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Systembeschreibung
EMR3
by DEUTZ AG
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© 2007 DEUTZ AG
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including No parts ofrecording,
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or by any means
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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.
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Inhalt
EMR3 1
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
Index 89
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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, finken.h@deutz.com). Wir bewerten jede Meldung sorgfältig und
veröffentlichen Neuauflagen dieses Dokumentes, sobald sein Inhalt verändert wurde.
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, finken.h@deutz.com). 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.
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1 EMR3
1.1 Foreword
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, benke.m@deutz.com).
Safety
The fuel systems described in this document operate under very high pressures. The
appropriate
the workbecause
fuel system guidelines from thethere
otherwise workshop manual
is a danger must be observed for all work on
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).
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EMR3 2
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.
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Speed sensors
Error lamp*
Diagnostic button*
Diagnostic socket*
low consumption,
quiet engine running,
long engine
efficient life,
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),
engine monitoring,
system diagnosis.
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EMR3 4
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Description of functions
The hardware of the EMR3 contains (roughly described):
o
oone
memoryCPU (MOTOROLA central processing unit)
flash-memory (for software and parameters)
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)
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.
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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.
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)
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o ECU controls a heating flange or the glow plugs or the flame heating
o Data communication
o Interfaces, diagnostics and programming
o Output of fault fault blink codes
o Simplified fault diagnosis
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EMR3 8
data interface /
protocol 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
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post injection (e.g. to higher the exhaust gas temperature for urea-injection)
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EMR3 10
The following schematic diagrams show the EMR3 system in connection with the injection system.
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EMR3 12
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The consecutive
connected systemdesignation
functions. aaa ... ddd indicates the development state of the software and the
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:
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)
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EMR3 14
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.
User defined combinations of warning strategies are not possible any more
(look
testedfunctional description of sales department) and the user has to use the
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
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EMR3 16
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
competence and parameters.
classes, The access tointhe
which are implemented theECU and the SerDia-Menu isThe
SerDia-Hardware-Interface. controlled by
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.
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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.
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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 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
can SERDIA.
be used TheCAN
with any SAE-J-1939
diagnosisprotocol on and
hardware the other handFor
software. is internationally
this, standard standardised
messages areand
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.
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 units.
control lines CAN-High and CAN-Low, for diagnostic purposes and communication between the
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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
Receive Messages:
Po Name Repetitio Identifier
DLC J1939 Identifier
s. n
Data Sourc
Reserve Page PDU PDU e
Priority d F S Addre rate
Byte 1 Bit Hex
3 Bit 1 1 ss (msec)
1 Bit (P+R+D Byte Byte
P) 1 Byte
1 Request 3 6 0 0 (18) EA 00 3 0 18 EA 00
03
Ignorie 0 08 FF 16
2 Engine Stop request 1 2 0 0 (08) FF 16
rt xx
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EMR3 20
Transmit Messages:
Pos Name DLC J1939 Identifier Repetitio Identifier
. n
Data PDU SrcA
Byte Priorit
y Reser
ved Page PDUF S ddr. RATE Hex
3 Bit 1 Bit 1 Bit 1 Byte 1 1 (msec)
(P+R+DP) Byte Byte
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
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EMR3 22
1.5.2 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.
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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)
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EMR3 24
pin assignment
A Battery minus (-)
B Battery plus (+)
K ISO 9141 K-Line Diagnosis
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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.
Circuit diagram
The marking of the relay-pins is not compatible to the DEUTZ wiring diagrams.
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EMR3 26
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EXAMPLE:
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EMR3 28
Pin assignment
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EMR3 30
Signalinput, analog, mit Pullup- multiple state switch Uin = 0...5 V, R up = 2,3 kW
D2.2.15
Widerstand for speed
Signalinput, analog, mit Pullup- multiple state switch Uin = 0...5 V, R up = 2,3 kW
D2.2.89
Widerstand for droop
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Uhigh = 3,7 V
D2.2.71 power supply (–), switched Oil signal lamp 0,3 A bei 12 V, 4 W bei 24
V
D2.2.51 power supply (+), switched Oil signal lamp Einschaltstrom 0,9 A
D2.2.76 power supply (–) oil temp sensor Intern mit UGnd connected
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EMR3 32
D2.2.59 power supply (–) Fan speed sensor Intern mit UGnd connected
R > 30 W bei 24 V
D2.2.73 power supply (+) fan control R > 10,6 W bei 12 V
L = 15...80 mH
Einschaltstrom 1,9 A bei
16 V (15 Minuten)
f max = 300Hz
D2.2.90 power supply (–), switched fan control
f min = 15Hz
D2.2.32 Signalinput, analog, mit Pullup- Temperaturesensor Uin = 0...5 V, R up = 1,3 kW
Widerstand (customerspecific)
Temperaturesensor Intern mit UGnd connected
D2.2.33 power supply (–)
(customerspecific)
Signalinput, analog, mit Pullup- exhaustgas temp Uin = 0...5 V, R up = 11,05
D2.2.34
Widerstand sensor kW
exhaustgas temp Intern mit UGnd connected
D2.2.35 power supply (–)
sensor
PDM-output Imax = 50 mA, f max = 1 KHz
D2.2.26 signal output, digital
(customerspecific)
PDM-output Intern mit U connected
power supply (–)
D2.2.39 (customerspecific) Gnd
D2.2.27 signal output, digital
PDM-output torque Imax = 50 mA, f max = 300 Hz
(customerspecific)
Externer Schalter zu UBat,
D2.2.74
Signalinput, digital, mit Pulldown- switch Rdown = 6,8 kW, Ulow = 2,2 V,
Widerstand (customerspecific)
Uhigh = 3,7 V
sensor UOut = 5 V
D2.2.24 power supply (+)
(customerspecific)
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D2.1.53
Signalinput, analog, mit Pullup- boost temp sensor Uin = 0...5 V, Rup = 1,28 kW
Widerstand
D2.1.20 Shield cam shaft sensor Intern mit UGnd connected
Signalinput (+), digital, mit Schmitt- Cam shaft speed
D2.1.10
Trigger mit Schwellwert-Anpassung sensor inductive sensor, Uin = 0,2...80
Signalinput (–), digital, mit Schmitt- Cam shaft speed V~
D2.1.50
Trigger mit Schwellwert-Anpassung sensor
D2.1.41 power supply (–) coolant temp sensor Intern mit UGnd connected
Signalinput, analog, mit Pullup- coolant temp sensor Uin = 0...5 V, Rup = 1,28 kW
D2.1.58
Widerstand
D2.1.7 Schirm crank shaft speed Intern mit UGnd connected
sensor
Signalinput (–), digital, mit Schmitt- crank shaft speed
D2.1.12
Trigger mit Schwellwert-Anpassung sensor inductive sensor, Uin = 0,2...80
Signalinput (+), digital, mit Schmitt- crank shaft speed V~
D2.1.27
Trigger mit Schwellwert-Anpassung sensor
power supply (–), switched, mit R > 42 W bei 24 V
exhaust gas break
D2.1.45 recovery diode zu U
valve control R > 14 W bei 12 V
Bat L < 480 mH bei 12 V
exhaust gas break
D2.1.29 power supply (+), switched
valve control
für 12-V-Anwendungen:
IOut = 1,7 A bei V bat = 14,4 V,
L = 160 mH, f = 300 Hz,
IOut = 3,1 A bei V bat = 14,4 V,
internal exhaust gas
D2.1.60 power supply (–), switched L = 10 mH, f = 1 Hz,
break or EGR
für 24-V-Anwendungen:
IOut = 0,9 A bei V bat = 28,8 V,
L = 600 mH, f = 300 Hz,
IOut = 1,7 A bei V bat = 28,8 V,
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EMR3 34
Signalinput, analog, mit Pullup- fuel temp sensor or UIn = 0...5 V, R up = 1,28 k
D2.1.52
Widerstand crankshafthousing
pressure sensor W
power supply (–), switched oder PWM- fuel valve flame INenn = 1,3 A bei 24 V
D2.1.59 starting or external
Signal EGR L = 0...15 mH bei 24 V
fuel valve flame
D2.1.25 power supply (+) starting or external
EGR
fuel low pressure Intern mit UGnd connected
D2.1.54 power supply (–)
sensor
Signalinput, analog, mit Pullup- fuel low pressure UIn = 0...5 V, R up = 680 k
D2.1.57
Widerstand sensor W
D2.1.51 power supply (–) oil pressure sensor Intern mit UGnd connected
D2.1.8 power supply (–) rail pressure sensor Intern mit UGnd connected
Signalinput, analog, mit Pullup- rail pressure sensor U = 0...5 V, R = 4,6 kW
D2.1.43
Widerstand In up
D2.1.26 power supply (+) rail pressure sensor UOut = 5 V
Lmax = 130 mH, I max = 6
D2.1.30 power supply (+), switched Starterrelay
A
D2.1.15 power supply (–), switched Starterrelay
Signalinput, digital, mit Pullup- engine stop switch Rup = 6,8 kW, Ulow = 2,2
D2.1.35
Widerstand (optional) V, Uhigh = 3,7 V
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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.
socket D2.3 for connecting the engine cable harness for the fuel measuring unit and fuel
injectors.
Pin assignment
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EMR3 38
R=down = 4,1
2,2V, kOhm,
Uhigh U low
= 3,8V
D2.1. Digital input (with Engine start switch Digital input external
pulldown Resistor) switch to UBAT,
74
Rdown = 4,1 kOhm, U low
< 0,28xUBAT,
Uhigh > 0,68xUBAT
D2.1. Digital input (with Oil-Level switch Digital input external
pulldown Resistor) switch to UBAT,
85
Rdown = 4,1 kOhm, U low
< 0,28xUBAT,
Uhigh > 0,68xUBAT
D2.1. Power output high Supply digital switches VOUT = UBAT, IMAX = 10 A
21
D2.1. Digital input (with Speed switch (+) Digital input external
pulldown Resistor) switch to UBAT,
31
Rdown = 4,1 kOhm, U low
< 0,28xUBAT,
Uhigh > 0,68xUBAT
D2.1. Digital input (with Speed switch (-) Digital input external
pulldown resistor) switch to UBAT,
64
Rdown = 4,1 kOhm, Ulow
< 0,28xUBAT,
Uhigh > 0,68xUBAT
D2.1. Digital input (with Speed switch (hold/resume) Digital input external
pulldown resistor) switch to UBAT,
46
Rdown = 4,1 kOhm, U low
< 0,28xUBAT,
Uhigh > 0,68xUBAT
D2.1. GND reference for Vehicle speed sensor ground Connected to UGND
70 sensors and actuators. inside of ECU.
D2.1. Digital input with Vehicle speed sensor signal Ri = 3,1 kOhm, Ulow =
comparator
71 1,0 V, Uhigh = 5,42 V
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f max= 5 kHz
D2.1. Digital output with Engine speed output signal 50mA
pullup resistor(small fmax 5kHz
33 signal), switch to GND,
PDM Output Standard: 60 pulse per
rev.
Power output UBat+
D2.1.
22 Diagnostic lamp supply HS 0,3A@12V;
nominal4W@24V
0,3A
inrush current 0,9A
D2.1. Power switching output Diagnostic lamp LS
low side to GND
30
D2.1. Power output UBat+ Battery plus output for warning VOUT = UBAT, IMAX = 10 A
13 lamps
D2.1. Power switching output Warning oil pressure/level lamp LS 0,3A@12V; 4W@24V
low side to GND nominal 0,3A
20
inrush current 0,9A
D2.1. Power switching output Warning fuel-/airfilter/fuelpress. 0,3A@12V; 4W@24V
low side to GND nominal 0,3A
38 lamp LS
inrush current 0,9A
D2.1. Power switching output Warning coolant temp/level lamp 0,3A@12V; 4W@24V
low side to GND nominal 0,3A
39 LS
Inrush current 0,9A
D2.1. Power switching output Preheat lamp LS 0,3A@12V; 4W@24V
low side to GND nominal 0,3A
54
inrush current 0,9A
D2.1. Power switching output Engine running/warning boost air temp 0,3A@12V; 4W@24V
low side to GND nominal 0,3A
56 lamp LS
inrush current 0,9A
D2.1. Power switching output Starter relay LS Lmax=130mH
low side to GND Imax=2A
17
D2.1. Power switching output Starter relay HS
high-side to Vbat+
37
D2.1. Sensor supply Fan speed sensor supply VOUT = 5V
68
D2.1. GND reference for Fan speed sensor ground Connected to UGND
67 sensors and actuators. inside of ECU.
D2.1. Digital input Fan speed sensor signal fmax=1kHz
69
D2.1. Power output high Fan control actuator HS Rmin >30Ohm @24V
14 Rmin >10,6Ohm @12V
L=15...80mH
inrush current
1,9A@16V (15
minutes)
fmax=300Hz
fmin=15Hz
D2.1. Power switching output Fan control actuator LS
low side to GND
15
D2.1. GND reference for Exhaust gas or cylinder head temperature Connected to UGND
24 sensors and actuators. sensor ground inside of ECU.
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EMR3 42
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EMR3 44
D2.1.65 GND reference for Multiple state or digital switch (Torque/droop Connected to UGND inside of
sensors and actuators. switch) ground ECU.
D2.1.62 Analog input (with pullup Multiple state or digital switch (Torque/droop Analog input, UIN = 0 ... 5 V, R
resistor) switch) signal up = 1,4 kOhm
D2.1.76 GND reference for Multiple state or digital switch (controller mode, Connected to UGND inside of
sensors and actuators. power boost) ground ECU.
D2.1.44 Analog input (with pullup Multiple state or digital switch (controller mode, Analog input, UIN = 0 ... 5 V, R
resistor) power boost) signal up = 3,4 kOhm
0,28xU
Uhigh BAT,
> 0,68xU BAT
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EMR3 46
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EMR3 48
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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.
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EMR3 50
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.
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EMR3 52
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EMR3 54
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EMR3 56
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EMR3 58
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EMR3 66
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EMR3 68
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EMR3 70
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.
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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.
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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.
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loose contact
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.
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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.
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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:
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:
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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:
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EMR3 78
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.
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EMR3 80
SerDia-
Level 1 Level 2 Level 3 Level 3A = 4 Level 3AS = 5
Interface
Error display and display and display and delete display and delete display and delete
memory 1 delete delete
display and delete display and delete
Error no display, no display, with interface- with interface-
no delete password only and password only and display and delete
memory 2 no delete within the first 50 within the first 50
enginehours enginehours
"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 DEUTZ-
GLOBAL-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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EMR3 82
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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 U bat+ 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
10 m @ harness environment 12 m @ harness environment temperature
max. distance between ECU and temperature 85 °C and if power-supply 85 °C
engine is wired parallel with and if power-supply is wired parallel with
diameter 3 x 2,5 mm². diameter 4 x 2,5 mm².
clamp 15 is OFF clamp 15 is OFF
I < 35 mA bei 12 V / 24 V I < 7,5 mA bei 12 V / 24 V
current consumption without load clamp 15 is ON clamp 15 is ON
I < 260 mA bei 12 V, I < 180 mA bei
I < 350 mA bei 12 V, I < 260 mA bei 24 V
24V
IRMS = 2 A IRMS = 7,5 A
with connected injection system: ca. 8 with connected injection system: ca. 12,5 W
max. power consumtion W
with connected external loads: ca. 15 W with connected external loads:: ca. 12,5 W
max permissable temperture
-40°C bis +85°C
range
max permissable stroring -40°C bis +40°C (10 years), +40° bis + 70°C (2000h)
temperture range
dimensions without plug 203 mm x 167 mm x 38 mm 260 mm x 218 mm x 70 mm
dimensions with not connected
203 mm x 254 mm x 38 mm 260 mm x 218 mm x ca.150 mm
plug
weight 0,7 kg without plug 1,6 kg without plug
mounting cabine mounted (not engine mounted), cooling via air convection
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EMR3 84
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EMR3 86
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Installation instructions
(Excerpt. For complete binding specification on fastening and installation position, among other
things, see DEUTZ installation guideline)
ItThe
must be ensured
pressure that no water
compensation (DAE)can get intoand
element thethe
control unitarea
sealing through
maythe
notpipes.
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 88
1.9 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-
ED 16 UC 40 28
EDC 16 UC 40 82
-C- error
Error memories
memory 2
Error path name
75
77
80
calibration 3 errormemory 1 77
CAN-bus 16 errormemory 2 77
CAN-Bus interface 18
CAN-Standard-Function 18 -F-
chemical resistance 82
complete dataset 3 fixed speed 65
connecting plugs 1 FMI description 80
current consumption 82 FMI-Codes 80
-H-
data interface 82
DCR 3, 88 hand throttle 60
Description of functions 3 humidity 82
DEUTZ ROAD-MAP 3
DEUTZ sales partner 75 -I-
DEUTZ-MOTDOK 70
Diagnostic interface 16 Installation instructions 82
diagnostic key 75
Diagnostic plug 23 ISO-9141 16
digital outputs 74 -K-
Dimension 82
dimensions 82 KWP2000 16
Displaying system errors 75 KWP2000-Codes 80
DMV 3, 88
Droop 1 63 -L-
Droop 2 64
DTC-List 80 limphome 66
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Index 90
-P-
part 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
-R-
Receive Messages 18
-S-
Sensors and actuators 1
SERDIA 75
SERDIA error memory window 80
SERDIA error no 80
SERDIA software 75
software combinations 13
SPN-Code 80
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