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Duetz EMR3
Duetz EMR3
Systembeschreibung
EMR3
by DEUTZ AG
© 2007 DEUTZ AG
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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
© 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, 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.
© 2007 DEUTZ AG
1 EMR3 System description
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 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
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 EMR3 System description
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 4
© 2007 DEUTZ AG
5 EMR3 System description
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
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.
© 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.
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
7 EMR3 System description
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
© 2007 DEUTZ AG
EMR3 8
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.
© 2007 DEUTZ AG
9 EMR3 System description
post injection (e.g. to higher the exhaust gas temperature for urea-injection)
© 2007 DEUTZ AG
EMR3 10
The following schematic diagrams show the EMR3 system in connection with the injection system.
© 2007 DEUTZ AG
11 EMR3 System description
15 = Diagnosis-, -
12 = engine main plug button, -plug, 21 = indicating
1 = fuel tank 7 = ECU
(X17) instrument
-lamp.
12a = connection
8 = high pressure harness 16 = ignition key 22 = Battery (clamp 31,
2 = prefilter
reservoir, Rail (clamp 15) 30)
ECU <-> engine
8a = DBV = high
pressure limiting valve 17 = switchable
12b = customer function (eg. fixed
3 = fuel pump (closed: Pmax = specific harness speed 1-2, droop 1-2
1800bar, opened: etc.)
Pmax ~ 700bar)
4 = fuel filter
9 = injectors 12c = engine harness 18 = clutch switch
© 2007 DEUTZ AG
EMR3 12
© 2007 DEUTZ AG
13 EMR3 System description
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:
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 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 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
© 2007 DEUTZ AG
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 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.
© 2007 DEUTZ AG
17 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 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.
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
19 EMR3 System description
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 Repetitio
Name DLC J1939 Identifier Identifier
s. n
Data Sourc
PDU PDU
Reserve Page e
Priority F S rate
Byte d 1 Bit Addre Hex
3 Bit 1 1 ss (msec)
1 Bit (P+R+D Byte Byte
P) 1 Byte
18 EA 00
1 Request 3 6 0 0 (18) EA 00 3 0
03
Ignorie 08 FF 16
2 Engine Stop request 1 2 0 0 (08) FF 16 0
rt xx
Delete active Error 18 FE D3
3 0 6 0 0 (18) FE D3 3 0
(DM11) 03
Delete Passive Error 18 FE CC
4 0 6 0 0 (18) FE CC 3 0
(DM3) 03
© 2007 DEUTZ AG
EMR3 20
Transmit Messages:
Pos Repetitio
Name DLC J1939 Identifier Identifier
. n
Data PDU SrcA
Priorit Reser
Page PDUF S ddr. RATE
Byte y ved Hex
1 Bit 1 Byte 1 1 (msec)
3 Bit 1 Bit
(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
Engine
6 8 6 0 0 (18) FE EE 0 1000 18 FE EE 00
Temperature
Inlet/Exhaust
7 8 6 0 0 (18) FE F6 0 500 18 FE F6 00
Conditions
Engine Fluid
8 8 6 0 0 (18) FE EF 0 500 18 FE EF 00
Level/Pressure
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
Vehicle Electrical
17 8 6 0 0 (18) FE F7 0 1000 18 FE F7 00
Power
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
Engine
21 8 6 0 0 (18) FE E3 0 5000 18 FE E3 00
Configuration
22 Engine Hours 8 6 0 0 (18) FE E5 0 Request 18 FE E5 00
Controller
23 8 6 0 0 (18) FF 0C 0 Request 18 FF 0C 00
Configuration
Software
24 8 6 0 0 (18) FE DA 0 Request 18 FE DA 00
Identification
1000 (by
25 Active Error (DM1) 8 6 0 0 (18) FE CA 0 active 18 FE CA 00
Error)
Error Number
26 3 6 0 0 (18) FE CE 0 Request 18 FE CE 00
(DM5)
Frese Frame
27 8 6 0 0 (18) FE CD 0 Request 18 FE CD 00
Parameter (DM4)
© 2007 DEUTZ AG
21 EMR3 System description
Passive Error
28 8 6 0 0 (18) FE CB 0 Request 18 FE CB 00
(DM2)
Multi package
29 8 6 0 0 (18) EC FF 0 18 EC FF 00
Transport
Multi package FFÚ
30 8 6 0 0 (18) EB 0 18 EB xx 00
Transport Protocol 03
31 Acknowledgment 8 6 0 0 (18) E8 FF 0 18 E8 FF 00
© 2007 DEUTZ AG
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.
© 2007 DEUTZ AG
23 EMR3 System description
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.
© 2007 DEUTZ AG
EMR3 24
pin assignment
A Battery minus (-)
B Battery plus (+)
K ISO 9141 K-Line Diagnosis
L ISO 9141 L-Line Diagnosis
M CAN 2 High (SAE J 1939)
F CAN 2 Low (SAE J 1939)
D A-Line (SAE J 1708/1587) Diagnosis
E B-Line (SAE J 1708/1587) Diagnosis
© 2007 DEUTZ AG
25 EMR3 System description
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.
© 2007 DEUTZ AG
EMR3 26
© 2007 DEUTZ AG
27 EMR3 System description
EXAMPLE:
© 2007 DEUTZ AG
EMR3 28
Pin assignment
© 2007 DEUTZ AG
29 EMR3 System description
D2.2.31 Signalinput, analog, mit Pulldown- handthrottle (setpoint) Uin = 0...5 V, Rdown =
Widerstand 2 100 kW
handthrottle (setpoint) Uout = 5 V
D2.2.46 power supply (+)
2
Positionsgeber Intern mit UGnd
D2.2.8 power supply (–)
Fahrpedal 2: verbunden
Externer Schalter zu U
idle switch footpedal Gnd,
D2.2.81 Signalinput, digital, mit Pullup-Widerstand Rup = 100 kW, Ulow =
2
2,1 V, Uhigh = 3,9 V
© 2007 DEUTZ AG
EMR3 30
Signalinput, analog, mit Pullup- multiple state switch Uin = 0...5 V, Rup = 2,3 kW
D2.2.15
Widerstand for speed
Signalinput, analog, mit Pullup- multiple state switch Uin = 0...5 V, Rup = 2,3 kW
D2.2.89
Widerstand for droop
© 2007 DEUTZ AG
31 EMR3 System description
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
engine running or
D2.2.7 power supply (+), switched 0,3 A bei 12 V, 4 W bei 24
boost temp lamp
V
engine running or Einschaltstrom 0,9 A
D2.2.94 power supply (–), switched
boost temp lamp
lamp Uout = UBat, Imax = 6 A
D2.2.29 power supply (+), switched
(customerspecific)
0,3 A bei 12 V, 4 W bei 24
coolant temp warn
D2.2.70 power supply (–), switched V
lamp
Einschaltstrom 0,9 A
0,3 A bei 12 V, 4 W bei 24
D2.2.92 power supply (–), switched heater lamp V
Einschaltstrom 0,9 A
fuel filter water level Intern mit UGnd connected
D2.2.63 power supply (–)
sensor
Signalinput, analog, mit Pullup- fuel filter water level Uin = 0...5 V, Rup = 120 k
D2.2.64
Widerstand sensor W
D2.2.76 power supply (–) oil temp sensor Intern mit UGnd connected
© 2007 DEUTZ AG
EMR3 32
D2.2.53 power supply (–) velocity sensorr Intern mit UGnd connected
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)
fmax = 300Hz
D2.2.90 power supply (–), switched fan control
fmin = 15Hz
Signalinput, analog, mit Pullup- exhaustgas temp Uin = 0...5 V, Rup = 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, fmax = 1 KHz
D2.2.26 signal output, digital
(customerspecific)
PDM-output Intern mit UGnd connected
D2.2.39 power supply (–)
(customerspecific)
sensor UOut = 5 V
D2.2.24 power supply (+)
(customerspecific)
© 2007 DEUTZ AG
33 EMR3 System description
für 12-V-Anwendungen:
IOut = 1,7 A bei Vbat = 14,4 V,
L = 160 mH, f = 300 Hz,
IOut = 3,1 A bei Vbat = 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 Vbat = 28,8 V,
L = 600 mH, f = 300 Hz,
IOut = 1,7 A bei Vbat = 28,8 V,
© 2007 DEUTZ AG
EMR3 34
D2.1.51 power supply (–) oil pressure sensor Intern mit UGnd connected
Signalinput, digital, mit Pullup- engine stop switch Rup = 6,8 kW, Ulow = 2,2
D2.1.35
Widerstand (optional) V, Uhigh = 3,7 V
© 2007 DEUTZ AG
35 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.
Pin assignment
© 2007 DEUTZ AG
EMR3 36
© 2007 DEUTZ AG
37 EMR3 System description
D2.1. GND reference for Accelerator pedal position sensor Connected to UGND
sensors and actuators.
78 1 ground inside of ECU.
D2.1. Analog input (with Accelerator pedal position sensor Analog input, UIN = 0 ...
pulldown resistor)
79 1 signal 5 V, Rdown = 100 kOhm
D2.1. Digtal input (with Low idle switch, throttle 1 Digital input external
pullup resistor)
48 switch to GND,
Rup = 100 kOhm, Ulow =
2,4V, Uhigh = 3,6V
D2.1. Sensor supply Accelerator pedal position sensor 2 VOUT = 5V
60 supply
D2.1. GND reference for Accelerator pedal position sensor Connected to UGND
sensors and actuators.
59 2 ground inside of ECU.
D2.1. Analog input (with Accelerator pedal position sensor Analog input, UIN = 0 ...
pulldown resistor)
61 2 signal 5 V, Rdown = 100 kOhm
D2.1. Digital input (with Low idle switch, throttle 2 Digital input external
pullup resistor)
80 switch to GND,
Rup = 100 kOhm, Ulow =
2,4V, Uhigh = 3,6V
D2.1. GND reference for Multiple state or digital switch ( Connected to UGND
sensors and actuators.
50 speed setpoint) ground inside of ECU.
D2.1. Analog input (with Multiple state or digital switch (speed Analog input, UIN = 0 ...
pullup resistor)
43 setpoint) signal 5 V, Rup = 3,4 kOhm
D2.1. GND reference for Multiple state or digital switch (Torque/ Connected to UGND
sensors and actuators.
65 droop switch) ground inside of ECU.
D2.1. Analog input (with Multiple state or digital switch (Torque/ Analog input, UIN = 0 ...
pullup resistor)
62 droop switch) signal 5 V, Rup = 1,4 kOhm
D2.1. GND reference for Multiple state or digital switch (controller Connected to UGND
sensors and actuators.
76 mode, power boost) ground inside of ECU.
D2.1. Analog input (with Multiple state or digital switch (controller Analog input, UIN = 0 ...
pullup resistor)
44 mode, power boost) signal 5 V, Rup = 3,4 kOhm
D2.1. GND reference for Digital switch input ground Connected to UGND
sensors and actuators.
29 inside of ECU.
D2.1. Digital input (with Override switch Digital input external
pullup Resistor)
32 switch to GND,
Rup = 4,1 kOhm, Ulow =
2,2V, Uhigh = 3,8V
D2.1. Digtal input (with Coolant level switch Digital input external
pullup resistor)
55 switch to GND,
Rup = 100 kOhm, Ulow =
2,3V, Uhigh = 3,6V
D2.1. Digital input (with Droop choice switch Digital input external
pullup resistor)
86 switch to GND,
Rup = 5 kOhm, Ulow =
4,6V, Uhigh = 8,7V
D2.1. Power output high Supply digital swiches VOUT = UBAT, IMAX = 10 A
21
D2.1. Digtal input (with Engine Stop-switch Digital input external
pulldown resistor)
41 switch to UBAT,
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EMR3 38
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39 EMR3 System description
fmax= 5 kHz
D2.1. Digital output with Engine speed output signal 50mA
pullup resistor(small
33 signal), switch to GND,
fmax 5kHz
PDM Output Standard: 60 pulse per
rev.
D2.1. Power output UBat+ Diagnostic lamp supply HS 0,3A@12V; 4W@24V
22 nominal 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
20 nominal 0,3A
inrush current 0,9A
D2.1. Power switching output Warning fuel-/airfilter/fuelpress. 0,3A@12V; 4W@24V
low side to GND
38 lamp LS nominal 0,3A
inrush current 0,9A
D2.1. Power switching output Warning coolant temp/level lamp 0,3A@12V; 4W@24V
low side to GND
39 LS nominal 0,3A
Inrush current 0,9A
D2.1. Power switching output Preheat lamp LS 0,3A@12V; 4W@24V
low side to GND
54 nominal 0,3A
inrush current 0,9A
D2.1. Power switching output Engine running/warning boost air temp 0,3A@12V; 4W@24V
low side to GND
56 lamp LS nominal 0,3A
inrush current 0,9A
D2.1. Power switching output Starter relay LS Lmax=130mH
low side to GND
17 Imax=2A
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
sensors and actuators.
67 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
sensors and actuators.
24 sensor ground inside of ECU.
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EMR3 40
D2.1. Analog input (with Exhaust gas temperature sensor Analog input, UIN = 0 ...
pullup resistor)
25 signal 5 V, Rup = 1,4 kOhm
D2.1. GND reference for Oil temperature sensor ground Connected to UGND
sensors and actuators.
28 inside of ECU.
D2.1. Analog input (with Oil temperature sensor signal Analog input, UIN = 0 ...
pullup resistor)
27 5 V, Rup = 1,35 kOhm
D2.1. Oil level sensor Oil level sensor Signal evaluation with
26 constant current source
247mA
D2.1. GND reference for Oil level sensor ground Connected to UGND
sensors and actuators.
72 inside of ECU
D2.1. Power switching output Torque PDM output signal IMAX = 50 mA, fMAX =
low side to GND
23 300Hz
D2.1. Power switching output Reserve 2 (LS), PDM IMAX = 50 mA, fMAX =
low side to GND
51 1kHz
D2.1. Power output UBat+ Reserve 1, Actuator HS VOUT = UBAT, IMAX = 2,4
57 A, LMAX = 130 mH
D2.1. Power switching output Reserve 1, Actuator LS
low side to GND
16
D2.1. Analog input (with Crank case pressure or engine speed Analog input, UIN = 0 ...
pullup resistor)
81 precontroller sensor signal 5 V, Rup = 100 kOhm
D2.1. Sensor supply Crank case pressure or engine speed VOUT = 5V
82 precontroller sensor supply
D2.1. GND reference for Crank case pressure or engine speed Connected to UGND
sensors and actuators.
83 precontroller sensor ground inside of ECU
D2.1. CAN driver Customer - Controller area network CAN low
34 CAN
D2.1. CAN driver CAN high
35
D2.1. CAN driver Diagnostic - Controller area CAN low
52 network CAN
D2.1. CAN driver CAN high
53
D2.1. ISO-K Interface K-Line communication Diagnostic,
89 programming
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41 EMR3 System description
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43 EMR3 System description
D2.3. Injector output low-side Injector 1 "low", Bank 1 Y15.1 CR 4 und 6 Zylinder /
13 (Y15.1) PLD 6 und 8 Zylinder
D2.3. Injector output low-side Injector 2 "low", Bank 2 Y15.2 CR 4 und 6 Zylinder /
15 (Y15.2) PLD 6 und 8 Zylinder
D2.3. Injector output low-side Injector 3 "low", Bank 1 Y15.3 CR 4 und 6 Zylinder /
06 (Y15.3) PLD 6 und 8 Zylinder
D2.3. Injector output low-side Injector 4 "low", Bank 2 Y15.4 CR 4 und 6 Zylinder /
14 (Y15.4) PLD 6 und 8 Zylinder
D2.3. Injector output low-side Injector 5 "low", Bank 1 Y15.5 CR 6 Zylinder / PLD 6
12 (Y15.5) und 8 Zylinder
D2.3. Injector output low-side Injector 6 "low", Bank 2 Y15.6 CR 6 Zylinder / PLD 6
16 (Y15.6) und 8 Zylinder
D2.3. Injector output low-side Injector 7 "low", Bank 1 Y15.7 PLD 8 Zylinder
07 (Y15.7)
D2.3. Injector output low-side Injector 8 "low", Bank 2 Y15.8 PLD 8 Zylinder
08 (Y15.8)
D2.3. Power switching output Fuel metering unit (MPROP) supply VOUT = UBAT, IMAX = 1,3
high-side
09 HS A
D2.3. Power switching output Fuel metering unit (MPROP) LS
low-side to GND
10
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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
D2.1.21 Power output high Supply digital swiches VOUT = UBAT, IMAX = 10 A
D2.1.41 Digtal input (with Digital input external switch to
pulldown resistor) UBAT,
Engine Stop-switch
Rdown = 4,1 kOhm, Ulow =
2,2V, Uhigh = 3,8V
D2.1.49 Digtal input (with Digital input external switch to
pulldown resistor) Parking brake optional redundant brake UBAT,
switch Rdown = 4,1 kOhm, Ulow =
2,2V, Uhigh = 3,8V
D2.1.66 Digital input (with Digital input external switch to
pulldown Resistor) UBAT,
Gear switch
Rdown = 4,1 kOhm, Ulow =
2,2V, Uhigh = 3,8V
D2.1.42 Digtal input (with Digital input external switch to
pulldown resistor) UBAT,
Air filter differential pressure switch Rdown = 4,1 kOhm, Ulow <
0,28xUBAT,
Uhigh > 0,68xUBAT
D2.1.47 Digital input (with Digital input external switch to
pulldown resistor) UBAT,
Engine brake switch
Rdown = 4,1 kOhm, Ulow =
2,2V, Uhigh = 3,8V
D2.1.74 Digital input (with Digital input external switch to
pulldown Resistor) UBAT,
Engine start switch Rdown = 4,1 kOhm, Ulow <
0,28xUBAT,
Uhigh > 0,68xUBAT
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45 EMR3 System description
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EMR3 46
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47 EMR3 System description
D2.2.33 Sensor supply Boost air pressure/temp. sensor supply (G1) VOUT = 5V
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EMR3 48
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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.
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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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51 EMR3 System description
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EMR3 52
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53 EMR3 System description
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EMR3 54
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55 EMR3 System description
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EMR3 56
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57 EMR3 System description
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EMR3 58
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59 EMR3 System description
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61 EMR3 System description
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63 EMR3 System description
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65 EMR3 System description
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67 EMR3 System description
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69 EMR3 System description
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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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71 EMR3 System description
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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73 EMR3 System description
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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75 EMR3 System description
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: info@wilbaer.de
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.
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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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77 EMR3 System description
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.
© 2007 DEUTZ AG
79 EMR3 System description
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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 with interface- with interface-
no display, no display,
password only and password only and display and delete
memory 2 no delete 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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81 EMR3 System description
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EMR3 82
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83 EMR3 System description
mounting cabine mounted (not engine mounted), cooling via air convection
chemical resistance Resistent against substances, that are used for enegines
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EMR3 84
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85 EMR3 System description
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87 EMR3 System description
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 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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89 EMR3 System description
Index -E-
ED 16 UC 40 28
EDC 16 UC 40 82
-A- EDC 7 UC 31 35, 82
EEPROM 69
application data 3 electrical system 1
Electrical welding 1
-B- EMC 82
EMR3-Systems 3
Base System functions 3 Engine control unit 3
blink code 75 environment protection 82
bootloader 70 environment resistance 82
BSW 3, 70 error lamp 75
-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 ISO-9141 16
Diagnostic plug 23
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
© 2007 DEUTZ AG
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: info@deutz.com
Gedruckt in Deutschland
Alle Rechte vorbehalten
1. Auflage, 08/2007
Bestell-Nr.: