Deutz EMR 2 System Description

System Description
Electronic Engine Governor

EMR 2

Chapter

EMR 2

Chapter Overview

Introduction

Important Notes

System Description

System Functions

Interfaces

Configuration and Parameter Setting

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6

Diagnostic Button and Fault Indicator Lamp

Replacement of System Components

Technical Data

Index of Specialist Terms

Index

Connection Diagams

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EMR 2

Chapter Overview

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EMR 2

Ta ble of Contents

Contents

1 Introduction

2 Important Notes

2.1 Operating instructions 67

2.2 Installation guidelines 67

2.3 Damage 67

2.4 Customer side wiring, plug connection 68

2.5 Remove plug 68

2.6 Electrical welding 68

3 System Description

3.1 Utilization of the EMR 2 69

3.2 System overview 69

3.3 Description of functions 70

3.4 Basic equipment 70

4 System Functions

4.1 Overview features 72

4.2 Function extensions 73

4.3 Speed control 74

4.4 Set point settings 76

4.5 Fuel quantity limitation (performance curve) 77

4.6 Droop control 78

4.7 Engine start/stop 78

4.8 Displays / Outputs (monitoring function) 79

4.9 LDA function 81

4.10 Temperature-dependent start control 81

4.11 Speed throttling (input F 7) 81

4.12 Engine protection functions 81

4.13 Altitude correction 82

4.14 Fuel volume control 82

4.15 Emergency running (limp home) 82

4.16 Cold start installation 82

Page

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69

71

5 Interfaces

5.1 Diagnostic interface (basic function) 83

5.2 CAN-Bus interface 83

6 Configuration and Parameter Setting

6.1 Function overview, pin assignment and configuration example 86

7 Diagnostic Button and Fault Indicator Lamp

7.1 Self-diagnostic (without operating the diagnostic button) 87

7.2 Diagnostic with Button and Error Code 90

7.3 Diagnostic possibilities with the SERDIA software 98

8 Replacement of system components

8.1 Replacement EMR

8.2 Features of the Replacement of the Control Unit 99

8.3 Features of the Replacement of the Actuator 100

8.4 Combination EMR, EMR 2, Control Unit and Actuator 100

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↔↔↔↔ EMR 2 99

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87

99

Tab l e of C o n t e nt s

EMR 2

9 Technical Data

9.1 General Data 101

9.2 Signal Specification 102

9.3 Plug assignments 103

9.4 Sensor Data 105

10 Index of Specialist Terms

11 Index

12 Connection diagrams

Appendix

12.1 Connection diagram - Vehicle side / Unit side 115

12.2 Connection diagram Engine side (sheet 1) 116

12.3 Connection diagram Engine side (sheet 2) 117

12.4 Connection diagram for CAN-Bus and Diagnostic Line 118

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1 Introduction

EMR 2

Introduction

This system description provides an overview of the design and operation of the electronic engine governor
(EMR 2) as a control unit when used in engines of the model series 1012/1013/2012/2013/1015

In addition, an explanation is given of the functions of the EMR 2 and how problems with the EMR 2 can be
recognized and overcome.

The EMR 2 is a further development of the previously utilized EMR.
Basically, it has the same functionality as the EMR, but is equipped with additional functions and extensi-

ons that are summarized in Chapter 4.2.
Reference is made to Chapter 8 for information regarding replacements,

1) Same system with Bosch EDC-actuator (1015).

1)

.

General notes

It is our aim to permanently improve and extend the contents of this brochure. For this purpose, the experi­ences of the circle of users can be particularly helpful.

Should you desire changes, extensions, improvements, etc., we would welcome your input (Engine mainte­nance technology department, VS-TI). Please make as much use of this as you wish. In this way, you are
assisting in making the next version more up-to-date. We pay close attention to every message and will
prepare a new issue of the brochure at the appropriate time. We thank you in advance for your cooperation.

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Maintenance technology engines

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EMR 2

Introduction

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2 Important Notes

2.1 Operating instructions

☞

IMPORTANT!

The purpose of this document is the explanation and clarification of the design and functions
of engines, engine components and systems.
The information contained herein always corresponds to the technical conditions valid at the
time of going into print and are not subject to any immediate alteration service.

☞

IMPORTANT!

Applicable for the operation, maintenance and start-up are exclusively the information of the
published and currently valid technical documentation, corresponding to the scope of deli­very and function (such as operating instructions, switching diagrams, workshop manual,
repair and adjustment instructions, technical circulars, service information, etc.).

EMR 2

Important Notes

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3

2.2 Installation guidelines

☞

IMPORTANT!

For the mechanical installation of the apparatus, reference should be made to the applicable
issue of the “Installation Guidelines for electronic systems of DEUTZ diesel engines”. More
information can be obtained from the DEUTZ AG, dept. technical operation support.

H

REMARKS!

Sufficient ventilation of control unit and actuator must be ensured in order to prevent limitati­ons of function and damage.

2.3 Damage

H

REMARKS!

Sensors and actuators may not be fitted individually to, or between, power sources for either
inspection or testing purposes but only in connection with the EMR 2, as there is a danger of
destruction!

H

REMARKS!

Despite polarity reversal protection in the control apparatus, it is necessary to prevent incor­rect polarity. Incorrect polarity can damage control units!

H

REMARKS!

The plug connections of the control units are only dust and watertight when plugged into
mating connection! Until the mating connector has been plugged in, the control units must be
protected against spray water!

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EMR 2

Important Notes

2.4 Customer side wiring, plug connection

☞

IMPORTANT!

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.

1

☞

IMPORTANT!

The connection between pins and individual wires must only be carried out with the proper
pinching tools.

2

H

REMARKS!

The voltage supply for inputs and outputs for the users must be able to be switched in a de­energized manner via the key switch (terminal 15) - not via continuous positive.

3

2.5 Remove plug

4

H

REMARKS!

Removing the 25-pole equipment plug and engine plug when the control unit is on, i.e. when
the voltage supply is on (terminal 15 on) is not permitted.

5

6

1. Voltage supply off

- only then -

2. pull out equipment plug and engine plug

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2.6 Electrical welding

H

REMARKS!

In order to prevent damage when carrying out ELECTRIC welding of the installation, the plug
connections at the control unit must first be pulled out.

H

REMARKS!

The ignition (terminal 15) must be switched off when working at the EMR 2.

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3 System Description

3.1 Utilization of the EMR 2

EMR 2

System Description

The purpose of the electronic engine governor (EMR 2) is the regulation of the speed of revolution of DEUTZ
Diesel engines of the model series 1012/1013/2012/2013/1015 for applications in agricultural and con­struction machinery as well as in generating sets. It is designed for heavy duty also under difficult environ­mental conditions and possesses the corresponding protection classes.

The governor fulfils all the functions of the mechanical governor (variable speed governing, torque limitati­ons, LDA function) and makes further functions available.

3.2 System overview

Basically, the EMR 2 consists of the sensors, the control unit and the actuator.
Engine-side as well as vehicle-side or plant-side installation are connected by means of separate cable har­nesses to the EMR control unit. The cabling on the plant side is carried out by the vehicle or plant manufac­turer.

For arrangement on the engine and plant/vehicle side, see the following figure.

Engine-side equipment

Charge-air pressure

sensor (optional)

Control rod position sensor/

actuator

-Control unit

Set and vehicle-side equipment

Power supply

Multi function displays

1

2

3

4

5

6

Coolant temperature

sensor

2nd Speed sensor

(optional)

*with atmospheric pressure sensor (otional)

Lifting solenoid

(optional)

Camshaft speed

sensor

Oil pressure sensor

(optional)

Cold start aid

(optional)

Fuel temperature

(optional)

Charge air temperature

(optional)

Outputs (modifiable)

Inputs (modifiable)
(PWM/digital/analog)

Accelerator pedel

Hand operated throttle
(optional)

Functions changeover
switch

Start/Stop
Key-operated switch

Diagnostic button

Fault indicator
lamp

Diagnosis interface/
CAN-Bus

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EMR 2

System Description

3.3 Description of functions

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

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2

3

4

5

pedal etc.), the EMR 2 controls an actuator that operates the control rod of the injection pump and thus
doses the fuel quantity in accordance with the performance requirements.

The exact position of the regulating rod is reported back and, if necessary, is corrected, by means of the
control rod travel sensor, situated together with the rotation magnets in a housing of the “actuator”.

The EMR 2 is equipped with safety devices and measures in the hardware and software in order to ensure
emergency running (Limp home) functions (see Chapter 7.1).

In order to switch the engine off, the EMR 2 is switched in a de-energized fashion over the ignition switch. A
strong spring in the actuator presses the control rod in the de-energized condition into the zero position. As
a redundancy measure, an additional solenoid serves for switching off and this, independently of the actua­tor, also moves the control rod in the de-energized condition into the zero position.

After the programming, that is carried out over the ISO 9141 interface, the EMR 2 is possesses a motor­specific data set and this is then fixedly assigned to the engine. Included in this are the various application
cases as well as the customer’s wishes regarding a particular scope of function. The result of this is that any
later alteration must be reported back to the DEUTZ AG so that, in case of replacement anywhere in the
world, the new control unit can be programmed with the current data set.

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3.4 Basic equipment

Besides the control unit, the following components are required as minimum equipment for the operation
of the engine:

Vehicle side:

! Energy supply (battery)
! Diagnostic interface (ISO 9141)
! Fault lamp/diagnostic lamp
! Diagnostic button
! Set point selection
! Key operated switch
! Function change-over switch
! Cable harness

Engine side:

! Actuator (contains control rod travel sensor and positioning magnet)
! Speed sensor (camshaft)
! Coolant temperature sensor (NTC)
! Cable harness

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Further components and installation are possible depending on the application case or the desired
functions (see chapters 4 and 6). The combination can be selected from the DEUTZ pocket handbook.

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EMR 2

System Functions

4 System Functions

The EMR 2 makes a broad range of functions available and these can be activated by the application­dependent configuration and the allocation of the inputs and outputs. It makes possible signal exchange
between the engine (via the engine plug) and the EMR 2, as well as between the vehicle (via the vehicle
plug) and the EMR 2. The signals can be transmitted as analog, digital, impulse modulated (PWM signals)
and as CAN-Bus messages.
Which functions are used, depends on the application conditions of the engine. Correspondingly, there are
different variations of the functions and the pin assignments of the plugs.

The functions of the EMR 2 refer to the speed control, quantity limitations (fuel injection), monitoring,
vehicle and apparatus functions and communication and diagnostic interfaces.

The EMR 2 offer a basic equipment on which all the optional variations can be structured.

1

2

3

Sensor inputs

Control rod travel

!

Speed

!

Coolant temperature

!

(Charge air pressure)

!

(Oil pressure)

!

(2nd speed)

!

(Coolant level)

!

(Charge air temperature)

!

(Fuel temperature)

!

(Tacho signal)

!

Actuator functions

Actuator

!

(Switch-off magnet)

!

:

EMR 2

(Atm pressure sensor)

Micro
processor

Memory for

operating

software

Set point input

Key-operated switch

!

(Pedal sensor)

!

(Throttle lever)

!

(Via CAN-Bus)

!

(Voltage 0 - 5 V)

!

(PWM signal)

!

Transfer switch for

functions

Interfaces

ISO 9141

!

CAN-Bus, SAE J1939

!

4

5

6

7

Energy supply

Memory for

Parameters

!

Char. curve

!

Char. diagram

!

Faults

!

Display functions /

outputs

Fault lamp

!

(Warning signals)

!

(Multi-function dis-

!

plays)

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9

The functions shown in brackets are optional.

© 06/02

Because of the numerous possibilities of combinations, DEUTZ has defined function ranges. These can be
crossed off in the DEUTZ pocket handbook. The switching diagram for each function range should also be
noted especially for the wiring required on the customers side.

© 06/02 Seite 71

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EMR 2

System Functions

4.1 Overview features

Feature Chapter Description

As variable speed, idling/end or fixed speed governor; choice

1

Speed control 4.3

of switchable governor features during operation, freezing
the current speed, fixed speed governor for network
synchronization or load distribution, overdrive speed

2

Set point input 4.4

3

4

Torque limitation 4.5

Governor behaviour (speed
droop)

4.6

By means of

! Pedal sensor and/or hand throttle
! External voltage signal (0 - 5 V)
! CAN Bus (remote electronics)
! Fixed speed signal (genset operation)
! Pulse width modulation (PWM)
! Touch control operation Up/Down (digital)

Optimal adaptation to different applications

Up to three performance curves can be set independently of
each other within the framework of the engine limits

Constant, variable or switchable speed droop from 0 - 80 %
for adaptation to the application

5

Engine Start/Stop 4.7

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7

8

Monitoring and signal
output functions

LDA function 4.9

Temperature-dependent
start control

4.8

4.10

Engine switch-off by means of EMR actuator (additional
safety using switch-off solenoid possible)

Coolant temperature and level, oil pressure, charge air
temperature, fuel temperature → fault display and/or
performance reduction or engine switch-off for engine
protection

Smoke limitation through charge air pressure and/or
temperature-dependent limitation of the adjustment speed of
the injection

Improving the starting ability, gentle cold start without smoke
ejection

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Altitude correction 4.13 Engine protection because of reduced air pressure

Fuel volume correction 4.14 Compensation for loss of performance due to fuel heating

Emergency running after failure of set point signal (e.g. using

Emergency running 4.15

Selection of cold
start help installations

Data communication 5 Interfaces, diagnostics and programming

Output of fault
fault blink codes

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4.16

7.2 Simplified fault diagnosis

accelerator pedal), the charge air sensor or the vehicle speed
signal

Failure of auxiliary control units, EMR 2 controls a selection
of heating flange, glow plugs or flame starting apparatus

EMR 2

System Functions

4.2 Function extensions

The EMR 2 has the same functions as the EMR but possesses extended and new functions.
The new functions in detail are:

! Improved speed control
! Third performance curve
! Smoke limitation = function of the charge air temperature
! Monitoring the charge air temperature, coolant level
! Altitude-referenced fuel quantity
! Control of an engine brake
! Special set point parameter for genset applications
! Special vehicle speed evaluation to DIN 11786
! New functions via the diagnostic button:

- fault blink codes

- clearing the fault memory 1

! 2 Independent fault memories (mirroring the first fault memory)
! Acquisition of a load collective
! Baud rate alteration for ISO communication possible
! Possibility of a software update for the operating software via the

ISO interface

! Newly introduced or changed commands in ISO communication
! CAN Bus protocol to SAE J1939 has been greatly extended,

but is upwards compatible to the present EMR applications.

Caution!

EMR and EMR 2 are separate systems. An exchange of control units and actuators is not possible (see
Chapter 8).

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EMR 2

System Functions

4.3 Speed control

Provision is made for various variations of speed control that must be programmed in advance (at the end
of the programming) depending on the application case (power generation, building or agricultural machi­nes) and usage conditions. The variations depend on the type of programmed and the selected functions.

1

The following types of speed regulation (switches) are optional and are programmed at the works depen­ding on the variant (pin assignment see Chapter 6.1):

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Function Variant Description Remarks

Variable speed
control

Genset
applications

Variable speed-,
Min/Max-control

Min/Max-control

1) Types of speed control

Variable speed control

For this type of control the speed of the engine is governed or kept constant with reference to the desired speed of revolution.
For changes of load, the new required amount of fuel is set in accordance with a PID control. The desired value can be
determined through various variants.

Min/Max control

For this type of control, the fuel injection quantity is determined on the basis of the desired value. the result of this is that, for
this type of control, a speed of revolution depending on the load situation is set. The idling (= Minimum) and the end
revolutions (= Maximum) are controlled taking into account the control parameter speed droop 1 and speed droop 2. The
basis for this type of control is the drive characteristic field.

2) Change-over switching see point 4.3.1.

Variable speed
governor

Fixed speed governor Variable speed governor with fixed, pre-defi-

Change-over
switching speed 1 /

2)

2
Change-over swit­ching speed fixed/

variable
Speed variable /

freeze

Speed memory
function
Power generation
governor with adju­stable speed range

Power generation for
network synchronisa­tion or Load distribu­tion
Power generation
governor with adju­stable speed and
switchable overdrive
speed
Variable speed,

Min/Max governor
Min/Max governor

1)

2)

2)

Pure variable speed governor without addi­tion and switch-over functions

ned speed for gensets (1,500 or 1,800 rpm),
desired speed of rotation is defined in the
scope of customer supply (KLU).

Variable speed governor with change-over
switching possibility between two speeds.

Variable speed governor with change-over
switching possibility between a fixed pro­grammed and a variable speed of revolution.

Variable speed governor with change-over
switching possibility between:
freezing a current desired speed as set point
independent of the pedal setting, and a varia­ble revolution.
Customer-specific solution for storing and
calling up two speeds of revolution.
As for change-over switching fixed/variable
speed. Without Load the speed can be adju-
sted in the speed range.

As for change-over switching fixed/variable
speed. The variable revolutions can be adju­sted in the revolution range for network syn­chronization or load distribution.
As for change-over switching fixed/variable
speed the power generator, in fixed speed
mode, can be used as the overdrive speed
without loading, in variable mode or for
parallel switching.
Switching over between variable speed and

2)

Min/Max control.

1)

Idling and end revolutions for vehicle
applications.

Only one vari­ant can be
selected

See also
system des­cription
EMR Genset,
TN 0297 9939

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EMR 2

System Functions

4.3.1 Switchable speed functions

The conditions for the switchable variants are selected by means of a switch (Input pin 18, GND pin 17
V plug). The switch closes a contact to -U

The following is applicable for the switchable speed functions:

Switchable speed functions

(for a selectable)

Batt

.

Switch open

(1/HIGH)

1)

Switch closed

(0/LOW)

1

Speed 1/ speed 2 Speed 1

Fixed / variable speed Variable Fixed

Speed variable / freeze Variable

Variable speed governor / Min/Max
governor

1) With an open switch, the underlined conditions above are activated as preset values (default values).

The switching condition can be displayed with the aid of the SERDIA diagnostic software (see Chapter 7.3)

4.3.2 Second speed input (optional)

This input can be used as a redundant speed input. If a second speed sensor has been installed, then the
engine will not be switched off on failure of the first speed sensor but will switch over to the second one.
The failure of a speed sensor is indicated by the continuous burning of the fault lamp. The operation of the
engine can be limited by defining a lower desired speed (see also Chapter 7.1).

4.3.3 Excess speed protection

when the speed limit is exceeded, the EMR 2 moves the control rod into the Stop position. The output,
engine switch off (Digital 3, M 2) is activated (if it is programmed) and a fault message is generated.

With applications in mobile machines the thrust mode is programmed as a safety measure.
Exceeding of the revolution limit can occur in thrust mode. In this case the control rod is moved to the zero
position and the fault lamp lights up. The engine is protected against excess revolutions also in this type of
operation.
After falling below the programmed recovery limit, the governing is again taken up and the fault lamp is
extinguished. The parameters “Above speed limit” and “Recovery limit” are adjustable.

Variable speed governor

Speed 2

Freeze

Min/Max regulator

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EMR 2

System Functions

4.4 Set point settings

The following variants for the set point settings of the governor can be configured:

1

Function Variant Description Remarks

Set point setting Accelerator

value sensor
(SWG 1)

Setting with potentiometer (5 V reference
voltage, max. 30 mA
input pin 24, GND pin 23, V-plug

1)

, typ. 1 kΩ linear, pin 25,

2)

)

2

Voltage Setting by means of external voltage (0.5 -

4.5 V, input pin 24, GND pin 23, V-plug)

3

Hand throttle
(SWG 2)

4

Memory
function

Setting with hand throttle. The set point in the
EMR 2 is determined by means of a maximum

function (5 V reference voltage, max. 30 mA
typ. 1 kΩ linear, pin 25, input pin 20,
GND pin 23 V-plug)

Freezing the current engine speed Only possible in con-

5

CAN Setting via the CAN interface

(see Chapter 6.1)

6

Internal (fixed
speed)

Setting via internal parameters.
The parameter is determined in the customer
scope of supply (KLU).

Replacement for
pedal value sensor

1)

,

nection with the
pedal value sensor
(SWG 1)

CAN = Controller
Area Network

For gensets

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PWM signal 1
PWM signal 2

1) PIN 25: I

2) V*plug = Vehicle plug / GND = Ground.

=30 mA (Pedal value sensor and hand throttle combined).

max

The desired value is set by means of an exter­nal PWM signal (frequecyz=100 Hz) with a
modulation of 5 % to 95 %
(see Chapter. 9.2) Input pin 18 or 20, GND pin
17 V-plug

Auxiliary for pedal
value sensor

12

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EMR 2

System Functions

4.5 Fuel quantity limitation (performance curve)

In order to set the engine performance and the desired torque course, the maximum injection quantity/
thrust must be limited in accordance with the settings.

Provision is made in the EMR 2 for three performance curves. The performance curve is created as a cha­racteristic curve with 13 freely selectable speed support points. The sampling points must be support
points, whereby the sample of the engine is carried out with performance curve 1. The performance curve 2
is correspondingly corrected with the correction data of performance curve 1.

1

Function Variant Description Remarks

Perfor­mance
curve

Performance curve change-over switching

Performance curve 1/ performance curve 2 Performance curve 1

1) With open switches, the underlined conditions above are activated as default values.

Performance
curve 1

Performance
curves 1/2

Performance
curves 1/2/3

(Input)

pin 19, GND pin17 V-plug

Quantity limitation with a performance curve (perfor­mance curve 1)

Switching between two performance curves

Change-over switching only via CAN

Switch open

(1/HIGH)

1)

Only 1 variant
can be selected

Switch closed

(0/LOW)

Performance curve 2

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EMR 2

System Functions

4.6 Droop control

One of the features of the electronic governing is that, in contrast to mechanical governors, the P-Gradient
can be set to 0 % and switched over between two defined P-gradients. The maximum value lies at 80 %.

1

For limiting the P-gradient relationship of the mechanical governor, provision is made for a speed-depen­dent P-gradient function by means of a characteristic curve with eight speed support points.

2

3

Function Var iant Description Remarks

P-gradient Constant P-gradient P-gradient is constant within the whole speed range. Only one

Variable P-gradient Speed-dependent P-gradient

P-gradients 1/2 Switching between two fixed P-gradients

Constant/variable Switching between constant and variable P-gradients

variant can
be selected

4

Switchable variant

pin 21, GND pin 17 V-plug

5

P-Gradient 1/ P-Gradient 2 P-gradient 1

Constant / variable P-gradient Constant

Switch open

(1/HIGH)

1)

Switch closed

(0/LOW)

P-gradient 2

Variable

6

1) With open switches, the underlined conditions above are activated as default values..

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4.7 Engine start/stop

As soon as the control apparatus recognizes the start-speed, the control rod is freed for the start.
For switching the engine off, the EMR 2 must be switched via the key-operated switch in a de-energized
manner. With this setting, the controlling rod is moved to the stop position by the spring action of the actua­tor and/or the redundancy solenoid.
The switching off of the engine can also be triggered by a fault in the EMR 2 (see Chapter 7.1, Self-Diagno­stic).

9

Function Variant Description

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Engine start/stop Switching off with the

EMR 2 actuator

Redundant switching­off with the solenoid

(pin M 2

1) M 2: Engine plug, pin 2

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1)

and M 1)

In a de-energized condition, the EMR 2 actuator moves
the control rod into the stop position and switches the
engine off

In addition, the engine is switched off by means of a sole­noid (must be programmed in the control unit)

EMR 2

System Functions

4.8 Displays / Outputs (monitoring function)

By means of the digital PWM outputs and depending on the configuration, various signals can be displayed
and output.

Fault lamp (Pin 4 vehicle plug)

A red fault lamp must be placed where it is easily visible at the customer apparatus side. The fault lamp ser­ves as a rough estimate of the fault that has occurred; here the following means:

! Lamp 2 s on: Self diagnosis with switched on the voltage supply. Result: There are no faults.
! Continuous light: There is a fault message; however the system is operational (possibly limited).
! Flashing: Serious malfunction - engine will be switched off or engine cannot be started.
! Blink code: Query malfunction locality by means of diagnostic button.

For detailed information see Chapter 7.1.

Output signals (maximum of 4 output signals possible)

Function Var iant Description

Display functions Speed 1

(pin 16, vehicle plug)

To rq ue
(pin 5, vehicle plug)

Warning signal coolant
temperature
(pin 3, vehicle plug)

Corresponding to the (No. of teeth on gear wheel)
symmetrical square signal (Voltage level from 0 V to
+U

)

Batt

PWM signal (100 Hz) with button relationship from 5 to
95 %. Reference value: performance curve in the working
point or M

Overstepping limiting value
High/Low change-over switching

dMax

1

2

3

4

5

6

7

Warning signal oil pres­sure
(pin 15, vehicle plug)

Warning signal
charge air monitor
(pin variable)

Freely selectable digital
output signal

Freely selectable measu­ring or calculation value
(PWM- signal)

Speed-dependent oil pressure control
High/Low change-over switching

General display for overstepping or falling below the limi­ting values

By arrangement

8

9

10

11

12

13

© 06/02 Seite 79

EMR 2

System Functions

Load collective

The EMR 2 measures the loading of the engine. For this purpose, the respective load and revolution regions
are allocated to the engine operating hours.

S1 to S9 are operating hours within the respective sector.

1

2

3

4

5

6

7

8

9

10

Torque referred to torque

100

S7 S8 S9

50

S4 S5 S6

30

S1 S2 S3

max

[%]

(torque

max

© 06/02

)

11

12

12

Speed [rpm]

1000 2000 4000

© 06/02

The load collective can only be displayed and printed with SERDIA.

Seite 80 © 06/02

EMR 2

System Functions

4.9 LDA function

For mobile applications, the injection quantity for acceleration and dynamic load increase is limited with
reference to the charge air pressure (smoke quantity-characteristic field). Usage: protection of the exhaust
turbo supercharger and prevention of smoke ejection.

4.10 Temperature-dependent start control

1

In order to prevent smoke ejection and for optimizing the governing relationship, the start quantity, the
speed ramp and the governor parameters are controlled with reference to the temperature (required basic
function).

4.11 Speed throttling (input F 7)

This function is designed for a driving speed evaluation is accordance with DIN 11786.

4.12 Engine protection functions

All monitoring functions can be provided with a message lamp on the plant side (dependent on the scope of
the function and the pins that can be assigned).

Oil pressure monitoring

The user is warned by means of the message lamp when

! the oil pressure has overstepped the warning limit and/or
! after a pre-warning period, the performance has been reduced by the EMR 2, or
! the oil pressure falls below the switch-off limit and, after a pre-warning period,

the engine is switched off.

Coolant temperature monitoring

The user is warned by means of the message lamp when

! the temperature exceeds the warning limit and/or
! after a pre-warning period, the performance has been reduced by the EMR 2, or
! the temperature exceeds the switch-off limit and, after a pre-warning period,

the engine is switched off

2

3

4

5

6

7

8

9

Charge air monitoring

The user is warned by means of the message lamp when

! the temperature exceeds the warning limit and/or
! after a pre-warning period, the performance has been reduced by the EMR 2, or
! The temperature exceeds the switch-off limit and after a pre-warning period, the engine is

switched off.

© 06/02 Seite 81

10

11

12

13

EMR 2

System Functions

Coolant monitoring

The user is warned by means of the message lamp when

! the coolant level falls below the warning limit and/or
! after a pre-warning period, the performance has been reduced by the EMR 2, or

1

! the the coolant level falls below the switch-off limit and, after a pre-warning period, the engine is

switched off.

2

4.13 Altitude correction

The altitude correction is carried out by means of an Atmospheric pressure sensor in the control unit. Two
different control unit variants are offered (with and without atmospheric pressure sensor).

3

4.14 Fuel volume control

4

5

6

7

8

Compensation for loss of performance due to fuel heating. Necessary variant with fuel temperature sensor.

4.15 Emergency running (limp home)

The EMR 2 provides comprehensive emergency running functions that are configured depending on the
field of application. These functions are necessary in order that, in an emergency, the operation can be con­tinued with auxiliary speed. In detail, this function can be activated by

a) set point default
b) charge air pressure
c) vehicle speed signal and/or
d) speed acquisition

It is also possible by the failure of the set point default to switch over via CAN Bus

a) on the accelerator pedal and
b) on auxiliary speed

The respective type of malfunction is defined in the fault memory.

9

10

11

12

12

4.16 Cold start installation

Failure of additional control units; if desired EMR 2 controls heating flange, glow plugs or flame start instal­lation.

Seite 82 © 06/02

EMR 2

Interfaces

5 Interfaces

The EMR 2 is equipped with various interfaces. The wiring is carried out on the customers side and must be
integrated in the vehicle plug. For pin assignment see the application-dependent switch diagrams.

5.1 Diagnostic interface (basic function)

1

The end programming of the EMR 2 is carried out via the serial diagnostic interface (according to
ISO 9141).

With the aid of a PC connected to an interface and the SERDIA (see also Chapter 7.3) diagnostic software ­measuring values, error messages and other parameters can be displayed and set - depending on access
authorization. Furthermore, new control units can be programmed.

Communication is only possible with the electric power switched on.

5.2 CAN-Bus interface

The CAN-Bus interface (Controller Area Network) is increasingly being used in vehicles and is suitable for
measuring values and data exchange with one or more apparatus-side control units (hydraulics, drive con­trol, etc.). The SAE J1939 protocol is utilized for communication.

The following is an aid to utilization of the respective scope of functions:

! Selection according to the DEUTZ pocket handbook
! Definition before supply of engine
! Connection in accordance with connection diagram (see Chapter 12.1 to 12.3)

Subsequent changes to the configuration is only possible in conjunction with the DEUTZ operating partner
and the aid of SERDIA (see Chapter 6).

2

3

4

5

6

7

8

9

10

11

12

13

© 06/02 Page 83

EMR 2

Interfaces

1

2

3

4

5

6

7

8

9

10

11

12

12

Page 84 © 06/02

EMR 2

Configuration and

Parameter Setting

6 Configuration and Parameter Setting

The EMR 2 is specially programmed and configured for each individual engine, which means that the
EMR 2 contains a specially engine-specific data set. Configuration is carried out via the externally accessi­ble diagnostic interface (ISO 9141) and is strongly dependent on the customer’s wishes, from the applica­tion cases and from the behaviour of a vehicle in operation.

Access to the various parameters is protected (by password) by means of access authorizations organized
on four levels and can only be carried out by authorized personnel.

More than 1200 different parameters are available. Access to these parameters, as well as to other data,
can be carried out by means of the special SERDIA diagnostic software installed on a PC (see Chapter

7.3).

1

2

☞

Important!

Rebuilding, as well as alteration to the parameters can only
the corresponding DEUTZ operating partners. For this purpose SERDIA Level III is required.
In connection with the above-mentioned possibilities, the changed data sets must be repor­ted back to DEUTZ (see Service Note No. 0199-99-9287).

Type of operation

e.g. parallel opera-

tion

Other type of

operation

desired

Scope of function

Part data set

be carried out in conjunction with

Switching

diagrams

3

4

5

6

7

8

Performance

dataset

Re-blocking

Other

performance data

desired

© 06/02 Page 85

! Other set speed
! Other performance
! Other set speed and

other performance

Complete data set

see “SERDIA” handbook

Notification

to DEUTZ

see “SM 0199-99-9287”

© 06/02

9

10

11

12

13

1

2

3

4

5

6

7

8

9

10

11

12

12

Configuration and

EMR 2

Parameter Setting

6.1 Function overview, pin assignment and configuration example

Summarized function overview with examples of function selection

The user-referenced selection is carried out using the DEUTZ pocket handbook

Functions

Scope of function 0211 2291
Model No. 0029 3766
No. of connection diagram engine side 0419 9752
No.of connection diagram vehicle/plant side 0419 9780

Sensor inputs

Speed sensor 1 (camshaft) E 12, 13 E !
Speed sensor 2 (crankshaft) E 10, 11 E ­Charge air sensor (LDA function) E 23, 24, 25 E ­Oil pressure sensor E 20, 21, 22 E !
Atmospheric pressure sensor (in control unit) - - - ­Coolant level sensor E 6, 8 E ­Charge air temperature sensor E 4, 8 E ­Fuel temperature sensor E 5, 8 E ­Coolant temperature sensor E 9, 8 E ­Control rod travel sensor E 16, 17, 18, 19 E !

Actuator functions

Operating solenoid E 14, 15 A ­Dig. output (PWM) E 3 A ­Solenoid E 2 A !

Default functions (set point defaults via)

Hand throttle V 23, 20, 25 E ­Voltage V 23, 24 E ­Accelerator pedal (potentiometer) V 23, 24, 25 E !
CAN V 12, 13 E/A !
PWM signal 1 V 17, 18 E ­PWM signal 2 V 17, 21 E -

Memory functions

Fixed speed (upper limit) V 17, 18 E ­Fixed speed (lower limit) V 17, 21 E ­Freeze current speed V 17, 19 E ­Limit fuel quantity of a performance curve !

Switch-over functions

speed 1 / 2 V 17, 18 E ­Fixed / variable speed V 17, 18 E ­Freezing / variable speeds V 17, 18 E ­Variable speed governor min/max regulation V 17, 18 E ­Performance curve1 / 2 V 17, 19 E ­Performance curve1 / 2 / 3 (via CAN) V 12, 13 E ­P-gradient 1 / 2 V 17, 21 E !
P-gradient const. / variable V 17, 21 E ­Key-operated Start/Stop, energy supply V 1, 14 !

Display / output functions

Fault lamp V 4, (Cl. 15) A !
Warning coolant temperature V 3, (Cl. 15) A !
Warning oil pressure V 15, (Cl.15) A !
speed V 16, (Cl. 15) A ­Torque (reserve) V 5, (Cl. 15) A ­Warning monitoring charge air ­Freely selectable digital output signal ­Freely selectable measuring or calculation value ­Load collective !

Diagnostic interface

ISO 9141-L V 10 E/A !
ISO 9141-K V 11 E/A !

CAN-Bus (SAE J1939 protocol

CAN-H V 12 E/A !
CAN-L V 13 E/A !

engine

Plug

/vehicle

Pin Input/Output

Scope of function

(Example

1)

)

1) Above example applicable to genset series 1012/1013, single frequency generating sets.

Page 86 © 06/02

EMR 2

Diagnostic Button and

Fault Indicator Lamp

7 Diagnostic Button and Fault Indicator Lamp

Diagnostic button and fault indicator lamp must be placed in the vehicle or plant on the customer side.
They can be used for diagnosis.

1

+U

Batt

Pin F 4

-U

Batt

Diagnostic button switch diagram

15

Fault indicator lamp

Diagnostic button

GND

© 06/02

7.1 Self-diagnostic (without operating the diagnostic button)

The EMR 2 possesses numerous protection functions for the engine - depending on the available measu­ring points or sensors. Depending on the seriousness of the recognized fault, the engine may run on in
reduced mode (limp home), whereby the fault indicator lamp is continuously lit, or the engine is switched
off, whereby the fault indicator lamp flashes.

A lit fault indicator lamp indicates an error in the wiring (short circuit, cable break) or a defect in the displays
of the corresponding sensors. A further source of faults could be falling below or exceeding the measuring
value limits (see Chapter 9.4).

Faults in the electronics are registered or stored in the control unit and shown by the fault indicator lamp.
The fault indicator lamp is extinguished as soon as the fault has been removed. Only when the electronics
has been switched to emergency running (-speed), need the engine be switched off briefly with the key­operated switch in order to extinguish the fault indicator lamp.

Also corrected or non-current faults remain stored in the control unit and can be read out or deleted with
the SERDIA diagnostic software (see Chapter 7.3).

2

3

4

5

6

7

8

9

10

© 06/02 Seite 87

11

12

13

Diagnostic Button and

EMR 2

Fault Indicator Lamp

Key switch (terminal 15)

On

1

Off

Time

2

On

3

Off

2 s

Case a) Lamp extinguished after 2 s: there is no active fault

Fault indicator lamp

Time

4

On

5

Off

2 s

Case b) Lamp flashes after 2 s: there is at least one serious fault.

the engine cannot be started.

1 s1 s

Time

6

On

7

Off

Case c) Continuous light: there is at least one fault.

Time

8

9

10

11

12

12

On

Off

2 s

Case d) As case c), only with monitoring delay t

selected setting.

t

v

dependent on

v

Time

© 06/02

Seite 88 © 06/02

EMR 2

Diagnostic Button and

Fault Indicator Lamp

Function control of the configured warning lamps

With the activation of the key switch (pin 15), the warning lamp is also switched on for the duration of the
self-diagnostic (2 s).

Key switch (terminal 15)

On

1

Off

On

Off

On

Off

2 s

2 s

Fault indicator lamp

e.g. warning lamp oil pressure

Time

Time

Time

© 06/02

2

3

4

5

6

7

8

9

10

11

12

13

© 06/02 Seite 89

Diagnostic Button and

EMR 2

Fault Indicator Lamp

7.2 Diagnostic with Button and Error Code

With the diagnostic button there is the possibility of reading out the existing faults as blink codes and to
delete the fault memory 1. The Diagnostic button and the fault indicator lamp are situated in the moving
part of the vehicle.

1

7.2.1 Reading out a current fault memory blink codes

The fault indicator lamp shows a fault, e.g., it flashes or lights continuously. The Diagnostic button is

2

3

depressed for a time period of 1 s to 3 s. The EMR 2 recognizes the request for a read out and starts to dis­play the faults. (see blink code overview, Chapter 7.2.3). The read-out of the blink code is only possible after
extinguishing of fault indicator lamp or after the initialization phase of the operating program. This means
that the fault indicator lamp can also show continuous lighting after switching on if a fault has been recogni­zed already after switching. The EMR 2 only shows active faults as blink codes.

Diagnostic button

4

5

6

7

8

9

10

11

On

1 - 3 s

Off

Fault indicator lamp

“2”“1”

On

2 s

Off

abcde

In the following the steps for reading out the first blink code are shown:
a The fault indicator lamp indicates a fault, e.g. it flashes of lights continuously.
! Press diagnostics buttons 1 to 3:

the flashing or continuous light of the fault indicator lamp is extinguished.

b After 2 s:

recognition by the EMR 2 (2×short flashes).

! Output of the flashing sequence of the first stored fault.

(example: fault number 01, “speed sensor 1“):

c after 2 s: 1×long
d after 2 s: 1×short

! After fault code output

e 5 s pause, then display of flashing or continuous light.

0.4 s

0.4 s

2 s

0.8 s

0.8 s

2 s

Time

“1”

5 s

Tim

© 06/02

12

12

Seite 90 © 06/02

EMR 2

Diagnostic Button and

Fault Indicator Lamp

Steps for reading out the next fault:
a The fault indicator lamp indicates a fault, e.g. it flashes of lights continuously.
! Press diagnostics buttons 1 to 3:

the flashing or continuous light of the fault indicator lamp is extinguished

b After 2 s:

recognition by the EMR 2 (2×short flashes).

! The next blink code is output (c, d)
! After fault code output

e 5 s pause, then display of flashing or continuous light.

The steps can be repeated until the last stored fault code is output. After that, the first fault code is shown
again.

1

2

3

4

5

6

7

8

9

© 06/02 Seite 91

10

11

12

13

Diagnostic Button and

EMR 2

Fault Indicator Lamp

7.2.2 Deletion of the fault memory 1

The EMR 2 has two fault memories (1 and 2). Every fault is stored in both memories at the same time. With
the aid of the diagnostic button it is possible to delete passive faults in fault memory 1. The fault memory 2
can only be deleted with SERDIA.

1

Diagnostic button

2

3

4

5

On

Off

On

Off

a

< 2 s

b

c

Time

Key switch (terminal 15)

Time

Fault indicator lamp

6

On

7

Off

8

2 s

de

0.4 s

0.4 s

Time

© 06/02

9

10

11

12

12

The following shows the steps for deleting the fault memory 1:

a Press, and keep depressed, the diagnostic button.
b Switch ignition on.
c Whilst the fault indicator lamp is lit up (duration 2 s) release diagnostic button.
d All passive faults in faults in fault memory 1 are deleted.
e The deletion process is confirmed by three short flash impulses.

Seite 92 © 06/02

EMR 2

Diagnostic Button and

Fault Indicator Lamp

1

Check distance. Check cable

connection. Check sensor and

replace if required.

Check cable connection and

Tacho. Replace if required.

Check parameter (21). Check

speed settings.

Check sensor cable. Check

sensor and replace if required.

Check fault limits for sensor.

2

3

Governor in emergency operation (if

sensor 2 available). Emergency

switch-off (if sensor 2 not available

or failed).

Governor in emergency operation

(with sensor 1)

Governor in emergency operation.

(see Chapter 4.15).

Engine stop.

Emergency switch-off (if sensor 1

not available or failed).

(see Chapter 4.3.3)

See Chapter 4.15 influencing fault

reaction. With failure of the sensor,

the associated monitoring function is

de-activated.

5

4

faults present

active

No

Sensor failure. Distance from gear

too far. Additional fault impulses.

Cable joint interrupted.

Tacho failed. Additional fault

impulses. Cable connection

interrupted.

Speed was/is in excess of limit.e.

Check PID setting. Check rods. Check actuator and replace if required. Check cable to actuator (impulse on

incorrect speed). Check No. of teeth. For vehicles check for possible thrust mode.

Fault at corresponding sensor entry

(e.g. short circuit or cable break).

6

7

8

9

Blink code FMI SPN Cause Remarks Help

0,4 s 0,8 s 0,4 s

short long short

2140190

221291

2222201

2262105

10

Fault locality/

Fault description

no.

Fault

(in SERDIA)

Fault

group

7.2.3 Fault blink code overview

© 06/02 Seite 93

-No faults 2--31 524287

Zero error

display

01 Speed sensor 1 2118190

02 Speed sensor 2 2128190

03 Speed sensor 213884

Revolutions

/ speed

acquisition

Excess speed switch-

off

04

Set point sensor 1

05

accelerator pedal)

Set point sensor 2

06

(hand throttle)

07 Charge air pressure 2232102

08 Oil pressure 2242100

Sensors

09 Coolant temperature 2252110

Charge air

temperature

10

11 Fuel temperature 2272174

11

12

13

Diagnostic Button and

EMR 2

Fault Indicator Lamp

1

Check engine (oil level, oil

pump). Check oil pressure

sensor and cable. Check oil

pressure warning line

characteristic.

Check coolant. Check coolant

temperature sensor and cable.

2

3

Check charge air. Check charge

air-temperature sensor and

cable.

Check coolant level. Check

coolant level sensor and cable.

Check parameters. Check speed

settings(21).

Check fuel. Check fuel

temperature sensor and cable.

4

5

6

7

8

9

10

Fault message (disappears when oil

pressure is again above recovery

limit).

After a delay time - fill limitation.

Fault message (disappears when

coolant temperature again drops

below recovery level). After a delay

time - fill limitation.

Fault message (disappears when

charge air temperature gain drops

below recovery level). After a delay

time - fill limitation.

Fault message.

See Chapter 4.3.3 Excess speed

protection.

Oil pressure below speed-

dependent warning line

characteristic

Blink code FMI SPN Cause Remarks Help

0,4 s 0,8 s 0,4 s

short long short

Coolant temperature has exceeded

2320110

warning level.

Charge air temperature has

2330105

exceeded warning level.

Switch input “Low coolant level” is

active.

revolutions was/is above (top)

revolution speed limit. “Thrust

mode” function is active.

23614 SID 190

Fault message (disappears when fuel

temperature again drops below

recovery level).

Check PID setting. Check rods. Check actuator and replace if required. Check cable to actuator. Check speed

sensor (impulses on incorrect speed). Check No. of teeth. For vehicles check for possible thrust mode.

Fuel-temperature has exceeded

warning level.

2370174

11

12

12

Fault locality/

Fault description

no.

Fault

(in SERDIA)

Fault

group

30 Oil pressure warning 2311100

Coolant temperature

warning

31

Charge air

32

temperature warning

34 Coolant level warning 2351111

Functional

fault

warning

Speed warning (with

thrust mode

35

operation).

Fuel temperature

warning

36

Seite 94 © 06/02

EMR 2

Diagnostic Button and

Fault Indicator Lamp

1

Check engine (oil level, oil

pump). Check oil pressure

sensor and cable. Check oil

pressure -switch-off limit.

Check coolant level. Check

coolant level sensor and cable.

Check switch-off limit.

Check charge air. Check charge

air-temperature sensor and

cable. Check switch-off limit.

Check coolant level. Check

coolant level sensor and cable.

Check actuator, replace if

required. Check cable, check

fault limits for “Confirmation”.

Check actuator, replace if

required. Check cable, check

fault limits for “Rifeness

Check actuator/actuator rods /

injection pump, replace if

required. Check actuator cable.

Check actuator and replaced if

required. Check feedback cable.

Check voltage supply/cables.

Check fault limits and reference

values of the feedback. Program

the fault limits for feedback, save

values. Switch ignition off and on

again.Check again. If faulty,

inform DEUTZ-Service and carry

out automatic equalization again.

confirmation”.

Set fault limits again.

2

3

Emergency stop

Emergency stop. Start lock.

Emergency switch-off. Actuator

cannot be operated.

Fault message (disappears when

difference is < 10 %).

Engine stop / start lock. Governor

cannot be taken into use. EDC

actuator calibration required

(see Chapter 8.4).

5

6

4

Oil pressure below switch-off limit

Coolant temperature has exceeded

switch-off limit.

Charge air temperature has

exceeded switch-off limit.

Switch input “Low coolant level” is

active.

Actuator not connected. Fault in

actuator confirmation.

Injection pump/actuator jammed or

not connected. Difference between

nominal/actual control travel is

> 10 % of the overall control path.

No automatic actuator equalization

possible. Incorrect input of the

actuator reference values.

7

12 SID 24

7SID 23

8

9

Blink code FMI SPN Cause Remarks Help

0,4 s 0,8 s 0,4 s

short long short

2311100

2320110

2330105

2351111

251

25213 SID 23

10

Fault locality/

Fault description

no.

Fault

(in SERDIA)

Fault

group

© 06/02 Seite 95

Oil pressure switch-

off

Coolant temperature

switch-off

Charge air

temperature switch-

off

Coolant level switch-

40

41

off

42

Functional

fault,

switch-off

44

50 Feedback

52 Reference feedback 13 SID 24

Control travel

difference

53

Actuator

Auto calibration

BOSCH-EDC pumps

faulty operation

59

11

12

13

Diagnostic Button and

EMR 2

Fault Indicator Lamp

1

Check cable of digital output

(cable break or short circuit).

2

3

Check CAN connection,

terminating resistor (see Chapter

12.4), Check control unit.

Check CAN connection, cable

connection. Check sensor and

replace if required.

Switch ignition off and on again.

Check again. If faulty inform

DEUTZ Service

Note values of parameters (3895

and 3896). Switch ignition off

and on again. Check again. If

faulty inform DEUTZ Service.

4

5

6

7

8

9

10

Driver level is switched off.

Fault message.

Fault (short circuit / cable break) at

digital output.

11 91

Blink code FMI SPN Cause Remarks Help

0,4 s 0,8 s 0,4 s

short long short

2612SID 51

2622SID 60

2616SID 51

262

Application-dependent.

CAN-controller for CAN-bus is

faulty. Fault removal despite re-

initialising continuously not

possible

Overflow in input buffer or a

transmission cannot be placed on

12 SID 231

the bus.

9 SID 231

14 SID 231

Fault in parameter programming in

12 SID 253

271

Emergency switch-off. engine cannot

be started.

the governor fixed value memory.

Constant monitoring of program

memory shows error (so-called

“Flash-test”).

Constant monitoring of working

memory shows error.

281

11

12

12

Fault locality/

Fault description

no.

Fault

(in SERDIA)

Fault

group

Digital output 3

(Switch-off solenoid,

pin M 2)

Digital output 6, pin

M7

Excess voltage

60

62

Hardware

switch-off solenoid

63

67 Error Hand Setp1

68 Error CAN Setp1 2 898

inputs/

outputs

70 CAN-Bus controller

CAN interface

SAE J 1939

Cable break,

short circuit or

bus-error

Parameter

programming

(write EEPROM)

71

Communi-

cation

74

76

77 Cyclic program test 12 SID 240

Memory

78 Cyclic RAM test 2 SID 254

Seite 96 © 06/02

EMR 2

Diagnostic Button and

Fault Indicator Lamp

1

Switch ignition off and on again.

Check again. If faulty inform

DEUTZ Service.

Check voltage supply. Switch

ignition off and on again. Check

again. If faulty inform DEUTZ

Service.

Switch ignition off and on again.

Check again. If faulty inform

DEUTZ Service.

Check data for correct settings.

Save parameters. Switch ignition

off and on again. Check again. If

faulty inform DEUTZ Service.

Note parameters (3897 and

3898). Switch ignition off and on

again. Check again. If faulty

inform DEUTZ Service.

2

3

Fault message (disappears when

power again in the normal range).

Fault message (disappears when

power again in the normal range).

Auxiliary value 5 V

Fault message (disappears when

power again in the normal range).

Fault message (disappears when

power again in normal range).

Atmospheric pressure monitoring

function de-activated.

Engine cannot be started.

Emergency switch-of f. Engine cannot

be started.

5

6

4

Power supply for actuator not in the

permissible range.

Reference voltage for actuator not

in the permissible range.

Internal temperature for control unit

not in permissible range.

Atmospheric pressure not in

permissible range.

No data found or checksum of data

is faulty (note: fault only occurs

during setting of parameter / saving

or reset.).

Internal calculation fault (so-called

“Stack overflow” fault).

7

2 SID 254

12 171

2 SID 253

8

9

Blink code FMI SPN Cause Remarks Help

short long short

2912 SID 254

0,4 s 0,8 s 0,4 s

282

292

2101

10

Fault locality/

Fault description

no.

Fault

(in SERDIA)

Fault

group

© 06/02 Seite 97

Power supply

80

(Actuator)

83 Reference voltage 1

84 Reference voltage 2 2 SID 254

85 Reference voltage 4 2 SID 254

Control unit

86 Internal temperature

hardware

87 Atmospheric pressure 12 108

Parameter fault

(EEPROM retrieval or

checksum faulty).

90

93 Stack overflow 2 SID 240

Program

logic

94 Internal fault 2 SID 254

11

12

13

Diagnostic Button and

EMR 2

Fault Indicator Lamp

7.3 Diagnostic possibilities with the SERDIA software

SERDIA (Service Diagnosis) is a software program with the aid of which the user can monitor the measure­ment value on a running diesel engine from a PC or Notebook computer and can thus recognize faulty ope­rating behaviour.

1

2

3

4

5

6

7

! With a stopped engine, it is possible to enter certain parameters in a targeted manner from the PC into

the control unit (parameter setting) in order to change the operating behaviour of the engine.

! With the aid of the SERDIA diagnostic software, the fault messages stored in the control unit can be

read out and evaluated.

Information is displayed on the following:

- Fault locality (e.g. pedal sensor, coolant temperature sensor).

- Fault type (e.g. lower limit exceeded, sporadic error).

- Environmental data/operating data (speed and operating hours at the time of the occurrence of the last
fault).

- Number of fault localities

- Frequency of the fault

- Fault status (active - fault persists / passive - fault eliminated).

Fault messages of non-current and eliminated faults can be deleted with SERDIA.
! Function test
In the function test, the outputs and the control rod travel can be activated with the engine stopped.
! Input/output assignment
Display of the current input/output assignment.
! Measuring value depiction
A large selection of measuring values are available and these can also be used if there is no EMR 2 error

(starting behaviour, engine saws, poor performance).
For this purpose, the PC is connected by an interface cable to the diagnostic interface. Communication

with the control unit is carried out via a special EMR 2 protocol.
Working with SERDIA is described in a separate operating instruction.

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Seite 98 © 06/02

EMR 2

Replacement of system

components

8 Replacement of system components

In case of malfunction, the individual system components such as sensors, control unit, actuators, can be
replaced but not repaired.

8.1 Replacement EMR ↔↔↔↔ EMR 2

The EMR 2 is a further development of the EMR. But are not compatible in the case of replacement. Only
the part numbers (TN) that count for the respective system can be utilized.

8.2 Features of the Replacement of the Control Unit

Each control unit is fixedly assigned to the engine (engine number) in accordance with its individual applica­tion case. In case of a replacement, therefore, the control unit must be equipped

a) with its engine-specific data set and
b) with a ticket [engine number...]

Programming with an engine-specific data set is only possible with SERDIA (Levels III and IIIa) and can be
carried out in two ways:

! By ordering a new control unit with information of the engine and part number (completion by DEUTZ-

Parts Logistics).

! Transferring the data set 1:1 from the “old” control unit to the “new” control unit (see SERDIA manual).

Remarks:

– TN on control unit

–TN in SERPIC

non programmed control unit (stores unit).

→

Engine cannot be started!
Control unit must be programmed.

programmed and completed control unit (with engine number - ticket)

→

1

2

3

4

5

6

7

Caution!

Only setting alterations that have been notified back to DEUTZ permit proper return of a programmed and
completed control unit with current data settings (see SM 0199-99-9287).

8

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13

© 07/02 Page 99

Replacement of system

EMR 2

components

8.3 Features of the Replacement of the Actuator

8.3.1 Model series1012/1013/2012/2013

The actuators are replaceable on a 1:1 basis without additional programming.

1

2

8.3.2 Model series 1015

Actuator (EDC-actuator) and Bosch pump belong together (one TN). In the case of a replacement, the
actuator (with the pump) must be calibrated with the control unit. This calibration is necessary (with SERDIA
Level IIIa), because the new characteristic curves must be stored in the control unit.

8.4 Combination EMR, EMR 2, Control Unit and Actuator

3

4

5

EMR control units, see also SM 0199-99-9334.

Control unit Actuator EMR

1012/1013/2012

EMR

EMR 2

The EMR 2 control unit automatically recognizes the actuator EMR or EMR 2. In order to limit errors, there­fore, an “old” EMR actuator can be combined with the EMR 2 control unit. In reverse, a “new” EMR 2
actuator is not accepted by the EMR control unit (fault message).

✓

✓✓

Actuator EMR 2
1012/1013/2012

Fault message

Engine cannot be started

EDC actuator

1015

Calibration

required

6

7

8

9

10

11

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12

Page 100 © 07/02

EMR 2

Technical Data

9 Technical Data

9.1 General Data

Designation Technical data / Remarks

Nominal voltage

Maximum cable length governor­engine

Current consumption (inc. actuator) ≤ 9 A, ≤ 11.5 A for 60 s, (fuse 15 A)
Permissible operating temperatures -40 ... +85 °C
Dimensions 231 × 204 × 62 mm (length × width × height)
Weight 1.6 kg
Air humidity < 98 % (at 55 °C)
Type of protection IP 66k, IP X7, IP X9k to DIN 40050
Shock permissibility < 50 g

Vibration

Resistance Resistant to usual materials in an engine environment
Housing material Cast aluminium, unvarnished
Diagnostic interface Serial interface to ISO 9141
Data interface CAN-Bus with protocol to ISO/DIS 11989, SAE J1939
Plug connection to vehicle/plant,

cable harness

EMV

Load dump

12 and 24 V

engine starting is possible from 6 V

5 m (remote engine extension)

< 1,5 mm (at 10 ... 20 Hz)
< 180 mm/s (at 21 ... 63 Hz)
< 7 g (at 64 ... 2.000 Hz)

Company AMP, 2 x 25-pole, coded, individual strand
isolation

Emitted interference to 95/54/EWG
interference immunity up to 100 V/m to ISO 11452-2,
ISO 7637, TR 10605

U < 60 V
(actuator not powered during the interference effects)

, working range 10 ... 36 V

DC

1

DC,

2

3

4

5

6

7

8

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3

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5

6

7

8

9

10

Technical Data

9.2 Signal Specification

1)

Pin

F4, F6, F7, F18, F19,
F20, F21, F24,
M6, M11, M21, M24

F4 Digital input

F20, F24,
M21, M24

F18, F21 PWM input

M11, M13 Frequency input
F7,

M11
M17, M18, M19 Inductive input

M4, M5, M9 Temperature input

F4 Digital output

F3, F5, F15, F16,
M3

M2

M7

M7 PWM power output

M14, M15 PWM power output

F5 PWM output

F16 Frequency output

F10, F11 ISO 9141-Bus

F12, F13 CAN-Bus

Pin type/Signal type Technical data / Remarks

Digital input

Analog input

Speed input

Digital output
(low side)

Digital power output
(high side)

Digital power output
(low side)

EMR 2

Inputs

U

< 2 V, U

low

I

< 0.5 A, U

sink

Diagnostic button (closing) after -U
Uin = 0 ... 5 V, fg = 7 Hz, Ri = 220 kΩ,

= 5 V ± 25 mV, I

U

ref

U

< 2 V, U

low

< 500 Hz (typ. 100 Hz), Tan/T

f

in

Inductive sensor, U

max. 255 Impulse/m

Control travel sensor
NTC resistance measurement, max. ± 4 °C (tolerance, typ. ±

2°C)

Outputs

I

< 0.5 A, U

sink

Diagnostic button (closing) after -U

I

< 0.5 A, U

sink

I

< 4 A, U

source

I

< 4 A, U

source

I

< 4 A, U

source

< 500 Hz (typ. 100 Hz), Tan/T

f

aus

Actuator control (actuator), to 11.5 A
I

< 0.5 A, U

sink

f

< 500 Hz (typ. 100 Hz), Tan/T

aus

I

< 0.5 A, U

sink

with Pull-Up resistance U

Interfaces

Baud rate typ. 9,600 Baud, stimulation via L-line,
communication via K-line

Extended CAN, < 250 kBaud

> 6,5 V, R

high

< 0.5 V, I

rest

> 6,5 V, R

high

< 0.5 V, I

rest

< 0.5 V, I

rest

< 0.5 V, I

rest

< 0.5 V, I

rest

< 0.5 V, I

rest

< 0.5 V, I

rest

< 0.5 V, I

rest

= 4.7 kΩ after +U

pull

< 0.1 mA (ground switching),

leck

Batt

= 25 mA

max

= 4,7 kΩ,

pull

= 0,2 ... 30 V AC, fin = 25 ... 9.000 Hz

in

aus

= 5 ... 95 %

per

< 0.1 mA (ground switching),

leck

Batt

< 0.1 mA (ground switching)

leck

< 0.1 mA (positive switching)

leck

< 0.1 mA (ground switching)

leck

< 0.1 mA (positive switching),

leck

leck

leck

= 5 % ... 95 %

per

< 0.1 mA (ground switching),

= 5 % ... 95 %

per

< 0.1 mA (ground switching),

= 0 ... +U

Batt

Batt

11

12

12

1) Double assignment possible.

All outputs are short circuit-protected against negative and positive polarity of the battery.

Seite 102 © 06/02

EMR 2

Technical Data

9.3 Plug assignments

The 25-pole plugs of the EMR 2 control unit are mechanically coded (different part numbers). Because of
the different pins, the vehicle plugs (F) or the plant plugs (F) and engine plug (M) only into the sockets provi­ded for them, so that incorrect plugging in is impossible.

9.3.1 Engine Plug (M)

1

Pb_mst1 © 06/02

Pin No. Designation Description

1 Reserve Reserve
2 Output: digital 3

3 Output: digital 4

4 Input (optional) Temp 1
5 Input (optional) Temp 2 Charge air temperature

6 Input (optional) DigIn 5 Coolant level / oil level
7 Output: PWM2/digital 6

8GND

9 Input: analog 7

10 GND

Multi-function input:

11

speed 2/DigIn 2

12 GND

13 Input: speed 1

14 STG - PWM output, signal for actuator coil
15 STG + PWM output, signal for actuator coil

16 Screen

17 RF -

18 RF REF

19 RF MESS

20 GND Reference potential for signal at pin 21

21 Input: analog 4/digital 9

22 +5 V REF

23 GND Reference potential for signal at pin 24

24 Input: analog 2/digital 7

25 +5 V LDA

Digital output for solenoid
For heating flange (optional)/

glow plug (optional)

Fuel temperature

Reference potential for analog signal at
pin 9

Analog input for
Coolant temperature sensor (NTC)

Reference potential for analog signal at
pin 11

Digital input second engine speed
(crankshaft) (optional) and speed signal
(optional)

Reference potential for analog signal at
pin 13

Digital input first
engine speed (camshaft)

Screening regulating rod travel sensor
(for lines 17, 18, 19)

General connection for
reference and measuring coil

Analog input, reference signal
of the reference coil

Analog input, measuring signal
of the measuring coil

Analog input 4 (sensor signal oil pressure
sensor) or digital input 9

+5 V Reference voltage for signal
at pin 21 (max. 15 mA)

Analog input 2 (sensor signal
charge air) or digital input 7

+5 V Reference potential for signal
at pin 24 (max. 15 mA)

2)

1)

2

3

4

5

6

7

8

9

10

11

12

1) For continuous power: < 4 A

2) Corresponds to special function”fuel temperature compensation at the EMR (0211 2571)

© 06/02 Page 103

13

1

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3

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5

6

7

8

9

10

Technical Data

9.3.2 Vehicle Plug (F) / Plant Plug

Pin-No. Designation Description

1 U Batt - Negative pole at battery (clamp 31)
2 GND Reference potential for signal

3 Output: digital 2

4 Input / output: DigInOut Fault lamp and diagnostic button

5 Output: PWM 1/Dig 1

6 Multi-function input: DigIn 3

7 Input: digital 10/velocity Speed signal (tacho input)
8 NC Not occupied

9 NC Not occupied
10 L-line Serial ISO 9141 interface
11 K-line Serial ISO 9141 interface
12 CAN high Interface for CAN-Bus
13 CAN low Interface for CAN-Bus
14 U Batt + Positive pole for battery (clamp 15)
15 Output: digital 5 Digital output, various functions

Pb_fst1 © 06/02

16 Output: digital 7/Frequency

17 Ground

18 Input: digital 1 / PWM 1

19 Multi-function input: DigIn 4

20

21 Input: digital 2 / PWM 2

22 Screen

23 GND Reference potential for signal at pin 24

24 Input: analog 1 / digital 6

25 +5 V REF

EMR 2

Multi-function input: digital 8 /
analog 3

PWM or digital output,
various functions

PWM or digital output,
various functions

Genset applications/gear shift/motor
brake

Frequency, PWM or digital output,
various functions

Reference potential for signal at pins 18,
19 and 21

PWM 1 or digital input 1,
various functions

Performance curve switching/genset
applications

Hand hand throttle/genset applications,
Digital (8) or analog input (3)

PWM 2 or digital input 2,
various functions

Screening (e.g. for lines
hand throttle or PWG)

Analog input 1 (pedal value sensor, PWG)
or digital input 6

+5 V Reference voltage for signal
at pin 24

11

12

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Seite 104 © 06/02

9.4 Sensor Data

Temperature sensor (NTC), coolant

Pins: Signal pin 9, GND pin 8, engine plug
Measuring range: -40 °C to 130 °C

EMR 2

Technical Data

1

Temperature sensor (NTC), fuel

Pins: Signal pin 5, GND pin 8, engine plug
Measuring range: -40 °C to 130 °C

Temperature sensor (NTC), charge air

Pins: Signal pin 4, GND pin 8, engine plug
Measuring range: -40 °C to 130 °C

Oil pressure sensor

Pins: Signal pin 21, GND pin 20, reference voltage +5 V pin 22, engine plug
Measuring range: 0 to 10 bar
Output signal: 0.5 V to 4.5 V DC

Charge air pressure sensor

Pins: Signal pin 24, GND pin 23, reference voltage +5 V pin 25, engine plug
Measuring range: 0.5 to 4 bar
Output signal: 0.5 V to 4.5 V DC

2

3

4

5

6

7

Speed sensor

Measuring range: 30 to 4,500 1/min
1st speed:
Conn. locality: camshaft, wheel box
Pins: Signal pin 13, GND pin 12, engine plug

- 44 Impulse/camshafts-revolutions for model series 1012/2012

- 48 Impulse/camshafts-revolutions for model series 1013/2013

- 167 Impulse/camshafts-revolutions for model series 1015
2nd speed (optional):
Conn. locality SAE-housing, crankshaft
Pins: Signal pin 11, GND pin 10, engine plug

- 129 Impulse/crankshafts-revolutions for model series 1012/1013

- Clamp w (dynamo impulses)

8

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© 06/02 Page 105

Technical Data

Coolant level sensor

Pins: Signal pin 6, GND pin 8, engine plug
Measuring range:

EMR 2

1

Atmospheric pressure sensor

Depending on unit configuration, integrated into control unit, see Chapter 4.13

2

3

4

5

6

7

8

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10

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12

12

Seite 106 © 06/02

EMR 2

Index of Specialist Terms

10 Index of Specialist Terms

AGR Exhaust gas return
Actuator Actuator
AMP plug Multi-pole plug of the AMP company
Baud rate Data transmission speed [Bit/s]
CAN-Bus Interface (Controler Area Network)
EDC-actuator Actuator of the Bosch company
EEPROM Memory module in the microprocessor
EER 2 Electronic engine governer
ELTAB Electronic engine pocket handbook
EMV Electromagnetic compatibility
F-plug Vehicle plug / plant-side plug at the control unit
GND Mass (Ground)
High Switch open (high)
ISO International Standard Organization
Clamp 31 Minus clamp at battery
KLU Scope of customer supply
KM-temperature Coolant temperature
LDA Charge air pressure dependent full load stop
Limp home Emergency running features
Load dump Noise limit
Low Switch closed (low)
M-plug Engine plug
M

d

NC Not assigned
NTC Negative temperature coefficient
P-grad Proportional gradient; P-grad = 0 (Isochronous); P-grad adjustable (Droop).
PID control Proportional, integral, differential parts of the control
Pin Plug pin
Pull-up resistance Resistance to supply voltage
PWM-signal Pulse width modulated signal
REF Reference voltage or potential
SERDIA DEUTZ service diagnosis software with interface
Setpoint Setpoint
SWG 1/2 Setpoint sensor 1/2

To rq ue

1

2

3

4

5

6

7

8

9

10

11

© 06/02 Page 107

12

13

EMR 2

Index of Specialist Terms

1

2

3

4

5

6

7

8

9

10

11

12

12

Page 108 © 06/02

11 Index

A

EMR 2

Index

Actuator ..................................................................................................................................................... 100

Actuator functions
Altitude correction
Atmospheric pressure sensor

....................................................................................................................................... 86

....................................................................................................................................... 82

.............................................................................................................. 82, 106

B

basic equipment .............................................................................................................................. 70, 71, 72

Blink codes

.................................................................................................................................................. 90

C

CAN-Bus ...................................................................................................................................................... 86

....................................................................................................................................... 83

CAN-Bus interface
Charge air monitoring
Charge air pressure sensor
Cold start installation
Configuration
Configuration example
Connection diagrams
Coolant level sensor
Coolant monitoring
Coolant temperature monitoring

.................................................................................................................................. 81

........................................................................................................................ 105

................................................................................................................................... 82

............................................................................................................................................... 85

................................................................................................................................. 86

................................................................................................................................. 113

.................................................................................................................................. 106

...................................................................................................................................... 82

.................................................................................................................. 81

D

Damages ...................................................................................................................................................... 67

Default functions
Description of functions
Diagnostic button
Diagnostic interface
Display / output functions

....................................................................................................................................................... 79

Displays
Droop control

.......................................................................................................................................... 86

............................................................................................................................... 70

........................................................................................................................................ 87

............................................................................................................................... 83, 86

............................................................................................................................ 86

............................................................................................................................................... 78

1

2

3

4

5

6

7

8

9

E

Electrical welding ......................................................................................................................................... 68

Emergency running

................................................................................................................................................ 103

Engine plug
Engine protection functions
Engine-start/stop
Error code
Excess speed protection

© 06/02 Seite 109

.................................................................................................................................................... 90

...................................................................................................................................... 82

......................................................................................................................... 81

......................................................................................................................................... 78

............................................................................................................................. 75

10

11

12

13

EMR 2

Index

F

Fault blink code overview ............................................................................................................................ 93

................................................................................................................................................... 93

Fault group
Fault indicator lamp

1

2

3

Fault lamp
Fault locality/fault description
Fault memory
Fault no.
Fuel quantity limitation (performance curve)
Fuel volume control
Function control
Function extensions
Function overview
Functions

I

..................................................................................................................................... 87

.................................................................................................................................................... 79

...................................................................................................................... 93

............................................................................................................................................... 92

....................................................................................................................................................... 93

................................................................................................ 77

..................................................................................................................................... 82

........................................................................................................................................... 89

..................................................................................................................................... 73

........................................................................................................................................ 86

..................................................................................................................................................... 86

4

5

6

7

8

9

10

Important notes ........................................................................................................................................... 67

.................................................................................................................................. 67

Installation guidelines
Interfaces
Introduction

............................................................................................................................................. 83, 102

.................................................................................................................................................. 65

L

LDA function ................................................................................................................................................ 81

................................................................................................................................................... 82

Limp home
Load collective

............................................................................................................................................. 80

M

Memory functions ........................................................................................................................................ 86

Min/Max control
Monitoring function

........................................................................................................................................... 74

...................................................................................................................................... 79

N

Notes ........................................................................................................................................................... 65

O

Oil pressure monitoring ................................................................................................................................81

Oil pressure sensor
Operating instructions
Output signals
Outputs

................................................................................................................................................ 79, 102

.................................................................................................................................... 105

................................................................................................................................. 67

.............................................................................................................................................. 79

11

12

13

P

Parameter setting ......................................................................................................................................... 85

Pin

.............................................................................................................................................................. 102

Pin assignment
Pin type
Plant plug
Plug assignments
Plug connection

Seite 110 © 06/02

............................................................................................................................................ 86

...................................................................................................................................................... 102

................................................................................................................................................... 104

...................................................................................................................................... 103

........................................................................................................................................... 68

EMR 2

Index

R

Replacement of system components .......................................................................................................... 99

S

Scope of function ........................................................................................................................................ 86

..................................................................................................................................... 75

Second speed input
Self-diagnostic
Sensor data
Sensor inputs
SERDIA
Set point settings
Signal specification
Signal type
Software
Speed control
Speed sensor
Speed throttling
Switchable speed functions
System description
System functions
System overview

................................................................................................................................................ 105

........................................................................................................................................................ 98

................................................................................................................................................. 102

....................................................................................................................................................... 98

............................................................................................................................................. 87

............................................................................................................................................... 86

......................................................................................................................................... 76

.................................................................................................................................... 102

.............................................................................................................................................. 74

............................................................................................................................................. 105

........................................................................................................................................... 81

......................................................................................................................... 75

...................................................................................................................................... 69

......................................................................................................................................... 71

.......................................................................................................................................... 69

T

Technical data ........................................................................................................................................... 101

Temperature sensor (NTC), charge air
Temperature sensor (NTC), coolant
Temperature sensor (NTC), fuel
Temperature-dependent start control

....................................................................................................... 105

........................................................................................................... 105

................................................................................................................. 105

......................................................................................................... 81

1

2

3

4

5

6

7

U

Utilization of the EMR 2 ............................................................................................................................... 69

V

Variable speed regulation ............................................................................................................................ 74

Vehicle plug

............................................................................................................................................... 104

W

Wiring ........................................................................................................................................................... 68

8

9

10

11

12

13

© 06/02 Seite 111

EMR 2

Index

1

2

3

4

5

6

7

8

9

10

11

12

13

Seite 112 © 06/02

EMR 2

Connection diagrams

12 Connection diagrams

The following connection diagrams present the maximum scope of the EMR2. Customer or model-specific
wishes are not taken into account.

12.1 Connection diagram vehicle / plant side

12.2 Connection diagram vehicle side (sheet 1)

12.3 Connection diagram vehicle side (sheet 2)

12.4 Connection diagram for CAN-Bus and diagnostic line

Only the switching diagram specific for the particular engine is binding. This is prepared by the DEUTZ
customer representative before supply of the first engine as the switching diagram is not part of the docu­mentation supplied with the engine.

Methods of obtaining the switching diagrams are:

! Sales or customer representative, or
! Dept. Sales Documentation (Format DIN-A2) or
! Sales drawing CD-ROM or
! Engine pocket handbook (from page 3.150, size DIN-A4) or
! ELTAB CD-ROM

1

2

3

4

5

6

7

8

9

10

11

12

© 06/02 Page 113

13

EMR 2 Anhang/

12.1 Anschlussplan Fahrzeug-/Anlagenseite Connection diagram - Vehicle side / Unit side

Appendix

geraeteseite © 06/02

© 06/02 Seite/Page 115

EMR 2Anhang

Appendix

12.2 Anschlussplan Motorseite (Blatt 1) Connection diagram - Engine side (sheet 1)

motorseite1 © 06/02

Seite/Page 116 © 06/02

EMR 2 Anhang/

12.3 Anschlussplan Motorseite (Blatt 2) Connection diagram - Engine side (sheet 2)

Appendix

motorseite2 © 06/02

© 06/02 Seite/Page 117

EMR 2Anhang

Appendix

12.4 Anschlussplan für CAN-Bus und Diagnoseleitung Connection Diagram for CAN-Bus and Diagnostic Line

emsemr2 © 06/02

Seite/Page 118 © 06/02