Deutz EMR3 210408 ENG System Description

EMR3 System Description

Notice: The document is the property of DEUTZ AG. The application of the document of a third party can only be authorized by DEUTZ AG! Copyright Version Date

Publisher DEUTZ AG Responsible for the content Application Engineering Author Fi Ko

0312 1985 1.4.1 28.4.2008

Content 1 EMR3

................................................................................................................................... 1 1.1 Important Notes ................................................................................................................................... 3 1.2 System components ......................................................................................................................................................... 10 1.2.1 Control and regulation functions 11 1.3 ................................................................................................................................... System functions ......................................................................................................................................................... 12 1.3.1 Monitoring functions ......................................................................................................................................................... 13 1.3.2 Diagnosis functions 14 1.4 ................................................................................................................................... Interfaces ......................................................................................................................................................... 16 1.4.1 Protocols ......................................................................................................................................................... 18 1.4.2 Wiring .................................................................................................................................................. 18 1.4.2.1 Diagnostic plug .................................................................................................................................................. 20 1.4.2.2 Main relay .................................................................................................................................................. 22 1.4.2.3 Control Unit EMR3-EDC16 .................................................................................................................................................. 27 1.4.2.4 Control Unit EMR3-EDC7 .................................................................................................................................................. 33 1.4.2.5 Circuit Diagrams 42 1.5 ................................................................................................................................... Diagnostics ......................................................................................................................................................... 43 1.5.1 Diagnosis with diagnostic button and error lamp ......................................................................................................................................................... 44 1.5.2 Diagnosis with SERDIA 47 1.5.3 Table......................................................................................................................................................... of system errors 48 1.6 ................................................................................................................................... Technical data

53 1.7 ................................................................................................................................... Glossary

2 ChangeHistory

Index

V.1.4.1

Foreword

Our aim is to continuously optimize 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: [emailprotected]). 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.

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, [emailprotected]). 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.

V.1.4.1

EMR3 System Description

EMR3

1.1

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

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 69) 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). According to the valid circuit diagram, the control unit can not be switched off via terminal 30. The engine can not be stopped via terminal 30. No input and output components are allowed to be connected on U+, if the control unit is switched off.

V.1.4.1

EMR3

Work on the electrical system The power supply (ignition, terminal 15) must be switched off before all work on the electrical system. Sensors and actuators must not be connected to external voltage sources for test purposes. They must be connected to EMR3-ECU only. The components could otherwise be damaged permanently. 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 In order to avoid damage, all plugs must be removed from the control unit during electrical welding on the vehicle or machine.

Cleaning jobs During the cleaning, please pay attention that no water is allowed too penetrate into the ECU and the plug. What's more, the high pressure cleaners and vapor stream equipment are not allowed to use.

V.1.4.1

1.2

EMR3 System Description

System components The engine control system EMR3 requires the following fundamental components for operating the engine:  Engine control unit (EMR3-EDC16 or EMR3-EDC7)*  Power supply (battery)*  Foot pedal, hand throttle or switch for nominal value preset*  Ignition start switch*  External main relay (only in EMR3-EDC16)*  Function switch*  Speed sensors  Pressure and temperature sensors  Cable harness, engine side / vehicle side*  Error lamp*  Diagnostic button*  Diagnostic socket* * Installation and wiring by customer The system can be extended by additional components according to the application-specific engine configuration. For further information, please contact the Department Application Engineering of DEUTZ AG.

Engine control unit The central component of the EMR3 system is the engine control unit. It is used to ensure the optimum running of the engine with the aims:  optimal exhaust behaviour,  low consumption,  quiet engine running,  long engine life, 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 provided functions. The most important functions include:  exact control of the injection process (including number, start and duration of injections),  governing of the idle speed,  governing of the exhaust return volume,  optimization of the balanced running (by correction of injection volume),  engine monitoring,  system diagnosis.

V.1.4.1

EMR3

DEUTZ ROAD-MAP for EMR3-Systems

V.1.4.1

EMR3 System Description

Description of functions The hardware of the EMR3 contains the following main components: 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 analog (continuous signals, inputs only) communication ports o ISO 9141 (Keyword protocol) o CAN-Bus (SAE J 1939 protocol) Power supplier and regulator In general, the EMR3-ECU contains different kinds of data: o main software (similar to the BIOS in PC - DEUTZ calling: "BSW") o application data (similar to an office-program on PC - DEUTZ calling: "dataset") The EMR3 can be programmed via the ISO 9141 interface (Programming via CAN-Bus is in pipeline). There are different program tasks: o complete dataset + BSW programming (needed for main software exchange) o complete dataset programming (needed for e.g. spare parts) o partial dataset programming (needed for e.g. special adjustment in small series production) o calibration (needed for adjustment in field e.g. foot pedal calibration) Many engine functions of the EMR3-Software are available via switches (digital or analog inputs) and CAN-Bus. These functions are chosen from a DEUTZ-configurator called ELTAB. The output of the configurator is the customer-specific dataset for serial production. In factory every EMR3 is programmed with a customer-specific complete dataset + BSW. After power calibration on the DEUTZ-testbench the EMR3 enters the status "engine specific" and receives a barcode label with the engine number printed on.

It's forbidden to exchange EMR3-ECU's (with or without barcode label), that don't match with the DEUTZ-engine-number. Or the warranty will be lost! 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 (+Ubat) must not be disconnected from EMR3. When

V.1.4.1

EMR3

the ECU leaves this mode the internal/external Main-Relay is shut off and terminal 30 is disconnected from EMR3 permanently.

Basic System Functions The following list gives an overview of the implemented EMR3-functions. Nearly all functions described in EMR2-system are available in EMR3. o Speed control o All speed governor, fuel governor (Min/Max-Governor), switchable governor mode during operation, freezing the current speed, fixed speed for synchronization or load distribution, overdrive speed o Set point input o nominal values

o o o o o o o

 Foot pedal and / or hand throttle  external voltage signal (0 - 5 V)  CAN Bus (remote electronics)  fixed speed signal (genset operation)  Touch control operation Up/Down (digital) optimal adaptation to different applications Torque limitation two top curves can be set P-Grad 1,2 engine start/Stop via keypad Diagnose and signal output function measurement of the temperature and status of coolant, oil pressure, charge air temperature, fuel temperature

o fault display and/or power reduction or switch-off-engine

o o o o o o

measurement of charge air pressure smoke limitation depending on charge air temperature-influenced start behaviour altitude correction (protect the exhaust turbocharger) fuel temperature compensation emergency running (limp home mode) with  defect foot pedal  defect sensor control the external cold start aid (heating flange, flame heating) data communication via network, bus system different interfaces for diagnosis and programming Blink code output warning of over-speeded simplified diagnosis

V.1.4.1

EMR3 System Description

DEUTZ-Labeling

EMR3-EDC7

EMR3-EDC16

Label of manufacturer

EDC 7 UC 31

EDC 16 UC 40

engine series

TCD 2015

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

injection system

DCR® = DEUTZ Common Rail / PLD = DEUTZ Magnet-Valve

supply voltage

12 and 24 V

operating temperature

-40 °C to +80 °C, cooling with air convection

mounting methods

chassis, cabin

main relay

internal

external

Max. number cylinders

electrical plugs environment category

protection

6 / 8 Zyl. @ (PLD),

4 / 6 Zyl. @ (DCR®)

89 + 36 + 16 Pins

94 + 60 Pins

IP 6K9 (with fitted plug)

data interface / protocol CAN / SAE J1939, ISO 9141 / KWP 2000 The following schematic diagrams show the EMR3 system in connection with the injection system.

V.1.4.1

EMR3

1 = fuel tank

7 = ECU

12 = engine main plug (X17)

15 = Diagnosis-, button, -plug, -lamp.

2 = prefilter

8 = high pressure reservoir, Rail

12a = connection harness ECU engine

16 = ignition key (clamp 22 = Battery (clamp 31, 15) 30)

3 = fuel pump

8a = DBV = high pressure limiting valve (closed: P = 12b = customer specific max harness 1800bar, opened: P max ~ 800bar)

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

9 = injectors

12c = engine harness

18 = clutch switch

5 = fuel high pressure pump

10 = Rail pressure sensor

13 = EGR exhaust gas recirculation (external)

19 = e.g. foot pedal, set point setting

6 = FCU = fuel control unit

11 = exhaust turbo charger

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

20 = Signal light, -lamp

4 = fuel filter

21 = indicating instrument

V.1.4.1

EMR3 System Description

Engine with DMV 1,2,3,6,7,8,9,10,11,12,13 sensor

V.1.4.1

Engine

24 = Diagnosis plug

16 = Signal light, -lamp

4 = engine main plug

21 = ignition key (clamp 15)

15 = indicating instrument

5 = ECU

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

14 = Battery (clamp 31, 30)

22 = Diagnosis button

19 = clutch switch

17 = not used

23 = Diagnosis lamp

18 = e.g. footpedal, setpoint setting

EMR3

1.2.1

Control and regulation functions

Regulation of the engine torque The basic task of an engine regulator is to call the respective engine torque necessary in every operating state from the engine to set a constant speed, for example, or to match the nominal value specified by the driver. The EMR3 engine control unit determines the torque in the following way: Starting from the position of the set point 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.

V.1.4.1

1.3

EMR3 System Description

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

Four software combinations Injection system DCR can be named at the moment:

Injection system DMV

Control unit EDC 7 (0421 4432)

MSW project name:

P_490_aaa

P_513_bbb

Control unit EDC 16 (0421 4367)

MSW project name:

P_491_ccc

P_492_ddd

The consecutive designation aaa ... ddd indicates the development state of the software and the connected system functions. The part numbers (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:

V.1.4.1

TN ASAP

TN BSW

Name BSW

TN EStG

Name EStG

0421 4633

0421 4632

P_491_220

0421 4367

EMR3-S (ED 16UC40)

0421 5113

0421 5112

P_491_302

0421 4367

EMR3-S (ED 16UC40)

0421 5436

0421 5435

P_491_310

0421 4367

EMR3-S (ED 16UC40)

0421 5546

0421 5545

P_491_400

0421 4367

EMR3-S (ED 16UC40)

0421 4689

0421 4688

P_492_213

0421 4367

EMR3-S (ED 16UC40)

0421 4680

0421 4679

P_513_214

0421 4432

EMR3-E (ED 7UC31)

0421 5330

0421 5329

P_513_300

0421 4432

EMR3-E (ED 7UC31)

EMR3

1.3.1

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

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

V.1.4.1

1.3.2

EMR3 System Description

Diagnosis functions The EMR3-ECUs offer a diagnosis via

 Blink-Code  CAN-Bus  K-Line (SerDia) The blink-code is described in Table of system errors 47 . 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 and error lamp 43 . The CAN-Bus protocol contains the standard messages from SAE J 1939 ( http://www.sae.org/products/j1939a.htm ). Not all telegrams have been implemented. Therefore ask your DEUTZ-Dealer or salesman (s.a. Diagnosis Functions 13 ). Via K-Line the ECU uses the KWP2000-protocol with crypted data stream. The DEUTZ-diagnosis tool SerDia2000 is able to read out and/or write the error memory, 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 42 .

The error lamp must be installed within the field of view of the operators.

V.1.4.1

EMR3

1.4

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

Application interface engine - control unit All the sensors installed in the engine (e.g. for oil pressure and coolant temperature) and actuators (solenoid valves, heating flange etc.) are usually wired at the factory by laying the individual cables in an engine cable harness at the engine adapter plug. The connecting cable from the engine adapter plug to the engine control unit is installed by the customer. The connecting cable can be ordered in a specified length (2.5m, 5m) from DEUTZ or can be assembled by the customer himself. There are no special demands on the wiring between the engine transfer plug and the control unit but you should make sure that the power cables of the injectors are not laid directly next to the sensor cables. Shielding the cables for these signal types is definitely an advantage. Please observe the DEUTZ wiring instructions.

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

Diagnostic interface The engine control units EMR3-EDC16 and EMR3-EDC7 have two interfaces via which the control unit data hardware can access the appropriate communication hardware (e.g. SERDIA USB interface) and diagnosis software (e.g. SERDIA). These are  the ISO-9141 bus (with KWP-2000 protocol, only K-line),  the CAN-bus 1 (with SAE-J-1939 protocol),  the CAN-bus 2 (not used at the moment). The wiring between the diagnosis socket and the engine control unit is done by the customer and is usually integrated in the cable harness of the application interface vehicle - control unit. The DEUTZ wiring instructions for CAN-bus cables must be observed. The ISO-9141 bus wiring between the control unit and the communication hardware should not exceed a total length of 10 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

V.1.4.1

EMR3 System Description 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.

V.1.4.1

EMR3

1.4.1

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.

CAN-Bus interface o Baud-Rate: 250 kBit/s o Several scopes of CAN-functionalities available o All source addresses 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 Diagnosis interrupts for 30s if battery-voltage drops under 9 Volt. o Data FFh means: not defined o Data FEh means: not valid

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

Don't care

CAN – Function

Transmit Messages, Engine Stop Request, Request

For ECU`s:

EMR3 (EDC16 and EDC7)

Data Sets:

CAN_3100

The CAN - BUS has got the following adjustments:    

The node address for the send message of EMR3 is 0. The rate of transmission is 250 kBaud CAN Function without Time Out detection. The node address for the received messages is 3.

V.1.4.1

EMR3 System Description

Receive Messages: Pos.

Name

DLC

J1939

Identifier

Byte

Priority Reserved 3 Bit 1 Bit

Data Page 1 Bit (P+R+DP)

Repetition Identifier PDUF PDUS 1 Byte 1 Byte

Source Address 1 Byte

rate (msec)

Hex

Request

0 (18)

18 EA 00 03

Engine Stop request

0 (08)

Ignoriert

08 FF 16 xx

Delete active Error (DM11)

0 (18)

18 FE D3 03

Delete Passive Error (DM3)

0 (18)

18 FE CC 03

J1939

Identifier

Transmit Messages: Pos.

V.1.4.1

Name

DLC

Repetition Identifier

Byte

Priority Reserved 3 Bit 1 Bit

Data Page PDUF PDUS 1 Bit 1 Byte 1 Byte (P+R+DP)

SrcAddr. 1 Byte

RATE (msec)

Hex

EEC1

0 (0C)

0C F0 04 00

EEC2

0 (0C)

0C F0 03 00

EEC3

0 (18)

250

18 FE DF 00

Fuel economy

0 (18)

100

18 FE F2 00

Cruise Control

0 (18)

100

18 FE F1 00

Engine Temperature

0 (18)

1000

18 FE EE 00

Inlet/Exhaust Conditions

0 (18)

500

18 FE F6 00

Engine Fluid Level/Pressure

0 (18)

500

18 FE EF 00

Measure 1

0 (18)

200

18 FF 04 00

Measure 2

0 (18)

100

18 FF 12 00

Measure 3

0 (18)

100

18 FF 13 00

Measure 4

0 (18)

100

18 FF 14 00

Measure 5

0 (18)

100

18 FF 1A 00

Measure 8

0 (18)

100

18 FF 1D 00

Measure 9

0 (18)

100

18 FF 19 00

Limitation

0 (0C)

100

0C FF 15 00

Vehicle Electrical Power

0 (18)

1000

18 FE F7 00

Ambient Conditions

0 (18)

1000

18 FE F5 00

State of Input 1

0 (18)

1000

18 FF 0A 00

State of Output 1

0 (18)

1000

18 FF 0B 00

Engine Configuration

0 (18)

5000

18 FE E3 00

Engine Hours

0 (18)

Request

18 FE E5 00

Controller Configuration

0 (18)

Request

18 FF 0C 00

Software Identification

0 (18)

Request

18 FE DA 00

Active Error (DM1)

0 (18)

1000

18 FE CA 00

Error Number (DM5)

0 (18)

Request

18 FE CE 00

Freeze (DM4)

0 (18)

Request

18 FE CD 00

Passive Error (DM2)

0 (18)

Request

18 FE CB 00

Multi package Transport

0 (18)

18 EC FF 00

Multi package Protocol

0 (18)

FFv03

18 EB xx 00

Acknowledgment

0 (18)

18 E8 FF 00

Frame

Parameter

Transport

EMR3

1.4.2

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 connections with each other is necessary. The plug assignment sketches and circuit diagrams illustrated below serve as a reference for this.

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

1.4.2.1

Diagnostic plug In order to be able to access the EMR3 control unit with the SERDIA 2000 diagnosis software, a connection must be made between the SERDIA-PC and the diagnostic interface of the EMR3 system. The connection is made with the interface cable HS-Light/HS-Light II from the USB port of the PC to the DEUTZ diagnostic socket which must be mounted easily accessible on the vehicle or device (e.g. in the instrument panel).

A diagnostic socket is the prerequisite for the possibility of using SERDIA for error diagnosis and changing the engine configuration. The diagnosis plug has got a connection to the CAN-Bus via PIN G and H. This connection is not used with EDC 7 and EDC 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.

V.1.4.1

EMR3 System Description

Circuit diagram (excerpt from the engine wiring diagram)

Pin assignment

V.1.4.1

Battery minus (-)

Battery plus (+)

ISO 9141 K-Line

Diagnosis

ISO 9141 L-Line

Diagnosis

CAN 2 High (SAE J 1939)

CAN 2 Low (SAE J 1939)

A-Line (SAE J 1708/1587) Diagnosis

B-Line (SAE J 1708/1587) Diagnosis

EMR3 1.4.2.2

Main relay The main relay serves to release the energy supply of the vehicle/device for the EMR3 system.  The engine control unit EMR3-EDC16 requires an external relay (see circuit diagram below).  The engine control unit EMR3-EDC7 has an internal electronic relay. For both control units applies: as soon as terminal 15 is not carrying battery + (i.e. the ignition is switched off), the main relay is switched off by the control unit after approx. 1% 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-EDC16 directly at the relay contact and in the EMR3-EDC7 at pin 1.13. Technical requests for the main relay:  min. current via switching contacts: 25A  coil response time and fall time: < 50 ms

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

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

V.1.4.1

EMR3 System Description

EXAMPLE:

V.1.4.1

EMR3 1.4.2.3

Control Unit EMR3-EDC16 The engine control unit EMR3-EDC16 has two connecting sockets arranged on the top of the housing:  socket D2.1 for connecting the engine cable harness,  socket D2.2 for connecting the vehicle/device side cable harness.

Pin assignment

Max. cable cross section: 2,5 mm², 1,5mm², 0,75 mm²

Pinout for EMR3-EDC16 Pin

Signal type

Function / components

Remark / Technical data

D2.2.1

power supply (+)

D2.2.3

power supply (+)

power supply ECUs

UBat (terminal 30)

D2.2.5

power supply (+)

D2.2.2

power supply (–)

D2.2.4

power supply (–)

power supply ECUs

UGnd (terminal 31)

D2.2.6

power supply (–)

D2.2.28

signal input, digital

operating signal for ECU

D2.2.72

power supply (–), switched

main relay

D2.2.9

signal input, analog, with Pulldown-resistance footpedal (setpoint)1

Uin= 0...5 V, Rdown = 100 kW

D2.2.22

power supply (+)

footpedal (setpoint)1

Uout = 5 V

D2.2.30

power supply (–)

footpedal (setpoint)1

Intern with UGnd connected

UBat switched (terminal 15) U > 4,79 V: ECU switched on U < 3,63 V: ECU switched off 12V: 140 mA, 120 mH at 1 kHz 24V: 80 mA, 350 mH at 1 kHz

external switch to UGnd, D2.2.58

signal input, digital, with Pullup-resistance

idle switch footpedal1

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

D2.2.31

signal input, analog, with Pulldown-resistance handthrottle (setpoint) 2

Uin = 0...5 V, Rdown = 100 kW

D2.2.46

power supply (+)

handthrottle (setpoint) 2:

Uout = 5 V

D2.2.8

power supply (–)

handthrottle (setpoint) 2:

Intern with UGnd connected external switch to UGnd,

D2.2.81

signal input, digital, with Pullup-resistance

idle switch footpedal2

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

D2.2.10

power supply (–)

Temperature sensor 2 (optional) internal with UGnd connected

D2.2.11

signal input, analog,with Pullup-resistance

Temperature sensor 2 (optional) Uin = 0...5 V, Rup = 1,3 kW

V.1.4.1

EMR3 System Description Pin

Signal type

Function / components

Remark / Technical data

D2.2.12

power supply (–)

Oil level sensor

internal with UGnd connected

D2.2.13

signal input, analog,with Pullup-resistance

Oil level sensor

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

D2.2.45

power supply (+)

Oil level sensor

Uout = 5 V

D2.2.14

power supply (–)

multiple state switch for speed

internal with UGnd connected

D2.2.15

signal input, analog,with Pullup-resistance

multiple state switch for speed

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

D2.2.86

power supply (–)

multiple state switch for droop

internal with UGnd connected

D2.2.89

signal input, analog,with Pullup-resistance

multiple state switch for droop

Uin = 0...5 V, Rup = 2,3 kW external switch to UBat ,

D2.2.17

signal input, digital, with Pulldown-resistance break switch

Rdown = 6,8 kW, Ulow = 2,2 V, Uhigh = 3,7 V external switch zu UBat ,

D2.2.80

signal input, digital, with Pulldown-resistance break switch

Rdown = 6,8 kW, Ulow = 2,2 V, Uhigh = 3,7 V external switch to UBat ,

D2.2.40

signal input, digital, with Pulldown-resistance clutch switch

Rdown = 6,8 kW, Ulow = 2,2 V, Uhigh = 3,7 V external switch to UBat ,

D2.2.54

signal input, digital, with Pulldown-resistance exhaust gas break switch

Rdown = 6,8 kW, Ulow = 2,2 V, Uhigh = 3,7 V external switch to UBat ,

D2.2.43

signal input, digital, with Pulldown-resistance Engine start switch

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

D2.2.77

external switch to UBat , intake air differential pressure R signal input, digital, with Pulldown-resistance down = 6,8 kW, Ulow = 2,2 V, switch Uhigh = 3,7 V external switch to UGnd,

D2.2.52

signal input, digital,with Pullup-resistance

switch (customer-specific)

Rup = 5 kW, Ulow = 2,2 V, Uhigh = 3,7 V external switch to UGnd,

D2.2.19

signal input, digital,with Pullup-resistance

Override switch

Rup = 5 kW, Ulow = 2,3 V, Uhigh = 3,7 V external switch to UGnd,

D2.2.79

signal input, digital,with Pullup-resistance

coolant level switch

Rup = 6,8 kW, Ulow = 2,2 V, Uhigh = 3,7 V external switch to UGnd,

D2.2.87

signal input, digital,with Pullup-resistance

governor mode switch

Rup = 6,8 kW, Ulow = 2,2 V, Uhigh = 3,7 V external switch to UGnd,

D2.2.57

signal input, digital,with Pullup-resistance

droop switch

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

V.1.4.1

D2.2.55

power supply (+), switched

diagnosis lamp

D2.2.71

power supply (–), switched

Oil alarm lamp

D2.2.51

power supply (+), switched

Oil alarm lamp

0,3 A at 12 V, 4 W at 24 V switch-on current 0,9 A 0,3 A at 12 V, 4 W at 24 V switch-on current 0,9 A

EMR3 Pin

Signal type

Function / components

Remark / Technical data

engine running or boost temp lamp 0,3 A at 12 V, 4 W at 24 V engine running or boost temp switch-on current 0,9 A lamp

D2.2.7

power supply (+), switched

D2.2.94

power supply (–), switched

D2.2.29

power supply (+), switched

Alarm lamp (customer-specific) Uout = UBat , Imax = 6 A

D2.2.70

power supply (–), switched

Temperature alarm lamp

0,3 A at 12 V, 4 W at 24 V switch-on current 0,9 A

D2.2.92

power supply (–), switched

heater lamp

0,3 A at 12 V, 4 W at 24 V switch-on current 0,9 A

D2.2.63

power supply (–)

fuel filter water level sensor

internal with UGnd connected

D2.2.64

signal input, analog,with Pullup-resistance

fuel filter water level sensor

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

D2.2.76

power supply (–)

Oil Temperature sensor

internal with UGnd connected

D2.2.66

signal input, analog,with Pullup-resistance

Oil Temperature sensor

Uin = 0...5 V, Rup = 1,28 kW external switch to UBat ,

D2.2.75

signal input, digital,with Pullup-resistance

Rup = 6,8 kW, Ulow = 2,2 V,

velocity sensor

Uhigh = 3,7 V internal with UGnd connected

D2.2.53

power supply (–)

velocity sensor

D2.2.48

signal output, digital (PWM),with Pullupengine speed sensor resistance, minus-switched

Imax = 50 mA, fmax 5kHz, Standard: 60 Impulse/Rotation

D2.2.23

power supply (+)

Fan speed sensor

UOut = 5 V

D2.2.84

signal input, digital,with Pullup-resistance

Fan speed sensor

Imax = 20 mA, fmax = 1 kHz

D2.2.59

power supply (–)

Fan speed sensor

internal with UGnd connected

D2.2.73

power supply (+)

Fan control

D2.2.90

power supply (–), switched

Fan control

R > 30 W at 24 V R > 10,6 W at 12 V L = 15...80 mH switch-on current 1,9 A at 16 V (15 Minutes) fmax = 300Hz fmin = 15Hz external switch to UGnd,

D2.2.83

signal input, digital,with Pullup-resistance

Rup = 100 kW, Ulow = 2,1 V,

PDM-setpoint

Uhigh = 3,9 V internal with UGnd connected

D2.2.85

power supply (–)

PDM-setpoint

D2.2.32

signal input, analog,with Pullup-resistance

Temperature sensor (customer- U = 0...5 V, R = 1,3 kW in up specific)

D2.2.33

power supply (–)

Temperature sensor (customer- internal with U Gnd connected specific)

D2.2.34

signal input, analog,with Pullup-resistance

exhaust sensor

gas

Temperature U = 0...5 V, R = 11,05 kW in up

D2.2.35

power supply (–)

exhaust sensor

gas

Temperature internal with U Gnd connected

D2.2.26

signal output, digital

PDM-output (customer-specific) Imax = 50 mA, fmax = 1 KHz

D2.2.39

power supply (–)

PDM-output (customer-specific) internal with UGnd connected

D2.2.27

signal output, digital

PDM-output torque (customer- I max = 50 mA, fmax = 300 Hz specific) external switch to UBat ,

D2.2.74

signal input, digital, with Pulldown-resistance switch (customer-specific)

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

V.1.4.1

EMR3 System Description Pin

Signal type

Function / components

Remark / Technical data

D2.2.24

power supply (+)

Sensor (customer-specific)

UOut = 5 V

D2.2.36

signal input, analog,with Pullup-resistance

Sensor (customer-specific)

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

D2.2.37

power supply (–)

Sensor (customer-specific)

internal with UGnd connected.

D2.2.61

Communication, CAN low

D2.2.62

Communication, CAN high

CAN-Bus application

D2.2.60

Communication, CAN low

D2.2.82

Communication, CAN high

D2.2.25

Communication, K-Line

ISO-9141-Bus

D2.1.23

power supply (–)

boost pressure sensor

internal with UGnd connected

D2.1.40

signal input, analog,with Pullup-resistance

boost pressure sensor

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

D2.1.14

power supply (+)

boost pressure sensor

UOut = 5 V

D2.1.53

signal input, analog,with Pullup-resistance

boost temperature sensor

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

D2.1.20

Shield

Cam shaft speed sensor

internal with UGnd connected

D2.1.10

signal input (+), digital, with Schmitt-Trigger Cam shaft speed sensor with Threshold-Application

D2.1.50

signal input (–), digital, with Schmitt-Trigger Cam shaft speed sensor with Threshold-Application

D2.1.41

power supply (–)

coolant Temperature sensor

internal with UGnd connected

D2.1.58

signal input, analog,with Pullup-resistance

coolant Temperature sensor

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

D2.1.7

Shield

crank shaft speed sensor

internal with UGnd connected

D2.1.12

signal input (–), digital, with Schmitt-Trigger crank shaft speed sensor with Threshold-Application

D2.1.27

signal input (+), digital, with Schmitt-Trigger crank shaft speed sensor with Threshold-Application

D2.1.45

R > 42 W at 24 V power supply (–), switched, with recovery exhaust gas break valve control R > 14 W at 12 V diode to UBat L < 480 mH at 12 V

D2.1.29

power supply (+), switched

for

customer

CAN-Bus 1, for diagnosis tasks

Inductive sensor, Uin = 0,2...80 V~

exhaust gas break valve control for 12-V-applications: IOut = 1,7 A at Vbat = 14,4 V, L = 160 mH, f = 300 Hz, IOut = 3,1 A at Vbat = 14,4 V,

D2.1.60

power supply (–), switched

internalal exhaust gas break or L = 10 mH, f = 1 Hz, EGR for 24-V-applications: IOut = 0,9 A at Vbat = 28,8 V, L = 600 mH, f = 300 Hz, IOut = 1,7 A at Vbat = 28,8 V, L = 44 mH, f = 1 Hz

V.1.4.1

D2.1.49

power supply (–), switched

fuel control unit (FCU, MPROP) UOut = UBat , Imax = 5 A

D2.1.19

power supply (+)

fuel control unit (FCU, MPROP)

D2.1.39

power supply (–)

fuel Temperature sensor or crankshaft housing pressure internal with UGnd connected sensor

D2.1.52

signal input, analog,with Pullup-resistance

fuel Temperature sensor or crankshaft housing pressure UIn = 0...5 V, Rup = 1,28 kW sensor

D2.1.59

power supply (–), switched or PWM-Signal

fuel valve flame starting or INenn = 1,3 A at 24 V external EGR L = 0...15 mH at 24 V

EMR3 Pin

Signal type

Function / components

D2.1.25

power supply (+)

fuel valve flame starting or external EGR

D2.1.54

power supply (–)

fuel low pressure sensor

internal with UGnd connected

D2.1.57

signal input, analog,with Pullup-resistance

fuel low pressure sensor

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

D2.1.11

power supply (+)

fuel low pressure sensor

UOut = 5 V

D2.1.24

power supply (+)

heater relay

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

D2.1.34

power supply (–), switched

heater relay

D2.1.21

signal input, digital,with Pullup-resistance

Remark / Technical data

external switch depending Mass, Rup = 6,8 kW, Ulow = 2,2 V,

sense for heater relay

Uhigh = 3,7 V D2.1.51

power supply (–)

Oil pressure sensor

internal with UGnd connected

D2.1.13

power supply (+)

Oil pressure sensor

UOut = 5 V

D2.1.56

signal input, analog,with Pullup-resistance

Oil pressure sensor

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

D2.1.8

power supply (–)

Rail pressure sensor

internal with UGnd connected

D2.1.43

signal input, analog,with Pullup-resistance

Rail pressure sensor

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

D2.1.26

power supply (+)

Rail pressure sensor

UOut = 5 V

D2.1.30

power supply (+), switched

Starter relay

Lmax = 130 mH, Imax = 6 A

D2.1.15

power supply (–), switched

Starter relay

D2.1.35

signal input, digital,with Pullup-resistance

engine stop switch (optional)

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

D2.1.22

power supply (–)

External EGR (optional)

internal with UGnd connected

D2.1.28

power supply (+)

crankshaft housing sensor (optional)

D2.1.16

power supply (+)

Injector 1 (Y15.1), 3 (Y15.3) and DCR, 4 and 6 cylinder 5 (Y15.5) = Y15.1/3/5 Bank 1

D2.1.1

power supply (+)

Injector 2 (Y15.2), 4 (Y15.4) and DCR, 4 and 6 cylinder 6 (Y15.6) = Y15.2/4/6 Bank 2

D2.1.47

power supply (–)

Injector 1 Y15.1

DCR, 4 and 6 cylinder

D2.1.31

power supply (–)

Injector 2 Y15.2

DCR, 4 and 6 cylinder

D2.1.48

power supply (–)

Injector 3 Y15.3

DCR, 4 and 6 cylinder

D2.1.32

power supply (–)

Injector 4 Y15.4

DCR, 4 and 6 cylinder

D2.1.33

power supply (–)

Injector 5 Y15.5

DCR, 6 cylinder

D2.1.46

power supply (–)

Injector 6 Y15.6

DCR, 6 cylinder

pressure U Out = 5 V

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. (See circuit diagram)

V.1.4.1

27 1.4.2.4

EMR3 System Description Control Unit EMR3-EDC7 The engine control unit EMR3-EDC7 has three connecting sockets arranged on the top of the housing:  socket D2.1 for connecting the vehicle/device side cable harness,  socket D2.2 for connecting the engine cable harness for sensors and actuators,  socket D2.3 for connecting the engine cable harness for the fuel measuring unit and fuel injectors.

Pin assignment

Max. cable cross section: 2,5 mm², 0,75 mm²

Pinbelegung für das Steuergerät EMR3-EDC7 Pin

Pinart / Signalart

D2.1.2

Power supply (+)

D2.1.3

Power supply (+)

D2.1.8

Power supply (+)

D2.1.9

Power supply (+)

D2.1.5

Power supply (–)

D2.1.6

Power supply (–)

Funktion / Komponente

Bemerkungen / Technische Daten

Power supply ECU

UBat (terminal 30)

Power supply ECU

UGnd (terminal 31)

D2.1.10 Power supply (–) D2.1.11 Power supply (–)

UBat switched (terminal 15)

V.1.4.1

D2.1.40 signal input, digital

Operating signal for ECU

U > 3,35 V: ECU switched on U < 2,81 V: ECU switched off

D2.1.77 Power supply (+)

footpedal (setpoint)1

UOut = 5 V

D2.1.78 Power supply (–)

footpedal (setpoint)1

Internal with UGnd connected

EMR3 Pin

Pinart / Signalart

Bemerkungen / Technische Daten

Funktion / Komponente

signal input, analog, with Pulldown footpedal (setpoint)1 D2.1.79 resistance

Uin = 0...5 V, Rdown = 100 kW external switch to UGnd,

signal input, D2.1.48 resistance

digital,

with

Pullup

Rup = 100 kW, Ulow = 2,4 V,

idle switch footpedal 1

Uhigh = 3,6 V

D2.1.60 Power supply (+)

handthrottle (setpoint) 2

UOut = 5 V

D2.1.59 Power supply (–)

handthrottle (setpoint) 2

internal with UGnd connected

signal input, analog, with Pulldown handthrottle (setpoint) 2 D2.1.61 resistance

Uin = 0...5 V, Rdown = 100 kW external switch to UGnd,

signal input, D2.1.80 resistance

digital,

with

Pullup

Rup = 100 kW, Ulow = 2,4 V,

idle switch footpedal 2

Uhigh = 3,6 V

D2.1.50 Power supply (–)

multiple state switch for speed

internal with UGnd connected

signal input, analog, with Pullup multiple state switch for speed D2.1.43 resistance

Uin = 0...5 V, Rup = 3,4 kW

D2.1.65 Power supply (–)

internal with UGnd connected

multiple state switch for droop

signal input, analog, with Pullup multiple state switch for droop D2.1.62 resistance

Uin = 0...5 V, Rup = 1,4 kW

multiple switch

state governor

mode internal with U Gnd connected

signal input, analog, with Pullup multiple D2.1.44 resistance switch

state governor

mode U = 0...5 V, R = 3,4 kW in up

D2.1.76 Power supply (–)

D2.1.29 Power supply (–)

Common potential for switch

internal with UGnd connected external switch to UGnd,

signal input, D2.1.32 resistance

digital,

signal input, D2.1.55 resistance

digital,

signal input, D2.1.86 resistance

digital,

with

Pullup

Override switch

Rup = 4,1 kW, Ulow = 2,2 V, Uhigh = 3,8 V external switch to UGnd,

with

Pullup

coolant temperature switch

Rup = 100 kW, Ulow = 2,3 V, Uhigh = 3,6 V external switch to UGnd,

D2.1.21 Power supply (+)

with

Pullup

droop switch

Rup = 5 kW, Ulow = 4,6 V, Uhigh = 8,7 V

Common potential for switch

UOut = UBat, Imax = 10 A external switch to UBat ,

signal input, digital, with Pulldown D2.1.41 resistance Engine stop switch

Rdown = 4,1 kW, Ulow = 2,2 V, Uhigh = 3,8 V external switch to UBat ,

signal input, digital, with Pulldown D2.1.49 resistance break switch

signal input, digital, with Pulldown D2.1.42 resistance air differential pressure switch

Rdown = 4,1 kW, Ulow = 2,2 V, Uhigh = 3,8 V external switch to UBat , Rdown = 4,1 kW, Ulow < 0,28 x UBat , Uhigh > 0,68 x UBat external switch to UBat ,

signal input, digital, with Pulldown D2.1.47 resistance exhaust gas break switch

Rdown = 4,1 kW, Ulow = 2,2 V, Uhigh = 3,8 V

V.1.4.1

EMR3 System Description Pin

Pinart / Signalart

Funktion / Komponente

signal input, digital, with Pulldown D2.1.74 resistance engine start switch

signal input, digital, with Pulldown D2.1.85 resistance switch (customer-specific)

Bemerkungen / Technische Daten external switch to UBat , Rdown = 4,1 kW, Ulow < 0,28 x UBat , Uhigh > 0,68 x UBat external switch to UBat , Rdown = 4,1 kW, Ulow < 0,28 x UBat , Uhigh > 0,68 x UBat

D2.1.21 Power supply (+)

Common potential for switch

UOut = UBat, Imax = 10 A

D2.1.70 Power supply (–)

velocity sensor

internal with UGnd connected

D2.1.71 signal input, digital, with comparator

velocity sensor

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

V.1.4.1

signal output, digital (PWM), with D2.1.33 Pullup resistance, minus-switched Engine speed

Imax = 50 mA, fmax = 5 kHz, Standard: 60 Impulse/Rotation

D2.1.22 Power supply (+)

diagnosis lamp

D2.1.30 Power supply (–), switched

diagnosis lamp

0,3 A at 12 V, 4 W at 24 V 0,9 A

D2.1.13 Power supply (+)

Common potential for alarm lamp UOut = UBat, Imax = 10 A

D2.1.20 Power supply (–), switched

Oil pressure/oil level alarm lamp

D2.1.38 Power supply (–), switched

fuel filter/air filter/ fuel pressure 0,3 A at 12 V, 4 W at 24 V alarm lamp switch-on current 0,9 A

D2.1.39 Power supply (–), switched

coolant temperature/coolant level 0,3 A at 12 V, 4 W at 24 V alarm lamp switch-on current 0,9 A

D2.1.54 Power supply (–), switched

Heater control lamp

D2.1.56 Power supply (–), switched

engine running or boost temp 0,3 A at 12 V, 4 W at 24 V lamp switch-on current 0,9 A

D2.1.17 Power supply (–), switched

Start relay

D2.1.37 Power supply (+), switched

Start relay

Lmax = 130 mH Imax = 2 A

D2.1.68 Power supply (+)

Fan speed sensor

UOut = 5 V

D2.1.67 Power supply (–)

Fan speed sensor

Intern with UGnd connected

D2.1.69 signal input, digital

Fan speed sensor

fmax = 1 kHz

D2.1.14 Power supply (+)

fan control

D2.1.15 Power supply (–), switched

fan control

D2.1.24 Power supply (–)

exhaust gas temperature sensor Intern with U Gnd connected or cylinder temperature sensor

0,3 A at 12 V, 4 W at 24 V switch-on current 0,9 A

R > 30 W at 24 V R > 10,6 W at 12 V L = 15...80 mH switch-on current 1,9 A at 16 V (15 Minutes) fmax = 300 Hz, fmin = 15 Hz

signal input, analog, with Pullup D2.1.25 resistance exhaust gas temperature sensor

Uin = 0...5 V, Rup = 1,4 kW

D2.1.28 Power supply (–)

Oil temperature sensor

Intern with UGnd connected

Power supply (+) and signal input, D2.1.27 analog, with multiplier Oil temperature sensor

Uin = 0...5 V, Rup = 1,35 kW

Power supply (+) and signal input, D2.1.26 analog Oil level sensor

constant current source 247mA

D2.1.72 Power supply (–)

Oil level sensor

Intern with UGnd connected

D2.1.23 Power supply (–), switched

PDM-output specific)

D2.1.51 Power supply (–), switched

PDM-output (customer-specific)

torque (customer- I max = 50 mA, fmax = 300 Hz Imax = 50 mA, fmax = 1 kHz

EMR3

Funktion / Komponente

Bemerkungen / Technische Daten

D2.1.57 Power supply (+)

actuator (customer-specific)

UOut = UBat, Imax = 2,4 A,

D2.1.16 Power supply (–), switched

actuator (customer-specific)

Lmax = 130 mH

Pinart / Signalart

signal input, analog, with voltage Sensor (customer-specific) D2.1.81 divider

Uin = 0...5 V, Rin = 100 kW

D2.1.82 Power supply (+)

Sensor (customer-specific)

UOut = 5 V

D2.1.83 Power supply (–)

Sensor (customer-specific)

Intern with UGnd connected

D2.1.34 communication, CAN low

CAN-Bus 2, applications

D2.1.35 communication, CAN high

for

customer

D2.1.52 communication, CAN low CAN-Bus 1, for diagnosis tasks

D2.1.53 communication, CAN high D2.1.89 communication, K-Line

ISO-9141-Bus

D2.2.3

Power supply (+), switched

Common components

potential

for U Bat

D2.2.7

Power supply (–), switched

L = 130 mH pre-heater relay or flame glow max R > 6 W at 12 V plug R > 16 W at 24 V

D2.2.8

signal input, resistance

D2.2.4

sense for heater relay

external switch depending on mass, Rup = 5 kW

Power supply (+), switched

fuel valve flame starting

INenn = 0,75 A at 24 V L = 14,5...15 mH at 24 V

D2.2.5

Power supply (–)

fuel valve flame starting external EGR (optional)

D2.2.3

Power supply (+), switched

Common components

D2.2.6

Power supply (–), switched

exhaust gas break valve control

R > 42 W at 24 V R > 14 W at 12 V L < 480 mH at 12 V

cam shaft speed sensor

Intern with UGnd connected

digital,

with

D2.2.10 Power supply (–) and Shield D2.2.9

potential

signal input (+), digital, with Schmitt- cam shaft speed sensor Trigger with Threshold-Application

D2.2.19 Power supply (–) and Schirm D2.2.23

Pullup

crank shaft speed sensor

signal input (+), digital, with Schmitt- crank shaft speed sensor Trigger with Threshold-Application

or Intern with U Gnd connected for U Bat

Inductive sensor, Uin = 0,2...80 V~ Intern with UGnd connected Inductive sensor, Uin = 0,2...80 V~

D2.2.12 Power supply (–)

Rail pressure sensor or crankshaft housing pressure Intern with UGnd connected sensor

D2.2.13 Power supply (+)

Rail pressure sensor or crankshaft housing pressure UOut = 5V, Imax = 50 mA sensor

pressure sensor or signal input, analog, with Pullup Rail D2.2.14 resistance crankshaft housing pressure Uin = 0...5 V, Rup = 5,6 kW sensor signal input, analog, with Pullup D2.2.15 resistance coolant temperature sensor

Uin = 0...5 V, Rup = 1,36 kW

D2.2.26 Power supply (–)

coolant temperature sensor

Intern with UGnd connected

D2.2.16 Power supply (+)

fuel low pressure sensor

UOut = 5 V

D2.2.18 Power supply (–)

fuel low pressure sensor

Intern with UGnd connected

signal input, analog, with Pullup fuel low pressure sensor D2.2.22 resistance

Uin = 0...5 V, Rup = 6,81 kW

D2.2.18 Power supply (–)

fuel temperature sensor

Intern with UGnd connected

signal input, analog, with Pullup D2.2.35 resistance fuel temperature sensor

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

V.1.4.1

EMR3 System Description Pin

Pinart / Signalart

D2.2.17 Power supply (–)

Funktion / Komponente

Bemerkungen / Technische Daten

Temperature sensor 1 (customer- Intern with U Gnd connected specific)

signal input, analog, with Pullup Temperature sensor 1 (customer- U = 0...5 V, R = 1,3 kW D2.2.29 resistance in up specific) D2.2.32 Power supply (+)

UOut = 5 V

oil pressure sensor

signal input, analog, with Pullup D2.2.27 resistance oil pressure sensor

Uin = 0...5 V, Rup = 6,81 kW

D2.2.24 Power supply (–)

oil pressure sensor

Intern with UGnd connected

D2.2.24 Power supply (–)

Fuel filter water level sensor

Intern with UGnd connected

signal input, analog, with Pullup D2.2.28 resistance Fuel filter water level sensor

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

D2.2.33 Power supply (+)

boost pressure sensor/boost U Out = 5V temperature sensor

D2.2.25 Power supply (–)

boost pressure sensor/boost Intern with U Gnd connected temperature sensor

signal input, analog, with Pullup D2.2.34 resistance boost pressure sensor

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

signal input, analog, with Pullup D2.2.36 resistance boost temperature sensor

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

D2.2.3

Power supply (+), switched

Common components

potential

D2.2.5

Power supply (–)

fuel valve flame starting external EGR (optional)

signal output, ddigital (PWM), minusExternal EGR (optional) D2.2.11 switched D2.2.2

Power supply (–)

for U Bat or Intern with U Gnd connected Imax = 50 mA, f = 200 Hz

Engine stop switch (optional) or Intern with U Gnd connected customer-specific switch

signal input, analog, with Pullup Engine stop switch (optional) or U = 0...5 V, R = 1,1 kW D2.2.21 resistance in up customer-specific switch Speed specific)

sensor

(customer- Intern with U Gnd connected

signal input (+), digital, with Schmitt- Speed Trigger with Threshold-Application specific)

sensor

(customer- Inductive sensor, U = 0,2...50 V~ in

D2.2.20 Power supply (–) and shield D2.2.30

for 12-V-applications: IOut = 1,7 A at Vbat = 14,4 V, L = 160 mH, f = 300 Hz, IOut = 3,1 A at Vbat = 14,4 V, D2.2.1

Power supply (–), switched

Internal exhaust gas break or L = 10 mH, f = 1 Hz, internal EGR for 24-V-applications: IOut = 0,9 A at Vbat = 28,8 V, L = 600 mH, f = 300 Hz, IOut = 1,7 A at Vbat = 28,8 V, L = 44 mH, f = 1 Hz

V.1.4.1

D2.3.4

Power supply (+)

injector 1 (Y15.1), 3 (Y15.3), 5 DCR 4 and 6 cylinder, (Y15.5) and 7 (Y15.7) = DMV 6 and 8 cylinder Y15.1/3/5/7 Bank 1

D2.3.3

Power supply (+)

injector 2 (Y15.2), 4 (Y15.4) 6 (Y15.6) and 8 (Y15.8) = DCR 4 and 6 cylinder, DMV 6 and 8 cylinder Y15.2/4/6/8 Bank 2

D2.3.13 Power supply (–)

injector 1

Y15.1

DCR 4 and 6 cylinder, DMV 6 and 8 cylinder

D2.3.15 Power supply (–)

injector 2

Y15.2

DCR 4 and 6 cylinder, DMV 6 and 8 cylinder

D2.3.6

Power supply (–)

injector 3

Y15.3

DCR 4 and 6 cylinder, DMV 6 and 8 cylinder

D2.3.14 Power supply (–)

injector 4

Y15.4

DCR 4 and 6 cylinder, DMV 6 and 8 cylinder

EMR3

Funktion / Komponente

Bemerkungen / Technische Daten

D2.3.12 Power supply (–)

injector 5

Y15.5

DCR 6 cylinder, DMV 6 and 8 cylinder

D2.3.16 Power supply (–)

injector 6

Y15.6

DCR 6 cylinder, DMV 6 and 8 cylinder

D2.3.7

Power supply (–)

injector 7

Y15.7

DMV 8 cylinder

D2.3.8

Power supply (–)

injector 8

Y15.8

DMV 8 cylinder

D2.3.9

Power supply (+)

fuel control unit (FCU, MPROP)

D2.3.10 Power supply (–), switched

fuel control unit (FCU, MPROP)

Pinart / Signalart

UOut = UBat, Imax = 1,3 A

V.1.4.1

33 1.4.2.5

EMR3 System Description Circuit Diagrams The following plans are a compendium of a great amount of plans, that are created for every application. For your own application you have to contact DEUTZ for a specific circuit diagram. The circuit diagrams are also in ELTAB available.

V.1.4.1

EMR3

Example engine wiring diagram TCD 2013 L6 4V with EDC 16

V.1.4.1

EMR3 System Description

Example engine wiring diagram TCD 2015 L6 6V with EDC 7

V.1.4.1

EMR3

Example engine wiring diagram TCD 2013 L6 4V with EDC7

V.1.4.1

EMR3 System Description

Example engine wiring diagram TCD 2012/13 L6 2V with EDC16

V.1.4.1

EMR3

Example engine wiring diagram EDC16 Vehicle side

V.1.4.1

EMR3 System Description

Example engine wiring diagram EDC16 Vehicle side coldstart

V.1.4.1

EMR3

Example engine wiring diagram EDC16 Vehicle side heatingflange

V.1.4.1

EMR3 System Description

Example engine wiring diagram EDC7

V.1.4.1

EMR3

1.5

Diagnostics The aim of every engine diagnosis is the quick detection of system errors 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 parameterization data of the engine control unit via its diagnostic interface. The diagnosis tool recommended by DEUTZ is the PC software SERDIA2000 which offers all functions necessary for diagnosis, setting and repair work on the EMR3 system. SERDIA2000 enables display and recording of measured values, display, editing, reading (from PC files) and writing (in PC files) of parameterization 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: [emailprotected] 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.

V.1.4.1

1.5.1

EMR3 System Description

Diagnosis with diagnostic button and error lamp The SERDIA2000 software is the first choice for all diagnosis tasks. The two elementary tasks of displaying active system errors and clearing the error memory can also be carried out with the diagnostic key and error lamp however.

Blink-Code-Modus to activate The Blink-Code shows all the errors in the memory, including the passive errors. To start the query of the Blink-Code, the terminal 15 of ECU must be switched off (ignition off) at first. Then, while switching on the terminal 15 (ignition on), press the diagnosis button at the same time for 1 second. Different Blink-Codes are listed in the error code list.

Displaying system errors by blink code If there is at least one active system error in the error memory of the EMR3 engine control unit, it is indicated automatically by an evenly flashing error lamp (for serious system errors) or steadily lit error lamp (for less serious system errors). In this case the output of the error cause can be initiated in the form of blink codes (blink sequences according to the scheme i x short blink, j x long blink, k x short blink). Which blink codes exist and what they mean can be seen in the table of system errors 47 . Reading out the blink codes for the active system errors requires the following steps:  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:

V.1.4.1

EMR3

1.5.2

Diagnosis with SERDIA

Error memory When looking for the cause of a fault in the EMR3 system, it worth to taking a look at the error memory of the engine control unit. The following figure shows the window of the EMR3 error memory in SERDIA2000:

V.1.4.1

EMR3 System Description

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

Password for Error memory 2 and Level 3 access

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

In EMR3-ECU-Error memory, 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.

V.1.4.1

EMR3

Interim values are nor stored. The environment data contain the measurements engine speed, boost pressure, torque, load, coolant temp, velocity, rail pressure, battery voltage, injection mass and engine hours. The variables "DTC-Status, type 1, type 2" are only for internal use.

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

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

Level 1

Level 2

Level 3

Errormemory 1

display delete

and display delete

Errormemory 2 no display

no display

Level 3A = 4 and display delete

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

Level 3AS = 5 and display delete

and

display, delete with interfacedisplay and password only delete without and within the limitation first 50 enginehours

V.1.4.1

1.5.3

EMR3 System Description

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

The tables of system errors ( = DTC-List = diagnostic trouble code list ) are 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 can save only a limited size number of errors. If the error memory is full, the saved error with low priority will be replaced with the new appeared error with high priority.

V.1.4.1

EMR3

1.6

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

EMR3-EDC16

EMR3-EDC7 12 V DC and 24 V DC,

8 - 32 V DC,

Supply voltage, working area

9 - 32 V DC, enginestart from 6 V on

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

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

10 m @ harness environment 12 m @ harness environment temperature 85 Max. distance between ECU and temperature 85 °C and if power-supply is °C engine wired parallel with and if power-supply is wired parallel with diameter 3 x 2,5 mm². diameter 4 x 2,5 mm².

Current consumption without load

Electrical grounding

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

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

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

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

IRMS = 2 A

IRMS = 7,5 A

chassis is connected via RC-Network with internal electric-ground-potential.

Max. power consumption

with connected injection system: ca. 8 W

with connected injection system: ca. 12,5 W

with connected external loads: ca. 15 W

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

Max permissible temperature range Max permissible temperature range

storing

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

Dimensions without plug

203 mm x 167 mm x 38 mm

260 mm x 218 mm x 70 mm

Dimensions plug

203 mm x 254 mm x 38 mm

260 mm x 218 mm x ca.150 mm

0,7 kg without plug

1,6 kg without plug

with not connected

Weight Mounting Data memory Humidity Environment protection

cabin mounted (not engine mounted), cooling via air convection data-conservation < 10 years < 95% (at +40°C), Standard: DIN-IEC 60068-2-2 IP 69K, Standard: DIN 40050

Internal strength against shock

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

Internal strength against shock

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

Chemical resistance ECU housing Diagnosis interface Data interface Plug connection EMC

Environment resistance

Resistant against substances, that are used for engines Aluminum, diescasting, not varnished ISO 9141 K-Line 2 x CAN-Bus, SAE-J1939 engine side: 1x 36-polig, 1 x 16-polig, vehicle side: 1x 89-polig

engine side 1x 60-polig, vehicle side:: 1x 94-polig

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

V.1.4.1

EMR3 System Description

EMR3

Dimension of ECU EMR3-EDC7

V.1.4.1

EMR3 System Description

Dimension of ECU EMR3-EDC16

V.1.4.1

EMR3

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).

V.1.4.1

1.7

EMR3 System Description

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.

V.1.4.1

EMR3

ChangeHistory Version Date

Chapter

Description

Revised by

1.2.4

16.01.2008

Diagnosis plug

Pinning (A,B) changed

1.3.1

10.03.2008

all

Text revised and error correction

1.4.1

21.04.2008

all

Text revised and error correction, Chapter 1.5 was deleted.

V.1.4.1

Index

Keywords -Aalternator pin D+ 20 application data 3 application interface 14

-Bbasic system function Baud-Rate 16 Blink-Code 13, 43

cable cross section 22, 27 CAN-Bus 13, 14, 16 CAN-Bus error monitoring 16 CAN-Bus interface 16 change history 54 circuit diagram 14, 33 cleaning job 1 complete dataset 3 control unit 11 Crimp connection 18 current consumption 48 customer wiring 1

-DDCR 3, 53 DEUTZ ROAD-MAP 3 diagnosis 13 Diagnosis button 14, 43 Diagnosis circuit diagram 18 diagnosis interface 14 Diagnosis socket 14, 18 Diagnosis tool 42 dimension 48

-E-

EMC 48 EMR3-EDC16 22, 48 EMR3-EDC7 27, 48 engine control system 3 engine control unit 3 engine torque 10 environment resistance 48 error list 47 error memory 43 errormemory 44 errormemory 1 44 errormemory 2 44 errormemory 2 access 44 errormemory window 47 external torque 10

-F-

-C-

early detection of error EDC 7 27 EDC16 22 electrical welding 1

FMI-Codes 47 function 3

-Hhardware 3 heater flange

-Iinjection system 11 Installation Guideline 1 Installation guideline electronics installation instruction 48 ISO-9141-Bus 14

-KK-Line 13 KWP 2000 16 KWP2000-Protocol

-Mmain relay 20 main software (BSW)

-P12 partial dataset 3 pin assignment 22, 27 PLD 3, 53 V.1.4.1

EMR3 System Description

power supply 1 priority 16 priority of the error 47 protection class 1

-RReceive Message

-SSAE J 1939 16 sensor 12 SerDia2000 18, 42 software-combination 11 source address 16 SPN 47 storing temperature 48 supply voltage 48

-TTransmit Message

-Wwarning 12 warning stratergy 12 weight 48 WILBÄR 42 wiring 14, 18 working temperature 48 workshop manuals 1

V.1.4.1

DEUTZ AG Application Engineering Ottostr. 1 51149 KÖLN Phone: +49 (0) 2 21 - 822 - 0 Fax: +49 (0) 2 21 - 822 - 5358 Internet: www.deutz.com Email: [emailprotected] Printed in Germany All rights reserved 1. Edition, 01/2008 Copyright.: 0312 1985

Deutz EMR3 210408 ENG System Description - PDFCOFFEE.COM (2024)