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Service Publication

Gear Control and Monitoring Unit


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

Documentation Parts 1, 3, 4, 5

E 532 091 / 00 E

DaimlerChrysler Off-Highway

MTU assuring you:


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

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

Guide

Page

General information about documentation


Documentation structure
Documentation
Part

Title/contents

Target group(s)

Structure and function

Operating personnel etc.

Operation

Operating personnel

Maintenance and repair

Plant personnel

Service manual

Electronic service personnel

Illustrated parts catalog

Operating personnel, electronic service


personnel, logistics personnel

Plant-specific configuration

Mechanical and electrical


installation

Electronic service personnel, installation


personnel, start-up personnel
Installation personnel
(electromechanical/mechatronic engineer)

Initial start-up

Start-up personnel

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

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

Reference numbers and reference lines


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

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Guide

Symbols
Rectification of a fault marked with this symbol either requires the customers service personnel
or service personnel provided by MTU. The affected assembly may have to be sent to MTU for
repairs.
Such a fault cannot be repaired by operating personnel.
Further troubleshooting or fault rectification requires work to be performed on the engine with
reference to the engine documentation.

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


assemblies or equipment with reference to the relevant documentation.

This symbol indicates cross-references to other manuals.

' Fig. X

MTU

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

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Structure and function


Table of contents

Part

Page

Part 1

Structure and function

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Part

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Structure and function


Table of contents

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Structure and function


Table of contents

Part

Page

III

Table of contents
1

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

1.1

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

1.1.1

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

1.1.2

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

1.1.2.1

External Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.2.2

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

1.1.2.3

Signal processing GCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.2.4

Signal processing PIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.3

Printed circuit boards of the GCU/GMU 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

1.1.3.1

Gear Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

1.1.3.2

Additional gear monitoring functions (Gear Monitoring Unit) . . . . . . . . . . . . . . . . . . . . . . . . .

13

1.2

Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

1.2.1

General information about the function of the Gear Control and Monitoring Unit GCU/GMU 1 . . .
16

1.2.2

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

17

1.2.2.1

Field bus PCS-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

1.2.2.2

Control functional section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

1.2.2.3

Monitoring functional section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

1.2.2.4

Data transfer via CAN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

1.2.2.5

Changeover from remote control mode to local mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

1.2.2.6

Connecting remote control systems of other manufacturers . . . . . . . . . . . . . . . . . . . . . . . . .

23

1.3

Electrical power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

1.4

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

25

1.4.1

Printed circuit board GCM 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

1.4.2

Printed circuit board ROB 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

1.5

Data storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

1.5.1

Overview of data structures which can be configured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

1.5.2

Software modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

1.5.2.1

Initial program loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

1.5.2.2

Basic software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

1.5.2.3

Logic programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

1.5.2.4

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

28

1.5.2.5

Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

1.5.3

Redundant back-up of project implementation data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

1.6

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

29

1.6.1

Gear Control Unit GCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

1.6.2

Gear Monitoring Unit GMU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34

1.7

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

37

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Structure and function


Table of contents

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Structure and function


Use and structure

Structure and function

1.1

Use and structure

1.1.1

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

Fig.

1:

Part
Page

1
1

Gear Control and Monitoring Unit GCU/GMU 1

The Gear Control and Monitoring Unit GCU/GMU 1 can be used for various gearboxes
and is an interface between the Propulsion Control System PCS-5, the MTU Remote Control System RCS-5 (or the remote control system of another manufacturer) and the gearbox.
The principal tasks are:

 For the gearbox:


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Connecting the gearbox sensors and watchdogs, activating the solenoid


valves on the gearbox
Power supply to the gearbox sensors

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2

Structure and function


Use and structure

 For the plant:


-

Supply voltage feed from the Local Operating Panel LOP 1


Interfaces (CAN bus) for connection to the Propulsion Control System
PCS-5 and thus for connection to the MTU Remote Control System RCS-5
Signal inputs and outputs (parallel) for connecting remote control systems
of other manufacturers

 For the operator:


-

In local control, the interface to the operator takes the form of appropriate
keys on the Local Operating Panel LOP 1
Depending on the gearbox type, the Local Operating Panel includes buttons
for ahead, astern and neutral (reversing gear) or for engaged and disengaged (step-down gear)

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

The Gear Control and Monitoring Unit GCU/GMU 1 is located in the engine room close to
the gearbox which is assigned to it. It is connected to the other assemblies of the Propulsion Control System PCS-5 (Local Operating Panel LOP 1) by means of a prefabricated
connection cable. Cable entries on the underside of the housing are used for the link-up to
the gearbox cabling.
Reference documentation:
The integration of the Gear Control and Monitoring Unit GCU/GMU 1 in the
overall system is documented in the system description of the propulsion control system Propulsion Control System PCS-5, MTU/DDC Series 4000, Marine
Application, document no. E 531 693.
The range of measuring points provided by the Gear Control Unit is expanded on the
monitoring side. This Gear Control and Monitoring Unit GCU/GMU 1 part also contains a
second, independent safety system for protecting the gearbox. The features of the monitoring system are as follows:

 Limit value monitoring of important measuring points


 Communication with equipment in the PCS-5 and the higher-level system via
field bus PCS-5 (CAN bus)

 Output of an engine stop signal in the event of a limit value violation (safety
channels)
The following division of functions is thus established:

 GCU: Monitoring and control


 GMU: Expansion of monitoring and safety system

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Structure and function


Use and structure

1.1.2

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

1.1.2.1

External Structure

1
3

3
4

Fig.

2:

Gear Control and Monitoring Unit GCU/GMU 1 - External structure


1
2
3
4
5
6
7
8

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

A removable flange plate (cable entry plate) on the underside of the Gear Control and Monitoring Unit GCU/GMU 1 is prepared for accommodating the cable
entries (gearbox cabling or remote control systems of other manufacturers).
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4

1.1.2.2

Structure and function


Use and structure

Internal structure
1

2
3

11

4
5
10
6
9

-A040
-A030

8
7

Fig.

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

Gear Control and Monitoring Unit GCU/GMU 1 - Internal structure


Housing
Holes for wall-mounting
Mounting plate
GCM for Gear Control Unit GCU
Holder for internal cable harness (MTU) and external cable harness (from cable entries)
Plug X21
External grounding screw
Holder for external ship wires
PIM 2 for Gear Monitoring Unit GMU
Grounding cable
Internal grounding screw

Two modules are used in the Gear Control and Monitoring Unit GCU/GMU 1:

 A GCM for gear control and monitoring


 A PIM Type 2 for expanded gear monitoring functions

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Use and structure

1
5

Gear Control Module (GCM)


This module is equipped with the printed circuit boards shown in Fig. 4.
MPU 23
BOB 1

ROB 1

AIB 1
BIB 2

ROB 1

GCM 1

Fig.

4:

Gear Control Module (GCM)

The range of functions of the Gear Control Module (GCM) is summarised below:

 =21.X+A002-A030:

GCU

(Gear Control Unit); the principal task here involves receiving and processing
signals for gear control. Furthermore, this module contains the signal inputs
and signal outputs for connecting another manufacturers RCS as well as a
safety circuit.
A housing with a special connection PCB GCM and two passive relay printed circuit
boards ROB 1 are used for multiplying and distributing the signals as required in the Gear
Control Unit (GCU). This approach considerably simplifies the connection.

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Structure and function


Use and structure

Peripheral Interface Module PIM


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

MPU 23
MFB 1

AIB 1

BIB 2

COB 1

Fig.

5:

Peripheral Interface Module of the Gear Monitoring Unit GMU 1

The range of functions of the Peripheral Interface Module PIM 2 (additional Gear Monitoring Unit GMU) is summarised below:

 =21.X+A002-A040:

GMU

(Gear Monitoring Unit); the principal task of this Peripheral Interface Module
PIM involves receiving and processing signals for additional gear monitoring
functions. In addition, this unit contains a redundant safety circuit.

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Use and structure

1.1.2.3

1
7

Signal processing GCM

The tables below describe the individual inputs and outputs of the GCM in the following
applications:

 Connection to an MTU Remote Control System RCS-5


 Connection to a remote control system of another manufacturer
Signal processing when using the MTU Remote Control System RCS-5
Item

No.

4/1

=21.X+A002-A030
GCU

PCB

Functions

MPU 23
AIB 1
BOB 1
BIB 2
ROB 1
ROB 1

Outputs:
 Valve activation:
- Ahead or engage**
- Neutral or disengage**
- Astern**
 Engine stop
 Spare relay
Inputs:









Remarks
-

Control oil pressure


Lube oil pressure*
Oil temperature
Oil filter pressure (binary signal)

External disengagement request


Trolling mode active
Checkbacks:
- Ahead active or engaged**
- Neutral or disengaged**
- Astern active**
Interfaces:
 PCS field bus
* Optional, presence depends on gearbox version
** Depending on the version of the Propulsion Control System PCS-5:
D with reversing gear
D with step-down gear

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

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Structure and function


Use and structure

Signal processing when using a remote control system of another manufacturer


Item

No.

4/1

=21.X+A002-A030
GCU

PCB
MPU 23
AIB 1
BOB 1
BIB 2
ROB 1
ROB 1

Functions

Remarks

Outputs:
 Valve activation:
- Ahead or engage**
- Neutral or disengage**
- Astern**
 Engine stop
 Checkbacks:
- Ahead active or engaged**
- Neutral or disengaged**
- Astern active**
 Disengagement window
 Local mode active

 Spare relay

Inputs:
 Control oil pressure
 Lube oil pressure*







Oil temperature
Oil filter pressure (binary signal)
External disengagement request
Trolling mode active
Checkbacks:
- Ahead active or engaged**
- Neutral or disengaged**
- Astern active**
Signal from another manufacturers
RCS:
- Request astern engage**
- Request neutral or disengage**
- Request forwards or engage**

Interfaces:

 PCS field bus (only to the Local Operating Panel)

* Optional, presence depends on gearbox version


** Depending on the version of the Propulsion Control System PCS-5:
D with reversing gear
D with step-down gear

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1.1.2.4

1
9

Signal processing PIM

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

No.

4/1

=21.X+A002-A040
GMU

PCB

Functions

MPU 23
AIB 1
MFB 1
BIB 2

Outputs:
 Engine stop
Inputs:
 Shaft speed (redundant)

Remarks
-

 Control oil pressure (analog and limit


value binary)

 Lube oil pressure* (analog and limit


value binary)

 Trolling mode active


 Checkbacks:


- Neutral or disengaged**
Oil level (limit value binary)

Interface:
 PCS field bus
* Optional, presence depends on gearbox version
** Depending on the version of the Propulsion Control System PCS-5:
D with reversing gear
D with step-down gear

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

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10

Structure and function


Use and structure

1.1.3

Printed circuit boards of the GCU/GMU 1

1.1.3.1

Gear Control Unit

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

Function

MPU 23 with CCB


1

Processor board PCS


2 x CAN interfaces (field bus)

AIB 1

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

BIB 2

Binary input,
electrical isolation
8 x Binary inputs (24 V internal)

BOB 1

4 x Relay outputs

ROB 1

7 x Relay outputs

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

LED displays

LED status display under normal


operating conditions

MPU 23 (GCM, slot 1)


LED
LED
LED
LED

1
2
3
4

LED 1 Voltage supply(green) applied

LED 1 On

LED 2 Off
LED 2 The microprocessor
LED 3 Flashes irregularly
(red)
is in RESET status and is
LED 4 Flashes irregularly
currently not working
(switched on during intialisation and if the supply voltage is too low)
LED 3 Data exchange on the
(yellow) MPU 23, CAN interface
LED 4 Data exchange on the
(yellow) MPU 23, second CAN interface

>>

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Use and structure

Printed circuit board

LED displays

1
11

LED status display under normal


operating conditions

>>

BOB 1 (GCM, slot 3)


LED
LED
LED
LED

1
2
3
4

LED 5

LED 1 Relay K1 activated


(yellow)

LED 1 Changes (depending on status)


Ahead/engage

LED 2 Relay K2 activated


(yellow)

LED 2 Changes (depending on status)


Neutral/disengage

LED 3 Relay K3 activated


(yellow)

LED 3 Changes (depending on status)


Astern

LED 4 Relay K4 activated


(yellow)

LED 4 Changes (depending on status)


GCU stop

LED 5 Fault
(red)

LED 5 Off

BIB 2 (GCM, slot 4)

LED 1
LED 2
LED 3
LED 4
LED 5
LED 6
LED 7
LED 8

LED 1 Channel 1 active


(yellow)

LED 1 Changes (depending on status)


External disengagement active

LED 2 Cable break


(red)
channel 1

LED 3 Changes (depending on status)


Trolling active

Odd number as LED number:


See LED 1
(channels 2 8)

LED 5 Changes (depending on status)


Astern engaged

Even number as LED number:


See LED 2
(channels 2 8)

LED 9
LED 10
LED 11
LED 12
LED 13
LED 14
LED 15
LED 16

LED 7 Changes (depending on status)


Neutral/disengaged
LED 9 Changes (depending on status)
Ahead engaged/
engaged
RCS of another manufacturer:
LED 11 Changes (depending on status)
Engage astern
LED 13 Changes (depending on status)
Neutral/disengage
LED 15 Changes (depending on status)
Engage ahead/engage
LEDs with even number as
LED number:
Off
>>

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12

Structure and function


Use and structure

Printed circuit board

LED displays

LED status display under normal


operating conditions

>>

ROB 1 (GCM, slot 5)

LED
LED
LED
LED
LED
LED
LED

1
2
3
4
5
6
7

LED 1 Relay K1 activated


(green)

LED 1 Changes (depending on status)


Checkback ahead (engaged)

LED 2 Relay K2 activated


(green)

LED 2 Changes (depending on status)


Checkback neutral (disengaged)

LED 3 Relay K3 activated


(green)

LED 3 Changes (depending on status)


Checkback neutral (disengaged)

LED 4 Relay K5 activated


(green)
LED 5 Relay K6 activated
(green)
LED 6 Relay K4 activated
(green)
LED 7 Relay K7 activated
(green)

LED 4 Changes (depending on status)


Checkback astern
LED 5 Changes (depending on status)
Trolling active
LED 6 Changes (depending on status)
Not used
LED 7 Changes (depending on status)
RESERVE

ROB 1 (GCM, slot 6)

LED
LED
LED
LED
LED
LED
LED

1
2
3
4
5
6
7

LED 1 Relay K1 activated


(green)

LED 1 Changes (depending on status)


Local mode active

LED 2 Relay K2 activated


(green)

LED 2 Changes (depending on status)


Local mode changeover for
ahead and neutral signal (from
RCS)

LED 3 Relay K3 activated


(green)
LED 4 Relay K5 activated
(green)

LED 3 Changes (depending on status)


Local mode changeover for disengagement enable and astern

LED 5 Relay K6 activated


(green)

LED 4 Changes (depending on status)


Disengagement

LED 6 Relay K4 activated


(green)

LED 5 Changes (depending on status)


Disengagement window

LED 7 Relay K7 activated


(green)

LED 6 Changes (depending on status)


Neutral for gearbox without
neutral switch
LED 7 Changes (depending on status)
Not used

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

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


Use and structure

1.1.3.2

1
13

Additional gear monitoring functions (Gear Monitoring Unit)

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

Function

MPU 23 with CCB


1

Processor board
1 x CAN interface (field bus)

AIB 1

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

BIB 2

Binary input,
electrical isolation
8 x binary inputs (24 V internal)

MFB 1

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

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

LED displays

LED status display under normal


operating conditions

MPU 23 (GMU, slot 1)


LED
LED
LED
LED

1
2
3
4

LED 1 Voltage supply


(green) applied

LED 1 On

LED 2 The microprocessor


(red)
is in RESET status and is
currently not working (switched on during intialisation
and if the supply voltage is
too low)

LED 3 Flashes irregularly

LED 2 Off
LED 4 Flashes irregularly

LED 3 Data exchange on the


(yellow) MPU 23 CAN interface
LED 4 Data exchange on the
(yellow) MPU 23, second CAN interface

>>

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Structure and function


Use and structure

Printed circuit board

LED displays

LED status display under normal


operating conditions

>>

MFB 1 (GMU, slot 3)


LED 1 Speed signal 1
Analog OK
LED 2 Speed signal 1
Binary OK
LED 1
LED 2

LED 3
LED 4

LED 3 Speed signal 2


Analog OK
LED 4 Speed signal 2
Binary OK
LED 5 Relay K2
Active
LED 6 Relay K1
Active
LED 7 +24 VDC
Available
LED 8 Ready

LED 5
LED 6
LED 7
LED 8

The display on the light emitting diodes


is dependent on the speed sensor
which is connected in each case.
LED 1 On (if the shaft is turning,
only when using an analog
sensor), speed sensor shaft
speed system 1
LED 2 On (if the shaft is turning,
only when using a sensor with
a binary output), speed sensor
shaft speed system 1
LED 3 On (if the shaft is turning,
only when using an analog
sensor), speed sensor shaft
speed system 2
LED 4 On (if the shaft is turning,
only when using a sensor with
a binary output), speed sensor
shaft speed system 2
LED 5 Changes (depending on status)
GMU stop
LED 6 Changes (depending on status)
RESERVE
LED 7 On
LED 8 On
>>

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Structure and function


Use and structure

Printed circuit board

LED displays

1
15

LED status display under normal


operating conditions

>>

BIB 2 (GMU slot 4)

LED 1
LED 2
LED 3
LED 4

LED 1 Channel 1 active


(yellow)

LED 1 Changes (depending on status)


Trolling mode on

LED 2 Cable break


(red)
channel 1

LED 3 Changes (depending on status)


Checkback clutch neutral

Odd number as LED number


See LED 1
(channels 2 8)

LED 5 Changes (depending on status)


Engine stop due to insufficient
gearbox control oil pressure

Even number as LED number:


See LED 2
(channels 2 8)

LED 7 Changes (depending on status)


Engine stop due to insufficient
gearbox lube oil pressure

LED 5
LED 6
LED 7
LED 8

LED 9 Changes (depending on status)


Gearbox oil level too low

LED 9
LED 10
LED 11
LED 12

LED 13 Off
Reserve

LED 13
LED 14
LED 15
LED 16

LED 11 Off
Reserve

LED 15 Off
Reserve
LEDs with even number as
LED number:
Off
Cable break configured for (if LED on,
cable interrupted):
LED 6 Control oil pressure
LED 8 Lube oil pressure

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

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

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Structure and function


Function

1.2

Function

1.2.1

General information about the function of the Gear Control and Monitoring Unit GCU/GMU 1

The Gear Control and Monitoring Unit contains two functional sections which operate
independently:

 Gear Control Unit (GCU)


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

RCS-5

MCS-5

Other propulsion
arrangements
Field bus PCS

EMU*
PCU*

ECU

GCU/GMU 1
LOP

Fig.

6:

* Optional

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

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

1
17

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

1.2.2

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

1.2.2.1

Field bus PCS-5

To LOP 1

Via LOP 1
to MCS or RCS*

Field bus PCS


(redundant)

MPU 23

BOB 1

ROB 1

MPU 23

GCU
AIB 1

Fig.
*

7:

BIB 2

MFB 1

GMU
ROB 1

AIB 1

BIB 2

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

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

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

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1.2.2.2

1
18

Structure and function


Function

Control functional section

The gear control functional section is implemented using the assemblies on the right-hand
side of the housing (GCM with six printed circuit boards, see chap. 1.1.2.2). In detail, the
following functions are performed:

 Reading in the clutch control commands via CAN bus telegrams (from the Local
Operating Panel (LOP) or from the Remote Control System RCS-5) or in parallel (when using remote control systems of other manufacturers):
Reversing gear

Step-down gear

Reversing gear with


waterjet

Engage ahead

Engage

Engage

Engage astern

Flush

Neutral

Disengage

Disenage

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


Operating Panel LOP or from the plant)

 Activation of engagement valves:


Reversing gear

Step-down gear

Reversing gear with


waterjet

Engage ahead

Engage

Engage

Engage astern

Flush

Neutral

Disengage

Disenage

This function only occurs in local mode when other manufacturers


remote control systems are used; signals from a remote control system of this type are looped through the GCU in remote control mode.

 Registering gearbox checkbacks (can be configured):

MTU

Reversing gear

Step-down gear

Reversing gear with


waterjet

Engaged ahead

Engaged

Engaged

Enaged astern

Flushing active

Neutral

Disengaged

Disengaged

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Function

Part
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19

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


(function is only possible in remote control mode when the Remote Control
System RCS-5 is used, whereas the function is possible even with other remote
control systems in local mode):
- Engine speed (via CAN bus),
- Interlock input (from the Local Operating Panel (LOP) or from the plant)
- Shaft speed (RCS-5 only)

 Outputting a signal for requesting all cylinders active when there is an engagement command or if there is no neutral/disengaged checkback (via CAN bus to
the Engine Control Unit ECU); this signal is also output when remote control
systems of other manufacturers are used.

 Providing a separate safety circuit (for gearbox control oil pressure) within the
Gear Control Unit (GCU) with the following functions:
- Input for gearbox control oil pressure 4 mA 20 mA
- Interlock generated from the following signals:
Clutch - Neutral (reversing gear)/disengaged (step-down gear), trolling mode
active, engine running (CAN bus telegram), clutch operation time lag
- Providing/creating two dynamic limit values (Limit_1, Limit_2) which are dependent on the engine speed
- Interlocking or issuing an alarm after an adjustable delay time (can be set
separately for both limit values)
- Stopping the engine in the event of a lower limit violation of the Limit_2
value (the relay for the appropriate output is activated)

 Performing the changeover between local mode and remote control mode by way of
the CAN bus (from the Local Operating Panel LOP); Gear Control Unit GCU in local
mode is output via the CAN bus for as long as local mode is active or subsequently
until the values specified by the Remote Control System RCS and Local Operating
Panel LOP are the same, or when the gearbox is in neutral or disengaged.

 Implementing communication with components of the PCS-5 (Local Operating


Panel LOP, Engine Control Unit ECU, Gear Monitoring Unit GMU, Remote Control System RCS) via a redundant CAN field bus with redundancy changeover;
the following signals are transmitted as CAN telegrams:
- Sent CAN telegrams:
Neutral/disengaged, Ahead/engaged, Astern checkbacks
Load change/cylinder cutout
GCU local mode
Control oil pressure and two limit values for control oil pressure
Lube oil pressure and two limit values for lube oil pressure (optional)
Oil temperature and a limit value for oil temperature
Oil filter pressure
Trolling mode active
External clutch disengagement

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Structure and function


Function

Received CAN telegrams:


Engine speed
Engine operating
Shaft speed
Local mode active
Clutch control signals in local mode
(Neutral/disengaged, Ahead/engaged, Astern)
Remote control signals Neutral/disengaged, Ahead/engaged, Astern

 Providing an ITS (Integrated Test System) for analog inputs, RAM, FEPROM,
watchdog, temperature, supply voltage, CAN bus failure

 Providing a separate safety circuit (for the gearbox lube oil pressure, for use as
an option) within the Gear Control Unit GCU with the following functions:
- Input for gearbox lube oil pressure 4 mA 20 mA
- Interlock generated from the following signals:
Clutch - Neutral (reversing gear)/disengaged (step-down gear),
trolling mode active, engine running (CAN bus telegram), clutch operation
time lag
- Creating two dynamic limit values (Limit_1, Limit_2) which are dependent
on the engine speed
- Interlocking or issuing an alarm after an adjustable delay time (can be set
separately for both limit values)
- Stopping the engine in the event of a lower limit violation of the Limit_2
value (the relay for the appropriate output is activated)

 Optional monitoring of the gearbox oil temperature (using a type Pt1000 sensor); the Limit_1 value has a time lag

 Simulation of gearbox checkback messages for the logic controller in trolling


mode (can be configured) because in this operating status, the actual checkbacks from the gearbox are no longer reliably generated by the pressure-operated switches or limit switches fitted on the gearbox (Clutch slipping)

 Outputting the trolling mode active signal on the CAN bus


The following different propulsion variants and corresponding gearboxes are provided for
configuration:

 Fixed pitch propeller with reversing gear


 Variable pitch propeller or waterjet with step-down gear
 Waterjet with back-flush (reversing gear)
Furthermore, the Gear Control Unit (GCU) can also be used in conjunction with remote
control systems of other manufacturers. All required signals are provided in the hardware
for this purpose (rather than via the CAN bus).

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Function

1.2.2.3

Part
Page

1
21

Monitoring functional section

The gear monitoring functional section is implemented using the assemblies on the lefthand side of the housing (PIM 2 with four printed circuit boards, see chap. 1.1.2.2). In detail, the following functions are performed:

 Providing a separate safety circuit (for gearbox control oil pressure) within the
Gear Control Unit GCU with the following functions:
- Input for gearbox control oil pressure 4 mA 20 mA; alternatively it is
possible to use a watchdog here (via a network of resistors)
- Interlock generated from the following signals:
Clutch - Neutral (reversing gear)/disengaged (step-down gear),
trolling mode active, engine running (CAN bus telegram), clutch operation
time lag
- Creating two dynamic limit values (Limit_1, Limit_2) which are dependent
on the engine speed; the Limit_1 value can only be used with a 4 mA
20 mA sensor
- Interlocking or issuing an alarm after an adjustable delay time (can be set
separately for both limit values)
- Stopping the engine in the event of a lower limit violation of the Limit_2
value (the relay for the appropriate output is activated)

 Implementing communication with components of the PCS-5 (Local Operating


Panel LOP, Engine Control Unit ECU, Gear Monitoring Unit GMU, Remote Control System RCS) via a redundant CAN field bus with redundancy changeover

 Providing an ITS (Integrated Test System) for analog inputs, binary inputs (control oil pressure and lube oil pressure only), RAM, FEPROM, watchdog, temperature, supply voltage, CAN bus failure

 Providing a separate safety circuit (for the gearbox lube oil pressure, for use as
an option) within the Gear Control Unit GCU with the following functions:
- Input for gearbox lube oil pressure 4 mA 20 mA, alternatively it is possible to use a watchdog here (via a network of resistors)
- Interlock generated from the following signals:
Clutch - Neutral (reversing gear)/disengaged (step-down gear),
trolling mode active, engine running (CAN bus telegram), clutch operation
time lag
- Creating two dynamic limit values (Limit_1, Limit_2) which are dependent
on the engine speed; the Limit_1 value can only be used with a 4 mA
20 mA sensor
- Interlocking or issuing an alarm after an adjustable delay time (can be set
separately for both limit values)
- Stopping the engine in the event of a lower limit violation of the Limit_2
value (the relay for the appropriate output is activated)

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22

Structure and function


Function

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

1.2.2.4

Data transfer via CAN bus

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

 Fast (every 200 ms)


 Medium (every 800 ms)
 Slow (every 5 s)
Data are assigned to one of these categories depending on how frequently they change.
As far as the monitoring measuring points are concerned, the dynamic limit values are
also transferred cyclically in the slow category.

1.2.2.5

Changeover from remote control mode to local mode

The changeover between the remote control and local operating modes is performed
using the appropriate luminous switch on the Local Operating Panel LOP 1. The contacts
in the switch are connected to the Gear Control and Monitoring Unit GCU/GMU 1 in parallel. At the same time, a Local Mode CAN telegram is generated using the control panel
PAN integrated in the Local Operating Panel LOP 1. These two items of information
(switch setting and CAN telegram) are evaluated by the Gear Control and Monitoring Unit
GCU/GMU 1 as follows (local mode active):

 Switch setting:
The clutch operation requests from a remote control system of another manufacturer are no longer issued to the actuators because this connection is interrupted by a relay (under hardware control).

 CAN telegram:
The clutch operation requests from the RCS (CAN telegrams) are no longer
carried out. Instead, the setting of the luminous pushbutton for clutch control on
Local Operating Panel LOP 1 is evaluated. This is performed in the logic controller of the Local Operating Panel LOP 1, consisting of a control panel (PAN)
and Peripheral Interface Module (PIM). The CAN telegrams created there are
then output (under software control) via the printed circuit board BOB 1 in the
form of activation signals for the actuators on the gearbox.
In the case of gearboxes which do not have a neutral switch, the Neutral signal is generated by an OR logic operation (2 diodes) on the Ahead and Astern signals. The Neutral signal is output (via a relay) if neither of these signals is active.
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Structure and function


Function

Local mode

Clutch control
Ahead
Neutral

1
23

Astern

Logic controller LOP 1

Local Operating Panel LOP 1

Bus PCS 5 (CAN)

Gear Control and


Monitoring Unit GCU/GMU 1

Bus PCS 5 (CAN)

Remote control system


of another manufacturer
Clutch operation requests

To RCS 5

Logic controller GCU/GMU 1

Ahead
Neutral
Astern

Gearbox
Gearbox neutral
for gearbox without
neutral switch

Fig.

8:

1.2.2.6

Ahead
Neutral
Astern
Actuators on gearbox

Changeover from local mode to remote control mode (simplified)

Connecting remote control systems of other manufacturers

The following signal interfaces are available for a remote control system of another manufacturer:

 Clutch operation requests (see also Fig. 8, parallel inputs)


 Floating relay contacts
-

Local mode active/Remote control mode active


Clutch engagement interlock (clutch operation window of ECU 4)
Clutch position checkback
Clutch disengagement command

Chaps 1.1.2.3 and 1.6 contain further information about connecting remote control systems of other manufacturers.
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1.3

1
24

Structure and function


Electrical power supply

Electrical power supply

The power supply to the Gear Monitoring Unit GCU/GMU 1 is provided via the Local Operating Panel LOP 1. In this arrangement, the power supplies for the Gear Control Unit
GCU (GCM) and the Gear Monitoring Unit GMU (PIM 2) are separate (two different
cables). These two potentials are separately fused in the Local Operating Panel (GCU:
fusible link on printed circuit board CIB 3, GMU: power circuit breaker F13) and are monitored there.
Reference documentation:
The structure of the electrical power supply and distribution in the propulsion
control system PCS-5 is explained in detail in the following documents:

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




MTU

Series 4000, Marine Application, document no. E 531 687


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

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Function of GCM 1 and ROB 1

1.4

Function of the printed circuit boards GCM 1 and ROB 1

1.4.1

Printed circuit board GCM 1

Part
Page

1
25

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

 6 slots for a printed circuit board MPU 23, 2 printed circuit boards ROB 1 and
two further I/O printed circuit boards

 Protection circuits for the electrical power supply:


-

Overvoltage protection
Cross-polarity protection
Overcurrent protection (self-resetting fuses)
EMC filter

 Protection circuits for the CAN bus connection


-

EMC filter

 Storage of data in a serial EEPROM (CAN node, baud rate, parameters)


 Filtering of the input voltage
The tasks of the printed circuit board GCM 1 are:

 Signal distribution in order to achieve optimum accessibility of the connections


 Multiplication of the signals:
-

Shaft brake
Clutch disengagement command
Clutch in neutral

 Interlinking signals:
-

Clutch engagement interlock with shaft brake

 Gearbox checkback messages as floating outputs for remote control systems


of other manufacturers

 Changing over the clutch operation relay via the Local mode input when remote control systems of other manufacturers are used

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1.4.2

Structure and function


Function of GCM 1 and ROB 1

Printed circuit board ROB 1

LED 1
LED 2
LED 3
LED 4
LED 5
LED 6
LED 7

Fig.

9:

Printed circuit board ROB 1

The relay printed circuit board ROB 1 is a passive board. It has 7 relays (changeover), the
connections of which are routed to terminals via the printed circuit board GCM 1. The differences between the individual relay circuits are as follows:

 Relays K2 and K3 have a higher switching capacity.


 Relays K2 and K3 are activated in parallel.
 Relay K5 can be activated by up to three different signals (OR logic operating
via diode matrix).
The switching states of the relays are displayed using green light emitting diodes.

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Structure and function


Data storage

1.5

Data storage

1.5.1

Overview of data structures which can be configured

1
27

The Gear Control Unit (GCU) contains certain software modules for performing its individual functions. These software modules are integrated into the hardware assemblies as follows:
Data type

Storage location

Redundant storage location

Initial program loader

Flash EPROM

Basic software

Flash EPROM

BDM

Logic programs

Flash EPROM

BDM

Project implementation table for


logic controller and I/O

Flash EPROM

BDM

Parameters

EEPROM in the HC11 assembly

Serial EEPROM on the printed circuit board COB

The functions of the individual software modules are described in more detail in chaps.
1.5.2.1 to 1.5.2.5.
1.5.2

Software modules

1.5.2.1

Initial program loader

The initial program loader is a neutral software item as far as the subsequent application
of the unit is concerned. It makes it possible to program the application-specific software
modules of the basic software, the logic program and the project implementation tables.
These programs then form part of the software of the Flash EPROMs in the printed circuit
board MPU 23.
The initial program loader is downloaded to the Flash EPROM after a printed circuit board
MPU 23 has been completed.
1.5.2.2

Basic software

The basic software contains the range of I/O functions which can be configured.
1.5.2.3

Logic programs

Logic programs represent an expansion to the range of I/O functions. The logic programs
include special functions, e.g. the separate safety circuit. Logic programs have an interface to the CAN bus, and consequently require a group of process variables. The I/O configuration and function of a logic program can be adjusted.
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1.5.2.4

1
28

Structure and function


Data storage

Project implementation tables for I/O channels and logic programs

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

1.5.2.5

Parameters

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

1.5.3

Redundant back-up of project implementation data

Configuration data and logic programs are also stored in the BDM of the propulsion arrangement. The BDM consists of a Programmable Process Station PPS which can be
connected to the dialog socket of the Local Operating Panel. It is used as a data server.
Both basic software and logic programs can be loaded.
If there is a Programmable Process Station PPS in the overall system (e.g.
when using an MCS-5), this programmable process station can take over the
tasks of the BDM.

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Structure and function


Connecting GCU/GMU 1

1.6

1
29

Connecting the Gear Control and Monitoring Unit GCU/GMU 1

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

1.6.1

Gear Control Unit GCU

Printed circuit board MPU 23 (slot 1)


Terminal

Name

X 101

+24 VDC

X 102

+24 VDC

X 103

+24 V ground

X 104

+24 V ground

X 105

CAN 1 GND

X 106

CAN 1 GND

X 107

CAN 1L

X 108

CAN 1L

X 109

CAN 1H

X 110

CAN 1H

X 111

CAN 2 GND

X 112

Unassigned

X 113

CAN 2L

X 114

CAN 2L

X 115

CAN 2H

X 116

CAN 2H

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Used for
Supply voltage*

Supply voltage (ground)*

CAN 1 (default)*

CAN 2 (redundant)*

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Part
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1
30

Structure and function


Connecting GCU/GMU 1

Printed circuit board AIB 1 (slot 2)


Terminal

Name

X 201

Reference voltage 10 V or 1 mA

X 202

Error voltage input (-)

X 203

Error voltage input (+)

X 204

Ground

X 205

Reference voltage 10 V or 1 mA

X 206

Error voltage input (-)

X 207

Error voltage input (+)

X 208

Ground

X 209

Reference voltage 10 V or 1 mA

X 210

Error voltage input (-)

X 211

Error voltage input (+)

X 212

Ground

X 213

Reference voltage 10 V or 1 mA

X 214

Error voltage input (-)

X 215

Error voltage input (+)

X 216

Ground

Used for

Gearbox control oil pressure (4 mA


20 mA)

Gearbox lube oil pressure


(4 mA 20 mA)

Gearbox oil temperature (Pt1000)

Gearbox oil filter pressure


(binary terminal 509 above 2.7
(binary,
2 7 kW to
+24 VDC)

Printed circuit board BOB 1 (slot 3)


Terminal

Name

Connection
with RCS-5

Other manufacturers RCS

X 301

Trolling, relay contact K1, common

Yes*

Yes*

X 302

Trolling, relay contact K1, NO contact

Yes*

Yes*

X 303

Clutch checkback Neutral/disengaged,


relay contact K2, common

Yes*

Yes*

X 304

Clutch checkback Neutral/disengaged,


relay contact K2, NO contact

Yes*

Yes*

X 305

Clutch checkback Neutral/disengaged,


relay contact K1, common

Yes*

Yes*

X 306

Clutch checkback Neutral/disengaged,


relay contact K1, NO contact

Yes*

Yes*

X 307

+ 24 VDC internal

Yes*

X 308

+ 24 VDC internal

X 309

+ 24 VDC internal

X 310

+ 24 VDC internal
>>

MTU

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Part
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Structure and function


Connecting GCU/GMU 1

Terminal

1
31

Name

Connection
with RCS-5

Other manufacturers RCS

X 311

Clutch disengagement control input 1

X 312

Clutch control local mode

No

Yes, from Local


Operating Panel
LOP*

X 313

Clutch operation window relay input +

No

Yes, from Local


Operating Panel
LOP*

X 314

Clutch operation window relay input -

No

Yes, from Local


Operating Panel
LOP*

X 315

Stop signal BOB 1 relay K1 common

X 316

Stop signal BOB 1 relay K1 NO contact

>>

Printed circuit board BIB 2 (slot 4)


Terminal

Name

Connection
with RCS-5

Other manufacturers RCS

X 401

+24 V internal

Yes*

Yes*

X 402

+24 V internal

Yes*

Yes*

X 403

+24 V internal

X 404

+24 V internal

X 405

Clutch disengagement, control input 2

X 406

Clutch disengagement, control input 3

X 407

Trolling, checkback input

X 408

Astern, clutch checkback input

X 409

Neutral/disengaged for gearbox without


neutral switch, relay K1, NC contact

X 410

Neutral/disengaged, clutch checkback


input

X 411

+24 V ext. supply voltage for clutch


relay contact

Yes*

Yes*

X 412

Ahead/engaged, clutch checkback


input

X 413

Clutch disengagement, relay contact


K1, common

No

Yes

X 414

Clutch disengagement, relay contact


K1, NO contact

No

Yes

X 415

Clutch disengagement, relay contact


K1, NC contact

No

Yes

X 416

Local mode, relay contact K1, common

E 532 091 / 00 E

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MTU

Part
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1
32

Structure and function


Connecting GCU/GMU 1

Printed circuit board ROB 1 (slot 5)


Terminal

Name

Connection
with RCS-5

Other manufacturers RCS

X 501

Ahead checkback, relay contact K1,


NO contact

No

Yes

X 502

Neutral checkback, relay contact K1,


NO contact

No

Yes

X 503

Astern checkback, relay contact K1,


NO contact

No

Yes

X 504

Ahead/neutral/astern, relay contact K1,


common

No

Yes

X 505

Clutch disengagement window, relay


contact K1, common

No

Yes

X 506

Clutch disengagement window, relay


contact K1, NO contact

No

Yes

X 507

Clutch disengagement window, relay


contact K1, NC contact

No

Yes

X 508

2.7 K resistor for watchdog

X 509

2.7 K resistor for watchdog

X 510

Reserve, relay contact K1, common

X 511

Reserve, relay contact K1, NO contact

X 512

Reserve, relay contact K1, NC contact

X 513

Reserve, relay + input

X 514

Reserve, relay - input

X 515

+24 V ext. supply voltage

X 516

GNDBATT ext.

Printed circuit board ROB 1 (slot 6)


Terminal

Name

Connection
with RCS-5

Other manufacturers RCS

X 601

Local mode, relay contact K1, NO contact

No

Yes

X 602

Local mode, relay contact K1, NC contact

No

Yes

X 603

Astern, relay 3 contact K2, common

No

Yes

X 604

Astern, relay 3 contact K2, NC contact

No

Yes

X 605

Astern, relay 3 contact K2, NO contact

Yes

No

X 606

Clutch disengagement enable, relay 3


contact K1, common

No

Yes
>>

MTU

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Part
Page

Structure and function


Connecting GCU/GMU 1

Terminal

1
33

Name

Connection
with RCS-5

Other manufacturers RCS

X 607

Clutch disengagement enable, relay 3


contact K1, NC contact

No

Yes

X 608

Clutch disengagement enable, relay 3


contact K1, NO contact

Yes

No

X 609

Neutral/disengaged, relay 2 contact K2,


common

No

Yes

X 610

Neutral/disengaged, relay 2 contact K2,


NC contact

No

Yes

X 611

Neutral/disengaged, relay 2 contact K2,


NO contact

Yes

No

X 612

Ahead/enagaged, relay 2 contact K1,


common

No

Yes

X 613

Ahead/enagaged, relay 2 contact K1,


NC contact

No

Yes

X 614

Ahead/enagaged, relay 2 contact K1,


NO contact

Yes

No

X 615

GNDBATT for the solenoid valves

X 616

GNDBATT for the solenoid valves

For terminals
603 to 614

For terminals
603 to 614

>>

E 532 091 / 00 E

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MTU

Part
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34

1.6.2

Structure and function


Connecting GCU/GMU 1

Gear Monitoring Unit GMU

The cables of the Gear Monitoring Unit GMU 1 are connected up as follows (connections
marked with an * are connected up using plug X21 on the MTU cable harness):
Printed circuit board MPU 23 (slot 1)
Terminal

Name

X 101

+24 VDC

X 102

+24 VDC

X 103

+24 V ground

X 104

+24 V ground

X 105

CAN 1 GND

X 106

CAN 1 GND

X 107

CAN 1L

X 108

CAN 1L

X 109

CAN 1H

X 110

CAN 1H

X 111

CAN 2 GND

X 112

Unassigned

X 113

CAN 2L

X 114

CAN 2L

X 115

CAN 2H

X 116

CAN 2H

MTU

Used for
Supply voltage*

Supply voltage (ground)*

CAN 1 (default)*

CAN 2 (redundant)*

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Part
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Structure and function


Connecting GCU/GMU 1

1
35

Printed circuit board AIB 1 (slot 2)


Terminal

Name

X 201

Reference voltage 10 V or 1 mA

X 202

Error voltage input (-)

X 203

Error voltage input (+)

X 204

Ground

X 205

Reference voltage 10 V or 1 mA

X 206

Error voltage input (-)

X 207

Error voltage input (+)

X 208

Ground

X 209

Reference voltage 10 V or 1 mA

X 210

Error voltage input (-)

X 211

Error voltage input (+)

X 212

Ground

X 213

Reference voltage 10 V or 1 mA

X 214

Error voltage input (-)

X 215

Error voltage input (+)

X 216

Ground

Used for

Gearbox control oil pressure (4 mA


20 mA)

Gearbox lube oil pressure


(4 mA 20 mA)

Printed circuit board MFB 1 (slot 3)


Terminal

Name

X 301

Speed input analog 1 (H)

X 302

Speed input analog 1 (L)

X 303

Speed input binary 1 (H)

X 304

Speed input binary 1 (L)

X 305

Speed input analog 2 (H)

X 306

Speed input analog 2 (L)

X 307

Speed input binary 2 (H)

X 308

Speed input binary 2 (L)

X 309

+24 VDC

X 310

+24 VDC ground

X 311

Relay K1 NC contact

X 312

Relay K1 NO contact

X 313

Relay K1 common

X 314

Relay K2 common

X 315

Relay K2 NO contact

X 316

Relay K2 NC contact

E 532 091 / 00 E

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Used for
Shaft speed system I (either an analog
sensor or a sensor with a binary output
can be connected)

Shaft speed system II (either an analog


sensor or a sensor with a binary output
can be connected)

Reserve

GMU stop

MTU

Part
Page

1
36

Structure and function


Connecting GCU/GMU 1

Printed circuit board BIB 2 (slot 4)


Terminal

Name

X 401

Trolling mode on (+24 VDC)

X 402

Trolling mode on (optocoupler input)

X 403

Checkback clutch Neutral/disengaged (+24 VDC)

X 404

Checkback clutch Neutral/disengaged (optocoupler input)

X 405

Gearbox control oil pressure (+24 VDC)

X 406

Gearbox control oil pressure (optocoupler input)

X 407

Gearbox lube oil pressure (+24 VDC)

X 408

Gearbox lube oil pressure (optocoupler input)

X 409

Gearbox oil level (+24 VDC)

X 410

Gearbox oil level (optocoupler input)

X 411

Reserve (+24 VDC)

X 412

Reserve (optocoupler input)

X 413

Reserve (+24 VDC)

X 414

Reserve (optocoupler input)

X 415

Reserve (+24 VDC)

X 416

Reserve (optocoupler input)

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Part
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Structure and function


Technical data

1.7

1
37

Technical data

Dimensions (W x H x D)

385 mm x 300 mm x 240 mm


Lateral disconnection dimension: +40 mm

Operating voltage

24 VDC, -50 %/+30 %

Operating temperature range

-25 C +55 C

Storage temperature range

-25 C +70 C

Vibration

2 Hz 13 Hz: 1.0 mm
13 Hz 100 Hz: 1 g

Ambient conditions

Max 95 % rel. humidity,


non-condensing

Resistance to salt spray mist, oil, cleaning agents


Degree of protection

GCM module or PIM:


with terminal box:

Insulation resistance

> 10 M (500 VDC)


(under laboratory conditions)

Electrical isolation

500 V (CAN against supply)

Dielectric strength

> 500 VAC


(under laboratory conditions)

Electromagnetic compatibility EMC

Emitted:
Conducted:
Burst:
Surge:
ESD:

E 532 091 / 00 E

- 04.2002 -

IP20
IP65

10 V/m - 30 kHz - 1 GHz


3 Vrms - 30 Hz 80 MHz
2 kV
1 kV sym. / 2 kV asym.
8 kV

MTU

Part
Page

1
38

Structure and function


Technical data

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Operation
Table of contents

Part

Page

Part 2

Operation

Not applicable

Not applicable

E 532 091 / 00 E

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MTU

Part
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2
II

Operation
Table of contents

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Maintenance and repair


Table of contents

Part

Page

Part 3

Maintenance and repair

E 532 091 / 00 E

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MTU

Part

Page

II

Maintenance and repair


Table of contents

(This page intentionally blank)

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Maintenance and repair


Table of contents

Part

Page

III

Table of contents
3

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

3.1

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

3.2

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

3.2.1

General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2

Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2.1

Task summary for scheduled maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2.2

Overview of the task - visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2.3

Checking fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2.4

Checking firm seating of plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2.5

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

3.2.2.6

Checking firm seating of internal assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

3.2.2.7

Overview of the task - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

3.2.2.8

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

12

3.2.2.9

Cleaning plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

3.3

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

14

3.3.1

Faults without fault code displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

3.3.2

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

18

3.4

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

22

3.4.1

Replacing printed circuit boards on Peripheral Interface Modules . . . . . . . . . . . . . . . . . . . .

22

3.4.2

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

26

E 532 091 / 00 E

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Part

Page

IV

Maintenance and repair


Table of contents

(This page intentionally blank)

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Page

Maintenance and repair


Safety requirements

Maintenance and repair

3.1

Safety requirements

3
1

IMPORTANT
These safety requirements shall be read and observed by all
personnel involved in operation, care, maintenance or repair of the
products concerned.
Furthermore, the following shall be observed:
 The safety requirements (if provided) in other relevant MTU manuals
 Warning and safety notes and operating and limit values attached to the
products as required
 National accident prevention and safety standards
 Appropriate regulations usual in the industry
 The safety notes (if provided) in the text of this manual
Conventions for safety notes in the text
Where necessary, this manual includes highlighted safety notes marked with a signal
word. These safety notes shall be observed to avoid injury or damage.
This type of note indicates a danger which may lead to injury or
death.
DANGER
This type of note indicates a danger which may lead to damage
or destruction of the product described or another part of the
system.
CAUTION

Intended use and user qualifications


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

E 532 091 / 00 E

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MTU

Part
Page

3
2

Maintenance and repair


Safety requirements

Safety requirements for maintenance and repair


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

MTU

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E 532 091 / 00 E

Part
Page

Maintenance and repair


Maintenance

3.2

Maintenance

3.2.1

General notes

3
3

This chapter lists work on Gear Control and Monitoring Unit GCU/GMU 1 which is
required in order to maintain availability. This work may be performed without the use of
test and measuring equipment.
Maintenance work on Gear Control and Monitoring Unit GCU/GMU 1 predominantly
involves visual checks to detect mechanical damage or to pinpoint loose parts and connections. Defective assemblies must be repaired or replaced immediately.

System failure
Failure to perform the following work in compliance with instructions and within the time interval indicated can lead to failure of
Gear Control and Monitoring Unit GCU/GMU 1 or failure of the
entire PCS-5 system.

CAUTION

If faults are detected, the cause of the fault can be determined and remedied by following
the instructions listed in the following chapters.
Terminology and structure used in the documentation
This documentation makes a distinction between two concepts:

 Activities
An activity is the sum of all the steps which belong to part of a task (e.g. removing cover of ECU 4 Engine Control Unit). Activities are assigned identification
numbers (Ident. no. or ID no.) which begin with the letter A (e.g.
A-P-ECU-0006)

 Task
A task is the sum of activities which bring about the desired end result (e.g.
exchanging ECU 4 Engine Control Unit).
Tasks are assigned identification numbers (Ident. no. or ID no.) which begin
with the letter T (e.g. T-P-ECU-0003).

E 532 091 / 00 E

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MTU

Part
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3
4

Maintenance and repair


Maintenance

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

Activity/activities

Fig. 10 :

Task overview - task description - activities

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

MTU

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Part
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Maintenance and repair


Maintenance

3.2.2

Maintenance work

3.2.2.1

Task summary for scheduled maintenance work

3
5

All work listed in the following table may be performed by plant personnel.
Maintenance work is performed at three different intervals:

 Maintenance echelon W2
 Maintenance echelon W3
 Maintenance echelon W4
The timing of these intervals is linked to the engine maintenance echelon W1 to W5 interval.
Weiterfhrende Dokumentation:
Refer to the engine documentation for details on the timing of maintenance
work within the interval.
The tables below list the maintenance measures which have to be performed, together
with the locations where they are carried out.
All work which has to be performed on a Gear Control and Monitoring Unit
GCU/GMU 1 (e.g. port engine or starboard engine) must, as a next step, be
performed separately on all other Gear Control and Monitoring Units GCU/
GMU 1 located in the ship.

Interval

Name of task

Qualificat.

Time

Task
ID

Page

Remarks

W4

Perform visual inspection (internal, external)

BP

0.2 h

T-P-GCU-0001

Any faults determined during


the checks must be rectified
immediately

W4

Clean the Gear Control and Monitoring


Unit GCU/GMU 1

BP

0.2 h

T-P-GCU-0002

11

Only perform if necessary

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MTU

Part
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3.2.2.2

3
6

Maintenance and repair


Maintenance

Overview of the task - visual inspection


Ident. no.:

T-P-GCU-0001

System components/units from the overall system PCS 5




Gear Control and Monitoring Unit GCU/GMU 1

Equipment


Torch

Reference documentation


Engine documentation

Documentation for the Gear Control and Monitoring Unit GCU/GMU 1,


document no. E 531 691

Requirements


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

Engine stopped

Additional safety notes




Comply with the general safety regulations: chap. 3.1

Comply with the safety notes prefixing the descriptions of activities

1.

Check fixture of assemblies

A-P-GCU-0001
Page 7

2.

Check cables

A-P-GCU-0003
Page 9

3.

Check firm seating of plugs

A-P-GCU-0002
Page 8

4.

Visual check of internal assemblies

A-P-GCU-0004
Page 10

The activities may be performed in any sequence

MTU

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Part
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Maintenance and repair


Maintenance

3.2.2.3

3
7

Checking fixture
Ident. no.:

A-P-GCU-0001

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

2. There is one mounting bolt (11/1...4) in


each of the four corners of the housing; check that these bolts are firmly
tightened
3. Use a suitable tool (depending on version) to tighten the bolts if they are not
firmly tightened

Fig. 11 :

4
Fixture of the Gear Control and Monitoring Unit GCU/GMU 1

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3
8

3.2.2.4

Maintenance and repair


Maintenance

Checking firm seating of plugs


Ident. no.:

A-P-GCU-0002

The Gear Control and Monitoring Unit


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

Proceed as follows to check that the plug


is firmly attached to the Gear Control and
Monitoring Unit GCU/GMU 1 (12/1):
1. Check that the two securing clips
(13/1, above and below the plug) are
clipped onto the lugs (13/2) so the
plug (13/3) is held firmly in the socket
on the housing of the Gear Control
and Monitoring Unit GCU/GMU 1
Fig. 12 :

Plug on the Gear Control and Monitoring Unit GCU/GMU 1

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


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

Fig. 13 :

MTU

Checking the plug is firmly seated

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Maintenance and repair


Maintenance

3.2.2.5

3
9

Checking cables
Ident. no.:

A-P-GCU-0003
1

Damaged cables must be insulated or replaced (if the damage is too severe) without delay.
1. If the external insulation is damaged
and the individual strands are visible
(e.g. 14/1), it is adequate for the cable
to be wrapped with insulating tape.
This only applies if none of the individual strands have been damaged.
2. The cable harness (or the relevant
part of the cable harness) must be replaced if individual strands are bare or
cut (e.g. 14/2)

Fig. 14 :

Examples of damaged cables

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Part
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3
10

3.2.2.6

Maintenance and repair


Maintenance

Checking firm seating of internal assemblies


Ident. no.:

A-P-GCU-0004

The assemblies inside the Gear Control


and Monitoring Unit GCU/GMU 1 are located on a mounting plate. Check that
their mounting screws are firmly tightened. In addition, all the assemblies on
this mounting plate must be checked to
make sure they are firmly seated.
1. Open the front door of the housing
2. There is one mounting screw (15/1 ...
15/4) in each of the four corners of the
mounting plate; check that these
screws are firmly tightened
3. Use a suitable hex key to tighten the
screws if they are not firmly tightened
4. Check that the other assemblies are
also firmly seated; this applies particularly to the two Peripheral Interface
Modules PIM (15/5, 15/6)

3
Fig. 15 :

MTU

5. Use a suitable tool to tighten any


screws which may have come loose

Fixture of the Gear Control and Monitoring Unit GCU/GMU 1

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Maintenance and repair


Maintenance

3.2.2.7

3
11

Overview of the task - Cleaning


Ident. no.:

T-P-GCU-0002

System components/units from the overall system PCS 5




Gear Control and Monitoring Unit GCU/GMU 1

Equipment


Soft cloth which will not fray or abrade

Isopropyl alcohol (propan-2-ol)

Requirements


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

Engine stopped

Additional safety notes




Comply with the general safety regulations: chap. 3.1

Comply with the safety notes prefixing the descriptions of activities

Do not damage any cables whilst cleaning

If any plugs are disconnected, make sure that the securing clips are
clipped back in again correctly

1.

Gear Control and Monitoring Unit


GCU/GMU 1

A-P-GCU-0005
Page 12

2.

Clean plugs

A-P-GCU-0006
Page 13

The activities may be performed in any sequence

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Part
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3
12

3.2.2.8

Maintenance and repair


Maintenance

Gear Control and Monitoring Unit GCU/GMU 1


Ident. no.:

A-P-GCU-0005

The Gear Control and Monitoring Unit


GCU/GMU 1 (16/1) consists of a housing
made from steel sheet. All electronic assemblies which belong to the Gear Control and Monitoring Unit GCU/GMU 1 are
integrated in this housing.
1. Use a cloth dipped in isopropyl alcohol
to clean coarse dirt off the surface of
this housing (16/2)
2. Make sure that the labelling sets on
the cables are legible. Make the lettering legible or replace the labels, if
necessary.

3
1
Fig. 16 :

Cleaning the Gear Control and


Monitoring Unit GCU/GMU 1

During cleaning work, take care not to damage anything and


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

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Maintenance and repair


Maintenance

3.2.2.9

3
13

Cleaning plugs
Ident. no.:

A-P-GCU-0006

In the long term, excessive contamination


on the plugs can contribute to an impairment of function. As a result, contamination of this type (oil, grease, fuel etc.)
should be removed.
1. Use a cloth dipped in isopropyl alcohol
to clean the surface of the plug (17/1)
2. Remove the plug in case of extreme
contamination (see also page 8)
3. Use isopropyl alcohol to clean the plug
housing (17/2) and the contacts thoroughly
4. Also thoroughly clean the plug socket
(17/3) on the housing of the Local Operating Panel LOP 1 using an adequate quantity of isopropyl alcohol
3
2
Fig. 17 :

Cleaning the plug on the Local Operating Panel LOP 1

During cleaning work, take care not to damage anything and


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

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14

Maintenance and repair


Troubleshooting

3.3

Troubleshooting

3.3.1

Faults without fault code displays

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

No.
1

Fault
Entire PCS-5 does not
react after being switched on

Fault cause(s)
1. No supply voltage
available

Action

See

Check if other parts of


the electrical system in
the ship are also unserviceable.

Ship manual

Other parts of the


system do not function.

Causes point 2

Only PCS-5 is unserviceable.

Causes point 3

2. No ship power

Switch on ship power

Ship manual

3. PCS-5 power supply


switched off; corresponding power circuit breaker tripped

Visual inspection; reset


existing power circuit
breakers if necessary

Ship manual

4. Keylock switch (if


used) for the system
not switched on correctly or not locked
into position properly

Turn key anti-clockwise,


pull it out then push it
back in again and turn
clockwise as far as the
stop

Ship manual

5. Keylock switch defective

Replace keylock switch

Ship manual
>>

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Maintenance and repair


Troubleshooting

No.

Fault

Fault cause(s)

Action

3
15

See

>>
2

Entire Gear Control and


Monitoring Unit GCU/
GMU 1 unserviceable,
other parts of the system
are functioning

No clutch control possible using another manufacturers RCS

Individual functions of
the control system for
another manufacturers
RCS do not function

1. Plug X21 on the Local


Operating Panel LOP
or on the Gear Control and Monitoring
Unit GCU/GMU 1 not
connected properly or
faulty

Connect plug properly,


clip on securing clips

A-P-GCU-0002
page 8

2. Power circuit breaker


in the supply assembly (on MTU PCS-5:
Local Operating Panel LOP 1) tripped or a
fuse has blown

Check power circuit


breaker or fusible link,
switch back on or
replace as necessary

E 531 687

1. Printed circuit board


ROB 1 (relay outputs)
faulty

Replace printed circuit


board ROB 1

A-P-GCU-0007
page 22

2. Cabling defective

Check cables and their


connections to terminals
and repair if necessary

A-P-GCU-0003
page 9

1. Plug-in fuse of printed


circuit board BOB 1
defective:
D F1: Ahead
(engage)
D F2: Neutral
(disengage)
D F3: Astern
(only with
reversing gear)
D F4: D F5: Stop request
from GCU

Replace plug-in fuse for


the corresponding relay
contacts on the printed
circuit board BOB 1

A-P-GCU-0008
page 26

2. Cabling defective

Check cables and their


connections to terminals
and repair if necessary

A-P-GCU-0003
page 9
>>

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No.

3
16

Maintenance and repair


Troubleshooting

Fault

Fault cause(s)

Action

No checkback for current


clutch position

1. Printed circuit board


ROB 1 (relay outputs)
faulty

Replace printed circuit


board ROB 1

2. External power supply faulty

Check the power supply


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

See

>>
5

A-P-GCU-0007
page 22

E 531 687

Fault message after activating Trolling function,


however operating mode
can be maintained

3. Cabling defective

Check cables and their


connections to terminals
and repair if necessary

1. No Trolling engaged
signal from the Trolling Control Unit

Check the Trolling Control Unit

A-P-GCU-0003
page 9

E 531 731
or
E 531 732
2. Printed circuit board
ROB 1 (relay outputs)
faulty

Replace printed circuit


board ROB 1

A-P-GCU-0007
page 22

3. Printed circuit board


BIB 2 (binary inputs)
in the GCU faulty

Replace printed circuit


board BIB 2

A-P-GCU-0007
page 22

4. Printed circuit board


BIB 2 (binary inputs)
in the GMU faulty

Replace printed circuit


board BIB 2

A-P-GCU-0007
page 22

Fault messages relating


to limit value violations
although the actual operating values are correct

One of the printed circuit


boards for registering the
operating values is
defective:
D AIB 1 in the GCU
D AIB 1 in the GMU
D BIB 2 in the GMU

Replace the appropriate


printed circuit board

A-P-GCU-0007
page 22

No shaft speed pick-up

1. Printed circuit board


MFB 1 in the GMU is
defective

Replace printed circuit


board MFB 1

A-P-GCU-0007
page 22

2. Cabling defective

Check cables and their


connections to terminals
and repair if necessary

A-P-GCU-0003
page 9
>>

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Maintenance and repair


Troubleshooting

No.

3
17

Fault

Fault cause(s)

Action

See

GCU or GMU is no longer detected in the overall system, fault message on LOP 1-01 (CAN
Node XX lost or similar)

1. EEPROM on motherboard defective or not


programmed

Replace the PIM housing, reprogram nodes


and the baud rate

Part 4

10

A bus is missing (redundant or default), fault


message on LOP 1-01

1. Cabling defective (terminals loose, cables


interrupted)

Check cables and their


connections to terminals
and repair if necessary

A-P-GCU-0003
Page 9

2. CAN interface of the


MPU 23 processor
PCB defective

Replace printed circuit


board MPU 23; download program via BDM if
necessary

Part 4

>>

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18

3.3.2

Maintenance and repair


Troubleshooting

Faults with plain text output on the display of the corresponding Local
Operating Panel LOP 1-01
Fault messages are only displayed in a system in the manner shown here provided the plant is equipped with an MTU Local Operating Panel LOP 1-01 (with
display DIS).

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

GCU

Alarm

P-GETRIEBESCHMIERL LIMIT LOACK


AL GETR. L FILT. VERSCHMUZTACK

YEL
YEL

F1

Fig. 18 :

F2

F3

F4

F5

Display of fault messages

Fault messages which can be traced back to the Gear Control and Monitoring Unit GCU/
GMU 1 are listed below.
The table gives an explanation of each fault message and provides information about
troubleshooting and fault rectification.
The operating personnel must evaluate the messages on the fault display and take whatever steps are necessary.
MTU

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Maintenance and repair


Troubleshooting

3
19

The overall PCS-5 system (system components ECU 4, LOP 1-01 and EMU 1 if fitted)
monitors, detects and processes faults and limit value violations in all operating situations
(when the system is switched on).
The fault display which appears on the display DIS (see Fig. 18) facilitates diagnosis by
providing information in plain text about the events which have occurred.
The display on the assembly which has sent a message (EMU, ECU , GCU, GMU) makes
it easy to allocate possible fault causes as well as to localise the input and output channels.
When assessing the displayed fault messages, note that one fault may give rise to followon faults which are also displayed.
The list of faults provides explanations about the faults which are registered, refers to
possible causes and gives information about repairs.
The meanings of the abbreviations in the individual rows are as follows:
Classifications of fault displays
AL

General alarm

LO

Range violation alarm (low)

HI

Range violation alarm (high)

SS

Alarm from the safety system

SD

Sensor defective

TD

Sensor comparison fault (transmitter deviation)

MG

Message

LO (suffix)

1st lower limit value

LOLO (suffix)

2nd lower limit value

HI (suffix)

1st upper limit value

HIHI (suffix)

2nd upper limit value

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20

Message,
fault display or
measuring point text

No.

Maintenance and repair


Troubleshooting

Measures or repair stage


(E - Electrical,
M - Mechanical)

Meaning

1.

P-gear control oil GCU Measuring point


Gearbox control oil pressure

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

2.

P-gear control oil


limit LO

3.

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

4.

LO P-gear control oil


GCU

Gearbox control oil pressure is


too low

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

5.

SS P-gear control oil


GCU

Safety system is measuring inadequate gearbox control oil


pressure

Safety system is measuring inadequate control oil pressure:


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

6.

P-gear lube oil GCU

Measuring point
Gearbox lube oil pressure

7.

P-gear lube oil limit


LO

1st limit value for the gearbox


lube oil pressure is displayed

8.

P-gear lube oil lim.


LOLO

2nd limit value for the gearbox


lube oil pressure is displayed

9.

LO P-gear lube oil GCU Gearbox lube oil pressure is


too low

1st limit value for the gearbox


control oil pressure is displayed

10. SS P-gear lube oil GCU Safety system is measuring inadequate gearbox lube oil
pressure

M: Gearbox documentation
Safety system is measuring inadequate lube oil pressure:
M: Gearbox documentation
E: Check the measuring channel if
the actual value on the gearbox is
correct; GMU PCB AIB 1
>>

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Maintenance and repair


Troubleshooting

No.

Message,
fault display or
measuring point text

3
21

Measures or repair stage


(E - Electrical,
M - Mechanical)

Meaning

>>
11. T-gear oil

Measuring point
Gearbox oil temperature

12. T-gear oil limit HI

Limit value for the gearbox oil


temperature is displayed

13. HI T-gear oil

Gearbox oil temperature too


high

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

14. AL gear oil filt. con- Gearbox oil filter contaminated


taminated

M: Gearbox documentation, clean


filter

15. Checkback astern

Measuring point of the Remote


Control System RCS

Message only

16. Checkback ahead/engaged

Measuring point of the Remote


Control System RCS

Message only

17. Neutral/disengaged

Measuring point of the Remote


Control System RCS

Message only

18. Ahead/engaged

Measuring point of the Remote


Control System RCS

Message only

19. Astern

Measuring point of the Remote


Control System RCS

Message only

20. RCS command neutral/


disengaged

Measuring point of the Remote


Control System RCS

Message only

21. RCS command ahead/engaged

Measuring point of the Remote


Control System RCS

Message only

22. RCS command astern

Measuring point of the Remote


Control System RCS

Message only

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


tral/disengaged
Control System RCS

Message only

24. Other RCS command


ahead/engaged

Measuring point of the Remote


Control System RCS

Message only

25. Other RCS command


astern

Measuring point of the Remote


Control System RCS

Message only

26. Valve neutral/disengaged

Measuring point of the Remote


Control System RCS

Message only

27. Valve ahead/engaged

Measuring point of the Remote


Control System RCS

Message only

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22

3.4

Maintenance and repair


Repair

Repair

The following table lists all the repair work described in this chapter.
No.

Name of task

Qualificat.

Time
(ca.)

Task ID

Page

Replacing printed circuit boards on Peripheral Interface Modules

AP

0.2 h

A-P-GCU-0007

22

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

AP

0.3 h

A-P-GCU-0008

26

3.4.1

Remarks

Replacing printed circuit boards on Peripheral Interface Modules


Ident. no.:

A-P-GCU-0007
Printed circuit board
MPU23

Printed circuit board

Printed circuit board

Printed circuit board

Slot 1

Fig. 19 shows the structure of a type 2


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

Slot 3

Slot 2
Slot 4

Module cassette
Printed circuit board
COB 3
(motherboard, internal)
Fig. 19 :

MTU

Module housing

Structure of a Peripheral Interface


Module PIM

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Maintenance and repair


Repair

3
23

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


a printed circuit board. All that is needed is to pull the appropriate module cassette out of the module housing.
Only replace printed circuit boards as complete units.

CAUTION

When changing a printed circuit board, consider whether the


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

Proceed as follows in order to replace a


printed circuit board:
1. Pull the module cassette (20/1) out of
the module housing (see Fig. 19)
2
1

Fig. 20 :

Module cassette

1
2

Fig. 21 :

2. Fold open the cover of the module


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

Opening the cover

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24

Maintenance and repair


Repair

CAUTION

Destruction by electrostatic charging.


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

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


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

Fig. 22 :

Pulling out a printed circuit board

Preconfigured printed circuit board

CAUTION

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


shall only be replaced by identically configured printed circuit
boards by plant personnel.
Spare parts must be ordered accordingly.
If unconfigured assemblies are used, they must be programmed
after installation. This is a task for service personnel and is described in part 4 of this manual.

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Maintenance and repair


Repair

3
25

4. Select the new printed circuit board


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

1
3
2

Fig. 23 :

Inserting a printed circuit board

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


cassette; make sure that the cover
clips into the housing of the module
cassette (24/2) properly
1

Fig. 24 :

7. Put the module cassette back into the


correct position in the appropriate
module housing; take care not to tilt
the module cassette when doing this

Closing the cover

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

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26

3.4.2

Maintenance and repair


Repair

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


Ident. no.:

A-P-GCU-0008

LEDs channel status relay


LED fault
Component side

There are five plug-in fuses on the printed


circuit board BOB 1 (fusible links).
It is necessary to remove the printed circuit board BOB 1 as described in chap.
3.4.1 (ID no. A-P-GCU-0007) steps 1. to
3. before it is possible to replace a plug-in
fuse. The position of the printed circuit
board BOB 1 is shown in chap. 1.
A plug-in fuse is replaced as follows:
1. Use a pair of pointed pliers to grip the
defective plug-in fuse and pull it out
(the positions are shown in the plan
view in Fig. 25)

Plug-in fuse F5
Plug-in fuse F4
Plug-in fuse F2
Plug-in fuse F3
Plug-in fuse F1
Fig. 25 :

Plug-in fuses on BOB 1

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


MT) onto the printed circuit board and
carefully press it into the socket (26/2),
taking care not to bend any of the connection pins

2
Fig. 26 :

3. Put the printed circuit board BOB 1


back into the appropriate module cassette as described in chap. 3.4.1 (ID
no. A-P-GCU-0007), steps 5. to 7.

Replacing a plug-in fuse

Replacement fuses which are used must have the correct electrical ratings:

 F1, F2, F3, F4, F5: 3.15 A MT


CAUTION

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Table of contents

Part

Page

Part 4

Service manual

E 532 091 / 00 E

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Part

Page

II

Service manual
Table of contents

(This page intentionally blank)

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Table of contents

Part

Page

III

Table of contents
4

Service manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1

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

4.2

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

4.2.1

General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.2

Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.2.1

Task summary for scheduled maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3

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

4.3.1

Faults without fault code displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.2

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

4.4

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

4.4.1

Replacing the housing of a Peripheral Interface Module with the motherboard . . . . . . . . .

4.4.2

Replacing the processor assembly of a Peripheral Interface Module . . . . . . . . . . . . . . . . . .

10

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Service manual
Table of contents

(This page intentionally blank)

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Service manual
Safety requirements

Service manual

4.1

Safety requirements

4
1

IMPORTANT
These safety requirements shall be read and observed by all
personnel involved in operation, care, maintenance or repair of the
products concerned.
Furthermore, the following shall be observed:
 The safety requirements (if provided) in other relevant MTU manuals
 Warning and safety notes and operating and limit values attached to the
products as required
 National accident prevention and safety standards
 Appropriate regulations usual in the industry
 The safety notes (if provided) in the text of this manual
Conventions for safety notes in the text
Where necessary, this manual includes highlighted safety notes marked with a signal
word. These safety notes shall be observed to avoid injury or damage.
This type of note indicates a danger which may lead to injury or
death.
DANGER
This type of note indicates a danger which may lead to damage
or destruction of the product described or another part of the
system.
CAUTION

Intended use and user qualifications


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

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2

Service manual
Safety requirements

Safety requirements for maintenance and repair


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

MTU

- 04.2002 -

E 532 091 / 00 E

Part
Page

Service manual
Maintenance

4.2

Maintenance

4.2.1

General notes

4
3

This chapter explains work required on Gear Control and Monitoring Unit GCU/GMU 1 to
maintain availability. This work has to be performed with using test and measuring equipment.
Maintenance work on Gear Control and Monitoring Unit GCU/GMU 1 predominantly
involves visual checks. This work is described in part 3 of this documentation. Defective
assemblies must be repaired or replaced immediately.

System failure

CAUTION

Failure to perform the following work in compliance with instructions and within the time interval indicated can lead to failure of
Gear Control and Monitoring Unit GCU/GMU 1 or failure of the
entire PCS-5 system.

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

E 532 091 / 00 E

- 04.2002 -

MTU

Part
Page

4
4

Service manual
Maintenance

4.2.2

Maintenance work

4.2.2.1

Task summary for scheduled maintenance work

All work listed in the following table may be performed by plant personnel.
Maintenance work is performed at three different intervals:

 Maintenance echelon W2
 Maintenance echelon W3
 Maintenance echelon W4
The timing of these intervals is linked to the engine maintenance echelon W1 to W5 interval.
Reference documentation:
Refer to the engine documentation for details on the timing of maintenance
work within the interval.
Tasks in connection with scheduled maintenance work are given in part 3 of this documentation. No further scheduled maintenance work is required for the GCU/GMU 1 assembly.
All work which has to be performed on a Gear Control and Monitoring Unit
GCU/GMU 1 (e.g. port engine or starboard engine) must, as a next step, be
performed separately on all other Gear Control and Monitoring Units GCU/
GMU 1 located in the ship.

MTU

- 04.2002 -

E 532 091 / 00 E

Part
Page

Service manual
Troubleshooting

4.3

Troubleshooting

4.3.1

Faults without fault code displays

4
5

The following table lists the possible faults which will be patently obvious to the operator,
but which cannot be rectified by the plant personnel.
No.

Fault

Fault cause(s)

Actions

See

GCU or GMU is no
longer detected in the
overall system, fault
message on LOP 1-01
(CAN Node XX lost or
similar)

1. EEPROM on motherboard defective or not


programmed

Replace the PIM housing, reprogram nodes


and the baud rate

A-P-GCU-0009
Page 6

A bus is missing (redundant or default), fault


message on LOP 1-01

2. CAN interface of the


MPU 23 processor
PCB defective

Replace printed circuit


board MPU 23; download program via BDM if
necessary

A-P-GCU-0010
Page 10

4.3.2

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

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

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Part
Page

4
6

Service manual
Repair

4.4

Repair

The following table lists all the repair work described in this chapter.
No.

Name of task

Qualificat.

Replacing the housing


of a Peripheral Interface Module with the
motherboard

SP

Replacing the processor assembly of a


Peripheral Interface
Module

SP

4.4.1

Time
(ca.)

Task ID

Page

Remarks

0h

A-P-GCU-0009

0h

A-P-GCU-0010

10

Replacing the housing of a Peripheral Interface Module with the motherboard


Ident. no.:

A-P-GCU-0009
Fig. 27 shows a type 1 Peripheral Interface Module PIM. The mechanical procedure for removal and installation is explained taking the example of a module of
this type. Removal and installation of a
type 2 Peripheral Interface Module PIM
and of the Gear Control Module GCM is
basically the same, it is merely that there
are more retaining clips (27/3). Proceed
as follows in order to dismantle the module housing:

1. Switch off the operating voltage


2. Open the door of the Gear Control
and Monitoring Unit GCU/GMU 1
3. Locate the appropriate housing:

3
2

1
Fig. 27 :

MTU

Unfastening the PIM




=21.X+A002-A030: GCU
=21.X+A002-A040: GMU

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Service manual
Repair

4
7

4. Note down the terminal assignment of


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

5. Use a screwdriver to unscrew all connection terminals (screw terminals,


27/2)

6. Pull all cables out of the terminals


7. Use a screwdriver to unscrew all
screws (28/1) on the retaining clips
(28/3) and remove the screws
3

Fig. 28 :

Unfastening the PIM

There is a washer (28/5) under


each screw. Make sure no
washers drop into the inside of
the housing.
8. Take the housing (28/4) forwards off
the mounting plate
Proceed as follows to mount a Peripheral
Interface Module PIM on the mounting
plate:
9. Place the new module on the mounting
plate (when doing this, make sure that
the threaded holes line up with the lugs
on the retaining clips)
10. Insert the mounting screws (28/1)
fitted with washers (28/5) and tighten
the screws

Fig. 29 :

Engaging the retaining clip

If the retaining clip (29/1)


happens to be open (pulled
out), push the clip fully in before putting on the module

Before the system is taken back into operation, it is first necessary to program the correct node address and transmission rate on
the newly fitted Peripheral Interface Module PIM. A programming
PCB PAB 2-01 is required to do this.
CAUTION

E 532 091 / 00 E

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MTU

Part
Page

4
8

Service manual
Repair

Do not replace electronics components when they are live!


De-energise the PIMs in question before starting work.
CAUTION
11. Connect the cables to the terminals in
accordance with the terminal assignment (see step 4.); also tighten terminals which are not occupied
Set the node address and the transmission rate as follows:

12. Insert the programming cassette SST


2-01 into the basic module of the Peripheral Interface Module PIM (Gear
Monitoring Unit GMU) or the Gear
Control Unit GCU

13. Make the following settings on the programming cassette using the four dial
switches:

Fig. 30 :

Inserting the programming cassette


SST 2-01

7
Fig. 31 :

MTU

Node number of the PIM within


the target system

Baud rates of the two CAN interfaces

14. The switches and light emitting diodes


of the programming cassette SST
2-01 have the following significance
and functions:
(31/1) MPU 23
(31/2) Diagnostic LEDs
(31/3) S4 Baud rate of 2nd CAN interface
(31/4) S3 Baud rate of 1st CAN interface
(31/5) S5 Programming start button
(31/6) S2 Node address 2nd digit
(31/7) S1 Node address 1st digit

Preparing the programming cassette SST 2-01

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Service manual
Repair

15. The switch settings depend on which


Peripheral Interface Module PIM has
been replaced:

Fig. 32 :

Arrangement of the two units, GCU


and GMU

4
9

GCU: =21.X+A002-A030 (32/1)


Transmission rate of both CAN interfaces 125 kilobaud,
node address can be found by reference to the order-specific documents
GMU: =21.X+A002-A040 (32/2)
Transmission rate of both CAN interfaces 125 kilobaud,
node address can be found by reference to the order-specific documents

16. Start programming by pressing the


button S5 (31/5); observe the diagnostic LEDs when you do this:
Programming was completed without
any mistakes if both yellow LEDs
(31/2) light up;
if this is not the case, determine the
cause by reference to the table in the
Appendix and correct the problem

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

E 532 091 / 00 E

- 04.2002 -

MTU

Part
Page

4
10

4.4.2

Service manual
Repair

Replacing the processor assembly of a Peripheral Interface Module


Ident. no.:

A-P-GCU-0010

Printed circuit board


MPU 23

Slot 1

Fig. 33 shows the structure of a type 2


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

Module cassette
Fig. 33 :

Position of the printed circuit board


MPU 23

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


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

MTU

- 04.2002 -

E 532 091 / 00 E

Part
Page

Service manual
Repair

4
11

Proceed as follows in order to replace the


printed circuit board MPU 23:
1. Pull the module cassette (34/1) out of
the module housing (see Fig. 33)
2
1

Fig. 34 :

Module cassette

1
2

Fig. 35 :

2. Fold open the cover of the module


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

Opening the cover

3. Pull the printed circuit board MPU 23


(36/1) up and out of the module cassette (36/2)

Fig. 36 :

Pulling out the printed circuit board


MPU 23

E 532 091 / 00 E

- 04.2002 -

MTU

Part
Page

4
12

Service manual
Repair

CAUTION

Destruction due to electrostatic charge.


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

4. Select the new printed circuit board


MPU 23 from your stock of spare parts
(note the type and part number, see
part 5 of this documentation)
1
3
2

Fig. 37 :

MTU

Inserting the printed circuit board


MPU 23

The new printed circuit board


MPU 23 must have been programmed with the initial program loader (this is normally
the case when replacement
printed circuit boards are ordered properly) before it is
used as a replacement printed
circuit board.
5. Insert the printed circuit board MPU 23
(37/1) into the grooves (37/3) in the
module cassette (37/2); take care not
to tilt the printed circuit board (37/1)
when doing this

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Service manual
Repair

4
13

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


cassette; make sure that the cover
clips into the housing of the module
cassette (38/2) properly
1

Fig. 38 :

7. Put the module cassette back into the


correct position in the appropriate
module housing; take care not to tilt
the module cassette when doing this

Closing the cover

The printed circuit board MPU 23 must now be programmed with the specific plant data.
The method of programming depends on whether the overall plant contains a Programmable Process Station PPS.
Reference documentation:
In plants which do not have a Programmable Process Station PPS in the overall configuration, it is necessary to perform a manual download using a Backup
Data Module BDM. The BDM tool and the operation of this unit are explained
in the MTU documentation Backup Data Module BDM for Monitoring Systems
PCS-5, documentation parts 1, 2, 5, document no. E 531 718.
In systems with a Programmable Process Station PPS in the overall configuration, the required data are downloaded automatically after the plant operating
voltage is switched on. The system messages on the Local Operating Panel
LOP 1-01 should be observed when this is happening.

E 532 091 / 00 E

- 04.2002 -

MTU

Part
Page

4
14

Service manual
Repair

(This page intentionally blank)

MTU

- 04.2002 -

E 532 091 / 00 E

Illustrated parts catalog


Table of contents

Part

Page

Part 5

Illustrated parts catalog

E 532 091 / 00 E

- 04.2002 -

MTU

Part

Page

II

Illustrated parts catalog


Table of contents

(This page intentionally blank)

MTU

- 04.2002 -

E 532 091 / 00 E

Illustrated parts catalog


Table of contents

Part

Page

III

Table of contents
5

Illustrated parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2

Bildtafeln und Tabellen


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

Querverweisliste
Cross-reference list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

5.3

E 532 091 / 00 E

- 04.2002 -

MTU

Part

Page

IV

Illustrated parts catalog


Table of contents

(This page intentionally blank)

MTU

- 04.2002 -

E 532 091 / 00 E

Illustrated parts catalog


Introduction

Illustrated parts catalog

5.1

Introduction

Part

Page

This illustrated parts catalog forms the basis for spare parts orders.
This parts catalog consists of drawings and corresponding tables as well as a cross-reference list.
The drawings and tables in the parts catalog are also useful when dismantling and re-assembling individual
assemblies. For this reason, the catalog also includes parts for which no spare parts provision has been
made.

Drawings and tables


The headers of the pages with drawings and tables contain the following information:











EDITION
PAGE
PROJECT
GAPL (name of the corresponding group in German)
EGC (name in the corresponding foreign language)
REFERENCE (Bill of Materials (BOM) No. for the part shown in the illustration)
CATALOG (parts catalog number)
ILL. TABLE (four-figure drawing number)
REG. NO. (six-figure registration number)

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




C/N

Location numbers provide a connection between the components in the


drawings and the parts numbers and designations in the corresponding
table.
The location numbers are sorted in a rising numerical sequence.

PART NO.

The part number of the component to be used when ordering spare parts

DESIGNATION

This cell contains the exact parts name.


A part whose designation is indented to the right in this column (indicated by
preceding dots) is included in a previous part (which is either not indented or
is less indented).

Q/U

Quantity in location. This number applies to the installation location.

E 532 091 / 00 E

- 04.2002 -

MTU

Part

Page




Illustrated parts catalog


Introduction

U/M

FN

Unit of measurement for the named part


EA = Each
KG = Kilogram
RL = Roll
SE = Set

MR = Meter

Footnote with references for spare parts queries


The following footnotes may be used:
AB Only available as a complete assembly, repairs only possible in the
manufacturers plant
KE Individual part not intended for delivery as a spare part
KF
Calibrated part: Read section Ordering spare parts prior to
ordering
NB Quantity stipulated by customer (as required)

SUPPLEM. DES./ This column contains standard part designations or manufacturers


REMARKS
designations for bought-out parts.

ILL.-REG.

This column gives the cross-reference to a drawing if this assembly is


illustrated in a separate drawing.

ITEM

For internal use only

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

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

Ordering spare parts


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







MTU

MTU order number


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

- 04.2002 -

E 532 091 / 00 E

Illustrated parts catalog


Introduction

Part

Page

When ordering a calibrated part (marked by KF in the FN column), add the following additional
information:




If the calibration No. is known (see parts nameplate): Add the calibration number preceded by
an oblique stroke as an extension to the part number: /xxxxx. Example: For calibration number
E1234, the part number 500 536 28 10 is extended resulting in 500 536 28 10/E1234.
If the calibration No. is not known:
Give a detailed description of the required parts installation location by quoting the complete
Device Description code (e.g. = 37.1.1 + A022 - F003) plus the part number extension /77
(e.g. 500 536 28 10/77).
In this case, the calibrated spare part will be supplied under a new part number. The Device
Description is found on the nameplate at the parts installation location, or in the corresponding
Wiring Diagram.

When ordering a non-calibrated adjustable part (marked by KF in the FN column) which should not be
calibrated by the factory:

Add extension /76 to the part number (e.g.: 500 536 28 10/76)

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

Delivery of repaired parts


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

E 532 091 / 00 E

- 04.2002 -

MTU

Part

Page

Illustrated parts catalog


Introduction

(This page intentionally blank)

MTU

- 04.2002 -

E 532 091 / 00 E

CATALOG: E 532 091 / 00 ED

EDITION: 03.2002
PAGE:
5
PROJECT: M101

5.2

Bildtafeln und Tabellen


Illustrations and tables

EDITION: 03.2002
PAGE:
6
PROJECT: M101

CATALOG:
ILL. TABLE:
REG. NO.:

GAPL:
84 berwachungseinrichtung
EGC:
84 Monitoring equipment
REFERENCE: 501 530 12 60

36, 37, 39, 40, 41

07 08

05

E 532 091 / 00 ED
84 01
E00634

A
25

36
37
84 01
E00635

38

84 01
E00629

A030

26

A040

50
39

49

X21
LOP

36

54

40
41

51
13, 14

54, 57
12

09, 10

08

A-A

01
61, 63

60
15
11

20, 21

EDITION: 03.2002
PAGE:
7
PROJECT: M101

GAPL:
84 berwachungseinrichtung
EGC:
84 Monitoring equipment
REFERENCE: 501 530 12 60

CATALOG:
ILL. TABLE:
REG. NO.:

ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION


BEMERKUNG / REMARKS

E 532 091 / 00 ED
84 01
E00634

ORTZ
C/N

SACHNUMMER
PART NO.

BENENNUNG
DESIGNATION

STO
Q/U

BZEH
U/M

FN
FN

BILD-REG.
ILL.-REG.

POS.-NR.
ITEM

000

501 530 12 60

ZB ST.G.GCU/GMU 1-02
HOUSING

001

EA

KF

01

500 533 13 03

.ZB GEHAEUSE GCU/GMU1


.HOUSING

001

EA

05

518 533 16 91

.FOTOPLATTE X21 LOP


.PHOTOPLATE

001

EA

KE

840030

06

500 530 05 26

.ZB KABELB. GCU/GMU1


.WIRING HARNESS

001

EA

KE

840032

07

500 533 42 89

.BESCHRIFTUNGSSATZ
.IDENTIFICATION PLATE

001

EA

KE

840034

08

000 533 11 90

.SCHUTZLEITERZEICHEN
.PLATE

004

EA

KE

840036

09

910001 003100

.NIET
.RIVET

002

EA

KE

AK 3,2X 7,49 N 10001

840038

10

700425 000032

.SCHILD
.PLATE

001

EA

KE

31 MMN 425

840040

11

000 533 13 90

.SCHILD MTU ELEKTRON.


.PHOTOPLATE

001

EA

KE

12

700425 000145

.SCHILD
.PLATE

001

EA

KE

13

000 533 07 32

.GRIFF -GEHAEUSE
.HANDLE

001

EA

14

000963 004001

.SENKSCHRAUBE
.COUNTERSUNK HD SCREW

002

EA

15

500 533 45 89

.HINW.SCHILD EINSTELL
.IDENTIFICATION PLATE

001

EA

20

002 531 57 81

.KABELB.BEFEST.SOCKEL
.BASE

012

EA

21

504 96

.BLINDNIET
.BLIND RIVET

012

EA

840026
840028

840042
64.1 MMN 425

840044
840046

M 4 X 10 DIN 963 4.8 DBL 8451.21


KE

840048
840050
840052

KE

840054

EDITION: 03.2002
PAGE:
8
PROJECT: M101

GAPL:
84 berwachungseinrichtung
EGC:
84 Monitoring equipment
REFERENCE: 501 530 12 60

Notizen / Notes

CATALOG:
ILL. TABLE:
REG. NO.:

E 532 091 / 00 ED
84 01
E00634

EDITION: 03.2002
PAGE:
9
PROJECT: M101

GAPL:
84 berwachungseinrichtung
EGC:
84 Monitoring equipment
REFERENCE: 501 530 12 60

ORTZ
C/N

SACHNUMMER
PART NO.

BENENNUNG
DESIGNATION

STO
Q/U

BZEH
U/M

25

528 530 92 69

.ZB INTERF.MODUL GCU


.MEASURE/MONITOR MOD

001

26

528 530 93 69

.ZB INTERF.MODUL GMU


.MEASURE/MONITOR MOD

36

200125 006401

37

FN
FN

CATALOG:
ILL. TABLE:
REG. NO.:

ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION


BEMERKUNG / REMARKS

E 532 091 / 00 ED
84 01
E00634
BILD-REG.
ILL.-REG.

POS.-NR.
ITEM

EA

84 01
E00629

840056

001

EA

84 01
E00635

840058

.SCHEIBE
.WASHER

007

EA

A 6,4 DIN 125 CUAL11NI6FE5 F73

840060

206797 006200

.ZAHNSCHEIBE
.TOOTHED WASHER

002

EA

J 6,4 DIN 6797 A2-70

840062

38

200933 006011

.SECHSKANTSCHRAUBE
.SCREW

001

EA

M 6 X 25 DIN 933 A4-70

840064

39

000934 006034

.SECHSKANTMUTTER
.HEX NUT

003

EA

M 6 DIN 934 A4-70

840066

40

000 159 21 79

.KABELSCHUH
.CABLE TERMINAL

004

EA

840068

41

002 531 14 80

.KABEL 1,23
.CABLE

001

MR

840070

49

015 531 49 83

.SCHUTZKAPPE GR.10
.MALE CONNECTOR

001

EA

50

000 533 38 83

.ANBAUGEH. 42-P.
.MALE CONNECTOR

001

EA

840074

51

000 533 41 83

.RAHMEN F.STECKERGEH.
.CONNECTOR HOUSING

001

EA

840076

54

207985 004100

.LINSENSCHRAUBE
.FILLISTER SCREW

012

EA

M 4 X 12 DIN 7985 4.8-H DBL 8454

840078

57

000125 004317

.SCHEIBE
.WASHER

008

EA

A 4,3 DIN 125 140 HV DBL 8451.11

840080

60

000 533 61 41

.ABSTANDSBOLZEN
.SPACER PIN

002

EA

61

207985 005103

.LINSENSCHRAUBE
.OVAL-HEAD SCREW

002

EA

AB

840072

840082
M 5 X 8 DIN 7985 A4-70-H

840084

EDITION: 03.2002
PAGE:
10
PROJECT: M101

GAPL:
84 berwachungseinrichtung
EGC:
84 Monitoring equipment
REFERENCE: 501 530 12 60

Notizen / Notes

CATALOG:
ILL. TABLE:
REG. NO.:

E 532 091 / 00 ED
84 01
E00634

EDITION: 03.2002
PAGE:
11
PROJECT: M101

GAPL:
84 berwachungseinrichtung
EGC:
84 Monitoring equipment
REFERENCE: 501 530 12 60

ORTZ
C/N

SACHNUMMER
PART NO.

BENENNUNG
DESIGNATION

STO
Q/U

BZEH
U/M

63

000125 005322

.SCHEIBE
.WASHER

002

EA

FN
FN

CATALOG:
ILL. TABLE:
REG. NO.:

ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION


BEMERKUNG / REMARKS
A 5,3 DIN 125 140 HV DBL 8451.11

E 532 091 / 00 ED
84 01
E00634
BILD-REG.
ILL.-REG.

POS.-NR.
ITEM
840086

EDITION: 03.2002
PAGE:
12
PROJECT: M101

CATALOG:
ILL. TABLE:
REG. NO.:

GAPL:
84 berwachungseinrichtung
EGC:
84 Monitoring equipment
REFERENCE: 528 530 92 69

E 532 091 / 00 ED
84 01
E00629

3, 4
7

Z1

Z1

MPU23
CCB1

102 316
101 315

BOB1

302
301

516
515

ROB1

502
501

201
202

AIB1

215 401
216 402

BIB2

415
416

601
602

ROB1

615
616

84 01
E00630

116
115

Z2
Z2

1
1

EDITION: 03.2002
PAGE:
13
PROJECT: M101

GAPL:
84 berwachungseinrichtung
EGC:
84 Monitoring equipment
REFERENCE: 528 530 92 69
FN
FN

CATALOG:
ILL. TABLE:
REG. NO.:

ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION


BEMERKUNG / REMARKS

E 532 091 / 00 ED
84 01
E00629

ORTZ
C/N

SACHNUMMER
PART NO.

BENENNUNG
DESIGNATION

STO
Q/U

BZEH
U/M

BILD-REG.
ILL.-REG.

POS.-NR.
ITEM

000

528 530 92 69

ZB INTERF.MODUL GCU
MEASURE/MONITOR MOD

001

EA

01

526 530 01 83

.ZB MODUL GCM 1-01


.MODULAR SYSTEM

001

EA

KF

840004

02

009 531 43 48

.IC EEPROM SER 8KX 8


.INTEGRATED CIRCUIT

001

EA

KF

840006

03

5295308212/S0001

.ZB STECKK.MPU 23-03


.PLUG-IN BOARD

001

EA

840008

04

504 530 78 92

.ZB STECKK. CCB 1-01


.PLUG-IN BOARD

001

EA

840010

05

529 530 86 12

.ZB STECKK. BOB 1-02


.PLUG-IN BOARD

001

EA

06

526 530 99 12

.ZB STECKK.ROB 1-01


.PLUG-IN BOARD

001

EA

840014

07

529 530 93 12

.ZB STECKK. AIB 1-02


.PLUG-IN BOARD

001

EA

840016

08

504 530 08 97

.ZB STECKK. BIB 2-01


.PLUG-IN BOARD

001

EA

840018

09

526 530 99 12

.ZB STECKK.ROB 1-01


.PLUG-IN BOARD

001

EA

840020

840002

84 01
E00630

840012

EDITION: 03.2002
PAGE:
14
PROJECT: M101

GAPL:
84 berwachungseinrichtung
EGC:
84 Monitoring equipment
REFERENCE: 529 530 86 12

01

CATALOG:
ILL. TABLE:
REG. NO.:

E 532 091 / 00 ED
84 01
E00630

EDITION: 03.2002
PAGE:
15
PROJECT: M101

GAPL:
84 berwachungseinrichtung
EGC:
84 Monitoring equipment
REFERENCE: 529 530 86 12
FN
FN

CATALOG:
ILL. TABLE:
REG. NO.:

ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION


BEMERKUNG / REMARKS

E 532 091 / 00 ED
84 01
E00630

ORTZ
C/N

SACHNUMMER
PART NO.

BENENNUNG
DESIGNATION

STO
Q/U

BZEH
U/M

BILD-REG.
ILL.-REG.

POS.-NR.
ITEM

000

529 530 86 12

ZB STECKK. BOB 1-02


PLUG-IN BOARD

001

EA

840022

01

001 531 76 86

.SICHERUNG 3,15A/F
.FUSE

005

EA

840024

EDITION: 03.2002
PAGE:
16
PROJECT: M101

GAPL:
84 berwachungseinrichtung
EGC:
84 Monitoring equipment
REFERENCE: 528 530 93 69

Z1
Z1

CATALOG:
ILL. TABLE:
REG. NO.:

E 532 091 / 00 ED
84 01
E00635

03, 04 84 01
E00636

07
05
06

116
115

MPU23
CCB1

102 316
101 315

MFB 1

302
301

201
202

AIB 1

215 401
216 402

BIB 2

415
416

Z2

Z2

01

01 02

EDITION: 03.2002
PAGE:
17
PROJECT: M101

GAPL:
84 berwachungseinrichtung
EGC:
84 Monitoring equipment
REFERENCE: 528 530 93 69
FN
FN

CATALOG:
ILL. TABLE:
REG. NO.:

ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION


BEMERKUNG / REMARKS

E 532 091 / 00 ED
84 01
E00635

ORTZ
C/N

SACHNUMMER
PART NO.

BENENNUNG
DESIGNATION

STO
Q/U

BZEH
U/M

BILD-REG.
ILL.-REG.

POS.-NR.
ITEM

000

528 530 93 69

ZB INTERF.MODUL GMU
MEASURE/MONITOR MOD

001

EA

01

528 530 19 83

.ZB MODUL PIM 2-03


.MODULAR SYSTEM

001

EA

KF

840090

02

009 531 43 48

.IC EEPROM SER 8KX 8


.INTEGRATED CIRCUIT

001

EA

KF

840092

03

5295308212/S0001

.ZB STECKK.MPU 23-03


.PLUG-IN BOARD

001

EA

840094

04

504 530 78 92

.ZB STECKK. CCB 1-01


.PLUG-IN BOARD

001

EA

840096

05

529 530 04 13

.ZB STECKK.MFB 1-01/A


.PLUG-IN BOARD

001

EA

06

504 530 08 97

.ZB STECKK. BIB 2-01


.PLUG-IN BOARD

001

EA

840100

07

529 530 93 12

.ZB STECKK. AIB 1-02


.PLUG-IN BOARD

001

EA

840102

840088

84 01
E00636

840098

EDITION: 03.2002
PAGE:
18
PROJECT: M101

GAPL:
84 berwachungseinrichtung
EGC:
84 Monitoring equipment
REFERENCE: 529 530 04 13

01

CATALOG:
ILL. TABLE:
REG. NO.:

E 532 091 / 00 ED
84 01
E00636

EDITION: 03.2002
PAGE:
19
PROJECT: M101

GAPL:
84 berwachungseinrichtung
EGC:
84 Monitoring equipment
REFERENCE: 529 530 04 13
FN
FN

CATALOG:
ILL. TABLE:
REG. NO.:

ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION


BEMERKUNG / REMARKS

E 532 091 / 00 ED
84 01
E00636

ORTZ
C/N

SACHNUMMER
PART NO.

BENENNUNG
DESIGNATION

STO
Q/U

BZEH
U/M

BILD-REG.
ILL.-REG.

POS.-NR.
ITEM

000

529 530 04 13

ZB STECKK.MFB 1-01/A
PLUG-IN BOARD

001

EA

840104

01

001 531 76 86

.SICHERUNG 3,15A/F
.FUSE

002

EA

840106

EDITION: 03.2002
PAGE:
20
PROJECT: M101

GAPL:
84 berwachungseinrichtung
EGC:
84 Monitoring equipment
REFERENCE: 529 530 04 13

Notizen / Notes

CATALOG:
ILL. TABLE:
REG. NO.:

E 532 091 / 00 ED
84 01
E00636

Querverweisliste / Cross Reference List


PROJECT: M101
EDITION:

5.3

03.2002

Querverweisliste
Cross-reference list

CATALOG: E 532 091 / 00 ED


21
PAGE:

Querverweisliste / Cross Reference List


PROJECT: M101
EDITION:

CATALOG: E 532 091 / 00 ED


22
PAGE:

03.2002

SACHNUMMER
PART NO.

BENENNUNG
DESIGNATION

BILDTAF.
ILL. TAB.

REG.NR.
REG.NO.

ORTZ
C/N

VERSORGUNGSNR.
STOCK NO.

000125 004317

SCHEIBE
WASHER

84 01

E00634

57

5310-12-174-7451

000125 005322

SCHEIBE
WASHER

84 01

E00634

63

5310-12-178-2567

000 159 21 79

KABELSCHUH
CABLE TERMINAL

84 01

E00634

40

000 533 07 32

GRIFF -GEHAEUSE
HANDLE

84 01

E00634

13

000 533 11 90

SCHUTZLEITERZEICHEN
PLATE

84 01

E00634

08

000 533 13 90

SCHILD MTU ELEKTRON.


PHOTOPLATE

84 01

E00634

11

000 533 38 83

ANBAUGEH. 42-P.
MALE CONNECTOR

84 01

E00634

50

000 533 41 83

RAHMEN F.STECKERGEH.
CONNECTOR HOUSING

84 01

E00634

51

000 533 61 41

ABSTANDSBOLZEN
SPACER PIN

84 01

E00634

60

000934 006034

SECHSKANTMUTTER
HEX NUT

84 01

E00634

39

000963 004001

SENKSCHRAUBE
COUNTERSUNK HD SCREW

84 01

E00634

14

001 531 76 86

SICHERUNG 3,15A/F
FUSE

84 01
84 01

E00630
E00636

01
01

002 531 14 80

KABEL 1,23
CABLE

84 01

E00634

41

002 531 57 81

KABELB.BEFEST.SOCKEL
BASE

84 01

E00634

20

009 531 43 48

IC EEPROM SER 8KX 8


INTEGRATED CIRCUIT

84 01
84 01

E00629
E00635

02
02

015 531 49 83

SCHUTZKAPPE GR.10
MALE CONNECTOR

84 01

E00634

49

200125 006401

SCHEIBE
WASHER

84 01

E00634

36

200933 006011

SECHSKANTSCHRAUBE
SCREW

84 01

E00634

38

206797 006200

ZAHNSCHEIBE
TOOTHED WASHER

84 01

E00634

37

207985 004100

LINSENSCHRAUBE
FILLISTER SCREW

84 01

E00634

54

207985 005103

LINSENSCHRAUBE
OVAL-HEAD SCREW

84 01

E00634

61

500 530 05 26

ZB KABELB. GCU/GMU1
WIRING HARNESS

84 01

E00634

06

500 533 13 03

ZB GEHAEUSE GCU/GMU1
HOUSING

84 01

E00634

01

500 533 42 89

BESCHRIFTUNGSSATZ
IDENTIFICATION PLATE

84 01

E00634

07

500 533 45 89

HINW.SCHILD EINSTELL
IDENTIFICATION PLATE

84 01

E00634

15

501 530 12 60

ZB ST.G.GCU/GMU 1-02
HOUSING

84 01

E00634

000

5305-12-166-5102

SACHNR. NEU
PART NO. NEW

Querverweisliste / Cross Reference List


PROJECT: M101
EDITION:

CATALOG: E 532 091 / 00 ED


23
PAGE:

03.2002

SACHNUMMER
PART NO.

BENENNUNG
DESIGNATION

BILDTAF.
ILL. TAB.

REG.NR.
REG.NO.

ORTZ
C/N

504 530 08 97

ZB STECKK. BIB 2-01


PLUG-IN BOARD

84 01
84 01

E00629
E00635

08
06

504 530 78 92

ZB STECKK. CCB 1-01


PLUG-IN BOARD

84 01
84 01

E00629
E00635

04
04

504 96

BLINDNIET
BLIND RIVET

84 01

E00634

21

518 533 16 91

FOTOPLATTE X21 LOP


PHOTOPLATE

84 01

E00634

05

526 530 01 83

ZB MODUL GCM 1-01


MODULAR SYSTEM

84 01

E00629

01

526 530 99 12

ZB STECKK.ROB 1-01
PLUG-IN BOARD

84 01

E00629

06
09

528 530 19 83

ZB MODUL PIM 2-03


MODULAR SYSTEM

84 01

E00635

01

528 530 92 69

ZB INTERF.MODUL GCU
MEASURE/MONITOR MOD

84 01
84 01

E00629
E00634

000
25

528 530 93 69

ZB INTERF.MODUL GMU
MEASURE/MONITOR MOD

84 01
84 01

E00634
E00635

26
000

529 530 04 13

ZB STECKK.MFB 1-01/A
PLUG-IN BOARD

84 01
84 01

E00635
E00636

05
000

5295308212/S0001

ZB STECKK.MPU 23-03
PLUG-IN BOARD

84 01
84 01

E00629
E00635

03
03

529 530 86 12

ZB STECKK. BOB 1-02


PLUG-IN BOARD

84 01
84 01

E00629
E00630

05
000

529 530 93 12

ZB STECKK. AIB 1-02


PLUG-IN BOARD

84 01
84 01

E00629
E00635

07
07

700425 000032

SCHILD
PLATE

84 01

E00634

10

700425 000145

SCHILD
PLATE

84 01

E00634

12

910001 003100

NIET
RIVET

84 01

E00634

09

VERSORGUNGSNR.
STOCK NO.

SACHNR. NEU
PART NO. NEW

Querverweisliste / Cross Reference List


PROJECT: M101
EDITION:

03.2002

Notizen / Notes

CATALOG: E 532 091 / 00 ED


24
PAGE:

Appendix
Page
I

Table of contents

Appendix

Reference documentation

E 532 091 / 00 E

- 04.2002 -

MTU

Appendix
Page
II

Table of contents

(This page intentionally blank)

MTU

- 04.2002 -

E 532 091 / 00 E

Appendix
Page
III

Table of contents

Table of contents
A

Reference documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E 532 091 / 00 E

- 04.2002 -

MTU

Appendix
Page
IV

Table of contents

(This page intentionally blank)

MTU

- 04.2002 -

E 532 091 / 00 E

Reference Documentation

Appendix
Page
1

Reference documentation

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

E 531 685

Engine Control Unit ECU 4

Parts 1, 3, 4, 5

E 531 686

Engine Monitoring Unit EMU 1

Parts 1, 3, 4, 5

E 531 687

Local Operating Panel LOP 1

Parts 1, 3, 4, 5

E 531 712

PCS-5 with FMEA

Part 1

E 531 693

PCS-5 system description

Part 1

E 532 091 / 00 E

- 04.2002 -

MTU

Appendix
Page
2

Reference Documentation

(This page intentionally blank)

MTU

- 04.2002 -

E 532 091 / 00 E

Page

Abbreviations

Abbreviations
a

Acceleration

BDM

Backup Data Module

BR

Series (in this case: Engine series)

CAN

Controller Area Network, bus designation

CCB

Connection board, printed circuit board with serial interface

CB

Connection Box

ECS

Engine Control System, MTU engine management system

ECU

Engine Control Unit

Formula for frequency,

fl

Limit frequency

FPP

Fixed Pitch Propeller

Acceleration due to gravity

GCM

Gear Control Module

GCU

Gear Control Unit

GMU

Gear Monitoring Unit

I/O

Input/Output

Formula for electrical current

IIn

Input current

IEC

International Electrotechnical Commission

IP

International Protection

LED

Light Emitting Diode

LOP

Local Operating Panel

mA

Milliamp

min

Minute

mV

Millivolt

MCS

Monitoring and Control System,


MTU control and monitoring system

E 532 091 / 00 E

- 04.2002 -

MTU

Page

ii

Abbreviations

Abbreviations (cont.)
MCS-PO

Main Control Station

MTU

Motoren- und Turbinen-Union

Speed

Pressure

PIM

Peripheral Interface Module

PPS

Programmable Process Station

Formula for electrical resistance

RAM

Random Access Memory

RCS

Remote Control System

RS422

Recommended Standard, interface standard

Second

SDAF

Shut Down Air Flap

SISY

Sicherheitssystem, safety system

SP

Spare part

STn

Plug designation

Temperature

Voltage

UOUT

Output voltage

UB

Ship voltage (+24 V)

UIN

Input voltage

Volt

VCC

Operating voltage

VDC

Voltage Direct Current

Vpp

Peak-to-peak voltage value

xpp

Vibration test deflection, peak-to-peak value

MTU

- 04.2002 -

E 532 091 / 00 E