Deutz-Fahr 150 – EMR3: Above target range with system reaction

The engine's electronic control unit has detected that the charge air temperature (intake manifold temperature) exceeds the predefined maximum limit, triggering a protective system reaction. This indicates that the air entering the intake manifold after the turbocharger and charge air cooler is too hot, representing a deviation from expected operational parameters that can lead to reduced engine performance, increased emissions, and potential engine damage.

• TCD 2012
• TCD 2013
• TCD 2015

1. 1

   Verify the fault code is active and note the conditions under which it appeared

2. 2

   Check the charge air cooler (intercooler) for blockages from debris (dirt, leaves) and ensure cooling fins are clean for proper heat dissipation. For marine applications, verify the cooling water intake is not clogged.

3. 3

   Inspect the wiring harness and connectors between the charge air temperature sensor and the EMR3 ECU for damage, corrosion, chafing, loose connections, short circuits, or breaks

4. 4

   Check for a 5-volt reference signal from the ECU at the sensor's electrical connector with the ignition on

5. 5

   Test the charge air temperature sensor (thermistor) by measuring its resistance at ambient temperature, then gently heat it with a heat gun (resistance should decrease smoothly as temperature rises)

6. 6

   Verify that the ECU has the correct and latest calibration, as software updates can sometimes address fault sensitivities

1. 1

   Clean charge air cooler

   If the charge air cooler is found to be blocked, clean it thoroughly to restore proper airflow and heat dissipation.

2. 2

   Repair wiring

   If any wiring faults are discovered during inspection, repair or replace the damaged section of the harness. Ensure all connections are clean and secure.

3. 3

   Replace the sensor

   If diagnostic checks point to a faulty sensor (e.g., incorrect resistance readings, no change with temperature), replace the charge air temperature sensor located in the intake manifold after the turbocharger.

4. 4

   Clear fault codes

   Cycle the ignition off, wait for the ECU to fully shut down, and then turn the ignition back on. A diagnostic tool may be required to clear the error memory on some systems.

5. 5

   Verify repair

   Operate the machine under the conditions that previously triggered the fault to ensure the repair has been successful and the code does not reappear.