actuator LS

D2.3.04

Injector output high-side Injektoren 1 (Y15.1), 3 (Y15.3), 5 (Y15.5) und 7 (Y15.7) = Bank 1

Y15.1/3 CR 4 und 6 Zylinder / PLD 6 und 8 Zylinder /5/7

D2.3.03

Injector output high-side Injektoren 2 (Y15.2), 4 (Y15.4) 6 (Y15.6) und 8 (Y15.8) = Bank 2

Y15.2/4 CR 4 und 6 Zylinder / PLD 6 und 8 Zylinder /6/8

D2.3.13


D2.3.15


D2.3.06


D2.3.14


D2.3.12


D2.3.16


D2.3.07

Injector 1 "low", Bank 1

(Y15.1)

Y15.1



(Y15.2)

Y15.2



(Y15.3)

Y15.3



(Y15.4)

Y15.4



(Y15.5)

Y15.5



(Y15.6)

Y15.6




(Y15.7)

Y15.7

PLD 8 Zylinder

D2.3.08



(Y15.8)

Y15.8

PLD 8 Zylinder

D2.3.09

Power switching output high-side

Fuel metering unit (MPROP) supply HS

D2.3.10


Fuel metering unit (MPROP) LS

© 2007 DEUTZ AG

VOUT = UBAT, IMAX = 1,3 A

49

EMR3 System description The table above illustrates the maximum assignment of the control unit pins. However, in practice, not all the named pins are actually assigned. Pins which are not listed are generally not used by the EMR3 system.

© 2007 DEUTZ AG

EMR3 1.5.2.5

Circuit diagrams The following plans are a compendium of a great amount of plans, that are created for every application. For your application you have to contact your dealer and ask for specific plan.

© 2007 DEUTZ AG

50

51


Example: engineside TCD 2013 L6 4V with EDC 16

© 2007 DEUTZ AG

EMR3

Example: engineside TCD 6V 2015 with EDC 7

© 2007 DEUTZ AG

52

53


Example: engineside TCD 2013 L6 4V with EDC7

© 2007 DEUTZ AG

EMR3

Example: engineside TCD 2012 L6 2V mwithEDC16

© 2007 DEUTZ AG

54

55


Example: vehicle side EDC16

© 2007 DEUTZ AG

EMR3

Example: vehicle side EDC16 and glowplug

© 2007 DEUTZ AG

56

57


Example: vehicle side EDC16 and heater

© 2007 DEUTZ AG

EMR3

Example: vehicle side with EDC7

© 2007 DEUTZ AG

58

59

1.6


Service tasks The engine control unit of the EMR3 system operates with a much greater number of arithmetic values (incl. measured values) and parameters, than its predecessor. As a comparison: approx. 600 parameters were stored in the EMR2 and 9,000 in the EMR3. Since only a small number of them are necessary for the normal service and maintenance work, this system description does not contain a list of all the arithmetic values and parameters but concentrates on the tasks which are stored for the EMR3 system in the SERDIA diagnosis software instead. The individual tasks are described below. Deutz reserves the right to control the access to individual tasks via the SERDIA interface.

© 2007 DEUTZ AG

EMR3

1.6.1

60

Calibrating foot pedal and hand throttle The EMR3 system must/can be calibrated for every newly integrated setpoint transmitter (foot pedal or hand throttle) to be able to process its signals correctly.

© 2007 DEUTZ AG

61


© 2007 DEUTZ AG

EMR3

1.6.2

Setting idle speed The user can finely adjust the lower idling of the engine to his system with this function.

© 2007 DEUTZ AG

62

63

1.6.3


Setting Droop 1 The user can adjust the Droop 1 of the data record here.

© 2007 DEUTZ AG

EMR3

1.6.4

Setting Droop 2 The user can adjust the Droop 2 of the data record here.

© 2007 DEUTZ AG

64

65

1.6.5


Setting fixed speed The user can adjust the fixed speed of the data record here.

© 2007 DEUTZ AG

EMR3

1.6.6

Setting emergency speed The user can adjust the emergency speed/limphome speed of the data record here.

© 2007 DEUTZ AG

66

67

1.6.7


Setting pulse rate for vehicle speed The user can adjust the wheel pulses of the system in the data record here.

© 2007 DEUTZ AG

EMR3

1.6.8

Setting vehicle maximum speed The user can adjust the maximum vehicle speed of the system in the data record here.

© 2007 DEUTZ AG

68

69

1.6.9


Initialize the EEPROM The user can perform initialisation of the EEPROM here after an operating software download.

© 2007 DEUTZ AG

EMR3

70

1.6.10 Updating operating software Unlike the previously mentioned service tasks, the Update Operating Software (mainsoftware = BSW) task cannot be reached with the Tasks button but has its own menu item.

A not programmed ECU from stock will appear with this SerDia-Window (bootloader mode, PA-Mode) Down to SerDia-interface Level 3 the user is able to program the ECU with new main software. With Level 3 you need an additional password for the interface. The password could be ordered from the DEUTZ headquarter.

The datasets will be copied from our database DEUTZ-MOTDOK and are available in different combinations. For main software-programming (means "program download") you need the crypted dataset. The crypted dataset has got a size of about 800kbytes and contains main software plus enginespecific dataset. It could only is transferred with SerDia.

© 2007 DEUTZ AG

71


Put in the wanted files.

Caution : In this mode the Service-Tool SerDia2000 doesn´t check the data-integrity. Programming the wrong main software to the wrong ECU may cause irreparable damage to the ECU.

From SerDia2000-Version 1.3.2 on, an automatic process has been implemented, which should lead the user through the programming process. Only if possible, serDia2000 makes an backup of existing ECU-dataset. After main software-transfer SerDia2000 tries to write back the old data, deletes both errormemories and initializes the internal EEPROM. If the ECU contains already main software, SerDia tries to save the stored ECU data itself to a backup file. The backup file is located in the activated SerDia-directory.

© 2007 DEUTZ AG

EMR3

72

If the communication is disturbed, the following message appears. Normally the ECU falls back into the bootloader-Mode. In bootloader-mode you can try to program the ECU once again. Sometimes it is possible, that the communication is disturbed, while ECU is flashing the protected area. In this case the ECU will not return to bootloader mode anymore, because the security areas of the ECU-memory have been damaged. Only the manufacturer is able to reanimate those ECU´s.

© 2007 DEUTZ AG

73


Disturbing the communication may have different reasons.  bad wiring  loose contact  too long wiring  bad USB-cable (length< 2m)  too high Baudrate (default is 57 600 Bits/sec)  corrupted file The following message is shown, when the basic initialisation (old dataset programming, store old counter values , EEPROM init, erase errormemory) was not finished correctly. In this case the user has to do the above mentioned precesses by hand.

© 2007 DEUTZ AG

EMR3

74

1.6.11 IO-Testing With this window you are able to toggle some digital outputs of the ECU, if they are activated. Caution: You are going to change the parameter and the dataset by doing this. Please, make sure, that the old configuration is active, when you leave this menu.

© 2007 DEUTZ AG

75

1.7


Diagnostics The aim of every engine diagnosis is the fast detection of system faults as a precondition for efficient, low-cost services. The self and system diagnosis carried out permanently by the ERM3 engine control unit in connection with entries in the error memory provides an efficient tool here. For diagnosis in cases in which no error is indicated but the engine still exhibits a malfunction, the control unit provides possibilities for monitoring and recording measured values and displaying and modifying parameterisation data of the engine control unit via its diagnostic interface. The diagnosis tool recommended by DEUTZ is the PC software SERDIA which offers all functions necessary for diagnosis, setting and repair work on the EMR3 system. SERDIA enables display and recording of measured values, display, editing, reading (from PC files) and writing (in PC files) of parameterisation data or display and deletion of the error memory content. It should be noted that the possibilities which SERDIA offers the service technician depend on the competence level of the connecting cable with which the connection between the SERDIA-PC and the EMR3 diagnostic socket is made. The SERDIA software and the interface cable can be ordered from the DEUTZ sales partner: WILBÄR Wilhelm Bäcker GmbH & Co.KG Postfach 140580 42826 Remscheid Germany Email: [email protected] Fax: 0049 (0)2191 - 9339 -200 Tel.: 0049 (0)2191 - 9339 - 0 For further information see also DEUTZ - Technical Circular 0199 - 99 - 1166/0 EN.

1.7.1

Diagnostics with diagnostic key and error lamp The SERDIA software is first choice for all diagnosis tasks. The two elementary tasks of displaying active system errors and clearing the error memory can also be carried out with the diagnostic key and error lamp however.

Displaying system errors by blink code If there is at least one active system error in the error memory of the EMR3 engine control unit, it is indicated automatically by an evenly flashing error lamp (for serious system errors) or steadily lit error lamp (for less serious system errors). In this case the output of the error cause can be initiated in the form of blink codes (blink sequences according to the scheme i x short blink, j x long blink, k x short blink). Which blink codes exist and what they mean can be seen in the table of system errors. Reading out the blink codes for the active system errors requires the following steps:

© 2007 DEUTZ AG

EMR3

76

 Keep the diagnostic key pressed (for 1 to 3 s) until the flashing or steady light extinguishes.  Observe the blink code of the first or next active error after approx. 2 s.  Wait until the error lamp shows the original flashing or steady light again after approx. 5 s. By repeatedly performing this sequence, all the active system errors can be called. If reading out is continued after calling the last error, the output starts again with the first error. Example: 1 x short blinking, 2 x long blinking, 8 x short blinking = blink code 1-2-8; this blink code indicates a break or short-circuit in the wiring of the charge air temperature sensor. The time sequence of the blink signals is shown in the figure below:

Clearing the error memories The EMR3 engine control unit has got two error memories. Every error is saved simultaneously in both memories. Using the diagnostic key, it is possible to clear the passive errors in the first error memory. The second error memory can only be cleared with SERDIA. Below the steps for clearing the first error memory:     

Press and hold diagnostic key. Switch on ignition. While the error lamp is alight (duration: 2 s) release the diagnostic key. All passive errors in the first error memory are cleared. The clearing process is confirmed by three short blink pulses.

© 2007 DEUTZ AG

77

1.7.2


Diagnosis with SERDIA

Error memory When looking for the cause of a fault in the EMR3 system, a look in the error memory of the engine control unit can give valuable hints. The following figure shows the window of the EMR3 error memory in SERDIA:

LOGIN window for Level 3

© 2007 DEUTZ AG

EMR3

78

Error memory 2 - window (Superuser-Access and Level 3 + PWD Access)

Password for Error memory 2 and Level 3 access

No errormemory 2 - access, because of exceeding 50 engine hours

In EMR3-ECU-Errormemory the errors are shown with the notes location (affected components or EMR3-function), type (mode of error), status (active or passive) and frequency. Additionally every error has got environmental data from the first appearance and the last appearance. Interim values are nor stored. The environment data contain the measurements engine speed, boostpressure, torque, load, coolant temp, velocity, railpressure, battery voltage, injection mass and engine hours. The variables "DTC-Status, type 1, type 2" are for internal use only.

© 2007 DEUTZ AG

79


Measurements and parameters in case of troubleshooting Owing to the complexity of the EMR3 engine control unit, the detection of problems in the parameterisation is a demanding task which also includes observing characteristic measured values. The appropriate knowledge is taught by the DEUTZ Training Center.

© 2007 DEUTZ AG

EMR3

80

errormemory 1 and errormemory 2 of the ECU SerDia2000 is able to manage both errormemories in ECU. The following competence-classes (Levels) have been implemented.

SerDiaInterface

Level 1

Level 2

Level 3

Level 3A = 4

Level 3AS = 5

Error display and display and display and delete display and delete display and delete delete memory 1 delete Error no display, memory 2 no delete

1.7.3

display and delete with interfaceno display, password only and no delete within the first 50 enginehours

display and delete with interfacepassword only and display and delete within the first 50 enginehours

Table of system errors The following table lists the system errors which are detected and handled by the EMR3 engine control unit. The data from the "Cause of error" and "SERDIA error no." columns correspond to the error locations displayed in the SERDIA error memory window. "Prio" means that the errors are prioritised. A maximum of 10 active errors are displayed simultaneously in the EDC control unit. If more active errors exist the errors with higher priority are displayed first. Only when these errors have been eliminated, those with lower priority "follow" into the SERDIA error window.

The table of system errors ( = DTC-List = diagnostic trouble code list ) is not implemented in the PDF-Document of this system description. See extra PDF-document "DTC-List EMR3" in DEUTZGLOBAL-SIS. The error memory of EMR3-ECUs has got a limited size. If the errormemory is full, because of too many system faults, the ECU-mainsoftware displays the errors with highest priority first. The other errors won´t get lost, but will appear in memory, if the higher priorized errors are repaired.

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© 2007 DEUTZ AG

EMR3

1.8

Technical data Below you will find a list of technical data for the engine control unit of the EMR3 system.

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EMR3 System description EMR3-S (EDC 16 UC 40)

EMR3-E (EDC 7 UC 31)

12 V DC and 24 V DC, Supply voltage, working area

8 - 32 V DC,

9 - 32 V DC, enginestart from 6 V on

protected against polarity reversal, if Ubat+ is protected as described in DIN 8820 electrical protection

short circuit protection of any Pins against Ubat+ or Ubat–, if Ubat+ is protected as described in DIN 8820

max. distance between ECU and engine

current consumption without load

electrical grounding max. power consumtion

10 m @ harness environment temperature 85 °C and if power-supply is wired parallel with diameter 3 x 2,5 mm².

12 m @ harness environment temperature 85 °C and if power-supply is wired parallel with diameter 4 x 2,5 mm².

clamp 15 is OFF I < 35 mA bei 12 V / 24 V

clamp 15 is OFF I < 7,5 mA bei 12 V / 24 V

clamp 15 is ON I < 260 mA bei 12 V, I < 180 mA bei 24V

clamp 15 is ON I < 350 mA bei 12 V, I < 260 mA bei 24 V

IRMS = 2 A

IRMS = 7,5 A

chassis is connected via RC-Network with internal electric-ground-potential. with connected injection system: ca. 8 W

with connected injection system: ca. 12,5 W

with connected external loads: ca. 15 W

with connected external loads:: ca. 12,5 W

max permissable temperture range max permissable stroring temperture range

-40°C bis +85°C -40°C bis +40°C (10 years), +40° bis + 70°C (2000h)

dimensions without plug

203 mm x 167 mm x 38 mm

260 mm x 218 mm x 70 mm

dimensions with not connected plug

203 mm x 254 mm x 38 mm

260 mm x 218 mm x ca.150 mm

weight

0,7 kg without plug

1,6 kg without plug

mounting

cabine mounted (not engine mounted), cooling via air convection

datamemory humidity environment protection

data-conservation < 10 Jahre < 95% (bei +40°C), Standard: DIN-IEC 60068-2-2 IP 69K, Standard: DIN 40050

internal strength against shock

acceleration: < 1000 m/s² @ 6 ms (max. 3 mal), Standards: DIN IEC 60068-2-27, DIN 40046

internal strength against shock

< 1,6 mm bei 10...25 Hz, < 12,00 g [m/s2] bei 100 Hz, < 6,00 g [m/s2] bei 400 Hz

chemical resistance ECU housing diagnosis interface data interface plug connection EMC

environment resistance

Resistent against substances, that are used for enegines Aluminium, diescasting, not varnished ISO 9141 K-Line 2 x CAN-Bus, SAE-J1939 engineside: 1x 36-polig, 1 x 16-polig, vehicleside: 1x 89-polig

engineside 1x 60-polig, vehicleside:: 1x 94-polig

EMC-terms of referenceEU 89/336/EWG, ISO 11541, ISO 11542, ENV 50204, EN 61000-4-3 up to 100 V/m ISO 7637, EN 61000, VDE 0879 salt atomized spray: nach DIN EN 60068-2-11 industrial envioronment DIN EN 60068-2-38 / -2 temperature variation: DIN EN 60068-2-14

© 2007 DEUTZ AG

EMR3

© 2007 DEUTZ AG

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Abmessungen des Motorsteuergerätes EMR3-E

© 2007 DEUTZ AG

EMR3

Abmessungen des Motorsteuergerätes EMR3-S

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Installation instructions (Excerpt. For complete binding specification on fastening and installation position, among other things, see DEUTZ installation guideline) It must be ensured that no water can get into the control unit through the pipes. The pressure compensation (DAE) element and the sealing area may not be immersed in water. The control unit may not bounce in the vehicle. The cable harnesses must be secured mechanically in the area in which the control unit is installed (distance < 150 mm). It must be ensured that the cable harnesses are excited with equal phase to the control unit (e.g. by fastening to the screw point of the control unit).

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EMR3

1.9

88

Glossary DCR® DEUTZ Common Rail. Injection system with central high pressure generation and pressure storage (in the rail). DMV DEUTZ solenoid valve: Injection system with high pressure generation per cylinder according to the pump-line-nozzle principle.

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Index

-E-

-Aapplication data

3

-BBase System functions blink code 75 bootloader 70 BSW 3, 70

3

-Ccalibration 3 CAN-bus 16 CAN-Bus interface 18 CAN-Standard-Function 18 chemical resistance 82 complete dataset 3 connecting plugs 1 current consumption 82

-Ddata interface 82 DCR 3, 88 Description of functions 3 DEUTZ ROAD-MAP 3 DEUTZ sales partner 75 DEUTZ-MOTDOK 70 Diagnostic interface 16 diagnostic key 75 Diagnostic plug 23 digital outputs 74 Dimension 82 dimensions 82 Displaying system errors 75 DMV 3, 88 Droop 1 63 Droop 2 64 DTC-List 80

ED 16 UC 40 28 EDC 16 UC 40 82 EDC 7 UC 31 35, 82 EEPROM 69 electrical system 1 Electrical welding 1 EMC 82 EMR3-Systems 3 Engine control unit 3 environment protection environment resistance error lamp 75 error memories 75 Error memory 2 77 Error path name 80 errormemory 1 77 errormemory 2 77

82 82

-Ffixed speed 65 FMI description 80 FMI-Codes 80 foot pedal 60

-Hhand throttle 60 humidity 82

-IInstallation instructions ISO-9141 16

82

-KKWP2000 16 KWP2000-Codes

80

-Llimphome

66

© 2007 DEUTZ AG

Index LOGIN window 77 lower idling 62

Supply voltage

-T-

-Mmain relay 25 main software 3 mainsoftware 70 manufacturing data 3 max. power consumption minimum equipment 3 monitoring functions 14

tasks 59 Technical Circular 75 terminal 15 25 terminal 30 25 Transmit Messages 18 82

-Vvehicle speed

-NNo errormemory 2

77 weight 82 wheel pulses 67 wiring diagram 50 70

-Ppart numbers 13 partitial dataset 3 passive errors 75 Password 77 Pin assignment 23, 28, 35 pin D+ 25 Pinout 28, 35 plug connection 82 Prio 80

-RReceive Messages

18

-SSensors and actuators 1 SERDIA 75 SERDIA error memory window SERDIA error no 80 SERDIA software 75 software combinations 13 SPN-Code 80

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-W-

-OOperating Software

82

80

90

Back Cover

DEUTZ AG Sales and Service Information Systems Ottostr. 1 51149 KÖLN Phone: +49 (0) 2 21 - 822 - 0 Fax: +49 (0) 2 21 - 822 - 5358 Internet: www.deutz.com Email: [email protected] Gedruckt in Deutschland Alle Rechte vorbehalten 1. Auflage, 08/2007 Bestell-Nr.:

Manual modulo EDC7UC311

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