Product Manual

Programmable Microprocessor-Based Pump Controller

for Electronic J1939 CAN Bus Diesel Engines
High Pressure Liquid Pump Applications

Part Number: EMT3-C10185

Customer:
Revision: 1.0
______________________________________________________________________________________________________________________________________
Copyright © Controls, Inc.
P.O. Box 368 • Sharon Center, OH 44274
Phone 330.239.4345 • Fax 330.239.2845 • www.controlsinc.com
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Basic Controller Operation

A. Engine Start/Stop
i. Rotate key to start position to crank engine.
ii. Once the engine has started, release key to run position.
iii. The controller will operate in manual throttle control mode when the toggle switch is
placed in “Manual” . Change in engine speed is achieved via the Hare / Turtle rocker
switch.
iv. To stop the engine, the key needs to be switched to the “Off” position.

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1) Introduction
1.1 The EMT3-C10185 is a microprocessor-based controller for industrial electronic engines with J1939 CAN
Bus. It is based on the Controls, Inc. 1410-000 series controller platform with Motorola/Freescale processor.
1.2 The product is housed in an 8”W x 10”H x 4”D polycarbonate enclosure that is rated NEMA 4X. The
controller is plug & play with all engine and accessory connectors incorporated into the enclosure.
1.3 The backlit digital display is 1”H x 4”W with two rows of 16 characters. Character height is approximately ½”.
1.4 Engine speed control is via Torque/Speed Controls (TSC) over the J1939 CAN Bus. Engine speed options
include:
1.4.1 Throttle with Memory – Operator can change the engine speed using the rabbit and turtle
membrane buttons within a programmed range (Min and Max Speed).
1.4.2 Manual / Automatic toggle is provided to integrate an operators discharge switch. The details of
switch integration are provided for later in the manual.
1.4.3 Note: All Bolded engine speed parameters above are programmable to allow engine
performance to match individual application requirements.
1.5 Engine Pre Alarm and Alarm codes are monitored with corresponding yellow or red LED illuminations above
the digital display.
1.6 Controller specific inputs / alarms are available for E-Stop (Digital), Fuel Level (Analog) with corresponding
engine shutdown, LED illumination and digital display message.
1.7 Controller is independent and does not require connection to a laptop computer to change programmable
settings.

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2) Interface
2.1 Display – The backlit digital display is 1”H x 4”W with two rows of 16 characters. Character height is
approximately ½”.
2.2 Display Parameters – The six full-time display parameters are:
· Water Temperature (Degrees F) · Battery Voltage
· Engine RPM · Fuel Rate (GPH) or Fuel Level (if fuel level sender installed)
· Oil Pressure (PSI) · Engine Hours
2.3 Menu & Enter Buttons – To access and scroll menus.
2.4 Hare/Turtle Rocker Switch – For engine speed (Up & Down) and for menu scrolling (Up & Down).
2.5 Key Switch – Auto/Off/Run
2.6 Fuse – 10 amp fuse
2.7 Controls, Inc can provide customer specific labels for the area below the LCD screen.
2.8 Amber (Pre Alarm) LED and Red (Alarm) LED located above the digital display to indicate Pre Alarm and
Shutdown indications.

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3) Enclosure
3.1 The product is housed in an 8”W x 10”H x 4”D polycarbonate enclosure that is rated NEMA 4X.
3.2 The enclosure is hinged. Door is held by four screws that are removable for internal access.
3.3 The controller is plug & play with all engine and accessory connectors incorporated into the enclosure.

Engine Harness System Interface

Connector Terminal Strip
HDP24-24-21PN

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4) Engine Start & Stop

4.1 The controller is manual start.
4.1.1 Manual Start – With the key in the manual start position, a display message of “Engine is Ready to
Start” will appear. Rotating the key to the start position will crank the engine. The engine is shut down
by turning the key to the “Off” position.

5) Engine Speed Control (Throttle Control)

5.1 Engine speed control is via Torque/Speed Controls (TSC) over the J1939 CAN Bus. With TSC, the
controller sends engine speed commands over the J1939 CAN Bus to the engine ECU/ECM (Engine
Control Unit/Module). The controller uses source address 44. The control panel source address can be
changed to 3, 17 or 44 using the controller menu system.
5.1.1 Vernier Memory Throttle
5.1.1.1 Manual Mode – Engine Speed can be changed within the programmed range using the Hare /
Turtle buttons.

(Max Speed) 2200 RPM

Engine
RPM

(Min Speed) 800 RPM

Engine Start Engine Off

5.1.1.2 Automatic Mode – Opening and closing the hydro Throttle Switch can change engine speed
between the programmed Minimum Speed and the Last Operating Speed for each run. The last
Operating Speed is the speed at which the engine was last when the Hydro Thottle switch was
opened, or the Throttle switch was changed to “Automatic”.

(Max Speed) 2200 RPM

(Last Operating Speed) 2000 RPM

Engine
RPM

(Min Speed) 800 RPM

Engine Start Engine Off

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6) Engine Pre Alarms & Alarms

6.1 The controller is a J1939 CAN reader. It gathers all engine related information from the CAN bus. Engine
Pre Alarms and Alarms/Faults can be managed by the engine ECU (Electronic Control Unit) and /or
monitored by the controller.
6.2 Engine Pre Alarms - In the case of an engine Pre Alarm, the yellow LED will illuminate (the engine will
continue to run). A trouble code, generated by the engine ECU will be displayed every 10 seconds on the
LCD.
6.2.1 If the Pre Alarm is generated by the engines ECU, the SPN.FMI (trouble code) will be flashed on the
LCD display every 15 seconds with a text message. These trouble codes correspond to the SPN.FMI
codes and are standardized codes used with the J1939 CAN Bus system. Each code represents a
specific engine issue. A partial list is located at the back of this manual.
6.2.2 If the controller generates the Pre Alarm, the display value will begin to flash on the LCD screen. If the
Pre Alarmed parameter is not a full time display parameter, a message will be displayed every 15
seconds on the display.
6.3 Engine Alarms/Faults - In the case of an engine Alarm/Fault, the red LED will illuminate and the engine will
shut down. A message will appear on the digital display. The message will be a brief description and/or a
reference to check the SPN.FMI code.
6.3.1 If the fault is generated by the engine’s ECU, the SPN.FMI (trouble code) will be displayed along with a
text message indicating which fault occurred. All engine ECU faults correspond to a specific SPN.FMI
(Suspect Parameter Number/Failure Mode Identifier) code. Each code represents a specific engine
issue.
6.3.2 The specific SPN.FMI codes can also accessed and viewed via the menu options (See Menus
Section). Both Active and Stored SPN.FMI codes can be retrieved. (A list of SPN.FMI codes is
provided in the SPN.FMI section.)
6.3.3 If the controller generates the Fault, a message will be displayed indicating which parameter caused
the fault. Example, “Low Oil Pressure Fault @ 9 PSI”.

7) Controller Specific Alarms

7.1 The controller monitors additional “system” inputs directly including:
7.1.1 Emergency Stop (Digital) - An Emergency Stop button can be attached to Term 12 on the control
board. Use a normally open button, which closes to ground. A shut down will occur when active.
7.1.2 Fuel Level Sender (Analog) - A Fuel Level Sender can be attached to Term 5 on the control board.
Use a 240 to 33 ohm scale for a 0 to 100% display. Attaching a fuel sender will automatically change
the LCD display from reading Fuel Rate to Fuel Level. A Pre Alarm is programmed at 20%. A shut
down will occur below 5%.
7.2 In the case of a fault, the engine will be shut down, the red LED will illuminate and a message will appear on
the digital display defining the specific shutdown condition.
7.3 To clear alarms, it is necessary to eliminate the cause of the alarm and cycle power to the controller (turn off
and back on).

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8) External Connectors
8.1 Engine Connection - The controller is connected to the engine via a 21-pin Deutsch plug (HDP24-24-21PN).
The pin out for the engine harness is shown below.

Pin B Battery + to Controller Pin J Battery + to Alternator

Pin D Battery + to Start Slave Relay Pin G Battery + to ECU/ECM
Pin E Battery - Pin L Analog Throttle Emulator
Pin F CAN Shield Pin M Analog Throttle Emulator
Pin V CAN High Pin C Analog Throttle Emulator
Pin U CAN Low Pin R Digital Throttle Emulator
Pin S Digital Throttle Emulator

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9) Controller Menus
9.1 The control panel has menus to view engine and controller parameters. These menus are accessible via a
four-button pad located on the face of the control panel.
9.2 Available Menus
Throttle Settings: Allows user to view & modify throttle settings.
(Requires password to modify)
Active SPN.FMI: View active SPN.FMI trouble codes.
Stored SPN.FMI: Retrieve stored SPN.FMI trouble codes.
CAN Link Configuration Allows user to modify source address for Torque Speed Signal
(Requires password to modify)
Engine Parameter: View active J1939 CAN Bus engine parameters.
Engine Configuration: View Speed, Torque and Governor Gain Information.

9.3 Menu Access & Navigation

9.3.1 Entering Menus

1. Press and hold the MENU key & simultaneously press the ENTER key.

9.3.2 Navigation
1. Press MENU to select the next menu category.
2. Press UP to view or edit the specific screen(s) in the category.
3. Use the UP and DOWN keys to move among the screens in the category.
4. Press MENU at any time within a category to jump back to the inner ring

9.3.3 Password Entry

The password screen is provided to restrict the edit of sensitive values to authorized personnel.
Not entering a password permits viewing, but no editing of restricted values. Upon encountering
the password screen, a series of dashes will be displayed. To enter the password:

1. Press ENTER to begin editing. The password zeroes will be bracketed.

2. Use the UP and DOWN keys to set the first (leftmost) digit, as you would for a cylinder
combination lock.
3. Press ENTER to freeze that digit and move to the next one on the right.
4. Repeat steps 2 and 3 until all digits have been set. After the final digit is set, the brackets
automatically disappear.
5. Press the UP key to proceed to the next screens.

If the correct password was entered earlier, navigating back over the password entry screen will
show the password as a row of stars. The password approval state is retained as long as the
panel is powered up.

9.3.4 Editing
Some screens permit parameter changes.
1. Press ENTER to start editing. The value on the screen will be surrounded by brackets. On
password-protected screens, brackets appear only when the correct password was entered
earlier.
2. Use the UP and DOWN keys to adjust the value. In the case of a selection list, the various
possible selections will be shown in a ring. In the case of a variable number, press the
appropriate key to step up/down. For larger changes, press and hold the UP or DOWN key.
(The value will step faster as the key is held down. Stepping will stop when preset value limits
are reached or the key is released.)

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3. Press ENTER to save the new value. The brackets will disappear.
4. To skip the edit and retain the old value, press MENU instead of ENTER.

9.3.5 Exiting
1. Press and hold the MENU key & simultaneously press the ENTER key.

Leaving during editing will abandon the edit and the old value will be retained. Exiting has no
effect on the password approval. To clear the approved password state, power cycle the panel.

9.4 Reset to Factory Settings – The factory default settings can be reset in two ways:
9.4.1 Reset Procedure (See picture below)
1. Turn the key to the Auto position.
2. Open the enclosure to access the circuit board.
3. Make connection between two pins labeled “JP10” with screwdriver or other metal
device
4. Push micro button down and release.

JP10Pins

Micro Button

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9.5 Factory Settings

Parameter Setting

Throttle Settings Manual 850 RPM 2400 RPM

CAN Link Config (Source Address) 44 3 – 17- 44

CAN Link Config (TSC1 Address) 44 3 – 17- 44

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10) Terminal Strip Connections

CAN Bus Connector

Control Inputs
Control Outputs

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10.1 Below is a list of connection definitions for circuit board mounted terminal connectors.

1 Battery Positive 17 Key ON Power to ECU

2 Battery Negative 18 Battery + Common
3 19 O
I
4 Panel Ground 20 Alternator Excite (D+) U
N
5 Fuel Level Sender 240-33 ohm T
P
7 Override Switch Input
P
U
U
T 8 Hydro Throttle Switch Input
T
S 12 Emergency Stop Input
S
45 CAN J1939 High
46 CAN J1939 Low
47 CAN J1939 Shield

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11) Dipswitches
11.1 Dipswitch Definitions - The controller is connected to the engine via a 21-pin Deutsch plug for direct plug
and play with the standard John Deere engine connector. The pin out for the engine harness is shown
below.
Dipswitch 1 Not Used.
Dipswitch 2 Not Used.
Dipswitch 3 Not Used.
Dipswitch 4 Not Used.
Dipswitch 5 Not Used.
Dipswitch 6 Not Used.
Dipswitch 7 Not Used.
Dipswitch 8 Not Used.

11.2 Changing Dipswitch Settings - When making a dipswitch setting change, it is necessary to cycle the power
to the controller before the new setting becomes active. (Excluding dipswitch 2)

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12) SPN.FMI Codes (Suspect Parameter Number/Failure Mode Identifier)

SPN FMI TEXT TRANSLATION

28 3 % Accelerator Position #3 (Throttle 2) Voltage Above Normal or Shorted to High Source H
28 4 Percent Accelerator Position #3 (Throttle 2) Voltage Below Normal or Shorted to Low Source
29 3 Percent Accelerator Position #2 (Throttle 1) Voltage Above Normal or Shorted to High Source
29 4 Percent Accelerator Position #2 (Throttle 1) Voltage Below Normal or Shorted to Low Source
91 3 Accelerator Pedal Position (Multi-State Throttle) Voltage Above Normal, or Shorted to High Source
91 4 Accelerator Pedal Position (Multi-State Throttle) Voltage Below Normal or Shorted to Low Source
91 9 Accelerator Pedal Position A valid throttle message is not being received or is late
91 14 Accelerator Pedal Position Throttle signal voltage is or has been out of range
94 1 Fuel Delivery Pressure Very low
94 3 Fuel Delivery Pressure Fuel Rail Pressure Voltage out of range high
94 4 Fuel Delivery Pressure Fuel Rail Pressure Voltage out of range low
94 10 Fuel Delivery Pressure Pressure dropping too fast
94 13 Fuel Delivery Pressure Out of calibration
94 16 Fuel Delivery Pressure High fuel pressure
94 17 Fuel Delivery Pressure No rail fuel pressure
94 18 Fuel Delivery Pressure Low fuel pressure
97 0 Water In Fuel Indicator Water In Fuel Detected
97 3 Water In Fuel Indicator Water In Fuel Voltage out of range high
97 4 Water In Fuel Indicator Water In Fuel Voltage out of range low
97 16 Water In Fuel Indicator Water In Fuel Detected
97 31 Water In Fuel Indicator Water In Fuel Detected
100 1 Engine Oil Pressure Low oil pressure
100 3 Engine Oil Pressure Voltage Above Normal or Shorted to High Source
100 4 Engine Oil Pressure Voltage Below Normal or Shorted to Low Source
100 16 Engine Oil Pressure Oil pressure reading incorrect
100 18 Engine Oil Pressure Low oil pressure
105 0 Intake Manifold 1 Temperature High manifold air temperature
105 3 Intake Manifold 1 Temperature Voltage Above Normal or Shorted to High Source
105 4 Intake Manifold 1 Temperature Voltage Below Normal or Shorted to Low Source
105 16 Intake Manifold 1 Temperature High manifold air temperature
107 0 Air Filter Differential Pressure Plugged air filter condition detected
107 31 Air Filter Differential Pressure Plugged air filter condition detected
110 0 Engine Coolant Temperature High coolant temperature
110 3 Engine Coolant Temperature Voltage Above Normal or Shorted to High Source
110 4 Engine Coolant Temperature Voltage Below Normal or Shorted to Low Source
110 15 Engine Coolant Temperature High coolant temperature
110 16 Engine Coolant Temperature High coolant temperature
111 1 Coolant Level Low coolant level
158 2 Keyswitch Intermittent
158 17 Keyswitch Circuit problem
174 0 Fuel Temperature High fuel temperature
174 3 Fuel Temperature Voltage Above Normal or Shorted to High Source
174 4 Fuel Temperature Voltage Below Normal or Shorted to Low Source
174 15 Fuel Temperature High fuel temperature
174 16 Fuel Temperature High fuel temperature

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174 31 Fuel Temperature Voltage out of range

189 31 Rated Engine Speed Speed Derate Condition Exists due to fault
190 0 Engine Speed Engine overspeed
190 2 Engine Speed Data Erratic, Intermittent or Incorrect
190 3 Engine Speed Voltage Above Normal or Shorted to High Source
190 4 Engine Speed Voltage Below Normal or Shorted to Low Source
190 5 Engine Speed Circuit is open
190 16 Engine Speed Engine overspeed
611 3 Injector Wiring Shorted to battery
611 4 Injector Wiring Shorted to ground
620 3 Sensor Supply Voltage 1 (+5V DC) Voltage Above Normal or Shorted to High Source
620 4 Sensor Supply Voltage 1 (+5V DC) Voltage Below Normal or Shorted to Low Source
627 1 Power Supply Low voltage to injectors
627 4 Power Supply Power interruption
629 13 Reprogram Controller ECU problem
629 19 ECU to Pump Communications Error ECU not receiving messages from Pump
632 2 Fuel Shutoff Valve Fuel Shutoff Error Detected
632 5 Fuel Shutoff Valve Fuel Shutoff Non-Functional
632 11 Fuel Shutoff Valve Fuel Shutoff Solenoid circuit is open or shorted
636 2 Engine Position Sensor Timing signal error
636 8 Engine Position Sensor Timing signal error
636 10 Engine Position Sensor Timing signal error
637 2 Timing (Crank) Sensor Timing signal error
637 7 Timing (Crank) Sensor Timing signal error
637 8 Timing (Crank) Sensor Timing signal error
637 10 Timing (Crank) Sensor Timing signal error
639 13 CAN Bus The CAN bus failure
651 5 Injector Cylinder #1 The current to the injector is less than expected
651 6 Injector Cylinder #1 The current to the injector increases too rapidly
651 7 Injector Cylinder #1 The injector fuel flow is lower than expected
652 5 Injector Cylinder #2 The current to the injector is less than expected
652 6 Injector Cylinder #2 The current to the injector increases too rapidly
652 7 Injector Cylinder #2 The injector fuel flow is lower than expected
653 5 Injector Cylinder #3 The current to the injector is less than expected
653 6 Injector Cylinder #3 The current to the injector increases too rapidly
653 7 Injector Cylinder #3 The injector fuel flow is lower than expected
654 5 Injector Cylinder #4 The current to the injector is less than expected
654 6 Injector Cylinder #4 The current to the injector increases too rapidly
654 7 Injector Cylinder #4 The injector fuel flow is lower than expected
655 5 Injector Cylinder #5 The current to the injector is less than expected
655 6 Injector Cylinder #5 The current to the injector increases too rapidly
655 7 Injector Cylinder #5 The injector fuel flow is lower than expected
656 5 Injector Cylinder #6 The current to the injector is less than expected
656 6 Injector Cylinder #6 The current to the injector increases too rapidly
656 7 Injector Cylinder #6 The injector fuel flow is lower than expected
729 3 Inlet Air Heater Driver #1 Inlet air heater stuck on
729 5 Inlet Air Heater Driver #1 Inlet air heater will not turn on
833 2 Rack Position Sensor Error
833 3 Rack Position Sensor Rack Position Voltage above normal

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833 4 Rack Position Sensor Rack Position Voltage below normal

834 2 Rack Actuator Rack Error
834 3 Rack Actuator Rack Actuator Circuit voltage above normal
834 5 Rack Actuator Rack Actuator Circuit open
834 6 Rack Actuator Rack Actuator Circuit grounded
834 7 Rack Actuator Rack Position Error
970 2 Auxiliary Engine Shutdown Switch External Engine Shutdown Switch intermittent
970 11 External Engine Protection Shutdown External Engine Protection Shutdown active
970 31 Auxiliary Engine Shutdown Switch External Engine Protection Shutdown active
971 31 Engine Derate Switch External Derate input has been activated
1041 2 Start Signal Indicator Start Signal Missing
1041 3 Start Signal Indicator Start Signal Always Active
1076 0 Fuel Injection Pump Fuel Control Value Error
1076 1 Fuel Injection Pump Fuel Control Value Error
1076 2 Fuel Injection Pump Fuel Control Valve Error
1076 3 Fuel Injection Pump Fuel Control Valve Error
1076 5 Fuel Injection Pump Fuel Control Valve Error
1076 6 Fuel Injection Pump Fuel Control Valve Error
1076 7 Fuel Injection Pump Fuel Control Valve Error
1076 10 Fuel Injection Pump Fuel Control Valve Error
1076 13 Fuel Injection Pump Fuel Control Valve Error
1077 7 Fuel Injection Pump Controller
1077 11 Fuel Injection Pump Controller
1077 12 Fuel Injection Pump Controller
1077 19 Fuel Injection Pump Controller
1077 31 Fuel Injection Pump Controller Power derated
1078 7 Fuel Injection Pump Speed/Position Sensor Error
1078 11 Fuel Injection Pump Speed/Position Sensor Error
1078 31 Fuel Injection Pump Speed/Position Sensor VP44 Unable to Achieve Desired Timing
1079 3 Sensor Supply Voltage 1 (+5V DC) Voltage Above Normal or Shorted to High Source
1079 4 Sensor Supply Voltage 1 (+5V DC) Voltage Below Normal or Shorted to Low Source
1080 3 Sensor Supply Voltage 2 (+5V DC) Voltage Above Normal or Shorted to High Source
1080 4 Sensor Supply Voltage 2 (+5V DC) Voltage Below Normal or Shorted to Low Source
1109 31 Engine Protection System Approaching Shutdown Approaching Shutdown
1110 31 Engine Protection System Engine has been shutdown
1347 5 Fuel Pump Assembly #1 The circuit is open, shorted to ground, or overloaded
1347 7 Fuel Pump Assembly #1 Rail pressure control mismatch
1347 10 Fuel Pump Assembly #1 Low fuel flow
1348 5 Fuel Pump Assembly #2 The circuit is open, shorted to ground, or overloaded
1348 10 Fuel Pump Assembly #2 Low fuel flow
1485 2 ECU Main Relay Pump power relay fault
1569 31 Engine Protection Torque Derate Fuel derate limit condition exists
2000 6 Fuel Injection Pump Fuel Control Valve Error
2000 13 Security Violation The proper controller has not been installed

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15) Warranty
CONTROLS, INC. is herein called “Seller”. The person, firm or corporation to whom or which the sale is
made is herein called “Buyer”. Seller warrants to the Buyer that all products furnished under this order
will conform to Seller’s specification, drawings as described in its current catalog or quotation and will be
free from defects in materials and workmanship. Seller must approve other special requirements asked
for by the Buyer in its purchase order in writing. Parts replaced or repaired in the warranty period shall
carry the unexpired portion of the original warranty. The foregoing is subject to the provisions that in no
case will the total warranty period extend beyond twelve (12) months from date seller ships equipment
from point of sale.

The Liability of Seller hereunder is limited to replacing or repairing at Seller’s factory any part or parts
which have been returned to the Seller and which are proved by buyer as defective or not conforming to
Seller’s specifications, drawings or other written descriptions, accepted by Seller, provided that such part
or parts are returned by the buyer within thirty (30) days after such defect is discovered. All items
returned to Seller for repair or replacement must be sent freight prepaid to its factory. Buyer must obtain
Seller’s Return Goods Authorization prior to returning items. The above conditions must be met if
warranty is valid. Seller will not be liable for any damage done by unauthorized repair work, unauthorized
misapplication in non-suitable environment.

In no event shall the Seller be liable for loss, damage, or expense directly or indirectly arising from the
use of the units, or from any other cause, except as expressly stated in the warranty. Seller makes no
warranties, express or implied, including any warranty as to merchantability of fitness for a particular
purpose or use. Seller is not liable for and buyer waives any right or action it has or may have against
seller for any consequential or special damages arising out of any breach of warranty, and for any
damages buyer may claim for damage to any property or injury or death to any person arising out of its
purchase or the use, operation or maintenance of the product. Seller will not be liable for any labor
subcontracted or performed by buyer for preparation of warranted item for return to Seller’s factory or for
preparation work for field repair or replacement. The Seller will not consider invoicing of Seller for labor
either performed or subcontracted by buyer as a liability. This warranty shall be exclusive of any and all
other warranties express or implied and may be modified only by a writing signed by an officer of the
Seller. With respect to accessories supplied by Seller, but manufactured by others, there is no warranty
of any kind, express or implied, and specifically there is no warranty of merchantability or fitness, except
as may be set forth in any warranty the manufactures have made to Seller and which can be passed to
the Buyer.

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