SERDIA

SETUP AND COMMUNICATIONS

9. SERDIA (LEVEL III)

1. SETUP AND COMMUNICATIONS
SERDIA is a software program. Together with the notebook and the interface, it constitutes a tool which serves as an aid to communication with the engine ECUs. SERDIA supports DEUTZ ECUs EMR, EMS and MVS. You can also communicate with three different ECUs using just one software product. Any changes you wish to make to the ECUs as far as settings, parametrizations, error deletion and calibra-tion are concerned are only possible with SERDIA. SERDIA runs under the MS Windows3.11 and Windows95 (98) user surface. You can choose English or German as the user language when carrying out program installation. The user surface enables the user to call up the functions required simply by clicking on the appropriate buttons. The menu points listed below are available: ECU selection Measured values Parameters Error memory Function test Extras

1.1 MINIMUM EQUIPMENT REQUIRED

To run SERDIA, the following minimum equipment configuration is required:

1.1.1 CONTROL UNITS

EMR1, Electronic engine controller System description TN 0297 7432 EMR2, electronic engine controller System description TN 0297 9885 MVS, solenoid valve system System description TN 0297 7488 EMS2, engine monitoring system System description TN 0297 7930

1.1.2 DIAGNOSTIC CONNECTOR

Serial diagnostic connector TN 0419 9615 as specified in ISO 9141 and SAE J1587

1.1.3 INTERFACE
Link from control module (engine) to PC Level adaptation for ISO 9141, SAE J1708 and RS 485 Security system with dongle, copy protection 12-24 V voltage supply range Supply source: engine Safety switching for protection against overvoltage and incorrect pole connection Galvanic isolation

1.1.4 PC/ NOTEBOOK

Minimum equipment required: Notebook or PC with 1 RS 232 serial interface PC (IBM-AT compatible) (should not be otherwise occupied, for example, mouse or IR interface). Parallel interface for printer Graphics card VGA/SVGA

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Processor 80486 (or higher) Clock speed >= 100 MHz Installed memory >= 8 MB RAM Hard disk >= 15 MB (free disk space) Disk drive 3.5 1.44 MB Software: Operating system MS Windows 3.11, 95 or 98

Installation is also possible under Windows 3.1. However, because of a Windows problem, this can cause access conflicts with the COM1 serial interface (see Chapter, "What to do if ...". For more details, please see the "Readme" file supplied with SERDIA.). With Windows 3.11, the standard (VGA) screen driver should be installed for correct display of SERDIA screens.

1.2

ORDERING
SAME-DEUTZ-FAHR ITALIA S.p.A. Viale F. CASSANI, 15 24047 TREVIGLIO (BG) - ITALIA

SERDIA can be ordered, like the DEUTZ special tools, through:

1.2.1 FIRST-TIME USERS

For first-time users, we recommend the SERDIA package Re-order No. 5.9030.740.4/10. Scope of supply: SERDIA software (1 x 3.5' installation diskette) Diagnostics interface with implemented user level Brief instructions on installation A list of tools and modifications usefui when troubleshooting, is included Carrying case

1.2.2 ORDERING SINGLE PARTS

Part Installation diskette Adapter Interface level III Major overhaul Competence level Re-order No. 5.9030.740.0 5.9030.741.0 5.9030.740.2

1.2.3 ADAPTER
Some OEMs have different diagnostics plugs for certain versions. An adapter is therefore required for the interface from the 12 pole DE UTZ plug to the appropriate OEM plug. The DEUTZ 12 pole counterpart is available as a genuine DEUTZ part. A ready-made adapter is available, for diagnostics on engines in DE UTZ Fahr tractors (DEUTZ 12 pole -> DFA 14 pole): DEUTZ Part No. 5.9030.741.0

1.2.4 SERDIA UPDATES

You will be informed of software updates by our service information department, as they occur. There is no automatic exchange against older versions of the software. When installing the update the target directory should contain the SERDIA version number.

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1.3

SWITCHING ON AND INSTALLING THE SOFTWARE

1.3.1 INSTALLING MS WINDOWS

If MS Windows is not already installed on your hard disk, it must first be installed following the installation instructions supplied with MS Windows 3.1, 95, 98 o 2000.

1.3.2 INSTALLING SERDIA FROM DISKETTES

To run the SERDIA software, an interface with a connection to an engine control module is required. If this interface is not present, SERDIA can still be installed, but will only run in Off-line mode. The software limitations imposed by off-line mode are described in Chapter "Off-line mode". Installation with Windows 3.1, 3.11: Start Windows. Insert SERDIA Installation diskette 1 in the disk drive (Drive A). Open "File Manager". Select disk drive A. Double-click on the "install.exe file to start installation. Follow the instructions appearing on the screen. When finished, remove Installation diskette 2 from the disk drive and store in a safe place together with diskette 1. After the computer is re-started, the SERDIA program group window opens. Double-click on the "Service diagnosis program group to start. Installation bei Windows 95, 98: Start Windows. Insert SERDIA Installation diskette 1 in the disk drive (Drive A) einlegen. Open "Windows Explorer". Select disk drive A. Double-click on the "install.exe file to start installation. The Installation window opens:

The name of the target directory should indicate the SERDIA Version number, for example "serdia35. Follow the instructions appearing on the screen. (If installing with Windows 98, select Windows 95 as the operating system) When finished, remove Installation diskette 2 from the disk drive and store in a safe place together with diskette 1. After the computer is re-started, the SERDIA program group window opens. Double-click on the "Service diagnosis program group to start.

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Special characteristic of Notebooks with Windows 98:

The ACPI entry (Advanced Configuration and Power Interface) may not appear under "Start\Settings\Control Panel\System\Device Manager\System components. In this case, follow the instructions in the "Readme.txt" file ("Windows 98" section) included on the SERDIA Installation disk. Proceed as follows: Check whether ACPI is enabled. If there are ACPI entries, switch off ACPI using the "disacpi.reg file. These files are in the SERDIA working directory. (ACPI can be switched on again using the "enacpi.reg file). Run the new hardware recognition program: Start\Settings\Control Panel\Add New Hardware\Next\ Search for new hardware. (The Installation CD may be required for Windows 98). Re-start the computer. Installation with Windows 2000: To install under Windows 2000, the 32Bit Version of SERDIA is required. This should be available from May 2002, and will be indicated in the service announcements.

1.3.3 INSTALLING SERDIA FROM THE SERPIC CD

Start Windows. Insert the SERPIC CD in the CD drive. Open "Windows Explorer". Select the CD drive. Open the SERDIA directory. Open the "Disk1 directory Double-click on the "install.exe file to start installation.

The Installation window opens:

The name of the target directory should indicate the SERDIA Version number, for example "serdia35. Follow the instructions appearing on the screen. (If installing with Windows 98, select Windows 95 as the operating system) Remove the CD from the drive and store in a safe place. After the computer is re-started, the SERDIA program group window opens. Double-click on the "Service diagnosis program group to start.

1.3.4 USER LEVEL, ACCESS RIGHTS

DEUTZ Service has defined four different user levels for the SERDIA software (I, II, III, IIIa), which are pre-set in the interface. The reason for the four different levels is to prevent unauthorised persons from accessing particular parameter settings (in the same way as the seals at injector pumps). The use of access rights means access is only allowed to those parameters and fields authorised for a particular user level.

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1.3.5 SETTING UP THE LINK BETWEEN CONTROL MODULE (ENGINE) AND NOTEBOOK
Communication characteristics: Serial communication BaudRate = 9600 Serialport = COM1 The SERDIA interface (supplied) is used to connect the control module to a Notebook. Despite the numerous safety precautions in the interface and control module (such as protection against wrong pole connection and overvoltage, and galvanic isolation), mistakes can still happen, and the following procedure should always be applied when connecting the Notebook to the control module. The connection is set up in the following order: 1) 2) Switch off the engine, ignition switch (Circuit 15) is Off. Do not switch on the Notebook yet. Connect the diagnostic connector to the vehicle / installation diagnostic socket.

The diagnostic connector must be provided by the customer, and can be supplied by DEUTZ on request. 3) Connect the other side (interface side) to the RS 232/COM1 serial interface. (9-pin connector on the back of your Notebook). Note: 4) 5) On PCs, the COM1 interface may already be occupied by the mouse. In this case, the interface must be connected to the PC's serial interface (COM2). This must then be configured (see Chapter, "What to do if ...).

The ignition switch (Ct.15) and Notebook can now be switched on. The engine remains off at first. The SERDIA can now be started as describe in Chapter 1.8, "Starting the Program".

1.3.6 STARTING THE PROGRAM

In the Windows environment, the SERDIA program is started by clicking twice on its icon. Starting for the first time: When the program is started forthe first time, the control module is interrogated. SERDIA does this to find out which control modules are connected and can therefore be addressed. This process can last for about 30 seconds, as the program interrogates all the possible control modules one after the other. While this is taking place, the message "Startup routine for connected ECUs is displayed. The "ECU selection subscreen then appears, in which unidentified control units are greyed out.

Select the desired control unit and click OK. The message "Initialisation is active! appears (and remains for about 7 seconds). Communications are then set up with the control unit.

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Starting the next time: SERDIA registers the control units identified the last time the program was started (for example the EMR2). If this control unit is connected the second time the program is started, SERDIA skips the interrogation stage and immediately initialises the control unit. This substantially reduces the program startup time. The message "Initialisation is active! appears (and remains for about 7 seconds). Communications are then set up with the control unit. If another control unit is connected the next time the program is started, the interrogation process is performed again (and lasts about 30 seconds). In engines with two control units (for example an EMR with EMS2), the desired control unit can be selected through another interrogation (see paragraph 2.1).

1.3.7 SETTING UP COMMUNICATIONS WITH THE CONTROL UNIT (ECU)

Communications possible: After communications have been successfully set up, the main "Service diagnosis screen appears, with the fields "ECU, "ECU identification and "Measured values (see Chapter 2, "ECU selection"). This screen contains a menu, and a "Tasks switch (see Chapter 8 , " Tasks"). EMR1 EMR2

The communication status between the PC/Notebook and the control unit is indicated by plain text messages, and by a colour code on the status bar: Yellow (flashing): ISO block processing, i.e. useful data (for example measurements) are being exchanged between SERDIA and the control unit. Green (flashing): ISO connection OK, i.e. only data blocks needed for maintaining communications between SERDIA and the control unit are exchanged. Red: Communications stopped. Communications not possible: It may not be possible to establish communications for the following reasons: No control unit connected. There is a communication error; see Chapter 9.1.1, "Communication errors". Setting up communications In both cases an error message is displayed, and SERDIA offers to go into Off-line mode; see Chapter, Off-line mode.

1.3.8 OFF-LINE MODE

If no control unit/engine and/or interface is available, SERDIA can be run in password-protected mode or Demo mode for training purposes.

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SERDIA always offers to go into password-protected mode or Demo mode when it has not been possible to establish communications successfully.

Click on "Ignore". The desired mode can be selected in the "Confirm" box.

1.3.9 PASSWORD-PROTECTED MODE

If "Yes" is selected to confirm, and there is no control unit, authorised users can enter a password (check with head office) and read and print configuration files, but not modify them.

1.3.10 DEMO MODE (TRAINING WITH NO CONTROL UNIT)

If "No" is selected in the Confirm box, the program goes into Demo mode. 1) In this mode, the user can practice working with SERDIA, without changing any values. 2) Graphic files can be read and printed. However, the graphic files must have been stored in digital form (filename extension *.egr). Also, functional tests cannot be performed on the control units.

1.4 USING THE PROGRAM

Quick start: 1) In Windows, start the SERDIA program 2) In the main SERDIA screen, click on "ECU selection" 3) In the "ECU selection screen, select the desired control unit 4) In the main SERDIA screen, select the desired menu

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1.4.1 MAIN SCREEN, MENU SELECTION

Menu ECU selection ECU selection Print Protocol Restart Program ECU Engine off Reset ECU Measured values actual measured values RAM-Values Data logger Input/output assignment CAN Status MVS Measured values Parameters Configuration Overall programming Calibration MVS pump class Error memory Error memory Error memory 2 MVS error memory Function test Extras Maximum speed Logistic data al Load spectrum Maintenance interval exceeded Override memory Maintenance data Help Tasks all EMR1, EMR2 General help for main screen and screen buttons. for certain service operations EMR1, EMR2 all EMR2, EMS2 EMS2 only EMS2 only Selection of three different maximum speeds all EMR2 only MVS only EMR1, EMR2 Reads, displays, and clears the error memory Reads, displays, and clears the error memory (Level III, IIIa only) Cylinder-specific error display To use the actuator control (Level III, IIIa only) MVS only all To view or modify configuration data all all EMS2 only all all MVS only Shows current actual values (also with engine off, but with battery voltage)) EMR1: Level IIIa only, EMR2: Level III, IIIa only Shows content of data logger Control unit pin/signal assignments Simple CAN Monitor cylinder-specific measurement display all all all all EMR2 only EMR2 only EMR2 only Selecting a control unit (only one can be selected at a time) Print measurements or control unit identification data on a printer or to a file Interface configuration (Level IIIa only) Interrogates control unit again Loads operating software into the EMR2 (Level IIIa only) Remote engine switch-off Resets control unit Control units Explanation

EMR1, EMR2, EMS2 Level III, IIIa only Calibration of transducers, for example pedal travel sensors pump class assignments

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1.4.2 "ECU SELECTION MENU

DEUTZ engines may be equipped with one or more control units (for example, an MVS/ EMS2 combination). However, SERDIA can only communicate with one control unit. Exception: error lists and measured values can also be read from the MVS control unit through an EMS2. The desired control unit must therefore be selected first in the "ECU selection menu. For more details, see Chapter 2, "ECU selection".

1.4.3 MEASURED VALUES" ("ACTUAL MEASURED VALUES) MENU

A number of measured values (including inputs/outputs) can be selected from a list of values and displayed. Displayed values falling outside the maximum or minimum limit (if present) are shown on a coloured background. Only measuring points that match the control unit are shown, with different display options: Read measured values Read measurement electronics Read logger data (special EMS2 menu) arranged by designation value unit Measured values are refreshed at a pre-set scan rate and can be displayed both with engine stopped and with engine running. For more details, see Chapter, "Measured values".

1.4.4 "PARAMETERS" MENU

The wide-ranging possibilities of DEUTZ control units require special programming to adapt them to their particular environment. Changes to parameters are necessary when access is required, due to customer request to adapt to local conditions to fit a replacement. Parameters can only be changed through SERDIA! This menu option can be used to replace the screwdriver setting (necessary with analog control units). Some of the parameters (for example, dynamic control response) can be modified within certain pre-set limits. Parameters are set through two screens, one for configuration and one for calibration. Access to the fields in the related screens depends on user authorisation. Unauthorised fields are not shown. For more details, see Chapter 4, "Parameters".

1.4.5 "ERROR MEMORY" MENU

This menu is used to read any error messages stored in the control units. Error messages are related exclusively to electrical parts of the engine, such as cable harness and transducer. For example, one error message could be "General fault or cable cut/short-circuit. Only passive error messages can be deleted; active messages are saved. Active error messages become passive messages when they have been cleared. Error messages are saved even when the battery/voltage supply is disconnected. Error messages contain the following information: Fault location Fault type Environmental data at time of fault Total error count (per fault location) Frequency Emergency mode (yes / no) For fault clearing, the user can refer to the SERDIA Help screens; it may also be helpful to refer to the "Measured values and "Function test menus. For more details, see Chapter 5, "Error memory".

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1.4.6 "FUNCTION TEST" MENU

SERDIA supports wide-ranging function tests, differentiating between the control units installed (for example, testing the actuator for the EMR1). The function test option also provides valuable help, especially for troubleshooting and maintenance work. Individual control unit outputs can be activated and checked separately. This is done by switching to Test mode. The engine must be switched off first! In the Function test, the control unit transmission program is bypassed and actuators are controlled by the test program. Actuators are switched on and off by clicking on the little control box in the Actual Value column, beside the actuator's designation reference. "Actual Value" shows the response for the actuator status set by the control unit. The actuator status test always takes place in the control unit, and can only be transferred to the SERDIA by the control unit itself. This means that if the desired actual value does not appear, there may be a wiring fault. The "Error memory and "Function test menu combination can be of help in determining the source of a fault. Indirect indications about engine condition can also be obtained using the "Function test" menu in combination with the MVS control unit. For more details about the function test, see Chapter, "Function test".

1.4.7 "EXTRAS" MENU

SERDIA supports wide-ranging options specific to the control unit. These are accessed through the related submenus, which have their own screens: Maximum speed Logistic data Load spectrum (EMR2 and EMS2) Maintenance interval exceeded Override memory Maintenance data For more details, see Chapter, "Extras".

1.4.8 HELP
The SERDIA Help function can be used in conjunction with these user instructions. In Windows, the Help function is opened by clicking on the "Help button.

1.5

CLOSING THE PROGRAM

Before disconnecting the cables between the Notebook and the engine control unit, go back to the main screen and click on the "Close button. If parameters have been changed, in many cases it is worthwhile checking the current parameter settings. To do this, follow the steps below: 1. Close SERDIA 2. Switch off the engine supply voltage, then switch on again 3. Re-start SERDIA 4. Activate the control unit again 5. Open the "Parameters menu 6. In the configuration screen, click on the "ECU->PC button 7. Print out the configuration data by clicking on the "Print button 8. Keep the printed data with the engine documentation.

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2. ECU SELECTION
2.1 SELECTING TWO CONTROL UNITS
DEUTZ engines can be equipped with two control units (for example, MVS in combination with EMS2). However, SERDIA can only communicate with one control unit. Exception: Error lists and measured values can also be read from the MVS control unit through an EMS2. SERDIA tries to set up a connection automatically to the last control unit identified. If another control unit is to be selected, the control unit recognition process must be repeated by opening the "ECU selection/Restart menu (this takes about 30 seconds).

After they have been successfully recognised, the control unit selection screen is opened. Only identified control units are presented for selection. Non-selectable control units are greyed out.

Possible control units are: EMR1, EMR2 (Electronic engine controller) MVS (Solenoid valve system) EMS2 (Engine Monitoring System)

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2.2 PRINTING
Like the data in other windows, the identification data for the selected control unit can be printed in two ways.

1) Printing to a printer.
In this case, the correct printer driver should be selected under Windows. At the top of all printouts are the logistics data: Type of control unit Date Time (as set in the Notebook system clock) Interface serial number These are followed by the control unit identification data and measurement data.

2) Control unit data can also be printed to a file.

This file can then be further processed with another program, such as Excel. The following table provides a summary of the data from the different screens, which can be saved: as printable files for further processing in other programs such as Excel. as configuration files for reporting modifications. as graphics files (*.egr), for viewing in SERDIA Demo mode. From screen Service diagnosis actual measured values RAM Values Button Print (file) File File Filename extension *.ecu *.msv *.msv Comment for further processing in other programs, such as Excel. for further processing in other programs, such as Excel. (EMR1: Level IIIa only, EMR2: Level III, IIIa only) for further processing in other programs, such as Excel. viewable in SERDIA Demo mode. for further processing in other programs, such as Excel Configuration file Partial data set, Level IIIa only Configuration file (Complete data set, Level III and IIIa) for further processing in other programs, such as Excel.

Graphics Input/Output assignment

(AscII) (Binary) Print (file) Print (file)

*.agr *.egr *.ino *.kfg *.hex *.tds *.hex *.err *.dat

Configuration

Save in file ECU -> file Print (file) Print (file)

Overall programming Error memory Logistic data

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2.3

PROTOCOL

This menu is for DEUTZ only, and is used for configuring the interface.

2.4

IDENTIFICATION AND MEASUREMENT DATA

2.4.1 EMR1 IDENTIFICATION DATA MEASUREMENT DATA

Meaning of identification data: DEUTZ part number: Part number of selected control unit. Business partner number: Product number Type of control unit selected: 1 = EMR1 2 = MVS 3 = EMS2 Hardware version number: Version number of the control unit. Software version number: Number of the EEPROM contained in the control unit. If the number before the point has changed (for example, 2.1 to 3.1), the data set will no longer match the control unit. In this case, company head office should be contacted. Day, Month, Year: Date at which the control unit parameters were last configured. Service ID: Serial number of interface used for previous access. The first digit indicates the authorised access level. OperHourCount:Engine[h]: numero delle ore di funzionamento del motore. Number of engine start Interface serial number: serial number of interface now being used. Measured values: The "Measured values field shows some of the measured values directly. This selection is not configurable.

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2.4.2 EMR2 IDENTIFICATION DATA MEASUREMENT DATA

Meaning of identification data: DEUTZ partNo: Part number of selected control unit. SupplierNo ProductNo: Type of control unit selected: 1 = EMR1 2 = MVS 3 = EMS2 Hardware Rev: Version number of the control unit. Software Rev: numero versione software Number of EEPROM contained in the control unit. If the number before the point has changed (for example, 2.1 to 3.1), the data set will no longer match the control unit. In this case, company head office should be contacted. Binary code checksum ISO Access control Identification data Measurement data Deutz SW-PN: Part number of EMR2 operating software ECU SerialNo Year ECU SerialNo Month ECU SerialNo Engine number Day, Month, Year of last change: Date at which the control unit parameters were last configured. Lats Service ID: Serial number of interface used for previous access. The first digit indicates authorised access level. Interface serial number: Serial number of interface now being used. Measured values: The "Measured values field shows some of the measured values directly. This selection is not configurable.

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3. MEASURED VALUES
3.1 ACTUAL MEASURED VALUES (GENERAL)
The measured values are read out cyclically and displayed on the "Actual measured values" screen.

Values outside the sensor's measuring range have coloured backgrounds: Yellow: Measuring range is exceeded, Blue: Below measuring range.

EXPLANATION OF THE FUNCTION BUTTONS:

Meas. values: The "Measured value selection" window containing all the available measured values is displayed. The measured values that are to be displayed can be selected from here. In general, the repeat rate of the display is increased if there are not many measured values to be displayed. The number of available measured values varies, depending on the type of control unit. Graphics: The button "Graphics" displays, in the form of a graphic, the progress over time of the selected measured values (maximum of 5). If more than 5 measured values are selected, an error message will appear. Collect. time: The recording period is displayed in the Measurement duration field in seconds. The minimum value for the recording period is one second. A few hours (expressed in seconds) can be entered for the upper measuring time. The default setting is 10 s. The shortest scanning rate is 40 ms for RAM values and 60 ms for other values. For a measuring period of 10s, therefore, the total number of measuring points for RAM values is: 10000 ms/40 ms = 250 and for other values: 10000 ms/60 ms = 166. Since the program records an approximate maximum of 2000 measuring points, the scanning rate is automatically adjusted - accordingly before the beginning of the data recording phase. The minimum possible scanning rate is determined by the duration of data transmission from the control unit to the PC. The more measured values that are to be displayed simultaneously, the longer the data transmission period and therefore the lower the scanning rate will be. File: The current measured values can be stored in a file and reloaded at a later date, for example for further processing in Excel. Print: The displayed measured values are printed out. Close: Return to the main window "Service diagnosis".

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3.1.1 MEASURED VALUE SELECTION

The list of available measured values is displayed.

The measured values to be displayed can be selected from this list. An individual measured value is selected by clicking on the associated check box. If a graphical display is required, not more than 5 measured values can be selected (see 3.1.2 Graphics). The four buttons on the right of the list can be used to activate and de-activate a collection of measured values. These have the following functions: Save: The displayed selection of measured values is saved to a file. Load: The selected measured values are loaded from a file. Delete selection: All measured values are de-activated for display. Select all: All measured values are activated for display. OK: Return to the display of the current measured values. The changes made to the selection of measured values are saved. Cancel: Return to the display of the current measured values. The changes made to the selection of measured values are cancelled. The following tables give an overview of the measured values which can be displayed. For some parameters, a configuration operation is also required (see Chapter 4 Parameters); this enables specific measuring points to be assigned to the inputs and outputs of the EMR1/EMR2 ("Configuration", "Page 11: assignment inputs/measured values and "Page 13: assignment outputs/measured values"). The values required for parameter configuration are shown in the tables. The assignment can be subsequently checked in the "Measured values" menu, with the window "Display of inputs and outputs" (see 3.4 Input/output assignment).

3.1.1.1 MEASUED VALUES EMR1

MEASURED VALUE SELECTION Name of measuring point Battery voltage Engine speed Control rod position (M9)Coolant temperature Fuel injection quantity Description Battery voltage Speed 1 (camshaft) Speed 2 (crankshaft) Control rod position Coolant temperature Fuel injection quantity 3551 Associated RAM value 2000 2002

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Name of measuring point Fuel consumption (F24)Accelerator pedal=SWG1 Rel.Accelerator pedal=SWG1 (M24)Boost pressure (M21)Oil pressure

Description Fuel consumption Voltage of accelerator pedal potentiometer Pick-off point for accelerator pedal potentiometer Charge air pressure Oil pressure Torque Oil pressure warning signal Reserve Speed 1 - Speed 2

Associated RAM value

3551 3551 3531 3541 2701 3011

2000 2002 3521

(F20)Hand throttle=SWG2

Hand throttle Summary of outputs

Selector switch Vehicle speed

Gear selector switch Driving speed

3.1.1.2 MEASURED VALUES EMR2

MEASURED VALUE SELECTION Name of measuring point Description Battery voltage Speed 1 (camshaft) Speed 1 (camshaft)) Speed 2 (crankshaft) Control rod position Control rod position Coolant temperature Fuel temperature Charge air temperature Voltage of accelerator pedal potentiometer Pick-off point for accelerator pedal potentiometer Hand throttle Charge air pressure Oil pressure Atmospheric pressura Coolant level Engine brake status Status of gear selector switch Error lamp Status of error indicating lamp Oil pressure Atmospheric pressur Coolant level Engine brake status Status of gear selector switch Error lamp Status of error indicating lamp 2901 2902 2903 2930 2820 2826 2827 2868 2000 2031 2002 2300 2330 2904 2906 2905 2900 Corresponding RAM value

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Name of measuring point SourceOfEngineStop VehicleVelocity state Vehicle-Velocity calc. FuelConsumption Fuel injection quantity FuelQtyLimitation ActFuelQtyLimitng ActualSetpoint ActPowerReduction ActTopCurve ActSpeedLimiting

Description

Associated RAM value

Driving speed Fuel consumption Fuel injection quantity Fuel quantity limitation Active fuel quantity limitation 2360 2350 2701

3145

Oil pressure warning signal (optional) Torque (optional) Outp:(F16)/Freq Outp:(F16) Digital 7 Outp:(M2) Digital 3 Inp:(F6)Digital 3 3 Inp:(F18) Dig/PWM 1 Inp:(F18)Digital/PWM 1 Inp:(F19)Digital 4 Inp:(F20)Digital/Analog 3 Inp:(F21)Digital/PWM 2 Input Input Input Input Input Input Input Input Charge air temperature Fuel temperature Input Coolant temperature Oil pressure sensor input Sensor input Charge air temperature 2904 2905 2906 Speed 1 - Speed 2 2000 2001 2002 2857 2853 2854 2856

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3.1.2 GRAPHICS
If up to any 5 measured values have been selected, the "Graphic display" window can be opened by clicking on "Graphics".

The measured values are displayed within the display range (minimum to maximum). The scaling divisions for the axes are set in the column called "Delta". It is possible to let the program carry out automatic scaling by activating the control field called "Auto". Because the program does this scaling based on the minimum and maximum values of the respective measured values, it is not possible to have automatic scaling for time-constant measured values. A maximum of two axes, one on the left and one on the right side of the graph will be drawn. A measured value can be assigned to a left or right axis in the columns marked L (left) and R (right).

EXPLANATION OF THE FUNCTION BUTTONS:

Start: The data recording operation is started using this function button. Update: This function button is used to update the information displayed. This is required if a change has been made to the minimum, maximum or delta values. The update takes account of the new values. Print : Clicking on this button will commence output to a printer. The printer selection screen is displayed first, then the user has the option of entering any comments before the graph is finally printed out. Save : The information displayed can be saved to a file in two different ways: 1) As an ASCII file (*.agr) for further processing, e.g. in Excel. 2) As a binary file (*.egr) for display of measurement graphics in offline mode, see 1.9 Offline mode.

Apri: Load : The graphics information stored in a file is loaded and displayed.

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3.2 RAM-VALUES
RAM values are calculated from the measured values with the aid of the microprocessors in the control units and are made available by SERDIA as additional data.

The following tables provide an overview of the possible RAM values which are used in the EMR2 control unit.

2000Speed 2001SpeedPickUp1 2002SpeedPickUp2 2003SpeedPickUp1Value 2004SpeedPickUp2Value 2005ActivePickUp 2025SpeedGradient 2031SpeedSetp 2032SpeedSetpRamp 2033SpeedSetpSelect 2041DigitalPotOffset 2100P_CorrFactor 2101I_CorrFactor 2102D_CorrFactor 2110FuelSpeedGovernor 2111SpeedGov:P-Part 2112SpeedGov:I-Part 2113SpeedGov:D-Part 2115StaticCorrActive 2120DroopPresent

2130IMFuelSetp 2131IMFuelSetpSelect 2132IMOrAllSpeedGov 2133IMGovAtMaxOrIdle 2134IMFuelSetOrGovernor 2135IMSetpoint 2140TorqueSetpoint 2141TorqueReserveMax 2142TorqueReserveCurve 2143TorqueLimitMax 2144TorqueLimitCurve 2145TorqueLimitCurveAct 2150EngineBrakeActive 2251LimitsDelay 2280GlowPlugActive 2281FlameGlowPlugActive 2282FlameValveActive 2283PreheatActive 2284PostheatActive 2285StartReadActive

2300ActPos 2330ActPosSetpoint 2350FuelQuantity 2353FuelQuantityCorr 2360FuelConsumption 2361FuelEconomy 2400Can:Online 2401Can:RxTelActive 2402Can:RxTelTimeOut 2403Can:RxTelVoltTimOut 2404Can:RxIRCount 2405Can:TxIRCount 2406Can:BusOffCount 2407Can:RxBufOverflow 2408Can:Tx0BufOverflow 2409Can:Tx1BufOverflow 2410Can:FragBufOverflow 2411Can:SetpointPhase 2412Can:SetpointError 2533FuelTempFuelCorr

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MEASURED VALUES

2600EngineNo:Low 2601EngineNo:High 2602FunctionSetNo:Low 2603FunctionSetNo:High 2604CanSetNo:Low 2605CanSetNo:High 2606ASAP2SetNo 2607SerdiaID:Low 2608SerdiaID:High 2609SerdiaDate:Day 2610SerdiaDate:Month 2611SerdiaDate:Year 2612EOLDate:Day 2613EOLDate:Month 2614EOLDate:Year 2701FuelLimitMax 2702FuelLimitStart 2703FuelLimitSpeed 2704FuelLimitBoost 2705FuelLimitSimBoost 2706FuelLimitVelocity 2707FuelLimitCan 2710FuelLimitMinActive 2711FuelLimitMaxActive 2712StartLimitActive 2713SpeedLimitActive 2714BoostLimitActive 2715SimBoostLimitActive 2716VelocityLimitActive 2717CanLimitActive 2720SpeedLimit1Active 2721SpeedLimit2Active 2722SpeedLimit3Active 2723ReduceCan 2724ReduceOilPressure 2725ReduceCharAirTemp 2726ReduceCoolantTemp 2727ReduceAmbientPress

2730SetpLimitCan 2731SetpLimitVelocity 2740Setp1Source:Analog 2741Setp1Source:PWM 2742Setp1Source:Subst 2743Setp1Source:Can 2750CurrSetp:Setpoint1 2751CurrSetp:Setpoint2 2752CurrSetp:SpeedFix1 2753CurrSetp:SpeedFix2 2754CurrSetp:Freeze 2755CurrSetp:FreezeSetp 2756CurrSetp:HoldButton 2757CurrSetp:MinButton 2758CurrSetp:MaxButton 2759CurrSetp:CalIdle 2761CurrSetp:VeloIdle 2810SwitchDroop2 2811SwitchDroopCurve 2812SwitchSpeedFix1 2813SwitchSpeedFix2 2814SwitchSpeedLimit2 2815SwitchSpeedLimit3 2816SwitchGovernIMOrAll 2817SwitchFreezeSpeed 2818SwitchFreezeSetp 2819SwitchOilLevel 2820SwitchCoolantLevel 2821SwitchSpeedInc 2822SwitchSpeedDec 2823SwitchMinButton 2824SwitchMaxButton 2825SwitchHoldButton 2826SwitchBrake 2827SwitchNeutral 2828SwitchGlowPlug 2829SwitchEngineStop 2851DigitalOut1

2852DigitalOut2 2853DigitalOut3 2854DigitalOut4 2855DigitalOut5 2856DigitalOut6 2857DigitalOut7 2861DigitalOut1State 2862DigitalOut2State 2863DigitalOut3State 2864DigitalOut4State 2865DigitalOut5State 2866DigitalOut6State 2867DigitalOut7State 2868StatusErrorLamp 2900Setpoint1Extern 2901Setpoint2Extern 2902BoostPressure 2903OilPressure 2904CoolantTemp 2905CharAirTemp 2906FuelTemp 2920BoostPressureCorr 2921FuelTempCorr 2930AmbientPressure 2931AmbientPressActive 3000ConfigurationError 3001ErrPickUp1 3002ErrPickUp2 3003ErrVelocity 3004ErrOverSpeed 3005ErrSetp1Extern 3006ErrSetp2Extern 3007ErrBoostPressure 3008ErrOilPressure 3009ErrCoolantTemp 3010ErrCharAirTemp 3011ErrFuelTemp 3030ErrOilPressWarn

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MEASURED VALUES

3031ErrCoolantTempWarn 3032ErrCharAirTempWarn 3033ErrOilLevelWarn 3034ErrCoolantLevelWarn 3035ErrWarnSpeed 3036ErrFuelTempWarn 3040ErrOilPressEcy 3041ErrCoolantTempEcy 3042ErrChargeAirTempEcy 3043ErrOilLevel 3044ErrCoolantLevel 3050ErrFeedback 3052ErrRefFeedback 3053ErrActuatorDiff 3059ErrFeedbackAdjust 3060ErrDigitalOutput3 3062ErrDigitalOutput7 3063ErrOverCurrentOD3 3067ErrHardwSetp1 3068ErrCanSetp1 3070ErrCanBus 3071ErrCanComm 3076ErrParamStore 3077ErrProgramTest 3078ErrRAMTest 3080ErrPowerCurrent 3083ErrRef1 3084ErrRef2 3085ErrRef4 3086ErrIntTemp 3087ErrAmbPressure 3090ErrData 3093ErrStack 3094ExceptionNumber 3095ExceptionAddrLow 3096ExceptionAddrHigh 3097ExceptionFlag 3098ErrorActive

3099EEPROMErrorCode 3101S1ErrPickUp1 3102S1ErrPickUp2 3103S1ErrVelocity 3104S1ErrOverSpeed 3105S1ErrSetp1Extern 3106S1ErrSetp2Extern 3107S1ErrBoostPressure 3108S1ErrOilPressure 3109S1ErrCoolantTemp 3110S1ErrChargeAirTemp 3111S1ErrFuelTemp 3130S1ErrOilPressWarn 3131S1ErrCoolTempWarn 3132S1ErrChAirTempWarn 3133S1ErrOilLevelWarn 3134S1ErrCoolLevelWarn 3135S1ErrWarnSpeed 3136S1ErrFuelTempWarn 3140S1ErrOilPressEcy 3141S1ErrCoolantTempEcy 3142S1ErrCharAirTempEcy 3143S1ErrOilLevel 3144S1ErrCoolantLevel 3150S1ErrFeedback 3152S1ErrRefFeedback 3153S1ErrActuatorDiff 3159S1ErrFeedbackAdjust 3160S1ErrDigitalOut3 3162S1ErrDigitalOut6 3163S1ErrOverCurrentOD3 3167S1ErrHardwSetp1 3168S1ErrCanSetp1 3170S1ErrCanBus 3171S1ErrCanComm 3174S1ErrCanPassive 3176S1ErrParamStore 3177S1ErrProgramTest

3178S1ErrRAMTest 3180S1ErrPowerCurrent 3183S1ErrRef1 3184S1ErrRef2 3185S1ErrRef4 3186S1ErrIntTemp 3187S1ErrAmbPressure 3190S1ErrData 3193S1ErrStack 3194S1ErrIntern 3201S2ErrPickUp1 3202S2ErrPickUp2 3203S2ErrVelocity 3204S2ErrOverSpeed 3205S2ErrSetp1Extern 3206S2ErrSetp2Extern 3207S2ErrBoostPressure 3208S2ErrOilPressure 3209S2ErrCoolantTemp 3210S2ErrChargeAirTemp 3211S2ErrFuelTemp 3230S2ErrOilPressWarn 3231S2ErrCoolTempWarn 3232S2ErrChAirTempWarn 3233S2ErrOilLevelWarn 3234S2ErrCoolLevelWarn 3235S2ErrWarnSpeed 3236S2ErrFuelTempWarn 3240S2ErrOilPressEcy 3241S2ErrCoolantTempEcy 3242S2ErrCharAirTempEcy 3243S2ErrOilLevel 3244S2ErrCoolantLevel 3250S2ErrFeedback 3252S2ErrRefFeedback 3253S2ErrActuatorDiff 3259S2ErrFeedbackAdjust 3260S2ErrDigitalOut3

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MEASURED VALUES

3262S2ErrDigitalOut6 3263S2ErrOverCurrentOD3 3267S2ErrHardwSetp1 3268S2ErrCanSetp1 3270S2ErrCanBus 3271S2ErrCanComm 3274S2ErrCanPassive 3276S2ErrParamStore 3277S2ErrProgramTest 3278S2ErrRAMTest 3280S2ErrPowerCurrent 3283S2ErrRef1 3284S2ErrRef2 3285S2ErrRef4 3286S2ErrIntTemp 3287S2ErrAmbPressure 3290S2ErrData 3293S2ErrStack 3294S2ErrIntern 3300Velocity 3350EGRValveActive 3351EGRFuelFilter 3352EGRBoostLimitActive 3353EGRFuelActive 3354EGRCoolantActive 3355EGRAmbientActive 3356EGRMapActive 3500PWMIn1 3501FrequencyIn1 3502PWMIn2 3503FrequencyIn2 3510AnalogIn1 3511AnalogIn1_Value 3520AnalogIn2 3521AnalogIn2_Value 3530AnalogIn3 3531AnalogIn3_Value 3540AnalogIn4

3541AnalogIn4_Value 3550TempIn1 3551TempIn1_Value 3560TempIn2 3561TempIn2_Value 3570TempIn3 3571TempIn3_Value 3600ServoCurrrent 3601PowerSupply 3603Reference1+5V 3604Reference2+5V 3605Reference4+5V 3606IntTemp 3700StartCounter 3701WorkingHours 3702WorkingSeconds 3720LoadWorkMap:h 3730LoadWorkMap:s 3740ElectronicTemp:T 3745ElectronicTemp:h 3750ElectronicTemp:s 3800EmergencyAlarm 3801CommonAlarm 3802EngineStop 3803EngineStopped 3804EngineStarting 3805EngineRunning 3806EngineReleased 3810ButtonActive 3821EEPROMAccess:ISO 3823EEPROMAccess:Button 3827EEPROMAccess:Memory 3828EEPROMAccess:Work 3830Phase 3840HardwareVersion 3841AddHardwareVersion 3842SoftwareVersion 3843BootSoftwareVersion

3844SerialDate 3845SerialNumber 3847BootDevelopmVersion 3850Identifier 3851LastIdentifier 3865CalculationTime 3870Timer 3895RAMTestAddr 3896RAMTestPattern 3897CStackTestFreeBytes 3898IStackTestFreeBytes 3905ServoPIDCorr 3906ServoStateStatic 3916ServoCurrentSetp 3917ServoCurrentCorr 3944EMR1ActuatorActive 3950Feedback 3955FeedbackReference 3960FeedbackCorrection

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MEASURED VALUES

3.3 DATA LOGGER (ONLY EMS2)

The screen for this menu item can only be selected if an EMS2 has been selected as the control unit.

3.4 INPUT/OUTPUT ASSIGNMENT

The inputs and outputs can be configured. This menu item displays the current input and output assignment. Limitation: EMR1 and EMS2 control units only.

3.5 CAN STATUS

This window displays the CAN bus activities of the EMR1 or EMR2. EMR1 EMR2

Sent: Contains the information Can:TxCounter (0 to 65535, word). The value is increased with every CAN send message and displays the sending activity of the EMR1. Received: Contains the information Can:RxIrCounter (0 to 65535, word). The value is increased with every CAN send message and displays the sending activity of the EMR1. Bus off: Counter indicating how often the EMR1 has disconnected from the CAN bus because of continuous errors (CanBusOffCounter 0 to 255, bytes). Status: CanOnline indicates whether the EMR1 is active on the CAN bus. A value 1, for online and a value 0, for offline, is sent via the ISO 9141 interface. The SERDIA program displays the text "online" (for value 1) or "offline" (for value 0).

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MEASURED VALUES

Phase: The variable CanSetPointPhase (0 to 255, bytes) is sent via the ISO 9141 interface. This variable displays the time sequence of the setpoint value specification: Code 0 1 2 3 4 5 6 7 Text 0:Engine standstill, initialization 1:Engine standstill, phase 1, no CAN error 2:Engine standstill, phase 2, no CAN timeout error 3:Engibe start, ... until idling speed is recognized 4:Engine runs, wait for CAN setpoint 5:Engine runs, setpoint preset via CAN is allright 6:Engine runs, emergency op., setpoint preset via CAN failed 7:This phase doesn't exist

ERROR INFORMATION/EVENT COUNTER:

The EMR1 sends an error number CanErrorNumber (0 to 255, bytes) via the ISO 9141 interface specially for CAN bus errors. In SERDIA, these numbers are assigned a text, which is displayed in the window of the -CAN interface. Cod. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 100 101 102 103 104 105 Testo 0: No fault existing 1: Message request not received at controller object 15 2: Invalid controller object 3:Engine start, ... until idling speed is recognized 4: CAN active, but no message activated 5: Diagnosis object not activated 6: Scan rate 0 in diagnosis message 7: Scan rate 0 in measure value telegram 8: preset engine speed config.6 does not match TSC2 activation 9: TSC1 activated, but Setpoint eng. speed not set to 6 10: GovernConf=6,neither TSC1 nor function shift is activated 11: GovernConf=6 & Setp.eng.speed=6, but TSC1 is not activated 12: TSC1 activated, but Governor config!=6 13:TSC1NotAct&FunctShiftAct&GovernConf.!=6=>ShiftMGovernMode!=0 14:TSC1Act&FunctShiftAct&GovernConf.=6=>ShiftMaskGovernMode!=0 100 Receipt message failed 101 Setpoint telegram failed w.eng.idle (repl. value) 102 Setpoint telegram missing w.eng.idle due to low battery voltage 103 Setpoint telegram missing after eng.start due to low battery 104 Setpoint telegram missing after eng.start, repl.value used 105 Setpoint telegram missing during eng.oper., repl.value used

TimeOut errors for receipt messages require special treatment. They are all reported with an error number of 100. To identify which message is causing a time-out error, SERDIA proceeds as follows: CanRxObjActive displays, in bit mode, the active messages, i.e. the messages that have actually been received. CanConf_bits contains the configured receipt messages, in bit mode.

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MEASURED VALUES

SERDIA rejects CabRxObjActive in bit mode (inactive message) and then carries out a bit-mode AND logic operation with CanConf_bits. The receipt messages which are configured and inactive (CanRxTimeOutBits) are received in bit mode as a result. A text is assigned to each bit of CanRxTimeOutBits; this text contains the name of the respective receipt messages. Because not all bits have to be used, entering "dc", for "don't care" into the text specifies that the text output for this bit is suppressed. If the text "100 receipt message failed" appears, a list of the missing receipt messages will also be output. Example of displayed error information: 100 Receipt message failed Engine Temperature Engine Fluid Level /Pressure Function shift Inlet / Exhaust Conditions VanRxTimeOutBit 0 1 2 3 4 5 Text Engine Temperature Inlet / Exhaust Conditions Engine Fluid Level /Pressure TSC1 Engine protection Function shift

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PARAMETERS

4. PARAMETERS
4.1 CONFIGURATION (GENERAL)
IMPORTANT: 1 - For safety reasons, the original data set should be saved before making any changes. 2 - Engine running tests are allowed for PID parts only, and should only be carried out by suitably qualified personnel. 3 - Incorrect settings may cause damage to the engine!

CONFIGURATION PROCEDURE
Select the "Parameters" menu on the menu bar to go into the "Configuration" screen. A configuration is carried out in the following steps: On the top line, click on the tab for the desired page or Using the "Next" and "Previous" buttons, browse to the page that contains the parameter to be set (For example: AccPedal (SWG1)up. ref on page 10: Setpoint gen. calibration values). Click in the "New value" field, and enter the required value. This should be between the indicated minimum and maximum values. Click on the "PC->ECU" button. All configuration data are transferred to the control unit. The data are now in the control unit and can be used for testing the engine setting. When the supply voltage is switched off, this data is lost. Next step using the "Save in ECU" button, save the data set in the control unit (the old data are overwritten). For checking, the data can be read and displayed by clicking the "ECU->PC" button. When the engine is running satisfactorily, click on the "Save in file" button to save the data on hard disk or diskette. DESCRIPTION OF SCREEN BUTTON: CENTR.->PC: Configuration data are read from the control unit and displayed. PC->CENTR.: Modified configuration data are transferred into the control unit. In the case of the EMR1, the "Save in ECU" button must be used to store the data permanently. Open file: Configuration data are read from a file (*.hex) and displayed. Save in file: All configuration data are stored in a file (*.hex). When saving, the engine number is prompted as the file name - this is only a suggestion. Any other name can be entered. Finally, click OK to confirm. The file (i.e. the engine data set) is then saved under the name <Engine number>.hex.

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Save in ECU (EMR1 only): The configuration data are stored in the control unit. ATTENTION! All modifications must be reported back! The reporting procedure is described in Service Announcement 0199-99-9287. Previous: The data on the previous screen are displayed. Next: The data on the next screen are displayed. Print: Print the displayed configuration data on the printer. The configuration window can be printed page by page, or in sets (from Page ... to Page ...), or in full.

4.2

OVERALL PROGRAMMING

Saving data from the control unit: By clicking "ECU->file menu, read the data from the control unit. The "Save as" window opens. Save the data under any name, in the form <Filename>.hex. The default name <Engine number>.hex is suggested; this can be replaced by any other name. Confirm by clicking OK. The file (i.e. engine data set) is saved under the selected filename. Overall control unit programming. Click on the "Programming" button; the "Open" window appears. Select the desired file and open it. Click on the "Save in ECU" button. Of the configuration data, only the operating data read from the control unit (Column 2) or file (Column 3) are displayed. Before the configuration data are transferred to the control unit, the operating data can be edited in Column 4. This data is also transferred to the control unit along with the configuration data. Overall programming is not allowed at user Level I or II. EMR1 EMR2

DESCRIPTION OF SCREEN BUTTON:

ECU->file: Configuration data are read from the control unit, displayed, and saved as a HEX file.

PROGRAMMING:
The modified configuration data, or the configuration data HEX file, is transferred to the control unit. In the case of the EMR1, the "Save in ECU" button must be used to store the data permanently. Save in ECU: Configuration data are permanently stored in the control unit.

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PARAMETERS

4.2

CALIBRATION

System components can only be calibrated through the diagnostic interface. The SERDIA diagnosis software is required for the calibration. Along with the EMR1, the accelerator pedal and hand throttle potentiometer (if present) must also be calibrated (does not apply to large assemblies). Important conditions: Engine off Supply voltage (Ignition/Circuit 15) on Integrated accelerator pedal

EXPLANATION OF CONCEPTS (EXAMPLES):

Acceler(SWG1) = Acc. pedal sensor (position sensor 1), Input 24 FS Hand throttle(SWG2) = Hand throttle pot. (position sensor 2), Input 20 FS

GENERAL CALIBRATION PROCEDURE:

Select calibration value in the upper window. Place accelerator pedal/Manual throttle potentiometer in the desired position. "Get value button enabled: Click the button. The calibration value assigned to the position appears in the Edit field. "Get value button disabled: Enter the calibration value in the Edit field. By clicking "PC->ECU", transfer the calibration value to the control unit. By clicking "Save in ECU", save the calibration value in the control unit. Switch the ignition on and off.

SCREEN BUTTON DESCRIPTION:

Get value: If the "Get value" button is enabled, it can be used to read the calibration value for a pedal position. PC->ECU: The displayed calibration value is transferred to the control unit. Save in ECU: The calibration data are permanently stored in the control unit.

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ERROR MEMORY

5. ERROR MEMORY
5.1 GENERAL
The error memory lists the diagnosable errors that have occurred since the last deletion. The current contents of the error memory can be displayed by selecting the menu item "Error memory".

If errors have been eliminated, the corresponding error messages can be deleted from the "Error memory" window : Display the error memory's error messages by clicking on the button "Read EM". In the "Error location" window, mark the displayed error location with the mouse. (Example: "8112:(M17)Rack travel sensor"). The background of the error location text becomes blue. Click on "Clear EM". The error location will be deleted, the message will disappear. Exit the "Error memory" by clicking on "Close".

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ERROR MEMORY

DESCRIPTION OF THE FIELDS:

Error location: List of error locations from which an individual error location can be selected for detailed information. Because there can be several causes of error for some components, this list may list some error locations several times. For example, oil pressure monitoring: Power rating and switch-off limit. Type of error: All the information contained in this field refers to the error location selected in the top field. Environment data: Additional details (e.g. measured values) which contain more information on the selected error location. Total no. of errors: Sum of all recorded error locations. Frequency: Frequency at which the selected error location occurs. Error status: Selected error active or passive.

EXPLANATION OF THE FUNCTION BUTTONS:

Read EM: This function button is used to read out the error memory again from the control unit and the display is updated. Clear EM: This function button sends a request to the control unit to delete the error memory

5.2

ERROR TABLE

5.2.1 EMR1 ERROR TABLE

8002:(F18)Signal monitoring PWM-Inp1 8012:(F21)Signal monitoring PWM-Inp2 8020:ECU (positioner actuation) 8030:shutoff magnet 8112:(M17)Rack travel sensor 8120:(F24)AccelerPedal(SWG1) 8130:(F20)HandThrottle(SWG2) 8140:(M9)CoolantTempSensor 8150:(M24)BoostPressureSensor 8160:(M21)OilPressureSensor 8170:(M13)Speed 1, camshaft 8180:(M11)Speed 2, terminal W 8190:(intern)ElectronicsTemperature 81A0:(M11)Engine speed sensor 8210:Data loss EEPROM 8220:Data loss coil data 8230:EDC calibration error 8305:Speed monitoring 8343:Coolant temp. monitoring 8345:Eng.OFF->CoolantTempMonit 8363:Oil pressure monitoring 8365:Eng.OFF->OilPressMonit 8405:Actuator (positioner, travel meter, fuel rack) 8500:ISO-Bus-Error 8600:CAN-Bus-Error The possible types of error are: (0) Broken cable or short-circuit (1) Broken cable or short-circuit (2) Measuring point defective (3) Power reduced (4) Limit exceeded, power reduction activated (5) Shutoff limit exceeded/ fallen below

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ERROR MEMORY

The following table can be used to assist in the elimination of possible causes of errors which have occurred. When doing this, the status of the fault indicator must be noted: Permanent light: Error statuses permitting limited engine operation. The error must be eliminated as quickly as possible to avoid further damage. Flashing light: Error statuses resulting in the engine being shut off or preventing the engine from being started. The error must be eliminated so that the engine can be put back into operation.

ERROR MESSAGES, CAUSES AND REMEDIES

Error messages (only readable with Serdia) Possible causes Error pilot lamp Type of error Error location 8120:(F24)AccelerPedal(SWG1)1 8130:(F20)HandThrottle(SWG2)2 8140:(M9)CoolantTempSensor3 (0) 8150:(M24)BoostPressureSensor 8160:(M21)OilPressureSensor 8170:(M13)Speed 1, camshaft4 8180:(M11)Speed 2, terminal W Permanent light (Engine operation restricted) (2) 8190: (intern)ElectronicsTemperature 8002: (F18)Signal monitoring PWMInp1 8012: (F21)Signal monitoring PWMInp2 Temperature warning limit exceeded too long. Fallen below oil pres-sure alarm limit for too long. Faulty configuration. (5)6 8305:Speed monitoring Overrun cond. activated. Plug-in connection interrupted OK Flashing (Engine off) camshaft7 Plug-in contacts contaminated or corroded OK Sensor defective OK Cable harness defective Check cable harness and replace if necessary Replace sensor Clean connector and replace if necessary Restore plug-in connection Check coolant Check oil level Check data in SERDIA menu Check configuration and change if necessary PWM signal cannot be evaluated Check signal Plug-in connection interrupted OK Plug-in contacts contaminated or corroded OK Sensor defective OK Cable harness defective Check cable harness and replace if necessary Replace sensor Clean connector and replace if necessary Remedy

n. O.K.
Restore plug-in connection

(3)5

8343:Coolant temp. monitoring 8363:Oil pressure monitoring

(0)

8170:(M13)Speed 1,

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Plug-in connection interrupted OK Plug-in contacts contaminated or corroded

Restore plug-in connection

Clean connector and replace if necessary Replace actuator Check cable harness and replace if necessary

(2)

8112:(M17)Rack travel sensor

OK Actuator defective OK

Flashing (Engine off)

Cable harness defective 8305:Speed monitoring Overspeed reached Temperature alarm limit exceeded for too long. Fallen below oil pres-sure alarm limit for too long. Faulty configuration (e.g. overrun cond. OFF).

8345: Eng.OFF->CoolantTempMonit.

Check coolant Check oil level Check data in SERDIA menu Configuration and change if necessary Replace actuator Check battery Check cable harness Replace ECU Replace ECU

(5)

8365: Eng.OFF->OilPressMonit

8405:Actuator (positioner, travel Actuator defective meter, fuel rack) (Engine start not possible)

(0)

8210:Data loss EEPROM 8220:Data loss coil data 8020:ECU (positioner actuation)

Battery or cable harness defective, ECU failure Error in central electronics, pro-gram in EMR was not executed Plug-in connection interrupted OK

a) Flashing b) Flashing or Permanent light c)Off (0) 8170:(M13)Speed 1, camshaft7

Restore plug-in connection

Plug-in contacts contaminated or corroded OK Actuator defective OK Cable harness defective

Clean connector and replace if necessary Replace actuator Check cable harness and replace if necessary Replace actuator

(5)

8405: Actuator (positioner, travel Actuator defective meter, fuel rack)

1 2 3 4 5 6 7

Switch to SWG 2 (if SWG 2 available). Fixed speed with 2% speed droop is set. Switch to SWG 1 (if SWG 1 available). Fixed speed with 2% speed droop is set.. Electronics temperature is evaluated. Continued running with reduced rated speed, if speed sensor 2 is available. Injected fuel limitation (if activated). The measured value exceeds maximum speed. Speed sensor 2 not available or defective.

It is recommended to use a multimeter as measurement aid.

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5.1.2 EMR2 ERROR TABLE

Fault no. (in SERDIA) Fault locality/ Fault description Ricon. EMR short 0,4 s 2 Blink codee long 0,8 s horts 0,4 s Cause Remarks Help

SERDIA

Fault group

Zero error display

No faults

No active faults present Governor in emergency operation (if sensor 2 available). Emergency switchoff (if sensor 2 not available or failed). Governor in emergency operation (with sensor 1) Emergency switchoff (if sensor 1 not available or failed). Governor in emergency operation. Check cable connection and tacho. (see Chapter 4.15). Replace if required. Check parameter (21). Check speed settings. 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. Check distance. Check cable connection. Check sensor and replace if required.

01

Speed sensor 1

1 Sensor failure. Distance from gear too far. Additional fault impulses. Cable joint interrupted.

Speed sensor 2

Revolutions / speed acquisition

03

Speed sensor

Tacho failed. Additional fault impulses. Cable connection interrupted.

04

Excess speed switch

Speed was/is in excess of limit. e. Engine stop. (see Chapter 4.3.3)

05 06 07 Sensors 08 09 10 11

Set point sensor 1 accelerator pedal) Set point sensor 2 (hand throttle) Charge air pressure Oil pressure Coolant temperature Charge air temperature Fuel temperature

2 2 2 2 2 2 2

2 2 2 2 2 2 2

1 2 3 4 5 6 7 Fault at corresponding sensor entry (e.g. short circuit or cable break). See Chapter 4.15 influencing fault reaction. With failure of the sensor, the associated monitoring function is de-activated. Check sensor cable. Check sensor and replace if required. Check fault limits for sensor.

EMR2 ERROR TABLE

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Functional fault warning Guasti funzionali, avvertenza

SERDIA

30

Oil pressure warning

Oil pressure below speed-dependent warning line characteristic

Fault message (disappears when oil pressure is again above recovery limit). Fault message (disappears when coolant temperature again drops below recovery level). After a delay time - fill limitation.

After a delay time - fill limitation. 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.

31

Coolant temperature warning Charge air temperature warning Coolant level warning

Coolant temperature has exceeded warning level.

32

Charge air temperature has exceeded warning level.

Fault message (disappears when Check charge air. charge air temperature again drops Check charge air temperature below recovery level). After a delay sensor and cable. time - fill limitation. Check coolant level. Check coolant level sensor and cable. Check parameters. Check speed settings (21). 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.

34

Switch input Low coolant level is Fault message. active.

35

Speed warning (with thrust mode operation).

Revolution was/is above (top) revolution speed limit. Thrust mode function is active.

See Chapter 4.3.3 Excess speed protection.

36

Fuel temperature warning

Fuel temperature has exceeded warning level.

Fault message (disappears when fuel temperature again drops below recovery level).

Check fuel. Check fuel temperature sensor and cable.

EMR2 ERROR TABLE

SERDIA

40

Oil pressure switch off

Oil pressure below switch-off limit

Emergency stop Check engine (oil level, oil pump). Check oil pressure sensor and cable. Check oil pressure switch-off limit. Emergency stop. Check coolant level. Check coolant level sensor and cable. Check switch-off limit. Check charge air. Check charge airtemperature sensor and cable. Check switch-off limit. Emergency stop. Start lock. Check coolant level. Check coolant level sensor and cable. Check actuator, replace if required. Check cable, check Confirmation. Check actuator, replace if required. Check cable, check fault limits for Rifeness confirmation. Check actuator/ actuator rods / injection pump, replace if required Check actuator cable.

Functional fault, switch-off

41

Coolant temperature switch-off

Coolant temperature has exceeded switch-off limit.

42

Charge air temperature switch-off Coolant level switch off

Charge air temperature has exceeded switch-off limit. Switch input Low coolant level is active.

44

50

Feedback Actuator not connected. Fault in actuator confirmation. Emergency switchoff. Actuator cannot be operated.

52

Reference feedback

1 Injection pump/actuator jammed or not connected. (disappears when Difference between nominal/actual Fault message10 %). difference is < control travel is > 10 % of the overall control path.

53 Actuator

Control travel difference

59

Auto calibration BOSCH-EDC pumps faulty operation

Check actuator and replaced if required. Check feedback cable. Check voltage supply/cables. Check fault limits and reference No automatic actuator equalization Engine stop / start lock. the feedback. possible. Governor cannot be taken into use. values of the fault limits for Incorrect input of the actuator EDC actuator calibration required Program save values. feedback, reference values. (see Chapter 8.4). Switch ignition off and on again. Check again.If faulty, inform DEUTZ-Service and carry out automatic equalization again. Set fault limits again.

EMR2 ERROR TABLE

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Hardware inputs/outputs Communication Memory Control unit hardware

SERDIA

60 62 63 67 68

Digital output 3 (Switch-off solenoid, pin M 2) Digital output 6, pin M 7 Excess voltage switch-off solenoid Error Hand Setp 1 Error CAN Setp 1

2 2 2 2 2

6 6 6 6 6

1 2 1 2 2

Fault (short circuit /cable break) at digital output.

Driver level is switched off. Fault message.

Check cable of digital output (cable break or short circuit).

70

CAN-Bus controller

CAN-controller for CAN-bus is faulty. Fault removal despite reinitialising continuously not possible Applicationdependent. Overflow nel buffer di ricezione oppure non possibile un invio tramite bus. Fault in parameter programming in the governor fixed value memory.

71

CAN interface SAE J 1939 Parameter programming (write EEPROM) Cyclic program test 2 8 1

Check CAN connection, terminating resistor (see Chapter 12.4). Check control unit.

76

77

Constant monitoring of program memory shows error (socalled Flash-test). Constant monitoring of working memory shows error.

Switch ignition off and on again. Check again. If faulty inform DEUTZ Service Emergency switchoff. engine cannot be started. Note values of parameters (3895 and 3896). Switch ignition off and on again. Check again. If faulty inform DEUTZ Service. and on again. Fault message (disappears when Switch ignition offfaulty inform Check again. If power again in the normal range). DEUTZ Service. Check voltage supply. Switch ignition off and on again. Check again. If faulty inform DEUTZ Service

78

Cyclic RAM test

80 83 84 85 86

Power supply (Actuator) Reference voltage 1 Reference voltage 2 Reference voltage 4 Internal temperature Atmospheric pressure

Power supply for actuator not in the permissible range.

(disappears when Reference voltage for actuator not Fault message the normal range). power again in in the permissible range. Auxiliary value 5 V Internal temperature for control unit Fault message (disappears when not in permissible range. power again in the normal range).

EMR2 ERROR TABLE

87

Atmospheric pressure not in permissible range.

Switch ignition off and on again. Fault message (disappears when Check again. If faulty inform power again in normal range). DEUTZ Service. Atmospheric pressure monitoring function de-activated.

SERDIA

90

Parameter fault (EEPROM retrieval or checksum faulty).

10

No data found or checksum of data is faulty (note: fault only occurs dur- Engine cannot be started. ing setting of parameter / saving or reset.).

Check data for correct settings. Save parameters. Switch ignition off and on again. Check again. If faulty inform DEUTZ Service.

Program logic Note parameters (3897 and 3898). Switch ignition off and on again. Check again. If faulty inform DEUTZ Service.

93

Stack overflow

10

Internal calculation fault (so-called Emergency switchoff. Stack overflow fault). Engine cannot be started.

94

Internal fault

EMR2 ERROR TABLE

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EMR2 ERROR TABLE

5.1.3 ERROR MEMORY 2

This error memory has the same functions as the error memory described previously, however errors can only be read out, displayed and deleted here with EMR2 and the interface for Level IIIa.

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EXTRA

6. EXTRAS

6.1

MAXIMUM SPEED

This screen can be used to select from three different maximum vehicle speeds (30, 40, 50 km/h) (not implemented yet in EMR2)..

6.2

LOGISTIC DATA

The screen is used to read and print the logistic data stored in the control unit. EMR1/EMR2: Engine Serial Number Part number, EMR function data set Part number, ASAP2 data set Date, month and year of manufacture EMR2 only: Part number, CAN function data set Hours of operation Number of engine starts

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EXTRA

Data can only be written and protected in the control unit by DEUTZ AG.. EMR2

6.3 LOAD SPECTRUM

This screen provides an overview of the engine speed and load ranges over which the engine has been operating. Users with the higher authorisation levels may delete entries in the control unit. Limitation: EMR2, EMS2 only

6.4

MAINTENANCE INTERVAL EXCEEDED

This screen shows maintenance intervals that have been exceeded. Users with higher authorisation levels can delete the exceeded maintenance intervals. Limitation: EMS2 only

6.5

OVERRIDE MEMORY

This screen shows, for certain measured quantities, any periods during which the engine was running in the alarm or shutoff range. Users with higher authorisation levels can delete the entries in the control unit. Limitation: EMS2 only

6.6

MAINTENANCE DATA

Limitation: EMS2 only

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TASKS

7. TASKS
7.1 EMR1
During service operations, this button on the SERDIA main screen is used to show the screens for the individual configuration tasks: Diagnosis and Testing Meas. governor performance Meas. start manoev. Meas. monitoring functions Meas. boost pressure Meas. sensors Meas. veh. speed Meas. setpoint value input Meas. dig. inputs/outputs Adjusting Set max. veh. speed Set idle speed Governor setting Set droop Define inputs and outputs Monitoring Error memory Read/delete error memory

7.1.1 EXAMPLE GOVERNOR SETTING

Proceed as follows: Click on the "Tasks" button. Click on the "Adjusting:Governor setting" menu option. The "Governor setting" menu opens.

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TASKS

Screen button functions: ECU->PC: Configuration data are read from the control unit and displayed. PC->ECU: Modified configuration data are transferred into the control unit. To store the data permanently, use the "Save in ECU" button. Save in ECU: Configuration data are permanently stored in the control unit. All modifications must be reported back! The reporting procedure is described in Service Announcement 0199-99-9287. Graphics: The "Graphics" button can be used to see a graphical representation of the selected measurement quantities over time (5 maximum). If more than 5 quantities are selected, an error message is displayed. Collect. time: The measurement collecting time is indicated in the "Collect. time" box, in seconds. The smallest unit of collecting time is one second. The highest time may be several hours (specified in seconds). The basic setting is 10 s. The shortest scan rate is 40 ms for RAM values 60 ms for other values. A measurement time of 10 s gives 10000 ms/40 ms = 250 measurement points for RAM values 10000 ms/60 ms = 166 measurement points for other values. Since the program takes around 2000 measurement points maximum, the scan rate is adapted automatically before data collection begins. The lowest possible scan is determined by the duration of data transfer from the control unit to the PC. The higher the number of measured quantities to be displayed at the same time, the longer the data transfer time, and the narrower the scan frequency. Print: Prints the measured values appearing on the screen. Close: Return to the "Tasks" menu.

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TASKS

7.1.2 EXAMPLE SPEED DROOP SETTING

Proceed as follows: Click on the "Tasks" button. Click on the "Adjusting: Set droop" menu option. The "Droop setting" menu opens.

Screen button functions: ECU->PC: Configuration data are read from the control unit and displayed. PC->ECU: Modified configuration data are transferred into the control unit. To store the data permanently, use the "Save in ECU" button. Save in ECU: Configuration data are permanently stored in the control unit. All modifications must be reported back! The reporting procedure is described in Service Announcement 0199-99-9287. Print: Prints the measured values appearing on the screen. Close: Return to the "Tasks" menu.

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TASKS

7.1.3 DEFINE INPUTS AND OUTPUTS

Using the "Tasks" button, the possible assignments 1. are displayed with the right mouse button 2. allocated with the left mouse button This screen also shows functions that can be inverted, and the measured values for all inputs and outputs (to view these, click on the "Measurement" button). This configuration feature is only present with Access Level III.

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WHAT TO DO IF...?

8. WHAT TO DO IF...?
8.1 SERDIA GENERAL

8.1.1 ERROR WHILESETTING UP COMMUNICATIONS

If communications cannot be set up although the interface and control unit have been connected, an error message is displayed:

Possible reasons for the error message: No supply voltage to the control unit or interface. Voltage supply was cut when the engine was switched off. Incorrect assignment of serial interface on PC (see 9.1.2). Wrong pole connection on voltage supply from engine to interface. Not all of the 4 wires (+, -, k, l) are connected. Wrong control unit, or control unit faulty. Remedy, quick checks: Yellow interface LED should light up when SERDIA is started. Measure the diagnostic connector supply voltage (the interface requires 8 - 28 V DC). In Windows, check the assignment of the serial interface (usually COM1). Connect another control unit. Further information on operating voltages for control units, interface and PC: EMR control units require an operating voltage from 10 V to 30 V (typically 12-24 V). Power consumption: 5 A at 12 V, 7 A at 24 V The MVS control unit takes a voltage of 24 V only. The interface is supplied by the engine and takes a voltage from 12 V to 24 V. The control units and interface are protected against wrong pole connection and overvoltage. However, an accidental incorrect connection, to a 230 V source for example, can still cause damage. Using an interface with an integrated optical link, the PC (Notebook, and printer) can be connected to the vehicle battery and ground with no risk for the control unit and interface, and no risk of loss of data.

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WHAT TO DO IF...?

8.1.2 INTERFACE CONFIGURATION WITH ISETUP

On PCs, the COM1 interface may already be occupied by the mouse. In this case, the interface must be connected to the other serial interface (COM2). This port can then be configured with ISETUP to allow it to communicate with the interface. Proceed as follows: Start the ISETUP.EXE program. Select the other COM port and click OK. The initialisation file ISODRV.INI is modified automatically. Re-start Windows. Note: On many PCs, the second serial interface is the 25-pin type. In this case, a hardware adapter (25-pin to 9pin) must be inserted to allow connection of the 9-pin diagnostic interface.

8.1.3 ACCESS CONFLICTS IN WINDOWS 3.1

The ISODRV.386 interface driver can only be loaded statically. In the Windows SYSTEM.INI file, the ISODRV.386 driver is entered in the [386Enh] section (with the working directory path). This may cause problems with other programs that access the same serial interface. Remedy: Start the ISETUP.EXE program. Delete the driver entry from the SYSTEM.INI file. Re-start Windows 3.11.

8.1.4 ERROR MESSAGE IN WINDOWS 3.11 WHEN STARTING SERDIA

When starting SERDIA in Windows 3.11, the following error message may appear:

This is because the VXDLDR.386 driver is not activated. Remedy: Start the ISETUP.EXE program. Check the "Device VXDLDR.386 enabled checkbox and click OK to confirm.The appropriate driver entry is made automatically in the SYSTEM.INI file. Re-start Windows 3.11.

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8.2 EMR1 8.2.1 ENGINE SURGES

Fault finding: Troubleshooting with the EMR1 is done in the same way as for engines with mechanical regulators, i.e. the engine components and functions such as pump, control rod movement, fuel supply, etc, are examined. In most cases, especially if the engine was running correctly before engine surges begin to occur, the fault does not lie in the EMR1. Controller setting: Controller setting is performed mainly for new operation modes, and should be thoroughly tested and documented with the system (engine and installation) in all operating conditions. If the new application is connected and enabled, the user-specific controller parameters must be confirmed with company headquarters. Follower engines with the same operation mode do not usually require any additional adjustments. Opening the menus: SERDIA main menu -> Tasks menu -> Governor setting -> Execute

General rules for setting correction: Setting correction is carried out with the engine running. Raising the P/I/D parts increases the control tolerance range. Enter the value to be corrected in the "new value field. One way of doing this is select the old value with the mouse, then simply type in the new value (the old value is deleted automatically). Click on the "PC->ECU" button to send the new value to the control unit. The governor applies the new setting, and the result will be detectable in the engine behaviour. After setting correction has been carried out successfully and before disconnecting the voltage supply (circuit 15), the new parameters must be stored in the EMR1. To do this, click on the "Save in ECU" button.

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WHAT TO DO IF...?

Governor basic setting: The control unit is programmed at the end of the band with the following standard values. Standard value Parameter (Variable) Assembly SpeedGvnr: P part SpeedGvnr: I part SpeedGvnr: D part SpeedGvnr: damping SpeedGvnr: damping range PosGvnr: P part PosGvnr: I part PosGvnr: D part PosGvnr: DT2 part SpeedGvnr: damping SpeedGvnr: damping 18-20 10,0 5-12 90,0 Vehicle 4,0 10,0 2,5 65,0 Basic setting gain factors for P/I/D parts. These parameters are independent of engine status (speed, load still active) and show the main instruments for governor setting. Lowering the governor parameter for the static range. Speed band around nominal value. Within this speed band, the engine runs smoothly and with precision, and does not respond strongly to speed variations. Comment

15,0 10,0 10-15 5-10 8,0 160-180 0,25

80,0 10,0 5,0 5,0 8,0 180,0 0,25

Setting corrections should only be made after confirming

Standard values may vary according to engine model and application Standard values, speed and load dependent parameters: 3 performance maps for the P, I, and D part = fkt (speed, quantity injected).. Parameter (Variable) X: Engine speed position values (r.p.m.) Y: Quantity position values (cmm/str) Map (%) Standard value Comment 602500 0, 20 100 100 7 speed values 4 injection quantity values Total 3 x 28 entries. A 100 % entry causes the speed governor PID parts to be accepted (Page 4). Corrections must be made at the related measurement point. EMR1

Making a setting correction: Before modifying any parameters, we recommend saving the current configuration using the "Save in file" menu option, and/or printing configuration pages 4, 5 and 17. The setting procedure consists of 3 stages: 1. PID governor basic parameters For the most part, the correction is made with the basic parameters. If a new governor basic setting is required, set all performance maps (Page 17) to 100%. The P part is the most important parameter and must be set first. Raise the parameter value for "SpeedGvnr: P part" by 10 % to begin with, until the engine accelerates under the the sudden load variation and vibration dips to f > 1 Hz. Then reduce the P part again by 25 %. Example: P part with vibration dip (unstable) = 12. 12-25 % of 12 = 9 (new setting value). The setting depends heavily on weight moment of inertia (engine + generator). For weight moments of inertia up to 8kgm2 the value range for the P part is between 10 and 45 %. At higher moments of inertia, the P part can be raised by up to 90 %. Note regarding major engine assemblies:The optimum governor values are determined at operating speed with different loads. Note the P part determined for each, and enter the average in "SpeedGvnr: P part". For double-frequency installations, the second frequency must be included in the average value calculation. Note regarding vehicle engines:The optimum governor values are determined at several engine speed and load points.

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WHAT TO DO IF...?

Note the P part determined for each, and enter the average in "SpeedGvnr: P part". The different P parts given by the various load and speed points must be corrected in the PID performance map. The D and I parts (Page 4) are now set applying the same procedure, i.e. raising the values by 5 % first till unstable, then reduce again by 25 %. 2. Parameters for static and dynamic operation. Setting the "SpeedGvnr: damping and "SpeedGvnr: damping range parameters (Page 4). The "SpeedGvnr: damping range parameter determines the speed band in which speed is in the static range. For example, entering a value of 15 r.p.m. sets a +/-15 r.p.m. band around the nominal speed . The "SpeedGvnr: damping" parameter determines the lowering of the governor parameter (PID parts) for the static range, i.e. if the speed is within the speed band around nominal value, the governor parameter (PID parts) falls to the value for the damping factor. For example, SpeedGvr: P part =10 % SpeedGvr: damping =65 % This has the effect that, in the static engine condition of nominal speed range +/- damping range, the P part falls to 6.5 %. The aim of this step is that the engine will run smoothly and precisely within the speed band, without responding strongly to slight speed changes. If the engine runs outside of the speed band due to a fault, the set governor parameters become effectively 100 % again and the governor will quickly correct the speed error as far as possible. Standard settings - see "Governor basic setting". Setting corrections can only be made through the engine running test. Speed and load dependent parameters. For the P, I, D basic parameters there are corresponding performance maps that depend on speed and injected quantity (load) (Page 17). The effective parameters are determined by multiplying the basic parameter by the content of the performance map. For example, SpeedGvr: P part =10 % Map P part =200 % at 2000 r.p.m. and 50 cmm/stroke Result: For the given operating point, the P part becomes effectively 20 %.

3.

8.2.2 ACCELERATOR PEDAL CALIBRATION

An accelerator pedal is usually designed as a foot pedal, operated by the driver of a vehicle. However, the input provided for the accelerator pedal (vehicle connector Pin 24) can also be used as a remote input, like those used in locomotives and ships. In all cases, calibration is required. Calibration must be carried out both at initial startup (either by the customer or by service engineers), and whenever a replacement is made. The accelerator pedal is not always supplied by DEUTZ AG. However, we recommend the pedal value sensor (DEUTZ Part No. 0419 9457. Other accelerator pedals can also be installed by the customer, subject to confirmation with company head office. The following are then required: Connection as in EMR1 System overview: Signal input (Pin 24/vehice connector) to GND (Pin 23/vehicle connector) Analog signal: > 0.5 V (accelerator pedal in 'parked' position), for example 1 V < 4.5 V (accelerator pedal at 'full throttle'), for example 4V The EMR1 provides a reference voltage at the vehicle connector (Pin 25, +5 V). This reference voltage is also intended for the manual throttle potentiometer. Therefore the total load current should not go over 25 mA if the pedal value sensor and manual throttle potentiometer are arranged in parallel, (i.e. total resistance > 200 .) Calibrazione acceleratore per mezzo del menu "Calibrazione": Accelerator pedal calibration using the "Calibration" menu: Calibration is menu-driven. Both end stops "parked position" and "full throttle" are calibrated as limit values. See "General procedure for calibration", Chapter ,"Calibration". Accelerator pedal calibration using the "Measured values" and "Configuration" menus: The aim of calibration is to inform the control unit of the limit values for the two end stops: "parked position" as the lower and "full throttle" as the upper reference point. Also, the "upper fault value" (+5 % from upper reference point) and "lower fault value" (-5 % from upper reference point) must be entered, relative to the two reference points.

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Parameter designations
Configuration screen AccPedal(SWG1)up. err val. AccPedal(SWG1)up. ref AccPedal(SWG1)lo. ref AccPedal(SWG1)lo. err val. Calibration screen Acceler(SWG1)upper fault limit [full throttle...5V] Acceler(SWG1)full throttle [pressed down, upper limit] Acceler(SWG1)parked position [lower limit] Acceler(SWG1)lower fault limit [0V...parked pos.] Value max. setpoint x 1.05+ max. setpoint Pedal at rest = Idle Pedal at rest - 0.05 x max. setpoint

Measuring the limit values: Open the "Measured values" menu, "Actual measured values". Measured value "(F24)Accelerator pedal=SWG1: with pedal in parked position (lower reference) and pedal pressed (lower reference), "Get value", transfer to the control unit and save. Configuration: Open the "Parameters menu, "Configuration" option. Enter values, referring to the following example table ("Acc. pedal input configuration", see below). Conversion: 5 V=1023 digits. Example: Acc. pedal input configuration Parameter AccPedal(SWG1)up.err val. AccPedal(SWG1)up. ref AccPedal(SWG1)lo. ref AccPedal(SWG1)lo. err val. Factory setting mV 4750 4500 500 250 digits 973 921 102 51 4150 670 Actual value/ measured value mV Calibration mV 4357 670 463
2 1

Configuration digits 893 850 137 95

4150

1) Measured value "upper reference point" + 5 % (v. upper reference point) 2) Measured value "lower reference point" -5 % (v.lower reference point)

8.2.3 MANUAL THROTTLE CALIBRATION

The manual throttle (Pin 20 FS) is intended for vehicles such as agricultural machines. When ploughing, for example, a driver can make the appropriate engine speed setting and then take his/her foot off the accelerator pedal. As with the mechanical adjusting levers, the manual throttle position must be set to zero (lowest engine speed) before starting the engine. The manual throttle positioning is combined with the accelerator pedal and determines minimum speed. In proportion to the preset nominal value, engine speed can be set between lower idle speed (for example 650 r.p.m.) and nominal engine speed (for example 2300 r.p.m.). Depending on the manual throttle setting, the engine responds in the same way as to an accelerator pedal. For example, if the speed is set with the hand throttle to 1500 r.p.m., accelerator pedal operation only becomes effective at higher speeds than this. Manual throttle positioning is not supplied by DEUTZ, but it still has to be programmed at the factory. A potentiometer can be used as the adjusting link, and installed by the customer. Requirements for manual throttle nominal value setting (potentiometer) when installed by customer: Input Pin 20 vehicle connector Potentiometer supply as pedal value sensor, 5V reference voltage Pin 25, and GND Pin 23. Loading reference voltage together with pedal value sensor < 25 mA. Protection system IP65 End stops adjusted to between 10 % and 90 % of the potentiometer value. For example, if potentiometer resistance = 1 k., the setting range between mechanical stops must then be between 100 and 900 . This setting range can be achieved by a) Narrowing the turning angle

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WHAT TO DO IF...?

b)

Series resistors in the supply lines.

Manual throttle calibration: The two potentiometer end stops must be calibrated. The aim of calibration is to inform the control unit of the limit values for the two end stops: "Potentiometer stop LI speed" as the lower and "Potentiometer rated speed" as the upper reference point. Also, the "upper fault value" (+5 % from upper reference point) and "lower fault value" (-5 % from upper reference point) must be entered relative to the two reference points.

Parameter designations
Configuration screen Hand thr.(SWG2)up. err val. Hand thr.(SWG2)up. ref Hand thr.(SWG2)lo. ref Hand thr.(SWG2)lo. err val. Calibration screen Hand throttle(SWG2) upper fault limit(upper limit...5V) Hand throttle(SWG2) max.eng. speed (upper limit) Hand throttle(SWG2) min. eng.speed (lower limit) Hand throttle(SWG2) lower fault limit (0V...lower limit) Value Rated engine speed x 1.05+ Rated engine speed Low idling engine speed LI engine speed - 0.05 x rated eng. speed

8.2.4 EXAMPLE OF FAULT FINDING

Fault finding:
Connection broken? OK Plug contacts dirty or corroded? OK Sensor faulty? OK Cable harness faulty? not OK Restore the connection.

not OK not OK not OK

Clean plug, replace if necessary. Replace sensor. Check the harness, replace if necessary.

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8.2.5 ENGINE DOES NOT START

Indication Starter speed > 160 r.p.m. not reached. Possible cause Check using multimeter: terminal voltage at starter < 7V (12V system). Remedy Replace battery. Clean earth wire connections.

Starter speed ok, fuel rack tra-vels Faulty fuel supply. to start position.

Restore fuel supply.

Remove vehicle connector and check for correct connections: No power supply, connected to Pin 14F=+Ubatt wrong pins or incorrect polarity. Pin 1F=-Ubatt Pin 2F=-Ubatt Shutoff solenoid defective or not connected. Starter speed ok, fuel rack stays at Fuel rack stiff. zero position. Speed sensor faulty. Locate site causing stiffness and remedy as appropriate. Replace sensor, check plug connection and line.

Starting fuel charge limitation is set Usin g SERDIA c heck m eas ured val ue too low or coolant temperature is (M9)coolant temperature in the menu too high for the EMR. current measured values.

Flashing pilot light.

There is a serious fault in the EMR system. You should remedy the fault before attempting any further Locate error using SERDIA. starts. Replace actuator, see service example, actuator replacement. Additional setting is not necessary.

Identification of fuel rack travel SERDIA error message: deviation, measured value in 8405: Actuator (positioner, travel shutdown range. meter, fuel rack). Shutoff solenoid defective or not connected. SERDIA error message: 8170:(M13)Speed 1, camshaft.

Short circuit or interruption on the Replace sensor, check plug connection for speed sensor (camshaft sensor) or contamination or corrosion, check lines besupply line or plug connection. tween vehicle plug and sensor for damage. Replace ECU. Transfer data from old ECU to the new one 1:1.

SERDIA error message: Memory error in the EMR 8210:Data loss EEPROM Memory error in the EMR 8220:Data loss coil data 8020:ECU (positioner actuation) ECU Failure SERDIA error message: 8160:(M21)OilPressure Sensor SERDIA error message: 8140:(M9)CoolantTemp Sensor

Oil pressure measured value (M21) Replace sensor, check plug connection for lies outside permitted range, also contamination or corrosion, check lines bewith engine switched off. tween vehicle plug and sensor for damage. Coolant temperature measured value (M9) lies outside the permitted range, also with engine switched off. Replace sensor, plug and line control

SERDIA error message: Accelerator pedal sensor 8120:(F24)Acceler Pedal(SWG1) incorrectly calibrated.

Check calibration values in the menu Calibration and change if necessary.

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8.2.6 ENGINE STOPS FOR NO KNOWN REASON

Indication

Possible cause Shutdown not initiated by error message in the EMR.

Remedy

Following shutdown: (Key switch not yet actuated, off/on) Error pilot light off !

Other possibilities: Fuel supply ! Restore fuel system. Speed monitoring independent of Check whether additional speed monitoring (e.g. solenoid) is available and make relevant EMR. system check. Interruption of supply voltage. Trace error location and error environment with SERDIA. Error message: Check EMR vehicle connector, fuse, key switch etc. for loose contact. Carry out systematic check depending on error message:

Following shutdown: (Key switch not yet actuated, Overspeed (is reached for instance Guide value: rated speed+15% to be correctoff/on) upon sudden load change) ed if necessary. Error pilot light Permanent light Check connector on oil pressure sensor for !e.g. Oil pressure additonal loose contact and replace sensor if necesremark: inactive. sary. Following shutdown: (Key switch not yet actuated, off/on) Error pilot light flashing Take action according to the indicated error There is a serious error in the EMR location. This may involve replacing the ECU, system. Prior to engine start, trace actuator or sensor. The additional remark inerror location with SERDIA. active indicates a loose contact at the indicated error location.

8.2.7 REPLACING THE EMR1 ACTUATOR

The actuator is a purely mechanical component of the EMR1, fixed to the engine. It contains a solenoid controlled by the EMR1, which positions the control rod and thus regulates the fuel feed to the engine. A fuel rack position sensor fitted into the actuator indicates the control rod position to the EMR1. The following error messages may make it necessary to replace the actuator: 8113:(M17)Rack travel sensor 8405:Actuator (positioner, travel meter, fuel rack)

Replacement instruction:
Switch off the voltage supply to the EMR1 and detach the connection cable from the actuator. For safety reasons, the positive terminal of the battery must be disconnected. Remove the actuator and clean the mounting surface on the engine. IMPORTANT: With the actuator removed, the control rod is at maximum filling position, i.e. the engine must not be started in any circumstances! Attach the new actuator with sealant (DEUTZ Part No. 0101 6102) to the engine. When fitting a new actuator, check that it is compatible with the control unit. At the moment, there are 3 possible combinations for replacement:

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Actuator/control unit compatibility Control unit, Part no. Software Version No. EMR1 Related actuator, Part No. 0211 1841 0211 1911 1.08 1.11 1.10 0211 1926 0211 1926 0211 1926 EDC actuator and pump are associated with each other. EDC actuator replacement: additional settings required. 1) Self-calibration (Level 4) 2) Transfer EDC Data to the control unit (Level 3) The actuator content is the same as 0211 1911. Only the attachment method for the housing is different.

Procedure for replacing the actuator This combination must be completely replaced by combination 0211 1911 / 0211 1910. Confirmation from company head office is required.

0211 1846 0211 1910 0211 2017 0211 2017 0211 2686 0211 2690 0211 6178 0419 9995

1.31

Bosch EDC

IMPORTANT: Special feature of the 1015. Note the pump with EDC actuator. Restore the connection to the control unit and start the engine. In SERDIA, select the "Parameters" menu ->"Configuration" and, with the "PC->ECU" button, transfer the parameters to the EMR1, and start the engine. When the engine is running satisfactorily, save the parameters in the control unit. When the tests with SERDIA are completed, clear the error memory. On the SERDIA main menu, print the control unit identification list, and in the "Extras" menu, print the logistics data for the documentation record. The document must be sent along with the old actuator to company head office.

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8.2.8 CONTROL UNIT REPLACEMENT

The control unit can be replaced in two ways: 1. 2. When the control unit is damaged, but the data are still readable (communications with SERDIA are possible). A new control unit is installed with engine data set programmed at the factory.

General overview of EMR1 control units

1012/1013/2013
- With MN label - Programmed -SERPIC Part No. 0211 2016 - Without MN label - Not programmed -Part No. on control unit 0211 2017 - With MN label - Programmed -SERPIC Part No. 0211 2016

1015
- Without MN label - Not programmed -Part No. on control unit 0211 2017

1012/1013 for Deutz-Fahr only

- With MN label - Programmed -SERPIC Part No. 0211 2451 - Without MN label - Not programmed -Part No. on control unit 0211 2088 See also: SM 130-99-9305

Replaced by 0211 2581

Replaced by 0211 2570 See also:

Replaced by 0422 6179

Replaced by 0422 6178

Replaced by 0211 2580

Replaced by 0211 2571 See also:

SM 130-27-9308 Replaced by 0211 26911 1) Replaced by 0211 2686 1) Replaced by 0419 4043 1) Replaced by 0419 9995 1)

SM 130-27-9308 Replaced by 0211 2692 1) Replaced by 0211 2690 1)

1) Current Part No., supplied if ordered. General overview of EM2 control units All model series - With MN label - Programmed - SERPIC Part No 0211 2704 Notes on the entries above: The completed control unit. - With MN label - Programmed - SERPIC Part No. To be able to operate with the engine, each control unit must be programmed with the specific data set for the engine (it has a label with the engine number attached). In this way, the engine and control unit together form an integrated unit. Therefore, when ordering a new control unit, the engine number (MN) is indicated along with the engine model. Control units are completed by DEUTZ. Unprogrammed control unit. The engine cannot be started with this control unit. For reconditioning operations, this control unit can be completed by transferring the specific engine data set from the 'old' control unit, using SERDIA Level III. See also SERDIA Manual - Without MN label "Complete programming". - Not programmed - Part No.on control unit For reconditioning purposes, this means that unprogrammed control units can also be ordered from DEUTZ Service partners (Competence Class II). They are then completed (with the MN label) by the service partner. If the data set cannot be read from the 'old' control unit, this can be requested by Email in the same way, as described in SM 0199-99-9287 "Confirming modifications to EMR data". - Without MN label - Not programmed - Part No.on control unit 0211 2850

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WHAT TO DO IF...?

METHOD 1. 1. Step: Read engine data set from old control unit: Switch on ignition/supply voltage. Open the SERDIA program. In SERDIA, select the "Parameters menu ->"Overall programming". Click on the "ECU -> file" button. The configuration data files are read. The "Save as " window then opens. Give the file a name, and save.

When saving, the engine number is prompted as the file name - this is only a suggestion. Any other name can be entered. Finally, click OK to confirm. The file (i.e. the engine data set) is then saved under the name <Engine number>.hex. The data transferred from the old control unit includes, among other things, indications of the number of operating hours and number of engine starts. Close the program. Switch off the ignition/supply voltage. 2. Step: Replacing the control unit: Control unit compatibility must be considered, and checked against the above table (Part Numbers should be the same.). Compatibility of the control unit with the actuator must also be checked and verified. Switch on ignition/supply voltage. Open the SERDIA program. In SERDIA, select the "Parameters menu ->"Overall programming". Click on the "Programming" button. The "Open" window is displayed. Select the saved engine data set (<Engine number>.hex) by double-clicking on it. Transfer the engine data set to the EMR1 by clicking on the "OK" button. Save the data set in the control unit by clicking on the "Save in ECU" button.

3. Step: Start the engine and check that it runs satisfactorily. In the "Error memory" menu clear the error memory.

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METHOD 2.:
Every EMR1 has a specific engine data set, which is kept in a central computer at DEUTZ AG when the engine is delivered. Any modifications to EMR1 configuration settings must be reported back to DEUTZ AG. When a new control unit is ordered, it is programmed with a data set available to DEUTZ AG under the corresponding engine number. Therefore, if setting corrections to the engine are not reported back to DEUTZ AG, these may not be taken into account when programming a new control unit. Switch off the ignition/supply voltage. Remove both connectors from the old control unit. Connect the control unit with the engine and vehicle connectors (both 25-pin). Switch on ignition/supply voltage. Open the SERDIA program. In the "Error memory" menu, clear the error memory. Start the engine and check that it runs satisfactorily.

8.2.9 ERROR READING THE CONFIGURATION DATA

This error message appears if SERDIA is unable to read the Hex file. The file possibly contains Umlauts (, , ), or other special characters not understood by SERDIA

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