Sie sind auf Seite 1von 90

Technical Publication

Engine Monitoring Unit

EMU 1

MTU/DDC Series 4000


DDC/MTU Series 2000
Marine applications
Documentation Parts 1, 3, 5, 7

E 531 686 / 04 E

DaimlerChrysler Off-Highway

Printed in Germany
E 2002 Copyright MTU Friedrichshafen GmbH
Diese Verffentlichung einschlielich aller seiner Teile ist urheberrechtlich geschtzt. Jede Verwertung oder Nutzung bedarf der vorherigen
schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere fr Vervielfltigung, Verbreitung, Bearbeitung,
bersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschlielich Datenbanken
und Online-Diensten.
Das Handbuch ist zur Vermeidung von Strungen oder Schden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen
Wartungs- und Bedienungspersonal zur Verfgung zu stellen.
nderungen bleiben vorbehalten.
Printed in Germany
E 2002 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of
MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on
electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation.
Subject to alterations and amendments.
Imprim en Allemagne
E 2002 Copyright MTU Friedrichshafen GmbH
Tout droit rserv pour cet ouvrage dans son intgralit. Toute utilisation ou exploitation requiert au pralable laccord crit de MTU
Friedrichshafen GmbH. Ceci sapplique notamment la reproduction, la diffusion, la modification, la traduction, larchivage sur microfiches,
la mmorisation et / ou le traitement sur des systmes lectroniques, y compris les bases de donnes et les services en ligne.
Le manuel devra tre observ en vue dviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous
lexploitant de le mettre la disposition du personnel charg de lentretien et de la conduite.
Modifications rserves.
Impreso en Alemania
E 2002 Copyright MTU Friedrichshafen GmbH
Esta publicacin se encuentra protegida, en toda su extensin, por los derechos de autor. Cualquier utilizacin de la misma, as como su
reproduccin, difusin, transformacin, traduccin, microfilmacin, grabacin y/o procesamiento en sistemas electrnicos, entre los que se
incluyen bancos de datos y servicios en lnea, precisa de la autorizacin previa de MTU Friedrichshafen GmbH.
El manual debe tenerse presente para evitar fallos o daos durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposicin del
personal de mantenimiento y de servicio.
Nos reservamos el derecho de introducir modificaciones.
Stampato in Germania
E 2002 Copyright MTU Friedrichshafen GmbH
Questa pubblicazione protetta dal diritto dautore in tutte le sue parti. Ciascun impiego od utilizzo, con particolare riguardo alla
riproduzione, alla diffusione, alla modifica, alla traduzione, allarchiviazione in microfilm ed alla memorizzazione od allelaborazione in
sistemi elettronici, comprese banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen
GmbH.
II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall utente al personale addetto
alla manutenzione e alla condotta.
Con riserva di modifiche.
Printed in Germany
2002 Copyright MTU Friedrichshafen GmbH
A presente publicao, inclusive todas as suas partes, est protegida pelo direito autoral. Qualquer aproveitamento ou uso exige a
autorizao prvia e por escrito da MTU Friedrichshafen GmbH.
Isto diz respeito em particular reproduo, divulgao, tratamento, traduo, microfilmagem, e a memorizao e/ou processamento em
sistemas eletrnicos, inclusive bancos de dados e servios on--line.
Para evitar falhas ou danos durante a operao, os dizeres do manual devem ser respeitados. Quem explora o equipamento
economicamente consequentemente deve coloc--lo disposio do respetivo pessoal da conservao, e disposito dos operadores.
Salvo alteraes.

Guide

Page

General information about documentation


Documentation structure
Documentation
Part

Title/contents

Target group(s)

Structure and function

Operating personnel etc.

Operation

Operating personnel

Maintenance and repair

Plant personnel

Service manual

Electronic service personnel

Illustrated parts catalog

Plant-specific configuration

Mechanical and electrical


installation
Initial start-up

Plant personnel, electronic service personnel,


logistics personnel
Electronic service personnel, installation
personnel, start-up personnel
Installation personnel
(electromechanical/mechatronic engineer)
Start-up personnel

Note: Not all parts of the documentation are written for every product.

Required knowledge
To understand each part of the documentation, we recommend reading the preceding parts, if applicable.

Reference numbers and reference lines


Details in figures are provided with reference numbers and reference lines if necessary.
If reference is made in the text to a detail provided with a reference number, the figure number and, separated by an oblique, the reference number of the detail are written in brackets. Example: (5/2) means fig. 5,
reference number 2.
A point at the end of the reference line means that the detail is visible in the figure.
An arrow at the end of the reference line indicates that the detail cannot be seen in the figure.

Symbols
The symbols used in safety notes are defined in the chapter Safety requirements.
This symbol indicates cross-references to other manuals.

E 531 686 / 04 E

03.2003

MTU

Page

II

Guide

This symbol indicates important information.

This symbol indicates detailed information.

Further troubleshooting or fault rectification of a fault marked with this symbol requires
mechanical work to be performed on other assemblies or equipment with reference to the
relevant documentation.
Further troubleshooting or fault rectification of a fault marked with this symbol requires work to
be performed on the engine with reference to the engine documentation.
Troubleshooting or rectification of a fault marked with this symbol either requires the customers
trained service personnel or service personnel provided by MTU. The affected assembly may
have to be sent to MTU for repairs. Such a fault cannot be repaired by plant personnel.
Some of the chapters in this manual contain structured task descriptions. The symbols used here are
explained at the relevant points by associated sub-titles.

ID numbers
Some of the chapters in this manual contain structured task and activity descriptions. Each task and each
activity is assigned an unambiguous identification number (ID no.). This number is structured as follows
X-X-XXX-xxxx whereby:
1st figure:
Either T for Task or A for Activity
2nd figure:
System affected (examples: M for MCS, R for RCS)
3rd 5th figure: Unit or assembly (generally corresponding to MTU type designations,
whereby version numbers are omitted)
6th 9th figure: Serial 4-figure number number (for differentiation when 1st 5th figures are identical)
Wildcards N (for none) may be used for the 1st to 5th figures when a task/activity is generally applicable to
all systems/units.

Qualification of users of the manual


Abbreviations are used in the manual to indicate qualification of personnel who may carry out the tasks/activities concerned. The abbreviations refer to the course types available in the MTU training program for the
product concerned and have the following meaning:
E1

The user must have completed a course aimed at operating personnel or have equivalent
knowledge. No metrological requirements are made.

E2

The user must have completed a course aimed at plant personnel or have equivalent
knowledge.

E3

The user must have completed a course aimed at service personnel (electronics).

E4

The user must have completed a course aimed at start-up personnel (electronics).

MTU

03.2003

E 531 686 / 04 E

Part
Page

Structure and function


Table of contents

1
I

Part 1

Structure and function

E 531 686 / 04 E

03.2003

MTU

Part
Page

1
II

Structure and function


Table of contents

(This page intentionally blank)

MTU

03.2003

E 531 686 / 04 E

Structure and function


Table of contents

Part
Page

1
III

Table of contents
1

Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

Use and structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.1

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.2

Structure of Engine Monitoring Unit EMU 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.2.1

External structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.2.2

Internal structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.2.3

Mounting Engine Monitoring Unit EMU 1 on the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2

Functions of electronic Engine Monitoring Unit EMU 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.1

Engine monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.1.1

Alarm generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

1.2.1.2

Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

1.2.2

Individual exhaust temperature monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

1.2.2.1

Mean value calculation and limit value monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

1.2.2.2

Individual exhaust temperature measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

1.2.2.3

Communication between Engine Control Unit ECU 4 and


Engine Monitoring Unit EMU 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

1.3

Assignment of cylinder numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

1.4

Definition of speed measuring failure monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

1.5

Engine Monitoring Unit EMU 1 as a safety system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

1.6

Status and fault displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

1.7

Communication and system integration via CAN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

1.8

Inputs and outputs of Engine Monitoring Unit EMU 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

1.8.1

Inputs and outputs on the engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

1.8.2

Inputs and outputs on the plant side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

1.8.3

Bus connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

1.9

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

E 531 686 / 04 E

03.2003

MTU

Part
Page

1
IV

Structure and function


Table of contents

(This page intentionally blank)

MTU

03.2003

E 531 686 / 04 E

Structure and function


Use and structure

Structure and function

1.1

Use and structure

1.1.1

Use

Part
Page

1
1

Engine Monitoring Unit EMU 1 is an independent, auxiliary safety system intended to protect the engine.
This is realized by an extended range of measuring points and additional (redundant) evaluation of appropriate variables.
Furthermore, Engine Monitoring Unit EMU 1 incorporates individual cylinder exhaust temperature measuring
equipment. The exhaust temperatures of the individual cylinders are acquired and used for engine monitoring.

Fig.

1:

Engine Monitoring Unit EMU 1

E 531 686 / 04 E

03.2003

MTU

Part
Page

1
2

Structure and function


Use and structure

Engine Monitoring Unit EMU 1 features:

MTU

Speed, level, temperature and pressure inputs

Communication with ECS-5 devices and the superordinate system via CAN bus

Extensive range of I/O features:


- Engine: 2 speed inputs
2 level inputs
2 temperature inputs
3 pressure inputs
20 exhaust temperature inputs
- Plant: 1 universal input (for pressure or level)
1 level input
3 transistor outputs
2 CAN bus interfaces

Engine and plant related variables in a pluggable memory module

Up to 20 exhaust temperature inputs for NiCr-Ni sensors


(housing reference temperature measuring on a printed circuit board of Engine Monitoring Unit
EMU 1)
Self-monitoring and diagnosis
- Transmission of fault messages via CAN to display units

Online programming by downloading (dialog unit), transmission via CAN bus


CAN programming via interface for programming adapter PAB 2
CAN node address in a pluggable EEPROM

03.2003

E 531 686 / 04 E

Part
Page

Structure and function


Use and structure

1.1.2

Structure of Engine Monitoring Unit EMU 1

1.1.2.1

External structure

1
3

Engine Monitoring Unit EMU 1 is integrated in a diecast housing with a screw-fitted cover. It is suitable for
mounting on Engine Control Unit ECU 4 where it is attached via the threaded bores provided.

300

53

1
2
3

268

8
2

4
84,5

W3

W2

W005

All dimensions in mm

Fig.

2:

Mechanical structure
1
2
3
4

Cover
Cover screws
Housing
Exhaust temperature sensor connector X13

5
6
7
8

Seals
Sensor connector X12
Plant connector X11
Fixing lugs

Engine Monitoring Unit EMU 1 is attached to Engine Control Unit ECU 4 by the three fixing lugs. The cover
is fixed on the housing by eight Phillips screws.
The housing between cover and base is sealed with cord packing.
Bayonet connectors are used to establish electrical connections

E 531 686 / 04 E

03.2003

MTU

Part
Page

1
4

Structure and function


Use and structure

Connections for the cable harness of the exhaust temperature sensors, the engine sensor cable harness
and the connection to Engine Control System ECS-5 are marked on the housing cover. Prefabricated
system cables or cable harnesses are connected to these connectors (X11 ... X13) (see table below).
Prefabricated cable harnesses are also used for engine wiring and employ pluggable sensors and actuators
(see table below).
Note:

The connectors cannot be misconnected as they are provided with different inserts. Connections of lines which are not in use are isolated.

Connection

Meaning

Connector X11
System cable W005

System connection (LOP power supply, CAN interfaces, system


outputs and inputs)

Connector X12
Cable harness W12

Connection for engine cable harness for sensors

Connector X13
Cable harness W13

Connection for engine cable harness with up to 20 exhaust temperature sensors

MTU

03.2003

E 531 686 / 04 E

Part
Page

Structure and function


Use and structure

1.1.2.2

1
5

Internal structure

Memory module
Printed circuit board
EMB 1

Cord packing

Housing
Connector for
cable

Fig.

3:

Internal structure of Engine Monitoring Unit EMU 1 (cover removed)

Printed circuit board EMB 1 inside the housing incorporates all electronic components.
Engine Monitoring Unit EMU 1 is not equipped with internal wiring to optimize operational reliability and facilitate maintenance and repair. Engine Monitoring Unit EMU 1 is supplied with power via Local Operating
Panel LOP 1.
Refer to Local Operating Panel Type LOP 1, MTU/DDC Series 4000, DDC/MTU Series 2000,
Marine applications, Documentation Part 1, document no. E 531 687 for a detailed description
of Local Operating Panel LOP 1.
Further information is also included in Engine Control System ECS-5, MTU/DDC Series 4000,
DDC/MTU Series 2000, Marine applications, document no. E 531 693.

E 531 686 / 04 E

03.2003

MTU

Part
Page

1
6

Structure and function


Use and structure

6 5

4
3
3

9
9

10

X13

X12

1
Fig.

4:
1
2
3
4
5
6
7
8
9
10

X11

Configuration of electronic components on the printed circuit board of Engine Monitoring Unit
EMU 1
Engine cable connector
ECS-5 connector
Power supply LED
Connection for programming adapter PAB 2
Processor
LED RESET
Program memory module MEM 6-01/A
Test connector (for MTU test procedures only)
Keys (not used)
Status/fault display

The data module is plugged in to facilitate replacement. The data module cannot be confused with other
modules as the connection is coded.

MTU

03.2003

E 531 686 / 04 E

Structure and function


Use and structure

1.1.2.3

Part
Page

1
7

Mounting Engine Monitoring Unit EMU 1 on the engine

Engine Control Unit ECU 4

Engine Monitoring Unit EMU 1

Fixing screws

Fig.

5:

Mounting Engine Monitoring Unit EMU 1 on Engine Control Unit ECU 4

Engine Monitoring Unit EMU 1 has been designed for engine mounting.
Fig. 5 shows direct mounting on the Engine Control Unit (view from the back to Engine Control Unit ECU 4).
Fig. 6 shows engine mounting via Engine Control Unit ECU 4 and 4 metal cable shock absorbers with 4
screws on the engine mounting brackets.

E 531 686 / 04 E

03.2003

MTU

Part
Page

1
8

Structure and function


Use and structure

2
1

3
10

13

12
11

8
7
Fig.

6:
1
2
3
4
5
6
7
8
9
10
11
12
13

MTU

Engine mounting of Engine Monitoring Unit EMU 1


Engine Control Unit ECU 4
Top adapter plate
Metal cable shock absorber
Top mounting bracket
Connectors of Engine Control Unit ECU 4
Connector sockets
Bottom adapter plate
Bottom mounting bracket
Bottom hex-head screws (screwed into the housing from the rear)
Top hex-head screws (screwed into the housing from the rear)
Engine Monitoring Unit EMU 1
Connector sockets of Engine Monitoring Unit EMU 1
Connectors of Engine Monitoring Unit EMU 1

03.2003

E 531 686 / 04 E

Structure and function


Functions

1.2

Functions of electronic Engine Monitoring Unit EMU 1

1.2.1

Engine monitoring

Part
Page

1
9

Engine monitoring features the following functions:

Monitoring of (max. 2) pressures as a function of engine speed; limit values are freely-programmable functions of engine speed:
pLimit = f(engine speed)

Monitoring of a pressure (static limit value)

Analog acquisition of (max. 2) levels

Transmission of all measured values, warnings and alarms to the Monitoring and Control
System via the CAN bus

Monitoring of a temperature as a function of engine speed; limit values are also freely-programmable functions of engine speed:
TLimit = f(engine speed)
Acquisition and monitoring of individual cylinder exhaust temperatures
Speed acquisition with limit value monitoring
Output of emergency stop and stop signals; signals are generated depending on the limit values
monitored

Refer to the measuring point list for details of order-specific configuration data.
Communication with other assemblies is effected via serial interfaces:

2 x CAN bus interface (redundant CAN bus) for communication with the following assemblies:
- Other ECS-5 devices
- Superordinate Monitoring and Control Systems
(Remote Control System RCS; Monitoring and Control System MCS)
- Also used as a dialog interface
- Download

E 531 686 / 04 E

03.2003

MTU

Part
Page

1
10

1.2.1.1

Structure and function


Functions

Alarm generation

All alarms are generated with an appropriate delay; the delays can be adjusted using the dialog unit.

1.2.1.2

Software

The software (program) is loaded into Engine Monitoring Unit EMU 1 via the dialog unit interface (CAN interface) when the engine is installed or on commissioning the electrical system.
Limit values and parameters required for engine monitoring are determined during the project implementation phase or engine trials and loaded into Engine Control System ECS-5 during the engine test run.
The use of a pluggable data module has the advantage of making it possible to use Engine Monitoring Unit
EMU 1 in conjunction with a variety of engines and applications by simply transferring the software module in
case of replacement.
Fig. 7 shows the software components in data module MEM 6-01/A:

Not
equipped

Not
equipped

Program
memory
EEPROM

Data module
MEM 6-01/A
Fig.

7:

MTU

Schematic representation of the memory module

03.2003

E 531 686 / 04 E

Part
Page

Structure and function


Functions

1.2.2

Individual exhaust temperature monitoring

Note:

The individual temperature monitoring option is only available for MTU/DDC Series 4000
engines.

1.2.2.1

Mean value calculation and limit value monitoring

1
11

Each measured value is compared with the average of all the measured values. An alarm is raised if a
deviation is detected which violates the tolerated upper or lower limits set by the limit value curves.

Alarm range

TIndivid.

TIndivid. = TMean

Alarm range

TMean value
Fig.

8:

Alarm signalling in case of individual cylinder exhaust temperature deviation

Upper and lower limit curve parameters can be programmed freely and changed with the dialog unit.
The average value is the arithmetic mean of all valid individual temperatures. The program has the following
functions to ensure that the calculated mean value is not compromised:

Cylinders which are cut out are not taken into consideration on generating the mean value

Channels on which a sensor fault has been detected are not included in the mean value

Cylinders which are cut out are not monitored (no alarm)
On switching over to full engine operation (all cylinders cut in), monitoring of additional cylinders
only commences after a delay (the system waits for temperatures to come into line), the
corresponding time limit, i.e. alarm delay, can be adjusted

E 531 686 / 04 E

03.2003

MTU

Part
Page

1
12

1.2.2.2

Structure and function


Functions

Individual exhaust temperature measuring

Engine Monitoring Unit EMU 1 must be able to detect the following in order to measure individual exhaust
temperatures:

How many cylinders does the engine actually have?


How many cylinders are currently active (e.g. in case of cylinder cutout)?

The individual exhaust temperature sensors are wired as follows to realize reliable and adjustment-free
EMU 1 software for individual exhaust temperature measuring:
The allocation of the temperature measuring channels for individual exhaust temperature measuring
(TEH1 ... 20) to the engine cylinders (A1...10, B1...10) reflects the firing sequence in just the same way as
the solenoid valve wiring of Engine Control Unit ECU 4 (i.e. TEH1 = first cylinder in the firing sequence,
TEH11 = second cylinder in the firing sequence, TEH2 = third cylinder in the firing sequence, etc.).

1.2.2.3

Communication between Engine Control Unit ECU 4 and Engine


Monitoring Unit EMU 1

Engine Control Unit ECU 4 signals by CAN telegram which cylinders are currently active. Cylinders which
are not physically present on the engine (e.g. cylinders 9, 10, 19, 20 on a 16 V engine) are considered cut
out by Engine Control Unit ECU 4.
Detecting cylinders which are cut out in Engine Monitoring Unit EMU 1
Engine Monitoring Unit EMU 1 evaluates the CAN telegram of Engine Control Unit ECU 4 and excludes
cylinders which are cut out from mean value calculation.

MTU

03.2003

E 531 686 / 04 E

Structure and function


Functions

1.3

Part
Page

1
13

Assignment of cylinder numbers

Engine Monitoring Unit EMU 1 and Engine Control Unit ECU 4 use the same cylinder numbers. Communication is thus independent of engine type. Only cylinder numbers are assigned (1, 2, 3 ... 20).
If messages are output on alphanumeric display systems which use standard cylinder designations (A1 ...
A10, B1 ... B10), the assignment of cylinder numbers used in ECS-5 (1, 2, 3 ... 20) to the standard cylinder
designations (A1 ... A10, B1 ... B10) is made in the respective display unit.

1.4

Definition of speed measuring failure monitoring

Speed acquisition failure in Engine Monitoring Unit EMU 1 is detected and signalled to the system operator
(visualization).
The speeds measured by Engine Control Unit ECU 4 and Engine Monitoring Unit EMU 1 are compared constantly. If a difference value is exceeded (adjustable with dialog unit), the speed measured by Engine Monitoring Unit EMU 1 is set to SD (Sensor Defect).

E 531 686 / 04 E

03.2003

MTU

Part
Page

1
14

1.5

Structure and function


EMU as a safety system

Engine Monitoring Unit EMU 1 as a safety system

Engine Monitoring Unit EMU 1 is used to cover the additional requirements and scope of redundant measuring points specified for classified marine plants. In such cases, EMU 1 also represents the second, independent safety system which protects the engine from assuming states which present a risk to continued operation.
In other, unclassified, applications, the Engine Monitoring Unit is integrated in ECS-5 as an option, e.g. in
applications in which individual exhaust temperature monitoring is required or desired.

NSE3*

CAN bus

UNI1*

Other
ECS-5 assemblies

ECU 4

System
EMU 1
Engine

TE1**

TE2*
NSE1*

NSE2*

f
n

Speed

Engine
speed

DME1** DME2*

Spare

Exhaust temperature
9:

Oil level

Exhaust temperature
Fig.

DE3*

Spare

TEH20*

Oil pressure

TEH1*

DE2*

External water pressure

DE1**

Coolant temperature

Spare

EMU 1 scope of measuring points

The sensors marked * in fig. 9 represent extended measuring points in comparison with applications involving Engine Control Unit ECU 4 only. Measuring points marked ** are redundant to those of Engine Control
Unit ECU 4.

MTU

03.2003

E 531 686 / 04 E

Part
Page

Structure and function


Status and fault displays

1.6

1
15

Status and fault displays


Up
key

Fig. 10 :

Down
key

Mode
key

RESET

IO_RESET

Display

--15 V +5 V +15 V

LEDs and display in Engine Monitoring Unit EMU 1

The following voltages are monitored:

+15 VDC (internal)


--15 VDC (internal)
+5 VDC (internal)

The processor state is indicated by:

RESET
The processor system is put into a defined state by a RESET. The engine is shut down.

IO_RESET
The processor resets all inputs and outputs at this time without itself assuming reset state.

The four-digit display indicates status and fault codes (refer to the table in part 3 of this documentation).
Note:

The three keys Mode, Up and Down are not used on Engine Monitoring Unit EMU 1.

1.7

Communication and system integration via CAN bus

The CAN bus is a standardized field bus for automation technology allowing various systems, devices, sensors and actuators to communicate with each other.
Engine Monitoring Unit EMU 1 is equipped with two CAN bus interfaces.
Tasks of the CAN bus:

Receiving plant signals and commands from the superordinate Remote Control System RCS
Output of all measured values/limit values for the Monitoring and Control System (MCS-5)
Alarm output for signalling and evaluation in the Monitoring and Control System (MCS-5)
Output of the signals relevant to engine control

E 531 686 / 04 E

03.2003

MTU

Part
Page

1
16

1.8

Structure and function


Inputs and outputs

Inputs and outputs of Engine Monitoring Unit EMU 1

The assignment of input and output channels and their respective functions is explained in the table below.

1.8.1
Channel

Inputs and outputs on the engine side


Measuring
point

Channel
type

Function

Engine oil
pressure

Analog-in Limit1 alarm, if poil,act. < P1

Comments

Inputs:
DE1

Limit2 alarm, if poil,act. < P2


P1 and P2 are programmable characteristic
curves as a function of engine speed
The stop output is activated in case of a
Limit2 alarm

DE2

DE3

TE1

External
water pressure after
seawater
pump

Analog-in Limit1 alarm, if pSW,act. < P1

Oil refill
pump
pressure

Analog-in Limit1 alarm, if poil,act. < P1;

P1 is a programmable characteristic curve as


a function of engine speed

P1 is a programmable characteristic curve as


a function of engine speed

Coolant tem- Analog-in Limit1 alarm, if Tact. > T1


perature after
Limit2 alarm, if Tact. > T2
engine
T1 and T2 are programmable parameters
In case of a Limit2 alarm, either the STOP
output is activated or automatic power reduction takes effect (indicated by Power reduct.
output)

Automatic power
reduction procedure is realized
in conjunction
with Engine Control Unit ECU

Selection by dialog unit


TE2

Spare

Analog-in

NSE1

Spare

Analog-in

NSE2

Spare

Analog-in

DME1

Engine
speed

Pulse-in

Limit2 alarm, if nact. > nmax.

Gear types:

nmax. is a programmable value

N teeth

The EMERGENCY STOP output is activated


in case of a Limit2 alarm

120-1 teeth

Failure detection (safety system)

MTU

03.2003

E 531 686 / 04 E

Part
Page

Structure and function


Inputs and outputs

Channel

Measuring
point

Channel
type

DME2

Spare

Pulse-in

TEH1 TEH20

Exhaust
temperature
cylinder
1 20

NiCr-Ni
analog-in

Function

Comments

Limit1 alarm, if Tact. deviates excessively from


the mean of all cylinders. Power reduction
may be initiated (procedure as for coolant
temp.)

See chap.
1.2.2.1 for
deviation limit
curves

1
17

Exhaust temperature monitoring may be


switched on/off by dialog unit
Power reduction may be switched on/off by
dialog unit
Note:

The range of sensors is defined in the standard scopes of supply for Engine Control System
ECS-5, MTU/DDC Series 4000 and DDC/MTU Series 2000.

E 531 686 / 04 E

03.2003

MTU

Part
Page

1
18

1.8.2

Structure and function


Inputs and outputs

Inputs and outputs on the plant side

Engine functions
Channel

Measuring
point

Channel
type

Function

Designations in
connection diagram

UNI1

Spare

Analog-in

UIN1

NSE3

Spare

Analog-in

UIN2

TAA1

Engine stop

Relay-out Activated when a


Limit2 alarm is
applied

TRANOUT1

TAA2

Emergency
stop

Relay-out Only activated on


detecting overspeed; not suppressed when an
override telegram is
received

TRANOUT2

TAA3

Power reduc- Relay-out Indicates automatic


tion
power reduction or
prompts the operator to reduce power

TRANOUT3

Comments

Inputs:

Outputs:

Refer to coolant
temperature and
exhaust temperature measuring
points

Communication functions
Channel

Measuring
point

Channel
type

Function

Comments

CAN1

CAN
ECS-5

All measured values/alarms/states are transmitted as a CAN telegram

STOP, EMERGENCY STOP


initiation and
power reduction
are also transmitted as a CAN
telegram

Software and data download (dialog)

CAN2

MTU

CAN
ECS-5

Redundant ECS
bus connection

03.2003

E 531 686 / 04 E

Part
Page

Structure and function


Inputs and outputs

1.8.3

1
19

Bus connections

The engine monitoring unit has two interfaces for communication with the system:

CAN1

CAN bus interface 1

CAN2

CAN bus interface 2

Channel

Function

Target

CAN1/
CAN2

Bus connection to external systems

MCS, RCS

Electrical isolation

BUS_H

CAN BUS

BUS_L
EMU 1

GND
Cable
W005
Fig. 11 :

Schematic diagram of the CAN bus interface

Note:

The CAN bus is connected to Engine Monitoring Unit EMU 1 in the system cable connector.
Disconnecting Engine Monitoring Unit EMU 1 thus has no effect on continued operation of the
overall system.

Channel specification
Physical level

ISO 11 898

CAN specification

Version 2.0 A

Data format

MTU specific (field bus 1)

Terminator

Not provided (bus not interrupted when connector removed, see


above)

Burst resistance

In accordance with IEC 1000-4

The CAN bus interfaces operate independently.

E 531 686 / 04 E

03.2003

MTU

Part
Page

1
20

1.9

Structure and function


Technical data

Technical data

Type

Engine Monitoring Unit EMU 1

Dimensions (W x H x D)

300 mm x 84.5 mm x 268 mm


Height + approx. 230 mm for connector

Weight

4.0 kg

Housing

Diecast aluminium housing

Colour/paint

Same as engine

Installation position

Plug connection from the side

Mounting

3 x hexagon bolt M6 x 20 on
Engine Control Unit ECU 4;
tightening torque 6 Nm

Connection

3 x bayonet connector

Grounding

Necessary

Operating voltage
Continuous voltage
Temporarily restricted operation

16.5 VDC ... 32 VDC


11 VDC ... 36 VDC

Power consumption

0.2 A 2.2 A

Power dissipation

Max. 6 W

Max. housing temperature

+75 C

Relative humidity

0 % ... 95 %, condensing

Protection according to DIN 40 050

IP 65

Shock

15 g, 11 ms semi-sinusoidal shock

Vibrostability
Frequency 2 Hz ... 25 Hz
Frequency 25 Hz ... 100 Hz
Frequency 20 Hz ... 2000 Hz

Travel amplitude xpp = 1.6 mm


Acceleration a = 4 g
Smoke 1.3 g rms

EMC protection

DIN EN 50081-2 and DIN EN 50082-2

Inputs
Plant side

Engine side

MTU

1 x binary input (NSE3)


1 x universal input (UNI1)
2 x serial interface (CAN1, 2)
2 x level input
2 x speed input
20 x exhaust temperature input
3 x pressure input
2 x temperature input

03.2003

E 531 686 / 04 E

Part
Page

Structure and function


Technical data
Outputs
Plant side

3 x transistor output 0.3 A

Diagnostic display

4-digit LED display,


visible with cover open

Status display

5 x LED,
visible with cover open
Reset
+5 VDC
+15 VDC
--15 VDC
IO_RESET

Replaceable data modules

MEM 6-01/A (program memory module)

E 531 686 / 04 E

1
21

03.2003

MTU

Part
Page

1
22

Structure and function


Technical data

(This page intentionally blank)

MTU

03.2003

E 531 686 / 04 E

Part
Page

Operation
Table of contents

2
I

Part 2

Operation

Not applicable
2

Not applicable

E 531 686 / 04 E

03.2003

MTU

Part
Page

2
II

Operation
Table of contents

(This page intentionally blank)

MTU

03.2003

E 531 686 / 04 E

Part
Page

Maintenance and repair


Table of contents

3
I

Part 3

Maintenance and repair

E 531 686 / 04 E

03.2003

MTU

Part
Page

3
II

Maintenance and repair


Table of contents

(This page intentionally blank)

MTU

03.2003

E 531 686 / 04 E

Maintenance and repair


Table of contents

Part
Page

3
III

Table of contents
3

Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1

Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2

General information about Part 3 of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1

Task duration and personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2

Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.3

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.4

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.4.1

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.4.2

Summary of tasks for scheduled maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.4.3

Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.4.3.1

Checking firm seating of all connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.4.3.2

Checking firm seating of the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.4.3.3

Checking all sensor glands for leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.4.3.4

Checking cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

3.2.4.4

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

3.2.4.4.1

Cleaning Engine Monitoring Unit EMU 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

3.2.4.4.2

Cleaning the connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

3.3

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

3.3.1

Faults which are not indicated by fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

3.3.2

Faults indicated by system fault display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

3.4

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

3.4.1

Replacing EMU 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

3.4.1.1

Removing the housing of Engine Control Unit ECU 4 from the engine . . . . . . . . . . . . . . . .

21

3.4.1.2

Removing the housing of Engine Monitoring Unit EMU 1 from


Engine Control Unit ECU 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

3.4.1.3

Removing the cover of Engine Monitoring Unit EMU 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

3.4.1.4

Transferring the memory module of Engine Monitoring Unit EMU 1 . . . . . . . . . . . . . . . . . .

25

3.4.1.5

Fitting the cover of Engine Monitoring Unit EMU 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

3.4.1.6

Fitting the housing of Engine Monitoring Unit EMU 1 onto Engine Control Unit ECU 4 . .

27

3.4.1.7

Fitting the housing of Engine Control Unit ECU 4 on the engine . . . . . . . . . . . . . . . . . . . . . .

28

E 531 686 / 04 E

03.2003

MTU

Part
Page

3
IV

Maintenance and repair


Table of contents

(This page intentionally blank)

MTU

03.2003

E 531 686 / 04 E

Part
Page

Maintenance and repair


Safety requirements

Maintenance and repair

3.1

Safety requirements

3
1

IMPORTANT:
These safety requirements shall be read and observed by all personnel
involved in operation, care, maintenance, repair, installation or commissioning
of the products described.
Furthermore, the following shall be observed:

The safety requirements (if provided) in other relevant MTU manuals

National accident prevention and safety standards

Warning and safety information and operating and limit values attached to the products
as required
Appropriate regulations usual in the industry
The safety notes (if provided) in the text of this manual

Conventions for safety notes in the text


Where necessary, this manual includes highlighted safety notes indicated by a signal word. These safety
notes shall be observed to avoid injury or damage.
This type of note indicates a danger which may lead to injury or death.

DANGER

This type of note indicates a danger which may lead to damage or


destruction of the product described or another part of the system.

CAUTION

Intended use and user qualifications


All devices and system components may only be put to their intended use.
Operation, maintenance, repair, installation and commissioning shall only be performed by qualified and
authorized personnel.

E 531 686 / 04 E

03.2003

MTU

Part
Page

3
2

Maintenance and repair


Safety requirements

Safety requirements for maintenance and repair


Maintenance and repair work shall be performed exactly and on schedule to ensure constant readiness and
reliability of the product.
Authorization must be obtained from the person in charge prior to commencing maintenance and repair work
and switching off parts of the electronic system required for this.
Prior to working on assemblies, the power supply of the appropriate areas must be switched off and secured
against unauthorized switching on.
Any measures requiring power supply are expressly defined as such at the appropriate place in the manual.
Maintenance and repair work shall be performed in accordance with the instructions in the manual by
authorized personnel.
Suitable tools, special MTU tools if necessary, shall be used for maintenance and repair work.
Genuine spare parts only may be used to replace defective components or assemblies. The manufacturer
accepts no liability whatsoever for damage caused by using other spare parts. The manufacturers warranty
shall also be voided in such cases.
The manufacturer shall not be held liable if unauthorized changes or modifications are made to the product
and the warranty shall be voided.
Spare parts shall be stored properly prior to replacement, i.e. particularly protected against the ingress of
moisture. Defective electronic components and assemblies must be suitably packed when despatched for
repair, i.e. particularly protected against the ingress of moisture and impact and wrapped in antistatic foil if
necessary.
Inform the MTU service department or its representative in case of damage which cannot be rectified by
plant personnel.
On completion of maintenance and repair work, ensure that no superfluous parts (tools etc.) remain inside
the device or system.
On completion of repair work, the device or system must be subjected to appropriate checks to verify
functionality. Separate testing of the repaired component without system integration is inadequate.
When working on the engine, suitable measures shall be taken to prevent accidental starting.

MTU

03.2003

E 531 686 / 04 E

Maintenance and repair


General information

3.2

Part
Page

3
3

General information about Part 3 of this manual


Refer to order-specific documents (e.g. drawings) if necessary in case of deviations from the
information provided in this manual.

3.2.1

Task duration and personnel qualification

Information about task duration is only intended to serve as a guide and is based on the work being carried
out under normal working conditions. The amount of time required may deviate from the times stated in
some cases.
The abbreviations explained in the preface to this manual are used to specify the minimum qualifications for
users carrying out the work described.
Familiarity with the contents of Part 1 of this manual is pre-requisite.

3.2.2

Terminology

The following terms are used in this manual:

Task:
A group comprising several activities. Performing all activities not necessarily in a specific
order results in the task being fulfilled.

Activity:
Sequence of steps to be carried out in a specific order. The result of each activity is a part of the
superordinate task.

Step:
The sequential execution of certain steps forms a superordinate activity.

Work:
Generic term for tasks, activities and steps.

E 531 686 / 04 E

03.2003

MTU

Part
Page

3
4

3.2.3

Maintenance and repair


General information

Structure

The chapters in this manual describing specific work are structured as shown in fig. 12.

Task
overview

Task
descriptions

Table
(Maintenance
schedule/fault code
table/troubleshooting
table)

Cross-referenced by
Task ID

Fig. 12 :

Activity
descriptions

Listing

Illustrated text

Listing

Illustrated text

Listing

Illustrated text
Cross-referenced by
Activity ID

Structure of the sub-chapters and terminology

Checkboxes are provided on the right margin of task description pages allowing each item to be checked off.
Note:

MTU

Task and activity descriptions are modular and often formulated in general terms (e.g. for a plant
with several control consoles). The information provided must be applied to the plant concerned
by analogy.

03.2003

E 531 686 / 04 E

Part
Page

Maintenance and repair


Maintenance

3.2.4

Maintenance

3.2.4.1

General information

3
5

This chapter describes preventive care and maintenance work to be performed on Engine Monitoring Unit
EMU 1 to maintain operational readiness. This work can be performed without measuring or test equipment.
Maintenance work on Engine Monitoring Unit EMU 1 primarily consists of visual inspections to detect mechanical damage or loose parts and fixtures. Faulty assemblies must be repaired or replaced immediately.
System failure

CAUTION

Engine Monitoring Unit EMU 1 or even the entire ECS-5 system may fail if the
work described below is not performed according to the instructions and at the
specified intervals.

Any faults which are detected can be located and rectified with the aid of the troubleshooting instructions in
the chapters below.

3.2.4.2

Summary of tasks for scheduled maintenance work

All the work described in the table below can be performed by plant personnel.
Maintenance work is performed at three intervals:

Maintenance echelon W2
Maintenance echelon W3
Maintenance echelon W4

The timing of these intervals is dependent on the engine maintenance echelons W1 to W5.
Refer to the engine documentation for details of the time frames within the intervals during
which maintenance work must be performed for this reason.
The tables below describe the maintenance work and list the locations at which this work is to be performed.
Note:

Interval

All work performed on one of the Engine Monitoring Units EMU 1 (e.g. port engine or starboard
engine) must be performed subsequently on all other Engine Monitoring Units EMU 1 on board
ship.

Task designation

Quali- Duraficat.
tion

Task ID

Page

Comments

W4

Perform visual
inspection

0.2 h

T-P-EMU-0001

Any faults detected on


inspection must be rectified
immediately

W4

Clean Engine Monitoring Unit EMU 1

0.2 h

T-P-EMU-0002

11

Perform as necessary

E 531 686 / 04 E

03.2003

MTU

Part
Page

3
6

Maintenance and repair


Maintenance

3.2.4.3

Visual inspection

ID no.:

T-P-EMU-0001

System components/devices in the overall ECS-5 system

Engine Monitoring Unit EMU 1 on the engine

Sensors on the engine

Cabling on the engine

Cabling to peripheral assemblies and systems

Cable ties if applicable

Equipment

Torch

Connector pliers

Reference documentation

Engine documentation

Documentation of Engine Monitoring Unit EMU 1,


document no. E 531 686

Requirements

Engine room accessible

Engine at a standstill

Additional safety notes

Observe general safety requirements: Chap. 3.1

Observe safety notes preceding the descriptions of the various activities

List of activities

Note:

MTU

ID no.

1. Check firm seating of connectors.

A-P-ECU-0003
Page 7

2. Check firm seating of all cables.

A-P-ECU-0004
Page 8

3. Check all sensor glands for leakage.

A-P-ECU-0005
Page 8

4. Check cabling.

A-P-ECU-0006
Page 10

The activities can be performed in random order.

03.2003

E 531 686 / 04 E

Part
Page

Maintenance and repair


Maintenance

3
7

3.2.4.3.1 Checking firm seating of all connectors


ID no.:

A-P-ECU-0003
Engine Monitoring Unit EMU 1 (13/1) is usually
attached to the rear of Engine Control Unit ECU 4.
This assembly is located at the end (auxiliary PTO
end) or top of the engine. Three connectors are
located on the side of the housing (max. depending on engine equipment (13/3).

Any sockets which are not in use are closed off by


a cap.
Proceed as follows to check firm seating of the
connectors on Engine Monitoring Unit EMU 1:
1. Attempt to turn the bayonet union nuts (13/2)
on the connectors at the side gently by hand.
2. If this is possible, tighten the bayonet union
nut (13/2) concerned by turning it clockwise
with the connector pliers (see fig. 14).
2

Fig. 13 :

Connectors on Engine Monitoring


Unit EMU 1

Fig. 14 :

Connector pliers

E 531 686 / 04 E

03.2003

All the various electrical assemblies on the engine


(sensors, solenoid valves, final control elements
etc.) are connected to the engine cable harness by
various plugs. Check that these plug connections
are also firmly seated plugging them in and locking
them in position as necessary.

MTU

Part
Page

3
8

Maintenance and repair


Maintenance

3.2.4.3.2 Checking firm seating of the cables


ID no.:

A-P-ECU-0004

1
2

Cabling on MTU/DDC Series 4000 engines is routed in a cable harness (or several cable harnesses
depending on the scope of electrical equipment
involved). They are routed in plastic tubes (15/2) to
preclude damage. These tubes are fastened to the
engine.
1. Check that the cable harnesses are properly
secured to the engine in their mounts (15/1)
and do not hang down; secure any hanging
cables.
2. Check that the mount fixing bolts (15/2) are
tight, tighten them using suitable tools if
necessary.
3. Check whether any of the cable ties have
come loose fitting new ones if necessary.

Fig. 15 :

MTU

Cable on the engine

03.2003

E 531 686 / 04 E

Part
Page

Maintenance and repair


Maintenance

3
9

3.2.4.3.3 Checking all sensor glands for leakage


ID no.:

A-P-ECU-0005

The sensors on MTU/DDC Series 4000 engines are screwed into the mechanical assemblies on the engine
(pressure sensors, temperature sensors, speed sensors). Check the sensor glands for any signs of leakage.
1. Locate the sensor.
2. Check whether any pressurized medium is
escaping or has escaped (fluids leave a trail)
at the sealing surface between engine and
sensor flange; tighten the sensor gland using
suitable tools (open-end wrench) if necessary.
3. If it is not possible to seal off the gland in this
way, remove the sensor and fit a new seal.

Fig. 16 :

Example of a sensor gland


Sensor fitting is described in the engine documentation. Refer to the engine documentation
without fail before removing a sensor.

Please note that level sensor glands have extremely low tightening torques.
Overtightening will destroy these sensors. Refer to the engine documentation
for details of tightening torques.
CAUTION

E 531 686 / 04 E

03.2003

MTU

Part
Page

3
10

Maintenance and repair


Maintenance

3.2.4.3.4 Checking cables


ID no.:

A-P-ECU-0006
1

Insulate or replace (in case of severe damage)


damaged cables immediately.
1. Inspect all cables on the engine.

Fig. 17 :

MTU

2. If only the outer sheath is damaged rendering


individual wires visible (example 17/1), it is
quite sufficient to tape up the cable within
insulating tape providing that none of the individual wires have been damaged.
3. Replace the cable harness (or a part thereof)
if individual wires are bare or broken (example
17/2).

Examples of damaged cables

03.2003

E 531 686 / 04 E

Part
Page

Maintenance and repair


Maintenance

3.2.4.4

Cleaning

ID no.:

T-P-EMU-0002

3
11

System components

Engine Monitoring Unit EMU 1 on the engine

Sensors on the engine

Cabling on the engine

Cabling to peripheral assemblies and systems

Equipment

Soft, lint-free, non-abrasive cloth

Isopropyl alcohol

Requirements

Engine room accessible

Engine at a standstill

Additional safety notes

Observe general safety requirements: Chap. 3.1

Observe safety notes preceding the descriptions of the various activities

Be careful not to damage any cables when cleaning

Be sure to close the bayonet locks properly on any connectors which have been
disconnected

List of activities

ID no.

1. Clean Engine Monitoring Unit EMU 1.

A-P-ECU-0007
Page 12

2. Clean connectors.

A-P-ECU-0008
Page 13

E 531 686 / 04 E

03.2003

MTU

Part
Page

3
12

Maintenance and repair


Maintenance

3.2.4.4.1 Cleaning Engine Monitoring Unit EMU 1


ID no.:

A-P-ECU-0007
Engine Monitoring Unit EMU 1 (18/1) is fully enclosed in a housing. All the electronic assemblies
belonging to Engine Monitoring Unit EMU 1 are
integrated in this housing.
1. Clean the housing with a cloth moistened with
isopropyl alcohol.
2. Make sure that cable identification (18/2) is
legible; if not, render legible or replace.

Fig. 18 :

Cleaning Engine Monitoring Unit


EMU 1

Be careful not to damage anything when cleaning and ensure that the connectors on the housing, particularly those between cable harness and sensors, are
not loosened.
CAUTION

MTU

03.2003

E 531 686 / 04 E

Part
Page

Maintenance and repair


Maintenance

3
13

3.2.4.4.2 Cleaning the connectors


ID no.:

A-P-ECU-0008
Functionality may be impaired in the long term if
the connectors are excessively dirty. Remove dirt
(oil, grease, fuel etc.) for this reason.
1. Clean the surface of the connector (19/1) and
the shrink-fit part on the connector with a cloth
moistened with isopropyl alcohol.
2. Remove the connector if it is extremely dirty
(see page 7).
3. Clean the connector housing (19/2) and the
contacts thoroughly with isopropyl alcohol.
4. Clean the connector socket on the housing of
Engine Monitoring Unit EMU 1 thoroughly with
isopropyl alcohol.

2
1

Fig. 19 :

Cleaning connectors on Engine


Monitoring Unit EMU 1
Be careful not to damage anything when cleaning and ensure that the connectors on the housing, particularly those between cable harness and sensors, are
not loosened. Proceed as described on page 7 when establishing connections.

CAUTION

E 531 686 / 04 E

03.2003

MTU

Part
Page

3
14

Maintenance and repair


Troubleshooting

3.3

Troubleshooting

3.3.1

Fault symptoms which are not indicated by fault codes

The table below lists a number of possible fault symptoms which are immediately apparent to the operator.
No.

Fault symptom

Cause(s)

Rectification

See

Entire ECS-5 does not


respond when switched
on

1. Power supply unavailable

Check whether other


parts of the ships electrical system are also out
of order

Ships manual

Other parts of the


system do not work

Causes no. 2

Only ECS-5 is out of


order

Causes no. 3

2. Ships voltage missing

Switch on ships voltage

Ships manual

3. ECS-5 power supply


switched off, corresponding power circuit
breaker tripped

Visual inspection; reset


any power circuit breakers

Ships manual

4. Key switch (if provided) of the system


not switched on properly or not locked in
position

Turn the key counterclockwise, pull it out;


then reinsert it and turn it
clockwise as far as it will
go

Ships manual

5. Key switch faulty

Replace the key switch

Ships manual

MTU

03.2003

E 531 686 / 04 E

Part
Page

Maintenance and repair


Troubleshooting

No.
2

Fault symptom
Engine Monitoring Unit
EMU 1 not operational

Cause(s)

Rectification

1. Supply voltage for


Engine Monitoring
Unit EMU 1 missing

Check whether other


parts of the ECS-5 are
also out of order
Other parts of the
system do not work
Only Engine Monitoring
Unit EMU 1 is out of
order

2. Relay for supply voltage switching faulty

3. Upstream fusible
cutout (if provided)
faulty

4. Connector not plugged on correctly

E 531 686 / 04 E

03.2003

Switch on the system


and simultaneously
check whether corresponding relay activates
(visual inspection); if it
does not, fit new relay
(e.g. in Local Operating
Panel LOP 1, if provided)
Replace upstream fusible cutout (e.g. in Local
Operating Panel LOP 1,
if applicable)

Plug in connector properly and lock it in place

3
15

See

Fault symptom
no. 1
Causes no.
2, 3, 4

E 531 687
(if applicable
only)

E 531 687
(if applicable
only, see also
ships manual)
A-P-ECU-0003

MTU

Part
Page

3
16

3.3.2

Maintenance and repair


Troubleshooting

Faults indicated by system fault display

In addition to faults which are immediately apparent to the operator, Engine Monitoring Unit EMU 1 outputs
alarm messages via the CAN bus to Local Operating Panel LOP 1 and a superordinate Monitoring and Control System (if connected). These system faults are structured as follows when displayed:

Alarm
LO
SD

Alarm

P LUBEOIL
OVERTEMP EMU

ACK
UNACK

YEL
RED

Type of fault
Plain-text display
Acknowledgement status
Type of alarm

Fig. 20 :

Structure of system fault messages from Engine Monitoring Unit EMU 1

The first two letters have the following meanings:

Note:

MTU

DL Bus error (DEFAULT BUS LOST)


RL Bus error (REDUNDANT BUS LOST), fault in the bus system

SD Sensor defect (SENSOR DEFECT), failure of a sensor used to


acquire a measured variable

AL
LO
HI
SS
TD

Alarm (ALARM), signalling an inadmissible operating state


(LOW) Lower limit value violation
(HIGH) Upper limit value violation
(SAFETY SYSTEM) Fault detected by the safety system
(TRANSMITTER DEVIATION) Deviation of measured values between
first and second sensor
MG Message (MESSAGE)
This information is only displayed when a Local Operating Panel LOP 1 or superordinate
Monitoring and Control System with facilities for displaying alphanumeric messages must be
connected (e.g. MCS-5 type 1).

03.2003

E 531 686 / 04 E

Part
Page

Maintenance and repair


Troubleshooting

3
17

Engine Monitoring Unit EMU 1 or its functional periphery is the source of the following alarm messages:
Fault
code

Fault text

Fault description

001

SD OVERTEMP EMU

Temperature sensor for


EMU temperature measuring is faulty
Printed circuit board
EMB 1-01 of Engine
Monitoring Unit EMU 1
faulty

002

003

BD CAN_A

OVERRUN FAILURE
CAN_A

E 531 686 / 04 E

03.2003

Rectification

See

Replace Engine Monito- T-P-EMU-0001


ring Unit EMU 1

Default CAN bus


unavailable for one or
more of the following
reasons:
1. CAN interface of
Engine Monitoring
Unit EMU 1 faulty

Replace Engine Monito- T-P-EMU-0001


ring Unit EMU 1

2. Connection to CAN
bus cable faulty,
connectors not properly plugged in

Plug connectors in
properly

A-P-ECU-0003

3. Short-circuit
between the CAN_H
and CAN_L line

Rectify fault by
replacing cables

A-P-ECU-0006

4. Bus terminators missing or faulty

Check bus terminators


and solder on or
replace as necessary

5. Printed circuit board


EMB 1-01 of Engine
Monitoring Unit
EMU 1 faulty

Replace Engine Monito- T-P-EMU-0001


ring Unit EMU 1

See BD CAN_A

See BD CAN_A

See
BD CAN_A

MTU

Part
Page

3
18

Maintenance and repair


Troubleshooting

Fault
code

Fault text

Fault description

004

BD CAN_B

Redundant CAN bus


missing for one or more
of the following reasons
Replace Engine Monito- T-P-EMU-0001
ring Unit EMU 1

2. Connection to CAN
bus cable faulty,
connectors not properly plugged in

Plug connectors in
properly

A-P-ECU-0003

3. Short-circuit
between the CAN_H
and CAN_L line

Rectify fault by
replacing cables

A-P-ECU-0006

4. Bus terminators missing or faulty

Check bus terminators


and solder on or
replace as necessary

5. Printed circuit board


EMB 1-01 of Engine
Monitoring Unit
EMU 1 faulty

Replace Engine Monito- T-P-EMU-0001


ring Unit EMU 1

See BD CAN_B

OVERRUN FAILURE
CAN_B

See BD CAN_B

006

AL EMU OVERTEMP

Temperature sensor in
the housing of Engine
Monitoring Unit EMU 1
is too high; this may be
caused by:

MTU

TEMPERATURE
COMPENSATION
FAILURE

See

1. CAN interface of
Engine Monitoring
Unit EMU 1 faulty

005

007

Rectification

1. Engine room currently overheated

Improve ventilation,
determine and rectify
the cause of overheating

2. Printed circuit board


EMB 1-01 or Engine
Monitoring Unit
EMU 1 faulty

Replace Engine Monito- T-P-EMU-0001


ring Unit EMU 1

Temperature sensor of
Engine Monitoring Unit
EMU 1 faulty

Replace Engine Monito- T-P-EMU-0001


ring Unit EMU 1

03.2003

Ships manual

E 531 686 / 04 E

Part
Page

Maintenance and repair


Repair

3.4

Repair

3.4.1

Replacing EMU 1

ID no.:

T-P-EMU-0001

3
19

System components

Engine Monitoring Unit EMU 1 on the engine

Replacement Engine Monitoring Unit EMU 1 assembly

Equipment

Set of double-head open-end wrenches

Phillips screwdriver

Reference documentation

Engine Monitoring Unit EMU 1 documentation,


document no. E 531 686

Requirements

Engine room accessible

Engine at a standstill

Additional safety notes

Observe general safety requirements: Chap. 3.1

Observe safety notes preceding the descriptions of the various activities

Transfer the two memory modules from the old Engine Monitoring Unit EMU 1 to
the new one, otherwise engine operation not possible

List of activities

ID no.

1. Remove the unit comprising Engine Monitoring Unit EMU 1


housing and Engine Control Unit ECU 4 housing from the
engine.

A-P-ECU-0001
Page 21

2. Remove the old Engine Monitoring Unit EMU 1 from Engine


Control Unit ECU 4.

A-P-EMU-0001
Page 23

3. Remove the cover from Engine Monitoring Unit EMU 1.

A-P-EMU-0002
Page 24

4. Transfer the memory module from Engine Monitoring Unit


EMU 1 (take the memory module out of the old Engine Monitoring Unit EMU 1 and install it in the new Engine Monitoring
Unit EMU 1).

A-P-EMU-0003
Page 25

5. Fit the cover on Engine Monitoring Unit EMU 1.

A-P-EMU-0004
Page 26

E 531 686 / 04 E

03.2003

MTU

Part
Page

3
20

Maintenance and repair


Repair
6. Fit the new Engine Monitoring Unit EMU 1 onto Engine Control Unit ECU 4.

A-P-EMU-0005
Page 27

7. Install the unit comprising Engine Monitoring Unit EMU 1


housing and Engine Control Unit ECU 4 housing on the
engine.

A-P-ECU-0002
Page 28

Tips and tricks

MTU

Disassembly and assembly of the unit comprising Engine Monitoring Unit EMU 1
housing and Engine Control Unit ECU 4 housing is basically the same as disassembly and assembly of Engine Control Unit ECU 4 on its own.

Fit the plastic caps (22/4) to close off the connectors on Engine Monitoring Unit
EMU 1 (see step 8. on page 22).

03.2003

E 531 686 / 04 E

Part
Page

Maintenance and repair


Repair

3.4.1.1

Removing the housing of Engine Control Unit ECU 4 from the engine

ID no.:

A-P-ECU-0001
Engine Control Unit ECU 4 (21/1) is located on the
end of the engine (auxiliary PTO side). It is screwed to two mounting brackets (21/4 and 21/8) on
the engine via three metal cable shock absorbers
(21/3). The two adapter plates (21/2 and 21/7)
connect the housing of Engine Control Unit ECU 4
to the metal cable shock absorbers.

2
1

3
21

3
10

4
Proceed as follows to remove Engine Control Unit
ECU 4:
1. Disconnect the connectors (21/5) on the side
one after the other.
2. Turn the bayonet nut (21/7) of each connector
counterclockwise.
3. Unplug the connector from the housing.
4. Unplug all the connectors on Engine Control
Unit ECU 4 in the same manner.
5. Unscrew and remove the two hex-head
bolts (21/9 and 22/1) which connect the
housing of Engine Control Unit ECU 4 (21/1)
and the adapter plate at the bottom (bracket
21/7) (the hex-head bolts are screwed into the
housing of Engine Control Unit ECU 4 from
the rear).
8
7
Fig. 21 :

Engine Control Unit ECU 4 on the


engine

E 531 686 / 04 E

03.2003

MTU

Part
Page

3
22

Maintenance and repair


Repair

Hold the housing of Engine Control Unit ECU 4 to prevent it falling when the
second bolt is unscrewed at the top.

CAUTION
6. Unscrew and remove the two hex-head bolts
(21/10 and 22/2) which connect the housing of
Engine Control Unit ECU 4 and the adapter
plate at the top (plate 21/2) (the hex-head
bolts are also screwed into the housing of
Engine Control Unit ECU 4 from the rear).

7. Remove the housing of Engine Control Unit


ECU 4 (22/2) from the engine.
8. Cover the connectors with (plastic) caps
(22/4) when the housing of Engine Control
Unit ECU 4 has been removed from the
engine and the connectors are not plugged in
to prevent the ingress of dirt into the connectors.

3
1
Fig. 22 :

MTU

Engine Control Unit ECU 4 removed

03.2003

E 531 686 / 04 E

Part
Page

Maintenance and repair


Repair

3.4.1.2

Removing the housing of Engine Monitoring Unit EMU 1 from Engine


Control Unit ECU 4

ID no.:

A-P-EMU-0001

3
23

1. Place the unit comprising Engine Monitoring


Unit EMU 1 (23/2) and Engine Control Unit
ECU 4 (23/1) on a level surface.

Fig. 23 :

Engine Monitoring Unit EMU 1 and


Engine Control Unit ECU 4
2

2. Engine Monitoring Unit EMU 1 (23/2) is secured to the housing of Engine Control Unit ECU
4 (23/1) by three Allen screws (24/1, 24/2 and
24/3); undo them one after the other with an
Allen key.

3. There is a spring washer under each of the


screws; be careful not to loose them.

3
Fig. 24 :

Undoing fixing screws on Engine


Monitoring Unit EMU 1

E 531 686 / 04 E

03.2003

MTU

Part
Page

3
24

Maintenance and repair


Repair

3.4.1.3

Removing the cover of Engine Monitoring Unit EMU 1

ID no.:

A-P-EMU-0002
1. Positiion Engine Monitoring Unit EMU 1 such
that the sockets are facing you.
2. The cover is secured by eight Phillips screws
on the housing of Engine Monitoring Unit
EMU 1, undo them one after the other with a
Phillips screrwdriver.
3. There is a plain washer and a spring washer
under each of the screws; be careful not to
loose them and ensure that they do not fall
into the housing.

Fig. 25 :

Removing the cover


4. Lift off the cover; be careful not to damage the
seal (e.g. if it sticks to the cover).

Fig. 26 :

MTU

Removing the cover

03.2003

E 531 686 / 04 E

Part
Page

Maintenance and repair


Repair

3.4.1.4

Transferring the memory module of Engine Monitoring Unit EMU 1

ID no.:

A-P-EMU-0003

3
25

The data module (program memory MEM 6-01/A,


27/1) must first be removed from the old Engine
Monitoring Unit EMU 1. Proceed as follows:
1. Grip data module MEM 6-01 (27/1) between
thumb and forefinger at the roughened surfaces and pull it straight off printed circuit board
ECB 4-01.
2. Remove the (unprogrammed!) data module
from the new EMU 1 in the same manner.

Fig. 27 :

Data module of Engine Monitoring


Unit EMU 1
3. Place the programmed data module MEM
6-01 (28/1) onto the two connector strips on
printed circuit board EMB 1-01 (28/2).
Check polarity!

1
3
CAUTION

Data module MEM 6-01


(28/1) cannot be inserted
when positioned the
wrong way round. Turn it
through 180 in this case.

4. Press data module MEM 6-01 (28/1) firmly


into the connector strips until the lower edge
(28/3) of the data module (28/1) touches printed circuit board ECB 4-01 (28/4).

4
Fig. 28 :

Inserting engine data and program


memory module EDM (MEM 6-01)

E 531 686 / 04 E

03.2003

MTU

Part
Page

3
26

Maintenance and repair


Repair

3.4.1.5

Fitting the cover of Engine Monitoring Unit EMU 1

ID no.:

A-P-EMU-0004
1. Check that the cord seal is not damaged,
replace the seal if necessary.
2. Check that the seal is firmly seated in the
groove in the housing.
3. Fit the cover onto the housing of Engine Monitoring Unit EMU 1 making sure it is the right
way round; fit the cover on the housing such
that the connector designations face the side
on which the connectors are located.

Fig. 29 :

Fitting the cover


4. Screw the ten screws together with their plain
washers and spring washers into the bores
and tighten by hand.

5. Tighten diagonally-opposed screws one after


the other (see example in fig. 30, first screw
(30/1) then screw (30/2) proceeding with
screw (30/3) and screw (30/4), etc.).

3
Fig. 30 :

MTU

Screwing down the cover

03.2003

E 531 686 / 04 E

Part
Page

Maintenance and repair


Repair

3
27

3.4.1.6

Fitting the housing of Engine Monitoring Unit EMU 1 onto Engine Control
Unit ECU 4

ID no.:

A-P-EMU-0005
2

1. Turn Engine Control Unit ECU 4 (31/4) with


the top facing down such that the connectors
face away from you.

2. Clean the contact surfaces of Engine Monitoring Unit EMU 1 (31/5) and Engine Control
Unit ECU 4 (31/4) thoroughly.
3. Place Engine Monitoring Unit EMU 1 (31/5)
onto Engine Control Unit ECU 4 (31/4).
4. Engine Monitoring Unit EMU 1 (31/5) is
secured to the housing of Engine Control Unit
ECU 4 (31/4) by three Allen screws (31/1,
31/2 and 31/3), screw them into the bores one
after the other by hand.
5. Tighten the three Allen screws (31/1, 31/2 and
31/3) with an Allen key.
6. There is a spring washer under each screw;
be sure to fit new spring washers on assembly.

5
Fig. 31 :

Inserting fixing bolts on Engine


Monitoring Unit EMU 1

E 531 686 / 04 E

03.2003

MTU

Part
Page

3
28

Maintenance and repair


Repair

3.4.1.7

Fitting the housing of Engine Control Unit ECU 4 on the engine

ID no.:

A-P-ECU-0002
1. Place Engine Control Unit ECU 4 on the adapter plates (plate 32/5 and bracket 32/4).

2. Screw the two hex-head bolts (32/2) through


the plate (32/5) into the housing of Engine
Control Unit ECU 4 by hand.
3. Screw the two hex-head bolts (32/1) through
the bracket (32/4) into the housing of Engine
Control Unit ECU 4 by hand.
5

4. Tighten all four bolts with a suitable open-end


wrench.
5. Connect up the first connector (33/1) of the
cable harness at the appropriate socket (33/2)
of Engine Control Unit ECU 4.

3
4
Fig. 32 :

Engine Control Unit ECU 4 mounting


6. Turn the bayonet union nut (33/4) clockwise
with connector pliers (33/2) until it locks into
place.
Do not tighten by
hand!

CAUTION
4

Tightening bayonet
union nuts by hand is
not sufficient. There is a
danger that the lock will
not engage fully resulting in the connector
coming loose when the
engine is running.
Always tighten union
nuts with connector
pliers!

2
1
3
Fig. 33 :

MTU

7. Connect up and lock the other connectors in


the same manner.

Engine Control Unit ECU 4 on the


engine
03.2003

E 531 686 / 04 E

Part
Page

Service manual
Table of contents

4
I

Part 4

Service manual

Not applicable
4

Not applicable

E 531 686 / 04 E

03.2003

MTU

Part
Page

4
II

Service manual
Table of contents

(This page intentionally blank)

MTU

03.2003

E 531 686 / 04 E

Part
Page

Illustrated parts catalog


Table of contents

5
I

Part 5

Illustrated parts catalog

E 531 686 / 04 E

03.2003

MTU

Part
Page

5
II

Illustrated parts catalog


Table of contents

(This page intentionally blank)

MTU

03.2003

E 531 686 / 04 E

Preface

Preface
This catalog is published for parts requisitioning purposes and provides assistance in engine disassembly and
reassembly. It contains a complete list of all engine components, including those which are not available as
replacement parts.
Illustrations
- The page heading includes a five-digit illustrated table number and, in the second section, an additional
illustration registration number.
Explanation of Columns
- C/N (Callout No.): Provides a cross-reference from illustration to text section. Non-illustrated parts are indicated
by the suffix Z after the C/N.
- Part No.: This is the number valid for ordering the associated part.
- Designation: In addition to the precise part name, this column provides indication as to whether it is a single
part, or an element of an assembly or functional group. An indented designation indicates the part concerned is
included in the previous less or non-indented designation.
- Q/U (Quantity in Unit): This column indicates the quantity of this part required for the functional group. Qty. 0
indicates part is replaced by an SA or KW part or that it is a repair stage component.
- U/M (Unit of Measure): The 2-character codes indicate: EA = each, KG = Kilogramm, MR = Meter, RL = Roll,
SE = Set.
- FN (Footnote): Provides additional parts information. The codes have the following meaning:
AB

Supplied as a complete assembly. Repair by manufacturer only.

KE

Individual parts not obtainable through the parts supply system

KF

Calibrated part. For ordering, observe Ordering Procedure as described below.

NB

As required

- Supplementary Designation: This column contains additional information, such as applicable standards,
subcontractor designations etc.
- Item No.: This is the line identification number within the parts group.
- Remarks: This column is intended for supplementary information.
Amendments Service
Part No. Changes and amendments which occur after publication of the catalog will not be published. We therefore
recommend updating of the catalog part numbers by the end user. This information is provided, for instance, in
order confirmations and/or on equipment labels.
Cross-reference List
A cross-reference list is published in association with this catalog which provides a consecutively numbered
reference to all parts listed in the catalog and their location on/in the engine. The list appears at the end of the
catalog.

EK175E

- 02.02 -

MTU

Preface

Ordering Procedure
The following information is essential for replacement order processing:
-

Order number

MTU serial number and type (see engine name plate)

Part number

Designation

Quantity and unit of measurement

Unit designation (e.g. A056)

When ordering a calibrated part (marked by "KF" in the "FN" column), add the following additional information:
If the calibration No. is known (see part's nameplate):
Add the calibration No., preceded by an oblique stroke, as an extension to the part number ("/xxxxx"); e.g.: 002 536
28 10/E1234.
Here, the extension "E1234" would be the part's calibration number on the nameplate.
If the calibration No. is not known:
Give a detailed description of the required part's installation location by quoting the complete Device Description
code (e.g. "= 37.1.1 + A022 - F003") plus the part number extension "/77" (e.g. 500 536 28 10/77).
In this case, the calibrated spare part will be supplied under a new part number. The Device Description is found on
the nameplate at the part's installation location, or in the corresponding Wiring Diagram.
When ordering a non-calibrated adjustable part (marked by "KF" in the "FN" column) which should not be
calibrated by the factory:
Add extension "/76" to the part number (e.g. 002 536 28 10/76).
To avoid errors, please confirm all telephone orders in writing.
Factory Repairs
Parts shipped to MTU for repair should have MTU order No. and engine serial number identification (tag or label,
for example).
Exchange Components (Reman)
Exchange components are parts overhauled by the manufacturer, providing the same properties with regard to
service life and quality as new parts.
Components which are included in the reman exchange procedure are marked by the following letters added
before the item number:
for instance:

E 524 010 3520 = new component in exchange procedure


R 524 010 3520 = reman component in exchange procedure
C 524 010 3520 = used part (core)

Exchange Procedure
With the introduction of exchange components, the so-called core deposit will also be charged for new parts. The
core deposit will be indicated separately on the invoice and the respective value will be credited upon return of
reusable components.
For further information refer to Service Information 01/S0028.

MTU

EK175E

- 02.02 -

508 95
00030B

EDITION :

04.03

GAPL

508

EGC : 508
PROJECT

EABB

ZUBEHOER FUER MOTORREGLER (ELEKTRONIS

CATALOG

ENGINE GOVERNOR (ELECTRONIC) CONTROL

ILLUST.TABLE:

508 95

REG.NO.

00030B

GA/SA/KW : 510.00393

E531686/04DE

ORTZ

BESTELLNUMMER

BENENNUNG

STO

BZEH

FN

ZUSATZBEZ./SUPPLEMENTARY DESIGNATION

C/N

PART NO.

DESIGNATION

Q/U

U/M

FN

BEMERKUNG / REMARKS

EA

AB

EA

EA

M 6 X 10 DIN 912 8.8 DBL 9400.00

500006

EA

M 6 X 20 DIN 912 8.8 DBL 8451.21

500008

EA

A 6,4 DIN 125 140 HV DBL 8451.11

500010

01

5275304360/S0002

ZB GEH. EMU 1-01/B

POS.-NR.
ITEM
500002

HOUSING
02

000 546 12 20

MASSEBAND

500004

EARTHING STRIP
03

000912 006001

ZYLINDERSCHRAUBE
SCREW

04

000912 006018

ZYLINDERSCHRAUBE
SCREW

05

000125 006431

SCHEIBE
WASHER

- 1 -

- 2 -

Part
Page

Plant-specific configuration
Table of contents

6
I

Part 6

Plant-specific configuration

Not applicable
6

Not applicable

E 531 686 / 04 E

03.2003

MTU

Part
Page

6
II

Plant-specific configuration
Table of contents

(This page intentionally blank)

MTU

03.2003

E 531 686 / 04 E

Part
Page

Mechanical and electrical installation


Table of contents

7
I

Part 7

Mechanical and electrical installation

E 531 686 / 04 E

03.2003

MTU

Part
Page

7
II

Mechanical and electrical installation


Table of contents

(This page intentionally blank)

MTU

03.2003

E 531 686 / 04 E

Mechanical and electrical installation


Table of contents

Part
Page

7
III

Table of contents
7

Mechanical and electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1

Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2

General information about this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2.1

Task duration and personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2.2

Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2.3

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

Plant/system overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4

Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5.1

Routing cables between installation locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5.2

Installing the EMU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5.2.1

Mounting Engine Monitoring Unit EMU 1 on Engine Control Unit ECU 4 . . . . . . . . . . . . . .

7.5.2.2

Mounting Engine Control Unit ECU 4 on the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

7.6

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

7.6.1

Connection to Local Operating Panel LOP 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

7.6.2

Connection of the sensors on the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

E 531 686 / 04 E

03.2003

MTU

Part
Page

7
IV

Mechanical and electrical installation


Table of contents

(This page intentionally blank)

MTU

03.2003

E 531 686 / 04 E

Part
Page

Mechanical and electrical installation


Safety requirements

Mechanical and electrical installation

7.1

Safety requirements

7
1

IMPORTANT:
These safety requirements shall be read and observed by all personnel
involved in operation, care, maintenance, repair, installation or commissioning
of the products described.
Furthermore, the following shall be observed:

The safety requirements (if provided) in other relevant MTU manuals

National accident prevention and safety standards

Warning and safety information and operating and limit values attached to the products as
required
Appropriate regulations usual in the industry
The safety notes (if provided) in the text of this manual

Conventions for safety notes in the text


Where necessary, this manual includes highlighted safety notes indicated by a signal word. These safety
notes shall be observed to avoid injury or damage.
This type of note indicates a danger which may lead to injury or death.

DANGER

This type of note indicates a danger which may lead to damage or


destruction of the product described or another part of the system.

CAUTION

Intended use and user qualifications


All devices and system components may only be put to their intended use.
Operation, maintenance, repair, installation and commissioning shall only be performed by qualified and
authorized personnel.

E 531 686 / 04 E

03.2003

MTU

Part
Page

7
2

Mechanical and electrical installation


Safety requirements

Safety requirements for installation and commissioning


To ensure constant readiness and reliability of the product, installation and commissioning work shall be
performed in accordance with the instructions given in the appropriate manual by authorized personnel using
suitable or special MTU tools tools as necessary.
Prior to commencing work, the power supply of the appropriate areas must be switched off and secured
against unauthorized switching on. Any measures requiring power supply are expressly defined as such at
the appropriate place in the manual.
Genuine spare parts only may be used to replace defective components or assemblies. The manufacturer
accepts no liability whatsoever for damage caused by using other spare parts. The manufacturers warranty
shall also be voided in such cases.
The manufacturer shall not be held liable if unauthorized changes or modifications are made to the product
and the warranty shall be voided.
During installation, protect the assemblies concerned and their surroundings from dust as far as possible.
Should this prove impractical, always clean away any dust or deposits immediately.
Observe the information in the manual pertaining to installation locations and the associated environmental
conditions. Take account of the admissible exposure of the component to external influences as indicated by
the IP rating in the manual.
Use only those connectors, cables and installation materials expressly approved by MTU for mechanical and
electrical installation.
Dimensional tolerances shall be strictly adhered to on installing the product.
The product/assemblies shall be handled carefully at all times.
Mechanical safety features shall be installed as specified in the appropriate manual/installation instructions
and fixing screws secured in accordance with the relevant instructions.
Ensure that the required sealing and protection against the ingress of moisture are afforded on installing in
exposed locations.
On completion of installation work, ensure that no superfluous parts (tools, installation materials etc.) remain
inside devices or the system.
Ensure that a suitable operating voltage is available and check polarity.

MTU

03.2003

E 531 686 / 04 E

Mechanical and electrical installation


General information about this manual

7.2

Part
Page

7
3

General information about this manual


Refer to order-specific documents (e.g. drawings) if necessary in case of deviations from the
information provided in this manual.

7.2.1

Task duration and personnel qualification

Information about task duration is only intended to serve as a guide and is based on the work being carried
out under normal working conditions. The amount of time required may deviate from the times stated in
some cases.
The abbreviations explained in the preface to this manual are used to specify the minimum qualifications for
users carrying out the work described.
Familiarity with the contents of Part 1 of this manual is pre-requisite.

7.2.2

Terminology

The following terms are used in this manual:

Task:
A group comprising several activities. Performing all activities not necessarily in a specific
order results in the task being fulfilled.

Activity:
Sequence of steps to be carried out in a specific order. The result of each activity is a part of
the superordinate task.

Step:
The sequential execution of certain steps forms a superordinate activity.

Work:
Generic term for tasks, activities and steps.

E 531 686 / 04 E

03.2003

MTU

Part
Page

7
4

7.2.3

Mechanical and electrical installation


General information about this manual

Structure

The chapters in this manual describing specific work are structured as shown in fig. 34.

Task
overview

Task
descriptions

Table
(Maintenance
schedule/fault code
table/troubleshooting
table)

Cross-referenced by
Task ID

Fig. 34 :

Activity
descriptions

Listing

Illustrated text

Listing

Illustrated text

Listing

Illustrated text
Cross-referenced by
Activity ID

Structure of the sub-chapters and terminology

Checkboxes are provided on the right margin of task description pages allowing each item to be checked off.
Note:

MTU

Task and activity descriptions are modular and often formulated in general terms (e.g. for a
plant with several control consoles). The information provided must be applied to the plant concerned by analogy.

03.2003

E 531 686 / 04 E

Part
Page

Mechanical and electrical installation


Plant/system overview

7.3

7
5

Plant/system overview

12

11

1
2

10
9
Fig. 35 :

Hardware structure

Pos.

Name

Meaning

LOP 1

Local Operating Panel with display and controls

GCU/GMU 1

Gear Control and Monitoring Unit

EMU 1

Engine Monitoring Unit, fitted on the engine

ECU 4

Engine Control and Monitoring Unit, fitted on the engine

Sensors/actuators

Sensors and actuators for the engine

Sensors/actuators

Sensors and actuators for the gear

Sensors/actuators

Sensors and actuators in the engine room

Signalling device

Signalling device in the engine room

Engine

10

Gear

11

RCS, MCS

Interface to other systems, see ECS-5 system description


Part 1, document no. E 531 892.

12

ECS-5 system demarcation


line

E 531 686 / 04 E

03.2003

MTU

Part
Page

7
6

7.4

Mechanical and electrical installation


Cabling

Cabling

Dat/Pow/Sig

MCS, RCS
U1
U2

LOP 1

1
EMU

ECU

M
G
M

Fig. 36 :

Cabling

Legend
Pow
Sig
Dat

Power supply cable


Signal cable
Data cable

Pos.

Meaning

Type

Local Operating Panel LOP 1 EMU 1 connection, cable W005

Exhaust temperature sensor connection, cable W3

Sensor connection, cable W2

MTU

Supplier

Pow, Sig,
Dat

MTU

Pow

MTU

Dat, Sig

MTU

03.2003

E 531 686 / 04 E

Part
Page

Mechanical and electrical installation


Mechanical installation

7.5

7
7

Mechanical installation
Do not open the devices!
Never open any of the devices during mechanical installation. Never allow swarf or
small parts to fall into a housing.
MTU accepts no liability for damage incurred by foreign bodies in any of the
devices.

CAUTION

7.5.1

Routing cables between installation locations

ID no.:

T-E-EMU-0001
Duration:

180 min.

Qualification:

E2

List of activities

ID no.

1. Route cable W3 to connect the individual exhaust temperature


sensors to the installation location of Engine Monitoring Unit
EMU 1, connector X13.

------

2. Route cable W2 between the sensors and the installation location of Engine Monitoring Unit EMU 1, connector X12.

------

3. Route cable W005 between Local Operating Panel LOP 1 and


the installation location of Engine Monitoring Unit EMU 1,
connector X11.

------

Additional information

Carry out all procedures consecutively for each propulsion line separately.

As the devices have not yet been mounted, check that the cables are long enough
to allow the connectors to be plugged into the devices when mounted.

E 531 686 / 04 E

03.2003

MTU

Part
Page

7
8

Mechanical and electrical installation


Mechanical installation

7.5.2

Installing the EMU

ID no.:

T-E-EMU-0002
Duration:

240 min.

Qualification:

E2

System components/devices

Engine Monitoring Unit EMU 1

Engine Control Unit ECU 4

Fixing screws

Requirements

Engine Control Unit ECU 4 must be dismounted

Equipment

Tool for tightening screws (socket wrench, screwdriver etc. depending on type)

List of activities

ID no.

1. Mounting Engine Monitoring Unit EMU 1 on Engine Control


Unit ECU 4.

A-P-EMU-0005
Page 9

2. Mounting the unit comprising the housings of Engine


Monitoring Unit EMU 1 and Engine Control Unit ECU 4 on the
engine.

A-P-ECU-0002
Page 28

Additional information

MTU

Carry out all procedures consecutively for each propulsion line separately.

03.2003

E 531 686 / 04 E

Part
Page

Mechanical and electrical installation


Mechanical installation

7.5.2.1

Mounting Engine Monitoring Unit EMU 1 on Engine Control Unit ECU 4

ID no.:

A-P-EMU-0005
2

7
9

1. Turn Engine Control Unit ECU 4 (37/4) with


the top facing down such that the connectors
face away from you.

2. Clean the contact surfaces of Engine Monitoring Unit EMU 1 (37/5) and Engine Control
Unit ECU 4 (37/4) thoroughly.
3. Place Engine Monitoring Unit EMU 1 (37/5) on
Engine Control Unit ECU 4 (37/4).
4. Engine Monitoring Unit EMU 1 (37/5) is
secured to the housing of Engine Control Unit
ECU 4 (37/4) by three Allen screws (37/1,
37/2 and 37/3), screw them into the bores one
after the other by hand.
5. Tighten the three Allen screws (37/1, 37/2 and
37/3) with an Allen key.
6. There is a spring washer under each screw;
be sure to fit new spring washers on assembly.

5
Fig. 37 :

Inserting fixing bolts on Engine


Monitoring Unit EMU 1

E 531 686 / 04 E

03.2003

MTU

Part
Page

7
10

Mechanical and electrical installation


Mechanical installation

7.5.2.2

Mounting Engine Control Unit ECU 4 on the engine

ID no.:

A-P-ECU-0002
1. Place Engine Control Unit ECU 4 on the adapter plates (plate 38/5 and bracket 38/4).

2. Screw the two hex-head bolts (38/2) through


the plate (38/5) into the housing of Engine
Control Unit ECU 4 by hand.
3. Screw the two hex-head bolts (38/1) through
the bracket (38/4) into the housing of Engine
Control Unit ECU 4 by hand.
5

4. Tighten all four bolts with a suitable open-end


wrench.
5. Connect up the first connector (39/1) of the
cable harness at the appropriate socket (39/2)
of Engine Control Unit ECU 4.

3
4
Fig. 38 :

Engine Control Unit ECU 4 mounting


6. Turn the bayonet union nut (39/4) clockwise
with connector pliers (39/2) until it locks into
place.
Do not tighten by
hand!

CAUTION
4

Tightening bayonet
union nuts by hand is
not sufficient. There is a
danger that the lock will
not engage fully resulting in the connector
coming loose when the
engine is running.
Always tighten union
nuts with connector
pliers!

2
1
3
Fig. 39 :

MTU

7. Connect up and lock the other connectors in


the same manner.

Engine Control Unit ECU 4 on the


engine
03.2003

E 531 686 / 04 E

Mechanical and electrical installation


Electrical installation

7.6

Electrical installation

7.6.1

Connection to Local Operating Panel LOP 1

Part
Page

7
11

Connection is established by means of a pre-cut cable (see chap. 7.4). Connect this cable to the appropriate
connectors on Local Operating Panel LOP 1 and Engine Monitoring Unit EMU 1 (both connectors are coded
and cannot be confused).

7.6.2

Connection of the sensors on the engine

All the sensors on the engine are connected by pre--cut cable harnesses with moulded connectors routed in
corrugated tubes. The scope of sensors is order-dependent. No other connections need be established on
the engine. It is only necessary to plug in the two connectors X12 and X13 at the EMU (see chap. 7.5.2.2).

E 531 686 / 04 E

03.2003

MTU

Part
Page

7
12

Mechanical and electrical installation


Electrical installation

(This page intentionally blank)

MTU

03.2003

E 531 686 / 04 E