Service Publication: Control Panel Pan 1 Pan 2 Pan 3 Pan 4

Service Publication
MCS-5 Control panel

PAN 1
PAN 2
PAN 3
PAN 4
General applications
Documentation Parts 1, 2, 3, 5, 7, 8
E 531 649 / 01 E
DaimlerChrysler Powersystems 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 Veröffentlichung einschließlich aller seiner Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen
schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Verbreitung, Bearbeitung,
Übersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschließlich Datenbanken
und Online-Diensten.
Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen
Wartungs- und Bedienungspersonal zur Verfügung zu stellen.
Änderungen bleiben vorbehalten.
Printed in Germany
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.
Imprimé en Allemagne
Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU
Friedrichshafen GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches,
la mémorisation et / ou le traitement sur des systèmes électroniques, y compris les bases de données et les services en ligne.
Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à
l’exploitant de le mettre à la disposition du personnel chargé de l’entretien et de la conduite.
Modifications réservées.
Impreso en Alemania
Esta publicación se encuentra protegida, en toda su extensión, por los derechos de autor. Cualquier utilización de la misma, así como su
reproducción, difusión, transformación, traducción, microfilmación, grabación y/o procesamiento en sistemas electrónicos, entre los que se
incluyen bancos de datos y servicios en línea, precisa de la autorización previa de MTU Friedrichshafen GmbH.
El manual debe tenerse presente para evitar fallos o daños durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposición del
personal de mantenimiento y de servicio.
Nos reservamos el derecho de introducir modificaciones.
Stampato in Germania
Questa pubblicazione è protetta dal diritto d’autore in tutte le sue parti. Ciascun impiego od utilizzo, con particolare riguardo alla
riproduzione, alla diffusione, alla modifica, alla traduzione, all’archiviazione in microfilm ed alla memorizzazione od all’elaborazione 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.
E 531 649 / 01 E – 04.2002 –  MTU

Page II Guide
Symbols
The symbols used in safety notes are defined in the chapter “Safety requirements”.
This symbol indicates cross-references to other manuals.
This symbol indicates important information.
This symbol indicates detailed information.
Further troubleshooting or fault rectification requires mechanical work to be performed on other

assemblies or equipment with reference to the relevant documentation.
Further troubleshooting or fault rectification requires work to be performed on the engine with
reference to the engine documentation.
Rectification of a fault marked with this symbol either requires the customer’s 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.
Some of the chapters in this manual contain structured task descriptions. The symbols used here are
explained at the relevant points by associated sub-titles.
ID numbers
Some of the chapters in this manual contain structured task and activity descriptions. Each task and each
activity is assigned an unambiguous identification number (ID no.). This number is structured as follows
X-X-XXX-xxxx whereby:
1st figure: Either “T” for “Task” or “A” for “Activity”

2nd figure: System affected (examples: “M” for MCS, “R” for RCS)
3rd – 5th figure: Unit or assembly (generally corresponding to MTU type designations,
whereby version numbers are omitted)
6th – 9th figure: Serial number (when 1st – 5th figures are identical)
Asterisks (“wildcards”) may be used for the 1st to 5th figures when a task/activity is generally applicable to
all systems/units or if the type designation is shorter than 3 figures.
 MTU – 04.2002 – E 531 649 / 01 E

Guide Page III
Qualification of users of the manual

Abbreviations are used in the manual to indicate qualification of personnel who may carry out the tasks/acti-
vities concerned. The abbreviations refer to the course types available in the MTU training program for the
product concerned and have the following meaning:
E1 The user must have completed a course aimed at operating personnel or have equivalent
knowledge. No metrological requirements are made.
E2 The user must have completed a course aimed at plant personnel or have equivalent
knowledge.
E3 The user must have completed a course aimed at service personnel (electronics).
E4 The user must have completed a course aimed at start-up personnel (electronics).
E 531 649 / 01 E – 04.2002 –  MTU

Page IV Guide
(This page intentionally blank)
 MTU – 04.2002 – E 531 649 / 01 E

Structure and function Part 1
Table of contents Page I
Part 1
Structure and function
E 531 649 / 01 E – 04.2002 –  MTU

Part 1 Structure and function
Page II Table of contents
 MTU – 04.2002 – E 531 649 / 01 E

Table of contents Page III
Table of contents
1 Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Structure of control panel PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.3.1 Control panel PAN 1 – electronic version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.1.1 External structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.1.2 Internal structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3.1.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3.2 Control panel PAN 2 – waterproof electronic version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3.2.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.3 Control panel PAN 3 – contact version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.3.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.4 Control panel PAN 4 – waterproof contact version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.4.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.1 Electronic version – PAN 1 and PAN 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.1.1 Luminous pushbuttons and operating state indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4.1.2 Cap layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4.1.3 Keys/switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.4.1.4 Signal lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.4.1.5 Buzzer (not for PAN 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.4.1.6 Dimming/lamp test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.4.1.7 Automatic process variable diversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.4.1.8 Controlled transition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.4.1.9 Alarm handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.4.1.10 Alarm handling for non-stored alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.4.1.11 Alarm handling for stored alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.4.2 Contact version – PAN 3 and PAN 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.4.2.1 Cap layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.4.2.2 Keys/switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.4.2.3 Signal lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.4.2.4 Buzzer (not for PAN 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.4.2.5 Luminous pushbuttons/switches and operating state indicator . . . . . . . . . . . . . . . . . . . . . . . 29
E 531 649 / 01 E – 04.2002 –  MTU

Page IV Table of contents
Table of contents (cont.)
1.4.3 Internal connection of the CAN buses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1.4.4 Sensor/actuator bus (S/A bus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.4.4.1 Non-redundant field bus 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.4.4.2 Redundant field bus 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.4.5 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.4.6 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.4.6.1 Interfaces on the electronic version – PAN 1 and PAN 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.4.6.2 Interfaces on the contact version – PAN 3 and PAN 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
 MTU – 04.2002 – E 531 649 / 01 E

Use Page 1
1 Structure and function
1.1 Use
Control panel PAN is an assembly which can be used as a display and/or command input unit. The control
panel is extremely versatile as the various functions are configurable (signal lamp only, key or switch, or buz-
zer in place of an LED) as are the colours of the caps and their inscriptions. Possible applications are in:
¯ Console to indicate/control system functions
¯ Engineer alarm system
¯ Local Operating Panel (LOP)
¯ ECS/MCS replacement
¯ Machinery telegraph
¯ Small-scale monitoring and control systems
Process station
Process bus
(redundant)
Field bus 1
Horn Horn
PIM
DIS DIS
S/A bus S/A bus

Control panel PAN Control panel PAN
Fig. 1: Schematic arrangement showing an engineer alarm system by way of example
Use of the control panel is illustrated in fig. 1 which shows an engineer alarm system as an example.
Communication between the control panel and the Monitoring and Control System (MCS) is realized on the
sensor/actuator bus connected to Peripheral Interface Module PIM and then via field bus 1 connected to the
process station (PPS).
The PIM serves as a bridge between the two segments of a network, the sensor/actuator bus and field bus
1, and is required to allow communication between the control panel and the PPS.
E 531 649 / 01 E – 04.2002 –  MTU

Page 2 Use
The PIM can also be used for the acquisition and output of data.
Note: A maximum of 6 control panels can be connected to any one PIM. An appropriate number of
PIMs are required if more control panels are to be incorporated in the system.
Process station PPS

Process bus
(redundant)
Field bus 1
PIM PIM
S/A bus
S/A bus
Control panel PAN Control panel PAN Control panel PAN
Fig. 2: Console application
The application illustrated in fig. 2 also shows a maximum of 6 control panels connected to any one PIM and
that the PIM can also be used to acquire data and/or control actuators.
 MTU – 04.2002 – E 531 649 / 01 E

Features Page 3
1.2 Features
Basic features of the PAN 1 to PAN 4 control panels are:

¯ Configurable cap layout for a wide range of applications
¯ Configurable design including protective flaps to prevent incorrect operation
¯ Configurable design with switches or keys (PAN 3 and PAN 4 only)
¯ CAN-based S/A bus for connection to MCS-5
¯ Housing for console or front panel installation
¯ Special mounting fixtures for installation in thin-walled front panels/console surfaces
¯ Parallel contacts for each key/switch (changeover contacts, PAN 3 and PAN 4 only)
¯ Keys can be programmed to function as switches by software (keytoggle function)
¯ Two separate indicators (which can be controlled independently) are provided for each key (or
switch):
-- Inscribed surface with background illumination
-- SPOT LED in the top-left corner of the inscribed surface
¯ Use in exposed locations possible, resistant to ultraviolet rays (PAN 2 and PAN 4 only)
E 531 649 / 01 E – 04.2002 –  MTU

Page 4 Structure
1.3 Structure of control panel PAN
The control panel is suitable for installation in front panels or consoles. There are 4 different versions:
¯ Control panel PAN 1 – electronic version
¯ Control panel PAN 2 – waterproof electronic version
¯ Control panel PAN 3 – contact version
¯ Control panel PAN 4 – waterproof contact version
The external and internal design of the 4 different versions of the control panel is described in the chapters
below.
1.3.1 Control panel PAN 1 – electronic version
The electronic version of the control panel comprises the following components:
¯ Sturdy cast aluminium housing
¯ 5 luminous pushbuttons with integral spot LED
¯ Buzzer available in place of an LED
¯ Dedicated power supply with supply voltage compensation
¯ Dimmer
¯ Watchdog with operating state indication via LED
¯ Sensor/actuator bus interface/CAN bus integrated in processor COP8
¯ Connection terminal box (for CAN bus and operating voltage)
4
2
Fig. 3: Control panel PAN 1 (front)

1 Spot LED
2 Operating state LED
3 Luminous pushbutton/lamp/horn
4 Protective flap
 MTU – 04.2002 – E 531 649 / 01 E

Structure Page 5
1.3.1.1 External structure
1
2
3
4
5
Fig. 4: Control panel PAN 1 – electronic version

1 Front panel/housing
2 Key/switch with spot LED
3 Protective flap
4 Connector
5 M4 stay-bolt
E 531 649 / 01 E – 04.2002 –  MTU

Page 6 Structure
1.3.1.2 Internal structure
8
9
Fig. 5: Control panel PAN 1 – electronic version

1 Pushbutton housing with actuator plunger and engraved inscription plate
2 Seal
3 Upper housing
4 Frame (of the actuator housing)
5 Knurled nut (of the actuator housing)
6 Printed circuit board incorporating all electronics
7 Connector
8 Rear cover
9 Rear cover fixing screws
 MTU – 04.2002 – E 531 649 / 01 E

Structure Page 7
1.3.1.3 Technical data
Dimensions (W x H x D) 220 mm x 56 mm x 67 mm
Mass 0.6 kg
Operating voltage 24 VDC, --50 % … +30 %
Residual ripple as per STANAG 1008 Less than 5 %
Power consumption Iin < 220 mA
Degree of protection as per DIN 40 050

Above console surface IP 65
When a buzzer is used IP 30
Below console surface IP 20
Ambient temperature 0 °C … +55 °C
Storage temperature --25 °C … +70 °C
Relative humidity 0 % … 95 %, non-condensing
Shock 15 g/11 ms
Vibrostability
2 Hz … 12.8 Hz xpp = 3 mm
12.8 Hz … 100 Hz a = 1 g
EMC EN 50 081-2/EN 50 082-2
E 531 649 / 01 E – 04.2002 –  MTU

Page 8 Structure
1.3.2 Control panel PAN 2 – waterproof electronic version

The waterproof electronic version of the control panel comprises the following components:
¯ Cast rear housing with waterproof cable entries
¯ 5 luminous pushbuttons with integral spot LED
¯ Silicone caps covering each luminous pushbutton
¯ Dimmer
¯ Connection terminal box (for CAN bus and operating voltage)
1
5
2 4
3

1 Spot LED
3 Luminous pushbutton/lamp
4 Silicone cap
5 Protective flap
1
2
3
4
5
Fig. 7: Control panel PAN 2 – waterproof electronic version

1 Front panel
2 Key/switch with spot LED and silicone cap
3 Protective flap
4 Cable entries
5 M4 stay-bolts
 MTU – 04.2002 – E 531 649 / 01 E

Structure Page 9
3
4
7
8
10
11
12
13
14
15
Fig. 8: Control panel PAN 2 – waterproof electronic version

1 Silicone cap
3 Seal
4 Spacer frame
5 Upper housing
6 Frame (for the actuator housing)
7 Knurled nut (for the actuator housing)
9 Connector
10 Seal
11 Rear housing
12 Sintered filter
13 Cable entry
14 Plug for cable entry
15 Rear housing fixing screws
E 531 649 / 01 E – 04.2002 –  MTU

Page 10 Structure
Mass 0.9 kg

Ambient temperature --25 °C … +70 °C
Shock 10 g/11 ms
Vibrostability
2 Hz … 12.8 Hz xpp = 3 mm
12.8 Hz … 100 Hz a = 1 g
EMC EN 50 081-2/EN 50 082-2
 MTU – 04.2002 – E 531 649 / 01 E

Structure Page 11
1.3.3 Control panel PAN 3 – contact version
The contact version of the control panel comprises the following components:
¯ 5 luminous pushbuttons and/or switches with integral spot LED
¯ Additional PCB frame with PCB for the 2nd key/switch contact level
¯ Dimmer
¯ Sensor/actuator bus interface CAN bus integrated in processor COP8
¯ 4 connection terminal blocks
-- 1 x CAN bus and operating voltage
-- 3 x additional key/switch connections (5 floating changeover contacts)
4
2

1 Spot LED
3 Luminous pushbutton/lamp/horn
4 Protective flap
E 531 649 / 01 E – 04.2002 –  MTU

Page 12 Structure
3
4
5
Fig. 10 : Control panel PAN 3 – contact version

2 Key/switch with spot LED
3 Protective flap
4 Connector
5 M4 stay-bolts
 MTU – 04.2002 – E 531 649 / 01 E

Structure Page 13
9
10
Fig. 11 : Control panel PAN 3 – contact version

2 Seal
3 Upper housing
6 Contacts
7 Printed circuit boards incorporating all electronics
8 Connector
9 Frame
10 Rear cover
E 531 649 / 01 E – 04.2002 –  MTU

Page 14 Structure
Mass 0.9 kg

When a buzzer is used IP 30
Ambient temperature 0 °C … +55 °C
Shock 15 g/11 ms
Vibrostability
2 Hz … 12.8 Hz xpp = 3 mm
12.8 Hz … 100 Hz a = 1 g
EMC EN 50 081-2/EN 50 082-2
2nd contact level load rating 250 V/1 A
 MTU – 04.2002 – E 531 649 / 01 E

Structure Page 15
1.3.4 Control panel PAN 4 – waterproof contact version
The contact version of the control panel comprises the following components:
¯ Sturdy cast iron housing
¯ Cast rear housing with waterproof cable entries
¯ 5 luminous pushbuttons and/or switches with integral spot LED
¯ Silicone caps covering each luminous pushbutton
¯ Additional PCB frame with PCB for the 2nd key/switch contact level
¯ Dimmer
¯ 4 internal connection terminal blocks
-- 1 x CAN bus and operating voltage
-- 3 x additional key/switch connections (5 floating changeover contacts)
1
5
2 4
3
Fig. 12 : Control panel PAN 4 (front)

1 Spot LED
2 Operating status LED
3 Luminous pushbutton/lamp
4 Silicone cap
5 Protective flap
E 531 649 / 01 E – 04.2002 –  MTU

Page 16 Structure
1
2
3
Fig. 13 : Control panel PAN 4 – waterproof contact version

2 Key/switch with spot LED and silicone cover
3 Protective flap
4 M4 stay-bolts
5 Cable entries
 MTU – 04.2002 – E 531 649 / 01 E

Structure Page 17
1
2
3
12
4
5 13
6
18
7 14
17
8
9
15
10
16
11
Fig. 14 : Control panel PAN 4 – waterproof contact version

1 Silicone cap
3 Seal
4 Spacer frame
5 Upper housing
8 Seal
9 Contacts
11 Connector
12 Frame
13 Seal
14 Rear housing
15 Cable entry
16 Plug for cable entry
17 Rear housing fixing screws
18 Sintered filter
E 531 649 / 01 E – 04.2002 –  MTU

Page 18 Structure
Mass 1.2 kg

Ambient temperature --25 °C … +55 °C
Shock 10 g/11 ms
Vibrostability
2 Hz … 12.8 Hz xpp = 3 mm
12.8 Hz … 100 Hz a = 1 g
EMC EN 50 081-2/EN 50 082-2
2nd contact level load rating 250 V/1 A
 MTU – 04.2002 – E 531 649 / 01 E

Functions Page 19
1.4 Functions
1.4.1 Electronic version – PAN 1 and PAN 2
Features of the electronic version of the PAN control panel are:

¯ Configurability
¯ Alarm handling (flashing, acknowledgement)
¯ Signal lamps (background illumination, spot, dimming)
¯ Buzzer in place of a multi-LED
(background illumination is not available for the remaining four signalling units (luminous push-
button/switch lamps or signal lamps) when a buzzer is used)
¯ Key/switch function
¯ Automatic process variable diversion
¯ Adjustable node address set by jumpers
¯ Integral self-test function with LED indication
¯ Lamp test
Node
addr. COP8 PWM
Multi-LEDs 24 VDC/
100 mA
Driver/ Power
dimming supply
Spots 5 VDC/
180 mA
12 VDC
to
32 VDC
BUS
driver
S/A bus
Pushbuttons
Contact design
Watch-
dog
Fig. 15 : Block circuit diagram of the electronic version of the control panel
Note: Electrical and electronic functionality are identical on both the PAN 1 and PAN 2 control panels.
However, PAN 2 has a higher protection index and is waterproof.
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Page 20 Functions
1.4.1.1 Luminous pushbuttons and operating state indicator
The 5 luminous pushbuttons (3/3) are all designed as keys. Function and configurability (key or switch, indi-
cator lamp only or buzzer, cap colour and inscription) are described in chap. 1.4.1.
Features:
¯ Multi-LEDs for pushbutton illumination (long service life)
¯ Adjustable brightness (dimming)
A green LED (3/2) to the left of the luminous pushbuttons indicates the operating state of the control panel
as follows:
¯ LED dark: No operating voltage
¯ LED lit: Normal operation, no fault detected (PAN active in CAN network)
¯ LED flashing slowly (at approx. 2 Hz):
Communication via CAN bus disrupted or failed (CAN timeout)
For redundant CAN bus (display), LED only flashes when both
buses have failed.
¯ LED flashing rapidly (at approx. 8 Hz):
Watchdog triggered (hardware faulty)
 MTU – 04.2002 – E 531 649 / 01 E

Functions Page 21
1.4.1.2 Cap layout
The control panel comprises a basic unit and project-specific components for the controls/signal lamps or
buzzer.
The basic unit is available in various versions, e.g.:

¯ None of the 5 pushbutton housings equipped with a protective flap
¯ 5th pushbutton housing (to the left of the MTU logo) equipped with a protective flap
Note: Any random combination of keys, switches, lamps and buzzers is basically conceivable.
Key/switch Signal lamp Buzzer

(not for PAN 2)
1
7
2
3
8
4
Basic unit
Fig. 16 : Cap layout (example for PAN 1)
1 Cap for switch/key 5 Multi-LED

2 Cap for signal lamp 6 Blocking ring
3 Inscription label (engraved plate) 7 Cap for buzzer
4 Actuator plunger 8 Buzzer
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Page 22 Functions
1.4.1.3 Keys/switches
All the controls are designed as pushbuttons. The switch function is realized by software programming. Both
sets of information (key and switch function) are transmitted to the PIM where configuration data determines
which function is applied. The various settings are therefore not stored for use when the power supply is
switched on.
The control panel can be configured with pushbutton/switch caps (16/1) in green, red, white, blue and yellow.
The engraved plate (16/3) can be inscribed with text (3 lines of 9 characters), symbols (1 symbol per push-
button) and special characters.
Light-emitting diodes (16/5) are available in green, red, blue and yellow to match the various caps.
1.4.1.4 Signal lamps
A different cap (16/2) is used in cases where controls only serve as signal lamps. These caps are also avai-
lable in green, red, white, blue and yellow.
The actuator plunger is secured by a blocking ring (16/6) in addition.
1.4.1.5 Buzzer (not for PAN 2)
A different cap (16/7) is used in cases where controls are replaced by a buzzer.
A buzzer (16/8) is used in place of a multi-LED.
Inscription plate and actuator plunger are not required in this configuration.
Note: Background illumination is not available for the remaining four signalling units (lights in a lumi-
nous pushbutton/switch or signal lamp) when a buzzer is used.
The degree of protection afforded is reduced to IP 30 in this case.
 MTU – 04.2002 – E 531 649 / 01 E

Functions Page 23
1.4.1.6 Dimming/lamp test
Field bus 1
PIM
Dimming value
PIM (12 stages)
DIM↑ DIM↓
S/A bus
PV 3 PV 1 PV 2
PV 4 (binary) (binary)
PV 5
(analog)
DIM ↑ DIM ↓ Lamp test
Fig. 17 : Dimming and lamp test
The appropriate pushbuttons must be configured to dim one or more control panels or to realize the lamp
test function.
Binary signals are transmitted to the PIM when the “DIM ↑” or “DIM ↓” pushbuttons are pressed.
The Peripheral Interface Module PIM subsequently transmits an analog dimming value (12 stages) to the
group of panels in 3 separate channels (for signal lamp, spot LED and background illumination). The desired
brightness is set by a PWM signal.
A binary signal is transmitted to the PIM when the “Lamp test” pushbutton is pressed.
A lamp test is triggered when the “Lamp test” command is transmitted from the PIM to the group of panels
(effective group range is configurable).
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Page 24 Functions
1.4.1.7 Automatic process variable diversion
Field bus 1
Process bus
(redundant)
PVy (binary)
Process station PPS
PIM BOB
PVx (binary)
Sensor/actuator bus
Fig. 18 : Dimming and lamp test
The “Automatic PV diversion” feature allows a maximum of 6 PVs to be multiplied in the PIM where they are
then available for use in the form of output signals.
1.4.1.8 Controlled transition
Field bus 1
Process bus
(redundant)
PVPushbutton (binary)
Process station PPS

PVLamp
PIM
PVPushb.
M
PVLamp (binary) PVPushbutton (binary)
Sensor/actuator bus
Fig. 19 : Controlled transition (e.g. start engine)
The “Controlled transition” function involves the signal lamp flashing once the pushbutton has been pressed
(e.g. start engine), until appropriate feedback (e.g. “Engine running” or “Speed reached”) causes the signal
lamp to light up steadily.
 MTU – 04.2002 – E 531 649 / 01 E

Functions Page 25
1.4.1.9 Alarm handling
Alarm acknowledgement can be local (pushbutton on the control panel) or global (external command unit).
Various forms of alarm acknowledgement can be programmed.
1.4.1.10 Alarm handling for non-stored alarms
Alarm status Tripped by CAN messsage Indication on PAN
No alarm Alarm = 0 Signal lamp in basic brightness
New alarm Alarm = 1 Horn/beacon on

Signal lamp flashing
Horn/beacon acknowledged 1st alarm acknowledgement Horn/beacon off

Signal lamp continues flashing
Alarm acknowledged 2nd alarm acknowledgement Signal lamp steady
Alarm cause no longer applied Alarm = 0 Signal lamp in basic brightness

without further alarm
acknowledgement
1.4.1.11 Alarm handling for stored alarms
Alarm status Tripped by CAN messsage Indication on PAN
New alarm Alarm = 1 Horn/beacon on

Signal lamp flashing
Horn/beacon acknowledged 1st alarm acknowledgement Horn/beacon off

Signal lamp continues flashing
Alarm acknowledged 2nd alarm acknowledgement Signal lamp steady
Alarm cleared Alarm reset Signal lamp in basic brightness
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Page 26 Functions
1.4.2 Contact version – PAN 3 and PAN 4
Features of control panel PAN are:

¯ Configurability
¯ Alarm handling (flashing, acknowledgement)
¯ Signal lamps (background illumination, spot, dimming)
¯ Buzzer in place of a multi-LED
¯ Pushbutton/switch function
¯ Additional 2nd key/switch contact level
¯ Automatic process variable diversion
¯ Adjustable node address set by jumpers
¯ Integral self-test function with LED indication
¯ Lamp test
The functions of the contact version of the control panel are identical to those of the electronic version.
Note: Only those features which differ from those of the electronic version are described in this
section.
Node PWM
addr. COP8
Multi-LEDs 24 VDC/
100 mA
Driver/ Power
dimming supply
Spots 5 VDC/
180 mA
12 VDC
Keys/switches to
32 VDC
BUS 1a 2a 3a 4a 5a
driver
S/A bus
2nd contact level
1b 2b 3b 4b 5b Contact design
Watch-
dog
Tl. 14
Tl. 12
Tl. 24
Tl. 21
Tl. 22
Tl. 34
Tl. 31
Tl. 32
Tl. 44
Tl. 41
Tl. 42
Tl. 54
Tl. 51
Tl. 52
Tl. 11
Connection terminals
Fig. 20 : Block circuit diagram of the contact version of the control panel
Note: Electrical and electronic functionality are identical on both the PAN 3 and PAN 4 control panels.
However, PAN 4 has a higher protection index and is waterproof.
 MTU – 04.2002 – E 531 649 / 01 E

Functions Page 27
1.4.2.1 Cap layout
The control panel comprises a basic unit and project-specific components for the controls/signal lamps or
buzzer.
The basic unit is available in various versions, e.g.:

¯ None of the 5 pushbutton housings equipped with a protective flap
¯ 5th pushbutton housing (to the left of the MTU logo) equipped with a protective flap
¯ 3 pushbutton housings (to the left of the MTU logo) equipped with a protective flap
Note: Any random combination of keys, switches, lamps and buzzers is basically conceivable.
Key/switch Signal lamp Buzzer

(not for PAN 4)
1
2 7
3
8
4
5
6
Basic units
10
Fig. 21 : Cap layout (example for PAN 1)

1 Cap for switch/key 6 Blocking ring
2 Cap for signal lamp 7 Cap for buzzer
3 Inscription label (engraved plate) 8 Buzzer
4 Actuator plunger 9 Switching unit (key/switch)
5 Multi-LED 10 Fixing screws
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Page 28 Functions
1.4.2.2 Keys/switches
The controls can be configured either as keys and as switches. Suitable contacts (21/9) must be used accor-
dingly (hardware). All the controls are programmed as keys in the software for this application as the swit-
ching function is realized by the hardware. The changeover contacts for the 2nd contact level are connected
as floating contacts on connector terminal blocks at the back of the panel.
The control panel can be configured with key/switch caps (21/1) in green, red, white, blue and yellow.
The engraved plate (21/3) can be inscribed with text (3 lines of 9 characters), symbols (1 symbol per push-
button) and special characters.
1.4.2.3 Signal lamps
A different cap (21/2) is used in cases where controls only serve as signal lamps. These caps are also avai-
lable in green, red, white, blue and yellow.
The actuator plunger is secured by a blocking ring (21/6) in addition.
1.4.2.4 Buzzer (not for PAN 4)
A different cap (21/7) is used in cases where controls are replaced by a buzzer.
A buzzer (21/8) is used in place of a multi-LED.
Inscription plate and actuator plunger are not required in this configuration.
 MTU – 04.2002 – E 531 649 / 01 E

Functions Page 29
1.4.2.5 Luminous pushbuttons/switches and operating state indicator
The 5 controls (3/3) can be designed either as keys or switches. They can also be equipped with protective
flaps as an option. They also incorporate a 2nd contact level which is connected to 3 connection terminal
blocks at the back of the control panel. The functions of the keys/switches and their configuration (key or
switch, signal lamp only, buzzer instead of multi-LED, cap colour and cap texts) are described in chap. 1.4.2.
Features:
¯ LEDs for key/switch illumination (long service-life)
¯ Adjustable brightness (dimming)
¯ 2nd contact level (5 floating changeover contacts)
A green LED (3/2) to the left of the luminous pushbuttons indicates the operating state of the control panel
as follows:
buses have failed.
E 531 649 / 01 E – 04.2002 –  MTU

Page 30 Functions
1.4.3 Internal connection of the CAN buses
Two different versions are used to connect the buses in a system involving PAN control panels:
¯ Version with non-redundant field bus 1
¯ Version with redundant field bus 1
These two versions differ with regard to the distribution of the CAN buses at the Peripheral Interface Module
(PIM).
Note: CAN bus connection is principally the same on all four versions/variants.
1.4.4 Sensor/actuator bus (S/A bus)
The S/A bus is used to adapt the control panel. Bus properties are listed below:
¯ Bus coupling and bus medium as per ISO 11898 Rev. 2.0 Part B
¯ Data rate 125 kbit/s
¯ CAN telegrams 8 byte user data
¯ Bus length max. 50 m
¯ Number of nodes max. 15
¯ Fault withstandability for voltages ranging between --6 V and +32 V
¯ Transmission output current > 1 mA
¯ 5 VDC power supply
¯ Linear bus topology
The connected control panels signal their state (ready for operation) after the reset phase.
The PIM then commences cyclical communication with the control panels.
Data transfer: From PIM to control panel

¯ Only changes are transmitted (delta generation in the PIMl)
¯ All states are transmitted in the timeout cycle
¯ An alive signal is transmitted every 500 ms
¯ A flashing synchronization signal is transmitted every 60 seconds
Data transfer: From control panel to PIM

¯ Only changes are transmitted (delta generation in the control panel)
¯ All states are transmitted in the timeout cycle
¯ An alive signal is transmitted every 500 ms
¯ Transmission of key/switch state data
 MTU – 04.2002 – E 531 649 / 01 E

Functions Page 31
1.4.4.1 Non-redundant field bus 1
Process bus
(redundant)
Field bus 1
Process station PPS
MPU 24 with SCB
Peripheral Interface Module

PIM
S/A bus
Control panel PAN
Fig. 22 : Connection of a PAN control panel on a non-redundant field bus 1
The sensor/actuator bus is connected to the SCB interface extension when one (or more) PAN control
panels are connected to a system in which field bus 1 is not of redundant design. The SCB is located on pro-
cessor printed circuit board MPU 23. In this case, field bus 1 is connected to the (standard) interface of the
processor printed circuit board.
E 531 649 / 01 E – 04.2002 –  MTU

Page 32 Functions
1.4.4.2 Redundant field bus 1
Field bus 1 Process bus

(redundant) Process station PPS (redundant)
MPU 24 with SCB
Peripheral Interface Module

SAB PIM
S/A bus
Control panel PAN
Fig. 23 : Connection of a PAN control panel to a redundant field bus 1
The sensor/actuator bus is connected to a separate type SAB 1 printed circuit board when one (or more)
PAN control panels are connected to a system with a redundant field bus 1.
The interface extension SCB located on printed circuit board MPU 23 is used to connect the (redundant)
field bus 1 in this case.
Field bus 1 (default) is also connected to the (standard) interface of processor printed circuit board MPU 24
in this case.
 MTU – 04.2002 – E 531 649 / 01 E

Functions Page 33
1.4.5 Configuration
The control panels do not differ with regard to their basic design and are only programmed for their final use
by appropriate configuration.
Configurable parameters/functions are:

¯ Node-specific information (PV name/type, node number)
¯ Measuring point description and assignment of the measuring point to the pushbutton/lamp
¯ Cap layout (inscription and symbols)
¯ Colours of signal lamps and pushbutton caps
¯ Type of acknowledgement (external acknowledgement/local acknowledgement)
¯ Assignment of alarms to acknowledgement measuring point
¯ Alarm stored/not stored
¯ Controls (keys/switches) or just signal lamp, or just buzzer
¯ Function of the controls (key or switch)
¯ Assignment of pushbutton measuring point to indicator measuring point (controlled transition)
¯ Dimming pushbutton measuring point
¯ Blinkmaster (flashing synchronization)
¯ Panel group for the alarm reset, alarm acknowledgement, dimming and lamp test functions
¯ Flashing frequency for alarm and controlled transition
(preset to: 2 Hz for alarm, 8 Hz for controlled transition)
The project configuration tool supplies the appropriate lists describing the panel. In conjunction with the
arrangement drawings, these are used to manufacture the control panel for its specific application.
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Page 34 Functions
1.4.6 Interfaces
1.4.6.1 Interfaces on the electronic version – PAN 1 and PAN 2
A terminal block is located on the back of the control panel to connect the sensor/actuator bus and the
operating voltage (+24 VDC) .
Jumpers for address setting

(node number)
+24 VDC Tl. 1

CAN H Tl. 61
PE Tl. 3
CAN L (CAN GND) Tl. 62
GND (--) Tl. 2
Fig. 24 : Control panel PAN (rear view of PAN 1)
Note: The connector and address setting jumpers are inaccessible on control panel PAN 2 until the
cast housing with the cable entries is removed after undoing the 6 screws.
 MTU – 04.2002 – E 531 649 / 01 E

Functions Page 35
1.4.6.2 Interfaces on the contact version – PAN 3 and PAN 4
4 terminal blocks are located on the back of the control panel.
One terminal block is used to connect the sensor/actuator bus and the operating voltage
(+24 VDC).
Three additional terminal blocks are provided for the 5 floating changeover contacts of the keys/switches.
Jumpers for address setting

(node number)
(C1) Tl. 11 (NC1) Tl. 12 (NO1) Tl. 14 +24 VDC Tl. 1

(C2) Tl. 21 (NC2) Tl. 22 (NO2) Tl. 24 CAN H Tl. 61
(C3) Tl. 31 (NC3) Tl. 32 (NO3) Tl. 34 PE Tl. 3
(C4) Tl. 41 (NC4) Tl. 42 (NO4) Tl. 44 CAN L (CAN GND) Tl. 62
(C5) Tl. 51 (NC5) Tl. 52 (NO5) Tl. 54 GND (--) Tl. 2
Fig. 25 : Control panel PAN (rear view of PAN 3)
Note: The connectors and address setting jumpers are inaccessible on control panel PAN 4 until the
cast housing with the cable entries is removed after undoing the 6 screws.
E 531 649 / 01 E – 04.2002 –  MTU

Page 36 Functions
 MTU – 04.2002 – E 531 649 / 01 E

Operation Part 2
Part 2
Operation
E 531 649 / 01 E – 04.2002 –  MTU

Part 2 Operation
 MTU – 04.2002 – E 531 649 / 01 E

Operation Part 2
Table of contents
2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.2 Operating procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.2.1 Operating the luminous pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.1.1 Lamp test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.1.2 Acknowledging a stored alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2.1.3 Acknowledging a non-stored alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2.1.4 Dimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
E 531 649 / 01 E – 04.2002 –  MTU

Part 2 Operation
 MTU – 04.2002 – E 531 649 / 01 E

Operation Part 2
Safety requirements Page 1
2 Operation
2.1 Safety requirements
IMPORTANT:
These safety requirements shall be read and observed by all personnel
involved in operation, care, maintenance, repair, installation or commissioning
of the products described.
Furthermore, the following shall be observed:

¯ The safety requirements (if provided) in other relevant MTU manuals
¯ Warning and safety information 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 indicated by a signal word. These safety
notes shall be observed to avoid injury or damage.
This type of note indicates a danger which may lead to injury or death.
DANGER
This type of note indicates a danger which may lead to damage or

destruction of the product described or another part of the system.
CAUTION
Intended use and user qualifications
All devices and system components may only be put to their intended use.
Operation, maintenance, repair, installation and commissioning shall only be performed by qualified and
authorized personnel.
E 531 649 / 01 E – 04.2002 –  MTU

Part 2 Operation
Page 2 Safety requirements
Safety requirements for commissioning
Before first using the electronic product, it must be installed in accordance with the instructions and
approved to MTU specifications.
Whenever the device or system is taken into operation

¯ All maintenance and repair work must have been completed
¯ Any loose parts must have been removed from rotating machine components
¯ All personnel must be clear of the danger zone represented by moving parts
Immediately after taking the device or system into operation, the control and display elements as well as the
monitoring, signalling and alarm systems must be tested for proper operation.
Safety requirements for operation
The emergency procedures must be practiced on a regular basis.
The operator must be familiar with the control and display elements.
The operator must know the effects of any action he/she performs.
The operator must proceed with the individual steps as specified in the documentation.
During operation, the display elements and monitoring assemblies must be supervised with respect to
current operating states, violation of limit values as well as warnings and alarm messages.
If a fault in the system is detected or signalled by the system, the appropriate steps must be taken
immediately and the fault reported to the person in charge.
Every message must be evaluated immediately. Emergency countermeasures shall be taken immediately as
required, e.g. emergency engine stopping.
 MTU – 04.2002 – E 531 649 / 01 E

Operation Part 2
Operating procedures Page 3
2.2 Operating procedures
2.2.1 Operating the luminous pushbuttons
A description of operation in general terms is not possible as both the design and function of the control
panels are configurable.
The examples below are based on the assumption that a control panel or a group of panels feature the
following operating functions:
¯ Lamp test
¯ Alarm acknowledgement
¯ Dimming
2.2.1.1 Lamp test
Incorrect interpretation of indicated states owing to a faulty signal lamp can be avoided by performing a lamp
test.
Pre-requisites
¯ Control panel active
Activity
1. Press luminous pushbutton LAMP TEST.
Effects
1. All signal lamps on the control panel or group of panels light up brightly.
E 531 649 / 01 E – 04.2002 –  MTU

Part 2 Operation
Page 4 Operating procedures
2.2.1.2 Acknowledging a stored alarm
New alarms are indicated by flashing of the appropriate signal lamp and/or an acknowledgement pushbutton.
A horn/beacon can also be activated.
Pre-requisites
¯ An alarm has been signalled
¯ Corresponding signal lamps flash
¯ Horn/beacon activated
1st activity
1. Press luminous pushbutton ACKNOWLEDGE.
Effects
1. Horn and beacon are switched off.
2nd activity
1. Press luminous pushbutton ACKNOWLEDGE again.
2. Alternatively: Acknowledgement is effected externally.
Effects
1. Flashing signal lamps/luminous pushbuttons change to steady illumination.
3rd activity
1. Cause of the alarm must be rectified.
2. Press luminous pushbutton ALARM RESET.
Effects
1. Signal lamps/luminous pushbutton light up in basic brightness.
 MTU – 04.2002 – E 531 649 / 01 E

Operation Part 2
Operating procedures Page 5
2.2.1.3 Acknowledging a non-stored alarm
New alarms are indicated by flashing of the appropriate signal lamp and/or an acknowledgement pushbutton.
A horn/beacon can also be activated.
Pre-requisites
¯ An alarm has been signalled
¯ Corresponding signal lamps flash
¯ Horn/beacon activated
1st activity
1. Press luminous pushbutton ACKNOWLEDGE.
Effects
1. Horn and beacon are switched off.
2nd activity
1. Press luminous pushbutton ACKNOWLEDGE again.
2. Alternatively: Acknowledgement is effected externally.
Effects
1. Flashing signal lamps/luminous pushbuttons change to steady illumination.
3rd activity
1. Cause of the alarm must be rectified.
Effects
1. Signal lamps/luminous pushbutton (automatically) light up again in basic brightness.
E 531 649 / 01 E – 04.2002 –  MTU

Part 2 Operation
Page 6 Operating procedures
2.2.1.4 Dimming
The brightness of the luminous pushbuttons and/or signal lamps on the control panel can be adjusted using
the luminous pushbuttons for dimming (e.g. DIM +/DIM -- or DIM ↑/DIM ↓ etc.).
Pre-requisites
Activity
1. Press luminous pushbutton for “Increase dimming”.
Effects
1. Brightness increases as long as the pushbutton is pressed.
Or activity
1. Press luminous pushbutton for “Decrease dimming”.
Effects
1. Brightness decreases as long as the pushbutton is pressed.
 MTU – 04.2002 – E 531 649 / 01 E

Maintenance and repair Part 3
Part 3
Maintenance and repair
E 531 649 / 01 E – 04.2002 –  MTU

Part 3 Maintenance and repair
 MTU – 04.2002 – E 531 649 / 01 E

Table of contents
3 Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3.1 Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3.2 General information about this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.2.1 Task duration and personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2.2 Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2.3 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Tools, expedients and consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.3.1 For care and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3.2 For repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4.1 Fault displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4.1.1 Fault indicator on control panel PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4.1.2 Fault displays on Monitoring and Control System MCS-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4.2 Fault symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5.1 Replacing an actuator plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5.1.1 Replacing an actuator plunger on PAN 1 and PAN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5.1.1.1 Replacing a plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.5.1.2 Replacing an actuator plunger in PAN 2 and PAN 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5.1.2.1 Replacing a plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5.2 Replacing an inscription label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.5.2.1 Replacing an inscription label in PAN 1 and PAN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.5.2.2 Replacing an inscription label in PAN 2 and PAN 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.5.3 Replacing an LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5.3.1 Replacing an LED in PAN 1 and PAN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5.3.1.1 Replacing an LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.5.3.2 Replacing an LED in PAN 2 and PAN 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.5.3.2.1 Replacing an LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.5.4 Replacing a contact (PAN 3 and PAN 4 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.5.4.1 Replacing a contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.5.5 Replacing a silicone cover (PAN 2 and PAN 4 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.5.6 Replacing a buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.5.6.1 Replacing a buzzer (PAN 1 and PAN 3 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.6.1 Maintenance overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.6.2 Visual inspection, mechanical testing and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.6.2.1 Cleaning PAN 1 – 4 externally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.6.2.2 Checking PAN 1 – 4 externally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.6.2.3 Checking PAN cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
E 531 649 / 01 E – 04.2002 –  MTU

 MTU – 04.2002 – E 531 649 / 01 E

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, repair, installation or commissioning
of the products described.
Furthermore, the following shall be observed:

¯ The safety requirements (if provided) in other relevant MTU manuals
¯ Warning and safety information 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 indicated by a signal word. These safety
notes shall be observed to avoid injury or damage.
This type of note indicates a danger which may lead to injury or death.
DANGER
This type of note indicates a danger which may lead to damage or

destruction of the product described or another part of the system.
CAUTION
Intended use and user qualifications
All devices and system components may only be put to their intended use.
Operation, maintenance, repair, installation and commissioning shall only be performed by qualified and
E 531 649 / 01 E – 04.2002 –  MTU

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 person in charge prior to commencing maintenance and repair work
and switching off parts of the electronic system required for this.
Prior to working on assemblies, the power supply of the appropriate areas must be switched off and secured
against unauthorized switching on.
Any measures requiring power supply are expressly defined as such at the appropriate place in the manual.
Maintenance and repair work shall be performed in accordance with the instructions in the manual by
Suitable tools, special MTU tools if necessary, shall be used for maintenance and repair work.
Genuine spare parts only may be used to replace defective components or assemblies. The manufacturer
accepts no liability whatsoever for damage caused by using other spare parts. The manufacturer’s warranty
shall also be voided in such cases.
The manufacturer shall not be held liable if unauthorized changes or modifications are made to the product
and the warranty shall be voided.
Spare parts shall be stored properly prior to replacement, i.e. particularly protected against the ingress of
moisture. Defective electronic components and assemblies must be suitably packed when despatched for
repair, i.e. particularly protected against the ingress of moisture and impact and wrapped in antistatic foil if
necessary.
Inform the MTU service department or its representative in case of damage which cannot be rectified by
plant personnel.
On completion of maintenance and repair work, ensure that no superfluous parts (tools etc.) remain inside
the device or system.
On completion of repair work, the device or system must be subjected to appropriate checks to verify
functionality. Separate testing of the repaired component without system integration is inadequate.
When working on the engine, suitable measures shall be taken to prevent accidental starting.
 MTU – 04.2002 – E 531 649 / 01 E

General information about this manual Page 3
3.2 General information about this manual
Refer to order-specific documents (e.g. drawings) if necessary in case of deviations from the
information provided in this manual.
3.2.1 Task duration and personnel qualification
Information about task duration is only intended to serve as a guide and is based on the work being carried
out under normal working conditions. The amount of time required may deviate from the times stated in
some cases.
The abbreviations explained in the preface to this manual are used to specify the minimum qualifications for
users carrying out the work described
Familiarity with the contents of Part 1 of this manual is pre-requisite.
3.2.2 Terminology
The following terms are used in this manual:

¯ Task:
A group comprising several activities. Performing all activities – not necessarily in a specific
order results in the task being fulfilled.
¯ Activity:
Sequence of steps to be carried out in a specific order. The result of each activity is a part of the
superordinate task.
¯ Step:
The sequential execution of certain steps forms a superordinate activity.
¯ Work:
Generic term for tasks, activities and steps.
E 531 649 / 01 E – 04.2002 –  MTU

Page 4 General information about this manual
3.2.3 Structure
The chapters in this manual describing specific work are structured as shown in fig. 26.
Task Task Activity

overview descriptions descriptions
Listing Illustrated text
Table Listing Illustrated text

(Maintenance
schedule/fault code
table/troubleshooting
table)
Listing Illustrated text
Cross-referenced by Cross-referenced by
Task ID Activity ID
Fig. 26 : Structure of the sub-chapters and terminology
Checkboxes are provided on the right margin of task description pages allowing each item to be checked off.
Note: Task and activity descriptions are modular and often formulated in general terms (e.g. for a plant
with several control consoles). The information provided must be applied to the plant concerned
by analogy.
 MTU – 04.2002 – E 531 649 / 01 E

Tools, expedients and consumables Page 5
3.3 Tools, expedients and consumables
3.3.1 For care and maintenance
The following expedients and consumables are required to carry out the care and maintenance work
described:
¯ Lint-free cleaning cloths (e.g. soft paper towels)
¯ Cleaning agent for synthetic surfaces (non-corrosive, non-abrasive, solvent-free
and grease-dissolving)
3.3.2 For repair
The following tools, expedients and consumables are required to carry out the repair work described:
¯ Tool kit SME 4-01 (see MTU publication “Tool kit SME 4-01, Part 5”)
E 531 649 / 01 E – 04.2002 –  MTU

Page 6 Malfunctions
3.4 Malfunctions
Risk of system failure!

Carrying out repair work on devices with the operating voltage switched on may
lead to short-circuiting and result in failure of the entire system during operation.
The engine can no longer be started in such cases.
For this reason:
DANGER Switch off the operating voltages for all devices and lock out/tag out to
preclude switching on before commencing repair work!
This chapter describes procedures for pinpointing faults in the control panel and appropriate measures for
fault rectification.
Rectify all malfunctions (even minor faults) immediately to ensure reliable

monitoring and control of the plant and to protect monitored parts of the plant
from damage.
DANGER
Check the following points before commencing troubleshooting:

¯ Have all the operating steps been carried out correctly or is there a chance of operator error?
¯ Is the operating state LED lit (see chap. 3.4.1.1)?
 MTU – 04.2002 – E 531 649 / 01 E

Malfunctions Page 7
3.4.1 Fault displays
Faults in a PAN control panel are displayed in the following ways:

¯ On the control panel itself by means of the operating status LED on the left of each control
panel
¯ By means of an appropriate fault message on a display of Monitoring and Control System
MCS-5 to which the affected PAN control panel is connected
3.4.1.1 Fault indicator on control panel PAN
Fig. 27 : Control panel PAN
A green operating status LED (27/1) provides information about the operating state of the control panel,
whereby:
buses have failed.
3.4.1.2 Fault displays on Monitoring and Control System MCS-5
The way in which faults are displayed on a superordinate MCS-5 Monitoring and Control
System depend greatly on the design and configuration of this system (on-screen process
visualization? LC display provided? etc.). Refer to the documentation of this system for details
of fault displays which are caused by a faulty control panel.
E 531 649 / 01 E – 04.2002 –  MTU

Page 8 Malfunctions
3.4.2 Fault symptoms
Note: The troubleshooting table below allows faults to be pinpointed in cases where the fault concerned is
not indicated by the display systems.
Risk of damage!
The operating voltage must be switched on for some of these troubleshooting
procedures.
Take care to avoid short-circuits when checking the cabling!
Switch off the operating voltage before commencing repair work!
DANGER
Symptom Cause Counteraction

Entire PAN does not respond, all A) Supply voltage not available 1. Are other parts of the electri-
luminous pushbuttons are dark, cal system also out of order?
operating status LED does not
Other parts of the system are
light up
also out of order → B)
All other parts of the system
are working properly, only the
PAN is out of order → C) and
D)
B) Plant power supply missing 2. Switch on power
C) PAN power supply missing 3. Switch on power
D) Connecting cable for PAN 4. Inspect the connection termi-
power supply loose or discon- nal block at the back of the
nected PAN, tighten terminals with a
suitable screwdriver as
necessary
Luminous pushbuttons dark, only A) Multi-LED faulty 1. Perform a lamp test and
some of the luminous pushbut- replace multi-LEDs as neces-
tons do not light up sary,
see ID: T-N-PAN-0005
Chap. 3.5.3.1
or
Chap. 3.5.3.2
Luminous pushbuttons dark, all A) Dimming set incorrectly 1. Increase dimming,
luminous pushbuttons do not see chap. 2.2.1.4
light up
 MTU – 04.2002 – E 531 649 / 01 E

Malfunctions Page 9
Symptom Cause Counteraction

No alarms/operating states indi- A) CAN timeout, the CAN bus 1. Are other parts of the system
cated, the controls or signal has failed also affected?
lamps no longer respond, the
Other parts of the system are
operating status LED flashes
also out of order → B)
slowly (2 Hz)
All other parts of the system
operate correctly, only the
PAN is out of order → C)
B) PIM has failed 2. –
C) Sensor/actuator bus failed 3. Inspect the appropriate
Connecting cable for S/A bus connection terminal block at
loose or disconnected at the the back of the PAN, insert
PAN wires properly into the con-
nection terminal block as
necessary
PAN cannot be operated, A) Watchdog tripped 1. Replace control panel
operating status LED flashes Hardware faulty
rapidly (8 Hz)
Luminous pushbutton jammed or A) Actuator plunger in the lumi- 1. Dismantle the luminous push-
tight, the pushbutton remains nous pushbutton faulty button and check the plunger,
depressed or only returns to its replace the plunger,
initial position very slowly when see ID: T-N-PAN-0001
pressed Chap. 3.5.1.1
or
B) Switching element faulty
Chap. 3.5.1.2
2. Unscrew the control panel
and check the switching unit,
replace the switching unit,
see ID: A-N-PAN-0005
Chap. 3.5.4
E 531 649 / 01 E – 04.2002 –  MTU

Page 10 Repair
3.5 Repair
3.5.1 Replacing an actuator plunger
3.5.1.1 Replacing an actuator plunger on PAN 1 and PAN 3

ID no.: T-N-PAN-0001
Duration: min. Qualification: E1
System components/devices
¯ Control panel
¯ New actuator plunger (or entire housing with plunger)
Equipment
¯ Cap puller
Additional safety notes

¯ Operating voltage must be switched off.
List of activities ID no.

1. Switching off the voltage. ------
2. Replacing a plunger. A-N-PAN-0001
Page 11
3. Performing function testing. ------
Additional information
¯ The inside of the actuator housing must be perfectly clean before it is
reassembled. Remove any foreign bodies (sand, crystallized salt etc.).
¯ Replace the entire actuator (plunger with housing) if this is not possible.
Tips and tricks

¯ The figures show the mechanical part of the housing when dismounted. It is not
necessary to remove the housing to replace the parts concerned.
 MTU – 04.2002 – E 531 649 / 01 E

Repair Page 11
3.5.1.1.1 Replacing a plunger

ID no.: A-N-PAN-0001
Removing a pushbutton cap
1. Pinpoint the affected pushbutton on the PAN

2 control panel (28/1).
2. Use the flat tongue on the cap puller (28/2) to
pull the pushbutton cap (28/4) out of the bot-
tom part of the pushbutton (28/6) in the direc-
tion indicated by arrow a.
3. The inscription label or scattering foil (28/5)
must also be removed.
3
Note:
a The side of the tongue which protrudes at the
slot (28/3) must face the pushbutton cap.
4
5
Fig. 28 : Removing a pushbutton cap
Removing a plunger
4. Unlock the plunger (29/1): Press the plunger

down in the direction indicated by arrow a and
turn it clockwise as far as it will go (approx.
15°) (direction indicated by arrow b) against
the body (29/2) of the actuator.
b 5. In this turned state, extract the plunger (29/1)
straight out of the body (29/2).
6. Clean the inside of the actuator body and dry
it thoroughly.
a
1 2
Fig. 29 : Removing a plunger
E 531 649 / 01 E – 04.2002 –  MTU

Page 12 Repair
Installing a plunger
7. In the turned state, insert the new plunger

(30/1) straight into the body (30/2) of the ac-
3 tuator. Check that it is properly positioned
(spot LED).
Note:
The edges of the plunger head must be at an
angle of approx. 15° to the corresponding
edges of the body.
a 2 Take care not to damage the O-ring (seal!)

(30/3)!
Fig. 30 : Inserting a plunger
8. Lock the plunger (31/1): Press the plunger

turn it counter-clockwise through approx. 15°
(direction indicated by arrow b) against the
body (31/2) of the actuator until the edges of
the plunger head lie parallel to the correspon-
ding edges of the actuator.
b
1 2
Fig. 31 : Locking a plunger
 MTU – 04.2002 – E 531 649 / 01 E

Repair Page 13
Installing a pushbutton cap

a
9. Re-insert the inscription label or scattering foil
(32/2) in the actuator. Check positioning (spot
1
LED).
2
Note:
The surface with the engraved text (if appli-
3 cable) must face the pushbutton cap.
10. Insert the pushbutton cap (32/1) in the bottom
part of the pushbutton (32/3).
Note:
Check correct positioning (spot LED).
11. Press the pushbutton firmly together until the
pushbutton cap is engaged.
Fig. 32 : Installing a pushbutton cap
E 531 649 / 01 E – 04.2002 –  MTU

Page 14 Repair
3.5.1.2 Replacing an actuator plunger in PAN 2 and PAN 4

¯ Control panel
Equipment
¯ Torque wrench
¯ Special socket for knurled nuts
¯ Cap puller
¯ Assembly tool for silicone covers


2. Replacing a plunger. A-N-PAN-0002
Page 15
 MTU – 04.2002 – E 531 649 / 01 E

Repair Page 15
3.5.1.2.1 Replacing a plunger

Opening the housing
1. Dismount the affected PAN control panel from

PAN 2: the console if it is not easily accessible from
behind.
2. Undo and remove the six screws (33/1 on
PAN 2 or 33/2 on PAN 4).
3. Pull the bottom part of the housing (33/3 or
33/4) off the top part of the housing. Take care
not to damage the seal.
3
Note:
The contacts are pulled out of their sockets in
the bottom part of the housing on control
PAN 4: panel PAN 4 during this procedure. For this
1
reason, considerable force must be exerted in
order to separate the two parts of the housing.
Fig. 33 : Opening the housing
PAN 4: 4. PAN 4 only:

The contacts are attached to the housing of
the actuator plunger in the top part of the hou-
sing. The affected contact must therefore be
disassembled.
To do this, turn the affected contact (34/1) in

the direction indicated by arrow a and then
pull it out in the direction indicated by arrow b.
2
a
b
1
Fig. 34 : Removing a contact
E 531 649 / 01 E – 04.2002 –  MTU

Page 16 Repair
Dismantling an actuator housing
5. Fit the special socket for knurled nuts (35/1)

on the torque wrench (35/2) and use it to undo
the knurled nut on the actuator housing (35/3)
inside the top part of the housing (35/4) and
remove the nut.
Fig. 35 : Undoing an actuator housing
6. Pull the actuator housing (36/1) forwards out

of the top part of the housing (36/2).
Fig. 36 : Removing an actuator housing
 MTU – 04.2002 – E 531 649 / 01 E

Repair Page 17
7. Take the silicone cover (37/1) off the actuator

1 (37/2).
Fig. 37 : Removing a silicone cover

1 tom part of the pushbutton (38/6) in the direc-
Note:
The side of the tongue which protrudes at the
2 slot (38/3) must face the pushbutton cap.
3
4
E 531 649 / 01 E – 04.2002 –  MTU

Page 18 Repair
Removing a plunger

12. Clean the inside of the actuator body and dry
it thoroughly.
a
1 2
13. In the turned state, insert the new plunger

(40/1) straight into the body (40/2) of the ac-
3
tuator. Check that it is properly positioned
(spot LED).
Note:
edges of the body.

(40/3)!
Fig. 40 : Inserting a plunger

b
1 2
 MTU – 04.2002 – E 531 649 / 01 E

Repair Page 19

a 15. Re-insert the inscription label or scattering foil
1 LED).
2
Note:
Note:
18. Fit the silicone cover (43/1) over the actuator
(43/2) by hand. Ensure that the protruding
1 edge of the actuator (43/4) is properly seated
in the groove in the silicone cover (43/3).
3
4
2
Fig. 43 : Fitting a silicone cover
Installing an actuator housing
19. Insert the actuator housing (44/1) into the top

part of the housing (44/2) from the front. En-
sure that the sealing surface (44/3) between
actuator housing and top part of the housing is
1 clean.
3 2
Fig. 44 : Inserting the actuator housing
E 531 649 / 01 E – 04.2002 –  MTU

Page 20 Repair
20. Fit the special socket for knurled nuts (45/1)

on the torque wrench (45/2).
21. Set the torque wrench to a torque of 1 Nm.
22. Place the knurled nut on the actuator housing
5
(45/3) and screw it on as far as possible by
hand.
23. Fit the assembly tool for silicone covers (45/5)
over the top of the silicone cover.
24. Use the torque wrench with the special socket
for knurled nuts to tighten the knurled nut to a
torque of 1 Nm.
3
Fig. 45 : Installing the actuator housing
PAN 4: 25. PAN 4 only:

Fit the appropriate contact (46/1) on the
actuator housing. It must lock into place.
Note:
Turn the contact slightly until the lugs engage
in the actuator housing if necessary.
Fig. 46 : Inserting the contact
 MTU – 04.2002 – E 531 649 / 01 E

Repair Page 21
Assembling the housing

PAN 2:
26. Fit the bottom part of the housing (47/3 or
47/4) onto the top part of the housing. Do not
forget the seal.
Note:
The contacts are inserted into the sockets in
the bottom part of the housing on control pa-
nel PAN 4 during this procedure. Considerable
3 force is therefore required to press the two
parts of the housing together. Ensure that the
blade connectors make proper contact in the
sockets.
PAN 4: 1
5 Note:
Check orientation of the two parts of the hou-
sing. Correct orientation is indicated by the
arrows (47/5 on PAN 2 or 47/6 on PAN 4). The
arrows must match up.
27. Insert the six screws (47/1 on PAN 2 or 47/2
on PAN 4) and tighten with a screwdriver.
4 28. Re-install the PAN control panel if necessary.
6
Fig. 47 : Assembling the housing
E 531 649 / 01 E – 04.2002 –  MTU

Page 22 Repair
3.5.2 Replacing an inscription label
3.5.2.1 Replacing an inscription label in PAN 1 and PAN 3

¯ Control panel
¯ New inscription label with correct inscription
Equipment
¯ Cap puller


1. See chapter 3.5.1.1.1: ------
Carry out steps 1. and 2. for removal.
2. Remove and destroy the old inscription label and use the new ------
inscription label in step 8.
3. See chapter 3.5.1.1.1: ------
Carry out steps 8. to 10. for assembly.
¯ Replace the entire actuator (plunger with housing) if this is not possible,
see chap. 3.5.1.1.
Tips and tricks

¯ The figures in chap 3.5.1.1.1 show the mechanical part of the housing when
dismounted. It is not necessary to remove the housing to replace the parts
concerned.
 MTU – 04.2002 – E 531 649 / 01 E

Repair Page 23
3.5.2.2 Replacing an inscription label in PAN 2 and PAN 4

¯ Control panel
¯ New inscription label with correct inscription
Equipment
¯ Torque wrench
¯ Cap puller


1. See chapter 3.5.1.2.1: ------
Carry out steps 1. and 8. for removal.
2. Remove and destroy the old inscription label and use the new ------
inscription label in step 14.
3. See chapter 3.5.1.2.1: ------
Carry out steps 14. to 27. for assembly.
see chap. 3.5.1.2.
E 531 649 / 01 E – 04.2002 –  MTU

Page 24 Repair
3.5.3 Replacing an LED
3.5.3.1 Replacing an LED in PAN 1 and PAN 3

¯ Control panel
¯ New LED
Equipment
¯ Cap puller


2. Replacing an LED. A-N-PAN-0003
Page 25
Tips and tricks

¯ The figures show the mechanical part of the housing when dismounted. It is not
necessary to remove the housing to replace the parts concerned.
¯ A buzzer is replaced in the same way.
 MTU – 04.2002 – E 531 649 / 01 E

Repair Page 25
3.5.3.1.1 Replacing an LED

1. Pinpoint the affected pushbutton on the PAN

2 control panel (48/1).
tom part of the pushbutton (48/6) in the direc-
3
Note:
a The side of the tongue which protrudes at the
slot (48/3) must face the pushbutton cap.
4
5
Removing a plunger

1 2
E 531 649 / 01 E – 04.2002 –  MTU

Page 26 Repair
Replacing an LED
6. Fit the cap puller (50/1) over the multi-LED

(50/3) in the pushbutton (50/2) and pull out the
multi-LED.
7. Note polarity of the faulty multi-LED on pulling
out! The new multi-LED must be inserted in
the same way!
8. Insert the new multi-LED (50/4).
2 Note:
Observe polarity!
3 The contact marked “+” must face the side
determined in step 7.
1
9. Press the multi-LED into the pushbutton
4 housing against light spring pressure until it
snaps into place.
Fig. 50 : Replacing a multi-LED
Only replace multi-LEDs with ones of the same colour.

Illumination states may otherwise be misinterpreted during operation.
CAUTION
10. In the turned state, insert the plunger (51/1)

straight into the body (51/2) of the actuator.
3 Check that it is properly positioned (spot
LED).
Note:
edges of the body.

(51/3)!
Fig. 51 : Installing a plunger
 MTU – 04.2002 – E 531 649 / 01 E

Repair Page 27

b
1 2

a
12. Re-insert the inscription label or scattering foil
1
LED).
2
Note:
Note:
E 531 649 / 01 E – 04.2002 –  MTU

Page 28 Repair
3.5.3.2 Replacing an LED in PAN 2 and PAN 4

¯ Control panel
¯ New LED
Equipment
¯ Torque wrench
¯ Cap puller


2. Replacing an LED. A-N-PAN-0004
Page 29
 MTU – 04.2002 – E 531 649 / 01 E

Repair Page 29
3.5.3.2.1 Replacing an LED

Opening the housing

behind.
3
Note:
1
PAN 4: Replacing an LED, PAN 4 only:
4. The contacts are attached to the housing of

sing. The contact on which the faulty LED is
mounted must therefore be disassembled.

2
a
b
1
E 531 649 / 01 E – 04.2002 –  MTU

Page 30 Repair
5. Pull the multi-LED out of the contact (56/2).

out! The new multi-LED must be inserted in
the same way!
1
Note:
Observe polarity!
The contact marked “+” must face the side
8. Press the multi-LED into the contact against
light spring pressure until it snaps into place.
2

CAUTION
9. Fit the contact (57/1) in the actuator housing.

It must lock into place.
Note:
Fig. 57 : Inserting a contact
 MTU – 04.2002 – E 531 649 / 01 E

Repair Page 31
Replacing an LED, PAN 2 only:

PAN 2:
10. The LEDs (61/1) are inserted in the soldered
contact sockets (61/2) in the bottom part of
the housing.
11. The printed circuit board must be removed
from the housing.
12. Undo the six screws (58/1).
Fig. 58 : PAN 2, separating the parts of the

housing
13. Remove the bottom part of the housing (59/1)

2 from the top part of the housing (59/2).
14. The printed circuit board (59/3, see broken
lines) is located in the top part of the housing
(59/2).
15. Disconnect the connector (59/4).
3 4
1
Fig. 59 : LEDs in PAN 2
16. There are five bores (60/1) in the printed cir-

cuit board (60/2, disassembled state illustra-
ted). Five locking screws are accessible
through these bores. Turn these screws
through 90° using a small screwdriver.
17. Remove the printed circuit board from the top
part of the housing.
1
Fig. 60 : Locking screws
E 531 649 / 01 E – 04.2002 –  MTU

Page 32 Repair
PAN 2: 18. Pull the multi-LED out of the contact socket

(61/2).
1
2 out! The new multi-LED must be inserted in
the same way!
Note:
Observe polarity!
Only replace multi-LEDs with

ones of the same colour.
Illumination states may other-
wise be misinterpreted during
operation.
Fig. 61 : LEDs in PAN 2 CAUTION
21. Press the multi-LED into the contact socket

PAN 2: (61/2) against light spring pressure until it
snaps into place.
22. Reinsert the printed circuit board in the upper
part of the housing and turn the five locking
screws through 90° with a small screwdriver
until they noticeably lock into place.
23. Reconnect the connector (cf. 59/4) in the
socket on the printed circuit board.
3

PAN 4: 62/4) onto the top part of the housing. Do not
1 forget the seal.
5
Note:
force is therefore required to press the two
4 blade connectors make proper contact in the
sockets.
2 arrows (62/5 on PAN 2 or 62/6 on PAN 4). The
6 on PAN 4) and tighten with a screwdriver.
Fig. 62 : Assembling the housing 26. Re-install the PAN control panel if necessary.
 MTU – 04.2002 – E 531 649 / 01 E

Repair Page 33
3.5.4 Replacing a contact (PAN 3 and PAN 4 only)

¯ Control panel
¯ New contact
Equipment
¯ Screwdriver


2. Replacing a contact element. A-N-PAN-0005
Page 34
E 531 649 / 01 E – 04.2002 –  MTU

Page 34 Repair
3.5.4.1 Replacing a contact

Opening the housing

behind.
3
Note:
1
4. The contacts are attached to the housing of

sing. The affected contact must therefore be
disassembled.

2
a
b
1
 MTU – 04.2002 – E 531 649 / 01 E

Repair Page 35
5. Pull the multi-LED out of the old contact

(65/2).
6. Note polarity of the multi-LED on pulling out!

The multi-LED must be inserted in the new
contact in the same way!
1
Note:
Observe polarity!
7. Press the multi-LED into the contact against

light spring pressure until it snaps into place.
2

CAUTION
8. Fit the new contact (66/1) on the actuator

housing. It must lock into place.
Note:
Fig. 66 : Inserting a contact
Pushbutton units shall only be replaced by ones with the same function (key
or switch).
Incorrect operation and/or misinterpretation may otherwise result during
operation.
CAUTION
E 531 649 / 01 E – 04.2002 –  MTU

Page 36 Repair

PAN 3:
67/4) onto the top part of the housing. Do not
forget the seal.
Note:
3 force is therefore required to press the two
blade connectors make proper contact in the
sockets.
PAN 4: 1
5 Note:
arrows (62/5 on PAN 3 or 62/6 on PAN 4). The
on PAN 4) and tighten with a screwdriver.
4 11. Re-install the PAN control panel if necessary.
6
Fig. 67 : Assembling the housing
 MTU – 04.2002 – E 531 649 / 01 E

Repair Page 37
3.5.5 Replacing a silicone cover (PAN 2 and PAN 4 only)

¯ Control panel
Equipment
¯ Torque wrench
¯ Cap puller


1. See chapter 3.5.1.2.1: ------
Carry out steps 1. to 7. for disassembly.
2. Remove and destroy the old silicone cover and use the new ------
silicone cover in step 17.
3. See chapter 3.5.1.2.1: ------
Carry out steps 18. to 27. for reassembly.
see chap. 3.5.1.2.
¯ The actuator plunger must operate smoothly in the housing.
E 531 649 / 01 E – 04.2002 –  MTU

Page 38 Repair
3.5.6 Replacing a buzzer

¯ Control panel
¯ New buzzer
Equipment
¯ Cap puller (pincer type)


2. Replacing a buzzer as described in chap. 3.5.3.1 (replacing an A-N-PAN-0006
LED in PAN 1 and PAN 3). Page 39
Tips and tricks

¯ The figures in chap 3.5.3.1.1 show the mechanical part of the housing when
dismounted. It is not necessary to remove the housing to replace the parts
concerned.
 MTU – 04.2002 – E 531 649 / 01 E

Repair Page 39
3.5.6.1 Replacing a buzzer (PAN 1 and PAN 3 only)

Removing a pushbutton cap and plunger
1. First remove the pushbutton cap and plunger.

Proceed in accordance with chap. 3.5.3.1.1,
steps 1. to 4.
2. Grip the buzzer (68/2) with the cap puller
(68/1) and pull it out.
3. Note polarity of the faulty buzzer on pulling
out! The new buzzer must be inserted in the
same way!
4. Insert the new buzzer (68/3).
Note:
Observe polarity!
1 2 3 determined in step 3.
5. Press the buzzer into the pushbutton housing
against light spring pressure until it snaps into
Fig. 68 : Replacing a buzzer place.
Installing a pushbutton cap and plunger
6. Now re-install the pushbutton cap and plunger.

Proceed in accordance with chap. 3.5.3.1.1,
steps 9. to 13.
E 531 649 / 01 E – 04.2002 –  MTU

Page 40 Maintenance
3.6 Maintenance
3.6.1 Maintenance overview
Periodic maintenance on the control panel
Column 2 in table 1 lists the intervals for routine maintenance work.
The maintenance intervals are adapted to the engine maintenance system.
Maintenance of electronic components by operating personnel (operators and plant personnel) is restricted
to maintenance echelons W1 to W3. Refer to Part E of the engine documentation for details of the intervals
(depending on operating hours or time).
Order Inter- Task designation Quali- Dur./ Task ID Page Additional

val ficat. min. information/remarks
1 W1 Lamp test E1 1 -- 3 See Part 2
2 W2 Visual inspection, E1 20 T-N-PAN-0010 41 Repair any faulty

mechanical testing devices
and cleaning
Tab. 1 : Maintenance table
Note: See fig. 26 for details of structure and navigation in this chapter.
 MTU – 04.2002 – E 531 649 / 01 E

Maintenance Page 41
3.6.2 Visual inspection, mechanical testing and cleaning

Duration: 20 min Qualification: E1
¯ Control panel PAN
Equipment
¯ Lint-free cleaning cloths (e.g. soft paper towels)
¯ Cleaning agent for synthetic surfaces (non-corrosive, non-abrasive,
solvent-free and grease-dissolving)
Pre-requisites
¯ Overall system switched off
¯ Be careful not to damage cabling when cleaning.
¯ Reconnect cables disconnected for purposes of testing or cleaning properly.
¯ Repair any faults immediately.

¯ Only use non-corrosive, non-abrasive and solvent-free cleaning agents and a
soft, lint-free cloth to clean the assemblies. The caps on the luminous pushbuttons
may otherwise become opaque.
¯ Ensure that no cables become loose or disconnected when working on the cabling
and take care to avoid short-circuits.

This sequence is recommended.
1. Cleaning PAN 1 – 4 externally if dirty. A-N-PAN-0007
Page 42
2. Checking PAN 1 – 4 externally. A-N-PAN-0008
Page 42
3. Checking PAN cabling. A-N-PAN-0009
Page 42
E 531 649 / 01 E – 04.2002 –  MTU

Page 42 Maintenance
3.6.2.1 Cleaning PAN 1 – 4 externally

1. Clean all listed devices with the recommended expedients.

2. Renew illegible identification and inscriptions on all listed devices.
3.6.2.2 Checking PAN 1 – 4 externally

1. Check all listed devices externally for dirt.
2. Check all listed devices externally for visible mechanical damage.
3. Check firm seating of all installed devices, tighten screws as necessary etc.
4. Check firm seating of connectors, cable glands, cable terminals etc. on all installed devices,
engage properly or secure as necessary.
5. Check that none of the luminous pushbutton caps are damaged (cracked etc.).
6. Ensure that there are no signs of moisture ingress in the luminous pushbutton housings (e.g.
caps misted on the inside).
7. Ensure that none of the seals between the housing of the luminous pushbuttons and the front of
the control panel are neither bulging or torn.
8. Check that all luminous pushbuttons are firmly seated.
3.6.2.3 Checking PAN cabling

Inspect the cabling visually. The following criteria are relevant:

1. Insulation not damaged
2. Terminal blocks and cables firmly seated
3. Terminal blocks not damaged
4. Cabling not damaged (cabling neither kinked nor chafed)
 MTU – 04.2002 – E 531 649 / 01 E

Service manual Part 4
Part 4
Service manual
Not applicable
4 Not applicable
E 531 649 / 01 E – 04.2002 –  MTU

Part 4 Service manual
 MTU – 04.2002 – E 531 649 / 01 E

Illustrated parts catalog Part 5
Part 5
Illustrated parts catalog
E 531 649 / 01 E – 04.2002 –  MTU

Part 5 Illustrated parts catalog
 MTU – 04.2002 – E 531 649 / 01 E

Inhaltsverzeichnis / Table of contents
ILL. TABLE REG.NO. REFERENCE PAGE

BILDTAFEL REGISTRIERNUMMER STÜCKLISTENNUMMER SEITE
84 01 069.700063/90 E00615 2
84 01 510 530 66 62 E00592 6
84 01 510 530 67 62 E00590 8
84 01 510 530 70 62 E00616 10
84 01 510 530 71 62 E00617 14
84 01 510 530 85 64 E00618 18
84 01 510 530 86 64 E00619 22
84 01 069.700063/91 E00620 26
84 01 510 530 18 08 E00614 32
84 01 510 530 72 62 E00070 34
84 01 510 530 73 62 E00187 36
84 01 510 530 74 62 E00072 38
84 01 510 530 22 08 E00625 40
84 01 510 530 76 62 E00621 42
84 01 510 530 77 62 E00622 44
84 01 510 530 29 64 E00623 46
84 01 510 530 38 64 E00624 48
Querverweisliste 51
Cross-reference list
E 531 649 / 01 E – 04.2002 –  MTU

 MTU – 04.2002 – E 531 649 / 01 E

Introduction Page 1
5 Illustrated parts catalog
5.1 Introduction
This illustrated parts catalog forms the basis for spare parts orders.
This catalog consists of illustrations and their associated tables plus a cross-reference list.
The illustrations and tables in the catalog also assist when dismantling and re-assembling the individual as-
semblies. The catalog therefore also includes certain parts not available as spares.
Illustrations and tables
The headings of the illustration pages and the associated tables contain the following information:
¯ EDITION (edition date)
¯ PAGE (page No.)
¯ PROJECT (project name)
¯ GAPL (group name in German)
¯ EGC (name in the foreign language)
¯ REFERENCE (Bill of Materials (BOM) No. for the part shown in the illustration)
¯ CATALOG (the parts catalog number)
¯ ILL. TABLE (four-digit illustration number)
¯ REG. NO. (six-digit registration number)
The contents of the main headings on the illustration pages and their associated table pages differ only in
their page numbers (PAGE). All other information is identical.
The row of headings on the table pages contains the following information:
¯ C/N Callout numbers in the illustrations crossreference to the parts numbers and
designations in the associated table.
The table’s callout numbers are in a rising numerical sequence.
¯ PART NO. Use the part number for ordering spare parts.
¯ DESIGNATION This space contains the exact part designation.
A part whose designation is intended to the right in this column (indicated by
preceding dots) is included in the preceding part(s) (either less intended or
not at all).
¯ Q/U Quantity required in unit at installation location.
E 531 649 / 01 E – 04.2002 –  MTU

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 most important footnotes are:
AB Only available as a complete assembly, repairs only possible at the
manufacturers.
KE Individual part not intended for delivery as a spare part.
KF A part that can be calibrated. When ordering, follow instructions in the
chapter, ”Ordering spare parts”).
NB Amount required by the customer.
¯ SUPPLEM. DES./ This column contains standardized part designations or manufacturer’s own
REMARKS designations for outsourced parts.
¯ ILL.-REG. This column gives the cross-reference to an illustration if a component is illu-
strated separately on its own page.
¯ ITEM For in-house use by the manufacturer.
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 NO. column. In addition, the DESIGNATION, ILL. TAB.,
REG. NO., 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 inform about any part number changes taking effect after completion of
the illustrated parts catalog. We therefore recommend that you personally mark down any information about
part number changes in the illustrated parts catalog. This information can be found in the order confirmation
and on the spare parts’ delivery 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 531 649 / 01 E

Introduction Page 3
When ordering a calibrated part (marked by ”KF” in the ”FN” column), add the following additional informa-
tion:
¯ If the calibration No. is known (see part’s nameplate):
Add the calibration No., preceded by an oblique stroke, as an extension to the part number
(”/xxxxx”); e.g.: 002 536 28 10/E1234.
Here, the extension ”E1234” would be the part’s calibration number on the nameplate.
¯ If the calibration No. is not known:
Give a detailed description of the required part’s installation location by quoting the complete
Device Description code (e.g. ”= 37.1.1 + A022 -- F003”) plus the part number extension ”/77”
(e.g. 500 536 28 10/77).
In this case, the calibrated spare part will be supplied under a new part number. The Device
Description is found on the nameplate at the part’s installation location, or in the corresponding
Wiring Diagram.
When ordering a non-calibrated adjustable part (marked by ”KF” in the ”FN” column) which should not be
calibrated by the factory:
¯ Add extension “/76” to the part number (e.g. 002 536 28 10/76).
To avoid errors, please confirm all telephone orders in writing.
Delivery of repaired parts
Parts sent to MTU Friedrichshafen for repair must be clearly marked with the MTU order number and engine
number.
E 531 649 / 01 E – 04.2002 –  MTU

Page 4 Introduction
 MTU – 04.2002 – E 531 649 / 01 E

EDITION: 04.2002 CATALOG: E 531 649 / 01 ED
PAGE: 5
PROJECT: M012
5.2 Bildtafeln und Tabellen

Illustrations and tables
EDITION: 04.2002 GAPL: 84 Überwachungseinrichtung CATALOG: E 531 649 / 01 ED
PAGE: 6 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
PROJECT: M012 REFERENCE: 069.700063/90 REG. NO.: E00615
Bestückungsplan Leuchte / Lamp: component mounting diagramm
Bestückungsplan Taster / Pushbutton: component mounting diagramm
02A, 02B, 02C, 02D, 02E

01A, 01B, 01C, 01D, 01E
Bestückungsplan Hupe / Horn: component mounting diagram
04
04 05
03
07
06A, 06B, 06C, 06D 06A, 06B, 06C, 06D
84 01
08A E00592
08B 84 01
E00590
84 01 +
11A E00616 +
11B 84 01 --
E00617
11C 84 01
E00618
11D 84 01
E00619
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
01A 001 534 19 01 TASTERKAPPE KLAR 001 EA 840084

KEYTOP
01B 001 534 20 01 TASTERKAPPE GRUEN 001 EA 840086
KEYTOP
01C 001 534 21 01 TASTERKAPPE ROT 001 EA 840088
KEYTOP
01D 001 534 22 01 TASTERKAPPE GELB 001 EA 840090
KEYTOP
01E 001 534 23 01 TASTERKAPPE BLAU 001 EA 840092
KEYTOP
02A 001 534 34 01 LEUCHTENKAPPE GRUEN 001 EA 840094
KEYTOP
02B 001 534 35 01 LEUCHTENKAPPE ROT 001 EA 840096
KEYTOP
02C 001 534 36 01 LEUCHTENKAPPE KLAR 001 EA 840098
KEYTOP
02D 001 534 37 01 LEUCHTENKAPPE BLAU 001 EA 840100
KEYTOP
02E 001 534 38 01 LEUCHTENKAPPE GELB 001 EA 840102
KEYTOP
03 001 534 33 01 TASTEREINSATZ HUPE 001 EA 840104
CONTACT BLOCK
04 001 534 24 01 GRAVIERPLATTE 001 EA 840106
CONTACT BLOCK
05 001 534 39 01 BLOCKIERRAHMEN 001 EA 840108
CONTACT BLOCK
06A 000 531 00 39 MULTI--LED T5,5K24 RT 001 EA 840110
LED
06B 000 531 14 39 MULTI--LED T5,5K24 GE 001 EA 840112
LED
Notizen / Notes
06C 000 531 13 39 MULTI--LED T5,5K24 GN 001 EA 840114

LED
06D 000 531 06 39 MULTI--LED 5,5K BLAU 001 EA 840116
LED
07 000 531 34 89 HUPENEINSATZ 001 EA 840118
HORN
08A 510 530 66 62 ZB TABLEAU PAN 1--01 001 EA 84 01 840120
PANEL E00592
08B 510 530 67 62 ZB TABLEAU PAN 1--01 001 EA 84 01 840122
PANEL E00590
PANEL E00616
PANEL E00617
11C 510 530 85 64 ZB TABLEAU PAN 2--01 001 EA 84 01 840128
PANEL E00618
11D 510 530 86 64 ZB TABLEAU PAN 2--01 001 EA 84 01 840130
PANEL E00619
PROJECT: M012 REFERENCE: 510 530 66 62 REG. NO.: E00592
11
01
10
25
07
04
31
20
000 510 530 66 62 ZB TABLEAU PAN 1--01 001 EA 840050

PANEL
01 510 533 44 36 .FRONTPLATTE ELEKTR. 001 EA 840052
.FRONT PANEL
04 510 533 12 40 .HALTER 001 EA 840054
.RETAINER
07 526 530 01 13 .ZB STECKK. PAN 1--02 001 EA KE 840056
.PLUG--IN BOARD
10 001 534 18 01 .BETAETIGER 005 EA 840058
.PUSHBUTTON
11 000 533 55 80 .DICHTUNG T=2,2 MM 005 EA 840060
.GASKET
20 510 533 02 89 .SCHILD,AO JUMPER 001 EA KE 840062
.INSTRUCTION PLATE
25 000 535 01 76 .DRUCKFEDER 002 EA 840064
.SPRING
31 000 533 01 70 .SCHRAUBE M 3X8 006 EA 840066
.SCREW
11
12
10
01
25
07
04
31
20
000 510 530 67 62 ZB TABLEAU PAN 1--01 001 EA 840030

PANEL
.FRONT PANEL
04 510 533 12 40 .HALTER 001 EA 840034
.RETAINER
.PLUG--IN BOARD
10 001 534 18 01 .BETAETIGER 005 EA 840038
.PUSHBUTTON
11 000 533 55 80 .DICHTUNG T=2,2 MM 004 EA 840040
.GASKET
12 001 533 10 31 .SCHUTZKLAPPE KDQ 001 EA 840042
.FLAP
.INSTRUCTION PLATE
25 000 535 01 76 .DRUCKFEDER 002 EA 840046
.SPRING
31 000 533 01 70 .SCHRAUBE M 3X8 006 EA 840048
.SCREW
11
13
13
12
12 14
01
11
32
08
05
25
02
17
19
38
27
18
000 510 530 70 62 ZB TABLEAU PAN 2--01 001 EA 840132

PANEL
.FRONT PANEL
02 510 535 00 91 .DECKEL PAN 2 001 EA 840136
.COVER
05 510 533 12 80 .DICHTUNG PAN 2+4 001 EA 840138
.GASKET
.PLUG--IN BOARD
11 001 534 25 01 .DICHTUNGSKAPPE TK27S 005 EA 840142
.CONTACT BLOCK
12 510 533 05 46 .RAHMEN 005 EA 840144
.FRAME
13 000 533 59 80 .DICHTUNG T=0,5 MM 005 EA 840146
.GASKET
14 001 534 18 01 .BETAETIGER 005 EA 840148
.PUSHBUTTON
17 000 531 40 76 .KABELEINFUEHRUNG M20 004 EA 840150
.CABLE ENTRY
18 000 533 46 76 .BLINDST. PG13,5/M20 004 EA 840152
.CABLE ENTRY
19 000 533 35 88 .DRUCKAUSGL.--ELEMENT 001 EA 840154
.FILTER
25 510 533 54 91 .SCHILD 001 EA AA 840156
.PHOTOPLATE
.INSTRUCTION PLATE
32 000 535 01 76 .DRUCKFEDER 002 EA 840160
.SPRING
Notizen / Notes
38 000 533 02 70 .SCHRAUBE M 3X16 006 EA 840162

.SCREW
11
Z
21
13
13
12 22
12
14
01
11
34
08
05
27
02
17
19
40
29
18
000 510 530 71 62 ZB TABLEAU PAN 2--01 001 EA 840164

PANEL
.FRONT PANEL
02 510 535 00 91 .DECKEL PAN 2 001 EA 840168
.COVER
05 510 533 12 80 .DICHTUNG PAN 2+4 001 EA 840170
.GASKET
.PLUG--IN BOARD
.CONTACT BLOCK
12 510 533 05 46 .RAHMEN 005 EA 840176
.FRAME
13 000 533 59 80 .DICHTUNG T=0,5 MM 005 EA 840178
.GASKET
14 001 534 18 01 .BETAETIGER 005 EA 840180
.PUSHBUTTON
.CABLE ENTRY
18 000 533 46 76 .BLINDST. PG13,5/M20 004 EA 840184
.CABLE ENTRY
.FILTER
21 510 535 06 91 .SCHUTZKLAPPE 001 EA KE 840188
.COVER
22 510 533 15 40 .LAGERBOCK 001 EA KE 840190
.RETAINER
27 510 533 54 91 .SCHILD 001 EA AA 840192
.PHOTOPLATE
Notizen / Notes

.INSTRUCTION PLATE
34 000 535 01 76 .DRUCKFEDER 002 EA 840196
.SPRING
40 000 533 02 70 .SCHRAUBE M 3X16 006 EA 840198
.SCREW
11
2x
Z
13 21
13
12
12 22
14
01
11
34
08
05
27
02
17
19
40
29
18
000 510 530 85 64 ZB TABLEAU PAN 2--01 001 EA 840200

PANEL
.FRONT PANEL
02 510 535 00 91 .DECKEL PAN 2 001 EA 840204
.COVER
05 510 533 12 80 .DICHTUNG PAN 2+4 001 EA 840206
.GASKET
.PLUG--IN BOARD
.CONTACT BLOCK
12 510 533 05 46 .RAHMEN 005 EA 840212
.FRAME
13 000 533 59 80 .DICHTUNG T=0,5 MM 005 EA 840214
.GASKET
14 001 534 18 01 .BETAETIGER 005 EA 840216
.PUSHBUTTON
.CABLE ENTRY
18 000 533 46 76 .BLINDST. PG13,5/M20 004 EA 840220
.CABLE ENTRY
.FILTER
.COVER
22 510 533 15 40 .LAGERBOCK 002 EA KE 840226
.RETAINER
27 510 533 54 91 .SCHILD 001 EA AA 840228
.PHOTOPLATE
Notizen / Notes

.INSTRUCTION PLATE
34 000 535 01 76 .DRUCKFEDER 002 EA 840232
.SPRING
40 000 533 02 70 .SCHRAUBE M 3X16 006 EA 840234
.SCREW
11
4x
Z
13 21
13
12
12 22
14
01
11
34
08
05
27
02
17
19
40
29
18
000 510 530 86 64 ZB TABLEAU PAN 2--01 001 EA 840236

PANEL
.FRONT PANEL
02 510 535 00 91 .DECKEL PAN 2 001 EA 840240
.COVER
05 510 533 12 80 .DICHTUNG PAN 2+4 001 EA 840242
.GASKET
.PLUG--IN BOARD
.CONTACT BLOCK
12 510 533 05 46 .RAHMEN 005 EA 840248
.FRAME
13 000 533 59 80 .DICHTUNG T=0,5 MM 005 EA 840250
.GASKET
14 001 534 18 01 .BETAETIGER 005 EA 840252
.PUSHBUTTON
.CABLE ENTRY
18 000 533 46 76 .BLINDST. PG13,5/M20 004 EA 840256
.CABLE ENTRY
.FILTER
.COVER
22 510 533 15 40 .LAGERBOCK 004 EA KE 840262
.RETAINER
27 510 533 54 91 .SCHILD 001 EA AA 840264
.PHOTOPLATE
Notizen / Notes

.INSTRUCTION PLATE
34 000 535 01 76 .DRUCKFEDER 002 EA 840268
.SPRING
40 000 533 02 70 .SCHRAUBE M 3X16 006 EA 840270
.SCREW
Bestückungsplan Leuchte / Lamp: component mounting diagramm
Bestückungsplan Taster / Pushbutton: component mounting diagramm

02A, 02B, 02C, 02D, 02E
01A, 01B, 01C, 01D, 01E
04 Bestückungsplan Hupe / Horn: component mounting diagram
04 05
03
07
06A, 06B, 06C, 06D 06A, 06B, 06C, 06D
84 01
E00621 13A
08A 84 01
84 01 E00070
E00622 13B
08B 84 01
E00187
84 01
E00623 13C 08C 84 01
E00072
84 01 21 23 24 22
E00624 13D
09A X2
09B X1 + --
09A
09B 10 84 01 13 14
E00614
11
84 01 14
E00625 12
11
12
01A 001 534 19 01 TASTERKAPPE KLAR 001 EA 840272

KEYTOP
01B 001 534 20 01 TASTERKAPPE GRUEN 001 EA 840274
KEYTOP
01C 001 534 21 01 TASTERKAPPE ROT 001 EA 840276
KEYTOP
01D 001 534 22 01 TASTERKAPPE GELB 001 EA 840278
KEYTOP
01E 001 534 23 01 TASTERKAPPE BLAU 001 EA 840280
KEYTOP
02A 001 534 34 01 LEUCHTENKAPPE GRUEN 001 EA 840282
KEYTOP
02B 001 534 35 01 LEUCHTENKAPPE ROT 001 EA 840284
KEYTOP
02C 001 534 36 01 LEUCHTENKAPPE KLAR 001 EA 840286
KEYTOP
02D 001 534 37 01 LEUCHTENKAPPE BLAU 001 EA 840288
KEYTOP
02E 001 534 38 01 LEUCHTENKAPPE GELB 001 EA 840290
KEYTOP
03 001 534 33 01 TASTEREINSATZ HUPE 001 EA 840292
CONTACT BLOCK
04 001 534 24 01 GRAVIERPLATTE 005 EA 840294
CONTACT BLOCK
05 001 534 39 01 BLOCKIERRAHMEN 001 EA 840296
CONTACT BLOCK
06A 000 531 00 39 MULTI--LED T5,5K24 RT 001 EA 840298
LED
06B 000 531 14 39 MULTI--LED T5,5K24 GE 001 EA 840300
LED
Notizen / Notes
06C 000 531 13 39 MULTI--LED T5,5K24 GN 001 EA 840302

LED
06D 000 531 06 39 MULTI--LED 5,5K BLAU 001 EA 840304
LED
07 000 531 34 89 HUPENEINSATZ 001 EA 840306
HORN
PANEL E00070
PANEL E00187
PANEL E00072
09A 005 534 11 10 TASTEREINSATZ 001 EA 840314
CONTACT BLOCK
09B 005 534 13 10 SCHALTELEMENT--SCHALT 001 EA 840316
SWITCH
10 510 530 18 08 ZB RAHMEN PAN 3 001 EA 84 01 840318
FRAME E00614
11 206797 003200 ZAHNSCHEIBE 004 EA J 3,2 DIN 6797 A2--70 840320
TOOTHED WASHER
12 207985 003104 LINSENSCHRAUBE 004 EA M 3 X 8 DIN 7985 A4--70--H 840322
OVAL--HEAD SCREW
PANEL E00621
PANEL E00622
PANEL E00623
13D 510 530 38 64 ZB TABLEAU PAN 4--01 001 EA 84 01 840330
PANEL E00624
Notizen / Notes
14 510 530 22 08 ZB RAHMEN PAN 4 001 EA 84 01 840332

FRAME E00625
07
24
10
01
04
21
15
000 510 530 18 08 ZB RAHMEN PAN 3 001 EA 840068

FRAME
01 510 533 02 46 .STECKKARTENRAHMEN 001 EA 840070
.FRAME
04 510 533 14 40 .HALTER 001 EA 840072
.RETAINER
07 526 530 02 13 .ZB STECKK. PAN 2--02 001 EA KF 840074
.PLUG--IN BOARD
10 502 04 .GLASGEWEBEFOLIE 000 QM NB 840076
.GLASS--FIBRE FOIL
.INSTRUCTION PLATE
21 000 533 01 70 .SCHRAUBE M 3X8 006 EA 840080
.SCREW
24 207985 002104 .LINSENSCHRAUBE 010 EA M 2,5X 6 DIN 7985 5.8--H A3C 840082
.OVAL--HEAD SCREW
06
07
01
06
000 510 530 72 62 ZB TABLEAU PAN 3--01 001 EA 840002

PANEL
01 510 533 42 36 .FRONTPLATTE 001 EA 840004
.FRONT PANEL
06 001 534 18 01 .BETAETIGER 005 EA 840006
.PUSHBUTTON
07 000 533 55 80 .DICHTUNG T=2,2 MM 005 EA 840008
.GASKET
06
07
08
06
01
000 510 530 73 62 ZB TABLEAU PAN 3--01 001 EA 840020

PANEL
01 510 533 42 36 .FRONTPLATTE 001 EA 840022
.FRONT PANEL
06 001 534 18 01 .BETAETIGER 005 EA 840024
.PUSHBUTTON
07 000 533 55 80 .DICHTUNG T=2,2 MM 004 EA 840026
.GASKET
.FLAP
06
07
08
06
01
000 510 530 74 62 ZB TABLEAU PAN 3--01 001 EA 840010

PANEL
01 510 533 42 36 .FRONTPLATTE 001 EA 840012
.FRONT PANEL
06 001 534 18 01 .BETAETIGER 005 EA 840014
.PUSHBUTTON
07 000 533 55 80 .DICHTUNG T=2,2 MM 002 EA 840016
.GASKET
.FLAP
08
19
30
16
01
05
13
02
11
21
27
12
000 510 530 22 08 ZB RAHMEN PAN 4 001 EA 840402

FRAME
01 510 533 02 46 .STECKKARTENRAHMEN 001 EA 840404
.FRAME
02 510 535 05 91 .DECKEL PAN 4 001 EA KE 840406
.COVER
05 510 533 13 80 .DICHTUNG PAN 4 001 EA 840408
.GASKET
08 526 530 02 13 .ZB STECKK. PAN 2--02 001 EA KF 840410
.PLUG--IN BOARD
.CABLE ENTRY
12 000 533 46 76 .BLINDST. PG13,5/M20 004 EA 840414
.CABLE ENTRY
.FILTER
16 502 04 .GLASGEWEBEFOLIE 000 QM NB 840418
.GLASS--FIBRE FOIL
19 510 533 54 91 .SCHILD 001 EA AA 840420
.PHOTOPLATE
.INSTRUCTION PLATE
27 000 533 02 70 .SCHRAUBE M 3X16 006 EA 840424
.SCREW
30 207985 002104 .LINSENSCHRAUBE 010 EA M 2,5X 6 DIN 7985 5.8--H A3C 840426
.OVAL--HEAD SCREW
06
08 09
07
06
08
07
09
01
13
000 510 530 76 62 ZB TABLEAU PAN 4--01 001 EA 840334

PANEL
01 510 533 41 36 .FRONTPLATTE 001 EA KE 840336
.FRONT PANEL
.CONTACT BLOCK
07 510 533 05 46 .RAHMEN 005 EA 840340
.FRAME
08 000 533 59 80 .DICHTUNG T=0,5 MM 005 EA 840342
.GASKET
09 001 534 18 01 .BETAETIGER 005 EA 840344
.PUSHBUTTON
13 510 533 12 80 .DICHTUNG PAN 2+4 001 EA 840346
.GASKET
06
08
09
07
06
08 12
07
13
01
09
Z
Z
17
000 510 530 77 62 ZB TABLEAU PAN 4--01 001 EA 840348

PANEL
.FRONT PANEL
.CONTACT BLOCK
07 510 533 05 46 .RAHMEN 005 EA 840354
.FRAME
08 000 533 59 80 .DICHTUNG T=0,5 MM 005 EA 840356
.GASKET
09 001 534 18 01 .BETAETIGER 005 EA 840358
.PUSHBUTTON
.COVER
13 510 533 15 40 .LAGERBOCK 001 EA KE 840362
.RETAINER
17 510 533 12 80 .DICHTUNG PAN 2+4 001 EA 840364
.GASKET
06
08 5x
09
07
06
08 12
07
13
01
09
Z
Z
17
000 510 530 29 64 ZB TABLEAU PAN 4--01 001 EA 840366

PANEL
.FRONT PANEL
.CONTACT BLOCK
07 510 533 05 46 .RAHMEN 005 EA 840372
.FRAME
08 000 533 59 80 .DICHTUNG T=0,5 MM 005 EA 840374
.GASKET
09 001 534 18 01 .BETAETIGER 005 EA 840376
.PUSHBUTTON
.COVER
13 510 533 15 40 .LAGERBOCK 005 EA KE 840380
.RETAINER
17 510 533 12 80 .DICHTUNG PAN 2+4 001 EA 840382
.GASKET
06
08
09
07
06
08 12
07
13
01
09
Z
Z
17
000 510 530 38 64 ZB TABLEAU PAN 4--01 001 EA 840384

PANEL
.FRONT PANEL
.CONTACT BLOCK
07 510 533 05 46 .RAHMEN 005 EA 840390
.FRAME
08 000 533 59 80 .DICHTUNG T=0,5 MM 005 EA 840392
.GASKET
09 001 534 18 01 .BETAETIGER 005 EA 840394
.PUSHBUTTON
.COVER
13 510 533 15 40 .LAGERBOCK 001 EA KE 840398
.RETAINER
17 510 533 12 80 .DICHTUNG PAN 2+4 001 EA 840400
.GASKET
PROJECT: M012 REFERENCE: 510 530

Sprache

Service Publication: Control Panel Pan 1 Pan 2 Pan 3 Pan 4

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Service Publication: Control Panel Pan 1 Pan 2 Pan 3 Pan 4

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Verfügbare Formate

Service Publication

MCS-5 Control panel

DaimlerChrysler Powersystems Off-Highway

General information about documentation

Documentation Title/contents Target group(s)

2 Operation Operating personnel

3 Maintenance and repair Plant personnel

4 Service manual Electronic service personnel

5 Illustrated parts catalog Operating personnel, electronic service

Reference numbers and reference lines

E 531 649 / 01 E – 04.2002 –  MTU

This symbol indicates cross-references to other manuals.

This symbol indicates important information.

This symbol indicates detailed information.

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

1st figure: Either “T” for “Task” or “A” for “Activity”

 MTU – 04.2002 – E 531 649 / 01 E

Qualification of users of the manual

E 531 649 / 01 E – 04.2002 –  MTU

(This page intentionally blank)

 MTU – 04.2002 – E 531 649 / 01 E

Structure and function

E 531 649 / 01 E – 04.2002 –  MTU

(This page intentionally blank)

 MTU – 04.2002 – E 531 649 / 01 E

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

1.3 Structure of control panel PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

E 531 649 / 01 E – 04.2002 –  MTU

Table of contents (cont.)

1.4.3 Internal connection of the CAN buses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

 MTU – 04.2002 – E 531 649 / 01 E

1 Structure and function

S/A bus S/A bus

Fig. 1: Schematic arrangement showing an engineer alarm system by way of example

E 531 649 / 01 E – 04.2002 –  MTU

Process station PPS

Control panel PAN Control panel PAN Control panel PAN

Control panel PAN Control panel PAN Control panel PAN

Control panel PAN Control panel PAN Control panel PAN

Fig. 2: Console application

 MTU – 04.2002 – E 531 649 / 01 E

Basic features of the PAN 1 to PAN 4 control panels are:

E 531 649 / 01 E – 04.2002 –  MTU

1.3 Structure of control panel PAN

1.3.1 Control panel PAN 1 – electronic version

Fig. 3: Control panel PAN 1 (front)

 MTU – 04.2002 – E 531 649 / 01 E

1.3.1.1 External structure

Fig. 4: Control panel PAN 1 – electronic version

E 531 649 / 01 E – 04.2002 –  MTU

1.3.1.2 Internal structure

Fig. 5: Control panel PAN 1 – electronic version

 MTU – 04.2002 – E 531 649 / 01 E

1.3.1.3 Technical data

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

Residual ripple as per STANAG 1008 Less than 5 %

Power consumption Iin < 220 mA

Degree of protection as per DIN 40 050

Ambient temperature 0 °C … +55 °C

Storage temperature --25 °C … +70 °C

Relative humidity 0 % … 95 %, non-condensing

EMC EN 50 081-2/EN 50 082-2