Mtu - Technical Documentation: Service

MTU_ValueService
Technical Documentation
System Documentation
CCU 2-05 Genoline
Genset for On-board Power Supply
Marine Application
Functional Description
Operating Instructions
Workshop Manual
Installation and Commissioning
Instructions
E532237/01E
Printed in Germany
© 2008 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the
prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution,
translation, microfilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or
damage during operation.
Subject to alterations and amendments.
Wichtig – Important – Importante
Bitte die Karte „Inbetriebnahmemeldung“ abtrennen und ausgefüllt an MTU Friedrichshafen GmbH
zurücksenden.
Die Informationen der Inbetriebnahmemeldung sind Grundlage für den vertraglich vereinbarten Logistik-
Support (Gewährleistung, Ersatzteile etc.).
Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH.
The Commissioning Note information serves as a basis for the contractually agreed logistic support
(warranty, spare parts, etc.).
Veuillez séparer la carte “Signalisation de mise en service“ et la renvoyer à la MTU Friedrichshafen

GmbH.
Les informations contenues dans la signalisation de mise en service constituent la base pour l'assistance en
exploitation contractuelle (garantie, rechanges, etc.).
Rogamos separen la tarjeta “Aviso de puesta en servicio“ y la devuelvan rellenada a MTU

Friedrichshafen GmbH.
Las informaciones respecto al aviso de puesta en servicio constituyen la base para el soporte logístico
contractual (garantía, piezas de repuesto, etc.).
Ritagliare “Avviso di messa in servizio“ e rispedirlo debitamente compilato alla MTU Friedrichshafen
GmbH.
Le informazioni ivi registrate sono la base per il supporto logistico contrattuale (garanzia, ricambi, ecc.).
É gentileza cortar o cartão "Participação da colocação em serviço", preenché-lo e devolvé-lo a MTU

Friedrichshafen.
Os dados referentes à colocação em serviço representam a base para o suporte logístico (garantia, peças
sobressalentes, etc.) estabelecido contratualmente.
Postcard
MTU Friedrichshafen GmbH

Technical Information Management
88040 Friedrichshafen
GERMANY

Bitte in Blockschrift ausfüllen!
Please use block capitals!
Prière de remplir en lettres capitales!
¡A rellenar en letras de imprenta!
Scrivere in stampatello!
Favor preencher com letras de forma!
Motornr.: Auftragsnr.: Inbetriebnahme-

Engine No.: MTU works order No.:
o
No du moteur: N° de commande: meldung
N de motor: N° de pedido:
Motore N.: N. commessa: Commissioning
No. do motor: No. do pedido:
Note
Motortyp: Inbetriebnahmedatum:
Engine model: Date put into operation: Notice de mise
Type du moteur: Mise en service le: en service
Tipo de motor: Fecha de puesta en servicio:
Motore tipo: Messa in servizio il:
Tipo do motor: Data da colocação em serviço: Aviso de puesta
en servicio
Eingebaut in: Schiffstyp / Schiffshersteller:
Installation site: Vessel/type/class / Shipyard:
Lieu de montage: Type du bateau / Constructeur: Avviso di messa
Lugar de montaje: Tipo de buque / Constructor: in servizio
Installato: Tipo di barca / Costruttore
Incorporado em: Tipo de embarcação/estaleiro naval:
Participação da
Endabnehmer/Anschrift: colocação em
End user`s address: serviço
Adresse du client final:
Dirección del cliente final:
Indirizzo del cliente finale:
Usuário final/endereço:
Bemerkung:
Remarks:
Remarques:
Observaciones:
Commento:
Observações:
Table of Contents 01
General Instructions ........................................................ 05

Functional Description ...................................................... 15
Operating Instructions ...................................................... 35
Workshop Manual .......................................................... 47
Installation and Commissioning Instructions .................................. 63
Annex ..................................................................... 137
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02 Table of Contents
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Table of Contents 03
General Instructions ........................................................ 05

1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07
1.1 General conditions ....................................................... 07
1.2 Personnel and organizational requirements .................................. 08
1.3 Safety requirements when working on the engine ............................. 09
1.4 Auxiliary materials, fire prevention and environmental protection ................ 12
1.5 Standards for warning notices in the publication .............................. 14
Functional Description ...................................................... 15

2 Structure and Function ......................................................... 17
2.1 System overview and features ............................................. 17
2.2 System Genset Interface – Detailed overview and design ....................... 20
2.3 CCU – Technical data ..................................................... 22
2.4 SAM ................................................................... 23
2.5 CCB 2 – Technical Data ................................................... 27
2.6 Central Control Unit CCU – Use and functions ................................ 28
2.7 Engine governor – Intended use and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.8 Engine Monitoring Unit – Use and functions .................................. 33
Operating Instructions ...................................................... 35

3 Operating Instructions .......................................................... 37
3.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.1.1 Ready for operation – Activation/deactivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.1.2 Engine start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.1.3 Engine stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.1.4 Emergency engine stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.1.5 Overspeed test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.1.6 Override function – Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.1.7 Override function – Deactivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.1.8 Engine stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.1.9 Emergency engine shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Workshop Manual .......................................................... 47

4 Task Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.1 Repair Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.1.1 Fuse on printed circuit board in SAM cassette – Replacement . . . . . . . . . . . . . . 49
4.1.2 CCU – Internal design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.1.3 CCU – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.1.4 CCU fuse – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.1.5 SAM – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.1.6 SAM fuse – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
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04 Table of Contents
Installation and Commissioning Instructions .................................. 63

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.1 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.1.1 CCU – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.2 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.2.1 Cable arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.2.2 Engine governor – Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.2.3 Engine Monitoring Unit EMU 1 – Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.2.4 Engine Monitoring Unit EMU 7 – Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.2.5 Starter and battery-charging generator connection diagram – Overview . . . . . . . 70
5.2.6 Battery-charging generator and starter – Connection . . . . . . . . . . . . . . . . . . . . . . 73
5.3 Interface Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.3.2 RS 422 serial interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.3.3 CANopen interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.3.4 J1939 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6 Initial Operation ............................................................... 119
6.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.1.1 Pre-startup checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.1.2 Operating voltage – Initial application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.1.3 Supply voltage distribution – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.1.4 CCU power supply – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6.1.5 CCU fuse – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.1.6 SAM device settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.2 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
6.2.1 SAM node address setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
6.2.2 CAN node – Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.2.3 Settings via MINIDIALOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6.3 Tests .................................................................. 135
6.3.1 CCU test mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Annex ..................................................................... 137

7 Annex ....................................................................... 139
7.1 Conversion tables ....................................................... 139
7.2 Abbreviations ........................................................... 145
7.3 MTU-contact person/service partner ........................................ 148
7.4 Index .................................................................. 149
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General Instructions 05
General Instructions
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06 General Instructions
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Safety 07
1 Safety
1.1 General conditions

General
In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory
regulations regarding accident prevention must be observed. This engine is a state-of-the art product and conforms
with all applicable specifications and regulations. Nevertheless, persons and property may be at risk in the event of:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Non-compliance with the Safety Instructions
Correct use
The engine is intended exclusively for the application specified in the contract or defined at the time
of delivery. Any other use is considered improper use. The manufacturer will accept no liability for
any resultant damage. The responsibility is borne by the user alone.
Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or Conversions
Modifications made by the customer to the engine may affect safety.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. In the
event of any damage caused by the use of other spare parts, no liability nor warranty claims
vis-à-vis the engine manufacturer will be accepted.
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1.2 Personnel and organizational requirements

Personnel
Work on the engine must only be carried out by properly qualified and instructed personnel.
The specified legal minimum age must be observed.
Responsibilities of the operating, maintenance and repair personnel must be specified.
Organization
This publication must be issued to all personnel involved in operation, maintenance, repair or transportation.
It must be kept at hand near the engine and accessible at any time to all personnel involved
in operation, maintenance, repair or transportation.
The personnel must be instructed on engine operation and repair by means of this publication,
and in particular the safety instructions must be explained.
This is especially important for personnel who work on the engine only on an occasional basis.
Such personnel must be given instructions repeatedly.
Working clothes and protective equipment
Wear proper work clothing for all work.
Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron.
Work clothing must be tight fitting so that it does not catch on rotating or projecting components.
Do not wear jewelry (e.g. rings, chains etc.).
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Safety 09
1.3 Safety requirements when working on the engine

Safety precautions when putting the equipment into operation
Prior to initial operation, the product must have been installed correctly and approved according to MTU specifications.
Before putting the device or the system into operation, always ensure
• that all maintenance and repair work is completed
• that all loose components have been removed from rotating parts
• that nobody is standing in the danger zone of moving engine components.
Immediately after putting the device or system into operation, make sure that all control and display
instruments as well as the signaling and alarm systems work properly.
Safety requirements for operators
Procedures for cases of emergency must be practiced regularly.
The operator must be familiar with the controls and displays.
The operator must know the consequences of each operation to be carried out.
The operator must carry out the individual operations according to the documentation.
During operation, the displays and monitoring units must be permanently observed with regard to present
operating status, violation of limit values and warning or alarm messages.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• notify the supervisory personnel in charge
• analyze the message
• if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
When the engine is running, always wear ear protectors.
Ensure that the engine room is well ventilated.
Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable bonding agent.
Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a health
hazard. The exhaust pipework must be free of leaks and discharge the gases to atmosphere.
During engine operation, do not touch battery terminals, generator terminals or cables.
Inadequate protection of electrical components can lead to electric shocks and serious injuries.
When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Maintenance and repair
Strict adherence to the maintenance and repair schedule is an essential safety factor.
Never carry out maintenance and repair work with the engine running unless expressly instructed to do so.
Lock-out/tag-out the engine to preclude undesired starting. Disconnect the battery when electrical starters are fitted.
Close the main valve on the compressed-air system and vent the compressed-air line when air starters are fitted. Post
the "Do Not Start" sign in the operating room or affix it to the controlling device! Persons not involved must keep clear.
Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools
required. Have maintenance and repair work carried out by qualified and authorized personnel only.
Use only proper, calibrated tools.
Do not work on engines or components which are only held by lifting equipment or crane. Always support by
suitable means which conform with the applicable regulations before commencing maintenance or repair work.
Before barring the engine, make sure that nobody is standing in the danger zone. After completing
work on the engine, check that all protective devices/safety guards have been installed and that
all tools and loose parts have been removed from the engine.
Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Before
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starting work, relieve pressure in systems and compressed-air lines which are to be opened.
Never put lines to any use other than that for which they are intended. Never use lines for climbing.
Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage fuel lines during maintenance and repair work. To tighten the connections when installing
the lines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly.
E532237/01E 08-07 © MTU

Ensure that all fuel injection lines and pressurized oil lines have sufficient distance to other
components to avoid contact with them. Do not place fuel or oil lines near hot components,
except when necessary for design reasons during installation.
Elastomers (e.g. "Viton" sealing rings) are stable under normal operating conditions. The material decomposes
when exposed to fire or temperatures exceeding 300 °C. Hydrogen fluoride vapors are released in this
case. The resulting acid leads to serious burning if it contacts the skin. Do not touch elastomeric seals
if they have carbonized or resinous appearance. Wear protective gloves!
Take care with hot fluids in lines, pipes and chambers ⇒ Risk of burning!
Note cooling period for components which are heated for installation or removal ⇒ Risk of burning!
Never touch hot parts of the compressor and exhaust system ⇒ Risk of burning!
Take special care when removing ventilation or plugs from engine. In order to avoid discharge of
highly pressurized liquids, hold a cloth over the screw or plug. It is even more dangerous if the
engine has recently been shut down, as the liquids can still be hot.
Take special care when draining hot fluids. ⇒ Risk of burning!
When draining, collect fluids in a suitable container, mop up any spilt fluids or wipe or
soak them with a suitable binding agent.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.
When working high on the engine, always use suitable ladders and work platforms. Make
sure components are placed on stable surfaces.
In order to prevent back injuries when lifting heavy components adults, depending on age and sex,
should only lift weights between max. 10 kg and 30 kg, therefore:
• Use lifting gear or seek assistance.
• Ensure that all chains, hooks, slings, etc. are tested and authorized, are sufficiently strong and that
hooks are correctly positioned. Lifting eyes must not be unevenly loaded.
Observe special cleanness when conducting maintenance and repair work on the engine plant. After completion
of maintenance and repair work, make sure that no loose objects are in/on the engine plant.
Welding work
Never carry out welding work on the engine or engine-mounted units. Cover the engine when welding in its vicinity!
Never use the engine as a ground connection. This prevents the welding current passing through
the engine resulting in burnt/scorched bearings, sliding surfaces and tooth flanks which may
lead to bearing seizure and/or other material damage.
Never route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise
induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system.
The welding unit ground connection must not be more than 60 cm from the weld point.
If components (e.g. exhaust manifold) are to be welded, they must be removed from the engine.
It is not necessary to remove the connector and the connections when carrying out welding operation
on MTU electronics if the master switch for power supply is switched from "ON" to "OFF" and the wire
is disconnected from the negative and positive poles on the battery.
Hydraulic installation and removal
Only the hydraulic installation and removal equipment specified in the work schedule and
in the assembly instructions must be used.
The max. permissible push-on pressure specified for the equipment must not be exceeded.
The H.P. lines for hydraulic installation and removal are tested with 3800 bar.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the system to
be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
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• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle
into shaft end until correct sealing is achieved.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed. As long as the system is under pressure, there is the risk that the
component to be installed/removed may be suddenly released from the pressure connection.
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Safety 11
Before use, the tools must be checked at regular intervals (crack test).
Working on electrical/electronic assemblies
Always obtain the permission of the person in charge before commencing maintenance and repair
work or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies. Any measures requiring a power
supply are expressly defined as such at the appropriate place in the manual.
Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery
acids to come in contact with skin or clothing. Wear protective goggles. Do not place tools on the
battery. Before connecting the cable to the battery, check battery polarity. Battery pole reversal may lead
to injury through the sudden discharge of acid or bursting of the battery body.
Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is not
damaged by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure wiring to fluid-carrying lines.
On completion of the maintenance and repair work, any cables which have become loose
must be correctly connected and secured.
On completion of all repair work, the component and system must be subjected to a function check.
Separate testing of the repaired component without system integration is insufficient.
If wires are installed beside mechanical components and there is a risk of chafing, use
cable clamps to properly support the wires.
For this purpose, no cable binders must be used as, during maintenance and / or repair work,
the binders can be removed but not installed a second time.
Spare parts shall be properly stored prior to replacement, i.e. particularly protected against moisture. Defective
electronic components and assemblies must be suitably packed when dispatched for repair, i.e. particularly
protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment
When working with laser equipment, always wear special laser-protection goggles.
Laser equipment can generate extremely intensive, concentrated radiation by the effect of stimulated emission
in the range of visible light or in the infrared or ultraviolet spectral range. The photochemical, thermal and
optomechanical effects of the laser can cause damage. The main danger is irreparable damage to the eyes.
Laser equipment must be fitted with the protective devices necessary for safe
operation according to type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be used:
• Laser devices of classes 1, 2 or 3A,
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a
maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.
Operation of electrical equipment
When operating electrical equipment, certain components of this equipment are live.
Noncompliance with the warning instructions given for this equipment may result in
serious injury or damage to property.
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1.4 Auxiliary materials, fire prevention and environmental

protection
Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires -
therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants
lying around on the engine. Do not store combustible fluids near the engine.
Do not weld pipes and components carrying oil or fuel. Before welding, clean with a non-combustible fluid.
When starting the engine with a foreign power source, connect the ground lead last and remove it first.
To avoid sparks in the vicinity of the battery, connect the ground lead from the foreign power source
to the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarize yourself with their use.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or
noises indicating danger are drowned.
At all workplaces with a sound pressure level over 85 dB(A), always wear ear protectors
(protective wadding, plugs or capsules).
Environmental protection
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Manipulation of the injection control system can influence the engine performance and exhaust emissions.
As a result, compliance with environmental regulations may no longer be guaranteed.
Only fuels of the specified quality required to achieve emission limits must be used.
In Germany, the VAwS (=regulations governing the use of plants that may affect water quality) is applicable, which
means work must only be carried out by authorized specialist companies (MTU is an authorized specialist company).
Auxiliary materials
Use only fluids and lubricants that have been tested and approved by MTU.
Fluids and lubricants must be kept in suitable, properly designated containers. When using fluids, lubricants and
other chemical substances, follow the safety instructions applicable to the product. Take care when handling
hot, chilled or caustic materials. When using inflammable materials, avoid sparks and do not smoke.
Lead
• When working with lead or lead-containing pastes, avoid direct contact with the
skin and do not inhale lead vapors.
• Adopt suitable measures to avoid the formation of lead dust!
• Switch on fume extraction system.
• After coming into contact with lead or lead-containing materials, wash hands!
Acids and alkaline solutions
• When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing.
• Immediately remove clothing wetted by acids and alkalis!
• Rinse injuries with plenty of water!
• Rinse eyes immediately with eyedrops or clean tap water.
Painting
• When painting in other than spray booths equipped with extractors, ensure good ventilation.
Make sure that adjacent work areas are not affected.
• No naked flames!
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• No smoking.
• Observe fire prevention regulations!
• It is absolutely necessary to wear masks providing protection against paint and solvent fumes.
Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
• Do not bring liquid nitrogen in contact with the body (eyes, hands), as this causes frostbite and numbing.
• Wear protective clothing, gloves, closed shoes and protective goggles!
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Safety 13
• Ensure the room is well ventilated. 88% contamination of breathing air with nitrogen will result in suffocation.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
Compressed air
Compressed air is air compressed at excess pressure and is stored in tanks from which it can be extracted.
The pressure at which the air is kept can be read off at pressure gauges which must be connected
to the compressed air tanks and the compressed air lines.
When working with compressed air, safety precautions must be constantly observed:
• Pay special attention to the pressure level in the compressed air network and pressure vessel!
• Connecting devices and equipment must either be designed for this pressure or, if the permitted
pressure for the connecting elements is lower than the pressure required, a pressure reducing
valve and safety valve (set to permitted pressure) must form an intermediate connection. Hose
coupling and connections must be securely attached!
• Always wear protective goggles when blowing off tools or extracting chips!
• The snout of the air nozzle is provided with a protective disc (e.g. rubber disc), which prevents
air-borne particles being reflected and thereby prevents injury to eyes.
• First shut off compressed air lines before compressed air equipment is disconnected from the
supply line or before equipment or tool is to be replaced!
• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII
and B) out of containers, results in a risk of explosion!
• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass)
for drying purposes or to check for leaks, results in a risk of bursting!
• Do not blow dirty clothing with compressed air when being worn on the body.
Used oil
Used oil may contain health-threatening combustion residues.
Rub barrier cream into hands!
Wash hands after contact with used oil.
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1.5 Standards for warning notices in the publication

In the event of immediate danger.
Consequences: Death or serious injury.
DANGER • Preventive measures
In the event of possibly dangerous situations.
Consequences: Death or serious injury.
WARNING • Preventive measures
In the event of dangerous situations.
Consequences: Slight injury or material damage.
CAUTION • Preventive measures
Note: This publication contains especially emphasized safety instructions in accordance with the American
standard ANSI Z535, which begin with one of the above signal words according to the degree of danger:
Warning notices
1. Read and become acquainted with all cautions and symbols before operating or repairing this product.
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel!
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Functional Description 15
Functional Description
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16 Functional Description
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Structure and Function 17
2 Structure and Function
2.1 System overview and features
General overview
1 Display instruments, controls 3 Central Control Unit CCU 5 Engine Control Unit (ECU)
2 ECS 4 Engine Monitoring Unit (EMU)
The genset interface system is used to operate, control and monitor an on-board genset.
The system incorporates a Central Control Unit (3) for data processing and devices for the functions engine
management (4, 5), monitoring and control (1). The interaction of these parts is represented schematically in the figure.
Central Control Unit (CCU)
CCU = Central Control Unit (3)
Central data processing functions of the system
Installed in the engine room
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Engine Control Unit (ECU)

The main tasks of the Engine Control Unit are engine management and engine governing, control of common
rail injection and sequential turbocharging, and monitoring of vital engine values.
• All sensors and actuators are connected directly to the engine governor. Sensor failure,
sensor operation and cabling damage are monitored.
• Closed-loop control
• Speed (as per setpoint signals)
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• Injection (fuel pressure, injection timing, injection duration, operating status)

• Open-loop control
• Sequential turbocharging (cutting-in/out of right exhaust turbocharger)
• Emergency stop by engine protection system
• Monitoring
• Exhaust gas temperature A-side
• Exhaust gas temperature B-side
• Engine speed, lube oil pressure, coolant temperature (redundant monitoring by EMU)
• Coolant level
• Charger speed
• Leak-off fuel
Engine Monitoring Unit (EMU)
The Engine Monitoring Unit monitors additional engine parameters. The vital values engine speed, lube oil
pressure and coolant temperature are monitored redundantly together with the Engine Control Unit.
The sensors are directly connected to the Engine Monitoring Unit, sensor failure and cabling damage are monitored.
The following values can be monitored:
EMU:
• Individual exhaust gas temperatures (option)
• Raw water pressure
ECU:
• Combined exhaust gas temperature A-side
• Combined exhaust gas temperature B-side
• Exhaust turbocharger speed
• Intake air temperature
• Fuel pressure (high-pressure)
• Fuel pressure after filter
• Fuel temperature
• Coolant pressure
• Coolant level
• Crankcase pressure
• Charge-air pressure
• Charge-air temperature
• Lube oil differential pressure at filter
• Lube oil temperature
• Camshaft speed
• Air temperature before air recirculation valve
ECU and EMU:
• Coolant temperature
• Lube oil pressure
• Engine speed (crankshaft)
SAM:
• Monitoring of installed barring device
Features
Structure and function
• Electronic engine control and monitoring optimizes consumption and performance
• Consideration of individual engine characteristics
• Digital data transmission
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• Compact LSI devices

Safety
• Integrated alarm system
• Integrated self-test features
• Redundant data bus with automatic switching
• Additional parallel wiring of safety-relevant signals
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Installation
• Straightforward installation and startup
• Central cabling of all system components in the engine room
• In-situ configuration without auxiliary equipment (compact flash memory card, minidialog in CCU)
Operation
• Straightforward operation
Service
• Fault message indication on minidisplay in CCU
• In-depth diagnosis and adjustment via connectable dialog unit (notebook) with special software
Extension and variation potential

• Connection of customer-specific pushbuttons and indicator lamps
• Connection of devices via CAN bus (instruments, display, control panel)
• Connection of a device via RS 422 interface
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2.2 System Genset Interface – Detailed overview and design
Genset Interface – Detailed overview and design
No. Designation Explanation
1 Display instruments for engine/generator Analog instruments

Customer supply - not included in MTU
2 Illuminated pushbuttons, indicator lamps scope of delivery
for operating states and horn
3 Central Control Unit CCU Located in the engine room;

Access required only for commissioning,
in case of defects or during
maintenance/repair work.
4 Interface To optional signal inputs/outputs of the

CCU (signals of shipyard’s scope of
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supply)
(→ Page 28)
5 Voltage supply For overall genset CCU system.
6 Interface To starter
7 Interface To battery-charging generator
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No. Designation Explanation
8 Interface To barring device (if fitted).
9 Engine Monitoring Unit Engine-mounted.
10 Engine –
11 Engine governor Engine-mounted.

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2.3 CCU – Technical data
Item Unit Value
Dimensions (W x H x D) mm 430 x 139 x 344
Weight kg Approx. 7.5
Power consumption A 15 (max. 30)
Operating voltage VDC 24, +30%, –25%
High voltage Remove assemblies with electronic components during the

test.
Ambient temperature °C 0 to +55
Storage temperature °C -10 to +70
Relative air humidity % 5 to 95, non-condensing
Shock g/ms 10/11
Vibrostability
2 to 13 Hz mm xpp = ± 1.0
13 to 100 Hz g a = ±0.7
Insulation resistance IEC 92–504 (550 VAC/min)
Degree of protection IP 00 DIN 40050
Installation position As desired ensuring legibility of the integral fault code monitor.
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2.4 SAM
Use/application
• Installation in closed control cabinets.
• Suitable for mounting on mounting rails (rail installation) or for installation with screws
on the rear wall of the cabinet (fixed installation).
• Suitable for connection wires or flexible wires up to AWG16 (US) (1.5 mm2).
Technical data
Term Unit Value
Installation position As desired, however, make sure that the installed fault display
is visible.
Operating voltage VDC 24 rated value (-30%; +30%, temporarily -50%)
Power consumption W Below 7 (0.25A at 24V) without additional loads.
Protection: IP 40 according to DIN 40 050
Joint:
Rail installation 10g, 11ms
Fixed installation 30g, 11ms
Vibrations:
Rail installation Hz 2 - 12.8: Xpp < ± 3mm

12.8 - 1000: a < 1g [rms]
Fixed installation Hz 2 - 12.8: Xpp < ± 3mm

12.8 - 100: a < 4g [rms]
Ambient temperature: °C -40 - +70 with circulating ambient air.
Storage temperature: °C -40 - +100
Relative humidity: % 5 - 97, no condensation.
Color: Blue (RAL5015)
Material: % Polycarbonate, reinforced with 10% fiberglass.
Dimensions: mm L * W * H (295 * 151 * 75)
Weight: kg approx. 1.6
Note: The values listed above can be limited if MCS 5 extension modules are used.
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EMI/EMC – Electromagnetic interference (general)

The SAM was checked according to the following standards and complies with the corresponding limit values:
Standard Test
EN 55011 (Conducted emission) 10 kHz - 30 MHz, class A
EN 55011 (Radiated emission) 30 MHz - 1 GHz
IEC-60533:1999 (Conducted emission) 10 kHz - 30 MHz (type test)
EC-60533:1999 (Radiated emission) 150 kHz - 2 GHz (type test)
EN 61000-4-2 (ESD interference immunity) ±8kV
EN 61000-4-3 (Radiated interference immunity) 80MHz - – 2GHz
EN 61000-4-4 (Burst interference immunity) ±2kV
EN 61000-4-5 (Surge interference immunity) ±1kV/±2kV
EN 50155 (Surge interference immunity) ±1.8kV
EN 61000-4-17 (LF line-related interference) 0.03 – 10 kHz / 3Veff
EN 61000-4-29 (Line fluctuations / STANAG 1008)
IEC 60092-504 (Dielectric strength) 550VAC / 10mA
EN 50155 (Isolation) 500V / 10MOhm
The following measures are required to comply with the EMI/EMC limit values:
• The SAM housing must be connected to the housing ground e.g. with a cable with a minimum
cross-section of 2.5 mm2. The length of the cable may not exceed 10 cm.
• Only twisted cables may be used to connect sensors and actuators. The maximum length of unshielded
cables is 5 m, of shielded cables 50 m (provided the wiring harness resistance allows for this).
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Electrical requirements
Term Unit Value
Operating voltage: V 24, -30% to +30% (+16.8 - +32)

Permissible residual ripple below 5% according to STANAG
1008.
Note: The processor is automatically reset if the voltage falls
below 7 V.
Power supply: W Below 7 W.

Without activated loads at the SAM outputs
Additional total output power amperage of positive or negative
line may not exceed 10 A DC.
Power connection terminals: mm 5.08 terminals (spring-type terminals)

• A wire diameter of AWG14 (US) or 2.5 mm2 is
recommended.
Electrical isolation: V • Supply ground is the common ground for the entire SAM
electronics.
This applies to the entire I/O area, with the exception of
some electrically isolated channels.
• The SAM electronics ground is not connected to the
housing ground.
• If signal cable shields are used, they must be connected
to the housing ground.
• If not specified otherwise, the maximum direct current
isolation voltage is 500.
Mechanical design
Term Unit Value
Installation position: • Horizontal (due to the legibility of the fault display and
labels on the SAM housing).
• For the installation of the SAM in control cabinets,
note that sufficient space is required for cabling at the
connection points at the top and bottom.
• The entire device is warmed up due to the power loss
by the SAM. Heat dissipation of the SAM takes place
through the rear panel.
Make sure that heat can be transferred from the rear
SAM panel to the assembly frame. Avoid any additional
heating up of the SAM by neighboring devices.
Signal connections
The SAM module is easy to replace. The input and output signal cables have modular connectors.
Common function channels are grouped together.
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The wires are connected using spring-type terminals.

It is possible to connect two wires to one terminal if the wires are connected in a core double sleeve
using crimp technology. Phoenix AL-TWIN 2* 0.75-10 can e.g. be used.
The connector modules are connected by clicking them in place. The connector modules
have code pins to prevent any polarity reversal.
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Terminals
Term Unit Value
Terminal strip modules: WAGO spring-type terminals
Current-carrying capacity (at 70 A 10 per contact

°C):
Rated voltage: V 250
Rated surge voltage: V 2500
Wire cross-sections: mm2 up to 1.5 or AWG15
Terminal range: mm2 0.08 – 1.5 or AWG15
Other terminals (RM 5.08) are used for power supply and CAN bus connections.
Additional boards in slots 1 ... 3

If additional boards are used in the SAM, the technical specifications that apply to
these boards must be taken into account.
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2.5 CCB 2 – Technical Data

Technical data CCB2
Term Unit Value
Input voltage VDC +5 (–5 %, +3%) from SAM

+24V (±5 %) from SAM
Power consumption mA With 5 VDC < 600

With 24 VDC < 60
Power loss W Approx. 4

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2.6 Central Control Unit CCU – Use and functions
Central data processing and control unit CCU

• Communication with Engine Control Unit, Engine Monitoring Unit and optional display via
redundant CAN field bus with redundancy switching.
• Integral Test System for:
• Analog inputs;
• RAM;
• EEPROM;
• Watchdog;
• Temperature;
• Supply voltage (analog acquisition);
• CAN bus failure.
• Conversion of setpoint signals from MCS and generator controller into control signals for
Engine Control Unit, Engine Monitoring Unit and generator.
• Acquisition and evaluation of generator operating states
• Conversion of measured values, feedback signals, fault signals etc. into displays/alarms on MCS.
• Limit value monitoring.
• In the event of impermissible states and limit value violations: Initiation of power reduction and engine shutdown.
• Configuration via minidialog:
• Optional devices and sensors can be switched off;
• limit values for alarm signaling and engine stop can be configured.
Engine-related functions
• Engine start:
Monitoring of starting-air pressure, starting sequence, starter control, start interlocks, repeat of starting sequence.
• Engine stop:
Stopping sequence, automatic safety shutdown.
• Monitoring of fuel prefilter
• Coolant level monitoring
• Engine start and engine stop can be initiated in local operating mode.
Engine start
• Electric via starter or
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• pneumatic via starting valve

• Starting conditions:
• Engine stops.
• Stop not activated.
• Emergency stop not activated.
• Housing cover/barring device closed.
• External start interlock not applied.
• Binary input “Ready for Operation” activated.
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• Test mode not active / “OFF”. (activated by Service Display of CCU)

• The start sequence is automatically terminated if the engine fails to reach idling speed within a plant-specific time.
• The engine cannot be started when the plant is in test mode.
• Priming is immediately interrupted when the engine receives a start request to allow the genset to be started
without delay. The engine can be restarted without priming within a fixed period following engine stop.
Engine stop
• Can be tripped by:
• External stop keys
• RS 422 stop
• CANopen stop
• EMU stop (on classified plants)
• Activating test mode at the minidisplay on the CCU
Emergency stop functions
Emergency stop can be initiated via emergency stop button.
• Acquisition of the emergency stop command signal from
• Engine Control Unit.
• Engine Monitoring Unit.
• External systems (shipyard’s scope of supply, propulsion plant sensors).
• Storage of the emergency stop signal.
• Acknowledgment/reset of the emergency stop signal.
Display and signaling functions
• Acquisition of signals from the illuminated pushbuttons.
• Control of instruments.
• Control of signal lamps and illuminated pushbuttons.
• Control of horn.
• Generation and acknowledgment of combined alarms.
• Alarm output on integrated minidisplay.
Further functions
• Acquisition of the key switch to switch CCU on/off.
• Power supply to the Engine Control Unit and the Engine Monitoring Unit.
• Power supply to additional optional equipment.
• Signal conditioning for instrument outputs.
• Monitoring of charging operation of battery-charging generator.
• Override (settings for safety shutdown and interlocks are canceled).
• Priming pump control (interval) via alternating relay contact at CCU;
• Output of a floating control signal to the priming pump controller.
• Reading-in a floating binary feedback signal from the priming pump controller (automatic mode).
• Binary signal outputs for:
• Engine start activated;
• engine stop activated;
• engine ready for start;
• rated engine speed reached.
• Binary switching outputs for:
• Combined alarm message;
• engine stop pending;
• engine stop activated.
• Extendible for RS 422 interface (MCS-5 protocol).
• Connection for a local start/stop/emergency stop controller - SIF connector
Generator monitoring features
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• Winding temperature monitoring; (PT100)

• Bearing temperature monitoring; (PT100)
• Coolant temperature monitoring; (PT100)
• Coolant leakage monitoring; floating contact
• Differential protection monitoring; floating contact
The CCU provides a binary input for connection of an external differential protection device.
The fault message is transferred to the superordinate monitoring system together with the
data acquired by the CCU (RS 422, CANopen).
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• Effective power output; (4 to 20 mA)

The CCU provides an analog input for the acquisition of effective generator power which is available
from an external instrument transformer. The value is transferred to the superordinate monitoring
system together with the data acquired by the CCU (RS 422, CANopen).
Control features
Analog speed setting (4 to 20 mA) or via keys (Up/Down) depending on selector switch input (speed demand switch).
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2.7 Engine governor – Intended use and functions
Engine governor ECU 4
Central engine control unit

• Conversion of input signals from MCS-5 and CCU signals to the engine
• Control of the injection system
• Acquisition and evaluation of engine operating states
• Limit value monitoring
• In the event of impermissible states and limit value violations: Initiation of power reduction,
engine stop or emergency engine stop (configurable)
Engine and propulsion-plant specific settings in exchangeable memory modules
Self-monitoring
Diagnostics via serial interface for dialog unit
Engine governor ECU 7

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Central control unit for the engine

• Conversion of input values from the monitoring, control and remote control systems into signals to the engine
• Control of the injection system
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•
Control of other actuators on the engine
•
Acquisition of measured values from sensors and evaluation of engine operating states
•
Limit value monitoring
•
In the event of impermissible states and limit value violations: Initiation of power reduction,
engine stop or emergency engine stop (configurable)
• Transfer of fault signals to the control and monitoring system
Engine and propulsion-plant related data are downloaded
Self-monitoring
Diagnosis with dialog unit (laptop)
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2.8 Engine Monitoring Unit – Use and functions
Engine Monitoring Unit EMU1
Engine Monitoring Unit EMU 1 extends the scope of measuring points offered by Engine Control Unit ECU
4. It also incorporates a second, independent safety system to protect the engine.
Engine Monitoring Unit EMU 1 features:
• Speed, level, temperature and pressure inputs
• Up to 20 exhaust temperature inputs for NiCr-Ni sensors
• Communication with PCS-5 devices and higher-level system via CAN bus
• Self-monitoring and diagnosis
• Limit value monitoring of vital measuring points
• In case of inadmissible states and limit value violations: Initiation of engine stop or
emergency engine stop (configurable)
• Engine- and plant-related settings in an exchangeable memory module
• Online programming via download (dialog unit)
Engine Monitoring Unit EMU7

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Engine Monitoring Unit EMU 7 extends the scope of measuring points offered by Engine Control Unit ECU
7. It also incorporates a second, independent safety system to protect the engine.
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Engine Monitoring Unit EMU 7 features:

• Speed, level, temperature and pressure inputs
• Exhaust gas temperature inputs for NiCr-Ni sensors
• Communication with PCS-5 devices and higher-level system via CAN bus
• Self-monitoring and diagnosis
• Limit value monitoring of vital measuring points
• In case of inadmissible states and limit value violations: Initiation of engine stop or
emergency engine stop (configurable)
• Online programming via download (dialog unit)
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Operating Instructions 35
Operating Instructions
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36 Operating Instructions
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3.1 Operation
3.1.1 Ready for operation – Activation/deactivation
Preconditions
• Overall CCU system is switched on.
• Plant is ready for operation.
Activating Ready for Operation
1. Activate binary input “READY FOR OPERATION”.
Result:
1. Starting requirements are checked:
• Barring gear housing is closed.
• Stop not activated.
• Emergency stop not activated.
• External start interlock not activated.
• Engine at a standstill.
• Ready for operation active.
2. Binary output “READY FOR START” active
3. Engine starting is enabled when the starting requirements have been fulfilled.
4. Alarms signaled if starting requirements are not fulfilled.
2. Start engine as required.
Deactivating Ready for Operation

1. Deactivate binary input “READY FOR OPERATION”.
Result:
1. Binary output “READY FOR START” not active.
2. Starting is interlocked.
2. Return plant to ready state.
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3.1.2 Engine start
Preconditions
• Engine has been prepared for startup (→ Engine operating instructions).
• Overall Generator Interface system is switched on.
• Binary input “Ready for Start” is active (press external “Ready for Operation” pushbutton briefly beforehand)
Unguarded rotating and moving engine components.

Risk of serious injury - danger to life!
DANGER • Before barring or starting the engine, ensure that nobody is in the danger zone.
• After working on the engine, check that all protective devices have been reinstalled
and all tools removed from the engine.
Starting the engine at the control stand

1. Activate binary input “Start”.
Result:
• Binary output “Start activated” is active.
• The automatic starting sequence is executed.
• A combined alarm is output if starting is terminated (RS 422/CANopen, Service Display in CCU or
binary output).
• Engine speed increases.
• Current measurands may be indicated on external display instruments.
• The engine runs at rated speed when the starting sequence is completed.
• Binary output “Start activated” is deactivated when the engine speed rises above 300 rpm.
2. Repeat this procedure for all other engines (if applicable).
Result:
• The starting sequence is repeated in the same way as for the first engine.
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3.1.3 Engine stop
Preconditions
• Engine is running.
Note: The engine can either be stopped with the hard-wired Stop pushbuttons on the control stands or by
appropriate commands on the serial RS 422 or CANopen interface. The engine is stopped if test mode is
activated at the minidisplay on the SAM in the CCU when the engine is running. Engine Monitoring Unit
EMU can also trip engine stop on classified plants.
Stopping the engine at the LOP

1. Actuate binary input “STOP”.
Result: Binary output “STOP ACTIVATED” is active.
2. Engine stops.
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3.1.4 Emergency engine stop
Preconditions
An emergency stop causes extreme stress to the engine.

Risk of overheating, damage to components!
CAUTION • Initiate emergency stop only in emergency situations.
Emergency engine stop

1. Activate binary input “EMERGENCY STOP”.
Result:
1. Binary output “EMERGENCY STOP” is activate.
2. ECU is switched off. (ECU 4 only)
3. Various system fault messages appear on the Alarm Page as the bus station ECU no longer exists.
(ECU 4 only)
4. Alarm “SS Emergency STOP” appears.
5. Binary output for activation of a horn/flashing lamp is activated.
6. The emergency stop memory is set.
2. Rectify the cause of the emergency engine stop.
Resetting the emergency stop relay

1. Actuate “ALARM ACKNOWLEDGE” pushbutton.
Result: EMERGENCY STOP signal is reset.
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3.1.5 Overspeed test
Preconditions
• Engine stopped or engine running at rated speed (e.g. 1500 rpm).
Overspeed test (engine at a standstill)
1. Activate binary input “OVERSPEED TEST”.
Result:
1. ECU is switched off. (ECU 4 only)
(ECU 4 only)
3. Alarm “System Emergency Stop” appears.
4. Binary output “EMERGENCY STOP” is active.
5. Binary output for horn/flashing lamp is activated.
2. Activate binary input “ALARM ACKNOWLEDGE”.
Result: ECU is reactivated.
Overspeed test (engine running)

1. “Speed Decrease” until lower speed limit is reached (e.g. 1335 rpm).
2. Activate binary input “OVERSPEED TEST” and keep it activated!
3. “Speed Increase”
4. An emergency engine stop is tripped when the “Overspeed” limit value set in the ECU is exceeded.
Result:
1. Engine speed is indicated on the relevant display instruments.
2. The ECU is switched on when the upper limit value is reached. (ECU 4 only)
(ECU 4 only)
4. Alarm “Emergency STOP” appears.
5. Binary output “EMERGENCY STOP” is active.
6. Binary output for horn/flashing lamp is activated.
8. Engine stops.
9. Deactivate binary input “Overspeed Test”
5. Activate binary input “ALARM ACKNOWLEDGE”.
Result: ECU is reactivated.
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3.1.6 Override function – Activation

Inadmissible operational condition.
Major material damage!
CAUTION • Use override function only in hazardous situations to ensure full capability in case
of engine malfunctions.
Note: The Override function involves a large number of operating states which would normally lead to automatic
power reduction or engine shutdown being ignored by the overall system:
• With the engine at a standstill:
Start interlocks are ignored.
• With the engine running:
Engine operating limit value violations no longer lead to power reduction or engine shutdown.
Exception: Violation of the overspeed limit value still leads to shutdown.
Refer to the order-specific governor program for details of limit values which are bypassed by the
Override function.
Activating Override at the control stand

Note: MTU refuses to accept warranty claims for engine damage incurred when the Override function is
active! Activation of the Override function is recorded in the engine governor.
1. Activate binary input Override (pulse).

Result:
• Binary output OVERRIDE is activated.
• Binary output for horn/flashing lamp is activated.
2. Activate the binary input ALARM/ACK..
Result:
• Binary output for horn/flashing lamp is deactivated.
• The engine runs in Override mode.
• Rectify any malfunctions and alarm messages manually.
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3.1.7 Override function – Deactivation
Preconditions
• Operating mode Override is activated.
Deactivating Override
1. Activate binary input “Override” (pulse).
Result:
• Binary output “Override activated” is deactivated.
• The operating mode Override is deactivated.
2. Set plant to ready state.
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3.1.8 Engine stop
Preconditions
• Engine is running at rated speed.
Engine stop, plant-side
1. Activate binary input STOP (pulse).
Result:
• Binary output STOP is activated
• Automatic stopping sequence is executed.
• Engine speed decreases.
• Current measurands may be indicated on external display instruments.
• Engine is shut down on completion of the automatic stopping sequence.
• Binary output STOP is deactivated.
2. Repeat the procedure for other engines (if applicable).
Result: Stopping sequence is repeated similarly to the first engine.
3. Take all the necessary measures on the engine following shutdown (→Engine Operating Instructions)
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3.1.9 Emergency engine shutdown
Preconditions
An emergency stop causes extreme stress to the engine.

Risk of overheating, damage to components!
CAUTION • Initiate emergency stop only in emergency situations.
Emergency engine stop – plant side

1. Activate binary input EMERGENCY STOP.
Result:
• Binary input EMERGENCY STOP is activated.
• Binary output for horn/flashing lamp is activated.
• Binary output “Emergency Stop” is activated.
• Engines with emergency air-shutoff flaps: Flaps close.
• Engine is shut down.
2. Activate binary input ALARM/ACKN..
Result:
• Binary output for horn/flashing lamp is deactivated.
3. Activated binary input COMB. ALARM/ACKN. again.
Result:
• Binary output ENGINE ALARM is activated.
• Alarm has been acknowledged.
4. Rectify cause of emergency stop.
5. Open the flaps manually on engines equipped with emergency air-shutoff flaps.
Result: Engine is ready for starting.
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Workshop Manual 47
Workshop Manual
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48 Workshop Manual
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Task Descriptions 49
4 Task Descriptions
4.1 Repair Work
4.1.1 Fuse on printed circuit board in SAM cassette – Replacement
Preconditions
• Engine shut down.
• Operating voltage is not present.
Spare parts
Designation / Use Part No. Qty.

Plug-in fuse 3.15 A 0015317686 1
Insufficiently protected electric circuits.

Risk of damage to electronic units or fire!
CAUTION • Ensure that fuses are replaced by ones with the same electrical rating.
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50 Workshop Manual
Removing a printed circuit board

Note: Between one and three printed circuit
boards may be provided depending on the
use of the SAM module. The plug-in fuses
are located on the printed circuit boards.
1. Note down the installation position and pull out the

module cassette (1).
2. Separate the bottom half of the cassette (1)

from the top half (3).
3. Remove the printed circuit board (2) from the
cassette.
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Replacing a plug-in fuse

1. Grasp the faulty plug-in fuse with a pair of pointed
pliers and pull it out (one or more plug-in fuses
(fusible cutouts) are provided on the printed
circuit board depending on design, the example
shows a BOB 1).
2. Place a new plug-in fuse (1) with a rating of 3.15
A MT on the printed circuit board (2) and press
it into the socket (2) ensuring that none of the
connector pins are bent.
Inserting a printed circuit board

1. Insert the printed circuit board (2) in the bottom
half (1) of the cassette.
2. Fit the cover (3).
3. Engage the cover properly in the bottom half of
the cassette.
4. Insert the module cassette as noted keeping it
straight until fully engaged.
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52 Workshop Manual
4.1.2 CCU – Internal design
Internal design
1 Motherboard CIB 4 4 Processor module SAM

2 Cassettes for I/O printed 5 SAM fuses F1 and F2
circuit boards 6 Plug connector for dialog unit
3 Printed circuit board CCB 2 for 7 Plug connectors for connection of
CAN communication (option) all devices and assemblies
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Connectors
X1 RS 422 serial interface X13 Pushbuttons, signal lamps X26 Generator cooling air temperature
X2 Not used X14 Level sensor fuel prefilter 1 X27 Dimming voltage for display
X3 CANopen X15 24 V power supply CCU instruments
X4 CAN extension 1 - not supported X16 Plant signals X28 Not used
X5 CANopen X17 Generator monitoring X29 CAN bus terminator 120 Ω
X6 Speed demand, oil priming pump X18 Not used X30 Oil priming pump, generator power,
X7 T-riser too high sensor X19 Not used bearing temperature
X8 Starting-air pressure sensor X20 Pushbuttons, signal lamps, X31 Not used
X9 External coolant sensor (outer emergency stop X32 Emergency stop, cable damage
jacket cooling) X21 CAN bus field bus devices monitoring
X10 Generator monitoring signals, X22 ECU connector signals - not used X33 Generator
signal lamps X23 ECU connector power - not used X34 Level sensor fuel prefilter 2
X11 Indicators X24 Starter, pneumatic valve X35 EMU power supply, CAN bus
X12 Not used X25 Key switch
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54 Workshop Manual
Fuses
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The CCU is equipped with plug-in fuses to protect the various functional areas. Fuse assignment is as follows:
No. Designation Value Protection of
1 F1 20 A Engine governor
2 F2 7.5 A Binary outputs and analog outputs for engine control, engine
speed instrument, horn/ flashing lamp
3 F3 7.5 A CAN bus
4 F4 30 A Starter, F4 and F5 are connected in parallel
5 F5 30 A
6 F17 3A Starter
7 F49 3A EMU (connector X35)
8 F45 3A CAN FB connector (X21)
9 F29 3A Dimmer instruments
10 F18 3A Spare
11 F8 3A Spare
12 F6 3A Spare
The three plug-in fuses in the top left corner are spares.
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56 Workshop Manual
Indicators
1 LEDs CIB 4 functions 4 LEDs supply voltage and status

2 LEDs CCB 2 CANopen interface indication of relay K1
3 Display 5 LEDs supply voltage
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1 CCB2 indicator lamp CAN1 SAEJ1939

2 CCB2 indicator lamp CAN2 CANopen
3 CCB2 indicator lamp CAN Hi PLD
4 CCB2 indicator lamp INFO
5 CCB2 indicator lamp ERROR
6 CCB2 indicator lamp RUN
E532237/01E 08-07 © MTU

The indicators have the following meanings:
No. LED No. On Color B

Meaning
1 V92 CIB 4 Green Not used.
V128 Green Emergency stop reset active.
V134 Green ECU switched off.
V113 Green Not used.
V122 Green Emergency stop tripped.
V87 Green Not used.
V38 Green EMU supply voltage applied.
V34 Green Supply voltage for emergency stop pushbuttons,

emergency stop lamps and SIF connector applied.
V40 Green Supply voltage for priming pump controller signals,

generator signals applied.
V32 Green Supply voltage for external start interlock, overspeed

test, coolant leak, “Engine running” relay and horn
applied.
V106 Green Not used.
V80 Green Spare relay 1 (K2) activated
V99 Green Not used.
V82 Green Spare relay 2 (K3) activated.
V146 Green Horn/flashing light switched on.
2 1 CCB 2 Yellow Indicator lamp CAN1 SAEJ1939
2 Yellow Indicator lamp CAN2 CANopen
3 Yellow Indicator lamp CAN Hi unit-pump system
4 Yellow Indicator lamp INFO
5 Red Indicator lamp ERROR
6 Green Indicator lamp RUN
3 Display SAM — See operating instructions.
4 V71 CIB Green “Power On” relay activated (K1).
V42 Green Plant supply voltage applied.
5 V30 CIB Green CAN bus supply voltage applied.

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V28 Green Generator supply voltage applied.
V26 Green ECU supply voltage applied.
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58 Workshop Manual
4.1.3 CCU – Replacement
Preconditions
• Engine is stopped and starting disabled.
Spare parts

CCU X00026165 1
Removing the CCU mounting plate

1. Undo but do not remove screws (3) at cable
entries.
2. Note down cable assignment.
3. Disassemble grounding cable at grounding
stud (2).
4. Disconnect all connectors of outgoing cables.
5. Undo screws (1).
6. Remove mounting plate.
7. Extract the CF-card (4).
1 Screws
2 Grounding stud
3 Screws
4 CF-card
Installing the CCU mounting plate

1. Align the CCU mounting plate.
2. Fit screws (1) and tighten.
3. Install grounding cable at grounding stud (2).
4. Connect cables according to the assignment
notes made earlier.
5. Tighten screws (3) on the cable entries.
6. Insert CF-card (4).
7. Perform functional check.
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1 Screws
2 Grounding stud
3 Screws
4 CF-card
E532237/01E 08-07 © MTU

4.1.4 CCU fuse – Replacement
Preconditions
• Engine is stopped.
• Operating voltage is not applied.
Spare parts

Fuse 7.5 A
Fuse 30.0 A
Fuse 20.0 A
Fuse 3.0 A
Fuse 4.0 A
Locating a fuse
1. Remove defective fuse using pliers.
Note: Spare fuses are provided in plug-in sockets
in the top left corner.
2. Place the new fuse carefully on the socket.

3. Press the fuse into the socket as far as it will go.
F1 Engine Control Unit

F2 Propulsion control levers, analog display instruments
and pushbuttons/lamps on both control stands, also
dimming voltage if applicable
F3 CAN bus
F4 Starter, F4 and F5 are connected in parallel
F17 Starter
F49 Supply X35 (EMU)
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60 Workshop Manual


F29 Dimming instruments

F45 Supply X21 (CAN FB connector)


F6 Trolling unit
F8 Yard signals (engine room)
F18 Gearbox / external RCS
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4.1.5 SAM – Replacement
Preconditions
Removing SAM
1. Remove CCU cover.
1.1. Undo and remove the screws.
1.2. Disconnect the grounding cable from the
ground terminal in the cover.
1.3. Remove cover.
2. Disconnect all connectors (1) between SAM
and CIB on the SAM.
3. Remove the screws (2).
4. Remove the SAM from the CCU housing.
5. Remove the CF-card (3) from the SAM.
6. Remove cassette with printed circuit board CCB
2 (5) from SAM.
3 Not assigned
4 Not assigned
5 CCB 2
Installing the SAM

1. Place a new SAM on printed circuit board CIB.
2. Install the screws (2).
3. Connect all cables to the SAM.
4. Insert the CF-card.
5. Insert the cassette with the printed circuit board CCB 2 (5) in the middle slot (remove empty cassette if
necessary).
6. Perform functional check.
7. Connect the grounding cable to the ground terminal in the cover.
8. Close the cover on the CCU.
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62 Workshop Manual
4.1.6 SAM fuse – Replacement
Preconditions
• Engine is shut down.
• Operating voltage is not applied.
Spare parts

Fuse 15 A 0015319186 2
Locating a fuse
1. Locate appropriate fuse and replace both fuses
if necessary.
2. Grasp the faulty fuse(s) between finger and
thumb and pull out.
3. Determine cause of fuse tripping and remedy.
1 SAM
2 F2 for SAM supply –
3 F1 for SAM supply +
Inserting a new fuse

1. Carefully place new fuse(s) onto the plug-in socket(s).
2. Press fuse(s) with finger to the stop in their sockets.
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Installation and Commissioning Instructions 63
Installation and
Commissioning Instructions
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64 Installation and Commissioning Instructions
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Installation 65
5 Installation
5.1 Mechanical Installation
5.1.1 CCU – Installation
Preconditions
Installing the CCU (mounting plate)
1. Select an installation location in the switchgear
cabinet. Make sure that adequate space is
provided in front of and at the sides of the
mounting plate (free access to the control panel of
the local control unit).
2. The CCUs of the various power trains must be
arranged such that there is absolutely no doubt as
to which CCU controls which power train.
3. Ensure that adequate space is left at the bottom
and at the sides to allow disconnection.
• Minimum distance between the two left bores
and an adjacent wall: 200 mm.
• Minimum distance between the two lower bores
and a floor: 200 mm.
4. Mark out the four bores in accordance with the
drilling pattern. Tolerance: ± 0.5 mm.
5. Drill bores with a diameter of 8.5 mm.
6. Hold the CCU against the wall and insert bolts
through the lugs and the bores in the wall.
7. Screw a nut with a plain washer and a spring
washer on the other side of each of the four bolts
and tighten finger-tight.
8. Tighten screws.
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5.2 Electrical Installation
5.2.1 Cable arrangement
Cable arrangement
The CCU is equipped with the following connectors on delivery:

• X01: RS 422 serial interface
• X03: CANopen
• X04: CAN extension 1 - not supported
• X05: CANopen
• X06: Speed demand, oil priming pump
• X07: T-riser too high sensor
• X08: Starting-air pressure sensor
• X09: Ext. coolant level sensor (outer jacket cooling)
• X10: Generator monitoring signals, signal lamps
• X11: Display instruments
• X12: Not used
• X13: Pushbuttons, signal lamps
• X14: Level sensor fuel prefilter 1
• X15: 24 V power supply CCU
• X16: Plant signals
• X17: Generator monitoring
• X20: Pushbuttons, signal lamps, emergency stop
• X21: CAN bus field bus devices
• X24: Starter, pneumatic valve
• X25: Key switch
• X26: Generator cooling air temperature
• X27: Dimming voltage for display instruments
• X29: Not used
• X30: Oil priming pump, generator power, bearing temperature
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• X32: Emergency stop, cable damage monitoring

• X33: Generator
• X34: Level sensor fuel prefilter 2
• X35: EMU power supply, CAN bus
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Installation 67
5.2.2 Engine governor – Connection
Preconditions
• Cables are routed properly.
• Cables are long enough.
Special tools

Connector pliers 0135315483 1
Connecting ECU 7
1. Remove cable clamps (6).
2. Plug connector X1 (4) into socket X1 (4) and latch.
3. Plug connector X3 (2) into socket X3 (3) and latch.
4. Route cables cable over the engine governor
away from the engine.
5. Secure cables (5) with cable clamps (6).
6. Screw in screws (8) with washers (7) and tighten.
Connecting ECU 4
1. Remove covers (3) from sockets (1, 2).
2. Plug connector X1 into socket X1.
4. Route the cables up away from the engine.
5. Turn the bayonet union nuts on the connectors (4)
clockwise using connector pliers (5) until they are
firmly engaged (do not tighten by hand!).
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5.2.3 Engine Monitoring Unit EMU 1 – Connection
Preconditions
• Cables properly routed.
• Cables long enough.
Special tools

Connector pliers 0135315483 1
Loose contact at plug connections.

Risk of malfunctions in engine operation!
CAUTION • Ensure that bayonet union nuts engage completely.
Connecting EMU 1
Note: The cable to the engine may already be
connected on delivery. Omit the associated
activities in this case.
1. Remove the caps (5) covering sockets X11 (2)

and X12 (1).
4. Turn the bayonet union nuts (4) on the connectors
clockwise with connector pliers (3) until they
engage. Do not tighten by hand!
5. Route cables up away from the engine.
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Installation 69
5.2.4 Engine Monitoring Unit EMU 7 – Connection
Preconditions
• Cables properly routed
• Cables long enough
Connecting EMU 7
Note: The cable to the engine may already be
connected on delivery. Omit the associated
activities in this case.
1. Unscrew cable clamps (8).

2. Plug connector X12 (4) into socket X12 (7) and
engage clip.
3. Plug connector X11 (3) into socket X11 (5) and
engage clip.
4. Secure cable (1) on device with cable clamps (8)
as shown.
5. Insert screws (2) with washers (3) into the
appropriate bores (6) and tighten.
6. Secure connected cables at suitable points on
the engine.
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5.2.5 Starter and battery-charging generator connection

diagram – Overview
Connection diagram with one starter
A Generator B Starter D Starter battery
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Installation 71
Connection diagram with two starters
A Starter A-side C Battery-charging genera- D Starter battery

B Starter B-side tor/alternator
Connector assignment
The connectors in the CCU for connection of the starter and battery-charging generator are to be connected as follows:
• Connector X24 (for Bosch/Prestolite starters):
• Pin 1: do not connect
• Pin 2: Tl. 30 B+
• Pin 3: Tl. 50 Start
• Pin 4: Tl. 50 Start
• Pin 5: Tl. 45 Engaged
• Pin 6: Tl. 31 B-
• Connector X24 (for Delco starter):
• Pin 2: Terminal BAT, B+
• Pin 3: Terminal S, Start
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• Pin 4: Terminal S, Start

• Pin 5: Terminal MTR 1, engaged
• Pin 6: Terminal G, B-
• Connector X33
• Pin 1: D+
E532237/01E 08-07 © MTU

• Pin 2: B+
• Pin 3: Terminal 30 B+, jumper to PIN 2
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Installation 73
5.2.6 Battery-charging generator and starter – Connection
Preconditions
• Cables are routed properly.
• Cables are long enough.
• Required cable cross-sections are observed.
Connecting starter and battery-charging generator to CCU
1. Route cables in accordance with connection diagram (→ Page 70).
2. Prepare connectors X24 and X33 for the CCU and plug into CCU.
Connection stud (starter, battery-charging

generator)
Note: Figure applies to following application only:
• Electric starting
• No emergency air-shutoff flaps
• Battery-charging generator charges
starter battery
• No barring gear
1. Fit cables and washers on the stud in the order

shown in the figure.
2. Tighten nut (1), countering nut (9) at the same time.
1 Nut
2 Spring washer
3 Plain washer
4 Ring terminal with thin cable
5 Ring terminal with thick cable to battery-charging generator
6 Ring terminal with thick cable to battery
7 Plain washer
8 Stud
9 Nut
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Connecting cable to starter, with one starter

(Bosch/Prestolite)
1. Route cable W014.1 (1) with the cable lead
from the CCU (connector X33) along the engine
to the starter.
2. Route two cables (4 and 14) of a suitable
cross-section from the battery to the starter.
3. Cut cable (1) to size and strip off approx. 100 mm
of outer insulation.
4. Fit a cable ring suitable for terminal 30 (5) on
core No. 1 (2).
core No. 2 (3).
core No. 3 (15).
core No. 4 (12).
8. Insulate crimp connections with heat-shrinkable
hose (red for +, blue or black for -).
9. Fit a cable ring suitable for terminal 30 to cable (4).
10. Fit a cable ring suitable for terminal 31 to cable
(10).
1 Cable W014.1
2 Core No. 1 to terminal 30
4 Cable from starter terminal 30 to starter battery
5 Terminal 30 (M12 stud)
7 Starer relay
8 Starter
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Installation 75
Connecting the cables

1. Terminal 30 (5):
1.1. Undo nut at terminal 30 (5).
1.2. Remove nut, plain washer and spring washer.
1.3. Fit the red cable (4) in addition (battery + ).
1.4. Additionally fit core No.1 (2) of cable (1).
1.5. Screw on nut with plain washer and spring washer and tighten
2. Terminal 31 (11):
2.1. Undo nut at terminal 31 (11).
2.3. Fit the black cable (10) (battery —).
2.4. Fit core No. 4 (3) of the cable W014.1 (1).
3. Terminal 50 (13):
3.1. Fit core No.3 (3) of cable (1).
3.2. Fit plain and spring washer.
3.3. Screw on nut and tighten.
4. Terminal 45 (6):
4.1. Undo nut at terminal 45 (6) (holds the bracket).
4.3. Fit core No. 2 (15) of cable (1).
5. Battery connection:
5.1. Fit suitable lugs on the cables to the positive terminals of the batteries.
5.2. Fit suitable lugs on the cables to the negative terminals of the batteries.
5.3. Connect both cables to the battery terminals.
Connecting cable to starter, with two starters (Bosch/Prestolite)

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1 Cable W014.1: Core No. 1 to 3 Cable W014.1: Core No. 3 to 30 Terminal 30 (M12 stud)
terminal 30 of starter A terminal 50 of starter A 30b Terminal 30b (M12 stud)
1 Cable W014.2: Core No. 1 to 4 Cable W014.1: Core No. 4 to 31 Terminal 31 (M12 stud)
terminal 50 of starter B terminal 31 of starter A 45 Terminal 45 (M12 stud)
2 Cable W014.1: Core No. 2 to A Starter A 50 Terminal 50 (M6 stud)
terminal 45 of starter A B Starter B
Connecting cable to starter, with two starters (Bosch/Prestolite)

1. Route cable (W014.1) with the cable lead to the starter.
2. Route two cables (GND_BAT) of a suitable cross-section from the battery to the starter.
3. Route a cable of a suitable cross-section from starter A to starter B.
4. Fit cable rings on both ends of this cable (terminals 30b and terminal 30)
5. Cut cable (W014.1) to size and strip off approx. 100 mm of outer insulation.
6. Core no.1: Fit cable ring.
10. Insulate crimp connections with heat-shrinkable hose (red for +, blue or black for -).
11. Fit cable ring for M12 stud (terminal 30) on cable +U_BAT (to positive battery pole).
TIM ID: 0000014515 – 002
12. Fit cable ring for M10 stud (terminal 31) on the two cables GND_BAT (to negative battery pole).
13. Properly secure cables to appropriate points using cable ties.
17. Connect cable as shown in the illustration. Ensure correct arrangement of washers and nuts.
E532237/01E 08-07 © MTU

Installation 77
1 Core No. 1 to terminal 30 30 Terminal 30 (M12 stud)

2 Core No. 2 to terminal 45 30b Terminal 30b (M12 stud)
B Starter 50 Terminal 50 (M6 stud)
Connecting cable to starter, with one starter (Bosch/Prestolite)

2. Route one cable (GND_BAT) of a suitable cross-section from the battery to the starter.
8. Insulate crimp connections with heat-shrinkable hose (red for +, blue or black for -).
9. Fit cable ring for M12 stud (terminal 30) on cable +U_BAT (to positive battery pole).
10. Fit cable ring for M10 stud (terminal 31) on the cable GND_BAT (to negative battery pole).
11. Connect cable as shown in the illustration. Ensure correct arrangement of washers and nuts.
TIM ID: 0000014515 – 002
12. Properly secure cables to appropriate points using cable ties.
E532237/01E 08-07 © MTU

Connecting starters A and B - Delco Remy

Note: The connection of Delco Remy starters is analogous to the procedure described for Bosch, Prestolite
starters.
1. Remove the metallic jumper between the connections MTR/1 and MTR/2 on starter A.
2. Connect starters analogously to the procedure described for starters A and B — Bosch, Prestolite starter.
Pin assignment Bosch, Prestolite — Delco Remy
Standard Function Terminal designation Terminal designation

Bosch, Prestolite Delco Remy
30 Input directly from positive 30 BAT

battery pole
50 Starter activation 50 S
30b Input from positive battery 30b MTR/2

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pole 2nd starter
45 Output on released starting 45 MTR/1

relay, input on starter (main
current)
31 Battery ground 31 G
E532237/01E 08-07 © MTU

Installation 79
Connecting cables to the battery-charging generator

1. Fit a cable ring suitable for terminal D+ generator (M4 stud) to core 1 (cable W014).
2. Jumper pin 2 and pin 3 on connector X33.
3. Terminal D+:
3.1. Undo the nut (M4) at connection D+.
3.3. Fit core 1.
Different connection for air-starting

1. Leave connector X 24 terminals 3, 5 and 6 free.
2. Jumper pin 1 and pin 2 on connector X24.
3. Connect the solenoid valve to open starting-air to connector X24: Terminal 7 (GND) and terminal 4 (Sig).
4. Connect the sensor for starting-air pressure to connector X8: Terminal 1 (24 V supply) and terminal 4 (Sig. 4
... 20 mA).
TIM ID: 0000014515 – 002
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5.3 Interface Description
5.3.1 General information
Engine management system ECS-5

MTU Series 2000 and 4000 engines are equipped with the ESC-5 engine management system on delivery.
Engine management system ECS-5 features Engine Control Unit ECU 4 or ECU-7 depending on the engine design
status. The Engine Control Unit incorporates engine governing, engine control and engine monitoring functions.
Engine management system ECS-5 is extended by Engine Monitoring Unit EMU 1 or EMU 7 for
classifiable plants. The Engine Monitoring Unit additionally monitors measuring points specified by the
classification rules, offers a redundant safety system to protect the engine e.g. in case of overspeeding,
and also monitor individual cylinder exhaust gas temperatures.
Engine management system ECS-5 used in on-board genset applications can also be extended by an additional
CCU interface module. The interface module communicates with the Engine Control Unit via the CAN bus and,
if applicable, with the Engine Monitoring Unit, acquires and monitors additional peripheral engine and generator
measurands and provides an interface to the superordinate Monitoring and Control System.
The CCU provides an RS 422 interface and optionally a CANopen or J1939 interface to transmit the wide range
of data acquired and generated by the engine management system (measurands, fault messages).
This document describes the data content of the relevant interfaces.
General information about the data interfaces

This document describes the data blocks and data telegrams used by the various
interfaces and the measuring points involved.
Regardless of the configuration of the engine management system (Monitoring 1 = standard scope, without EMU,
Monitoring 2 = classifiable scope, with EMU) all the measuring points listed here are always transmitted. Measuring
points which, for example, are not supported in the standard scope are encoded with the value Missing Data (MD).
“Comments” column
The numbers listed in the “Comments” column have the following meanings:
1. Order-related/optional
2. Series 2000 only
3. Series 2000 only, Monitoring 2 (with EMU)
4. Series 4000 only
5. Series 4000 only, Monitoring 2 (with EMU)
6. Generator signals
Fault message identifiers

Each fault message is preceded by two letters followed by a blank. The meaning of these code letters is as follows:
• MG (Message)
Is followed by an informative message indicating impaired engine operation (operator error, etc.).
• AL (Alarm)
The fault message which follows indicates a fault in the electronic system or on the
engine, or inadmissible engine operational data.
• HI (High) and LO (Low)
Admissible upper or lower limit values set by MTU have been violated. This is usually indicative of a
mechanical fault on the engine. Such faults must be rectified immediately.
• SS (Safety System)
Reference to safety channels:
TIM ID: 0000030665 – 001
Engine management system ECS-5 takes action to protect the engine if admissible upper or lower limit
values continue to be violated. Depending on the type and severity of the limit value violation such
action may involve a request to reduce power or even an engine shutdown.
• TD (Transmitter Deviation)
An alarm is signaled in the case of analog measuring points (redundant) acquired by two different
systems if the deviation between the measured values is excessive.
E532237/01E 08-07 © MTU

Installation 81
5.3.2 RS 422 serial interface
General information about the RS 422 interface

Initialization is not necessary in order to start serial communication. No handshake mechanisms are
used. Serial data communication is realized in full-duplex mode. The data transmission rules described
in this chapter apply both to the transmission and reception of data.
Serial communication (transmission and reception) is realized cyclically in an infinite loop. The
cycle times for the transmission of all data blocks are specified. The minimum interval to
be maintained between any two data blocks is 50 ms.
The data block order in the data cycle is determined by the specified block number.
Block 1: 100 measurands
The occurrence of alarms leads to a change in the data block order.

The data flow is monitored by the receiver concerned. The receiver generates a fault
message on detecting data transmission failure.
Data is transmitted in blocks whereby a differentiation is made between three different types
of block (xxh - number in hexadecimal format).
Block type Block type code
Analog measurand block 03h
Binary measurand block 02h
Request block 01h
2 bytes are provided for block type identification (unsigned, Motorola memory format).
The data blocks are embedded in a data frame with an identical structure for each block type.
Data frame
Start_1 Start_2 Block Block Frame Mea- ... Mea- Check- End_1 End_2
no. type size surand surand sum
1 byte 1 byte 2 byte 2 byte 4 byte X byte X byte 4 byte 1 byte 1 byte
Data block
The beginning and end of the data frame are identified by the following values:
Start_1 ⇒ FAh
Start_2 ⇒ F5h
End_1 ⇒ AFh
TIM ID: 0000030726 – 001
End_2 ⇒ 5Fh
The block number (unsigned 2-byte integer value, Motorola memory format) which is determined by
MTU specifically for the order concerned follows the start code. The block number “0” is reserved for
the request block and is used both by the transmitter and the receiver.
The “Frame Size” entry (unsigned 4-byte integer value, Motorola memory format) contains the number of all
bytes transmitted within the data frame, i.e. the number of bytes from Start_1 to End_2.
E532237/01E 08-07 © MTU

Between 25 (CPS) and 100 measurands (PIM) can be transmitted and received depending on the interface coupler.
The interface of the third-party system should be designed to facilitate the reception
and processing of 100 measurands.
The minimum number of measurands in a data block is 4 (block 1).
Transmitted data is assigned to the measuring points in accordance with the measuring-point list compiled by MTU.
The defined order of the measurands must be strictly observed in order to ensure trouble-free data transmission.
A checksum (unsigned 4-byte integer value, Motorola memory format) is transmitted after the data block. The check
sum incorporates the sum of all bytes commencing at “Start_1” and ending at the last data byte prior to the checksum.
The data frame is terminated by the end code.
The end code can only be checked following reception of the bytes specified by “Frame Size” as it is possible
that the end code appears in the data block when transmitting analog measurand blocks.
Analog measurand block

Basic structure of an analog measurand block (X … max. number of measurands)
Data block
Analog measurands are transmitted by signed 4-byte integer values in Motorola memory format. The most
significant byte of the integer value is transmitted first in this memory format.
Analog measurand “15032” corresponds to “3AB8h” in Motorola memory format
Byte 4 Byte 3 Byte 2 Byte 1

Most significant byte Least significant byte
00h 00h 3Ah B8h
The measurands must be normalized in accordance with the measuring-point list specified by MTU.
The value 8000 0000h is transmitted in case of sensor defect. Missing data are identified by the value 7FFF FFFFh.
”Missing Data” does not represent a critical value. In this case there is simply no information about
the state of the measuring point. The connected third-party system must assume a safe state on
receiving from a measuring point signaling “Missing Data”.
Binary measurand block

Basic structure of a binary measurand block (X … max. number of measurands)
Data block
TIM ID: 0000030726 – 001
E532237/01E 08-07 © MTU

Installation 83
Binary measurands are transmitted by signed 1-byte values. The binary measurand may assume the following values:
01h ⇒ True
00h ⇒ False
80h ⇒ Sensor Defect
7Fh ⇒ Missing Data
Alarm messages
Transmission of the alarm block within a data cycle depends on the interface coupler used.
Generally the data cycle always begins with transmission of the alarm blocks (the number of
alarm blocks depends on the order concerned). The other data blocks are transmitted after the
alarm blocks in accordance with the specified block order.
Should an alarm occur during transmission of a data block, the transmission is duly completed.
The data cycle recommences following a pause.
If an alarm becomes active in the period between the end of a data cycle and the start of the next
data cycle, the interface coupler responds immediately or after a pause.
Sequence of functions
• Alarm transmission
When an alarm occurs the corresponding binary measurand is set to 01h and transmitted in
accordance with the specification for the exchange of alarm messages.
The binary value remains at 01h as long as the alarm conditions are fulfilled, or, in
the case of stored alarms, until the alarm is reset.
The MTU system does not acknowledge alarms/horn from the third-party system. Any third-party
system connected must store and acknowledge alarms independently.
Request block
Basic structure of the request block
Start_1 Start_2 Block no. Block type Frame Check- End_1 End_2
size sum
1 byte 1 byte 2 byte 2 byte 4 byte 4 byte 1 byte 1 byte
FAh F5h 00h 01h 10h 200h AFh 5Fh
The request block is preset. It is not a fixed part of the data cycle.
The request block is used to request all data blocks on detecting faulty data transmission, i.e. the receiver
terminates the current data cycle and starts a new data cycle on receiving a request block.
It is transmitted when no valid data blocks are received over a period of 3 s.
The period between any two request blocks must be at least 500 ms. This mechanism applies
both to the interface coupler and the third-party system.
The interface coupler detects a timeout and generates a fault message if no valid data is
received after transmitting four request blocks.
TIM ID: 0000030726 – 001
Interface parameters
The PIM supports full-duplex mode and provides electrical isolation.
E532237/01E 08-07 © MTU

The transmission parameters of the RS 422 interface are:
Baud rate: 9600
Data bits: 8
Stop bit: 1
Parity: No parity
Classification of measurands and data blocks

The data transmission cycle times have the following values (“transmission” and “reception”
defined from the interface coupler’s viewpoint):
• Transmission block: 950 msec
• Reception block: 100 msec
• Pause between the various data blocks: 50 msec
Transmission values – Block 1

General information:
• Block number: 1
• Block type: Binary
• Direction: Reception
Analog value
PV no.
range Start
Process variable Comments
Serial Sys. Index Min. Max. value
no. no. phys. phys.
1 600 911 Start Command RS 422 0 1 0 1)
2 600 912 Stop Command RS 422 0 1 0 1)
3 600 914 Override Command RS 422 0 1 0 1)

• Block number: 2
• Block type: Alarm
• Direction: Transmission
Analog value
PV no.
range Start
no. no. phys. phys.
1 410 009 SS Autom. Power Reduct. active 0 1 0 -
2 410 029 LO P-Lube Oil (ECU) 0 1 0 -

TIM ID: 0000030726 – 001
3 410 030 SS P-Lube Oil (ECU) 0 1 0 -
4 410 034 HI P-Crankcase 0 1 0 4)
5 410 035 SS P-Crankcase 0 1 0 4)
6 410 039 LO P-Coolant 0 1 0 -
E532237/01E 08-07 © MTU

Installation 85
Analog value
PV no.
range Start
no. no. phys. phys.
7 410 040 SS P-Coolant 0 1 0 -
8 410 047 LO P-Fuel 0 1 0 -
9 410 048 SS P-Fuel 0 1 0 -
10 410 050 LO P-Charge Air (a) 0 1 0 -
11 410 133 HI T-Charge Air 0 1 0 -
12 410 168 SS T-Charge Air 0 1 0 -
13 410 054 HI P-Oil Filter Difference 0 1 0 3), 5)
14 410 055 LO Coolant Level 0 1 0 -
15 410 056 HI Fuel Leakage 0 1 0 -
16 410 058 HI ETC 1 Speed 0 1 0 4)
17 410 070 SS ETC 1 Overspeed 0 1 0 4)
18 410 060 HI ETC 2 Speed 0 1 0 4)
19 410 071 SS ETC 2 Overspeed 0 1 0 4)
20 410 064 LO P-Fuel (Common Rail) 0 1 0 4)
21 410 065 HI P-Fuel (Common Rail) 0 1 0 4)
22 410 116 AL ECU Defect 0 1 0 -
23 410 122 LO ECU Power Supply Voltage 0 1 0 -
24 410 270 LOLO ECU Power Supply Voltage 0 1 0 -
25 410 123 HI ECU Power Supply Voltage 0 1 0 -
26 410 271 HIHI ECU Power Supply Voltage 0 1 0 -
27 410 129 HI T-Coolant (ECU) 0 1 0 -
28 410 130 SS T-Coolant (ECU) 0 1 0 -
29 410 143 HI T-Lube Oil 0 1 0 -
30 410 144 SS T-Lube Oil 0 1 0 -
31 410 147 HI T-Exhaust Combined A 0 1 0 3), 4)
32 410 296 SS T-Exhaust Combined A 0 1 0 3), 4)

TIM ID: 0000030726 – 001
33 410 150 HI T-Exhaust Combined B 0 1 0 3), 4)
34 410 297 SS T-Exhaust Combined B 0 1 0 3), 4)
35 410 170 HI T-ECU 0 1 0 -
36 410 177 SS Engine Speed Low 0 1 0 -
37 410 178 AL ECU Error/Check Fail Code 0 1 0 -
E532237/01E 08-07 © MTU

Analog value
PV no.
range Start
no. no. phys. phys.
38 410 185 AL Common Rail Leakage 0 1 0 -
39 410 187 HI ETC 2 Idle Speed 0 1 0 4)
40 410 188 HI ETC Speed Difference 0 1 0 4)
41 410 189 AL ETC 2 Cut in Failure 0 1 0 4)
42 410 200 HIHI T-Fuel 0 1 0 -
43 410 294 HI T-Charge Air Seq Ctrl Valve 0 1 0 4)
44 410 295 SS T-Charge Air Seq Ctrl Valve 0 1 0 4)
45 410 299 HI T-Fuel 0 1 0 -
46 412 029 LO P-Lube Oil (EMU) 0 1 0 3), 5)
47 412 030 SS P-Lube Oil (EMU) 0 1 0 3), 5)
48 412 129 HI T-Coolant (EMU) 0 1 0 3), 5)
49 412 130 SS T-Coolant (EMU) 0 1 0 3), 5)
50 412 301 HI T-Exhaust A1 0 1 0 1), 5)
51 412 302 HI T-Exhaust A2 0 1 0 1), 5)
52 412 303 HI T-Exhaust A3 0 1 0 1), 5)
53 412 304 HI T-Exhaust A4 0 1 0 1), 5)
54 412 305 HI T-Exhaust A5 0 1 0 1), 5)
55 412 306 HI T-Exhaust A6 0 1 0 1), 5)
56 412 307 HI T-Exhaust A7 0 1 0 1), 5)
57 412 308 HI T-Exhaust A8 0 1 0 1), 5)
58 412 311 HI T-Exhaust B1 0 1 0 1), 5)
59 412 312 HI T-Exhaust B2 0 1 0 1), 5)
60 412 313 HI T-Exhaust B3 0 1 0 1), 5)
61 412 314 HI T-Exhaust B4 0 1 0 1), 5)
62 412 315 HI T-Exhaust B5 0 1 0 1), 5)
63 412 316 HI T-Exhaust B6 0 1 0 1), 5)

TIM ID: 0000030726 – 001
64 412 317 HI T-Exhaust B7 0 1 0 1), 5)
65 412 318 HI T-Exhaust B8 0 1 0 1), 5)
66 412 401 LO T-Exhaust A1 0 1 0 1), 5)
67 412 402 LO T-Exhaust A2 0 1 0 1), 5)
68 412 403 LO T-Exhaust A3 0 1 0 1), 5)
E532237/01E 08-07 © MTU

Installation 87
Analog value
PV no.
range Start
no. no. phys. phys.
69 412 404 LO T-Exhaust A4 0 1 0 1), 5)
70 412 405 LO T-Exhaust A5 0 1 0 1), 5)
71 412 406 LO T-Exhaust A6 0 1 0 1), 5)
72 412 407 LO T-Exhaust A7 0 1 0 1), 5)
73 412 408 LO T-Exhaust A8 0 1 0 1), 5)
74 412 411 LO T-Exhaust B1 0 1 0 1), 5)
75 412 412 LO T-Exhaust B2 0 1 0 1), 5)
76 412 413 LO T-Exhaust B3 0 1 0 1), 5)
77 412 414 LO T-Exhaust B4 0 1 0 1), 5)
78 412 415 LO T-Exhaust B5 0 1 0 1), 5)
79 412 416 LO T-Exhaust B6 0 1 0 1), 5)
80 412 417 LO T-Exhaust B7 0 1 0 1), 5)
81 412 418 LO T-Exhaust B8 0 1 0 1), 5)
82 412 503 LO P-Raw Water 0 1 0 1), 3), 5)
83 412 507 AL Transistor Output 1/2 Fail 0 1 0 -
84 412 510 SS Request Power Reduction 0 1 0 1), 3), 5)
85 412 512 AL Exhaust Monitoring Fail 0 1 0 1), 3), 5)
86 412 513 AL Press Monitoring Fail (EMU) 0 1 0 3), 5)
87 412 516 SS Security Channel Def EMU 0 1 0 3), 5)
88 412 518 TD T-Coolant 0 1 0 3), 5)
89 412 519 TD P-Lube Oil 0 1 0 3), 5)
90 414 601 AL Power Amplifier 1 Failure 0 1 0 -
91 414 602 AL Power Amplifier 2 Failure 0 1 0 -
92 414 603 AL Status Transistor Outputs 0 1 0 -
93 416 010 Combined Alarm (ECU) 0 1 0 -

TIM ID: 0000030726 – 001

• Block number: 3
E532237/01E 08-07 © MTU

Analog value
PV no.
range Start
no. no. phys. phys.
1 412 006 SS Overspeed (EMU) 0 1 0 3), 5)
2 412 506 LO P-Oil Re-Fill Pump 0 1 0 1), 3), 5)
3 414 354 MG External Start Interlock 0 1 0 -
4 414 360 AL Barring Gear Engaged 0 1 0 -
5 414 435 AL HI T-Riser 0 1 0 -
6 414 489 SS Security Shutdown 0 1 0 -
7 414 490 SS Emergency Stop 0 1 0 -
8 414 591 AL Diff Protection Tripped 0 1 0 1), 6)
9 414 593 AL Coolant Leakage Generator 0 1 0 1), 6)
10 414 495 SS Overspeed (ECU) 0 1 0 -
11 414 553 HI T-Winding L1 0 1 0 1), 6)
12 414 554 HIHI T-Winding L1 0 1 0 1), 6)
13 414 558 HI T-Winding L2 0 1 0 1), 6)
14 414 559 HIHI T-Winding L2 0 1 0 1), 6)
15 414 563 HI T-Winding L3 0 1 0 1), 6)
16 414 564 HIHI T-Winding L3 0 1 0 1), 6)

• Block number: 4
TIM ID: 0000030726 – 001
E532237/01E 08-07 © MTU

Installation 89
Analog value
PV no.
range Start
no. no. phys. phys.
1 414 408 AL Priming Pump Fail 0 1 0 1)
2 414 411 AL Water in Fuel Prefilter 0 1 0 -
3 414 416 AL Battery Charger Failure 0 1 0 -
4 414 421 LO P-Start Air 0 1 0 1)
5 414 470 AL Override Activated 0 1 0 -
6 414 573 HI T-Bearing Driven End 0 1 0 1), 6)
7 414 574 HIHI T-Bearing Driven End 0 1 0 1), 6)
8 414 578 HI T-Bearing Non Driven End 0 1 0 1), 6)
9 414 579 HIHI T-Bearing Non Driven End 0 1 0 1), 6)
10 414 583 HI T-Cooling Air 0 1 0 1), 6)
11 414 584 HIHI T-Cooling Air 0 1 0 1), 6)
12 416 020 AL Safety System Fail (EMU) 0 1 0 1), 3), 5)
13 416 810 AL Shutdown expected 0 1 0 1)

• Block number: 5
• Block type: Binary
TIM ID: 0000030726 – 001
E532237/01E 08-07 © MTU

Analog value
PV no.
range Start
no. no. phys. phys.
1 410 001 Stop Activated 0 1 0 -
2 410 068 Engine Running 0 1 0 -
3 410 069 ETC 2 Cut In 0 1 0 -
4 410 078 Rated Speed Reached 0 1 0 -
5 410 190 AL Shutdown expected 0 1 0 -
6 410 290 Coolant Level Switch 0 1 0 -
7 410 291 Fuel Leakage Level Switch 0 1 0 -
8 414 001 Combined Alarm Red 0 1 0 -
9 414 002 Combined Alarm Yellow 0 1 0 -
10 414 265 FB CCU Start 0 1 0 -
11 414 270 FB CCU Stop 0 1 0 -
12 414 290 Ready for Start 0 1 0 -
13 414 355 MG Not Ready for Operation 0 1 0 -
14 414 540 WB Emergency Stop CTR Stand 1 0 1 0 -
15 414 541 WB Emergency Stop CTR Stand 2 0 1 0 -
16 414 594 Priming Pump Automatic Mode 0 1 0 1)
17 416 416 Override Activated (Display) 0 1 0 -
18 416 416 Priming Pump On 0 1 0 1)

• Block number: 6
• Block type: Analog
TIM ID: 0000030726 – 001
E532237/01E 08-07 © MTU

Installation 91
Integer value
PV no.
range Start
Process variable Unit Scaling Comments
no. no. phys. phys.
rpm
1 410 002 Engine Speed (ECU) (1/min)10 0 30.000 0 -
2 410 026 P-Lube Oil (ECU) bar 100.000 0 1.000.000

0 -
3 410 027 L1L P-Lube Oil (ECU) bar 100.000 0 1.000.000

0 -
4 410 028 L2L P-Lube Oil (ECU) bar 100.000 0 1.000.000

0 -
-
5 410 031 P-Crankcase mbar 100 7.000 7.000 0 4)
-
6 410 032 U1L P-Crankcase mbar 100 7.000 7.000 0 4)
-
7 410 033 U2L P-Crankcase mbar 100 7.000 7.000 0 4)
8 410 036 P-Coolant bar 100.000 0 600.0000 3), 5)
9 410 037 L1L P-Coolant bar 100.000 0 600.0000 3), 5)
10 410 038 L2L P-Coolant bar 100.000 0 600.0000 3), 5)
11 410 046 P-Fuel bar 100.000 0 1.500.000

0 -
12 410 049 P-Charge Air (a) bar 100.000 0 500.0000 -
13 410 163 LL P-Charge Air (a) bar 100.000 0 500.000- -
14 410 057 ETC 1 Speed krpm 10.000 0 1.000.000

0 4)
15 410 160 U1L ETC 1 Speed krpm 10.000 0 1.000.000

0 4)
16 410 172 U2L ETC 1 Speed krpm 10.000 0 1.000.000

0 4)
17 410 059 ETC 2 Speed krpm 10.000 0 1.000.000

0 4)
18 410 161 U1L ETC 2 Speed krpm 10.000 0 1.000.000

0 4)
19 410 173 U2L ETC 2 Speed krpm 10.000 0 1.000.000

0 4)
20 410 075 ECU Failure Codes digit 1 0 2.147.483.647

0 -
21 410 115 ECU Operating Hours h 1 0 100.0000 -

-
22 410 126 T-Coolant (ECU) degC 100 2.000 12.000 0 -
-
23 410 127 U1L T-Coolant (ECU) degC 100 2.000 12.000 0 -
TIM ID: 0000030726 – 001
-
24 410 128 U2L T-Coolant (ECU) degC 100 2.000 12.000 0 -
-
25 410 131 T-Charge Air degC 100 2.000 12.000 0 -
E532237/01E 08-07 © MTU

Integer value
PV no.
range Start
no. no. phys. phys.
-
26 410 132 U1L T-Charge Air degC 100 2.000 12.000 0 -
-
27 410 167 U2L T-Charge Air degC 100 2.000 12.000 0 -
-
28 410 140 T-Lube Oil degC 100 2.000 12.000 0 -
-
29 410 141 U1L T-Lube Oil degC 100 2.000 12.000 0 -
-
30 410 142 U2L T-Lube Oil degC 100 2.000 12.000 0 -
31 410 145 T-Exhaust Combined A degC 100 0 100.0000 3), 4)
32 410 146 U1L T-Exhaust Combined A degC 100 0 100.0000 3), 4)
33 410 261 U2L T-Exhaust Combined A degC 100 0 100.0000 3), 4)
34 410 148 T-Exhaust Combined B degC 100 0 100.0000 3), 4)
35 410 149 U1L T-Exhaust Combined B degC 100 0 100.0000 3), 4)
36 410 262 U2L T-Exhaust Combined B degC 100 0 100.0000 3), 4)

-
37 410 151 T-Intake Air degC 100 2.000 12.000 0 -
-
38 410 152 T-Fuel degC 100 2.000 12.000 0 -
39 410 158 L1L P-Fuel bar 100.000 0 1.500.000

0 -
40 410 159 L2L P-Fuel bar 100.000 0 1.500.000

0 -
rpm
41 410 162 UL Engine Speed (1/min)10 0 30.000 0 -
-
42 410 199 U2L T-Fuel degC 100 2.000 12.000 0 -
43 410 216 Injection in Relation to DBR % 1.000 0 100.0000 -
44 410 258 T-Charge Air Seq Ctrl Valve degC 100 0 100.0000 4)
45 410 259 U1L T-Charge Air Seq Ctr Valve degC 100 0 100.0000 4)
46 410 260 U2L T-Charge Air Seq Ctr Valve degC 100 0 100.0000 4)
-
47 410 298 U1L T-Fuel degC 100 2.000 12.000 0 -
TIM ID: 0000030726 – 001
-
48 410 300 UL T-ECU degC 100 2.000 12.000 0 -
rpm
49 412 002 Engine Speed (EMU) (1/min)10 0 30.000 0 3), 5)
50 412 026 P-Lube Oil (EMU) bar 100.000 0 1.000.000

0 1), 5)
E532237/01E 08-07 © MTU

Installation 93
Integer value
PV no.
range Start
no. no. phys. phys.
51 412 027 L1L P-Lube Oil (EMU) bar 100.000 0 1.000.000

0 1), 5)
52 412 028 L2L P-Lube Oil (EMU) bar 100.000 0 1.000.000

0 1), 5)
-
53 412 126 T-Coolant (EMU) degC 100 2.000 12.000 0 1), 5)
-
54 412 127 U1L T-Coolant (EMU) degC 100 2.000 12.000 0 1), 5)
-
55 412 128 U2L T-Coolant (EMU) degC 100 2.000 12.000 0 1), 5)
rpm
56 412 162 UL Engine Speed (1/min)10 0 30.000 0 1), 5)
57 412 201 T-Exhaust A1 degC 100 0 100.0000 1), 5)
58 412 202 T-Exhaust A2 degC 100 0 100.0000 1), 5)
59 412 203 T-Exhaust A3 degC 100 0 100.0000 1), 5)
60 412 204 T-Exhaust A4 degC 100 0 100.0000 1), 5)
61 412 205 T-Exhaust A5 degC 100 0 100.0000 1), 5)
62 412 206 T-Exhaust A6 degC 100 0 100.0000 1), 5)
63 412 207 T-Exhaust A7 degC 100 0 100.0000 1), 5)
64 412 208 T-Exhaust A8 degC 100 0 100.0000 1), 5)
65 412 211 T-Exhaust B1 degC 100 0 100.0000 1), 5)
66 412 212 T-Exhaust B2 degC 100 0 100.0000 1), 5)
67 412 213 T-Exhaust B3 degC 100 0 100.0000 1), 5)
68 412 214 T-Exhaust B4 degC 100 0 100.0000 1), 5)
69 412 215 T-Exhaust B5 degC 100 0 100.0000 1), 5)
70 412 216 T-Exhaust B6 degC 100 0 100.0000 1), 5)
71 412 217 T-Exhaust B7 degC 100 0 100.0000 1), 5)
72 412 218 T-Exhaust B8 degC 100 0 100.0000 1), 5)
73 412 221 T-Exhaust Mean degC 100 0 100.0000 1), 5)
74 412 224 UL T-Exhaust degC 100 0 100.0000 1), 5)

TIM ID: 0000030726 – 001
75 412 225 LL T-Exhaust degC 100 0 100.0000 1), 5)
76 412 501 P-Raw Water bar 100.000 0 600.0000 1), 3), 5)
77 412 502 LL P-Raw Water bar 100.000 0 600.0000 1), 3), 5)
78 414 550 T-Winding L1 degC 100 0 12.000 0 1), 6)
79 414 551 U1L T-Winding L1 degC 100 0 12.000 0 1), 6)
E532237/01E 08-07 © MTU

Integer value
PV no.
range Start
no. no. phys. phys.
81 414 555 T-Winding L2 degC 100 0 12.000 0 1), 6)
84 414 560 T-Winding L3 degC 100 0 12.000 0 1), 6)

• Block number: 7
• Block type: Analog
Integer value
PV no.
range Start
no. no. phys. phys.
1 412 504 P-Oil Re-Fill Pump bar 100.000 0 600.0000 1), 3), 5)
2 412 505 LL P-Oil Re-Fill Pump bar 100.000 0 600.0000 1), 3), 5)
3 414 420 P-Start Air bar 100.000 0 5.000.000

0 1)
4 414 422 LL P-Start Air bar 100.000 0 5.000.000

0 1)
5 414 570 T-Bearing Driven End degC 100 0 12.000 0 1), 6)
6 414 575 T-Bearing Non Driven End degC 100 0 12.000 0 1), 6)
7 414 580 T-Cooling Air degC 100 0 12.000 0 1), 6)
8 414 595 Gen Actual Power kW 1.000 0 3.000.000

0 1), 6)
Comments
The numbers listed in the “Comments” column have the following meanings:
• 1): Order-related/optional
• 2): Series 2000 only
TIM ID: 0000030726 – 001
• 3): Series 2000 only, Monitoring 2 (with EMU)

• 4): Series 4000 only
• 5): Series 4000 only, Monitoring 2 (with EMU)
• 6): Generator signals
E532237/01E 08-07 © MTU

Installation 95
5.3.3 CANopen interface
General information about the CANopen interface

The Process Data Objects (referred to below as PDOs) which may be up to 8 bytes long
having a total of 64 bits can transmit the following values:
• Binary values
• Analog values
• Diagnostic messages
• Binary setpoints/values
• Analog setpoints/values
Physical specifications
• CAN specification: ISO11898, CAN 2.0A/B, electrically isolated, 3 core
• The following node and baud rate settings apply:
• Node no.: 2
• Baud rate: 125kB
• 11bit identifier
• Start/stop CANopen devices
CANopen NMT and communication
• CANopen specification: DS301 V 4.01
• The MTU system operates as a slave and waits to be started by a master.
• Static mapping, dynamic mapping is not supported.
• SDOs are not supported
• No write access to the object directory via SDOs
• Support of standard PDOs
• Transmitted data format: Intel format
• NMT monitoring is realized exclusively by means of a heartbeat.
• Heartbeat Producer Time: 500 ms
• Transmission Type 255
• Inhibit Time: 250 ms
• Event Time 20 s
• Analog values are transmitted in Unsigned32 format
• Boolean values are transmitted in Boolean format
IMPORTANT:
MTU uses data packages with less than 8 data bytes. The definition is recorded in the
DCF/EDS file compiled by MTU (supplied on request).
Missing data detection, Missing Data (MD)/Sensor Defect (SD)
The following values are transmitted in case of faults:
• Analog values:
• MD value: 0x7FFFFFFF
• SD value: 0x80000001
• Boolean values
The standard dictates that in the case of PDOs which transmit binary values, bytes 0-3
contain the user data and 4-7 the status values:
Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8
MV MV MV MV MD/SD MD/SD MD/SD MD/SD

status status status status
TIM ID: 0000030727 – 001
Example:
Measurand in byte 1 is e.g. 0
The associated status is given in byte 5:
• e.g. 0 for measurand is OK
• e.g. 1 for measurand is MD/SD
E532237/01E 08-07 © MTU

PDO data table

Receiving objects
Integer value
PV no.
range Start
Sys. Index Min. Max. value
no. phys. phys.
600 901 Start Command CAN Open Binary --- 0 1 0 1)
600 902 Stop Command CAN OPEN Binary --- 0 1 0 1)
600 904 Override CAN OPEN Binary --- 0 1 0 1)
Transmission objects
Integer value
PV no.
range Start
no. phys. phys.
410 001 Stop Activated S --- 0 1 0

rpm
410 002 Engine Speed (ECU) (1/min) 10 0 30.000 0
410 009 SS Autom. Power Reduct. active Alarm --- 0 1 0
410 026 P-Lube Oil (ECU) bar 100.000 0 1.000.000 0
410 027 L1L P-Lube Oil (ECU) bar 100.000 0 1.000.000 0
410 028 L2L P-Lube Oil (ECU) bar 100.000 0 1.000.000 0
410 029 LO P-Lube Oil (ECU) Alarm --- 0 1 0
410 030 SS P-Lube Oil (ECU) Alarm --- 0 1 0
410 031 P-Crankcase mbar 100 -7.000 7.000 0 4)
410 032 U1L P-Crankcase mbar 100 -7.000 7.000 0 4)
410 033 U2L P-Crankcase mbar 100 -7.000 7.000 0 4)
410 034 HI P-Crankcase Alarm --- 0 1 0 4)
410 035 SS P-Crankcase Alarm --- 0 1 0 4)
410 036 P-Coolant bar 100.000 0 600.000 0 3), 5)
410 037 L1L P-Coolant bar 100.000 0 600.000 0 3), 5)
410 038 L2L P-Coolant bar 100.000 0 600.000 0 3), 5)

TIM ID: 0000030727 – 001
410 039 LO P-Coolant Alarm --- 0 1 0
410 040 SS P-Coolant Alarm --- 0 1 0
410 046 P-Fuel bar 100.000 0 1.500.000 0
410 047 LO P-Fuel Alarm --- 0 1 0
E532237/01E 08-07 © MTU

Installation 97
Integer value
PV no.
range Start
no. phys. phys.
410 048 SS P-Fuel Alarm --- 0 1 0
410 049 P-Charge Air (a) bar 100.000 0 500.000 0
410 050 LO P-Charge Air (a) Alarm --- 0 1 0
410 054 HI P-Oil Filter Difference Alarm --- 0 1 0 3), 5)
410 055 LO Coolant Level Alarm --- 0 1 0
410 056 HI Fuel Leakage Alarm --- 0 1 0
410 057 ETC 1 Speed krpm 10.000 0 1.000.000 0 4)
410 058 HI ETC 1 Speed Alarm --- 0 1 0 4)
410 059 ETC 2 Speed krpm 10.000 0 1.000.000 0 4)
410 060 HI ETC 2 Speed Alarm --- 0 1 0 4)
410 064 LO P-Fuel (Common Rail) Alarm --- 0 1 0 4)
410 065 HI P-Fuel (Common Rail) Alarm --- 0 1 0 4)
410 068 Engine Running S
410 069 ETC 2 Cut In S
410 070 SS ETC 1 Overspeed Alarm --- 0 1 0 4)
410 071 SS ETC 2 Overspeed Alarm --- 0 1 0 4)
410 075 ECU Failure Codes digit 1 0 2.147.483.647

0
410 078 Rated Speed Reached S
410 115 ECU Operating Hours h 1 0 100.000 0
410 116 AL ECU Defect Alarm --- 0 1 0
410 122 LO ECU Power Supply Voltage Alarm --- 0 1 0
410 123 HI ECU Power Supply Voltage Alarm --- 0 1 0
410 126 T-Coolant (ECU) degC 100 -2.000 12.000 0
410 127 U1L T-Coolant (ECU) degC 100 -2.000 12.000 0
410 128 U2L T-Coolant (ECU) degC 100 -2.000 12.000 0
410 129 HI T-Coolant (ECU) Alarm --- 0 1 0

TIM ID: 0000030727 – 001
410 130 SS T-Coolant (ECU) Alarm --- 0 1 0
410 131 T-Charge Air degC 100 -2.000 12.000 0
410 132 U1L T-Charge Air degC 100 -2.000 12.000 0
410 133 HI T-Charge Air Alarm --- 0 1 0
410 140 T-Lube Oil degC 100 -2.000 12.000 0
E532237/01E 08-07 © MTU

Integer value
PV no.
range Start
no. phys. phys.
410 141 U1L T-Lube Oil degC 100 -2.000 12.000 0
410 142 U2L T-Lube Oil degC 100 -2.000 12.000 0
410 143 HI T-Lube Oil Alarm --- 0 1 0
410 144 SS T-Lube Oil Alarm --- 0 1 0
410 145 T-Exhaust Combined A degC 100 0 100.000 0 3), 4)
410 146 U1L T-Exhaust Combined A degC 100 0 100.000 0 3), 4)
410 147 HI T-Exhaust Combined A Alarm --- 0 1 0 3), 4)
410 148 T-Exhaust Combined B degC 100 0 100.000 0 3), 4)
410 149 U1L T-Exhaust Combined B degC 100 0 100.000 0 3), 4)
410 150 HI T-Exhaust Combined B Alarm --- 0 1 0 3), 4)
410 151 T-Intake Air degC 100 -2.000 12.000 0
410 152 T-Fuel degC 100 -2.000 12.000 0
410 158 L1L P-Fuel bar 100.000 0 1.500.000 0
410 159 L2L P-Fuel bar 100.000 0 1.500.000 0
410 160 U1L ETC 1 Speed krpm 10.000 0 1.000.000 0 4)
410 161 U1L ETC 2 Speed krpm 10.000 0 1.000.000 0 4)

rpm
410 162 UL Engine Speed (1/min) 10 0 30.000 0
410 163 LL P-Charge Air (a) bar 100.000 0 500.000 0
410 167 U2L T-Charge Air degC 100 -2.000 12.000 0
410 168 SS T-Charge Air Alarm --- 0 1 0
410 170 HI T-ECU Alarm --- 0 1 0
410 172 U2L ETC 1 Speed krpm 10.000 0 1.000.000 0 4)
410 173 U2L ETC 2 Speed krpm 10.000 0 1.000.000 0 4)
410 177 SS Engine Speed Low Alarm --- 0 1 0
410 178 AL ECU Error/Check Fail Code Alarm --- 0 1 0
410 185 AL Common Rail Leakage Alarm --- 0 1 0

TIM ID: 0000030727 – 001
410 187 HI ETC 2 Idle Speed Alarm --- 0 1 0 4)
410 188 HI ETC Speed Difference Alarm --- 0 1 0 4)
410 189 AL ETC 2 Cut in Failure Alarm --- 0 1 0 4)
410 190 AL Shutdown expected Alarm --- 0 1 0
E532237/01E 08-07 © MTU

Installation 99
Integer value
PV no.
range Start
no. phys. phys.
410 199 U2L T-Fuel degC 100 -2.000 12.000 0
410 200 HIHI T-Fuel Alarm --- 0 1 0
410 216 Injection in Relation to DBR % 1.000 0 100.000 0
410 258 T-Charge Air Seq Ctrl Valve degC 100 0 100.000 0 4)
410 259 U1L T-Charge Air Seq Ctr Valve degC 100 0 100.000 0 4)
410 260 U2L T-Charge Air Seq Ctr Valve degC 100 0 100.000 0 4)
410 261 U2L T-Exhaust Combined A degC 100 0 100.000 0 3), 4)
410 262 U2L T-Exhaust Combined B degC 100 0 100.000 0 3), 4)
410 270 LOLO ECU Power Supply Voltage Alarm --- 0 1 0
410 271 HIHI ECU Power Supply Voltage Alarm --- 0 1 0
410 290 Coolant Level Switch S
410 291 Fuel Leakage Level Switch S
410 294 HI T-Charge Air Seq Ctrl Valve Alarm --- 0 1 0 4)
410 295 SS T-Charge Air Seq Ctrl Valve Alarm --- 0 1 0 4)
410 296 SS T-Exhaust Combined A Alarm --- 0 1 0 3), 4)
410 297 SS T-Exhaust Combined B Alarm --- 0 1 0 3), 4)
410 298 U1L T-Fuel degC 100 -2.000 12.000 0
410 299 HI T-Fuel Alarm --- 0 1 0
410 300 UL T-ECU degC 100 -2.000 12.000 0

rpm
412 002 Engine Speed (EMU) (1/min) 10 0 30.000 0 3), 5)
412 006 SS Overspeed (EMU) Alarm --- 0 1 0 3), 5)
412 026 P-Lube Oil (EMU) bar 100.000 0 1.000.000 0 1), 5)
412 027 L1L P-Lube Oil (EMU) bar 100.000 0 1.000.000 0 1), 5)
412 028 L2L P-Lube Oil (EMU) bar 100.000 0 1.000.000 0 1), 5)
412 029 LO P-Lube Oil (EMU) Alarm --- 0 1 0 3), 5)
412 030 SS P-Lube Oil (EMU) Alarm --- 0 1 0 3), 5)

TIM ID: 0000030727 – 001
412 126 T-Coolant (EMU) degC 100 -2.000 12.000 0 1), 5)
412 127 U1L T-Coolant (EMU) degC 100 -2.000 12.000 0 1), 5)
412 128 U2L T-Coolant (EMU) degC 100 -2.000 12.000 0 1), 5)
412 129 HI T-Coolant (EMU) Alarm --- 0 1 0 3), 5)
E532237/01E 08-07 © MTU

Integer value
PV no.
range Start
no. phys. phys.
412 130 SS T-Coolant (EMU) Alarm --- 0 1 0 3), 5)

rpm
412 162 UL Engine Speed (1/min) 10 0 30.000 0 1), 5)
412 201 T-Exhaust A1 degC 100 0 100.000 0 1), 5)
412 202 T-Exhaust A2 degC 100 0 100.000 0 1), 5)
412 203 T-Exhaust A3 degC 100 0 100.000 0 1), 5)
412 204 T-Exhaust A4 degC 100 0 100.000 0 1), 5)
412 205 T-Exhaust A5 degC 100 0 100.000 0 1), 5)
412 206 T-Exhaust A6 degC 100 0 100.000 0 1), 5)
412 207 T-Exhaust A7 degC 100 0 100.000 0 1), 5)
412 208 T-Exhaust A8 degC 100 0 100.000 0 1), 5)
412 211 T-Exhaust B1 degC 100 0 100.000 0 1), 5)
412 212 T-Exhaust B2 degC 100 0 100.000 0 1), 5)
412 213 T-Exhaust B3 degC 100 0 100.000 0 1), 5)
412 214 T-Exhaust B4 degC 100 0 100.000 0 1), 5)
412 215 T-Exhaust B5 degC 100 0 100.000 0 1), 5)
412 216 T-Exhaust B6 degC 100 0 100.000 0 1), 5)
412 217 T-Exhaust B7 degC 100 0 100.000 0 1), 5)
412 218 T-Exhaust B8 degC 100 0 100.000 0 1), 5)
412 221 T-Exhaust Mean degC 100 0 100.000 0 1), 5)
412 224 UL T-Exhaust degC 100 0 100.000 0 1), 5)
412 225 LL T-Exhaust degC 100 0 100.000 0 1), 5)
412 501 P-Raw Water bar 100.000 0 600.000 0 1), 3), 5)
412 502 LL P-Raw Water bar 100.000 0 600.000 0 1), 3), 5)
412 503 LO P-Raw Water Alarm --- 0 1 0 1), 3), 5)
412 504 P-Oil Re-Fill Pump bar 100.000 0 600.000 0 1), 3), 5)
412 505 LL P-Oil Re-Fill Pump bar 100.000 0 600.000 0 1), 3), 5)
TIM ID: 0000030727 – 001
412 506 LO P-Oil Re-Fill Pump Alarm --- 0 1 0 1), 3), 5)
412 507 AL Transistor Output 1/2 Fail Alarm --- 0 1 0
412 510 SS Request Power Reduction Alarm --- 0 1 0 1), 3), 5)
412 512 AL Exhaust Monitoring Fail Alarm --- 0 1 0 1), 3), 5)
E532237/01E 08-07 © MTU

Installation 101
Integer value
PV no.
range Start
no. phys. phys.
412 513 AL Press Monitoring Fail (EMU) Alarm --- 0 1 0 3), 5)
412 516 SS Security Channel Def EMU Alarm --- 0 1 0 3), 5)
412 518 TD T-Coolant Alarm --- 0 1 0 3), 5)
412 519 TD P-Lube Oil Alarm --- 0 1 0 3), 5)
414 001 Combined Alarm Red Alarm --- 0 1 0
414 002 Combined Alarm Yellow Alarm --- 0 1 0
414 265 FB CCU Start S
414 270 FB CCU Stop S
414 290 Ready for Start S
414 354 MG External Start Interlock Alarm --- 0 1 0
414 355 MG Not Ready for Operation Alarm --- 0 1 0
414 360 AL Barring Gear Engaged Alarm --- 0 1 0
414 408 AL Priming Pump Fail Alarm --- 0 1 0 1)
414 411 AL Water in Fuel Prefilter Alarm --- 0 1 0
414 416 AL Battery Charger Failure Alarm --- 0 1 0
414 420 P-Start Air bar 100.000 0 5.000.000 0 1)
414 421 LO P-Start Air Alarm --- 0 1 0 1)
414 422 LL P-Start Air bar 100.000 0 5.000.000 0 1)
414 435 AL HI T-Riser Alarm --- 0 1 0
414 470 AL Override Activated Alarm --- 0 1 0
414 489 SS Security Shutdown Alarm --- 0 1 0
414 490 SS Emergency Stop Alarm --- 0 1 0
414 495 SS Overspeed (ECU) Alarm --- 0 1 0
414 540 WB Emergency Stop CTR Stand 1 Alarm --- 0 1 0
414 541 WB Emergency Stop CTR Stand 2 Alarm --- 0 1 0
414 550 T-Winding L1 degC 100 0 12.000 0 1), 6)

TIM ID: 0000030727 – 001
414 551 U1L T-Winding L1 degC 100 0 12.000 0 1), 6)
414 553 HI T-Winding L1 Alarm --- 0 1 0 1), 6)
414 554 HIHI T-Winding L1 Alarm --- 0 1 0 1), 6)
414 555 T-Winding L2 degC 100 0 12.000 0 1), 6)
E532237/01E 08-07 © MTU

Integer value
PV no.
range Start
no. phys. phys.
414 560 T-Winding L3 degC 100 0 12.000 0 1), 6)
414 570 T-Bearing Driven End degC 100 0 12.000 0 1), 6)
414 573 HI T-Bearing Driven End Alarm --- 0 1 0 1), 6)
414 574 HIHI T-Bearing Driven End Alarm --- 0 1 0 1), 6)
414 575 T-Bearing Non Driven End degC 100 0 12.000 0 1), 6)
414 578 HI T-Bearing Non Driven End Alarm --- 0 1 0 1), 6)
414 579 HIHI T-Bearing Non Driven End Alarm --- 0 1 0 1), 6)
414 580 T-Cooling Air degC 100 0 12.000 0 1), 6)
414 583 HI T-Cooling Air Alarm --- 0 1 0 1), 6)
414 584 HIHI T-Cooling Air Alarm --- 0 1 0 1), 6)
414 591 AL Diff Protection Tripped Alarm --- 0 1 0 1), 6)
414 593 AL Coolant Leakage Generator Alarm --- 0 1 0 1), 6)
414 594 Priming Pump Automatic Mode S 1)
414 595 Gen Actual Power kW 1.000 0 3.000.000 0 1), 6)
414 601 AL Power Amplifier 1 Failure Alarm --- 0 1 0
414 602 AL Power Amplifier 2 Failure Alarm --- 0 1 0
414 603 AL Status Transistor Outputs Alarm --- 0 1 0
416 010 Combined Alarm (ECU) Alarm --- 0 1 0

TIM ID: 0000030727 – 001
416 011 Override Activated (Display) S
416 020 AL Safety System Fail (EMU) Alarm --- 0 1 0 1), 3), 5)
416 032 Priming Pump On S 1)
416 810 AL Shutdown expected Alarm --- 0 1 0 1)
E532237/01E 08-07 © MTU

Installation 103
5.3.4 J1939 interface
J1939 interface – General information

Message structure
A CAN message is structured as follows:
• 29 bit CAN identifier
• Information on the length of the data field
• Up to 8 data bytes (J1939/21)
MTU also uses data packets with less than 8 data bytes, therefore, the analysis of the data field length is mandatory.
Message structure – Identifier
The 29 bit CAN identifier consists of the following components:
• Message priority
The priority is preset to 6 for all PGNs
• PGN (Parameter Group Number)
This number is structured as follows:
• Res - a bit which is reserved for later applications and currently always set to 0
• DP - bit for the extension of the subsequent PDU (Process Data Unit) format field
• PF - PDU format
Field to distinguish between communication services. Together with other constituents of
the PGN, it allows to describe the subsequent data field. MTU uses the PDU2 format,
which defines a message-oriented transmission.
• DA/GE — PDU-specific field
Since MTU uses a message-oriented transmission method, this field provides one or more
physical values in a summarized form under one given PGN for all bus users without the need
for the sender (i.e. the MTU components) to know the receivers. On the reception side (i.e.
the OEM components), messages are filtered based on the identifier PGN. This ensures that a
message which is of interest for several nodes can be received by several nodes at the same time.
Therefore, the message must be unambiguously specified by the SAE.
• Source address
This is the unique device address consisting of 8 bits (0 to 253).
The structure of the identifier can be summarized as follows:
28 to 26 25 24 23 to 16 15 to 8 7 to 0
Priority PGN (Parameter Group Number) Source address
Res DP PF DA/GE
Abbreviations:
• Res: Reserved
• DP: Data Page
• DA: Destination Address
• GE: Group Extension
PDU message structure
The maximum length of the data field is 8 byte. MTU also uses shorter data fields, in order to reduce the
volume of data to be transmitted. Therefore the Dlc (Data length code) must be evaluated.
TIM ID: 0000030728 – 001
E532237/01E 08-07 © MTU

A request message then has, for example, the following structure (see also SAE J1939-21
Section 5.2.7.1 “Data from 0 to 8 Bytes”):
29 bit identifier Dlc PDU data field
28 to 26 25 24 23 to 16 15 to 8 7 to 0 3 d0 d1 d2
Priority PGN (Parameter Group Number) Source Requested

address PGN
Res DP PF DA/GE
Nodes and Baud Rate

The following values are set for nodes and baud rates:
• SAM: Node no.: 2
• Baud rate: 250kb
• Deterministic
PNG data table

J1939 standard objects — Sending (MTU to External Device)
J 1939 Standard MTU PV
System Designation Description

Index
SPN PGN No.
898 0 900 994 J1919 Test As per standard
92 61443 410 216 Injection in Relation to DBR As per standard
190 61444 410 002 Engine Speed (ECU) As per standard
513 61444 410 072 Injection Quantity 0-120% As per standard
2629 64979 410 131 T-Charge Air As per standard
2433 65031 410 148 T-Exhaust Combined B As per standard
2434 65031 410 145 T-Exhaust Combined A As per standard
1239 65169 410 056 HI Fuel Leakage As per standard
1206 65171 414 360 AL Barring Gear Engaged As per standard
2435 65172 412 501 P-Raw Water As per standard
1169 65179 410 059 ETC 2 Speed As per standard
1149 65184 412 215 T-Exhaust B5 As per standard

TIM ID: 0000030728 – 001
E532237/01E 08-07 © MTU

Installation 105

Index
SPN PGN No.
1141 65186 412 205 T-Exhaust A5 As per standard
1136 65188 410 169 T-ECU As per standard
1122 65191 414 575 T-Bearing Non Driven End As per standard
1123 65191 414 570 T-Bearing Driven End As per standard
1124 65191 414 550 T-Winding L1 As per standard
623 65226 414 001 Combined Alarm Red As per standard
624 65226 414 002 Combined Alarm Yellow As per standard
103 65245 410 057 ETC 1 Speed As per standard
247 65253 410 115 ECU Operating Hours As per standard
110 65262 410 126 T-Coolant (ECU) As per standard
174 65262 410 152 T-Fuel As per standard
175 65262 410 140 T-Lube Oil As per standard
94 65263 410 046 P-Fuel As per standard
100 65263 410 026 P-Lube Oil (ECU) As per standard
101 65263 410 031 P-Crankcase As per standard
109 65263 410 036 P-Coolant As per standard
102 65270 410 049 P-Charge Air (a) As per standard

TIM ID: 0000030728 – 001
105 65270 410 151 T-Intake Air As per standard
158 65271 410 104 ECU Power Supply Voltage As per standard
E532237/01E 08-07 © MTU

J1939 proprietary objects — Sending (MTU to an external device)

PGN 65280
Transmit repetition: 1000 ms
Data length: 8
Data page: 0
PDU format: 255
PDU-specific: 0
Preset priority: 6
TIM ID: 0000030728 – 001
E532237/01E 08-07 © MTU

Installation 107
Parameter group number: 65280 (0xFF00)

Index
SPN PGN No.
520197 65280 410 029 LO P-Lube Oil (ECU) Binary XY_table
520198 65280 410 030 SS P-Lube Oil (ECU) Binary XY_table
520199 65280 410 047 LO P-Fuel Binary XY_table
520200 65280 410 048 SS P-Fuel Binary XY_table
520201 65280 410 050 LO P-Charge Air (a) Binary XY_table
520202 65280 410 054 HI P-Oil Filter Difference Binary XY_table
520203 65280 410 055 LO Coolant Level Binary XY_table
520204 65280 410 058 HI ETC 1 Speed Binary XY_table
520205 65280 410 064 LO P-Fuel (Common Rail) Binary XY_table
520206 65280 410 065 HI P-Fuel (Common Rail) Binary XY_table
520207 65280 410 070 SS ETC 1 Overspeed Binary XY_table
520208 65280 410 116 AL ECU Defect Binary XY_table
520209 65280 410 122 LO ECU Power Supply Voltage Binary XY_table
520210 65280 410 123 HI ECU Power Supply Voltage Binary XY_table
520211 65280 410 129 HI T-Coolant (ECU) Binary XY_table
520212 65280 410 130 SS T-Coolant (ECU) Binary XY_table
520213 65280 410 133 HI T-Charge Air Binary XY_table
520214 65280 410 143 HI T-Lube Oil Binary XY_table
520215 65280 410 144 SS T-Lube Oil Binary XY_table
520216 65280 410 168 SS T-Charge Air Binary XY_table
520217 65280 410 170 HI T-ECU Binary XY_table
520218 65280 410 177 SS Engine Speed Low Binary XY_table
520219 65280 410 178 AL ECU Error/Check Fail Code Binary XY_table
520220 65280 410 185 AL Common Rail Leakage Binary XY_table
520221 65280 410 200 HIHI T-Fuel Binary XY_table
520222 65280 410 270 LOLO ECU Power Supply Voltage Binary XY_table
TIM ID: 0000030728 – 001
520223 65280 410 271 HIHI ECU Power Supply Voltage Binary XY_table
PGN 65281
Data length: 7
Data page: 0
E532237/01E 08-07 © MTU

PDU format: 255

PDU-specific: 1
Preset priority: 6

Index
SPN PGN No.
520224 65281 410 147 HI T-Exhaust Combined A Binary XY_table
520225 65281 410 150 HI T-Exhaust Combined B Binary XY_table
520226 65281 410 296 SS T-Exhaust Combined A Binary XY_table
520227 65281 410 297 SS T-Exhaust Combined B Binary XY_table
520228 65281 410 299 HI T-Fuel Binary XY_table
520229 65281 414 265 FB CCU Start Binary XY_table
520230 65281 414 270 FB CCU Stop Binary XY_table
520231 65281 414 354 MG External Start Interlock Binary XY_table
520232 65281 414 355 MG Not Ready for Operation Binary XY_table
520233 65281 414 411 AL Water in Fuel Prefilter Binary XY_table
520234 65281 414 416 AL Battery Charger Failure Binary XY_table
520235 65281 414 435 AL HI T-Riser Binary XY_table
520236 65281 414 470 AL Override Activated Binary XY_table
520237 65281 414 489 SS Security Shutdown Binary XY_table
520238 65281 414 490 SS Emergency Stop Binary XY_table
520239 65281 414 495 SS Overspeed (ECU) Binary XY_table
520240 65281 414 540 WB Emergency Stop CTR Stand 1 Binary XY_table
520240 65281 414 541 WB Emergency Stop CTR Stand 2 Binary XY_table
520241 65281 416 810 AL Shutdown expected Binary XY_table
520243 65281 410 187 HI ETC 2 Idle Speed Binary XY_table
520244 65281 410 188 HI ETC Speed Difference Binary XY_table
520245 65281 410 189 AL ETC 2 Cut in Failure Binary XY_table
520246 65281 410 060 HI ETC 2 Speed Binary XY_table
520247 65281 410 069 ETC 2 Cut In Binary XY_table

TIM ID: 0000030728 – 001
520248 65281 410 071 SS ETC 2 Overspeed Binary XY_table
PGN 65296
Data length: 3
Data page: 0
E532237/01E 08-07 © MTU

Installation 109
PDU format: 255

PDU-specific: 16
Preset priority: 6
Parameter group number: 65296(0xFF10)

Index
SPN PGN No.
520249 65296 410 068 Engine Running Binary XY_table
520250 65296 410 078 Rated Speed Reached Binary XY_table
520251 65296 414 290 READY FOR START Binary XY_table
520252 65296 414 408 AL Priming Pump Fail Binary XY_table
520253 65296 414 421 LO P-Start Air Binary XY_table
520254 65296 414 594 Priming Pump Automatic Mode Binary XY_table
520255 65296 414 601 AL Power Amplifier 1 Failure Binary XY_table
520256 65296 414 602 AL Power Amplifier 2 Failure Binary XY_table
520257 65296 414 603 AL Status Transistor Outputs Binary XY_table
520258 65296 416 032 Priming Pump On Binary XY_table
PGN 65297
Data length: 2
Data page: 0
PDU format: 255
PDU-specific: 17
Preset priority: 6

Index
SPN PGN No.
520259 65297 410 034 HI P-Crankcase Binary XY_table
520260 65297 410 035 SS P-Crankcase Binary XY_table
520261 65297 410 039 LO P-Coolant Binary XY_table
520262 65297 410 040 SS P-Coolant Binary XY_table
520263 65297 414 553 HI T-Winding L1 Binary XY_table

TIM ID: 0000030728 – 001
520264 65297 414 554 HIHI T-Winding L1 Binary XY_table
PGN 65298
Data length: 3
E532237/01E 08-07 © MTU

Data page: 0
PDU format: 255
PDU-specific: 18
Preset priority: 6

Index
SPN PGN No.
520270 65298 414 573 HI T-Bearing Driven End Binary XY_table
520271 65298 414 578 HI T-Bearing Non Driven End Binary XY_table
520272 65298 414 579 HIHI T-Bearing Non Driven End Binary XY_table
520273 65298 414 583 HI T-Cooling Air Binary XY_table
520274 65298 414 584 HIHI T-Cooling Air Binary XY_table
520275 65298 414 591 AL Diff Protection Tripped Binary XY_table
520276 65298 414 593 AL Coolant Leakage Generator Binary XY_table
520800 65298 414 574 HIHI T-Bearing Driven End Binary XY_table
PGN 65299
Data length: 7
Data page: 0
PDU format: 255
PDU-specific: 19
Preset priority: 6
TIM ID: 0000030728 – 001
E532237/01E 08-07 © MTU

Installation 111

Index
SPN PGN No.
520277 65299 412 006 SS Overspeed (EMU) Binary XY_table
520278 65299 412 029 LO P-Lube Oil (EMU) Binary XY_table
520279 65299 412 030 SS P-Lube Oil (EMU) Binary XY_table
520280 65299 412 129 HI T-Coolant (EMU) Binary XY_table
520281 65299 412 130 SS T-Coolant (EMU) Binary XY_table
520282 65299 412 502 LL P-Raw Water Pressure 2kPa/bit
520283 65299 412 503 LO P-Raw Water Binary XY_table
520284 65299 412 504 P-Oil Re-Fill Pump Pressure 2kPa/bit
520285 65299 412 505 LL P-Oil Re-Fill Pump Pressure 2kPa/bit
520286 65299 412 506 LO P-Oil Re-Fill Pump Binary XY_table
520287 65299 412 507 AL Transistor Output 1/2 Fail Binary XY_table
520288 65299 412 512 AL Exhaust Monitoring Fail Binary XY_table
520289 65299 412 513 AL Press Monitoring Fail (EMU) Binary XY_table
520290 65299 412 516 SS Security Channel Def EMU Binary XY_table
520291 65299 412 518 TD T-Coolant Binary XY_table
520292 65299 412 519 TD P-Lube Oil Binary XY_table
520293 65299 416 020 AL Safety System Fail (EMU) Binary XY_table
PGN 65300
Data length: 7
Data page: 0
PDU format: 255
PDU-specific: 20
Preset priority: 6
TIM ID: 0000030728 – 001
E532237/01E 08-07 © MTU


Index
SPN PGN No.
520192 65300 410 027 L1L P-Lube Oil (ECU) Pressure 4kPa/bit
520194 65300 410 028 L2L P-Lube Oil (ECU) Pressure 4kPa/bit
520195 65300 410 032 U1L P-Crankcase Pressure 128kPa/bit
520196 65300 410 033 U2L P-Crankcase Pressure 128kPa/bit
520242 65300 410 075 ECU Failure Codes 2 Byte 1:1 Range 0 to 64255
PGN 65302
Data length: 8
Data page: 0
PDU format: 255
PDU-specific: 22
Preset priority: 6

Index
SPN PGN No.
520295 65302 410 037 L1L P-Coolant Pressure 2kPa/bit
520296 65302 410 038 L2L P-Coolant Pressure 2kPa/bit
Temp. 1 deg C/bit -40C

520297 65302 410 127 U1L T-Coolant (ECU) offset

520298 65302 410 128 U2L T-Coolant (ECU) offset
Temperature 0.03125 deg

520299 65302 410 132 U1L T-Charge Air C/bit

520300 65302 410 167 U2L T-Charge Air C/bit
PGN 65303
Data length: 7
Data page: 0
PDU format: 255
TIM ID: 0000030728 – 001
PDU-specific: 23
Preset priority: 6
E532237/01E 08-07 © MTU

Installation 113

Index
SPN PGN No.

520301 65303 410 141 U1L T-Lube Oil C/bit

520303 65303 410 142 U2L T-Lube Oil C/bit

520304 65303 410 199 U2L T-Fuel offset

520305 65303 410 298 U1L T-Fuel offset

520310 65303 410 300 UL T-ECU C/bit
PGN 65304
Data length: 7
Data page: 0
PDU format: 255
PDU-specific: 24
Preset priority: 6

Index
SPN PGN No.
Torque 1%/bit Offset =

520306 65304 410 073 UL Injection 0-120% -125%
520307 65304 410 158 L1L P-Fuel Pressure 4kPa/bit
520308 65304 410 159 L2L P-Fuel Pressure 4kPa/bit
520309 65304 410 163 LL P-Charge Air (a) Pressure 2kPa/bit
PGN 65306
Data length: 7
Data page: 0
PDU format: 255
PDU-specific: 26
Preset priority: 6
TIM ID: 0000030728 – 001
E532237/01E 08-07 © MTU

Parameter group number: 65306 (0xFF1A)

Index
SPN PGN No.
520311 65306 410 266 L1L ECU Power Supply Voltage Voltage 0.05 V/bit
520312 65306 410 267 L2L ECU Power Supply Voltage Voltage 0.05 V/bit
520312 65306 410 268 U1L ECU Power Supply Voltage Voltage 0.05 V/bit
520313 65306 410 269 U2L ECU Power Supply Voltage Voltage 0.05 V/bit
PGN 65307
Data length: 8
Data page: 0
PDU format: 255
PDU-specific: 27
Preset priority: 6
Parameter group number: 65307 (0xFF1B)

Index
SPN PGN No.
520315 65307 414 422 LL P-Start Air Pressure 16 kPa/bit
520316 65307 414 595 Gen Actual Power 0-32,127.5 kW 0.5 kW/bit
520500 65307 410 162 UL Engine Speed Speed 0.125 rpm/bit
520753 65307 414 420 P-Start Air Pressure 16 kPa/bit
PGN 65309
Data length: 7
Data page: 0
PDU format: 255
PDU-specific: 29
Preset priority: 6
TIM ID: 0000030728 – 001
E532237/01E 08-07 © MTU

Installation 115
Parameter group number: 65309 (0xFF1D)

Index
SPN PGN No.

520317 65309 410 146 U1L T-Exhaust Combined A C/bit

520318 65309 410 149 U1L T-Exhaust Combined B C/bit

520319 65309 410 261 U2L T-Exhaust Combined A C/bit

520320 65309 410 262 U2L T-Exhaust Combined B C/bit
PGN 65310
Data length: 7
Data page: 0
PDU format: 255
PDU-specific: 30
Preset priority: 6
Parameter group number: 65310 (0xFF1E)

Index
SPN PGN No.
520321 65310 410 160 U1L ETC 1 Speed Speed 4 rpm/bit
PGN 65311
Data length: 8
Data page: 0
PDU format: 255
PDU-specific: 31
Preset priority: 6
TIM ID: 0000030728 – 001
E532237/01E 08-07 © MTU

Parameter group number: 65311(0xFF1F)

Index
SPN PGN No.

520325 65311 414 551 U1L T-Winding L1 offset






520331 65311 414 571 U1L T-Bearing Driven End offset

520332 65311 414 572 U2L T-Bearing Driven End offset
PGN 65312
Data length: 8
Data page: 0
PDU format: 255
PDU-specific: 32
Preset priority: 6

Index
SPN PGN No.
520333 65312 412 002 Engine Speed (EMU) Speed 0.125 rpm/bit
520334 65312 412 026 P-Lube Oil (EMU) Pressure 4kPa/bit
520335 65312 412 027 L1L P-Lube Oil (EMU) Pressure 4kPa/bit
520336 65312 412 028 L2L P-Lube Oil (EMU) Pressure 4kPa/bit
520337 65312 412 162 UL Engine Speed Speed 0.125 rpm/bit

TIM ID: 0000030728 – 001

520338 65312 414 576 U1L T-Bearing Non Driven End offset
PGN 65313
Data length: 8
E532237/01E 08-07 © MTU

Installation 117
Data page: 0
PDU format: 255
PDU-specific: 33
Preset priority: 6

Index
SPN PGN No.

520339 65313 412 126 T-Coolant (EMU) offset

520340 65313 412 127 U1L T-Coolant (EMU) offset

520341 65313 412 128 U2L T-Coolant (EMU) offset

520342 65313 412 221 T-Exhaust Mean C/bit

520343 65313 412 224 UL T-Exhaust C/bit

520344 65313 414 577 U2L T-Bearing Non Driven End offset
PGN 65314
Data length: 5
Data page: 0
PDU format: 255
PDU-specific: 34
Preset priority: 6

Index
SPN PGN No.

520345 65314 412 225 LL T-Exhaust C/bit

520346 65314 414 580 T-Cooling Air offset

520347 65314 414 581 U1L T-Cooling Air offset

TIM ID: 0000030728 – 001
520348 65314 414 582 U2L T-Cooling Air offset
PGN 65315
Data length: 7
Data page: 0
E532237/01E 08-07 © MTU

PDU format: 255

PDU-specific: 35
Preset priority: 6

Index
SPN PGN No.

520349 65315 410 258 T-Charge Air Seq Ctrl Valve C/bit

520350 65315 410 259 U1L T-Charge Air Seq Ctr Valve C/bit

520351 65315 410 260 U2L T-Charge Air Seq Ctr Valve C/bit
520352 65315 410 294 HI T-Charge Air Seq Ctrl Valve Binary XY_table
520353 65315 410 295 SS T-Charge Air Seq Ctrl Valve Binary XY_table
TIM ID: 0000030728 – 001
E532237/01E 08-07 © MTU

Initial Operation 119
6 Initial Operation
6.1 Preparation
6.1.1 Pre-startup checks

Checking system installation
Note: The tasks listed below must be carried out in the order stated before switching on the operating
voltage for the first time:
1. Check that all cables have been properly connected to the starter; ensure that cables, lugs etc. are not touching.
2. Check that all connectors are properly plugged in at the ECU and EMU and that the connectors are properly
secured.
3. Check that all cables have been properly connected to the batteries and there is no risk of short circuit.
4. Check that the engine and the individual devices are connected to ground.
5. Check that all plug connectors on printed circuit board CIB 4 in the CCU are properly plugged in (check
connector designation and firm seating, connector housing must be pressed fully in and screwed tight).
6. Check that all connectors are properly connected to user devices (check connector designations and firm
seating).
7. Check that all cables on the CCU mounting plate have been properly secured (strain relief, shielding
connected).
8. Check that the individual devices are connected to ground.
9. Check that all cables are secured.
10. Check that the cables on the engine have been suitably secured. These cables (leading to starter and
ECU/EMU on the engine) must not hang free at any point; they must be secured to the engine.
11. Check that all cables are neatly routed. Connector and cable designations should be legible even when
installed if at all possible.
12. Never route cables over sharp edges without adequate protection against chafing.
13. Route cables around doors or flaps such that they cannot be sheared off when the doors or flaps are closed.
14. Ensure that all bus terminators and jumper plugs are installed in the control units.
Checking CCU supply voltage (→ Page 122)
Checking supply voltage distribution (→ Page 121)

1. Prepare the multimeter for voltage measuring (connect leads to appropriate jacks, set voltage measuring
range to min. 30 V).
2. Check that the supply voltage is applied and is within the tolerated range at the fuses or connectors of the
individual devices.
TIM ID: 0000016800 – 002
E532237/01E 08-07 © MTU

6.1.2 Operating voltage – Initial application
Preconditions
• Pre-startup checks completed.
Preparatory steps
1. Remove fuses F1 to F5 in the CCU.
2. Remove fuses F1 and F2 on the SAB assembly.
Applying the operating voltage

1. Switch on the propulsion engine at the key switch.
Result: Operating voltage is switched on, but is only applied to the CCU.
2. Observe the CCU closely!
• Providing that the CCU does not show any signs of assuming inadmissible operating states, take the
ECU into operation.
3. Switch off the propulsion engine at the key switch.
Result: Operating voltage is not present.
4. Insert fuse F1 in the CCU.
Result: Operating voltage is applied to CCU and ECU.
6. Observe the CCU!
• Check that no excessively high current is drawn due to the ECU. Fuse F1 (20A) must not trip.
8. Insert fuse F2 in the CCU.
Result:
1. Operating voltage is applied to CCU and ECU.
2. LEDs light up.
11. Insert fuses F4 and F5 in the CCU.
Result: Operating voltage is applied to CCU, ECU and starter circuit.
13. Observe the CCU!
• Check components for excessive heating or unusual behavior (SAM display blank etc.).
15. Insert F3 fuses (optional CAN bus extensions) in the CCU.
Result: Operating voltage applied to various devices on the CAN bus.
16. Observe devices!
• Check components for excessive heating or unusual behavior.
17. Check other power trains in the same way.
TIM ID: 0000016801 – 002
E532237/01E 08-07 © MTU

6.1.3 Supply voltage distribution – Check

The +Ub power supply for all subsystem devices is connected at the CCU.
No. Function name Meaning
1 ECU Engine Control Unit (engine

governor installed on engine)
2 FSt. 1 Output circuit, control stand 1 supply
3 FSt. 2 Output circuit, control stand 2 supply
4 CAN CAN bus supply
5 M Starter
6 +Ub Main supply
7 X15 Connector, power supply input
8 CCU Central Connection Unit
9 F1 SAM Fuses, positive path and negative

path for internal supply of the SAM
10 F2 SAM control module
The starter is connected directly to the battery which supplies it.

The individual supply voltages for all devices requiring a power supply are derived from the internal +Uint voltage.
They are protected individually in the CCU and subsequently distributed to the devices.
Two additional fuses are provided inside the SAM module. They protect the internal supply
of the module in the positive and negative paths.
TIM ID: 0000017044 – 002
E532237/01E 08-07 © MTU

6.1.4 CCU power supply – Check
Preconditions
• Supply voltage is available.
Special tools

Multimeter 0005362539 1
Test prod, red 0005385230 2
Test prod, black 0005385130 2
Test prod, red 0005385430 2
Test prod, black 0005385330 2
Assembly tool 0005385530 3
Assembly tool 0005385630 3
Cable set 0025314380 1
Insulating bushing 0005316682 2
Insulating bushing 0005316782 2
Checking on-board supply voltage

1. Switch off on-board supply voltage.
2. Disconnect connector X15 from the CIB of the
CCU.
3. Prepare the multimeter for voltage measuring:
3.1. Plug the leads into the appropriate jacks
3.2. Set the voltage measuring range to min.
30 V
4. Switch on on-board supply voltage.
5. Measure the voltage between positive pin (1) and
negative pin (3) of connector X15. Desired value:
Voltage must be between 19.5 V and 30 V.
5.1. If the measured value deviates from the
desired value, check on-board power supply.
5.2. If no voltage is present, check cabling.
5.3. In case of wrong polarity, rectify cable
connections (→ Page 66)
6. Measure the voltage between positive pin (2) and
negative pin (4) of connector X15. Desired value:
Voltage must be between 19.5 V and 30 V.
6.1. If the measured value deviates from the
desired value, check on-board power supply.
6.2. If no voltage is present, check cabling.
TIM ID: 0000016812 – 001
6.3. Correct cable connections in case of wrong

polarity (→ Page 66).
7. Plug connector into socket X15 on CIB 4 in CCU.
8. Switch on on-board supply voltage.
E532237/01E 08-07 © MTU

Checking internal supply voltages

1. Remove the cover on the CCU.
2. Check the LEDs against the table below:
Position Result Task
Motherboard V30 LED (green) for external CAN bus Replace fuse F3 (→ Page 124)
supply voltage dark
Motherboard V28 LED (green) for control stand supply Replace fuse F2 (→ Page 124)
voltage dark
Motherboard V26 LED (green) for ECU supply voltage Replace fuse F1 (→ Page 124)
dark.
TIM ID: 0000016812 – 001
E532237/01E 08-07 © MTU

6.1.5 CCU fuse – Replacement
Preconditions
• Engine shut down.
Spare parts

Fuse 7.5 A 0025310586 1
Fuse 30.0 A 0015318486 1
Locating a fuse
1. Pinpoint the appropriate fuse.
2. Grasp the faulty fuse between finger and thumb
and pull it out.
F1 Engine Control Unit

F2 Engine control keys, engine speed instrument,
horn/flashing light
F3 CAN bus
Inserting a new fuse

Note: Spare fuses are provided in plug-in sockets in the top left corner.

2. Press the fuse into the socket with one finger as far as it will go.
TIM ID: 0000016797 – 001
E532237/01E 08-07 © MTU

6.1.6 SAM device settings
Preconditions
• De-energize the SAM assembly by removing fuses F1 and F2 on the SAM assembly.
Startup procedure for new SAM device (from stock)
1. Insert compact flash card (CF-card) in the appropriate slot.
2. Reinsert fuses F1 and F2 in the appropriate fuseholders on the SAM assembly.
Result: Display shows:
• In the first line: “Startup error”
• In the second line: “No valid config.”
Note: SAM has no valid configuration data. The configuration data are stored redundantly in the OnBoard
Flash and on the CF-card.
3. Press any key.

Result: Configuration menu is started.
TIM ID: 0000016803 – 001
E532237/01E 08-07 © MTU

6.2 Settings
6.2.1 SAM node address setting
Preconditions
• Operating voltage applied.
• CCU with SAM accessible.
Checking the setting
1. Select “View Config page” by pressing “Arrow ↑” (2)
or “Arrow ↓” (1) keys on printed circuit board SAM.
2. Press ENTER key (4).
Result:
• Display first line e.g. CAN 1 FB 1
• Display second line e.g. Nd: 7 Bd: 125
3. Select other settings with “Arrow ↑” (2) and
“Arrow ↓” (1) keys.
4. Compare settings with defaults:
• CAN 1 Node = 07
• CAN 1 Node = 125
• CAN 2 Node = 07
• CAN 2 Baud = 125
• CAN 3 COORD
• CAN 3 Node = 02 / 03 (set by plant parameters,
cannot be adjusted)
• CAN 3 Baud = 125
• Serial Usage = NO TERMINAL
• Enable BDM = YES
• Source Download = NO
5. Correct any deviating settings → 2. .
Minidialog SAM, changing node setting

1. Switch off operating voltage.
2. Press and hold down keys “ESC” (3) and “ENTER” (4).
3. Switch on operating voltage.
Result: Display shows “Configuration requested”.
4. Press “ENTER” key (4).
Result: First value is displayed.
5. Press “ENTER” key (4) repeatedly until desired value is displayed.
5.1. Correct value with “Arrow ↑” (2) and “Arrow ↓” (1) keys.
5.2. Change other values in same way if necessary.
• Go to next value with “ENTER” (4) key.
• Go to previous value with “ESC” (3) key.
5.3. Press “Enter” key (4) repeatedly until “EXIT and SAVE” appears in second line.
5.4. Select “SAVE” and confirm with “ENTER” (4), or;
Result: Inputs are saved.
TIM ID: 0000016807 – 002
5.5. Select “EXIT” and confirm with “ESC” key (3).

Result: Inputs are not saved.
E532237/01E 08-07 © MTU

6.2.2 CAN node – Configuration
Devices with CAN connection

The following devices of each power train are equipped with a CAN interface and are therefore defined by a CAN node:
• Engine governor ECU
• CCU
• MTU display
• Engine Monitoring Unit EMU
Node numbers
Each node number can only be allocated once on each power train.
Device Node number
Engine governor 2
CCU 7
MTU display 4
EMU 3
TIM ID: 0000016808 – 001
E532237/01E 08-07 © MTU

6.2.3 Settings via MINIDIALOG
Preconditions
• Operating voltage is available.
Entering a hexadecimal number in the SAM minidialog
1. Press ↑ or ↓ key on SAM in the CCU repeatedly until “Select Initial Page” appears on the display.
2. Press ENTER key.
3. Press ↑ or ↓ key until “Password Page” appears on the display.
Note: When a page which requires input of a hexadecimal number is displayed, the cursor is positioned
at the highest digit position of the number. The subsequent input can be terminated at any point
by pressing the ESC key.
• Password for engine with ECU connected: Engine running hours in the form of a hexadecimal value
Determine engine running hours as follows: Go to “Monitor page” by pressing the ↑ or ↓ keys.
• Password for engine without ECU: ACDC
4. Change the value displayed at this position with the ↑ or ↓ keys.

5. Press ENTER key.
Result: Value is confirmed. Cursor skips to next lower digit position of the number.
6. Repeat the steps above for all digit positions of the number.
Result: The entire hexadecimal number is accepted when the lowest digit position is confirmed.
Note: The “Download completed” message only appears when the plant is switched on if the plant has been
properly configured. Never start the engine for the first time before!
SAM node address setting (→ Page 126).
Setting engine type

1. Press ↑ or ↓ key on SAM in the CCU repeatedly until “Select Parameter Page” appears on the display.
2. Press ENTER key.
Result: Engine type is displayed in the second line.
3. Press ↑ or ↓ key on SAM repeatedly until the relevant engine type appears on the display. Possible values:
• 16 V 2000 M 50
• 16 V 2000 M 40
• 12 V 2000 M 50
• 12 V 2000 M 40
• 20 V 4000 M 50
• 20 V 4000 M 40
• 16 V 4000 M 50
• 16 V 4000 M 40
• 12 V 4000 M 50
• 12 V 4000 M 40
• 8 V 4000 M 50
• 8 V 4000 M 40
4. Press ENTER key.
Result: Selected engine type, e.g.: 16 V 2000 M 40 is displayed
Note: Carry out step 5 after completing all settings.
TIM ID: 0000016758 – 002
5. Press ↑ or ↓ key until “Save Changes? Exit-Yes” appears, confirm with Yes (Enter).
Entering classification
2. Press ENTER key.
3. Press ↑ or ↓ key on SAM repeatedly until “Classified” appears on the display.
E532237/01E 08-07 © MTU

4. Press ENTER key.

Result: The currently set value is displayed in the second line.
5. Set classification with ↑ or ↓ keys on SAM. Possible values:
• No
• Yes
6. Press the ENTER key, “Classified, YES” appears on the display.
Exhaust gas monitoring

2. Press ENTER key.
3. Press ↑ or ↓ key on SAM repeatedly until “Exhaust Gas Mon” appears on the display.
4. Press ENTER key.
5. Set exhaust gas monitoring with ↑ or ↓ keys on SAM. Possible values:
• No
• Yes
6. Press the ENTER key, “Exhaust Gas Moni, YES” appears on the display.
Setting the lube oil refill pump

2. Press ENTER key.
3. Press ↑ or ↓ key on SAM repeatedly until “Oil Refill Pump” appears on the display.
4. Press ENTER key.
5. Set lube oil replenishment pump with ↑ or ↓ keys on SAM. Possible values:
• No
• Yes
6. Press the ENTER key, “Oil Refill Pump, YES” appears on the display.
Setting rated speed

2. Press ENTER key.
3. Press ↑ or ↓ key on SAM repeatedly until “Nominal Speed” appears on the display.
4. Press ENTER key.
5. Set nominal speed with ↑ or ↓ keys on SAM. Possible values:
• 1500 rpm
TIM ID: 0000016758 – 002
• 1800 rpm
6. Press the ENTER key, “Nominal Speed” appears on the display.
E532237/01E 08-07 © MTU

Setting the display

2. Press ENTER key.
3. Press ↑ or ↓ key on SAM repeatedly until “MTU Display” appears on the display.
4. Press ENTER key.
5. Set display with ↑ or ↓ keys on SAM. Possible values:
• YES
• NO
6. Press the ENTER key, “MTU Display” appears on the display.
Setting oil priming pump

2. Press ENTER key.
3. Press ↑ or ↓ key on SAM repeatedly until “Priming Pump” appears on the display.
4. Press ENTER key.
5. Set priming pump with ↑ or ↓ keys on SAM. Possible values:
• YES
• NO
6. Press the ENTER key, “Priming Pump, YES” appears on the display.
Setting generator (24V)/ battery-charging generator

2. Press ENTER key.
3. Press ↑ or ↓ key on SAM repeatedly until “Generator(24V)” appears on the display.
4. Press ENTER key.
5. Set generator/alternator with ↑ or ↓ keys on SAM. Possible values:
• Yes
• No
6. Press the ENTER key, “Generator(24V), YES” appears on the display.
Setting air starter

2. Press ENTER key.
TIM ID: 0000016758 – 002
3. Press ↑ or ↓ key on SAM repeatedly until “Start Air” appears on the display.
4. Press ENTER key.
5. Set pneumatic starter with ↑ or ↓ keys on SAM. Possible values:
• Yes
• No
E532237/01E 08-07 © MTU

6. Press the ENTER key, “Start Air, YES” appears on the display.
Setting generator bearing (driving end)

2. Press ENTER key.
3. Press ↑ or ↓ key on SAM repeatedly until “Gen Bear DE” appears on the display.
4. Press ENTER key.
5. Set driving end generator bearing with ↑ or ↓ keys on SAM. Possible values:
• Yes
• No
6. Press the ENTER key, “Gen Bear DE, YES” appears on the display.
Setting 1st upper limit value for generator bearing temperature (driving end)
2. Press ENTER key.
3. Press ↑ or ↓ key on SAM repeatedly until “U1L T-GenBearDE” appears on the display.
4. Press ENTER key.
5. Set the 1st upper limit value for bearing temperature with the ↑ or ↓ keys on SAM. Possible values:
• NONE
• 90 °C
• Manual setting
6. Press the ENTER key, “U1L T-GenBearDE, 90 °C” appears on the display.
Setting 2nd upper limit value for generator bearing temperature (driving end)
2. Press ENTER key.
3. Press ↑ or ↓ key on SAM repeatedly until “U2L T-GenBearDE” appears on the display.
4. Press ENTER key.
5. Set the 2nd upper limit value for bearing temperature with the ↑ or ↓ keys on SAM. Possible values:
• NONE
• 95 °C
• Manual setting
6. Press the ENTER key, “U2L T-GenBearDE, 95 °C” appears on the display.
TIM ID: 0000016758 – 002
Setting generator bearing (non-driving end)

2. Press ENTER key.
3. Press ↑ or ↓ key on SAM repeatedly until “Gen Bear NDE” appears on the display.
E532237/01E 08-07 © MTU

4. Press ENTER key.

5. Set free end generator bearing with ↑ or ↓ keys on SAM. Possible values:
• Yes
• No
6. Press the ENTER key, “Gen Bear NDE, YES” appears on the display.
Setting 1st upper limit value for generator bearing temperature (non-driving end)
2. Press ENTER key.
3. Press ↑ or ↓ key on SAM repeatedly until “U1L T-GenBearNDE” appears on the display.
4. Press ENTER key.
5. Set the 1st upper limit value for bearing temperature with the ↑ or ↓ keys on SAM. Possible values:
• NONE
• 90 °C
• Manual setting
6. Press the ENTER key, “U1L T-GenBearNDE, 90 °C” appears on the display.
Setting 2nd upper limit value for generator bearing temperature (non-driving end)
2. Press ENTER key.
3. Press ↑ or ↓ key on SAM repeatedly until “U2L T-GenBearNDE” appears on the display.
4. Press ENTER key.
5. Set the 2nd upper limit value for bearing temperature with the ↑ or ↓ keys on SAM. Possible values:
• NONE
• 95 °C
• Manual setting
6. Press the ENTER key, “U2L T-GenBearNDE, 95 °C” appears on the display.
Setting 1st upper limit value – generator winding temperature

2. Press ENTER key.
3. Press ↑ or ↓ key on SAM repeatedly until “U1L T-Gen Wind” appears on the display.
4. Press ENTER key.
TIM ID: 0000016758 – 002
5. Set the 1st upper limit value for winding temperature with the ↑ or ↓ keys on SAM. Possible values:
• NONE
• 125 °C
• 140 °C
• 155 °C
• Manual setting
E532237/01E 08-07 © MTU

6. Press the ENTER key, “U1L T-Gen Wind” appears on the display.
Setting 2nd upper limit value – generator winding temperature

2. Press ENTER key.
3. Press ↑ or ↓ key on SAM repeatedly until “U2L T-Gen Wind” appears on the display.
4. Press ENTER key.
5. Set the 2nd upper limit value for winding temperature with the ↑ or ↓ keys on SAM. Possible values:
• NONE
• 130 °C
• 145 °C
• 160 °C
• Manual setting
6. Press the ENTER key, “U2L T-Gen Wind” appears on the display.
Setting generator cooling air temperature monitoring

2. Press ENTER key.
3. Press ↑ or ↓ key on SAM repeatedly until “T-Cooling Air” appears on the display.
4. Press ENTER key.
5. Set cooling air temperature monitoring with ↑ or ↓ keys on SAM. Possible values:
• NO
• YES
6. Press the ENTER key, “T-Cooling Air, YES” appears on the display.
Setting 1st upper limit value – generator cooling air temperature

2. Press ENTER key.
3. Press ↑ or ↓ key on SAM repeatedly until “U1L T-Cool Air” appears on the display.
4. Press ENTER key.
5. Set the 1st upper limit value for cooling air temperature with the ↑ or ↓ keys on SAM. Possible values:
• NO
• 85 °C
• Manual setting
TIM ID: 0000016758 – 002
6. Press the ENTER key, “U1L T-Cool Air, 85 °C” appears on the display.
E532237/01E 08-07 © MTU

Setting 2nd upper limit value – generator cooling air temperature

2. Press ENTER key.
3. Press ↑ or ↓ key on SAM repeatedly until “U2L T-Cool Air” appears on the display.
4. Press ENTER key.
5. Set the 2nd upper limit value for cooling air temperature with the ↑ or ↓ keys on SAM. Possible values:
• NO
• 90 °C
• Manual setting
6. Press the ENTER key, “U2L T-Cool Air, 90 °C” appears on the display.
Setting actual generator power display

2. Press ENTER key.
3. Press ↑ or ↓ key on SAM repeatedly until “Act Power Displ” appears on the display.
4. Press ENTER key.
5. Set generator power display with ↑ or ↓ keys on SAM. Possible values:
• NO
• YES
6. Press the ENTER key, “Act Power Displ, YES” appears on the display.
Setting test mode/configuration mode

2. Press ENTER key.
3. Press ↑ or ↓ key on SAM repeatedly until “Test/Conf.Mode:” appears on the display.
4. Press ENTER key.
5. Set Test mode / Configuration mode with ↑ or ↓ keys on SAM. Possible values:
• ON
• OFF
6. Press the ENTER key, “Test/Conf.Mode, ON or OFF” appears on the display.
TIM ID: 0000016758 – 002
E532237/01E 08-07 © MTU

6.3 Tests
6.3.1 CCU test mode
Preconditions
• CCU operating voltage switched on.
• All fuses inserted.
Activating test mode
1. Open Local Operating Panel LOP.
2. Select the “Password page” on SAM with the “Arrow ↑” and “Arrow ↓” keys.
3. Enter the password.
4. Confirm by pressing the ENTER key.
Result: Menu options for Service personnel opens.
5. Select the “Parameter page” with the “Arrow ↑” and “Arrow ↓” keys.
7. Select the “Testmode” page with the “Arrow ↑” and “Arrow ↓” keys.
9. Change setting from “Off” to “On” with the “Arrow ↑” and “Arrow ↓” keys.
Result: Test mode is switched on.
Instrument test
1. Press illuminated pushbutton STOP.
Result: Instrument test is active. All instruments show full-scale deflection.
2. Press illuminated pushbutton “COMBINED ALARM/ACK.”.
Result: The “Engine Speed” display instrument shows full-scale deflection, all other instruments show 0.
3. Press illuminated pushbutton “COMBINED ALARM/ACK.” repeatedly.
Result: The various instruments show full-scale deflection one after the other, whereas the other instruments
show 0. The order in which the instruments show full-scale deflection must be as follows:
1. Engine lube oil pressure
2. Engine coolant temperature
3. Engine lube oil temperature
Lamp test
1. Press illuminated pushbutton “STOP” repeatedly until all indicator lamps are brightly lit.
Result: Lamp test activated.
2. Press illuminated pushbutton “COMBINED ALARM/ACK.” repeatedly.
Result: The various lights in the indicator lamps and illuminated pushbuttons come on, whereas the other
lamps remain dark. At the same time, the speed display instrument indicates an additional 100 rpm every time
switching takes place. The order in which the lamps light up must be as follows:
• 1. START Activated
• 2. STOP Activated
• 3. COMBINED ALARM
• 4. Rated Speed Reached
• 5. Ready for Start
TIM ID: 0000016809 – 002
• 6. Automatic/Emergency Shutdown
• 7. Shutdown Expected
• 8. AL Override Activated
E532237/01E 08-07 © MTU

3. After testing the 8 lamps press illuminated pushbutton “COMBINED ALARM/ACK.” 4 more times.
Result: Lamp test initial state. Speed display instrument is at “0”.
Note: The engine cannot be started when test mode is active!
4. Deactivate test mode via minidialog “OFF”.
TIM ID: 0000016809 – 002
E532237/01E 08-07 © MTU

Annex 137
Annex
E532237/01E 08-07 © MTU

138 Annex
E532237/01E 08-07 © MTU

Annex 139
7 Annex
7.1 Conversion tables
Length
Unit A multiplied by factor = Unit B
in 25.4 = mm
ft 0.3048 =m
yd 0.9144 =m
stat. mile 1.609 = km

nm 1.852 = km
yd 3 = ft
yd 36 = in
Unit B multiplied by factor = Unit A

mm 0.03937 = in
m 3.281 = ft
km 0.6215 = stat. mile
Area
in2 645.16 = mm2
ft2 0.0929 = m2
yd2 0.8361 = m2
stat. mile2 2.5889 = km2
Unit B multiplied by factor Unit A

mm2 0.00155 = in2
m2 10.7643 = ft2
m2 1.1960 = yd2
TIM ID: 0000000413 – 005
km2 0.3863 stat. mile2
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140 Annex
Volume
in3 16387 = mm3
ft3 0.02832 = m3
yd3 0.7646 = m3
gallon (US) 3.787 = dm3
gallon (Brit.) 4.546 = dm3

cm3 0.06102 = in3
m3 35.31 = ft3
dm3 0.2642 = gallon (US)
dm3 0.22 = gallon (Brit.)
Speed
ft/s 0.3048 = m/s
stat. mile/h (mph) 1.609 = km/h
knot (Brit.) 1.852 = km/h
Unit B multiplied by factor = Unit B
m/s 3.281 = ft/s
km/h 0.6215 = stat. mile/h (mph)
km/h 0.54 = knot (Brit.)

TIM ID: 0000000413 – 005
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Annex 141
Mass
lb 0.4536 = kg
oz 28.35 =g
ton 1.016 =t

g 0.03527 = oz
kg 2.205 = lb
t 0.9843 = ton
Force
lb 0.4536 = kp
lb 4.4483 =N
kp 2.205 = lb
N 0.101972 = kp
kp 9.80665 =N
Density
lb s2/ft4 515.4 = kg/m3
kg/m3 0.00194 = lb s2/ft4

TIM ID: 0000000413 – 005
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142 Annex
Torque
ft lb 1.3563 = Nm
Nm 0.7373 = ft lb
Pressure
lb/sq in (psi) 703.1 = kp/m2 (mm WS)
lb/sq in (psi) 0.06895 = bar
lb/sq ft 47.883 = Pa
in QS 0.03386 = bar
in QS 345.3 = kp/m2
atm 760 = mm QS
atm 1.0133 = bar
atm 10332 = kp/m2 (mm WS)
atm 1.0332 = kp/cm2 (at)
atm 14.696 = lb/sq in
bar 14.503 = lb/sq in
Mass moment, 2nd grade

ft lb s2 1.3563 = kg m2
kg m2 0.7373 = ft lb s2
TIM ID: 0000000413 – 005
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Annex 143
Energy
ft lb 1.356 =J
kcal 4186.8 =J
BTU 1055 =J
CHU 1899 =J
J 0.7376 = ft lb
J 0.0002389 = kcal
J 0.0009479 = BTU
J 0.00052656 = CHU
Power
HP (horse power) 0.7355 = kW
HP 0.7457 = kW
BTU/s 1.055 = kW
kcal/h 1.163 =W
HP 550 = ft lb/s
kW 1.36 = PS
kW 1.341 = HP
kW 0.9479 = BTU/s
W 0.8598 = kcal/h
ft lb/s 0.0018 = HP
TIM ID: 0000000413 – 005
E532237/01E 08-07 © MTU

144 Annex
Temperature
Celsius Kelvin Fahrenheit Réaumur
x °C = x + 273.15 K = 9/5x + 32 °F = (4/5x) °R
xK = x − 273. 15 °C = 9/5(x − 273.15) + 32 °F = 4/5(x − 273.15) °R
x°F = 5/9(x − 32) °C = 5/9(x − 32) + 273.15 = 4/9(x − 32) °R

K
x°R = 5/4x °C = (5/4x) + 273.15 K = (9/4x) + 32 °F
Fuel consumption
mile/gal (US) 0.4251 = km/l
gal/mile (US) 2.3527 = l/km
km/l 2.3527 = mile/gal (US)
l/km 0.4251 = gal/mile (US)
TIM ID: 0000000413 – 005
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Annex 145
7.2 Abbreviations
Abbrevia- Meaning Explanation

tion
ADEC Advanced Diesel Engine Control Engine governor
AL Alarm
ANSI American National Standards Institute Umbrella organization administering and coordinating
U.S. standards
ATL Abgasturbolader Exhaust turbocharger
BR Baureihe Series
CAN Controller Area Network Data bus system, bus standard
CPP Controllable Pitch Propeller
°C Degrees Celsius
DIN Deutsches Institut für Normung e. V. German Standardization Organization, at the same
time identifier of German standards (“Deutsche
Industrie-Norm”)
DIS Display Unit
DL Default Lost Alarm: Default CAN bus failure
DTS Depot Test System Test system
ECS Engine Control System Engine management system
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EEPROM Electrically Erasable and Programmable Memory module

Read Only Memory
EPROM Electrically Programmable Read Only Memory module

Memory
EMU Engine Monitoring Unit
ESD Electrostatic Device Component susceptible to electrostatic discharge
ETC Electronic Transmission Controller J1939 message
FDH Field Data Handling
FL MTU Fluids and Lubricants Specifications Publication No. A001016/..
FPP Fixed Pitch Propeller
GCU Gear Control Unit

TIM ID: 0000006649 – 007
GMU Gear Monitoring Unit
h Hour
HI High Alarm: Measured value exceeds 1st maximum limit

value
E532237/01E 08-07 © MTU

146 Annex

tion
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
value
HT High Temperature
Hz Hertz
ICFN ISO - Continuous rating - Fuel stop power Power specification in accordance with DIN-ISO 3046-7
- Net
IDM Interface Data Module Memory module for interface data
IMO International Maritime Organization
IP Degree of protection against contact,

dust and moisture as per DIN 40050
ISO International Organization for

Standardization
kg Kilogram
kΩ Kiloohm
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
LCD Liquid Crystal Display, Liquid Crystal Liquid crystal display

Device
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode
LMU Local Monitoring Unit LOP subassembly
LO Low Alarm: Measured value lower than 1st minimum limit

value
LOLO Low Low Alarm: Measured value lower than 2nd minimum limit
value
LOP Local Operating Panel
LOS Local Operating Station
MCD Marine Control Drive Remotely-controllable and regulated fluid coupling
MCS Monitoring and Control System
MD Missing Data No data available
MFD Multifunction Display

TIM ID: 0000006649 – 007
MG Message
MPU Microprocessor Unit, Microprocessing

Unit
mm Millimeter
MTU Motoren- und Turbinen-Union
E532237/01E 08-07 © MTU

Annex 147

tion
MΩ Megaohm
ms Millisecond
OT Oberer Totpunkt Top dead center
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel Control panel
PCU Propeller Control Unit
PGN Parameter Group Number J1939 message
PIM Peripheral Interface Module
PVC Polyvinylchloride
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAE Society of Automotive Engineers U.S. standardization organization
SAM Service and Automation Module
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps Emergency air-shutoff flap(s)
SE System Error Operating system error
SPC Spare Parts Catalog
SPN Suspect Parameter Number J1939 message
SS Safety System Indicated alarm is initiated by the safety system
SSK Emergency air-shutoff flap(s)
T-xyz Temperature-xyz Temperature measuring point xyz
TC Tool Catalog
TD Transmitter Deviation Alarm: Sensor comparison fault
UT Unterer Totpunkt Bottom dead center
VS Voith Schneider Voith Schneider drive
WJ Water Jet Waterjet drive
ZKP Relationship category parameter Numbering scheme for ADEC engine governor signals
TIM ID: 0000006649 – 007
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148 Annex
7.3 MTU-contact person/service partner

You will find the MTU-contact person/service partner for your region at www.mtu-online.com.
TIM ID: 0000029792 – 001
E532237/01E 08-07 © MTU

Annex 149
7.4 Index
A Engine start . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . 145 Engine stop . . . . . . . . . . . . . . . . . . . . . . . . . . . 39,
Auxiliary materials, fire prevention and 44
environmental protection . . . . . . . . . . . . . . . . . 12
F
B Fuse on printed circuit board in SAM cassette –
Battery-charging generator and starter – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
G
C General conditions . . . . . . . . . . . . . . . . . . . . . 07
Cable arrangement . . . . . . . . . . . . . . . . . . . . . 66 General information . . . . . . . . . . . . . . . . . . . . 80
CAN node – Configuration . . . . . . . . . . . . . . . 127
CANopen interface . . . . . . . . . . . . . . . . . . . . . 95 I
CCB 2 – Technical Data . . . . . . . . . . . . . . . . . 27 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
CCU – Installation . . . . . . . . . . . . . . . . . . . . . . 65 Interface Description . . . . . . . . . . . . . . . . . . . . 80
CCU – Internal design . . . . . . . . . . . . . . . . . . . 52 CANopen interface . . . . . . . . . . . . . . . . 95
CCU – Replacement . . . . . . . . . . . . . . . . . . . . 58 General information . . . . . . . . . . . . . . . 80
J1939 interface . . . . . . . . . . . . . . . . . . . 103
CCU – Technical data . . . . . . . . . . . . . . . . . . . 22 RS 422 serial interface . . . . . . . . . . . . . 81
CCU fuse – Replacement . . . . . . . . . . . . . . . . 59,
124
CCU power supply – Check . . . . . . . . . . . . . . 122
J
J1939 interface ........................ 103
CCU test mode . . . . . . . . . . . . . . . . . . . . . . . . 135
Central Control Unit CCU – Use and
functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 M
Conversion tables . . . . . . . . . . . . . . . . . . . . . . 139 Mechanical Installation . . . . . . . . . . . . . . . . . . 65
CCU – Installation . . . . . . . . . . . . . . . . . 65
MTU-contact person/service partner . . . . . . . . 148
E
Electrical Installation . . . . . . . . . . . . . . . . . . . . 66
Battery-charging generator and starter – O
Connection . . . . . . . . . . . . . . . . . . . . . . 73 Operating voltage – Initial application . . . . . . . 120
Cable arrangement . . . . . . . . . . . . . . . . 66 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Engine governor – Connection . . . . . . . 67 Emergency engine shutdown . . . . . . . . 45
Engine Monitoring Unit EMU 1 – Emergency engine stop . . . . . . . . . . . . 40
Connection . . . . . . . . . . . . . . . . . . . . . . 68 Engine start . . . . . . . . . . . . . . . . . . . . . 38
Engine Monitoring Unit EMU 7 – Engine stop . . . . . . . . . . . . . . . . . . . . . . 39,
Connection . . . . . . . . . . . . . . . . . . . . . . 69 44
Starter and battery-charging generator Override function – Activation . . . . . . . . 42
connection diagram – Overview . . . . . . 70 Override function – Deactivation . . . . . . 43
Emergency engine shutdown . . . . . . . . . . . . . 45 Overspeed test . . . . . . . . . . . . . . . . . . . 41
Emergency engine stop . . . . . . . . . . . . . . . . . 40 Ready for operation – Activation/deacti-
Engine governor – Connection . . . . . . . . . . . . 67 vation . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Engine governor – Intended use and Override function – Activation . . . . . . . . . . . . . 42
TIM ID: 0000029792 – 001
functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Override function – Deactivation . . . . . . . . . . . 43

Engine Monitoring Unit – Use and Overspeed test . . . . . . . . . . . . . . . . . . . . . . . . 41
functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Engine Monitoring Unit EMU 1 – P
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Personnel and organizational require-
Engine Monitoring Unit EMU 7 – ments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Pre-startup checks . . . . . . . . . . . . . . . . . . . . . 119
E532237/01E 08-07 © MTU

150 Annex
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 SAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

CCU fuse – Replacement . . . . . . . . . . . 124 SAM – Replacement . . . . . . . . . . . . . . . . . . . . 61
CCU power supply – Check . . . . . . . . . 122
SAM device settings . . . . . . . . . . . . . . . . . . . . 125
Operating voltage – Initial
application . . . . . . . . . . . . . . . . . . . . . . 120 SAM fuse – Replacement . . . . . . . . . . . . . . . . 62
Pre-startup checks . . . . . . . . . . . . . . . . 119 SAM node address setting . . . . . . . . . . . . . . . 126
SAM device settings . . . . . . . . . . . . . . . 125 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Supply voltage distribution – Check . . . 121 CAN node – Configuration . . . . . . . . . . 127
SAM node address setting . . . . . . . . . . 126
R Settings via MINIDIALOG . . . . . . . . . . . 128
Ready for operation – Activation/deactiva- Settings via MINIDIALOG . . . . . . . . . . . . . . . . 128
tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Standards for warning notices in the
Repair Work . . . . . . . . . . . . . . . . . . . . . . . . . . 49 publication . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CCU – Internal design . . . . . . . . . . . . . 52 Starter and battery-charging generator
CCU – Replacement . . . . . . . . . . . . . . . 58 connection diagram – Overview . . . . . . . . . . . 70
CCU fuse – Replacement . . . . . . . . . . . 59 Supply voltage distribution – Check . . . . . . . . 121
Fuse on printed circuit board in SAM System Genset Interface – Detailed overview
cassette – Replacement . . . . . . . . . . . . 49 and design . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SAM – Replacement . . . . . . . . . . . . . . . 61
SAM fuse – Replacement . . . . . . . . . . . 62 System overview and features . . . . . . . . . . . . 17
RS 422 serial interface . . . . . . . . . . . . . . . . . . 81
T
S Tests ................................ 135
CCU test mode . . . . . . . . . . . . . . . . . . . 135
Safety requirements when working on the
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09
TIM ID: 0000029792 – 001
E532237/01E 08-07 © MTU

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MTU_ValueService

Veuillez séparer la carte “Signalisation de mise en service“ et la renvoyer à la MTU Friedrichshafen

Rogamos separen la tarjeta “Aviso de puesta en servicio“ y la devuelvan rellenada a MTU

É gentileza cortar o cartão "Participação da colocação em serviço", preenché-lo e devolvé-lo a MTU

MTU Friedrichshafen GmbH

Motornr.: Auftragsnr.: Inbetriebnahme-

General Instructions ........................................................ 05

E532237/01E 08-07 © MTU

E532237/01E 08-07 © MTU

General Instructions ........................................................ 05

Functional Description ...................................................... 15

Operating Instructions ...................................................... 35

Workshop Manual .......................................................... 47

E532237/01E 08-07 © MTU

Installation and Commissioning Instructions .................................. 63

Annex ..................................................................... 137

E532237/01E 08-07 © MTU

E532237/01E 08-07 © MTU

E532237/01E 08-07 © MTU

1.1 General conditions

E532237/01E 08-07 © MTU

1.2 Personnel and organizational requirements

TIM ID: 0000000508 – 001

E532237/01E 08-07 © MTU

1.3 Safety requirements when working on the engine

E532237/01E 08-07 © MTU

E532237/01E 08-07 © MTU

E532237/01E 08-07 © MTU

1.4 Auxiliary materials, fire prevention and environmental

E532237/01E 08-07 © MTU

E532237/01E 08-07 © MTU

1.5 Standards for warning notices in the publication

TIM ID: 0000008386 – 001

E532237/01E 08-07 © MTU

E532237/01E 08-07 © MTU

E532237/01E 08-07 © MTU

2 Structure and Function

2.1 System overview and features

Engine Control Unit (ECU)

E532237/01E 08-07 © MTU

• Injection (fuel pressure, injection timing, injection duration, operating status)

• Compact LSI devices

E532237/01E 08-07 © MTU

Extension and variation potential

E532237/01E 08-07 © MTU

2.2 System Genset Interface – Detailed overview and design

Genset Interface – Detailed overview and design

No. Designation Explanation

1 Display instruments for engine/generator Analog instruments

3 Central Control Unit CCU Located in the engine room;

4 Interface To optional signal inputs/outputs of the

5 Voltage supply For overall genset CCU system.

7 Interface To battery-charging generator

E532237/01E 08-07 © MTU

No. Designation Explanation

8 Interface To barring device (if fitted).

9 Engine Monitoring Unit Engine-mounted.

11 Engine governor Engine-mounted.

E532237/01E 08-07 © MTU