1600 Series Parts and Overview
1600 Series Parts and Overview
1600 Series Parts and Overview
Functional Description
Electronic governor
ECU 8
for MTU Series 1600
Genset application
E532291/01E
Printed in Germany
© 2011 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐
filming 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.
1 ........ General .......................................................................................................................................................... 6
1.1 General requirements ..................................................................................................................................... 6
1.1.1 General ..................................................................................................................................................................... 6
1.1.2 Intended use ............................................................................................................................................................. 6
1.1.3 Modifications or changes .......................................................................................................................................... 6
1.1.4 Spare parts ............................................................................................................................................................... 6
1.2 Safety regulations for maintenance and repair work ...................................................................................... 7
1.2.1 Safety regulations for commissioning ....................................................................................................................... 7
1.2.2 Safety regulations for operation ................................................................................................................................ 7
1.2.3 Engine operation ...................................................................................................................................................... 7
1.2.4 Maintenance and repairs .......................................................................................................................................... 7
1.2.5 Welding .................................................................................................................................................................... 8
1.2.6 Pressing and pulling work ......................................................................................................................................... 9
1.2.7 Work on electric/electronic assemblies ..................................................................................................................... 9
1.2.8 Working with laser devices ..................................................................................................................................... 10
1.2.9 Operation of electrical devices................................................................................................................................ 10
1.3 Designation of the sides of the engine and the cylinders ............................................................................. 11
2 ........ Overview ...................................................................................................................................................... 12
2.1 MTU Engine Control Unit ECU8 ................................................................................................................... 12
2.1.1 Overview ................................................................................................................................................................ 12
2.1.1.1 System devices ................................................................................................................................................ 12
2.1.2 Design .................................................................................................................................................................... 13
2.2 Scope of delivery .......................................................................................................................................... 14
2.2.1 MTU basic equipment ............................................................................................................................................. 14
2.2.1.1 Engine sensors, actuators ............................................................................................................................... 14
2.2.1.2 Engine wiring + injection wiring ........................................................................................................................ 14
2.2.1.3 ECU8 Engine Control Unit ............................................................................................................................... 14
2.2.1.4 Engine Control Unit connecting cable to system/power supply........................................................................ 14
2.2.1.5 24V DC power supply ...................................................................................................................................... 14
2.2.1.6 Smart Connect ................................................................................................................................................. 14
2.2.2 OEM parts .............................................................................................................................................................. 14
2.2.2.1 External sensors .............................................................................................................................................. 14
2.2.2.2 Connecting cables/wires for external sensors.................................................................................................. 14
2.3 Customer interface/operator's devices ......................................................................................................... 15
2.3.1 System overview/customer interface ...................................................................................................................... 15
2.3.1.1 Instrument outputs ........................................................................................................................................... 15
2.3.1.2 Binary inputs .................................................................................................................................................... 16
2.3.1.3 Transistor outputs ............................................................................................................................................ 16
2.4 Diagnosis and tools ...................................................................................................................................... 17
2.4.1 Device's own diagnosis .......................................................................................................................................... 17
2.4.1.1 Flashing frequencies ........................................................................................................................................ 18
2.4.2 DiaSys .................................................................................................................................................................... 19
2.4.3 Smart Connect........................................................................................................................................................ 20
2.4.3.1 Functional description ...................................................................................................................................... 20
2.4.3.2 Description of Smart Connect hardware .......................................................................................................... 20
2.4.3.3 Overview of interfaces ..................................................................................................................................... 21
2.4.3.4 Settings ............................................................................................................................................................ 23
2.4.4 Engine Identification Label EIL ............................................................................................................................... 27
3 ........ Use and design ........................................................................................................................................... 28
3.1 Functions ...................................................................................................................................................... 28
3.2 Function of the ignition (IGI)/emergency stop (ESI) ..................................................................................... 29
3.2.1 Ignition input (IGI Tl.15) .......................................................................................................................................... 29
3.2.2 Emergency stop input (ESI) .................................................................................................................................... 29
3.3 Installation on engine.................................................................................................................................... 30
3.3.1 Specifications ......................................................................................................................................................... 30
3.3.2 Mechanical design/installation location ................................................................................................................... 30
3.4 Technical data of ECU8................................................................................................................................ 31
Connections:
X1 System wiring harness
X2 Engine wiring harness
KV Coolant supply line
KR Coolant return line
The ECU8 Engine Control Unit was specially developed for application in BR 1600 engines and can be used for
6R, 8V, 10V and 12V.
It is especially suitable for offroad applications like genset, C&I and railway applications.
The injector output stage is only suitable for Common Rail systems.
There are three current levels that can be set – Bootpeak/Boost/Hold current.
The housing is mounted to the engine on dampers.
The housing is designed with connections to the cooling system for applications at high ambient temperatures and
heavy soiling.
2.1.1.1 System devices
The basic equipment for genset is composed of the following devices
ECU8
Smart Connect
Functions:
BATT Battery
CAN/SC Smart Connect device for ECU setting
X1 System wiring harness
X2 Engine wiring harness
IN Inductors
SS Sensors
St Starter
A1 Battery-charging generator
OEM MTU
AO1 Display instrument Series 1600 engine with ECU8
TOP1 - 3 Indicator lamps X1 System wiring harness
CAN –S Diagnostic system DiaSys ECU8 Engine Control Unit
K1 Terminal block/control box X2 Internal engine wiring harness
BATT Battery SC Smart Connect
GS Generator control
All of the devices/parts required by the operator to control and monitor the engine are included in the OEM scope of
delivery.
2.3.1.1 Instrument outputs
There are 2 outputs for analog display instruments for displaying the engine operating values (AO1/AO2). They can
be used for the following displays:
Coolant temperature
Lube-oil pressure
1 Diagnosis lamp
1 Laptop
2 CD-ROM with DiaSys 2.53 software (SP1 or higher)
A more in depth diagnosis of the electronic system can be made using the DiaSys® dialog system, consisting of
one laptop with the DiaSys® 2.53 SP1 or higher program, one user dongle and one CAN interface.
The main purpose of the dialog system is to change the settings in the ECU8.
Connector X2 – RS485
Channel Signal Pin Signal description Twisting Cross-
ti
RS485 B 1 Signal B (120 ohm connected between A and B) a >0.5 mm²
RS485 A 2 Signal B (120 ohm connected between A and B) a >0.5 mm²
RS485 GND 3 50 V isolated a >0.5 mm²
Connector X3 – CAN1
Channel Signal Pin Signal description Twisting Cross-
ti
CAN1 High 1 50 V isolated b >0.5 mm²
(install 120 ohm in connector as necessary)
CAN1 Low 2 50 V isolated b >0.5 mm²
(install 120 ohm in connector as necessary)
CAN1 CAN_GND 3 50 V isolated b >0.5 mm²
Connector X4 – CAN2
Channel Signal Pin Signal description Twisting Cross-
ti
CAN2 High 1 50 V isolated c >0.5 mm²
(install 120 ohm in connector as necessary)
CAN2 Low 2 50 V isolated c >0.5 mm²
(install 120 ohm in connector as necessary)
CAN2 CAN_GND 3 50 V isolated c >0.5 mm²
SC Smart Connect
K1 Terminal block
S1 System cable (X1 system wiring harness)
2.4.3.4 Settings
2.4.3.4.1 Overview of functions available for selection with DIP switches
The Smart Connect unit is equipped with 6 DIP switches to facilitate configuration for ECU8 (eight switches are
provided in total, however the last two switches 7 and 8 are only used internally by Smart Connect.
The Smart Connect switch settings are transmitted by a message via CAN1 to the ECU cyclically at one second
intervals.
Changes made to the switch settings do not take effect until the ECU has been restarted.
The configuration which can be set using the switches is preset and cannot be modified. The figures below
illustrate the assignment of the switches.
Note: All switches are set to “0” on delivery. The switches must be set (customized) for the specific application
concerned during commissioning.
1 Speed demand
2 Speed droop
3 Frequency
4 Internal
The speed demand is set with the three DIP switches (2³ = 8 variants), see table below.
The EIL ensures that only the data record which was specifically compiled for a certain engine is used with the
engine concerned. The engine is shut down after 15 minutes should it have become necessary to use the ECU of
another engine on the engine concerned. Yellow alarm “615 AL EIL Protection” and red alarm “454 SS Power
Reduction Active” are set during this time. This makes it possible to pinpoint or localize a fault by replacing with
an ECU from another engine.
A new ECU with a valid data record for the engine concerned must be ordered and subsequently installed in case
of a fault in the ECU.
Note: Any manipulation of the EIL will render your warranty null and void. Normal engine operation is also no
longer possible in such cases.
Central open- and closed loop control unit for the engine
Implementation of the specifications of the monitoring, control and remote control systems as signals sent
to the engine control
Control of the injection system
Control of other actuators on the engine
Recording of sensors and evaluation of the operating states of the engine
Monitoring of the limits and triggering an engine stop if states/limits become impermissible.
Sending fault messages to the monitoring and control systems
Downloading of settings for engine and system.
Self-monitoring ITS
Diagnosis with dialog unit (laptop)
On 8V, 10V and 12 V engines the ECU8 control unit is mounted at the top of the engine in an easily accessible
location facing in the direction of the driving end (KS). On 6R engines the ECU8 control unit is installed on the left
side of the engine at the bottom left.
The control unit cannot, however, be mounted away from the engine.
B1 Camshaft speed
A19 Engine Identity Label EIL
B13 Crankshaft speed
M8 Fuel pump HPP
X1 Smart Connect connection/system wiring harness
X2 ECU connector engine wiring harness
XY39.1 Injector connection 1
XY39.2 Injector connection 2
B48 Fuel pressure
B6 Coolant temperature
B16 Coolant pressure
Connections:
1 Supply voltage 3 Ventilation
2 Output voltage 4 Ground
1 Supply voltage
2 Output voltage
4 Ground
Connectors
B5/B16 connector
1 Supply voltage
2 Output voltage
3 Dummy
4 Ground
Use
The sensor is used for:
B10 Charge-air pressure
1 Supply voltage
2 Output voltage
4 Ground
Connectors
B10 Connectors
1 GND/Ground
2 Output
3 Supply voltage
Use
The sensor is used for:
B48.1 High-pressure fuel
B48.2 High-pressure fuel
S Pressure sensor
ECU Engine Control Unit
1 Ground
2 Output voltage
3 Supply voltage
Connectors
1 Connection B
2 Connection A
4.2.2.1 Use
The sensor is used for:
B1 Camshaft speed
B13 Crankshaft speed
S Sensor
ECU Engine Control Unit
ITS Fault detection OFF-LINE
A Analog signal
B Analog signal
Connectors
B1 Camshaft speed
Use
The sensor is used for:
B6 Coolant temperature
B9 Charge-air temperature
Block diagram
1 Input
2 GND/Ground
B6 Coolant temperature
B9 Charge-air temperature
Power Supply Power supply ECU8 Engine Control Unit -X1 Connector X1 at Engine Control Unit ECU8
Smart Connect Fault display of ECU8 F1-3 Circuit breaker Ground GND/Ground
The injector wiring harness is connected to the XY39A1/XY39A2/XY39B/1XY39B2 connectors. The connections of
the injector wiring harness are designed as “Window Gasket” and are located in the cylinder heads.
B Battery
+U Engine Control Unit operating voltage
V Vehicle
X Battery master switch
E Emergency stop (NC contact)
-U GND
7.1.2.11 DI 8 – Override
The “Override” function is used to override certain safety functions. Otherwise, when limits are violated this would
lead to a reduction in performance or an emergency stop of the engine. Note: Internal performance maps cannot
be overridden!
Parameters:
Open-line monitoring override: (2.7002.804)
Logic override: (2.7002.805)
1. Inductive load
2. Ohmic load
7.1.6.4 CAN 1
This CAN interface is used to connect the Engine Control Unit to the other MTU or OEM devices through the CAN
bus.
This interface can only transmit, i.e., received objects cannot be evaluated on this bus. All objects transmitted on
CAN 2 - J1939 (see below) are also transmitted here.
Counter faults.
102 1.8004.624 AL Counter Faulty
(Alarm configuration parameter, for explanation see PR 2.8008.100)
Open circuit fault in the injector wiring for cylinder B1. Result: Misfire.
=> Check injection wiring for breaks and rule out any breaks in the solenoid valve
351 1.8004.550 AL Cylinder B1 Open Circuit (e.g. by
replacing injector). Fault rectified: after each working cycle.
(Alarm configuration parameter, for explanation see PR 2.8008.100)
Open circuit fault in the injector wiring for cylinder B2. Result: Misfire.
=> Check injection wiring for breaks and rule out any breaks in the solenoid valve
(e.g. by
352 1.8004.551 AL Cylinder B2 Open Circuit
replacing injector). Fault rectified: after each working cycle.
(Alarm configuration parameter, for explanation see PR 2.8008.100)