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Service Publication

Gear Control and Monitoring Unit


GCU/GMU 1
DDC/MTU series 2000
MTU/DDC series 4000
Marine applications

Documentation Parts 1, 3, 4, 5

E 532 091 / 00 E

DaimlerChrysler Off-Highway
MTU assuring you:
 ISO 9001 certification
Quality assurance in design/development, production, installation and service
 CE conformity
- Guideline 73/23/EEC Low voltage guideline
dated February 19, 1973 with amendment dated July 22, 1993
(guideline 93/68/EEC)
- Guideline 89/336/EEC Guideline on electromagnetic compatibility
dated May 3, 1989 with amendment dated April 28, 1992
(guideline 92/31/EEC)
CE conformity is influenced if the product is installed incorrectly, an assembly or system is misused
and/or genuine MTU components are not used.

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.
Guide Page I

General information about documentation

Documentation structure

Documentation Title/contents Target group(s)


Part
1 Structure and function Operating personnel etc.

2 Operation Operating personnel

3 Maintenance and repair Plant personnel

4 Service manual Electronic service personnel

5 Illustrated parts catalog Operating personnel, electronic service


personnel, logistics personnel
6 Plant-specific configuration Electronic service personnel, installation
personnel, start-up personnel
7 Mechanical and electrical Installation personnel
installation (electromechanical/mechatronic engineer)
8 Initial start-up Start-up personnel

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

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, separa-
ted 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.

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Page II Guide

Symbols

Rectification of a fault marked with this symbol either requires the customers 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 operating personnel.

Further troubleshooting or fault rectification requires work to be performed on the engine with
reference to the engine documentation.

Further troubleshooting or fault rectification requires mechanical work to be performed on other


assemblies or equipment with reference to the relevant documentation.

This symbol indicates cross-references to other manuals.

' Fig. X Refer to fig. X for more information (cross reference to a figure).

MTU - 04.2002 - E 532 091 / 00 E


Structure and function Part 1
Table of contents Page I

Part 1

Structure and function

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Part 1 Structure and function
Page II Table of contents

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Structure and function Part 1
Table of contents Page III

Table of contents

1 Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Use and structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


1.1.1 Use of the Gear Control and Monitoring Unit GCU/GMU 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.2 Structure of the Gear Control and Monitoring Unit GCU/GMU 1 . . . . . . . . . . . . . . . . . . . . . 3
1.1.2.1 External Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2.2 Internal structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.2.3 Signal processing GCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1.2.4 Signal processing PIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1.3 Printed circuit boards of the GCU/GMU 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1.3.1 Gear Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1.3.2 Additional gear monitoring functions (Gear Monitoring Unit) . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.1 General information about the function of the Gear Control and Monitoring Unit GCU/GMU 1 . . .
16
1.2.2 Functions of the Gear Control and Monitoring Unit GCU/GMU 1 . . . . . . . . . . . . . . . . . . . . . 17
1.2.2.1 Field bus PCS-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.2.2 Control functional section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.2.3 Monitoring functional section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.2.4 Data transfer via CAN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.2.5 Changeover from remote control mode to local mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.2.6 Connecting remote control systems of other manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.3 Electrical power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.4 Function of the printed circuit boards GCM 1 and ROB 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 25


1.4.1 Printed circuit board GCM 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.4.2 Printed circuit board ROB 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.5 Data storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27


1.5.1 Overview of data structures which can be configured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.5.2 Software modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.5.2.1 Initial program loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.5.2.2 Basic software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.5.2.3 Logic programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.5.2.4 Project implementation tables for I/O channels and logic programs . . . . . . . . . . . . . . . . . . . 28
1.5.2.5 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.5.3 Redundant back-up of project implementation data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.6 Connecting the Gear Control and Monitoring Unit GCU/GMU 1 . . . . . . . . . . . . . . . . . . . . . . 29


1.6.1 Gear Control Unit GCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.6.2 Gear Monitoring Unit GMU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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Part 1 Structure and function
Page IV Table of contents

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Structure and function Part 1
Use and structure Page 1

1 Structure and function

1.1 Use and structure

1.1.1 Use of the Gear Control and Monitoring Unit GCU/GMU 1

Fig. 1: Gear Control and Monitoring Unit GCU/GMU 1

The Gear Control and Monitoring Unit GCU/GMU 1 can be used for various gearboxes
and is an interface between the Propulsion Control System PCS-5, the MTU Remote Con-
trol System RCS-5 (or the remote control system of another manufacturer) and the gear-
box.
The principal tasks are:
 For the gearbox:
- Connecting the gearbox sensors and watchdogs, activating the solenoid
valves on the gearbox
- Power supply to the gearbox sensors

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Part 1 Structure and function
Page 2 Use and structure

 For the plant:


- Supply voltage feed from the Local Operating Panel LOP 1
- Interfaces (CAN bus) for connection to the Propulsion Control System
PCS-5 and thus for connection to the MTU Remote Control System RCS-5
- Signal inputs and outputs (parallel) for connecting remote control systems
of other manufacturers
 For the operator:
- In local control, the interface to the operator takes the form of appropriate
keys on the Local Operating Panel LOP 1
- Depending on the gearbox type, the Local Operating Panel includes buttons
for ahead, astern and neutral (reversing gear) or for engaged and disen-
gaged (step-down gear)

One Gear Control and Monitoring Unit GCU/GMU 1 is used for each engine
and therefore for each clutch.

The Gear Control and Monitoring Unit GCU/GMU 1 is located in the engine room close to
the gearbox which is assigned to it. It is connected to the other assemblies of the Propul-
sion Control System PCS-5 (Local Operating Panel LOP 1) by means of a prefabricated
connection cable. Cable entries on the underside of the housing are used for the link-up to
the gearbox cabling.

Reference documentation:
The integration of the Gear Control and Monitoring Unit GCU/GMU 1 in the
overall system is documented in the system description of the propulsion con-
trol system Propulsion Control System PCS-5, MTU/DDC Series 4000, Marine
Application, document no. E 531 693.

The range of measuring points provided by the Gear Control Unit is expanded on the
monitoring side. This Gear Control and Monitoring Unit GCU/GMU 1 part also contains a
second, independent safety system for protecting the gearbox. The features of the moni-
toring system are as follows:
 Limit value monitoring of important measuring points
 Communication with equipment in the PCS-5 and the higher-level system via
field bus PCS-5 (CAN bus)
 Output of an engine stop signal in the event of a limit value violation (safety
channels)

The following division of functions is thus established:


 GCU: Monitoring and control
 GMU: Expansion of monitoring and safety system

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Structure and function Part 1
Use and structure Page 3

1.1.2 Structure of the Gear Control and Monitoring Unit GCU/GMU 1

1.1.2.1 External Structure

6 4

Fig. 2: Gear Control and Monitoring Unit GCU/GMU 1 - External structure

1 Front door
2 Plug X21 (to Local Operating Panel LOP 1)
3 Grounding screw
4 Cable entries (supplied loose)
5 Cable to the gearbox or to remote control systems of other manufacturers
6 Cable entry plate
7 Door handle
8 Door lock

A removable flange plate (cable entry plate) on the underside of the Gear Con-
trol and Monitoring Unit GCU/GMU 1 is prepared for accommodating the cable
entries (gearbox cabling or remote control systems of other manufacturers).

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Part 1 Structure and function
Page 4 Use and structure

1.1.2.2 Internal structure

11 3

4
5
10

9 -A040
-A030

8
7

Fig. 3: Gear Control and Monitoring Unit GCU/GMU 1 - Internal structure

1 Housing
2 Holes for wall-mounting
3 Mounting plate
4 GCM for Gear Control Unit GCU
5 Holder for internal cable harness (MTU) and external cable harness (from cable entries)
6 Plug X21
7 External grounding screw
8 Holder for external ship wires
9 PIM 2 for Gear Monitoring Unit GMU
10 Grounding cable
11 Internal grounding screw

Two modules are used in the Gear Control and Monitoring Unit GCU/GMU 1:
 A GCM for gear control and monitoring
 A PIM Type 2 for expanded gear monitoring functions

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Structure and function Part 1
Use and structure Page 5

Gear Control Module (GCM)

This module is equipped with the printed circuit boards shown in Fig. 4.

MPU 23

BOB 1

ROB 1

AIB 1
BIB 2

ROB 1

GCM 1

Fig. 4: Gear Control Module (GCM)

The range of functions of the Gear Control Module (GCM) is summarised below:
 =21.X+A002-A030: GCU
(Gear Control Unit); the principal task here involves receiving and processing
signals for gear control. Furthermore, this module contains the signal inputs
and signal outputs for connecting another manufacturers RCS as well as a
safety circuit.

A housing with a special connection PCB GCM and two passive relay printed circuit
boards ROB 1 are used for multiplying and distributing the signals as required in the Gear
Control Unit (GCU). This approach considerably simplifies the connection.

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Part 1 Structure and function
Page 6 Use and structure

Peripheral Interface Module PIM

The Peripheral Interface Module PIM 2 forms the Gear Monitoring Unit GMU. It is
equipped with the printed circuit boards shown in Fig. 5.

MPU 23

MFB 1
AIB 1

BIB 2

COB 1

Fig. 5: Peripheral Interface Module of the Gear Monitoring Unit GMU 1

The range of functions of the Peripheral Interface Module PIM 2 (additional Gear Monitor-
ing Unit GMU) is summarised below:
 =21.X+A002-A040: GMU
(Gear Monitoring Unit); the principal task of this Peripheral Interface Module
PIM involves receiving and processing signals for additional gear monitoring
functions. In addition, this unit contains a redundant safety circuit.

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Structure and function Part 1
Use and structure Page 7

1.1.2.3 Signal processing GCM

The tables below describe the individual inputs and outputs of the GCM in the following
applications:
 Connection to an MTU Remote Control System RCS-5
 Connection to a remote control system of another manufacturer

Signal processing when using the MTU Remote Control System RCS-5

Item No. PCB Functions Remarks

4/1 =21.X+A002-A030 MPU 23 Outputs: -


GCU AIB 1  Valve activation:
BOB 1 - Ahead or engage**
BIB 2 - Neutral or disengage**
ROB 1 - Astern**
ROB 1
 Engine stop
 Spare relay
Inputs:
 Control oil pressure
 Lube oil pressure*
 Oil temperature
 Oil filter pressure (binary signal)
 External disengagement request
 Trolling mode active
 Checkbacks:
- Ahead active or engaged**
- Neutral or disengaged**
- Astern active**
Interfaces:
 PCS field bus

* Optional, presence depends on gearbox version

** Depending on the version of the Propulsion Control System PCS-5:


D with reversing gear
D with step-down gear

Reference documentation:
The description of the functions and the structure of the individual printed circuit
boards within the GCM is part of the MTU documentation Process Level As-
sembly Catalog MCS-5, part 1, document no. E 531 439 (exception: printed
circuit board GCM 1 and relay printed circuit board ROB 1, see chap. 1.4).

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Part 1 Structure and function
Page 8 Use and structure

Signal processing when using a remote control system of another manufacturer

Item No. PCB Functions Remarks

4/1 =21.X+A002-A030 MPU 23 Outputs: -


GCU AIB 1  Valve activation:
BOB 1 - Ahead or engage**
BIB 2 - Neutral or disengage**
ROB 1 - Astern**
ROB 1
 Engine stop
 Checkbacks:
- Ahead active or engaged**
- Neutral or disengaged**
- Astern active**
 Disengagement window
 Local mode active
 Spare relay
Inputs:
 Control oil pressure
 Lube oil pressure*
 Oil temperature
 Oil filter pressure (binary signal)
 External disengagement request
 Trolling mode active
 Checkbacks:
- Ahead active or engaged**
- Neutral or disengaged**
- Astern active**
 Signal from another manufacturers
RCS:
- Request astern engage**
- Request neutral or disengage**
- Request forwards or engage**
Interfaces:
 PCS field bus (only to the Local Operat-
ing Panel)

* Optional, presence depends on gearbox version

** Depending on the version of the Propulsion Control System PCS-5:


D with reversing gear
D with step-down gear

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Structure and function Part 1
Use and structure Page 9

1.1.2.4 Signal processing PIM

The following table describes the individual inputs and outputs of the PIM 2.

Item No. PCB Functions Remarks

4/1 =21.X+A002-A040 MPU 23 Outputs: -


GMU AIB 1  Engine stop
MFB 1
BIB 2 Inputs:
 Shaft speed (redundant)
 Control oil pressure (analog and limit
value binary)
 Lube oil pressure* (analog and limit
value binary)
 Trolling mode active
 Checkbacks:
- Neutral or disengaged**
 Oil level (limit value binary)
Interface:
 PCS field bus

* Optional, presence depends on gearbox version

** Depending on the version of the Propulsion Control System PCS-5:


D with reversing gear
D with step-down gear

Reference documentation:
The description of the functions and the structure of the individual printed circuit
boards within the Peripheral Interface Modules PIM is part of the MTU docu-
mentation Process Level Assembly Catalog MCS-5, part 1, document no.
E 531 439.

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Part 1 Structure and function
Page 10 Use and structure

1.1.3 Printed circuit boards of the GCU/GMU 1

1.1.3.1 Gear Control Unit

The following printed circuit boards are used in the module of the Gear Control Unit:

PCB Function

MPU 23 with CCB Processor board PCS


1 2 x CAN interfaces (field bus)

AIB 1 Analog input


4 x Analog inputs
(PT1000, 4 mA 20 mA, 0 V 10 V,
NiCr-Ni, potentiometer)

BIB 2 Binary input,


electrical isolation
8 x Binary inputs (24 V internal)

BOB 1 4 x Relay outputs

ROB 1 7 x Relay outputs

Each of the printed circuit boards has several light emitting diodes for displaying its status.
These light emitting diodes have the following functions:

Printed circuit board LED displays LED status display under normal
operating conditions

MPU 23 (GCM, slot 1)


LED 1 LED 1 Voltage supply- LED 1 On
LED 2 (green) applied LED 2 Off
LED 3
LED 4 LED 2 The microprocessor LED 3 Flashes irregularly
(red) is in RESET status and is
currently not working LED 4 Flashes irregularly
(switched on during intialisa-
tion and if the supply volt-
age is too low)
LED 3 Data exchange on the
(yellow) MPU 23, CAN interface
LED 4 Data exchange on the
(yellow) MPU 23, second CAN inter-
face

>>

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Structure and function Part 1
Use and structure Page 11

Printed circuit board LED displays LED status display under normal
operating conditions

>>

BOB 1 (GCM, slot 3)


LED 1 LED 1 Relay K1 activated LED 1 Changes (depending on status)
LED 2 (yellow) Ahead/engage
LED 3
LED 4 LED 2 Relay K2 activated LED 2 Changes (depending on status)
(yellow) Neutral/disengage
LED 5
LED 3 Relay K3 activated LED 3 Changes (depending on status)
(yellow) Astern
LED 4 Relay K4 activated LED 4 Changes (depending on status)
(yellow) GCU stop
LED 5 Fault LED 5 Off
(red)

BIB 2 (GCM, slot 4)


LED 1 Channel 1 active LED 1 Changes (depending on status)
(yellow) External disengagement active
LED 2 Cable break LED 3 Changes (depending on status)
(red) channel 1 Trolling active
LED 1 Odd number as LED number: LED 5 Changes (depending on status)
LED 2
LED 3 See LED 1 Astern engaged
LED 4 (channels 2 8) LED 7 Changes (depending on status)
Even number as LED number: Neutral/disengaged
LED 5 See LED 2 LED 9 Changes (depending on status)
LED 6 (channels 2 8) Ahead engaged/
LED 7
LED 8 engaged
RCS of another manufacturer:
LED 9
LED 10 LED 11 Changes (depending on status)
LED 11
LED 12 Engage astern
LED 13 Changes (depending on status)
LED 13 Neutral/disengage
LED 14 LED 15 Changes (depending on status)
LED 15
LED 16 Engage ahead/engage

LEDs with even number as


LED number:
Off

>>

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Part 1 Structure and function
Page 12 Use and structure

Printed circuit board LED displays LED status display under normal
operating conditions

>>

ROB 1 (GCM, slot 5)


LED 1 Relay K1 activated LED 1 Changes (depending on status)
(green) Checkback ahead (engaged)
LED 2 Relay K2 activated LED 2 Changes (depending on status)
(green) Checkback neutral (disengaged)
LED 1 LED 3 Relay K3 activated LED 3 Changes (depending on status)
LED 2 (green) Checkback neutral (disen-
LED 3
LED 4 gaged)
LED 5 LED 4 Relay K5 activated
LED 6 (green) LED 4 Changes (depending on status)
LED 7 Checkback astern
LED 5 Relay K6 activated
(green) LED 5 Changes (depending on status)
Trolling active
LED 6 Relay K4 activated
(green) LED 6 Changes (depending on status)
Not used
LED 7 Relay K7 activated
(green) LED 7 Changes (depending on status)
RESERVE

ROB 1 (GCM, slot 6)


LED 1 Relay K1 activated LED 1 Changes (depending on status)
(green) Local mode active
LED 2 Relay K2 activated LED 2 Changes (depending on status)
(green) Local mode changeover for
ahead and neutral signal (from
LED 3 Relay K3 activated RCS)
(green)
LED 1
LED 2 LED 3 Changes (depending on status)
LED 3
LED 4 Relay K5 activated Local mode changeover for dis-
LED 4 (green) engagement enable and astern
LED 5
LED 6 LED 5 Relay K6 activated LED 4 Changes (depending on status)
LED 7 (green) Disengagement
LED 6 Relay K4 activated LED 5 Changes (depending on status)
(green) Disengagement window
LED 7 Relay K7 activated LED 6 Changes (depending on status)
(green) Neutral for gearbox without
neutral switch
LED 7 Changes (depending on status)
Not used

The printed circuit board AIB 1 (analog pick-up) does not have any light emitting
diodes.

When the supply voltage for the Gear Control and Monitoring Unit GCU/GMU 1 is switched on
at the Local Operating Panel (LOP), the LEDs make it possible to check whether all supply volt-
ages are present and that plausible states are being displayed.

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Structure and function Part 1
Use and structure Page 13

1.1.3.2 Additional gear monitoring functions (Gear Monitoring Unit)

The following printed circuit boards are used in the module of the Gear Monitoring Unit:

PCB Function

MPU 23 with CCB Processor board


1 1 x CAN interface (field bus)

AIB 1 Analog input


4 x Analog inputs
(PT1000, 4 mA 20 mA, 0 V 10 V,
NiCr-Ni, potentiometer)

BIB 2 Binary input,


electrical isolation
8 x binary inputs (24 V internal)

MFB 1 Multifunctional
2 x Speed inputs
(tachogenerator, inductive sensor, electronics sensor)
2 x Relay outputs (changeover contact)

Each of the printed circuit boards has several light emitting diodes for displaying the
status. These light emitting diodes have the functions shown in the table below:

Printed circuit board LED displays LED status display under normal
operating conditions

MPU 23 (GMU, slot 1)


LED 1 LED 1 Voltage supply LED 1 On
LED 2 (green) applied LED 2 Off
LED 3
LED 4 LED 2 The microprocessor LED 3 Flashes irregularly
(red) is in RESET status and is
currently not working (swit- LED 4 Flashes irregularly
ched on during intialisation
and if the supply voltage is
too low)
LED 3 Data exchange on the
(yellow) MPU 23 CAN interface
LED 4 Data exchange on the
(yellow) MPU 23, second CAN inter-
face

>>

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Part 1 Structure and function
Page 14 Use and structure

Printed circuit board LED displays LED status display under normal
operating conditions

>>

MFB 1 (GMU, slot 3)


LED 1 Speed signal 1 The display on the light emitting diodes
Analog OK is dependent on the speed sensor
LED 2 Speed signal 1 which is connected in each case.
Binary OK LED 1 On (if the shaft is turning,
LED 3 Speed signal 2 only when using an analog
Analog OK sensor), speed sensor shaft
LED 1 speed system 1
LED 2 LED 4 Speed signal 2
Binary OK LED 2 On (if the shaft is turning,
only when using a sensor with
LED 3 LED 5 Relay K2 a binary output), speed sensor
LED 4 Active shaft speed system 1
LED 6 Relay K1 LED 3 On (if the shaft is turning,
Active only when using an analog
LED 7 +24 VDC sensor), speed sensor shaft
Available speed system 2
LED 8 Ready LED 4 On (if the shaft is turning,
only when using a sensor with
LED 5 a binary output), speed sensor
LED 6 shaft speed system 2
LED 7
LED 8
LED 5 Changes (depending on status)
GMU stop
LED 6 Changes (depending on status)
RESERVE
LED 7 On
LED 8 On

>>

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Structure and function Part 1
Use and structure Page 15

Printed circuit board LED displays LED status display under normal
operating conditions

>>

BIB 2 (GMU slot 4)


LED 1 Channel 1 active LED 1 Changes (depending on status)
(yellow) Trolling mode on
LED 2 Cable break LED 3 Changes (depending on status)
(red) channel 1 Checkback clutch neutral
Odd number as LED number LED 5 Changes (depending on status)
See LED 1 Engine stop due to insufficient
LED 1 (channels 2 8) gearbox control oil pressure
LED 2
LED 3 Even number as LED number: LED 7 Changes (depending on status)
LED 4
See LED 2 Engine stop due to insufficient
(channels 2 8) gearbox lube oil pressure
LED 5 LED 9 Changes (depending on status)
LED 6
LED 7 Gearbox oil level too low
LED 8
LED 11 Off
LED 9 Reserve
LED 10 LED 13 Off
LED 11
LED 12 Reserve
LED 15 Off
LED 13 Reserve
LED 14
LED 15 LEDs with even number as
LED 16 LED number:
Off
Cable break configured for (if LED on,
cable interrupted):
LED 6 Control oil pressure
LED 8 Lube oil pressure

The printed circuit board AIB 1 (analog pick-up) does not have any light emit-
ting diodes.

When the supply voltage for the Gear Monitoring Unit GMU 1 is switched on at the Local
Operating Panel (LOP), the LEDs make it possible to check whether all supply voltages
are present and that plausible states are being displayed.

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Part 1 Structure and function
Page 16 Function

1.2 Function

1.2.1 General information about the function of the Gear Control and Monitor-
ing Unit GCU/GMU 1

The Gear Control and Monitoring Unit contains two functional sections which operate
independently:
 Gear Control Unit (GCU)
 Gear Monitoring Unit (GMU)

These two functional sections within the Gear Control and Monitoring Unit GCU/GMU 1
have the task of undertaking independent gear control and monitoring within the Propul-
sion Control System PCS-5.





RCS-5

MCS-5

Other propulsion

arrangements

Field bus PCS

EMU* ECU
PCU* GCU/GMU 1

LOP




























* Optional

Fig. 6: Integration of the Gear Control and Monitoring Unit GCU/GMU 1 into the overall PCS-5 system
(one propulsion arrangement)

The three independent functions of control, monitoring and the safety circuit are implem-
ented by two independent units. The function of the safety circuit is performed by both
units operating in a redundant arrangement.

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Structure and function Part 1
Function Page 17

Gear control is always undertaken in local mode by the Gear Control and Monitoring Unit
GCU/GMU 1; in remote control mode, it is only undertaken in conjunction with the Remote
Control System RCS-5. The display units (lamps, instruments) are not operated directly
from the Gear Control and Monitoring Unit GCU/GMU 1. The corresponding information is
sent in the form of data telegrams via the (redundant) field bus PCS-5 and evaluated on
the Local Operating Panel (LOP). There, the information is displayed or registered with
the appropriate luminous pushbuttons.

1.2.2 Functions of the Gear Control and Monitoring Unit GCU/GMU 1

1.2.2.1 Field bus PCS-5

Via LOP 1
To LOP 1 Field bus PCS
to MCS or RCS*

(redundant)

MPU 23 BOB 1 ROB 1 MPU 23 MFB 1

GCU GMU

AIB 1 BIB 2 ROB 1 AIB 1 BIB 2

Fig. 7: Gear Control and Monitoring Unit GCU/GMU 1 on the PCS-5 field bus

* The bus is terminated with a 120 W resistor in the Local Operating Panel (LOP) if
neither an MCS nor an RCS are connected

The PCS-5 field bus connection is established via the CAN bus interfaces on the pro-
cessor printed circuit boards MPU 23. Each of these is equipped with an expansion
printed circuit board CCB 1 in order to provide the second required interface for the redun-
dant bus.

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Part 1 Structure and function
Page 18 Function

1.2.2.2 Control functional section

The gear control functional section is implemented using the assemblies on the right-hand
side of the housing (GCM with six printed circuit boards, see chap. 1.1.2.2). In detail, the
following functions are performed:
 Reading in the clutch control commands via CAN bus telegrams (from the Local
Operating Panel (LOP) or from the Remote Control System RCS-5) or in paral-
lel (when using remote control systems of other manufacturers):

Reversing gear Step-down gear Reversing gear with


waterjet

Engage ahead Engage Engage

Engage astern - Flush

Neutral Disengage Disenage

 Reading in the disengagement command/engagement interlock (from the Local


Operating Panel LOP or from the plant)
 Activation of engagement valves:

Reversing gear Step-down gear Reversing gear with


waterjet

Engage ahead Engage Engage

Engage astern - Flush

Neutral Disengage Disenage

This function only occurs in local mode when other manufacturers


remote control systems are used; signals from a remote control sys-
tem of this type are looped through the GCU in remote control mode.
 Registering gearbox checkbacks (can be configured):

Reversing gear Step-down gear Reversing gear with


waterjet

Engaged ahead Engaged Engaged

Enaged astern - Flushing active

Neutral Disengaged Disengaged

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Structure and function Part 1
Function Page 19

 Clutch interlocking; this is generated in accordance with the following signals


(function is only possible in remote control mode when the Remote Control
System RCS-5 is used, whereas the function is possible even with other remote
control systems in local mode):
- Engine speed (via CAN bus),
- Interlock input (from the Local Operating Panel (LOP) or from the plant)
- Shaft speed (RCS-5 only)
 Outputting a signal for requesting all cylinders active when there is an engage-
ment command or if there is no neutral/disengaged checkback (via CAN bus to
the Engine Control Unit ECU); this signal is also output when remote control
systems of other manufacturers are used.
 Providing a separate safety circuit (for gearbox control oil pressure) within the
Gear Control Unit (GCU) with the following functions:
- Input for gearbox control oil pressure 4 mA 20 mA
- Interlock generated from the following signals:
Clutch - Neutral (reversing gear)/disengaged (step-down gear), trolling mode
active, engine running (CAN bus telegram), clutch operation time lag
- Providing/creating two dynamic limit values (Limit_1, Limit_2) which are de-
pendent on the engine speed
- Interlocking or issuing an alarm after an adjustable delay time (can be set
separately for both limit values)
- Stopping the engine in the event of a lower limit violation of the Limit_2
value (the relay for the appropriate output is activated)
 Performing the changeover between local mode and remote control mode by way of
the CAN bus (from the Local Operating Panel LOP); Gear Control Unit GCU in local
mode is output via the CAN bus for as long as local mode is active or subsequently
until the values specified by the Remote Control System RCS and Local Operating
Panel LOP are the same, or when the gearbox is in neutral or disengaged.
 Implementing communication with components of the PCS-5 (Local Operating
Panel LOP, Engine Control Unit ECU, Gear Monitoring Unit GMU, Remote Con-
trol System RCS) via a redundant CAN field bus with redundancy changeover;
the following signals are transmitted as CAN telegrams:
- Sent CAN telegrams:
Neutral/disengaged, Ahead/engaged, Astern checkbacks
Load change/cylinder cutout
GCU local mode
Control oil pressure and two limit values for control oil pressure
Lube oil pressure and two limit values for lube oil pressure (optional)
Oil temperature and a limit value for oil temperature
Oil filter pressure
Trolling mode active
External clutch disengagement

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Part 1 Structure and function
Page 20 Function

- Received CAN telegrams:


Engine speed
Engine operating
Shaft speed
Local mode active
Clutch control signals in local mode
(Neutral/disengaged, Ahead/engaged, Astern)
Remote control signals Neutral/disengaged, Ahead/engaged, Astern
 Providing an ITS (Integrated Test System) for analog inputs, RAM, FEPROM,
watchdog, temperature, supply voltage, CAN bus failure
 Providing a separate safety circuit (for the gearbox lube oil pressure, for use as
an option) within the Gear Control Unit GCU with the following functions:
- Input for gearbox lube oil pressure 4 mA 20 mA
- Interlock generated from the following signals:
Clutch - Neutral (reversing gear)/disengaged (step-down gear),
trolling mode active, engine running (CAN bus telegram), clutch operation
time lag
- Creating two dynamic limit values (Limit_1, Limit_2) which are dependent
on the engine speed
- Interlocking or issuing an alarm after an adjustable delay time (can be set
separately for both limit values)
- Stopping the engine in the event of a lower limit violation of the Limit_2
value (the relay for the appropriate output is activated)
 Optional monitoring of the gearbox oil temperature (using a type Pt1000 sen-
sor); the Limit_1 value has a time lag
 Simulation of gearbox checkback messages for the logic controller in trolling
mode (can be configured) because in this operating status, the actual check-
backs from the gearbox are no longer reliably generated by the pressure-oper-
ated switches or limit switches fitted on the gearbox (Clutch slipping)
 Outputting the trolling mode active signal on the CAN bus

The following different propulsion variants and corresponding gearboxes are provided for
configuration:
 Fixed pitch propeller with reversing gear
 Variable pitch propeller or waterjet with step-down gear
 Waterjet with back-flush (reversing gear)

Furthermore, the Gear Control Unit (GCU) can also be used in conjunction with remote
control systems of other manufacturers. All required signals are provided in the hardware
for this purpose (rather than via the CAN bus).

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Structure and function Part 1
Function Page 21

1.2.2.3 Monitoring functional section

The gear monitoring functional section is implemented using the assemblies on the left-
hand side of the housing (PIM 2 with four printed circuit boards, see chap. 1.1.2.2). In de-
tail, the following functions are performed:
 Providing a separate safety circuit (for gearbox control oil pressure) within the
Gear Control Unit GCU with the following functions:
- Input for gearbox control oil pressure 4 mA 20 mA; alternatively it is
possible to use a watchdog here (via a network of resistors)
- Interlock generated from the following signals:
Clutch - Neutral (reversing gear)/disengaged (step-down gear),
trolling mode active, engine running (CAN bus telegram), clutch operation
time lag
- Creating two dynamic limit values (Limit_1, Limit_2) which are dependent
on the engine speed; the Limit_1 value can only be used with a 4 mA
20 mA sensor
- Interlocking or issuing an alarm after an adjustable delay time (can be set
separately for both limit values)
- Stopping the engine in the event of a lower limit violation of the Limit_2
value (the relay for the appropriate output is activated)
 Implementing communication with components of the PCS-5 (Local Operating
Panel LOP, Engine Control Unit ECU, Gear Monitoring Unit GMU, Remote Con-
trol System RCS) via a redundant CAN field bus with redundancy changeover
 Providing an ITS (Integrated Test System) for analog inputs, binary inputs (con-
trol oil pressure and lube oil pressure only), RAM, FEPROM, watchdog, tem-
perature, supply voltage, CAN bus failure
 Providing a separate safety circuit (for the gearbox lube oil pressure, for use as
an option) within the Gear Control Unit GCU with the following functions:
- Input for gearbox lube oil pressure 4 mA 20 mA, alternatively it is poss-
ible to use a watchdog here (via a network of resistors)
- Interlock generated from the following signals:
Clutch - Neutral (reversing gear)/disengaged (step-down gear),
trolling mode active, engine running (CAN bus telegram), clutch operation
time lag
- Creating two dynamic limit values (Limit_1, Limit_2) which are dependent
on the engine speed; the Limit_1 value can only be used with a 4 mA
20 mA sensor
- Interlocking or issuing an alarm after an adjustable delay time (can be set
separately for both limit values)
- Stopping the engine in the event of a lower limit violation of the Limit_2
value (the relay for the appropriate output is activated)

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Part 1 Structure and function
Page 22 Function

 Optional monitoring of the oil level (via binary input), delayed Limit_1 value
 Optional pick-up of shaft speed using two speed inputs with ahead/astern
detection

1.2.2.4 Data transfer via CAN bus

Data transfer within the CAN bus is performed cyclically in 3 categories:


 Fast (every 200 ms)
 Medium (every 800 ms)
 Slow (every 5 s)

Data are assigned to one of these categories depending on how frequently they change.
As far as the monitoring measuring points are concerned, the dynamic limit values are
also transferred cyclically in the slow category.

1.2.2.5 Changeover from remote control mode to local mode

The changeover between the remote control and local operating modes is performed
using the appropriate luminous switch on the Local Operating Panel LOP 1. The contacts
in the switch are connected to the Gear Control and Monitoring Unit GCU/GMU 1 in paral-
lel. At the same time, a Local Mode CAN telegram is generated using the control panel
PAN integrated in the Local Operating Panel LOP 1. These two items of information
(switch setting and CAN telegram) are evaluated by the Gear Control and Monitoring Unit
GCU/GMU 1 as follows (local mode active):
 Switch setting:
The clutch operation requests from a remote control system of another manu-
facturer are no longer issued to the actuators because this connection is inter-
rupted by a relay (under hardware control).
 CAN telegram:
The clutch operation requests from the RCS (CAN telegrams) are no longer
carried out. Instead, the setting of the luminous pushbutton for clutch control on
Local Operating Panel LOP 1 is evaluated. This is performed in the logic con-
troller of the Local Operating Panel LOP 1, consisting of a control panel (PAN)
and Peripheral Interface Module (PIM). The CAN telegrams created there are
then output (under software control) via the printed circuit board BOB 1 in the
form of activation signals for the actuators on the gearbox.

In the case of gearboxes which do not have a neutral switch, the Neutral signal is gener-
ated by an OR logic operation (2 diodes) on the Ahead and Astern signals. The Neu-
tral signal is output (via a relay) if neither of these signals is active.

MTU - 04.2002 - E 532 091 / 00 E


Structure and function Part 1
Function Page 23

Clutch control
Local mode Ahead Neutral Astern

Logic controller LOP 1


Local Operating Panel LOP 1

Gear Control and Bus PCS 5 (CAN)


Monitoring Unit GCU/GMU 1 Bus PCS 5 (CAN) To RCS 5

Remote control system


of another manufacturer Logic controller GCU/GMU 1
Clutch operation requests
Ahead

Neutral

Astern

Gearbox
Gearbox neutral
for gearbox without
neutral switch Ahead Neutral Astern
Actuators on gearbox

Fig. 8: Changeover from local mode to remote control mode (simplified)

1.2.2.6 Connecting remote control systems of other manufacturers

The following signal interfaces are available for a remote control system of another manu-
facturer:
 Clutch operation requests (see also Fig. 8, parallel inputs)
 Floating relay contacts
- Local mode active/Remote control mode active
- Clutch engagement interlock (clutch operation window of ECU 4)
- Clutch position checkback
- Clutch disengagement command

Chaps 1.1.2.3 and 1.6 contain further information about connecting remote control sys-
tems of other manufacturers.

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Part 1 Structure and function
Page 24 Electrical power supply

1.3 Electrical power supply

The power supply to the Gear Monitoring Unit GCU/GMU 1 is provided via the Local Op-
erating Panel LOP 1. In this arrangement, the power supplies for the Gear Control Unit
GCU (GCM) and the Gear Monitoring Unit GMU (PIM 2) are separate (two different
cables). These two potentials are separately fused in the Local Operating Panel (GCU:
fusible link on printed circuit board CIB 3, GMU: power circuit breaker F13) and are moni-
tored there.

Reference documentation:
The structure of the electrical power supply and distribution in the propulsion
control system PCS-5 is explained in detail in the following documents:

 Local Operating Panel LOP 1, DDC/MTU Series 2000 and MTU/DDC


Series 4000, Marine Application, document no. E 531 687
 Propulsion Control System PCS-5, MTU/DDC Series 4000, Marine
Application, document no. E 531 693

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Structure and function Part 1
Function of GCM 1 and ROB 1 Page 25

1.4 Function of the printed circuit boards GCM 1 and ROB 1

1.4.1 Printed circuit board GCM 1

The characteristics of the printed circuit board GCM 1 are as follows:


 6 slots for a printed circuit board MPU 23, 2 printed circuit boards ROB 1 and
two further I/O printed circuit boards
 Protection circuits for the electrical power supply:
- Overvoltage protection
- Cross-polarity protection
- Overcurrent protection (self-resetting fuses)
- EMC filter
 Protection circuits for the CAN bus connection
- EMC filter
 Storage of data in a serial EEPROM (CAN node, baud rate, parameters)
 Filtering of the input voltage

The tasks of the printed circuit board GCM 1 are:


 Signal distribution in order to achieve optimum accessibility of the connections
 Multiplication of the signals:
- Shaft brake
- Clutch disengagement command
- Clutch in neutral
 Interlinking signals:
- Clutch engagement interlock with shaft brake
 Gearbox checkback messages as floating outputs for remote control systems
of other manufacturers
 Changing over the clutch operation relay via the Local mode input when re-
mote control systems of other manufacturers are used

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Part 1 Structure and function
Page 26 Function of GCM 1 and ROB 1

1.4.2 Printed circuit board ROB 1

LED 1

LED 2

LED 3
LED 4
LED 5
LED 6
LED 7

Fig. 9: Printed circuit board ROB 1

The relay printed circuit board ROB 1 is a passive board. It has 7 relays (changeover), the
connections of which are routed to terminals via the printed circuit board GCM 1. The dif-
ferences between the individual relay circuits are as follows:
 Relays K2 and K3 have a higher switching capacity.
 Relays K2 and K3 are activated in parallel.
 Relay K5 can be activated by up to three different signals (OR logic operating
via diode matrix).

The switching states of the relays are displayed using green light emitting diodes.

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Structure and function Part 1
Data storage Page 27

1.5 Data storage

1.5.1 Overview of data structures which can be configured

The Gear Control Unit (GCU) contains certain software modules for performing its individ-
ual functions. These software modules are integrated into the hardware assemblies as fol-
lows:

Data type Storage location Redundant storage location

Initial program loader Flash EPROM -

Basic software Flash EPROM BDM

Logic programs Flash EPROM BDM

Project implementation table for Flash EPROM BDM


logic controller and I/O

Parameters EEPROM in the HC11 assembly Serial EEPROM on the printed cir-
cuit board COB

The functions of the individual software modules are described in more detail in chaps.
1.5.2.1 to 1.5.2.5.

1.5.2 Software modules

1.5.2.1 Initial program loader

The initial program loader is a neutral software item as far as the subsequent application
of the unit is concerned. It makes it possible to program the application-specific software
modules of the basic software, the logic program and the project implementation tables.
These programs then form part of the software of the Flash EPROMs in the printed circuit
board MPU 23.

The initial program loader is downloaded to the Flash EPROM after a printed circuit board
MPU 23 has been completed.

1.5.2.2 Basic software

The basic software contains the range of I/O functions which can be configured.

1.5.2.3 Logic programs

Logic programs represent an expansion to the range of I/O functions. The logic programs
include special functions, e.g. the separate safety circuit. Logic programs have an inter-
face to the CAN bus, and consequently require a group of process variables. The I/O con-
figuration and function of a logic program can be adjusted.

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Part 1 Structure and function
Page 28 Data storage

1.5.2.4 Project implementation tables for I/O channels and logic programs

The project implementation tables describe the I/O channels of the units based on HC11
as well as their communication. Project implementation tables are created in accordance
with the order on the basis of the project implementation environment. Each unit contains
its own project implementation table.

1.5.2.5 Parameters

Parameters are used for adjusting the units to the particular situation in the ship. Limit va-
lues are an example of this.
The default parameter values are set by the project implementation environment. It is
possible to edit these data subsequently using the dialog system.

1.5.3 Redundant back-up of project implementation data

Configuration data and logic programs are also stored in the BDM of the propulsion ar-
rangement. The BDM consists of a Programmable Process Station PPS which can be
connected to the dialog socket of the Local Operating Panel. It is used as a data server.
Both basic software and logic programs can be loaded.

If there is a Programmable Process Station PPS in the overall system (e.g.


when using an MCS-5), this programmable process station can take over the
tasks of the BDM.

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Structure and function Part 1
Connecting GCU/GMU 1 Page 29

1.6 Connecting the Gear Control and Monitoring Unit GCU/GMU 1

The cables of the Gear Control and Monitoring Unit GCU/GMU 1 are connected up in ac-
cordance with chap. 1.6.1 (control unit side, GCM module) and chap. 1.6.2 (monitoring
side, PIM). (Connections marked with an * are connected up using plug X21 on the MTU
cable harness).

1.6.1 Gear Control Unit GCU

Printed circuit board MPU 23 (slot 1)


Terminal Name Used for
X 101 +24 VDC
Supply voltage*
X 102 +24 VDC
X 103 +24 V ground
Supply voltage (ground)*
X 104 +24 V ground
X 105 CAN 1 GND
X 106 CAN 1 GND
X 107 CAN 1L
CAN 1 (default)*
X 108 CAN 1L
X 109 CAN 1H
X 110 CAN 1H
X 111 CAN 2 GND
X 112 Unassigned
X 113 CAN 2L
CAN 2 (redundant)*
X 114 CAN 2L
X 115 CAN 2H
X 116 CAN 2H

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Part 1 Structure and function
Page 30 Connecting GCU/GMU 1

Printed circuit board AIB 1 (slot 2)


Terminal Name Used for
X 201 Reference voltage 10 V or 1 mA
X 202 Error voltage input (-) Gearbox control oil pressure (4 mA
X 203 Error voltage input (+) 20 mA)
X 204 Ground
X 205 Reference voltage 10 V or 1 mA
X 206 Error voltage input (-) Gearbox lube oil pressure
X 207 Error voltage input (+) (4 mA 20 mA)
X 208 Ground
X 209 Reference voltage 10 V or 1 mA
X 210 Error voltage input (-)
Gearbox oil temperature (Pt1000)
X 211 Error voltage input (+)
X 212 Ground
X 213 Reference voltage 10 V or 1 mA
X 214 Error voltage input (-) Gearbox oil filter pressure
(binary terminal 509 above 2.7
(binary, 2 7 kW to
X 215 Error voltage input (+) +24 VDC)
X 216 Ground

Printed circuit board BOB 1 (slot 3)


Terminal Name Connection Other manufac-
with RCS-5 turers RCS
X 301 Trolling, relay contact K1, common Yes* Yes*
X 302 Trolling, relay contact K1, NO contact Yes* Yes*
X 303 Clutch checkback Neutral/disengaged, Yes* Yes*
relay contact K2, common
X 304 Clutch checkback Neutral/disengaged, Yes* Yes*
relay contact K2, NO contact
X 305 Clutch checkback Neutral/disengaged, Yes* Yes*
relay contact K1, common
X 306 Clutch checkback Neutral/disengaged, Yes* Yes*
relay contact K1, NO contact
X 307 + 24 VDC internal Yes*
X 308 + 24 VDC internal
X 309 + 24 VDC internal
X 310 + 24 VDC internal
>>

MTU - 04.2002 - E 532 091 / 00 E


Structure and function Part 1
Connecting GCU/GMU 1 Page 31

Terminal Name Connection Other manufac-


with RCS-5 turers RCS
>>
X 311 Clutch disengagement control input 1 * *
X 312 Clutch control local mode No Yes, from Local
Operating Panel
LOP*
X 313 Clutch operation window relay input + No Yes, from Local
Operating Panel
LOP*
X 314 Clutch operation window relay input - No Yes, from Local
Operating Panel
LOP*
X 315 Stop signal BOB 1 relay K1 common * *
X 316 Stop signal BOB 1 relay K1 NO contact * *

Printed circuit board BIB 2 (slot 4)


Terminal Name Connection Other manufac-
with RCS-5 turers RCS
X 401 +24 V internal Yes* Yes*
X 402 +24 V internal Yes* Yes*
X 403 +24 V internal
X 404 +24 V internal
X 405 Clutch disengagement, control input 2
X 406 Clutch disengagement, control input 3
X 407 Trolling, checkback input
X 408 Astern, clutch checkback input
X 409 Neutral/disengaged for gearbox without
neutral switch, relay K1, NC contact
X 410 Neutral/disengaged, clutch checkback
input
X 411 +24 V ext. supply voltage for clutch Yes* Yes*
relay contact
X 412 Ahead/engaged, clutch checkback
input
X 413 Clutch disengagement, relay contact No Yes
K1, common
X 414 Clutch disengagement, relay contact No Yes
K1, NO contact
X 415 Clutch disengagement, relay contact No Yes
K1, NC contact
X 416 Local mode, relay contact K1, common

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Part 1 Structure and function
Page 32 Connecting GCU/GMU 1

Printed circuit board ROB 1 (slot 5)

Terminal Name Connection Other manufac-


with RCS-5 turers RCS
X 501 Ahead checkback, relay contact K1, No Yes
NO contact
X 502 Neutral checkback, relay contact K1, No Yes
NO contact
X 503 Astern checkback, relay contact K1, No Yes
NO contact
X 504 Ahead/neutral/astern, relay contact K1, No Yes
common
X 505 Clutch disengagement window, relay No Yes
contact K1, common
X 506 Clutch disengagement window, relay No Yes
contact K1, NO contact
X 507 Clutch disengagement window, relay No Yes
contact K1, NC contact
X 508 2.7 K resistor for watchdog
X 509 2.7 K resistor for watchdog
X 510 Reserve, relay contact K1, common
X 511 Reserve, relay contact K1, NO contact
X 512 Reserve, relay contact K1, NC contact
X 513 Reserve, relay + input
X 514 Reserve, relay - input
X 515 +24 V ext. supply voltage
X 516 GNDBATT ext.

Printed circuit board ROB 1 (slot 6)

Terminal Name Connection Other manufac-


with RCS-5 turers RCS
X 601 Local mode, relay contact K1, NO con- No Yes
tact
X 602 Local mode, relay contact K1, NC con- No Yes
tact
X 603 Astern, relay 3 contact K2, common No Yes
X 604 Astern, relay 3 contact K2, NC contact No Yes
X 605 Astern, relay 3 contact K2, NO contact Yes No
X 606 Clutch disengagement enable, relay 3 No Yes
contact K1, common
>>

MTU - 04.2002 - E 532 091 / 00 E


Structure and function Part 1
Connecting GCU/GMU 1 Page 33

Terminal Name Connection Other manufac-


with RCS-5 turers RCS
>>
X 607 Clutch disengagement enable, relay 3 No Yes
contact K1, NC contact
X 608 Clutch disengagement enable, relay 3 Yes No
contact K1, NO contact
X 609 Neutral/disengaged, relay 2 contact K2, No Yes
common
X 610 Neutral/disengaged, relay 2 contact K2, No Yes
NC contact
X 611 Neutral/disengaged, relay 2 contact K2, Yes No
NO contact
X 612 Ahead/enagaged, relay 2 contact K1, No Yes
common
X 613 Ahead/enagaged, relay 2 contact K1, No Yes
NC contact
X 614 Ahead/enagaged, relay 2 contact K1, Yes No
NO contact
X 615 GNDBATT for the solenoid valves For terminals For terminals
X 616 GNDBATT for the solenoid valves 603 to 614 603 to 614

E 532 091 / 00 E - 04.2002 - MTU


Part 1 Structure and function
Page 34 Connecting GCU/GMU 1

1.6.2 Gear Monitoring Unit GMU

The cables of the Gear Monitoring Unit GMU 1 are connected up as follows (connections
marked with an * are connected up using plug X21 on the MTU cable harness):

Printed circuit board MPU 23 (slot 1)


Terminal Name Used for
X 101 +24 VDC
Supply voltage*
X 102 +24 VDC
X 103 +24 V ground
Supply voltage (ground)*
X 104 +24 V ground
X 105 CAN 1 GND
X 106 CAN 1 GND
X 107 CAN 1L
CAN 1 (default)*
X 108 CAN 1L
X 109 CAN 1H
X 110 CAN 1H
X 111 CAN 2 GND
X 112 Unassigned
X 113 CAN 2L
CAN 2 (redundant)*
X 114 CAN 2L
X 115 CAN 2H
X 116 CAN 2H

MTU - 04.2002 - E 532 091 / 00 E


Structure and function Part 1
Connecting GCU/GMU 1 Page 35

Printed circuit board AIB 1 (slot 2)

Terminal Name Used for


X 201 Reference voltage 10 V or 1 mA
X 202 Error voltage input (-) Gearbox control oil pressure (4 mA
X 203 Error voltage input (+) 20 mA)
X 204 Ground
X 205 Reference voltage 10 V or 1 mA
X 206 Error voltage input (-) Gearbox lube oil pressure
X 207 Error voltage input (+) (4 mA 20 mA)
X 208 Ground
X 209 Reference voltage 10 V or 1 mA
X 210 Error voltage input (-)
-
X 211 Error voltage input (+)
X 212 Ground
X 213 Reference voltage 10 V or 1 mA
X 214 Error voltage input (-)
-
X 215 Error voltage input (+)
X 216 Ground

Printed circuit board MFB 1 (slot 3)

Terminal Name Used for


X 301 Speed input analog 1 (H)
X 302 Speed input analog 1 (L) Shaft speed system I (either an analog
sensor or a sensor with a binary output
X 303 Speed input binary 1 (H) can be connected)
X 304 Speed input binary 1 (L)
X 305 Speed input analog 2 (H)
X 306 Speed input analog 2 (L) Shaft speed system II (either an analog
sensor or a sensor with a binary output
X 307 Speed input binary 2 (H) can be connected)
X 308 Speed input binary 2 (L)
X 309 +24 VDC
X 310 +24 VDC ground
X 311 Relay K1 NC contact
X 312 Relay K1 NO contact Reserve
X 313 Relay K1 common
X 314 Relay K2 common
X 315 Relay K2 NO contact GMU stop
X 316 Relay K2 NC contact

E 532 091 / 00 E - 04.2002 - MTU


Part 1 Structure and function
Page 36 Connecting GCU/GMU 1

Printed circuit board BIB 2 (slot 4)


Terminal Name
X 401 Trolling mode on (+24 VDC)
X 402 Trolling mode on (optocoupler input)
X 403 Checkback clutch Neutral/disengaged (+24 VDC)
X 404 Checkback clutch Neutral/disengaged (optocoupler input)
X 405 Gearbox control oil pressure (+24 VDC)
X 406 Gearbox control oil pressure (optocoupler input)
X 407 Gearbox lube oil pressure (+24 VDC)
X 408 Gearbox lube oil pressure (optocoupler input)
X 409 Gearbox oil level (+24 VDC)
X 410 Gearbox oil level (optocoupler input)
X 411 Reserve (+24 VDC)
X 412 Reserve (optocoupler input)
X 413 Reserve (+24 VDC)
X 414 Reserve (optocoupler input)
X 415 Reserve (+24 VDC)
X 416 Reserve (optocoupler input)

MTU - 04.2002 - E 532 091 / 00 E


Structure and function Part 1
Technical data Page 37

1.7 Technical data

Dimensions (W x H x D) 385 mm x 300 mm x 240 mm


Lateral disconnection dimension: +40 mm

Operating voltage 24 VDC, -50 %/+30 %

Operating temperature range -25 C +55 C

Storage temperature range -25 C +70 C

Vibration 2 Hz 13 Hz: 1.0 mm


13 Hz 100 Hz: 1 g

Ambient conditions Max 95 % rel. humidity,


non-condensing

Resistance to salt spray mist, oil, cleaning agents

Degree of protection GCM module or PIM: IP20


with terminal box: IP65

Insulation resistance > 10 M (500 VDC)


(under laboratory conditions)

Electrical isolation 500 V (CAN against supply)

Dielectric strength > 500 VAC


(under laboratory conditions)

Electromagnetic compatibility EMC Emitted: 10 V/m - 30 kHz - 1 GHz


Conducted: 3 Vrms - 30 Hz 80 MHz
Burst: 2 kV
Surge: 1 kV sym. / 2 kV asym.
ESD: 8 kV

E 532 091 / 00 E - 04.2002 - MTU


Part 1 Structure and function
Page 38 Technical data

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MTU - 04.2002 - E 532 091 / 00 E


Operation Part 2
Table of contents Page I

Part 2

Operation

Not applicable

2 Not applicable

E 532 091 / 00 E - 04.2002 - MTU


Part 2 Operation
Page II Table of contents

(This page intentionally blank)

MTU - 04.2002 - E 532 091 / 00 E


Maintenance and repair Part 3
Table of contents Page I

Part 3

Maintenance and repair

E 532 091 / 00 E - 04.2002 - MTU


Part 3 Maintenance and repair
Page II Table of contents

(This page intentionally blank)

MTU - 04.2002 - E 532 091 / 00 E


Maintenance and repair Part 3
Table of contents Page III

Table of contents

3 Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3.1 Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2.2.1 Task summary for scheduled maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2.2.2 Overview of the task - visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2.2.3 Checking fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2.2.4 Checking firm seating of plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2.2.5 Checking cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2.2.6 Checking firm seating of internal assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2.2.7 Overview of the task - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.2.8 Gear Control and Monitoring Unit GCU/GMU 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2.2.9 Cleaning plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3.1 Faults without fault code displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3.2 Faults with plain text output on the display of the corresponding Local Operating Panel
LOP 1-01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.4 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.4.1 Replacing printed circuit boards on Peripheral Interface Modules . . . . . . . . . . . . . . . . . . . . 22
3.4.2 Replacing plug-in fuses on the printed circuit board BOB 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 26

E 532 091 / 00 E - 04.2002 - MTU


Part 3 Maintenance and repair
Page IV Table of contents

(This page intentionally blank)

MTU - 04.2002 - E 532 091 / 00 E


Maintenance and repair Part 3
Safety requirements Page 1

3 Maintenance and repair

3.1 Safety requirements

IMPORTANT
These safety requirements shall be read and observed by all
personnel involved in operation, care, maintenance or repair of the
products concerned.

Furthermore, the following shall be observed:


 The safety requirements (if provided) in other relevant MTU manuals
 Warning and safety notes and operating and limit values attached to the
products as required
 National accident prevention and safety standards
 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 marked with 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 and repair shall only be performed by qualified and authorized
personnel.

E 532 091 / 00 E - 04.2002 - MTU


Part 3 Maintenance and repair
Page 2 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 commanding officer prior to commencing mainte-
nance 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 is in no way responsible for damage caused by using other spare parts.
The manufacturers guarantee is also voided in such cases.
The manufacturer shall not be held responsible if unauthorized changes or modifications
are made to the product and the guarantee shall be voided.
Spare parts shall be properly stored prior to replacement, i.e. particularly protected
against moisture. Defective electronic components and assemblies must be suitably
packed when despatched for repair, i.e. particularly protected against 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 all repair work, the system must be subjected to a function check. Sepa-
rate testing of the repaired component without system integration is insufficient.
When working on the engine, suitable measures shall be taken to prevent accidental start-
ing.

MTU - 04.2002 - E 532 091 / 00 E


Maintenance and repair Part 3
Maintenance Page 3

3.2 Maintenance

3.2.1 General notes

This chapter lists work on Gear Control and Monitoring Unit GCU/GMU 1 which is
required in order to maintain availability. This work may be performed without the use of
test and measuring equipment.

Maintenance work on Gear Control and Monitoring Unit GCU/GMU 1 predominantly


involves visual checks to detect mechanical damage or to pinpoint loose parts and con-
nections. Defective assemblies must be repaired or replaced immediately.

System failure

Failure to perform the following work in compliance with instruc-


tions and within the time interval indicated can lead to failure of
CAUTION Gear Control and Monitoring Unit GCU/GMU 1 or failure of the
entire PCS-5 system.

If faults are detected, the cause of the fault can be determined and remedied by following
the instructions listed in the following chapters.

Terminology and structure used in the documentation

This documentation makes a distinction between two concepts:


 Activities
An activity is the sum of all the steps which belong to part of a task (e.g. remov-
ing cover of ECU 4 Engine Control Unit). Activities are assigned identification
numbers (Ident. no. or ID no.) which begin with the letter A (e.g.
A-P-ECU-0006)
 Task
A task is the sum of activities which bring about the desired end result (e.g.
exchanging ECU 4 Engine Control Unit).
Tasks are assigned identification numbers (Ident. no. or ID no.) which begin
with the letter T (e.g. T-P-ECU-0003).

E 532 091 / 00 E - 04.2002 - MTU


Part 3 Maintenance and repair
Page 4 Maintenance

A summary of all maintenance tasks is included in the introduction to the description of all
scheduled maintenance work. This summary includes references to individual task
descriptions which, in turn, comprise a series of activities, each of which are described
after the task description.

Task overview

Task description

Activity/activities

Fig. 10 : Task overview - task description - activities

All repair work is also split up into tasks and associated activities. The introduction to the
repair chapter lists a summary of all the tasks described therein.

MTU - 04.2002 - E 532 091 / 00 E


Maintenance and repair Part 3
Maintenance Page 5

3.2.2 Maintenance work

3.2.2.1 Task summary for scheduled maintenance work

All work listed in the following table may be performed by plant personnel.

Maintenance work is performed at three different intervals:


 Maintenance echelon W2
 Maintenance echelon W3
 Maintenance echelon W4

The timing of these intervals is linked to the engine maintenance echelon W1 to W5 inter-
val.

Weiterfhrende Dokumentation:
Refer to the engine documentation for details on the timing of maintenance
work within the interval.

The tables below list the maintenance measures which have to be performed, together
with the locations where they are carried out.

All work which has to be performed on a Gear Control and Monitoring Unit
GCU/GMU 1 (e.g. port engine or starboard engine) must, as a next step, be
performed separately on all other Gear Control and Monitoring Units GCU/
GMU 1 located in the ship.

Inter- Quali- Task


Name of task Time Page Remarks
val ficat. ID

W4 Perform visual in- BP 0.2 h T-P-GCU-0001 6 Any faults determined during


spection (internal, ex- the checks must be rectified
ternal) immediately

W4 Clean the Gear Con- BP 0.2 h T-P-GCU-0002 11 Only perform if necessary


trol and Monitoring
Unit GCU/GMU 1

E 532 091 / 00 E - 04.2002 - MTU


Part 3 Maintenance and repair
Page 6 Maintenance

3.2.2.2 Overview of the task - visual inspection


Ident. no.: T-P-GCU-0001

System components/units from the overall system PCS 5


 Gear Control and Monitoring Unit GCU/GMU 1

Equipment
 Torch

Reference documentation
 Engine documentation
 Documentation for the Gear Control and Monitoring Unit GCU/GMU 1,
document no. E 531 691

Requirements
 Access to the engine room and the Gear Control and Monitoring Unit
GCU/GMU 1
 Engine stopped

Additional safety notes


 Comply with the general safety regulations: chap. 3.1
 Comply with the safety notes prefixing the descriptions of activities

1. Check fixture of assemblies A-P-GCU-0001


Page 7
2. Check cables A-P-GCU-0003
Page 9
3. Check firm seating of plugs A-P-GCU-0002
Page 8
4. Visual check of internal assemblies A-P-GCU-0004
Page 10

The activities may be performed in any sequence

MTU - 04.2002 - E 532 091 / 00 E


Maintenance and repair Part 3
Maintenance Page 7

3.2.2.3 Checking fixture


Ident. no.: A-P-GCU-0001

The Gear Control and Monitoring Unit GCU/GMU 1 is attached to a ships wall by means
of four mounting bolts. These can be accessed from inside the housing. Check that these
bolts are firmly tightened.

1. Open the front door of the housing


1 2
2. There is one mounting bolt (11/1...4) in
each of the four corners of the hous-
ing; check that these bolts are firmly
tightened
3. Use a suitable tool (depending on ver-
sion) to tighten the bolts if they are not
firmly tightened

3 4

Fig. 11 : Fixture of the Gear Control and Moni-


toring Unit GCU/GMU 1

E 532 091 / 00 E - 04.2002 - MTU


Part 3 Maintenance and repair
Page 8 Maintenance

3.2.2.4 Checking firm seating of plugs


Ident. no.: A-P-GCU-0002

1 2 The Gear Control and Monitoring Unit


GCU/GMU 1 (12/1) is located close to the
engine (directly in the machine room or in
its immediate vicinity). There is a plug
(12/2) on the right-hand side of the hous-
ing.

Proceed as follows to check that the plug


is firmly attached to the Gear Control and
Monitoring Unit GCU/GMU 1 (12/1):

1. Check that the two securing clips


(13/1, above and below the plug) are
clipped onto the lugs (13/2) so the
plug (13/3) is held firmly in the socket
on the housing of the Gear Control
and Monitoring Unit GCU/GMU 1

Fig. 12 : Plug on the Gear Control and Moni-


toring Unit GCU/GMU 1

2. If they are not, push the clips by hand


in the direction indicated by the arrows
1 (see Fig. 13) until you can feel them
clip into place

1 2 3

Fig. 13 : Checking the plug is firmly seated

MTU - 04.2002 - E 532 091 / 00 E


Maintenance and repair Part 3
Maintenance Page 9

3.2.2.5 Checking cables


Ident. no.: A-P-GCU-0003

1 Damaged cables must be insulated or re-


placed (if the damage is too severe) with-
out delay.

1. If the external insulation is damaged


and the individual strands are visible
(e.g. 14/1), it is adequate for the cable
2 to be wrapped with insulating tape.
This only applies if none of the individ-
ual strands have been damaged.
2. The cable harness (or the relevant
part of the cable harness) must be re-
placed if individual strands are bare or
cut (e.g. 14/2)

Fig. 14 : Examples of damaged cables

E 532 091 / 00 E - 04.2002 - MTU


Part 3 Maintenance and repair
Page 10 Maintenance

3.2.2.6 Checking firm seating of internal assemblies


Ident. no.: A-P-GCU-0004

The assemblies inside the Gear Control


1 2 and Monitoring Unit GCU/GMU 1 are lo-
cated on a mounting plate. Check that
their mounting screws are firmly tigh-
tened. In addition, all the assemblies on
this mounting plate must be checked to
make sure they are firmly seated.

1. Open the front door of the housing


2. There is one mounting screw (15/1 ...
15/4) in each of the four corners of the
mounting plate; check that these
screws are firmly tightened
3. Use a suitable hex key to tighten the
screws if they are not firmly tightened
4. Check that the other assemblies are
also firmly seated; this applies particu-
larly to the two Peripheral Interface
Modules PIM (15/5, 15/6)

3 5 6 4 5. Use a suitable tool to tighten any


screws which may have come loose
Fig. 15 : Fixture of the Gear Control and Moni-
toring Unit GCU/GMU 1

MTU - 04.2002 - E 532 091 / 00 E


Maintenance and repair Part 3
Maintenance Page 11

3.2.2.7 Overview of the task - Cleaning


Ident. no.: T-P-GCU-0002

System components/units from the overall system PCS 5


 Gear Control and Monitoring Unit GCU/GMU 1

Equipment
 Soft cloth which will not fray or abrade
 Isopropyl alcohol (propan-2-ol)

Requirements
 Access to the engine room and the Gear Control and Monitoring Unit
GCU/GMU 1
 Engine stopped

Additional safety notes


 Comply with the general safety regulations: chap. 3.1
 Comply with the safety notes prefixing the descriptions of activities
 Do not damage any cables whilst cleaning
 If any plugs are disconnected, make sure that the securing clips are
clipped back in again correctly

1. Gear Control and Monitoring Unit A-P-GCU-0005


GCU/GMU 1 Page 12
2. Clean plugs A-P-GCU-0006
Page 13

The activities may be performed in any sequence

E 532 091 / 00 E - 04.2002 - MTU


Part 3 Maintenance and repair
Page 12 Maintenance

3.2.2.8 Gear Control and Monitoring Unit GCU/GMU 1


Ident. no.: A-P-GCU-0005

The Gear Control and Monitoring Unit


2 GCU/GMU 1 (16/1) consists of a housing
made from steel sheet. All electronic as-
semblies which belong to the Gear Con-
trol and Monitoring Unit GCU/GMU 1 are
integrated in this housing.

1. Use a cloth dipped in isopropyl alcohol


to clean coarse dirt off the surface of
this housing (16/2)
2. Make sure that the labelling sets on
the cables are legible. Make the letter-
ing legible or replace the labels, if
necessary.

Fig. 16 : Cleaning the Gear Control and


Monitoring Unit GCU/GMU 1

During cleaning work, take care not to damage anything and


avoid disconnecting plugs from the housing (16/3).

CAUTION

MTU - 04.2002 - E 532 091 / 00 E


Maintenance and repair Part 3
Maintenance Page 13

3.2.2.9 Cleaning plugs


Ident. no.: A-P-GCU-0006

In the long term, excessive contamination


on the plugs can contribute to an impair-
ment of function. As a result, contamina-
tion of this type (oil, grease, fuel etc.)
should be removed.

1. Use a cloth dipped in isopropyl alcohol


to clean the surface of the plug (17/1)
2. Remove the plug in case of extreme
contamination (see also page 8)
3. Use isopropyl alcohol to clean the plug
housing (17/2) and the contacts thor-
oughly
4. Also thoroughly clean the plug socket
(17/3) on the housing of the Local Op-
erating Panel LOP 1 using an ad-
equate quantity of isopropyl alcohol

2
1

Fig. 17 : Cleaning the plug on the Local Oper-


ating Panel LOP 1

During cleaning work, take care not to damage anything and


avoid inadvertently disconnecting plugs from the housing. Follow
the instructions on page 8 when connecting the plugs.

CAUTION

E 532 091 / 00 E - 04.2002 - MTU


Part 3 Maintenance and repair
Page 14 Troubleshooting

3.3 Troubleshooting

3.3.1 Faults without fault code displays

The following table lists the possible faults which will be patently obvious to the operator.

No. Fault Fault cause(s) Action See

1 Entire PCS-5 does not 1. No supply voltage Check if other parts of Ship manual
react after being swit- available the electrical system in
ched on the ship are also unservi-
ceable.

Other parts of the Causes point 2


system do not function.

Only PCS-5 is unservi- Causes point 3


ceable.

2. No ship power Switch on ship power Ship manual

3. PCS-5 power supply Visual inspection; reset Ship manual


switched off; corre- existing power circuit
sponding power cir- breakers if necessary
cuit breaker tripped

4. Keylock switch (if Turn key anti-clockwise, Ship manual


used) for the system pull it out then push it
not switched on cor- back in again and turn
rectly or not locked clockwise as far as the
into position properly stop

5. Keylock switch defec- Replace keylock switch Ship manual


tive

>>

MTU - 04.2002 - E 532 091 / 00 E


Maintenance and repair Part 3
Troubleshooting Page 15

No. Fault Fault cause(s) Action See

>>

2 Entire Gear Control and 1. Plug X21 on the Local Connect plug properly, A-P-GCU-0002
Monitoring Unit GCU/ Operating Panel LOP clip on securing clips page 8
GMU 1 unserviceable, or on the Gear Con-
other parts of the system trol and Monitoring
are functioning Unit GCU/GMU 1 not
connected properly or
faulty

2. Power circuit breaker Check power circuit E 531 687


in the supply assem- breaker or fusible link,
bly (on MTU PCS-5: switch back on or
Local Operating Pan- replace as necessary
el LOP 1) tripped or a
fuse has blown

3 No clutch control possi- 1. Printed circuit board Replace printed circuit A-P-GCU-0007
ble using another manu- ROB 1 (relay outputs) board ROB 1 page 22
facturers RCS faulty

2. Cabling defective Check cables and their A-P-GCU-0003


connections to terminals page 9
and repair if necessary

4 Individual functions of 1. Plug-in fuse of printed Replace plug-in fuse for A-P-GCU-0008
the control system for circuit board BOB 1 the corresponding relay page 26
another manufacturers defective: contacts on the printed
RCS do not function D F1: Ahead circuit board BOB 1
(engage)
D F2: Neutral
(disengage)
D F3: Astern
(only with
reversing gear)
D F4: -
D F5: Stop request
from GCU

2. Cabling defective Check cables and their A-P-GCU-0003


connections to terminals page 9
and repair if necessary

>>

E 532 091 / 00 E - 04.2002 - MTU


Part 3 Maintenance and repair
Page 16 Troubleshooting

No. Fault Fault cause(s) Action See

>>

5 No checkback for current 1. Printed circuit board Replace printed circuit A-P-GCU-0007
clutch position ROB 1 (relay outputs) board ROB 1 page 22
faulty

2. External power sup- Check the power supply


ply faulty (on MTU PCS-5: Local
Operating Panel LOP 1)

E 531 687

3. Cabling defective Check cables and their A-P-GCU-0003


connections to terminals page 9
and repair if necessary

6 Fault message after acti- 1. No Trolling engaged Check the Trolling Con-
vating Trolling function, signal from the Trol- trol Unit
however operating mode ling Control Unit
can be maintained
E 531 731
or
E 531 732

2. Printed circuit board Replace printed circuit A-P-GCU-0007


ROB 1 (relay outputs) board ROB 1 page 22
faulty

3. Printed circuit board Replace printed circuit A-P-GCU-0007


BIB 2 (binary inputs) board BIB 2 page 22
in the GCU faulty

4. Printed circuit board Replace printed circuit A-P-GCU-0007


BIB 2 (binary inputs) board BIB 2 page 22
in the GMU faulty

7 Fault messages relating One of the printed circuit Replace the appropriate A-P-GCU-0007
to limit value violations boards for registering the printed circuit board page 22
although the actual ope- operating values is
rating values are correct defective:
D AIB 1 in the GCU
D AIB 1 in the GMU
D BIB 2 in the GMU

8 No shaft speed pick-up 1. Printed circuit board Replace printed circuit A-P-GCU-0007
MFB 1 in the GMU is board MFB 1 page 22
defective

2. Cabling defective Check cables and their A-P-GCU-0003


connections to terminals page 9
and repair if necessary

>>

MTU - 04.2002 - E 532 091 / 00 E


Maintenance and repair Part 3
Troubleshooting Page 17

No. Fault Fault cause(s) Action See

>>

9 GCU or GMU is no lon- 1. EEPROM on mother- Replace the PIM hou- Part 4
ger detected in the over- board defective or not sing, reprogram nodes
all system, fault mes- programmed and the baud rate
sage on LOP 1-01 (CAN
Node XX lost or similar)

10 A bus is missing (redun- 1. Cabling defective (ter- Check cables and their A-P-GCU-0003
dant or default), fault minals loose, cables connections to terminals Page 9
message on LOP 1-01 interrupted) and repair if necessary

2. CAN interface of the Replace printed circuit Part 4


MPU 23 processor board MPU 23; down-
PCB defective load program via BDM if
necessary

E 532 091 / 00 E - 04.2002 - MTU


Part 3 Maintenance and repair
Page 18 Troubleshooting

3.3.2 Faults with plain text output on the display of the corresponding Local
Operating Panel LOP 1-01

Fault messages are only displayed in a system in the manner shown here pro-
vided the plant is equipped with an MTU Local Operating Panel LOP 1-01 (with
display DIS).

Measuring points and fault messages are output in text format on the display DIS of a
Local Operating Panel LOP 1-01.

1
Alarm
GCU
P-GETRIEBESCHMIERL LIMIT LOACK YEL
AL GETR. L FILT. VERSCHMUZTACK YEL

F1 F2 F3 F4 F5

Fig. 18 : Display of fault messages

Fault messages which can be traced back to the Gear Control and Monitoring Unit GCU/
GMU 1 are listed below.

The table gives an explanation of each fault message and provides information about
troubleshooting and fault rectification.

The operating personnel must evaluate the messages on the fault display and take what-
ever steps are necessary.

MTU - 04.2002 - E 532 091 / 00 E


Maintenance and repair Part 3
Troubleshooting Page 19

The overall PCS-5 system (system components ECU 4, LOP 1-01 and EMU 1 if fitted)
monitors, detects and processes faults and limit value violations in all operating situations
(when the system is switched on).

The fault display which appears on the display DIS (see Fig. 18) facilitates diagnosis by
providing information in plain text about the events which have occurred.

The display on the assembly which has sent a message (EMU, ECU , GCU, GMU) makes
it easy to allocate possible fault causes as well as to localise the input and output chan-
nels.

When assessing the displayed fault messages, note that one fault may give rise to follow-
on faults which are also displayed.

The list of faults provides explanations about the faults which are registered, refers to
possible causes and gives information about repairs.

The meanings of the abbreviations in the individual rows are as follows:

Classifications of fault displays

AL General alarm

LO Range violation alarm (low)

HI Range violation alarm (high)

SS Alarm from the safety system

SD Sensor defective

TD Sensor comparison fault (transmitter deviation)

MG Message

LO (suffix) 1st lower limit value

LOLO (suffix) 2nd lower limit value

HI (suffix) 1st upper limit value

HIHI (suffix) 2nd upper limit value

E 532 091 / 00 E - 04.2002 - MTU


Part 3 Maintenance and repair
Page 20 Troubleshooting

Message, Measures or repair stage


No. fault display or Meaning (E - Electrical,
measuring point text M - Mechanical)

1. P-gear control oil GCU Measuring point M: Gearbox documentation


Gearbox control oil pressure E: Check the measuring channel if
the actual value on the gearbox is
correct;
check the Trolling Control Unit TCU if
the fault message occurs after Trol-
ling mode has been activated (the
Trolling signal may be missing)

2. P-gear control oil 1st limit value for the gearbox -


limit LO control oil pressure is displayed

3. P-gear control oil li- 2nd limit value for the gearbox -
mit LOLO control oil pressure is displayed

4. LO P-gear control oil Gearbox control oil pressure is M: Gearbox documentation


GCU too low E: Check the measuring channel if
the actual value on the gearbox is
correct: GCU PCB AIB 1

5. SS P-gear control oil Safety system is measuring in- Safety system is measuring inad-
GCU adequate gearbox control oil equate control oil pressure:
pressure M: Gearbox documentation
E: Check the measuring channel if
the actual value on the gearbox is
correct;
check the Trolling Control Unit TCU if
the fault message occurs after Trol-
ling mode has been activated (the
Trolling signal may be missing)

6. P-gear lube oil GCU Measuring point -


Gearbox lube oil pressure

7. P-gear lube oil limit 1st limit value for the gearbox -
LO lube oil pressure is displayed

8. P-gear lube oil lim. 2nd limit value for the gearbox -
LOLO lube oil pressure is displayed

9. LO P-gear lube oil GCU Gearbox lube oil pressure is M: Gearbox documentation
too low

10. SS P-gear lube oil GCU Safety system is measuring in- Safety system is measuring inad-
adequate gearbox lube oil equate lube oil pressure:
pressure M: Gearbox documentation
E: Check the measuring channel if
the actual value on the gearbox is
correct; GMU PCB AIB 1

>>

MTU - 04.2002 - E 532 091 / 00 E


Maintenance and repair Part 3
Troubleshooting Page 21

Message, Measures or repair stage


No. fault display or Meaning (E - Electrical,
measuring point text M - Mechanical)

>>

11. T-gear oil Measuring point -


Gearbox oil temperature

12. T-gear oil limit HI Limit value for the gearbox oil -
temperature is displayed

13. HI T-gear oil Gearbox oil temperature too M: Gearbox documentation


high E: Check the measuring channel if
the actual value on the gearbox is
correct: GCU PCB AIB 1

14. AL gear oil filt. con- Gearbox oil filter contaminated M: Gearbox documentation, clean
taminated filter

15. Checkback astern Measuring point of the Remote -


Control System RCS Message only

16. Checkback ahead/en- Measuring point of the Remote -


gaged Control System RCS Message only

17. Neutral/disengaged Measuring point of the Remote -


Control System RCS Message only

18. Ahead/engaged Measuring point of the Remote -


Control System RCS Message only

19. Astern Measuring point of the Remote -


Control System RCS Message only

20. RCS command neutral/ Measuring point of the Remote -


disengaged Control System RCS Message only

21. RCS command ahead/en- Measuring point of the Remote -


gaged Control System RCS Message only

22. RCS command astern Measuring point of the Remote -


Control System RCS Message only

23. Other RCS command neu- Measuring point of the Remote -


tral/disengaged Control System RCS Message only

24. Other RCS command Measuring point of the Remote -


ahead/engaged Control System RCS Message only

25. Other RCS command Measuring point of the Remote -


astern Control System RCS Message only

26. Valve neutral/disen- Measuring point of the Remote -


gaged Control System RCS Message only

27. Valve ahead/engaged Measuring point of the Remote -


Control System RCS Message only

E 532 091 / 00 E - 04.2002 - MTU


Part 3 Maintenance and repair
Page 22 Repair

3.4 Repair

The following table lists all the repair work described in this chapter.

No. Name of task Quali- Time Task ID Page Remarks


ficat. (ca.)
1 Replacing printed cir- AP 0.2 h A-P-GCU-0007 22 -
cuit boards on Periph-
eral Interface Modules

2 Replacing plug-in AP 0.3 h A-P-GCU-0008 26 -


fuses on the BOB 1
printed circuit board

3.4.1 Replacing printed circuit boards on Peripheral Interface Modules


Ident. no.: A-P-GCU-0007

Printed circuit board Fig. 19 shows the structure of a type 2


MPU23 Peripheral Interface Module PIM (contain-
ing four printed circuit boards). The posi-
tion of printed circuit board MPU 23 is the
Printed circuit board Printed circuit board same in every PIM (slot 1) whereas the
other three slots may be fitted with any
printed circuit boards. The numbering of
Printed circuit board
the slots shown in Fig. 19 is the same in
all Peripheral Interface Modules PIM
Slot 1 (fixed definition).

Slot 3

Slot 2

Slot 4

Module cassette

Printed circuit board Module housing


COB 3
(motherboard, internal)

Fig. 19 : Structure of a Peripheral Interface


Module PIM

MTU - 04.2002 - E 532 091 / 00 E


Maintenance and repair Part 3
Repair Page 23

There is no need to dismantle the module housing of a PIM in order to replace


a printed circuit board. All that is needed is to pull the appropriate module cas-
sette out of the module housing.

Only replace printed circuit boards as complete units.

When changing a printed circuit board, consider whether the


board in question contains specific data (information about this is
CAUTION given below).

Proceed as follows in order to replace a


printed circuit board:

1. Pull the module cassette (20/1) out of


the module housing (see Fig. 19)
2

Fig. 20 : Module cassette

2. Fold open the cover of the module


cassette as follows:
Insert a small screwdriver into the re-
cess (20/2) and lever open the cover
1 (21/1);
it is then possible to fold back the
2 cover (21/1)

Fig. 21 : Opening the cover

E 532 091 / 00 E - 04.2002 - MTU


Part 3 Maintenance and repair
Page 24 Repair

Destruction by electrostatic charging.


(C)MOS components and assemblies equipped with (C)MOS
components may be destroyed by electrostatic charging.
Therefore:
CAUTION  Ensure that personnel, tools and worktops are electrostatically
discharged by touching them with earthed metal parts before
they touch electronic components or modules.
 Avoid touching electronic components or assemblies with non-
conductive materials.
 Do not change components or assemblies when the voltage is
switched on.

3. Pull the printed circuit board (22/1) in


question up and out of the module
cassette (22/2)

Fig. 22 : Pulling out a printed circuit board

Preconfigured printed circuit board

The two MPU 23 printed circuit boards are factory-configured and


shall only be replaced by identically configured printed circuit
CAUTION boards by plant personnel.

Spare parts must be ordered accordingly.

If unconfigured assemblies are used, they must be programmed


after installation. This is a task for service personnel and is des-
cribed in part 4 of this manual.

MTU - 04.2002 - E 532 091 / 00 E


Maintenance and repair Part 3
Repair Page 25

4. Select the new printed circuit board


from your stock of spare parts (note
the type and part number, see part 5
of this documentation)
5. Insert the printed circuit board (23/1)
in question into the grooves (23/3) in
1 the module cassette (23/2); take care
not to tilt the printed circuit board
3 (23/1) when doing this

2 3

Fig. 23 : Inserting a printed circuit board

6. Close the cover (24/1) of the module


cassette; make sure that the cover
clips into the housing of the module
cassette (24/2) properly
7. Put the module cassette back into the
1
correct position in the appropriate
module housing; take care not to tilt
the module cassette when doing this
2

Fig. 24 : Closing the cover

Refer to the Internal structure chapter (chap. 1.1.2.2) to see which printed cir-
cuit boards belong in which slots. Also, the part numbers and types are given in
part 5 of this documentation.

E 532 091 / 00 E - 04.2002 - MTU


Part 3 Maintenance and repair
Page 26 Repair

3.4.2 Replacing plug-in fuses on the printed circuit board BOB 1


Ident. no.: A-P-GCU-0008

There are five plug-in fuses on the printed


LEDs channel status relay
LED fault circuit board BOB 1 (fusible links).
Component side
It is necessary to remove the printed cir-
cuit board BOB 1 as described in chap.
3.4.1 (ID no. A-P-GCU-0007) steps 1. to
3. before it is possible to replace a plug-in
fuse. The position of the printed circuit
board BOB 1 is shown in chap. 1.

A plug-in fuse is replaced as follows:

1. Use a pair of pointed pliers to grip the


defective plug-in fuse and pull it out
(the positions are shown in the plan
Plug-in fuse F5
view in Fig. 25)
Plug-in fuse F4
Plug-in fuse F2
Plug-in fuse F3
Plug-in fuse F1
Fig. 25 : Plug-in fuses on BOB 1

2. Put a new plug-in fuse (26/1, 3.15 A


MT) onto the printed circuit board and
carefully press it into the socket (26/2),
taking care not to bend any of the con-
nection pins
3. Put the printed circuit board BOB 1
back into the appropriate module cas-
sette as described in chap. 3.4.1 (ID
no. A-P-GCU-0007), steps 5. to 7.
1
2

Fig. 26 : Replacing a plug-in fuse

Replacement fuses which are used must have the correct electri-
cal ratings:
 F1, F2, F3, F4, F5: 3.15 A MT
CAUTION

MTU - 04.2002 - E 532 091 / 00 E


Service manual Part 4
Table of contents Page I

Part 4

Service manual

E 532 091 / 00 E - 04.2002 - MTU


Part 4 Service manual
Page II Table of contents

(This page intentionally blank)

MTU - 04.2002 - E 532 091 / 00 E


Service manual Part 4
Table of contents Page III

Table of contents

4 Service manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4.1 Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.2.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.2.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2.2.1 Task summary for scheduled maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3.1 Faults without fault code displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3.2 Faults with plain text output on the display of the corresponding Local Operating Panel
LOP 1-01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4.4 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.4.1 Replacing the housing of a Peripheral Interface Module with the motherboard . . . . . . . . . 6
4.4.2 Replacing the processor assembly of a Peripheral Interface Module . . . . . . . . . . . . . . . . . . 10

E 532 091 / 00 E - 04.2002 - MTU


Part 4 Service manual
Page IV Table of contents

(This page intentionally blank)

MTU - 04.2002 - E 532 091 / 00 E


Service manual Part 4
Safety requirements Page 1

4 Service manual

4.1 Safety requirements

IMPORTANT
These safety requirements shall be read and observed by all
personnel involved in operation, care, maintenance or repair of the
products concerned.

Furthermore, the following shall be observed:


 The safety requirements (if provided) in other relevant MTU manuals
 Warning and safety notes and operating and limit values attached to the
products as required
 National accident prevention and safety standards
 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 marked with 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 and repair shall only be performed by qualified and authorized
personnel.

E 532 091 / 00 E - 04.2002 - MTU


Part 4 Service manual
Page 2 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 commanding officer prior to commencing mainte-
nance 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 is in no way responsible for damage caused by using other spare parts.
The manufacturers guarantee is also voided in such cases.
The manufacturer shall not be held responsible if unauthorized changes or modifications
are made to the product and the guarantee shall be voided.
Spare parts shall be properly stored prior to replacement, i.e. particularly protected
against moisture. Defective electronic components and assemblies must be suitably
packed when despatched for repair, i.e. particularly protected against 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 all repair work, the system must be subjected to a function check. Sepa-
rate testing of the repaired component without system integration is insufficient.
When working on the engine, suitable measures shall be taken to prevent accidental start-
ing.

MTU - 04.2002 - E 532 091 / 00 E


Service manual Part 4
Maintenance Page 3

4.2 Maintenance

4.2.1 General notes

This chapter explains work required on Gear Control and Monitoring Unit GCU/GMU 1 to
maintain availability. This work has to be performed with using test and measuring equip-
ment.

Maintenance work on Gear Control and Monitoring Unit GCU/GMU 1 predominantly


involves visual checks. This work is described in part 3 of this documentation. Defective
assemblies must be repaired or replaced immediately.

System failure

Failure to perform the following work in compliance with instruc-


tions and within the time interval indicated can lead to failure of
CAUTION Gear Control and Monitoring Unit GCU/GMU 1 or failure of the
entire PCS-5 system.

If faults are detected, the cause of the fault can be determined and remedied by following
the instructions listed in the following chapters.

E 532 091 / 00 E - 04.2002 - MTU


Part 4 Service manual
Page 4 Maintenance

4.2.2 Maintenance work

4.2.2.1 Task summary for scheduled maintenance work

All work listed in the following table may be performed by plant personnel.

Maintenance work is performed at three different intervals:


 Maintenance echelon W2
 Maintenance echelon W3
 Maintenance echelon W4

The timing of these intervals is linked to the engine maintenance echelon W1 to W5 inter-
val.

Reference documentation:
Refer to the engine documentation for details on the timing of maintenance
work within the interval.

Tasks in connection with scheduled maintenance work are given in part 3 of this docu-
mentation. No further scheduled maintenance work is required for the GCU/GMU 1 as-
sembly.

All work which has to be performed on a Gear Control and Monitoring Unit
GCU/GMU 1 (e.g. port engine or starboard engine) must, as a next step, be
performed separately on all other Gear Control and Monitoring Units GCU/
GMU 1 located in the ship.

MTU - 04.2002 - E 532 091 / 00 E


Service manual Part 4
Troubleshooting Page 5

4.3 Troubleshooting

4.3.1 Faults without fault code displays

The following table lists the possible faults which will be patently obvious to the operator,
but which cannot be rectified by the plant personnel.

No. Fault Fault cause(s) Actions See

1 GCU or GMU is no 1. EEPROM on mother- Replace the PIM hous- A-P-GCU-0009


longer detected in the board defective or not ing, reprogram nodes Page 6
overall system, fault programmed and the baud rate
message on LOP 1-01
(CAN Node XX lost or
similar)

2 A bus is missing (redun- 2. CAN interface of the Replace printed circuit A-P-GCU-0010
dant or default), fault MPU 23 processor board MPU 23; down- Page 10
message on LOP 1-01 PCB defective load program via BDM if
necessary

4.3.2 Faults with plain text output on the display of the corresponding Local
Operating Panel LOP 1-01

Possible fault messages are explained in part 3 of this documentation.

E 532 091 / 00 E - 04.2002 - MTU


Part 4 Service manual
Page 6 Repair

4.4 Repair

The following table lists all the repair work described in this chapter.

No. Name of task Quali- Time Task ID Page Remarks


ficat. (ca.)
1 Replacing the housing SP 0h A-P-GCU-0009 6 -
of a Peripheral Inter-
face Module with the
motherboard

2 Replacing the pro- SP 0h A-P-GCU-0010 10 -


cessor assembly of a
Peripheral Interface
Module

4.4.1 Replacing the housing of a Peripheral Interface Module with the mother-
board
Ident. no.: A-P-GCU-0009

4 Fig. 27 shows a type 1 Peripheral Inter-


face Module PIM. The mechanical pro-
cedure for removal and installation is ex-
plained taking the example of a module of
this type. Removal and installation of a
type 2 Peripheral Interface Module PIM
and of the Gear Control Module GCM is
basically the same, it is merely that there
are more retaining clips (27/3). Proceed
as follows in order to dismantle the mod-
ule housing:

1. Switch off the operating voltage


2. Open the door of the Gear Control
and Monitoring Unit GCU/GMU 1

3 3. Locate the appropriate housing:


2
1  =21.X+A002-A030: GCU
 =21.X+A002-A040: GMU
Fig. 27 : Unfastening the PIM

MTU - 04.2002 - E 532 091 / 00 E


Service manual Part 4
Repair Page 7

4. Note down the terminal assignment of


4
the module to be replaced (allocation
of cable colour to terminal number,
27/1)

1 5. Use a screwdriver to unscrew all con-


nection terminals (screw terminals,
27/2)
5
6. Pull all cables out of the terminals
7. Use a screwdriver to unscrew all
screws (28/1) on the retaining clips
(28/3) and remove the screws

3 2
There is a washer (28/5) under
each screw. Make sure no
washers drop into the inside of
Fig. 28 : Unfastening the PIM the housing.

8. Take the housing (28/4) forwards off


the mounting plate

Proceed as follows to mount a Peripheral


Interface Module PIM on the mounting
plate:

9. Place the new module on the mounting


plate (when doing this, make sure that
the threaded holes line up with the lugs
on the retaining clips)
10. Insert the mounting screws (28/1)
fitted with washers (28/5) and tighten
the screws

1
If the retaining clip (29/1)
happens to be open (pulled
Fig. 29 : Engaging the retaining clip out), push the clip fully in be-
fore putting on the module

Before the system is taken back into operation, it is first necess-


ary to program the correct node address and transmission rate on
the newly fitted Peripheral Interface Module PIM. A programming
PCB PAB 2-01 is required to do this.
CAUTION

E 532 091 / 00 E - 04.2002 - MTU


Part 4 Service manual
Page 8 Repair

Do not replace electronics components when they are live!

De-energise the PIMs in question before starting work.

CAUTION

11. Connect the cables to the terminals in


accordance with the terminal assign-
ment (see step 4.); also tighten ter-
minals which are not occupied

Set the node address and the trans-


1
mission rate as follows:

12. Insert the programming cassette SST


2-01 into the basic module of the Pe-
ripheral Interface Module PIM (Gear
Monitoring Unit GMU) or the Gear
Control Unit GCU
2
13. Make the following settings on the pro-
gramming cassette using the four dial
switches:

 Node number of the PIM within


the target system
 Baud rates of the two CAN in-
Fig. 30 : Inserting the programming cassette terfaces
SST 2-01
14. The switches and light emitting diodes
1 2
of the programming cassette SST
2-01 have the following significance
and functions:
(31/1) MPU 23
(31/2) Diagnostic LEDs
(31/3) S4 Baud rate of 2nd CAN inter-
face
(31/4) S3 Baud rate of 1st CAN inter-
face
(31/5) S5 Programming start button
7 6 5 4 3 (31/6) S2 Node address 2nd digit
(31/7) S1 Node address 1st digit
Fig. 31 : Preparing the programming cas-
sette SST 2-01

MTU - 04.2002 - E 532 091 / 00 E


Service manual Part 4
Repair Page 9

15. The switch settings depend on which


2 1 Peripheral Interface Module PIM has
been replaced:
 GCU: =21.X+A002-A030 (32/1)
Transmission rate of both CAN inter-
faces 125 kilobaud,
node address can be found by refer-
ence to the order-specific documents
 GMU: =21.X+A002-A040 (32/2)
Transmission rate of both CAN inter-
faces 125 kilobaud,
node address can be found by refer-
ence to the order-specific documents

16. Start programming by pressing the


button S5 (31/5); observe the diagnos-
tic LEDs when you do this:
Programming was completed without
Fig. 32 : Arrangement of the two units, GCU any mistakes if both yellow LEDs
and GMU (31/2) light up;
if this is not the case, determine the
cause by reference to the table in the
Appendix and correct the problem

This completes the programming procedure. Now switch off the supply voltage. The pro-
gramming cassette can now be removed and the regular cassettes from the removed Pe-
ripheral Interface Module PIM can be inserted.

E 532 091 / 00 E - 04.2002 - MTU


Part 4 Service manual
Page 10 Repair

4.4.2 Replacing the processor assembly of a Peripheral Interface Module


Ident. no.: A-P-GCU-0010

Fig. 33 shows the structure of a type 2


Printed circuit board
MPU 23
Peripheral Interface Module PIM (GMU) of
the Gear Control and Monitoring Unit
GCU/GMU 1 with the four printed circuit
boards. The position of printed circuit
board MPU 23 is the same in both assem-
Slot 1 blies (GCU and GMU) (slot 1) whereas
the other slots are fitted with printed circuit
boards for recording and outputting sig-
nals.

Module cassette

Fig. 33 : Position of the printed circuit board


MPU 23

There is no need to dismantle the module housing of the corresponding PIM in


order to replace a printed circuit board. All that is needed is to pull the module
cassette and the printed circuit board MPU 23 out of the module housing.

MTU - 04.2002 - E 532 091 / 00 E


Service manual Part 4
Repair Page 11

Proceed as follows in order to replace the


printed circuit board MPU 23:

1. Pull the module cassette (34/1) out of


the module housing (see Fig. 33)
2

Fig. 34 : Module cassette

2. Fold open the cover of the module


cassette as follows:
Insert a small screwdriver into the re-
cess (34/2) and lever open the cover
1 (35/1);
it is then possible to fold back the cov-
2 er (35/1)

Fig. 35 : Opening the cover

3. Pull the printed circuit board MPU 23


(36/1) up and out of the module cas-
sette (36/2)

Fig. 36 : Pulling out the printed circuit board


MPU 23

E 532 091 / 00 E - 04.2002 - MTU


Part 4 Service manual
Page 12 Repair

Destruction due to electrostatic charge.


(C)MOS components and assemblies equipped with (C)MOS
components may be destroyed by electrostatic charging.
Therefore:
CAUTION  Ensure that personnel, tools and worktops are electrostatically
discharged by touching them with earthed metal parts before
they touch electronic components or modules.
 Avoid touching electronic components or assemblies with non-
conductive materials.
 Do not change components or assemblies when the voltage is
switched on.

4. Select the new printed circuit board


MPU 23 from your stock of spare parts
(note the type and part number, see
part 5 of this documentation)

1 The new printed circuit board


MPU 23 must have been pro-
3 grammed with the initial pro-
gram loader (this is normally
2 3 the case when replacement
printed circuit boards are or-
dered properly) before it is
used as a replacement printed
circuit board.

5. Insert the printed circuit board MPU 23


(37/1) into the grooves (37/3) in the
Fig. 37 : Inserting the printed circuit board module cassette (37/2); take care not
MPU 23
to tilt the printed circuit board (37/1)
when doing this

MTU - 04.2002 - E 532 091 / 00 E


Service manual Part 4
Repair Page 13

6. Close the cover (38/1) of the module


cassette; make sure that the cover
clips into the housing of the module
cassette (38/2) properly
1 7. Put the module cassette back into the
correct position in the appropriate
module housing; take care not to tilt
2 the module cassette when doing this

Fig. 38 : Closing the cover

The printed circuit board MPU 23 must now be programmed with the specific plant data.
The method of programming depends on whether the overall plant contains a Program-
mable Process Station PPS.

Reference documentation:
In plants which do not have a Programmable Process Station PPS in the over-
all configuration, it is necessary to perform a manual download using a Backup
Data Module BDM. The BDM tool and the operation of this unit are explained
in the MTU documentation Backup Data Module BDM for Monitoring Systems
PCS-5, documentation parts 1, 2, 5, document no. E 531 718.

In systems with a Programmable Process Station PPS in the overall configur-


ation, the required data are downloaded automatically after the plant operating
voltage is switched on. The system messages on the Local Operating Panel
LOP 1-01 should be observed when this is happening.

E 532 091 / 00 E - 04.2002 - MTU


Part 4 Service manual
Page 14 Repair

(This page intentionally blank)

MTU - 04.2002 - E 532 091 / 00 E


Illustrated parts catalog Part 5
Table of contents Page I

Part 5

Illustrated parts catalog

E 532 091 / 00 E - 04.2002 - MTU


Part 5 Illustrated parts catalog
Page II Table of contents

(This page intentionally blank)

MTU - 04.2002 - E 532 091 / 00 E


Illustrated parts catalog Part 5
Table of contents Page III

Table of contents

5 Illustrated parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Bildtafeln und Tabellen


Illustrations and tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

5.3 Querverweisliste
Cross-reference list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

E 532 091 / 00 E - 04.2002 - MTU


Part 5 Illustrated parts catalog
Page IV Table of contents

(This page intentionally blank)

MTU - 04.2002 - E 532 091 / 00 E


Illustrated parts catalog Part 5
Introduction Page 1

5 Illustrated parts catalog

5.1 Introduction

This illustrated parts catalog forms the basis for spare parts orders.

This parts catalog consists of drawings and corresponding tables as well as a cross-reference list.

The drawings and tables in the parts catalog are also useful when dismantling and re-assembling individual
assemblies. For this reason, the catalog also includes parts for which no spare parts provision has been
made.

Drawings and tables

The headers of the pages with drawings and tables contain the following information:
 EDITION
 PAGE
 PROJECT
 GAPL (name of the corresponding group in German)
 EGC (name in the corresponding foreign language)
 REFERENCE (Bill of Materials (BOM) No. for the part shown in the illustration)
 CATALOG (parts catalog number)
 ILL. TABLE (four-figure drawing number)
 REG. NO. (six-figure registration number)

The contents of the headers on the drawing and table pages differ only in their page numbers (PAGE). All
other information is identical.

The table title row contains the following information:


 C/N Location numbers provide a connection between the components in the
drawings and the parts numbers and designations in the corresponding
table.
The location numbers are sorted in a rising numerical sequence.
 PART NO. The part number of the component to be used when ordering spare parts
 DESIGNATION This cell contains the exact parts name.
A part whose designation is indented to the right in this column (indicated by
preceding dots) is included in a previous part (which is either not indented or
is less indented).
 Q/U Quantity in location. This number applies to the installation location.

E 532 091 / 00 E - 04.2002 - MTU


Part 5 Illustrated parts catalog
Page 2 Introduction

 U/M Unit of measurement for the named part


EA = Each KG = Kilogram MR = Meter
RL = Roll SE = Set
 FN Footnote with references for spare parts queries
The following footnotes may be used:
AB Only available as a complete assembly, repairs only possible in the
manufacturers plant
KE Individual part not intended for delivery as a spare part
KF Calibrated part: Read section Ordering spare parts prior to
ordering
NB Quantity stipulated by customer (as required)
 SUPPLEM. DES./ This column contains standard part designations or manufacturers
REMARKS designations for bought-out parts.
 ILL.-REG. This column gives the cross-reference to a drawing if this assembly is
illustrated in a separate drawing.
 ITEM For internal use only

Cross-reference list

The cross-reference list includes all part numbers contained in the spare parts catalog. The part numbers are
sorted in a rising numerical sequence in the part number column. In addition, the DESIGNATION, ILL.-REG.,
ITEM, C/N and, in some cases, the STOCK NO. and PART NO. NEW are listed for each part number.

Modification service

No modification service is provided to take account of conversions and modifications to part numbers subse-
quent to the completion of the spare parts catalog. We therefore recommend that you mark information about
changes to part numbers in the spare parts catalog. This information is included in the order confirmation
and appears on spare parts labels.

Ordering spare parts

The following information is required in order to process a spare parts order:


 MTU order number
 Engine number and engine model (see nameplate)
 Part number
 Designation
 Quantity and unit of measurement

MTU - 04.2002 - E 532 091 / 00 E


Illustrated parts catalog Part 5
Introduction Page 3

When ordering a calibrated part (marked by KF in the FN column), add the following additional
information:
 If the calibration No. is known (see parts nameplate): Add the calibration number preceded by
an oblique stroke as an extension to the part number: /xxxxx. Example: For calibration number
E1234, the part number 500 536 28 10 is extended resulting in 500 536 28 10/E1234.
 If the calibration No. is not known:
Give a detailed description of the required parts 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 parts 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.: 500 536 28 10/76)

To avoid errors, please confirm all telephone orders in writing.

Delivery of repaired parts

Parts sent to MTU Friedrichshafen for repair must be clearly marked with the MTU order number and engine
number.

E 532 091 / 00 E - 04.2002 - MTU


Part 5 Illustrated parts catalog
Page 4 Introduction

(This page intentionally blank)

MTU - 04.2002 - E 532 091 / 00 E


EDITION: 03.2002 CATALOG: E 532 091 / 00 ED
PAGE: 5
PROJECT: M101

5.2 Bildtafeln und Tabellen


Illustrations and tables
EDITION: 03.2002 GAPL: 84 berwachungseinrichtung CATALOG: E 532 091 / 00 ED
PAGE: 6 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
PROJECT: M101 REFERENCE: 501 530 12 60 REG. NO.: E00634

05 07 08 36, 37, 39, 40, 41


X A
84 01
36 25 E00629
37
A030

38 84 01 26 A040
E00635
50
39 49
X21
LOP
36 54
40
41 51
13, 14 54, 57
20, 21
12

09, 10 08 X
A

A-A
01

61, 63

60

15
11
EDITION: 03.2002 GAPL: 84 berwachungseinrichtung CATALOG: E 532 091 / 00 ED
PAGE: 7 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
PROJECT: M101 REFERENCE: 501 530 12 60 REG. NO.: E00634

ORTZ SACHNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION BILD-REG. POS.-NR.
C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ILL.-REG. ITEM

000 501 530 12 60 ZB ST.G.GCU/GMU 1-02 001 EA KF 840026


HOUSING
01 500 533 13 03 .ZB GEHAEUSE GCU/GMU1 001 EA 840028
.HOUSING
05 518 533 16 91 .FOTOPLATTE X21 LOP 001 EA KE 840030
.PHOTOPLATE
06 500 530 05 26 .ZB KABELB. GCU/GMU1 001 EA KE 840032
.WIRING HARNESS
07 500 533 42 89 .BESCHRIFTUNGSSATZ 001 EA KE 840034
.IDENTIFICATION PLATE
08 000 533 11 90 .SCHUTZLEITERZEICHEN 004 EA KE 840036
.PLATE
09 910001 003100 .NIET 002 EA KE AK 3,2X 7,49 N 10001 840038
.RIVET
10 700425 000032 .SCHILD 001 EA KE 31 MMN 425 840040
.PLATE
11 000 533 13 90 .SCHILD MTU ELEKTRON. 001 EA KE 840042
.PHOTOPLATE
12 700425 000145 .SCHILD 001 EA KE 64.1 MMN 425 840044
.PLATE
13 000 533 07 32 .GRIFF -GEHAEUSE 001 EA 840046
.HANDLE
14 000963 004001 .SENKSCHRAUBE 002 EA M 4 X 10 DIN 963 4.8 DBL 8451.21 840048
.COUNTERSUNK HD SCREW
15 500 533 45 89 .HINW.SCHILD EINSTELL 001 EA KE 840050
.IDENTIFICATION PLATE
20 002 531 57 81 .KABELB.BEFEST.SOCKEL 012 EA 840052
.BASE
21 504 96 .BLINDNIET 012 EA KE 840054
.BLIND RIVET
EDITION: 03.2002 GAPL: 84 berwachungseinrichtung CATALOG: E 532 091 / 00 ED
PAGE: 8 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
PROJECT: M101 REFERENCE: 501 530 12 60 REG. NO.: E00634

Notizen / Notes
EDITION: 03.2002 GAPL: 84 berwachungseinrichtung CATALOG: E 532 091 / 00 ED
PAGE: 9 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
PROJECT: M101 REFERENCE: 501 530 12 60 REG. NO.: E00634

ORTZ SACHNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION BILD-REG. POS.-NR.
C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ILL.-REG. ITEM

25 528 530 92 69 .ZB INTERF.MODUL GCU 001 EA 84 01 840056


.MEASURE/MONITOR MOD E00629
26 528 530 93 69 .ZB INTERF.MODUL GMU 001 EA 84 01 840058
.MEASURE/MONITOR MOD E00635
36 200125 006401 .SCHEIBE 007 EA A 6,4 DIN 125 CUAL11NI6FE5 F73 840060
.WASHER
37 206797 006200 .ZAHNSCHEIBE 002 EA J 6,4 DIN 6797 A2-70 840062
.TOOTHED WASHER
38 200933 006011 .SECHSKANTSCHRAUBE 001 EA M 6 X 25 DIN 933 A4-70 840064
.SCREW
39 000934 006034 .SECHSKANTMUTTER 003 EA M 6 DIN 934 A4-70 840066
.HEX NUT
40 000 159 21 79 .KABELSCHUH 004 EA 840068
.CABLE TERMINAL
41 002 531 14 80 .KABEL 1,23 001 MR 840070
.CABLE
49 015 531 49 83 .SCHUTZKAPPE GR.10 001 EA AB 840072
.MALE CONNECTOR
50 000 533 38 83 .ANBAUGEH. 42-P. 001 EA 840074
.MALE CONNECTOR
51 000 533 41 83 .RAHMEN F.STECKERGEH. 001 EA 840076
.CONNECTOR HOUSING
54 207985 004100 .LINSENSCHRAUBE 012 EA M 4 X 12 DIN 7985 4.8-H DBL 8454 840078
.FILLISTER SCREW
57 000125 004317 .SCHEIBE 008 EA A 4,3 DIN 125 140 HV DBL 8451.11 840080
.WASHER
60 000 533 61 41 .ABSTANDSBOLZEN 002 EA 840082
.SPACER PIN
61 207985 005103 .LINSENSCHRAUBE 002 EA M 5 X 8 DIN 7985 A4-70-H 840084
.OVAL-HEAD SCREW
EDITION: 03.2002 GAPL: 84 berwachungseinrichtung CATALOG: E 532 091 / 00 ED
PAGE: 10 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
PROJECT: M101 REFERENCE: 501 530 12 60 REG. NO.: E00634

Notizen / Notes
EDITION: 03.2002 GAPL: 84 berwachungseinrichtung CATALOG: E 532 091 / 00 ED
PAGE: 11 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
PROJECT: M101 REFERENCE: 501 530 12 60 REG. NO.: E00634

ORTZ SACHNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION BILD-REG. POS.-NR.
C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ILL.-REG. ITEM

63 000125 005322 .SCHEIBE 002 EA A 5,3 DIN 125 140 HV DBL 8451.11 840086
.WASHER
EDITION: 03.2002 GAPL: 84 berwachungseinrichtung CATALOG: E 532 091 / 00 ED
PAGE: 12 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
PROJECT: M101 REFERENCE: 528 530 92 69 REG. NO.: E00629

3, 4
7
5 84 01
8 Z1 E00630
Z1 9 6

116 102 316 302 516 502


115 MPU23 101 315 BOB1 301 515 ROB1 501
CCB1
201 215 401 415 601 615
202 AIB1 216 402 BIB2 416 602 ROB1 616

Z2
Z2

1
1 2
EDITION: 03.2002 GAPL: 84 berwachungseinrichtung CATALOG: E 532 091 / 00 ED
PAGE: 13 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
PROJECT: M101 REFERENCE: 528 530 92 69 REG. NO.: E00629

ORTZ SACHNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION BILD-REG. POS.-NR.
C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ILL.-REG. ITEM

000 528 530 92 69 ZB INTERF.MODUL GCU 001 EA 840002


MEASURE/MONITOR MOD
01 526 530 01 83 .ZB MODUL GCM 1-01 001 EA KF 840004
.MODULAR SYSTEM
02 009 531 43 48 .IC EEPROM SER 8KX 8 001 EA KF 840006
.INTEGRATED CIRCUIT
03 5295308212/S0001 .ZB STECKK.MPU 23-03 001 EA 840008
.PLUG-IN BOARD
04 504 530 78 92 .ZB STECKK. CCB 1-01 001 EA 840010
.PLUG-IN BOARD
05 529 530 86 12 .ZB STECKK. BOB 1-02 001 EA 84 01 840012
.PLUG-IN BOARD E00630
06 526 530 99 12 .ZB STECKK.ROB 1-01 001 EA 840014
.PLUG-IN BOARD
07 529 530 93 12 .ZB STECKK. AIB 1-02 001 EA 840016
.PLUG-IN BOARD
08 504 530 08 97 .ZB STECKK. BIB 2-01 001 EA 840018
.PLUG-IN BOARD
09 526 530 99 12 .ZB STECKK.ROB 1-01 001 EA 840020
.PLUG-IN BOARD
EDITION: 03.2002 GAPL: 84 berwachungseinrichtung CATALOG: E 532 091 / 00 ED
PAGE: 14 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
PROJECT: M101 REFERENCE: 529 530 86 12 REG. NO.: E00630

01
EDITION: 03.2002 GAPL: 84 berwachungseinrichtung CATALOG: E 532 091 / 00 ED
PAGE: 15 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
PROJECT: M101 REFERENCE: 529 530 86 12 REG. NO.: E00630

ORTZ SACHNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION BILD-REG. POS.-NR.
C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ILL.-REG. ITEM

000 529 530 86 12 ZB STECKK. BOB 1-02 001 EA 840022


PLUG-IN BOARD
01 001 531 76 86 .SICHERUNG 3,15A/F 005 EA 840024
.FUSE
EDITION: 03.2002 GAPL: 84 berwachungseinrichtung CATALOG: E 532 091 / 00 ED
PAGE: 16 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
PROJECT: M101 REFERENCE: 528 530 93 69 REG. NO.: E00635

Z1 03, 04 84 01
E00636
Z1
07
05
06

116 102 316 302


115 MPU23 101 315 MFB 1 301
CCB1

201 215 401 415


202 AIB 1 216 402 BIB 2 416

Z2 Z2

01

01 02
EDITION: 03.2002 GAPL: 84 berwachungseinrichtung CATALOG: E 532 091 / 00 ED
PAGE: 17 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
PROJECT: M101 REFERENCE: 528 530 93 69 REG. NO.: E00635

ORTZ SACHNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION BILD-REG. POS.-NR.
C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ILL.-REG. ITEM

000 528 530 93 69 ZB INTERF.MODUL GMU 001 EA 840088


MEASURE/MONITOR MOD
01 528 530 19 83 .ZB MODUL PIM 2-03 001 EA KF 840090
.MODULAR SYSTEM
02 009 531 43 48 .IC EEPROM SER 8KX 8 001 EA KF 840092
.INTEGRATED CIRCUIT
03 5295308212/S0001 .ZB STECKK.MPU 23-03 001 EA 840094
.PLUG-IN BOARD
04 504 530 78 92 .ZB STECKK. CCB 1-01 001 EA 840096
.PLUG-IN BOARD
05 529 530 04 13 .ZB STECKK.MFB 1-01/A 001 EA 84 01 840098
.PLUG-IN BOARD E00636
06 504 530 08 97 .ZB STECKK. BIB 2-01 001 EA 840100
.PLUG-IN BOARD
07 529 530 93 12 .ZB STECKK. AIB 1-02 001 EA 840102
.PLUG-IN BOARD
EDITION: 03.2002 GAPL: 84 berwachungseinrichtung CATALOG: E 532 091 / 00 ED
PAGE: 18 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
PROJECT: M101 REFERENCE: 529 530 04 13 REG. NO.: E00636

01
EDITION: 03.2002 GAPL: 84 berwachungseinrichtung CATALOG: E 532 091 / 00 ED
PAGE: 19 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
PROJECT: M101 REFERENCE: 529 530 04 13 REG. NO.: E00636

ORTZ SACHNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION BILD-REG. POS.-NR.
C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ILL.-REG. ITEM

000 529 530 04 13 ZB STECKK.MFB 1-01/A 001 EA 840104


PLUG-IN BOARD
01 001 531 76 86 .SICHERUNG 3,15A/F 002 EA 840106
.FUSE
EDITION: 03.2002 GAPL: 84 berwachungseinrichtung CATALOG: E 532 091 / 00 ED
PAGE: 20 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
PROJECT: M101 REFERENCE: 529 530 04 13 REG. NO.: E00636

Notizen / Notes
Querverweisliste / Cross Reference List
PROJECT: M101 CATALOG: E 532 091 / 00 ED
EDITION: 03.2002 PAGE: 21

5.3 Querverweisliste
Cross-reference list
Querverweisliste / Cross Reference List
PROJECT: M101 CATALOG: E 532 091 / 00 ED
EDITION: 03.2002 PAGE: 22

SACHNUMMER BENENNUNG BILDTAF. REG.NR. ORTZ VERSORGUNGSNR. SACHNR. NEU


PART NO. DESIGNATION ILL. TAB. REG.NO. C/N STOCK NO. PART NO. NEW
000125 004317 SCHEIBE 84 01 E00634 57 5310-12-174-7451
WASHER
000125 005322 SCHEIBE 84 01 E00634 63 5310-12-178-2567
WASHER
000 159 21 79 KABELSCHUH 84 01 E00634 40
CABLE TERMINAL
000 533 07 32 GRIFF -GEHAEUSE 84 01 E00634 13
HANDLE
000 533 11 90 SCHUTZLEITERZEICHEN 84 01 E00634 08
PLATE
000 533 13 90 SCHILD MTU ELEKTRON. 84 01 E00634 11
PHOTOPLATE
000 533 38 83 ANBAUGEH. 42-P. 84 01 E00634 50
MALE CONNECTOR
000 533 41 83 RAHMEN F.STECKERGEH. 84 01 E00634 51
CONNECTOR HOUSING
000 533 61 41 ABSTANDSBOLZEN 84 01 E00634 60
SPACER PIN
000934 006034 SECHSKANTMUTTER 84 01 E00634 39
HEX NUT
000963 004001 SENKSCHRAUBE 84 01 E00634 14 5305-12-166-5102
COUNTERSUNK HD SCREW
001 531 76 86 SICHERUNG 3,15A/F 84 01 E00630 01
FUSE 84 01 E00636 01
002 531 14 80 KABEL 1,23 84 01 E00634 41
CABLE
002 531 57 81 KABELB.BEFEST.SOCKEL 84 01 E00634 20
BASE
009 531 43 48 IC EEPROM SER 8KX 8 84 01 E00629 02
INTEGRATED CIRCUIT 84 01 E00635 02
015 531 49 83 SCHUTZKAPPE GR.10 84 01 E00634 49
MALE CONNECTOR
200125 006401 SCHEIBE 84 01 E00634 36
WASHER
200933 006011 SECHSKANTSCHRAUBE 84 01 E00634 38
SCREW
206797 006200 ZAHNSCHEIBE 84 01 E00634 37
TOOTHED WASHER
207985 004100 LINSENSCHRAUBE 84 01 E00634 54
FILLISTER SCREW
207985 005103 LINSENSCHRAUBE 84 01 E00634 61
OVAL-HEAD SCREW
500 530 05 26 ZB KABELB. GCU/GMU1 84 01 E00634 06
WIRING HARNESS
500 533 13 03 ZB GEHAEUSE GCU/GMU1 84 01 E00634 01
HOUSING
500 533 42 89 BESCHRIFTUNGSSATZ 84 01 E00634 07
IDENTIFICATION PLATE
500 533 45 89 HINW.SCHILD EINSTELL 84 01 E00634 15
IDENTIFICATION PLATE
501 530 12 60 ZB ST.G.GCU/GMU 1-02 84 01 E00634 000
HOUSING
Querverweisliste / Cross Reference List
PROJECT: M101 CATALOG: E 532 091 / 00 ED
EDITION: 03.2002 PAGE: 23

SACHNUMMER BENENNUNG BILDTAF. REG.NR. ORTZ VERSORGUNGSNR. SACHNR. NEU


PART NO. DESIGNATION ILL. TAB. REG.NO. C/N STOCK NO. PART NO. NEW
504 530 08 97 ZB STECKK. BIB 2-01 84 01 E00629 08
PLUG-IN BOARD 84 01 E00635 06
504 530 78 92 ZB STECKK. CCB 1-01 84 01 E00629 04
PLUG-IN BOARD 84 01 E00635 04
504 96 BLINDNIET 84 01 E00634 21
BLIND RIVET
518 533 16 91 FOTOPLATTE X21 LOP 84 01 E00634 05
PHOTOPLATE
526 530 01 83 ZB MODUL GCM 1-01 84 01 E00629 01
MODULAR SYSTEM
526 530 99 12 ZB STECKK.ROB 1-01 84 01 E00629 06
PLUG-IN BOARD 09
528 530 19 83 ZB MODUL PIM 2-03 84 01 E00635 01
MODULAR SYSTEM
528 530 92 69 ZB INTERF.MODUL GCU 84 01 E00629 000
MEASURE/MONITOR MOD 84 01 E00634 25
528 530 93 69 ZB INTERF.MODUL GMU 84 01 E00634 26
MEASURE/MONITOR MOD 84 01 E00635 000
529 530 04 13 ZB STECKK.MFB 1-01/A 84 01 E00635 05
PLUG-IN BOARD 84 01 E00636 000
5295308212/S0001 ZB STECKK.MPU 23-03 84 01 E00629 03
PLUG-IN BOARD 84 01 E00635 03
529 530 86 12 ZB STECKK. BOB 1-02 84 01 E00629 05
PLUG-IN BOARD 84 01 E00630 000
529 530 93 12 ZB STECKK. AIB 1-02 84 01 E00629 07
PLUG-IN BOARD 84 01 E00635 07
700425 000032 SCHILD 84 01 E00634 10
PLATE
700425 000145 SCHILD 84 01 E00634 12
PLATE
910001 003100 NIET 84 01 E00634 09
RIVET
Querverweisliste / Cross Reference List
PROJECT: M101 CATALOG: E 532 091 / 00 ED
EDITION: 03.2002 PAGE: 24

Notizen / Notes
Appendix
Table of contents Page I

Appendix

Reference documentation

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Appendix
Page II Table of contents

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Appendix
Table of contents Page III

Table of contents

A Reference documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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Appendix
Page IV Table of contents

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Appendix
Reference Documentation Page 1

A Reference documentation

Refer to the following MTU manuals for detailed information on the individual assemblies
associated with and used in the Propulsion Control System PCS:

E 531 685 Engine Control Unit ECU 4 Parts 1, 3, 4, 5


E 531 686 Engine Monitoring Unit EMU 1 Parts 1, 3, 4, 5
E 531 687 Local Operating Panel LOP 1 Parts 1, 3, 4, 5
E 531 712 PCS-5 with FMEA Part 1
E 531 693 PCS-5 system description Part 1

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Appendix
Page 2 Reference Documentation

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Abbreviations Page i

Abbreviations
a Acceleration

BDM Backup Data Module


BR Series (in this case: Engine series)

CAN Controller Area Network, bus designation


CCB Connection board, printed circuit board with serial interface
CB Connection Box

ECS Engine Control System, MTU engine management system


ECU Engine Control Unit

f Formula for frequency,


fl Limit frequency
FPP Fixed Pitch Propeller

g Acceleration due to gravity


GCM Gear Control Module
GCU Gear Control Unit
GMU Gear Monitoring Unit

I/O Input/Output
I Formula for electrical current
IIn Input current
IEC International Electrotechnical Commission
IP International Protection

LED Light Emitting Diode


LOP Local Operating Panel

mA Milliamp
min Minute
mV Millivolt
MCS Monitoring and Control System,
MTU control and monitoring system

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Page ii Abbreviations

Abbreviations (cont.)

MCS-PO Main Control Station


MTU Motoren- und Turbinen-Union
n Speed

p Pressure
PIM Peripheral Interface Module
PPS Programmable Process Station

R Formula for electrical resistance


RAM Random Access Memory
RCS Remote Control System
RS422 Recommended Standard, interface standard

s Second
SDAF Shut Down Air Flap
SISY Sicherheitssystem, safety system
SP Spare part
STn Plug designation

T Temperature

U Voltage
UOUT Output voltage
UB Ship voltage (+24 V)
UIN Input voltage

V Volt
VCC Operating voltage
VDC Voltage Direct Current
Vpp Peak-to-peak voltage value

xpp Vibration test deflection, peak-to-peak value

MTU - 04.2002 - E 532 091 / 00 E