E531685 - 01 (MDEC For BR4000)

Engine Control Unit
Type ECU 4
BR 4000
Marine applications
Documentation
Part 1, 3, 4, 5
- Structure and function
- Maintenance and repair (Plant personnel)
- Maintenance and repair (Service personnel)
- Illustrated parts catalog
E 531 685 / 01 E
assuring you
y certification:
Quality assurance in design/development,

production, installation and service
y 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.
Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen
Wartungs- und Bedienungspersonal zur Verfügung zu stellen. Außerhalb dieses Verwendungszwecks darf das Handbuch ohne unsere
vorherige Zustimmung nicht benutzt, vervielfältigt oder Dritten sonstwie zugänglich gemacht werden.
Änderungen bleiben vorbehalten.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation.
Other than for this purpose, the handbook shall not be reproduced, used or disclosed to others without our prior consent.
Subject to alterations and amendments.
Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à
l’exploitant de le mettre à la disposition du personnel chargé de l’entretien et de la conduite. En dehors de cet usage, le manuel ne pourra
être utilisé ni reproduit ou rendu accessible de quelque autre manière à des tiers, sans notre consentement préalable.
Nous nous réservons le droit d’entreprendre toute modification.
El Manual debe tenerse presente para evitar anomalias o daños durante el servicio, y, por dicho motivo, el usuario debe ponerlo a
disposición del personal de mantenimiento y de servicio. Fuera de este fin de aplicación, el Manual no se debe utilizar, copiar ni poner
en manos de terceros, sin nuestro consentimiento previo.
Nos reservamos el derecho de introducir modificaciones.
No sentido de evitar falhas ou danos durante o servicio, o usuário deberá cuidar de que o Manual esteja sempre à disposição do pessoal
encarregado com a manutenção e operação. Além desta sua finalidade, o Manual não deverá, sob qualquer pretexto, ser reproduzido
parcial ou totalmente ou franqueado a terceiros sem prévia e expressa autorização de nossa parte.
Reservamo-nos o direito de proceder modificações.
Il 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. Senza nostra approvazione preventiva non è ammesso impiegare il manuale per scopi diversi, riprodurlo
o metterlo a disposizione di terzi.
Con riserva di modifiche.
Käyttöhäiriöiden ja teknisten vaurioiden välttämiseksi on noudatettava käsikirjassa annettuja ohjeita, joten kirja on luovutettava huoltoja
käyttöhenkilökunnan käyttöön. Käsikirjaa ei saa ilman sen laatijan lupaa käyttää muuhun tarkoitukseen, monistaa tai luovuttaa
ulkopuolisille.
Oikeudet muutoksiin pidätetään.
Ë 1998
MTU Motoren- und Turbinen-Union Friedrichshafen GmbH
88040 Friedrichshafen / Germany
Phone (0 75 41) 90 - 0 Telex 7 34 280 -- 50 mt d Telefax (0 75 41) 90 - 61 23
Guide Page I
FRIEDRICHSHAFEN
Table of contents
Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI
General information about documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII
1 Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.1 Use and structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1.2 Structure of Engine Control Unit ECU 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.2.1 External structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.2.2 Internal structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.2.3 Attachment of Engine Control Unit ECU 4 to the engine . . . . . . . . . . . . . . . . 8
1.2 Functions of Engine Control Unit ECU 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.1 Engine governing/control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.2 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.3 Speed/injection governing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2.4 Common Rail injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.5 Angle measuring/determining control timing . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2.6 Adjustable speed droop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.7 Power limitation (fuel flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.7.1 Dynamic fuel flow limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.7.2 Fixed fuel flow limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.7.3 Control of fuel flow during engine starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.7.4 Speed limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.8 Nominal speed value handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.9 Recirculating ETC control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.10 Cylinder cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3 Start and stop functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3.1 Engine start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3.2 Emergency engine start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Table of contents (cont.)
1.3.3 Engine stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3.4 Emergency engine stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.3.5 Safety system override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4 Engine monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4.1 Engine protection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4.2 Integral Test System (ITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.4.2.1 Monitoring the electronics of Engine Control Unit ECU 4 . . . . . . . . . . . . . . . 23
1.4.2.2 Monitoring the sensors/actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.4.2.3 Monitoring bus communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.5 Status and fault displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.6 Communication and system integration via CAN bus . . . . . . . . . . . . . . . . . . 25
1.7 Inputs/outputs of Engine Control Unit ECU 4 . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.7.1 Inputs on the plant side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.7.1.1 Assignment of inputs on the plant side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.7.1.2 Input specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.7.2 Inputs on the engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.7.2.1 Assignment of inputs on the engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.7.2.2 Input specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.7.3 Outputs on the plant side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1.7.3.1 Assignment of outputs on the plant side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.7.3.2 Output specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.7.4 Outputs on the engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

1.7.4.1 Assignment of outputs on the engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.7.4.2 Output specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.7.5 Bus connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1.7.5.1 Serial interface RS232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.7.5.2 CAN bus interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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Guide Page III
FRIEDRICHSHAFEN
1.8 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
(Not applicable)
3 Maintenance and repair (Plant personnel) . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.1 Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.2.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.2.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3.2.2.1 Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.2.2.2 Task summary for scheduled maintenance work . . . . . . . . . . . . . . . . . . . . . . 56
3.2.3 Task overview -- visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3.2.3.1 Checking firm seating of all connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.2.3.2 Checking firm seating of cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.2.3.3 Checking screwed sensor connections for leaks . . . . . . . . . . . . . . . . . . . . . . 60
3.2.3.4 Checking cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.2.4 Task overview -- cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

3.2.4.1 Cleaning Engine Control Unit ECU 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.2.4.2 Cleaning connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.3.1 Faults without fault code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.3.2 Faults with fault code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.3.3 Faults indicated by LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.4 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.4.1 Replacing Engine Control Unit ECU 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

3.4.1.1 Removing the housing of Engine Control Unit ECU 4 from the engine . . . 90
3.4.1.2 Removing the cover of Engine Control Unit ECU 4 . . . . . . . . . . . . . . . . . . . . 92
3.4.1.3 Transferring the memory modules of Engine Control Unit ECU 4 . . . . . . . . 93
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3.4.1.4 Fitting the cover of Engine Control Unit ECU 4 . . . . . . . . . . . . . . . . . . . . . . . . 95

3.4.1.5 Mounting the housing of Engine Control Unit ECU 4 on the engine . . . . . . 96
3.4.2 Replacing the fusible cutout in ECU 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

3.4.2.1 Removing the cover of Engine Control Unit ECU 4 when mounted on the
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.4.2.2 Replacing the fusible cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.4.2.3 Fitting the cover of Engine Control Unit ECU 4 when mounted on the engine101
4 Maintenance and repair (Service personnel) . . . . . . . . . . . . . . . . . . . . . . . 105
4.1 Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.2.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.2.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.3.1 Faults with fault code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.4 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.4.1 Replacing data module IDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

4.4.1.2 Replacing Interface Data Module IDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.4.1.3 Fitting the cover of Engine Control Unit ECU 4 when mounted on the engine 118
4.4.2 Replacing data module EDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

4.4.2.2 Replacing Engine Data Module EDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.4.2.3 Fitting the cover of Engine Control Unit ECU 4 . . . . . . . . . . . . . . . . . . . . . . . . 122
4.5 Metrological tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.5.1 Testing the CAN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

4.5.1.1 CAN bus short-circuit test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.5.1.2 Checking and repairing shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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Guide Page V
FRIEDRICHSHAFEN
5 Illustrated parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.2 Drawings and tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.3 Cross-reference list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Connector pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Input circuitry of the ECU channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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Abbreviations
a Acceleration
BR Baureihe, series (in this case engine series)
CAN Controller Area Network (bus designation)

CR Common Rail (fuel injection technology)
DBR Drehzahlabhängige Füllzahlbegrenzung, speed-dependent feeding limitation

DDC Detroit Diesel Corporation
ECB Engine Control Board

ECS Engine Control System, MTU engine management system
ECU Engine Control Unit
EDM Engine Data Module
EPROM Electrically Programmable ROM
ETC Exhaust Turbocharger
f Formula for frequency

fL Limit frequency
g Acceleration due to gravity
I/O Input/Output
I Formula for electrical current
IDM Interface Data Module
IIn Input current
IEC International Electrotechnical Commission
IP International Protection
LED Light Emitting Diode

LOP Local Operating Panel
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Guide Page VII
FRIEDRICHSHAFEN
Abbreviations (cont.)
mA Milliampere
MCS Monitoring and Control System, MTU control and monitoring system
MEM Memory Module
min Minute
mm Millimeter
MTU Motoren- und Turbinen-Union
mV Millivolt
n Speed
p Pressure
PCS Propulsion Control System
PIDT Proportional/Integral/Differential controller
PP Plant Personnel
PWM Pulse Width Modulation
R Formula for electrical resistance

RAM Random Access Memory
RCS Remote Control System
ROM Read Only Memory
RS422 Recommended Standard (interface standard)
s Second
Sisy Sicherheitssystem, safety system
SP Service Personnel
SP Spare Part
STn Connector designation
SV Solenoid valve
T Temperature
U Voltage
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Page VIII Guide
FRIEDRICHSHAFEN
Abbreviations (cont.)
UB Ship’s voltage (+24 V)

UIn Input voltage
UOut Output voltage
V Volt
VCC Operating voltage
VDC Voltage Direct Current
Vpp Voltage value from peak to peak
xpp Vibration test deflection, peak -- peak value
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Guide Page IX
FRIEDRICHSHAFEN
General information about documentation
Documentation structure
Documentation Title/contents Target group

Part
1 Structure and function Operating personnel, plant personnel
2 Operation Operating personnel
3 Maintenance and Operating personnel, plant personnel

repair
(Plant personnel)
4 Maintenance and Electronics service personnel
repair familiar with the plant
(Service personnel)
5 Illustrated Operating, service and logistics personnel
parts catalog
6 Order-specific Electronics service personnel
adaptation
7 Installation Electromechanical specialists
Note: Not all documentation parts are written for every product!
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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Conventions for symbols
Rectification of a fault marked with this symbol either requires the

customer’s service personnel or service personnel provided by MTU.
The affected assembly can be sent to MTU for repairs.
Such a fault cannot be repaired by ship’s 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 per-

formed on other assemblies or equipment with reference to the relevant docu-
mentation.
Refer to other MTU manuals for more information.
Additional information provided for reasons of clarity (e.g. if an explanation is of

an exemplary nature only).
Fig. X Refer to fig. X for more information (cross-reference to a figure).
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Part 1
Structure and function
FRIEDRICHSHAFEN Page 1
Part 1
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Part 1
Page 2 FRIEDRICHSHAFEN
1 Structure and function
1.1 Use and structure
1.1.1 Use
The ECU 4 assembly is a speed and injection governor for MTU/DDC series 4000 en-
gines. It is located at the engine.
Fig. 1: Engine Control Unit ECU 4
Engine Control Unit ECU 4 features:

y Control of mapped individual CR (Common Rail) injection systems
y Up to 20 injection valves can be controlled
y Communication with Propulsion Control System PCS-5 units and superordinate
systems via CAN bus
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y Self-monitoring and diagnosis

-- Integral status/fault indication
-- Fault memory
y Extensive I/O features:
-- Plant side: 12 inputs, 10 outputs, 3 serial interfaces
-- Engine side: 26 inputs, 26 outputs, 1 serial interface
y Engine and plant-related settings in pluggable memory modules
y Diagnosis via RS232 interface for dialog unit
y Online programming by downloading (dialog unit)
y Configurable via interface (RS232)
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1.1.2 Structure of Engine Control Unit ECU 4
1.1.2.1 External structure
Engine Control Unit ECU 4 is installed in a diecast housing with a screw-fitted cover.
1 3
455
Approx. 48 4
12
2
2
277
11
91 12
5 6 7 8 9 10
W3 W2 W4
W003
W004
All dimensions in mm
Fig. 2: Mechanical structure
1 Cover 7 Connector plug for extended range of sensors

2 Cover screws 8 Power supply connector plug (LOP)
3 Housing 9 Cable harness connector plug
4 Seals 10 Dialog unit connector plug
5 Plant connector plug (LOP) 11 Mounting bracket
6 Cable harness connector plug 12 Mounting plate
Engine Control Unit ECU is installed on the engine with four mounting brackets on the
mounting plate. The cover is screwed onto the housing with 10 Phillips screws.
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Cord packing is used to seal the housing between the cover and the bottom part of the
housing.
The connections for system, power supply, dialog unit and the cable harnesses are
marked on the housing cover. Pre-cut system cables and cable harnesses are connected
to these connectors (X1 ... X6 -- see table below).
Electrical connections are established via bayonet connectors. A dust cap is used to pro-
tect connection X6 which is not used when the engine is in operation.
Dialog unit connector X6 is only used temporarily to connect the dialog unit for servicing.
Pre-cut cable harnesses with pluggable sensors and actuators serve as engine wiring.
The connector inserts are coded to prevent misconnection. Connections of lines which are
not in use are isolated.
Connection Meaning
Connector X1 Connection for plant (system cable to LOP)
System cable W003
Connector X2 Connection for engine side I cable harness for sensors/actuators
Cable harness W2
Connector X3 Connection for engine side II cable harness for sensors/actuators
Cable W3
Connector X4 Connection for solenoid valve cable harness;
Cable harness W4 the number of available solenoid valves depends on the number of
cylinders on the engine
Connector X5 Power supply connection
System cable W004 (system cable to LOP)
Connector X6 Connection for dialog unit
Dialog cable
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1.1.2.2 Internal structure
Printed circuit board Cord packing

ECU 4
Flat fuse
Housing
Connecting cable
Fig. 3: Internal structure of Engine Control Unit ECU 4 (cover removed)
One ECB 4-02 printed circuit board is located inside the housing; it incorporates all the
electronic components (with the exception of the smoothing capacitor).
The replaceable flat fuse (30 A) protects the power supply of the entire Engine Control
Unit ECU 4.
Engine Control Unit ECU 4 has no internal wiring with the exception of the capacitor con-
nection. This optimizes operational reliability and facilitates maintenance.
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4 5 3 1 2 1 1 1 10
X1 X3 X2 X5 X4 X6
6 6 6 7 9 6 8
Fig. 4: Configuration of the electronic components on printed circuit board ECB 4-01
1 LED power supply (+24 VDC, +15 VDC, --15 VDC, +5 VDC)
2 LED RESET
3 Processor
4 Engine data and program memory module EDM (MEM 6)
5 Interface data module IDM
6 Engine cable harness and LOP connector
7 Power supply connector
8 Dialog unit connector
9 Fuse 30 A
10 Status/fault display
The two data modules are plugged into two sockets to facilitate replacement (IDM with
clip). The data modules differ in shape and cannot be interchanged.
The 4-figure LED display (4/10) indicates the current status and any faults which may
have occurred. The code numbers are explained in the table in part 3 of this manual.
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1.1.2.3 Attachment of Engine Control Unit ECU 4 to the engine
2
1 3
10
8
7 6 5
3 9
Fig. 5: Attachment of Engine Control Unit ECU 4 to the engine
1 Engine Control Unit ECU 4

2 Upper adapter plate
3 Metal cable shock absorber
4 Upper mounting bracket
5 Connector plug
6 Connector socket
7 Lower adapter plate
8 Lower mounting bracket
9 Lower hex-head bolts (screwed into the housing from the back)
10 Upper hex-head bolts (screwed into the housing from the back)
Engine Control Unit ECU 4 has been purpose-built for engine mounting.
Fig. 5 illustrates mounting using 3 or 4 cable shock absorbers with 4 bolts on the engine
mounting brackets.
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1.2 Functions of Engine Control Unit ECU 4
1.2.1 Engine governing/control
Engine Control Unit ECU 4 features the following engine governing and control functions:
y Stop and emergency stop control
y Speed governing
y Injection regulation for solenoid valve controlled injection with mapped injection
start regulation
y Adjustable speed droop
y Nominal speed setting by
-- CAN bus, analog speed setting
-- CAN bus, speed setting Up/Down
-- 4 mA ... 20 mA/0 ... 10 V, analog speed setting
-- Up/down signal, binary speed setting
y Control of the fuel injected as a function of engine loading, speed, charge air
pressure, fuel temperature
y ETC circuit
y High-pressure fuel regulator
y Cylinder cutout
Engine Control Unit ECU 4 also performs the following monitoring tasks:
y Control of analog indicators for
-- Engine speed
-- Engine lube oil pressure
-- Engine coolant temperature
-- Engine loading
y Transmission of all measured values, warnings and alarms to the Monitoring
and Control System via CAN bus
y Automatic shutdown (emergency stop) in case of
-- Overspeeding
y Shutdown or power limitation (configurable) in case of
-- Low engine lube oil pressure
-- High engine coolant temperature
Refer to the measuring point list for details of order-specific configuration data.
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Communication with other assemblies is realized via serial interfaces:

y 2 x CAN bus interface (redundant CAN bus) for communication with the follow-
ing assemblies:
-- Additional Propulsion Control System PCS-5 units
-- Superordinate monitoring and control systems
(Remote Control System RCS, Monitoring and Control System MCS)
1.2.2 Software
The software (program) is loaded into Engine Control Unit ECU 4 via the dialog unit inter-
face when the engine is installed or on initial start-up of the electrical system.
Limit values and parameters for engine control, governing and monitoring are finalized
during the project implementation or engine trial phase and loaded into Propulsion Control
System PCS-5 of MTU/DDC Series 4000 during the test run. These values can be edited
with the dialog unit.
The use of pluggable data modules has the advantage of making it possible to use an
Engine Control Unit ECU 4 on a wide range of engines in a great variety of applications by
simply transferring the software modules should replacement become necessary.
Fig. 6 illustrates the distribution of the software over the two data modules:
Engine data Interface data

Program
memory
Backup Backup
interface data engine data
EDM Flash EPROM
Engine data module Interface data module

MEM 6 IDM
Fig. 6: Software modules
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1.2.3 Speed/injection governing
The engine speed governor integrated in Engine Control Unit ECU 4 has the following
functions:
y Maintaining the desired engine speed under varying load conditions
y Adjusting the engine speed when settings are changed by the operator
Other tasks of Engine Control Unit ECU 4 with regard to speed governing are:
y Setting a defined fuel flow to be injected on starting the engine
y Engine safety shutdown
y Optimizing performance characteristics, exhaust emission values and fuel con-
sumption
y Protecting the engine against overloading
Engine governing incorporates protective functions for the engine, e.g. power limitation by
limiting the amount of fuel injected depending on certain operating values and conditions.
Engine speed setting (nominal value) can be switched between

y Remote Control System RCS (setting via CAN bus or analog/binary signal)
y Local operation at the LOP with speed up/down pushbuttons
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1.2.4 Common Rail injection system
Unlimited Nominal Firing

Speed Speed governor nominal Fuel flow limitation Characteristic maps Inj. start/end gov.
fuel flow order
setting fuel flow
PI(DT1)
Injection start SV closing/

Max. fuel flow Injection duration Actuating opening
M = f (speed) Nom. fuel high pulses point
M = f (charging pressure) pressure
M = f (fuel temperature) Power electronics
etc.
Current engine speed
Nom. fuel
Pressure regulator high pressure Fuel
PI(DT1) Fuel high pressure

Common Rail
Power electronics Injection valves
PWM
High-pressure pump
Speed Crankshaft Camshaft gear
calculation angle
Crankshaft gear
Engine
Fig. 7: Control loop
The speed governor compares the speed setting (control lever, up/down keys) with the
current engine speed. If the two values deviate, it adapts its output signal (nominal injec-
tion fuel flow) to compensate the difference. The PID characteristics ensure rapid
response to changes and precise speed setting.
Dynamic fuel flow limitation (operating point-dependent) protects the engine against over-
loading.
The nominal fuel flow after limitation is the input signal for the injection start/injection end
governor (controlled by map). The power electronics activate the injection valves of the
individual cylinders according to its settings. Engine Control Unit ECU 4 also regulates the
injection pressure of the Common Rail system.
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1.2.5 Angle measuring/determining control timing
Control times are generated in the electronics on the basis of information from the angle
measuring sensors on two measuring gears. One measuring gear is mechanically coupled
to the crankshaft and one to the camshaft.
During normal operation, the crankshaft sensor determines the precise angle of the crank-
shaft to determine the control times for injection and also derive the engine speed.
During normal operation, the camshaft sensor allows differentiation between intake and
ignition cycle.
Crankshaft:
The measuring gear on the crankshaft turns at the speed of the engine. Each tooth on the
measuring gear generates a pulse in the inductive sensor (channel KW 1). The crankshaft
angle is determined by evaluating the number of pulses from the sensor. Counting is syn-
chronized by a tooth space (i.e. sensor pulse is omitted) at a defined angle position.
Camshaft:
The measuring gear on the camshaft turns at half the engine speed. Only the tooth space
is evaluated by Engine Control Unit ECU 4 during normal operation.
This tooth space enables the electronics to differentiate between the intake and ignition
cycles of cylinder A1.
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1.2.6 Adjustable speed droop
Fig. 8 shows the principle control range of the engine governor and the effect of adjust-
able speed droop (load-dependent nominal speed value change).
Speed droop is required to compensate for loading on coupled drives. Speed droop is set
specifically for the plant and can be changed using the dialog unit.
Speed droop is defined as a relative change in speed when the engine is unloaded.
Speed droop is referenced to the nominal speed (= maximum speed at maximum power
output). Every point in the operating range is influenced when the load changes.
Maximum speed (zero load) nZero -- Nominal speed nNom

Speed droop= x 100 %
Nominal speed nNom
Load
DBR curve
Resultant
speed at
load L1
L1
Zero load
nL Idling speed
Speed setting value
Speed
droop
nNom Nominal speed Engine
speed
nZero Maximum speed at zero load
Fig. 8: Graphic representation of the speed setting range and speed droop
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1.2.7 Power limitation (fuel flow limitation)
1.2.7.1 Dynamic fuel flow limitation
Dynamic fuel flow limits, e.g. variable fuel injection limits, protect the engine against over-
loading and optimize the exhaust emission values. Engine Control Unit ECU 4 determines
the maximum injection fuel flow on the basis of preset and stored engine characteristic
maps.
The result is:

y Speed-dependent fuel flow limitation (DBR)
y Fuel flow limitation as a function of charge air pressure
y Fuel flow limitation as a function of fuel temperature
y Fuel flow limitation in case of charger overspeeding
1.2.7.2 Fixed fuel flow limitation
Fixed fuel flow limits used for power limitation and reduction protect the engine in case of
y High coolant temperature (second limit value)
(configurable)
y Electronic malfunctions
y Supply voltage out of range
1.2.7.3 Control of fuel flow during engine starting
The amount of fuel injected on starting the engine is increased from a preset initial value
over a time ramp to a specified value. This value is calculated by the function fInjection =
f(speed). The amount of fuel injected is limited as a function of speed in this way. This fuel
flow limit applies until idling speed has been reached for the first time.
1.2.7.4 Speed limitation
Engine speed limitation also represents a way of protecting the engine against overload-
ing (e.g. thermal overloading). The speed is limited when the coolant temperature is too
high (second limit value violated) (configurable).
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1.2.8 Nominal speed value handling
The speed setting (= nominal speed value) is the reference variable for the engine speed
control loop.
The nominal speed is set via CAN bus communication under normal operating conditions
(with Remote Control System RCS-5 connected).
Binary input BE 8 “Switch nominal speed” switches between the following variants:
y Nominal speed value setting from the Remote Control System
The nominal speed can be adjusted between idling and maximum speed.
The internal nominal speed follows the set speed value applied via a configur-
able acceleration or deceleration curve (speed ramp). Should the signal fail, the
set value which was previously applied is maintained or the engine throttled
back to idling speed.
The response can be configured as required.
-- Nominal speed value setting via CAN bus
-- Nominal speed value setting via a nominal speed setting analog input
(0 V ... 10 V, 4 mA ... 20 mA, potentiometer), the default setting is 4 mA ...
20 mA for remote control systems produced by other manufacturers
y Nominal value processing via the “Nominal speed up” (BE 5)/“Nominal speed
down” (BE 6) binary inputs.
The nominal speed can be adjusted between idling speed and maximum
speed. Briefly activating the appropriate optocoupler input for less than 1 s
(configurable, tset > 0.5 s selected) increases or decreases the nominal speed
by a fixed value (1 rpm is standard).
When the input is activated for more than 1 s, the nominal speed is adjusted
automatically at a configurable rate (50 rpm per second is standard).
Response on switching (“Switch nominal speed”):
Analog @ Up/down The current analog nominal speed is maintained on switching over and
can be changed with the up/down keys
Up/down @ Analog The speed is set to the given analog value
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1.2.9 Recirculating ETC control
The exhaust turbochargers (ETCs) supply the diesel engine with the quantity of air
required for combustion at overpressure. This results in a higher degree of efficiency and
increased engine performance.
The ETC control has an optimum charging effect over a broad power band.
ETC 1 does not switch. It serves as the basic charger as soon as the engine is running.
The speed of ETC 1 is measured via speed input DME 1.
ETC 1 overspeed protection:
The engine speed is reduced to protect the ETC in case of ETC overspeeding.
ETC switching for ETC 2:
ETC 2 cuts in or out depending on the operating point.
Possible switching criteria (configurable) are:

y Engine speed
y ETC 1 speed
ETC 2 is cut in and out by opening and closing a hydraulically-actuated ETC switching
valve. The ETC switching valve is activated by a solenoid valve controlled by Engine Con-
trol Unit ECU 4.
Recirculation
Turbocharger efficiency is increased by diverting a part of the compressed (“charged”) air

to the exhaust channel at certain speeds. This process is referred to as “recirculation”. It is
initiated by activating the recirculation valve.
The two switching valves are activated by the transistor outputs TAM 1 (switching valve
ETC 1) and TAM 2 (recirculation valve).
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1.2.10 Cylinder cutout
Cylinder cutout controlled by Engine Control Unit ECU 4 switches off the fuel supply to the
injection valves of individual cylinders in certain operating ranges. During low-load opera-
tion, this results in engine operation involving little smoke emission and favourable con-
sumption.
Engine Control Unit ECU 4 activates and deactivates cylinder cutout under normal operat-
ing conditions depending on the engine operating point.
The plant signal “Cylinder cutout off” (binary input BE 2) prevents switching. The engine
runs on all cylinders (cylinder cutout off) as long as this signal is active.
1.3 Start and stop functions
1.3.1 Engine start
The start sequence is controlled by the LOP.
Reference documentation:
The start sequence is described in “Local Operating Panel LOP for MTU/DDC
Series 4000”, Documentation Part 1, document no. E 531 687.
Engine Control Unit ECU 4 commences injection as soon as the starter has run the
engine up to a defined speed threshold and no stop command has been received from the
plant.
The engine can be started by

y Superordinate Monitoring and Control System MCS in Remote mode
y LOP in Local mode (Local signal active)
Additional signals may also be checked in the LOP as a requirement for initiating the start
sequence.
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1.3.2 Emergency engine start
An emergency start function is incorporated in the LOP. This starts the engine in emer-
gency situations without regard to the normal starting requirements. Exception: The
engine must be ready for operation and no external start interlock may be active.
The emergency start sequence is described in “Local Operating Panel LOP for
MTU/DDC Series 4000”, Documentation Part 1, document no. E 531 687.
The emergency start function is activated by an external key.
1.3.3 Engine stop
The engine is stopped by an external stop command (plant signal BE 1) or an automatic

shutdown by disabling all injection valves and reducing the fuel pressure to zero.
The stop command is output to Engine Control Unit ECU 4 which subsequently shuts off
fuel injection.
The engine stop sequence is described in “Local Operating Panel LOP for
MTU/DDC Series 4000”, Documentation Part 1, document no. E 531 687.
Engine stopping can be tripped by the following assemblies and systems:

y Superordinate Monitoring and Control System MCS in Remote mode
y Local Operating Panel LOP in Local mode (only when the “Local” signal is
active)
y Safety system in case of limit value violations (safety system engine stop com-
mands are ignored and not output to Engine Control Unit ECU 4 when the
“Safety system override” signal is active at Local Operating Panel LOP).
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1.3.4 Emergency engine stop
An emergency stop is executed unconditionally when an emergency stop signal is

detected.
The emergency shutdown is controlled by the LOP.

In the case of an automatic emergency shutdown (overspeeding), an emergency stop signal
is transmitted from Engine Control Unit ECU 4 (plant signal TAA 1) to the LOP which then
activates the emergency shutdown.
Depending on the accessories fitted on the engine, emergency stopping is realized by:
y De-energizing Engine Control Unit ECU 4
y Activating the shut down air flap(s)
An engine stop signal is simultaneously output at the LOP with the emergency stop signal.
The emergency engine stop sequence is described in “Local Operating
Panel LOP for MTU/DDC Series 4000”, Documentation Part 1, document no.
E 531 687.
An emergency engine stop can be tripped by the following assemblies and systems:
y Superordinate Monitoring and Control System MCS
y Local Operating Panel LOP
y Safety system in case of limit value violations (overspeeding)
1.3.5 Safety system override
The override function is activated at the superordinate Monitoring and Control System
MCS and executed by the Local Operating Panel LOP. Engine Control Unit ECU 4 logs
the safety system override status.
The safety system override feature is described in “Local Operating
Panel LOP for MTU/DDC Series 4000”, Documentation Part 1, document no.
E 531 687.
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Part 1
1.4 Engine monitoring
1.4.1 Engine protection system
Engine
Sensors Final control

elements
Engine protection
system
Governor
Nominal
value Power supply
Fig. 9: Governor and engine protection system
The engine is protected by an integral engine protection system. It monitors the engine
operating values.
When limit values are reached, the engine protection system

y Protects the engine from assuming critical operating states
y Warns operating personnel via a connected Monitoring and Control System
y Temporarily adapts operation to the remaining possibilities
Depending on the values which are measured, warnings, start interlocks, power reduction,
engine shutdown by reducing feeding or closing the shut down air flaps take place.
Possible activities of the engine protection system are:

y Fault message output
y Alarm output
y Dynamic feeding limitation
y Engine stop by feeding reduction
y Emergency engine stop by activating emergency shutdown
If the engine protection system detects failure of a sensor signal, a fault message is output
via the Monitoring and Control System.
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The activities of the engine protection system allow Engine Control Unit ECU 4 to maintain
engine operation or emergency engine operation.
Safety shutdowns
Safety shutdowns to protect the diesel engine take effect when the limit values of the fol-
lowing measuring points are violated:
y Engine speed
y Engine lube oil pressure
y Coolant temperature (configurable)
y Coolant level (configurable)
Refer to the measuring point list for details of the order-specific configuration data.
1.4.2 Integral Test System (ITS)
The Integral Test System ITS monitors all important functions of Engine Control Unit
ECU 4:
y Electronics of the actual engine governor inside Engine Control Unit ECU 4
y Sensors
y Actuators
y Bus communication
y Power supply
The ITS detects any faults as they occur, pinpoints and signals them to the superordinate
Monitoring and Control System MCS and hence the operator by combined alarm, internal
display and CAN bus.
Any faults which occur are saved for evaluation at a later date. They can be read out with
the dialog unit.
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Fault messages are stored in two memories:

y Chronological memory
The fault messages are stored in chronological order of their occurrance or
cancellation together with the operating hours counter reading in a ring
memory. The ring memory saves the last 80 setting/resetting procedures.
y Statistical memory
The occurrance of fault messages is registered in a statistical memory. Each
fault message number can be registered up to a maximum of 10000 times.
1.4.2.1 Monitoring the electronics of Engine Control Unit ECU 4
The hardware and software of Engine Control Unit ECU 4 has been designed to detect
faults in the electronics, to respond to them and to indicate appropriately.
The internal housing temperature of Engine Control Unit ECU 4 is monitored. Should it
rise above a (configurable) limit value, the fault is signalled to the superordinate Monitor-
ing and Control System MCS via the combined alarm output and the CAN bus.
1.4.2.2 Monitoring the sensors/actuators
The sensor and actuator channels of the engine control system are designed to tolerate
faults (e.g. short-circuit proof) as far as possible.
Faults such as line interruption, short-circuit etc. are detected by a plausibility check and
indicated to the superordinate Monitoring and Control System MCS.
1.4.2.3 Monitoring bus communication
Bus communication is monitored by a plausibility and timeout check. Any faults which are
detected are indicated by a combined alarm and signalled to the system via the CAN bus
if possible.
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1.5 Status and fault displays
RESET/HALT
24 V --15 V +5 V +15 V Display
Fig. 10 : LEDs and display in Engine Control Unit ECU 4
The following voltages are monitored:

y +24 VDC supply voltage
y +15 VDC (internal)
y --15 VDC (internal)
y +5 VDC (internal)
The processor state is indicated by:

y RESET/HALT
The processor system is put into a defined state by a RESET. The engine is
shut down.
The four-figure display indicates status and faults codes (refer to the table in part 3 of this
manual).
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Part 1
1.6 Communication and system integration via CAN bus
The CAN bus is a standardized field automation bus allowing various systems, devices,
sensors and actuators to communicate with each other.
Engine Control Unit ECU 4 is equipped with two CAN bus interfaces.
Tasks of the CAN bus:

y Receiving plant signals and commands from the superordinate control system
RCS
y Output of all measuring values/limit values for the Monitoring and Control Sys-
tem (MCS-5)
y Alarm output for signalling and evaluation in the Monitoring and Control System
(MCS-5)
y Output of the signals relevant to engine control (for representation)
1.7 Inputs/outputs of Engine Control Unit ECU 4
1.7.1 Inputs on the plant side
1.7.1.1 Assignment of inputs on the plant side
The following inputs are available on the plant side:
Signal Channel Designation in

connection diagram
Engine stop BE 1 OCIN 1
Cylinder cutout off BE 2 OCIN 2
Fixed speed BE 4 OCIN 4
Nominal speed up BE 5 OCIN 5
Nominal speed down BE 6 OCIN 6
Nominal speed setting switching BE 8 OCIN 8
Coolant level outer jacket cooling BE 9 OCIN 9
Nominal speed (analog) IUE 1 IIN/UIN 1
Nominal speed (PWM) FE 1 FREQU. IN
Battery voltage UBATT +24 VDC/GND
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1.7.1.2 Input specifications
Binary inputs BE 1 ... BE 9
Function Source
Acquisition of binary signals, á 50 V isolated Switch, key, monitor, contact
Uext = 24 V
ECU 4
+IN
--IN
Cable
W003
Fig. 11 : Schematic diagram of binary input BE
Channel specification
Type Isolated binary input, external supply
Input signal UIn (high) = 24 V (min. 8 V)

UIn (low) = 0 V (max. 4 V)
Electrical isolation á 50 V
Fault detection None
Additional information Reverse-battery protection up to 36 V without affecting adjacent

channels
Burst resistance 1000 V, 70 V/2 ms, 50 V/50 ms
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Current and voltage input IUE 1
Function Source
Measuring voltages (0 ... 10 VDC) and currents (4 ... 20 mA), E.g. accelerator pedal, control lever
e.g. analog nominal speed setting
e.g. accelerator
UISO = 5 V
e.g. control lever pedal
5V_ISO
ECU 4
I_IN
U_IN
GND_ISO
Cable
W003
Fig. 12 : Schematic diagram of voltage/current input IUE
Measuring channel specification
Measuring range UIn = 0 ... 10 VDC/IIn = 4 ... 20 mA
Potentiometer R = 1 ... 10 kW
Potentiometer supply 5 V/5 mA
Measuring channel accuracy Less than 5 % (voltage measuring)

Less than 4 % (current measuring)
Resolution Less than 5 mV or 10 mA
Electrical isolation á 50 V
Response to failure Line interruption/short-circuit by failure ranges
Additional information Reverse-battery protection to 36 V without affecting adjacent

channels
Burst resistance to 1000 V
Isolation voltage greater than 500 V
U_IN1 and I_IN1 must not be used at the same time. The same applies to
U_IN2 and I_IN2.
Inputs IUE1 and IUE2 are not isolated from each other.
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1.7.2 Inputs on the engine side
1.7.2.1 Assignment of inputs on the engine side
The engine operating values are acquired with the aid of the following inputs:
Signal Channel
Differential lube oil pressure NSE 1*
Leak fuel level NSE 2
Coolant level NSE 3
Crankshaft speed KW 1
Camshaft speed NW 1
ETC 1 speed DME 1
Coolant temperature TE 1
Charge air temperature TE 2
Fuel temperature TE 3
Intake air temperature TE 5
Lube oil temperature TE 7
Combined exhaust temperature engine side A TE 8
Combined exhaust temperature engine side B TE 9
Coolant pressure DE 1*
Crankcase pressure DE 2
Fuel pressure after filter DE 3*
Lube oil pressure DE 5
Charge air pressure DE 7
High-pressure fuel pump DEH
The ranges of sensors are defined in the standard scopes of supply of Propulsion Control
System PCS-5 for MTU/DDC Series 4000.
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Part 1
1.7.2.2 Input specifications
Level sensor inputs NSE 1 ... NSE 3
Function Sensor
Level monitoring Level monitor, e.g. BEDIA coolant level

sensor
UB = 24 V
24V_NSE Overcurrent
protection
+5V
Level
monitor IN
GND
ECU 4
Cable
W2
Fig. 13 : Schematic diagram of level switching input TAA
Sensor Open collector, ground switching

BEDIA coolant level sensor; with automatic self-test (contact switches
to ground approx. 2 s after switching on)
Electrical isolation None
Additional information Reverse-battery protection to 36 V without affecting adjacent chan-

nels (excepting GND)
Burst resistance to 1000 V, 70 V/2 ms, 50 V/50 ms
E 531 685 / 01 E -- 08.98 --

Part 1
Angle of rotation measuring inputs KW 1 and NW 1
Channel Function Sensor
KW1 Measuring crankshaft angle and crankshaft speed VDO inductive sensor
NW1 Measuring camshaft angle and camshaft speed VDO inductive sensor
ECU 4
n/d
+IN
U/f
--IN
Inductive sensor
Cable
W2
Fig. 14 : Schematic diagram of angle measuring input KW1/NW1
Limit frequency fL = 26 kHz
Input voltage 1.5 Vpp < UIn < 180 Vpp
Hysteresis H % 150 mV
Common-mode rejection Greater than 20 dB
Fault detection Idling and short-circuit by plausibility check
Immunity Burst resistance to 1000 V
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Part 1
Speed measuring input DME 1
Function Sensor
Measuring speeds (e.g. ETC) VDO inductive sensor
ECU 4
n
+IN
U/f
--IN
Inductive sensor
Cable
W2
Fig. 15 : Schematic diagram of speed measuring input DME
Limit frequency fL = 26 kHz
Input voltage 0.9 Vpp < UIn < 180 Vpp
Hysteresis H = 400 mV
Additional information Other characteristics such as angle measuring input

(see page 30)
E 531 685 / 01 E -- 08.98 --

Part 1
Temperature inputs TE 1 ... TE 9
Function Sensor
Temperature measuring Temperature-dependent resistor

NI1000
Uref = 5 V
IN ECU 4
NI1000
-J
GND
Cable
W2
Fig. 16 : Schematic diagram of temperature measuring input TE
Measuring range 0 oC ... 130 oC
Measuring channel accuracy Less than 1 %
Fault detection Line interruption/short-circuit by failure ranges
Additional information Reverse-battery protection to 36 V without affecting adjacent chan-

nels (excepting GND)
Channels TE8 and TE9 have a different scale (for Pt100).
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Part 1
Pressure inputs DE 1 ... DE 7
Function Sensor
Pressure measuring between 0 ... 10 bar Pressure sensor
Uref = 5 V
5V_BUF
p ECU 4
IN
U
GND
Pressure sensor
Cable
W2
Fig. 17 : Schematic diagram of pressure measuring input DE
Channel DE1 ... DE3/UE1/UE2
Measuring range Sensor-dependent
Output signal UOut 0.5 ... 4.5 VDC
Sensor supply 5 V 250 mV
Measuring channel accuracy Less than 0.6 %
Resolution 12 bit
Additional information Reverse-battery protection to 36 V without affecting adjacent channels

(excepting GND)
E 531 685 / 01 E -- 08.98 --

Part 1
High-pressure pump pressure measuring input DEH (RAILPRESSURE)
Function Sensor
Pressure measuring between 0 ... 1500 bar Pressure sensor
Uref = 5 V
5V_BUF5 ECU 4
Fuse
p
IN
Filter
U R
GND
Pressure sensor
Cable
W3
Fig. 18 : Schematic diagram of pressure measuring input DEH
Channel DEH1
Measuring range Sensor-dependent
Output signal UOut 0.5 ... 4.5 VDC
Sensor supply 5 V 250 mV
Sensor accuracy 1 %
Measuring channel accuracy Less than 0.8 %
Additional information Reverse-battery protection to 36 V without affecting adjacent channels
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Part 1
1.7.3 Outputs on the plant side
1.7.3.1 Assignment of outputs on the plant side
The following signals are output in parallel to facilitate the acquisition of signals on the
plant side without using the CAN interface.
Signal Channel Designation in

connection diagram
Emergency stop TAA 1 TRANOUT 1
Automatic engine stop TAA 2 TRANOUT 2
Combined alarm TAA 3 TRANOUT 3
n > 300 rpm (engine running) TAA 4 TRANOUT 4
Power reduction active TAA 5 TRANOUT 5
Speed window TAA 6 TRANOUT 6
Engine speed UA 1 UOUT 1
Injection fuel flow/engine loading UA 2 UOUT 2
Oil pressure UA 3 UOUT 3
Coolant temperature UA 4 UOUT 4
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Part 1
1.7.3.2 Output specifications
Transistor outputs TAA 1 ... TAA 6
Function Target
Switching output Plant
UB = 24 V
OUT
GND
ECU 4
Cable
W003
Fig. 19 : Schematic diagram of transistor output TAA
Channel TAA1 ... TAA5
Output current IOut = 300 mA max.
Switching frequency Less than 2 Hz
Load inductivity Max. 140 mH
State after processor reset Switched off
Short-circuit protection Yes, channel switched off automatically in case of short-circuit
Line interruption detection Yes
Overvoltage/undervoltage Yes, transistor is switched off when supply voltage is outside the range
protection 11 V < UB < 42 V
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Part 1
Voltage outputs UA 1 ... UA 4
Function Target
Output voltage 0 ... 10 V, Plant

e.g. for display instruments
U = 15 V
OUT
GND
ECU 4
Cable
W003
Fig. 20 : Schematic diagram of transistor output TAA
Output voltage UOut = 0 ... 10 V
Output current IOut = 8 mA max.
Accuracy 2.5 %
Resolution Less than 40 mV
Protection All 4 voltage outputs multifused to ground
Short-circuit resistance Yes
Additional information Reverse-battery protection to 36 V, burst resistance to 1000 V
E 531 685 / 01 E -- 08.98 --

Part 1
1.7.4 Outputs on the engine side
1.7.4.1 Assignment of outputs on the engine side
The engine is controlled via the following signal outputs:
Signal Channel
ETC 2 switching valve TAM 1
Recirculation TAM 2
High-pressure pump PDM 2
Injection solenoid valves MVA 1 ... MVA 20

(depending on the number of cylinders)
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Part 1
1.7.4.2 Output specifications
Transistor outputs TAM 1 and TAM 2
Function Target
Switching output Engine
UB = 24 V
OUT
GND
ECU 4
Cable
W003
Fig. 21 : Schematic diagram of transistor output TAM
Channel TAM1 ... TAM6
Output current IOut = 1.5 A max.
Switching frequency Less than 2 Hz
Load inductivity Max. 140 mH
Short-circuit resistance Yes, channel switched off automatically in case of short-circuit
Overvoltage/undervoltage Yes, transistor is switched off when supply voltage is outside the range
protection 11 V < UB < 42 V, GND not protected
E 531 685 / 01 E -- 08.98 --

Part 1
Pulse width modulation output PDM 1
Function Target
Switching output Engine
UB = 24 V
ECU 4
Cable
W1
Fig. 22 : Schematic diagram of output PDM
Output current IOut = 5 A max. at a pulse duty factor of 50 %
Switching frequency fS < 500 Hz
Short-circuit resistance Yes, channel switched off automatically in case of short-circuit
Overvoltage/undervoltage Yes, transistor is switched off when supply voltage is out of range
protection 11 V < UB < 42 V
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Part 1
Solenoid valve outputs MVA 1 ... MVA 20
Function Target
Control of the injection nozzle solenoid valves Injection solenoid valve
SV 1
...
SV 20
ECU 4
Cable
W4
Fig. 23 : Schematic diagram of solenoid valve output MVA (injector control)
Output signal IOut max. = 20 A
Clock frequency fclock max. = 100 kHz
Short-circuit resistance Yes
Fault detection Open load/short-circuit/grounding
Additional information Reverse-battery protection to 36 V

Simple overlapping of SV 1--10 and SV 11--20
Solenoid valve motion monitoring
Programmable sequence control for injection valves
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Part 1
1.7.5 Bus connections
y RS232 Interface for dialog unit

y CAN1 CAN bus interface 1
y CAN2 CAN bus interface 2
1.7.5.1 Serial interface RS232
Channel Function Target
RS232 Serial interface for the transmission of data between Dialog unit
dialog unit and ECU 4
Connector XC6
RS232 RS232
TxD RxD
A
RxD TxD
Dialog B ECU 4
unit
GND GND
F
Dialog
cable
Fig. 24 : Schematic diagram of the dialog unit connection
Baud rate 9600 baud
Data format MTU format
Electrical isolation No
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Part 1
1.7.5.2 CAN bus interface
Channel Function Target
CAN1/ Bus connection to external systems MCS, RCS

CAN2
Electrical isolation
CAN (H)
Terminator
CAN BUS CAN (L)
CAN (GND)
ECU 4
Cable
W1
Fig. 25 : Schematic diagram of the CAN bus interface
Physical level ISO 11 898
CAN specification Version 2.0 A
Data format MTU specific (field bus 1)
Terminator In connector (bus not interrupted when connector removed)
Burst resistance In accordance with IEC1000-4-4
Baud rate 125 kbaud
Electrical isolation Yes
The CAN bus interfaces operate independently.
E 531 685 / 01 E -- 08.98 --

Part 1
1.8 Technical data
Type Engine Control Unit ECU 4
Dimensions (W x H x D) 455 mm x 277 mm x 91 mm

Height + approx. 230 mm for connector
Weight 7 kg
Housing Diecast aluminium housing
Colour/paint Same as engine
Mounting 4 x M6 x 60 hex-head bolt

Tightening torque 4 Nm
Connection 6 x bayonet connector
Grounding Is necessary (on engine)
Operating voltage
Continuous voltage 16.5 VDC ... 32 VDC
Temporarily restricted operation 11 VDC ... 36 VDC
Residual ripple Max. 8 Vpp
Power consumption 0.3 A ¤ 17 A
Heat dissipation Max. 35 W
Protection 30 A flat fuse
Max. housing temperature +75 oC
Relative humidity 0 %... 95 %, condensing
Degree of protection to DIN 40 050 IP 65
Shock 15 g, 11 ms semi-sinusoidal shock
Vibrostability
Frequency 2 Hz ... 25 Hz Travel amplitude xpp = á1.6 mm
Frequency 25 Hz ... 100 Hz Acceleration a = á4 g
Frequency 20 Hz ... 2000 Hz Smoke 1.3 g rms
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Part 1
EMC protection DIN EN 50081-2 and DIN EN 50082-2

IEC1000-4-2
IEC1000-4-3
IEC1000-4-4
IEC1000-4-5
IEC1000-4-6
Inputs
Plant side 9 x binary input
1 x frequency input
2 x analog input voltage/current
Engine side 3 x level input
2 x crankshaft/camshaft speed
2 x speed input
10 x temperature input
9 x pressure input
Outputs
Plant side 4 x voltage output 0 V ... 10 V
6 x transistor output 0.3 A
Engine side 4 x transistor output 1.5 A
Max. 20 x solenoid valve output injection valves
2 x PDM
Serial interfaces In accordance with RS232 (for dialog unit)

2 x High Speed CAN (acc. to ISO 11898)
Diagnostic display Four-figure LED display,

visible after opening the cover
Status display 5 x LED,

visible after opening the cover
y Reset
y +5 VDC
y +15 VDC
y --15 VDC
y +24 VDC
Pluggable data modules IDM (interface data module)

MEM 6 (engine data and program memory
module, accessible after opening the cover)
Configurable With dialog unit
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Part 1
(This page intentionally blank)
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Part 2
Operation
Part 2
Operation
(Not applicable)
E 531 685 / 01 E -- 08.98 --

Part 2
Operation
2 Bedienung
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Part 3
Maintenance and repair
Part 3

(Plant personnel)
E 531 685 / 01 E -- 08.98 --

Part 3
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Part 3
3 Maintenance and repair (Plant personnel)
3.1 Safety requirements
IMPORTANT
These safety requirements shall be read and observed by all
personnel involved in operation, care, maintenance or repair of the
products concerned.
Furthermore, the following shall be observed:

y The safety requirements (if provided) in other relevant MTU manuals
y Warning and safety notes and operating and limit values attached to the
products as required
y National accident prevention and safety standards
y Appropriate regulations usual in the industry
y 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 531 685 / 01 E -- 08.98 --

Part 3
Safety requirements for maintenance and repair

Maintenance and repair work shall be performed exactly and on schedule to ensure
constant readiness and reliability of the product.
Authorization must be obtained from the commanding officer prior to commencing mainte-
nance and repair work and switching off parts of the electronic system required for this.
Prior to working on assemblies, the power supply of the appropriate areas must be
switched off and secured against unauthorized switching on.
Any measures requiring power supply are expressly defined as such at the appropriate
place in the manual.
Maintenance and repair work shall be performed in accordance with the instructions in the
manual by authorized personnel.
Suitable tools, special MTU tools if necessary, shall be used for maintenance and repair
work.
Genuine spare parts only may be used to replace defective components or assemblies.
The manufacturer is in no way responsible for damage caused by using other spare parts.
The manufacturer’s guarantee is also voided in such cases.
The manufacturer shall not be held responsible if unauthorized changes or modifications
are made to the product and the guarantee shall be voided.
Spare parts shall be properly stored prior to replacement, i.e. particularly protected
against moisture. Defective electronic components and assemblies must be suitably
packed when despatched for repair, i.e. particularly protected against moisture and impact
and wrapped in antistatic foil if necessary.
Inform the MTU service department or its representative in case of damage which cannot
be rectified by plant personnel.
On completion of maintenance and repair work, ensure that no superfluous parts (tools
etc.) remain inside the device or system.
On completion of all repair work, the system must be subjected to a function check. Sepa-
rate testing of the repaired component without system integration is insufficient.
When working on the engine, suitable measures shall be taken to prevent accidental start-
ing.
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Part 3
3.2 Maintenance
3.2.1 General notes
This chapter lists work on the Engine Control Unit ECU 4 which is required in order to
maintain operational readiness. This work may be performed without the use of test and
measuring equipment.
Maintenance work on the Engine Control Unit ECU 4 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 operations in compliance with

instructions and within the time interval indicated can lead to fai-
CAUTION lure of the Engine Control Unit ECU 4 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 531 685 / 01 E -- 08.98 --

Part 3
Terminology and structure used in the documentation
This documentation makes a distinction between two concepts:

y Activities
An activity is the sum of all the steps which belong to part of a task (e.g. remov-
ing cover from 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)
y 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).
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.
-- 08.98 -- E 531 685 / 01 E

Part 3
Task overview
Task description
Activity/activities
Fig. 26 : 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.
E 531 685 / 01 E -- 08.98 --

Part 3
3.2.2 Maintenance work
3.2.2.1 Maintenance intervals
All work listed in the following table may be performed by plant personnel.
Maintenance work is performed at three different intervals:

y Maintenance echelon W2
The timing of these intervals is linked to the engine maintenance echelon W1 to W6 inter-
val.
Refer to the engine documentation for details on the timing of maintenance
work within the interval.
3.2.2.2 Task summary for scheduled maintenance work
The following table lists the maintenance work which should be performed together with
the areas affected.
Inter- Task Quali- Dura- Task ID Page Remarks

val ficat. tion
(appr.)
W4 Visual inspection PP 0.2 h T-P-ECU-0001 57 Immediately rectify
faults or errors detected
during the inspections
W4 Cleaning of Engine PP 0.2 h T-P-ECU-0002 62 Only to be performed if

Control Unit ECU 4 necessary
All work performed on one ECU 4 Engine Control Unit (e.g. port engine or star-
board engine) must then be performed separately on all the other ECU 4
Engine Control Units in the ship.
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Part 3
3.2.3 Task overview -- visual inspection

Ident. no.: T-P-ECU-0001
Required assemblies/equipment from complete PCS-5 system

y Engine Control Unit ECU 4 on the engine
y Sensors on the engine
y Wiring on the engine
y Wiring to peripheral assemblies and systems
y Cable ties as required
Recommended tools
y Torch
y Connector pliers
Reference documentation
y Engine documentation
y Documentation of Engine Control Unit ECU 4,
document no. E 531 685
Requirements
y Engine room accessible
y Engine at a standstill
Additional safety notes

y Observe general safety requirements: Chap. 3.1
y Observe specific safety instructions included in the descriptions of
activities
List of activities ID no.
1. Checking firm seating of connectors A-P-ECU-0012

Page 58
2. Checking firm seating of all cables A-P-ECU-0009,
Page 59
3. Checking all screwed sensor connections for leaks A-P-ECU-0010
Page 59
4. Checking wiring A-P-ECU-0008,
Page 61
The activities may be performed in any order.
E 531 685 / 01 E -- 08.98 --

Part 3
3.2.3.1 Checking firm seating of all connectors

Ident. no.: A-P-ECU-0012
Engine Control Unit ECU 4 (27/1) is

located on the end of the engine (auxiliary
PTO end).There are up to 5 connectors
3 (27/4) on the side of the housing (depend-
ing on engine equipment). The sixth
socket (27/3) is used to connect a dialog
unit and is closed off by a covering cap
during normal engine operation.
All other sockets which are not in use are

4 also closed off by a covering cap.
Proceed as follows to check firm seating

of the connectors on Engine Control Unit
ECU 4:
1. Attempt to turn the bayonet union nuts

(27/2) of the connectors on the side
gently by hand
2. If they move, tighten the bayonet
union nut (27/2) concerned by turning
it clockwise with connector pliers (see
fig. 28)
2 All electrical assemblies on the engine

1 (sensors, solenoid valves, final control
elements etc.) are connected to the
Fig. 27 : Connectors on Engine Control Unit engine cable harness by various plug con-
ECU 4 nections. Check firm seating of these plug
connections as well and plug them in and
secure them as required.
Fig. 28 : Connector pliers
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Part 3
3.2.3.2 Checking firm seating of cables

The cables on MTU/DDC series 4000

engines are routed in one or more cable
harnesses (depending on electrical equip-
ment). The cables are protected against
damage by plastic tubing (29/3). This tub-
1
ing is secured to the engine.
2
1. Check that the cable harnesses are
secured to the engine in their fixtures
(29/1) and do not hang free;
secure any loose cables in a suitable
manner
2. Check that the fixture fastening bolts
(29/2) are tight. Otherwise tighten
them using a suitable tool
3
3. Check for loose cable ties and fit new
cable ties as necessary
Fig. 29 : Cables on the engine
E 531 685 / 01 E -- 08.98 --

Part 3
3.2.3.3 Checking screwed sensor connections for leaks

The sensors on MTU/DDC series 4000 engines are screwed into the mechanical assem-
blies on the engine (pressure sensors, temperature sensors, speed sensors). Check the
screwed connections of these sensors for leaks.
1. Locate the sensor

2. Check for pressure medium leakage
at the sealing surface between engine
and sensor flange (liquid media leave
a trail);
tighten the screwed sensor connec-
tions with a suitable tool (open-end
wrench)
3. If it is not possible to seal off the
screwed connection in this way,
remove the sensor and fit a new seal
Fig. 30 : Example of a screwed sensor

connection
Sensor installation is described in the engine documentation. Consult this
manual before removing a sensor.
Please note that screwed level sensor connections are fitted with
an extremely low tightening torque. Excessive tightening destroys
this type of sensor. Refer to the engine description for details of
tightening torques.
CAUTION
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Part 3
3.2.3.4 Checking cables

1 Insulate damaged cabling immediately or

replace if severely damaged.
1. Inspect all engine cables

2. If the outer insulating sheath is dam-
aged and individual wires are visible
2
(example 31/1), it is sufficient to tape
up the cable with insulating tape pro-
viding that none of the individual wires
are damaged
3. If individual wires are bare or broken,
the cable harness (or the affected
part) must be replaced (example 31/2)
4. Check continuity in accordance with
the tables in Appendix A of this
manual. To do this, disconnect the
appropriate Engine Control Unit
Fig. 31 : Examples of damaged cabling
ECU 4 connector (see page 58) and
the connector on the assembly on the
engine (e.g. on a sensor). Short this connection then use a multimeter to check the electri-
cal connection between the appropriate pins in the connector of the ECU.
Example:
To check the cable connecting the speed sensor on the camshaft to the ECU:
y Disconnect connector X2 on Engine Control Unit ECU 4
y Disconnect the connector on the camshaft speed sensor, short these two con-
tacts with a strap
y Check continuity between pins T and n in connector X2 using a multimeter
y The cable in the cable harness is defective if there is no connection and the
cable harness must be replaced
E 531 685 / 01 E -- 08.98 --

Part 3
3.2.4 Task overview -- cleaning

Required assemblies
y Sensors on the engine
y Cabling on the engine
y Cabling to peripheral assemblies and systems
Recommended tools
y Soft, lint-free, non-abrasive cloth
y Isopropyl alcohol
Requirements

activities
y Never damage cables when cleaning
y Ensure that bayonet locks are properly fastened when reconnecting
1. Cleaning Engine Control Unit ECU 4 A-P-ECU-0001

Page 63
2. Cleaning connectors A-P-ECU-0002

Page 64
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Part 3
3.2.4.1 Cleaning Engine Control Unit ECU 4

Engine Control Unit ECU 4 (32/1) com-

prises a fully enclosed housing. All elec-
tronic assemblies of Engine Control Unit
ECU 4 are integrated in this housing.
1. Clean dirt off the surface of the hou-

sing with a cloth moistened with iso-
propyl alcohol
2. Check that the inscriptions on the
cables (32/2) are legible, otherwise
clean or replace
1 2
Fig. 32 : Cleaning Engine Control Unit ECU 4
Be careful to avoid damaging anything when cleaning, take care

not to loosen or disconnect any connectors on the housing -- par-
ticularly intermediate connectors between cable harness and sen-
sors.
CAUTION
E 531 685 / 01 E -- 08.98 --

Part 3
3.2.4.2 Cleaning connectors

Excessively dirty connectors may impair

operation in the long term. They should
therefore be cleaned thoroughly (remove
oil, grease, fuel etc.).
1. Clean the surface of the connector

(33/1) and the shrink-fit part on the
connector with a cloth soaked in iso-
propyl alcohol
2. Disconnect the connector if it is
extremely dirty (see page 58)
3. Clean the connector housing (33/2)
and the contacts thoroughly with iso-
propyl alcohol
4. Clean the connector socket on the
housing of Engine Control Unit ECU 4
thoroughly with isopropyl alcohol
5. Ensure that both connector and socket
are completely dry before connecting
up; connect up as described on page
2 58
1
Fig. 33 : Cleaning connectors on Engine Con-
trol Unit ECU 4
Be careful to avoid damaging anything when cleaning, take care

not to loosen or disconnect any connectors on the housing -- par-
ticularly intermediate connectors between cable harness and sen-
sors. Connect up as described on page 58.
CAUTION
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Part 3
3.3 Troubleshooting
3.3.1 Faults without fault code display
The table below lists obvious faults which may occur that are immediately apparent to the
operator.
No. Fault Cause(s) Countermeasures Task ID P.

1 Entire PCS-5 does not a) Supply voltage Are any other parts of
respond after switching unavailable the ship’s electrical
on system also out of
order?
b) Other ship’s
systems (or parts
thereof) also out of
operation d)
c) All other ship’s

systems operating
normally, only
PCS-5 is out of
order e)
d) Ship’s voltage Check other systems, Ship’s manual

missing switch on ship’s vol-
tage if necessary
e) PCS-5 power Visual inspection; reset

supply switched off, power circuit breakers
appropriate power if applicable
circuit breaker
tripped E 531 687
f) Key switch (if provi- Turn the key counter- Ship’s manual
ded) of the system clockwise, pull it out,
not switched on pro- then insert it again and
perly or not locked turn it clockwise as far
in place as it will go
g) Key switch faulty Replace the key switch Ship’s manual
>>
E 531 685 / 01 E -- 08.98 --

Part 3

>>
2 Engine Control Unit Has an emergency

ECU 4 out of operation stop (automatic or
manual) been tripped
at the Monitoring and
Control System; i.e.
has an alarm been
received?
a) Alarm received
c)
b) No alarm received
d)
c) Inadmissible opera- Check Monitoring and

ting values or emer- Control System
gency stop button
actuation have
resulted in emer- E 531 687
gency engine shut-
down
d) Fusible cutout in the Remove and check T-P-ECU-0004 98

engine control unit fusible cutout; replace
faulty as necessary
d) Upstream fusible Replace upstream Ship’s manual

cutout (if provided) fusible cutout
faulty
e) Supply voltage Switch the system on

switching relay and simultaneously
faulty check whether the
appropriate relay
switches (visual
inspection); if not, E 531 687
replace the relay
>>
-- 08.98 -- E 531 685 / 01 E

Part 3

>>
3 Speed cannot be chan- For RCS supplied by

ged in Local mode another manufacturer
only: Can the speed be
adjusted in Remote
mode?
a) Yes c)
b) No d)
c) Remote Local Check whether the

mode switching relay switches on swit-
relay faulty ching over to Local
mode; replace as
necessary E 531 687
d) ECU 4 is faulty Fault message by

ECU 4 or superordi-
nate assemblies
E 531 687 88
Replace ECU 4 T-P-ECU-0003
Appropriate system Repair pushbutton Appropriate

pushbutton faulty documentation
4 Engine cannot be Start possible in Local

started mode?
a) Yes c)
b) No d)
c) Fault in superordi- Check assemblies with Appropriate

nate assemblies reference to appro- documentation
priate documentation
Appropriate system Repair pushbutton

pushbutton faulty
d) Is the fusible cutout e) Yes Replace T-P-ECU-0004 98

in the engine control fusible cutout
unit faulty?
f) No g)
g) ECU 4 is faulty Fault message from T-P-ECU-0003 88

superordinate assem-
blies; replace ECU 4
E 531 685 / 01 E -- 08.98 --

Part 3
3.3.2 Faults with fault code display
In addition to the alarm messages on the Monitoring and Control System MCS-5, fault
codes are also indicated on a four-figure display on the printed circuit board in Engine
Control Unit ECU 4.
The fault code display has the following structure:
24 V --15 V +5 V +15 V Four-figure seven-segment display
Fig. 34 : LEDs and display in Engine Control Unit ECU 4
The four figures are defined as follows:

y The first figure indicates that a fault has occurred
(the example in fig. 34 shows: ))
y The second to fourth figures on the display indicate the three-figure fault code
(see table below, the example in fig. 34 shows: )
Open the housing cover to read off the display on the printed circuit board in
Engine Control Unit ECU 4 (see page 99).
-- 08.98 -- E 531 685 / 01 E

Part 3
Function may be impaired!

Excessive dirt in the ECU may impair operation of the engine
management system.
For this reason, the ECU must be closed again after reading off
CAUTION the display or finishing repair work. Ensure that the surface of the
seal is clean and that the cover is seated correctly.
Make sure that the interior of the housing is dry (no conden-
sation etc.) before closing!
The table below lists the fault codes and the appropriate measures for rectification.
Measures for fault rectification listed for the individual fault codes are described
in the chapter on “Repair”.
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
Fault Fault text
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Fault description Repair See
ÁÁÁÁ
code
009 L1 T-INTERCOOLER
Limit value 1 charge Reduce power
air coolant tempera-
ture
010 L2 T-INTERCOOLER Limit value 2 charge Reduce power E 531 687

air coolant tempera-
ture
ÁÁÁÁ
015 L1 P-LUBE OIL
Limit value 1 oil pres- Check oil level,
sure engine documentation
ÁÁÁÁ
016
ÁÁÁÁ
L2 P-LUBE OIL
Limit value 2 oil pres-
sure
Check oil level,
engine documentation
019 L1 T-EXHAUST A Limit value 1 exhaust Power reduction neces-

temperature engine sary
side A
021 L1 T-EXHAUST B Limit value 1 exhaust Power reduction neces- E 531 687
temperature engine sary
side B
ÁÁÁÁ
023 L1 COOLANT LEVEL
Limit value 1 coolant Check coolant level
level
024 L2 COOLANT LEVEL Limit value 2 coolant Check coolant level

level
>>
E 531 685 / 01 E – 08.98 –

Part 3
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
Fault Fault text Fault description Repair See
code
>>
ÁÁÁÁ
025 L1 P-OILFILTER DIFF.
Limit value 1 oil filter Check oil filter
differential pressure
ÁÁÁÁ
ÁÁÁÁ
027 L1 LEVEL LEAKAGEFUEL
Limit value 1 leakage
fuel
Seal off leaks in the fuel
line
ÁÁÁÁ
030 ENGINE OVERSPEED Engine overspeeding 1. Alarm reset
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 2. Attempt restarting
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ when the engine has
come to a standstill 1. E 531 687
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 3. Check additional 2. E 531 687
fault messages if the
engine does not start 3. E 531 687
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ 4. Inform specialist per- 4. Teil 4
sonnel if fault per-
sists
031 CHARGER1 OVERSPEED Exhaust turbocharger 1. Check air filter
1 overspeeding
2. Engine control auto-
matically reduces
power (system
response)
032 CHARGER2 OVERSPEED Exhaust turbocharger 1. Check air filter
2 overspeeding
2. Engine control auto-
matically reduces
power (system
response)
050 L1 COOLANT LEVEL EXT Limit value 1 coolant Check coolant level,
level for outer jacket check supply
cooling too low
>>
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Part 3
code
>>
051 L1 T-LUBE OIL Limit value 1 lube oil Power reduction neces-
temperature too high sary
E 531 687
057 L1 P-COOLANT Limit value 1 coolant Check coolant circuit

pressure too low
058 L2 P-COOLANT Limit value 2 coolant Check coolant circuit

pressure too low;
Engine shut down

automatically
063 L1 P-CRANKCASE Limit value 1 crank- Engine repair

case pressure too
high
064 L2 P-CRANKCASE Limit value 2 crank- Engine repair

case pressure too
high
065 L1 P-FUEL Limit value 1 fuel pres- Check fuel pump

sure (assignment con-
figurable)
067 L1 T-COOLANT Limit value 1 coolant Reduce power

temperature too high
E 531 687
068 L2 T-COOLANT Limit value 2 coolant Automatic engine power –
temperature too high reduction
ÁÁÁÁ
100
ÁÁÁÁ
EDM NOT VALID
Faulty engine data
checksum (Engine
Data Module,
EDM must be replaced
at the next scheduled
maintenance interval if
Part 4
EEPROM1) the fault persists
Engine control pos-
sible due to redundant
IDM
>>
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Part 3
code
>>
ÁÁÁÁ
101 IDM NOT VALID
Interface data check- Replace the IDM at the Part 4
sum faulty (Interface next scheduled mainte-
Data Module, nance interval if the
EEPROM2) fault persists
Engine control pos-
EDM
102 INVALID FUEL CONS. 1 Consumption display Replace the EDM at the Part 4
1 is invalid; fault in next scheduled mainte-
EDM (Engine Data nance interval if the
Module, EEPROM1) fault persists
ÁÁÁÁ
103 INVALID FUEL CONS. 2
Consumption display Replace the IDM at the Part 4
ÁÁÁÁ
2 is invalid; fault in
ÁÁÁÁÁÁÁÁÁ
IDM (Interface Data
next scheduled mainte-
nance interval if the
ÁÁÁÁ
104 OP HOURS1 NOT VALID
Operating hours coun- Replace the EDM at the Part 4
ter in EDM invalid next scheduled mainte-
(Engine Data Module, nance interval if the
ÁÁÁÁ
EEPROM1)
ÁÁÁÁÁÁÁÁÁ
fault persists
Operating hours coun-
ter remains in opera-
ÁÁÁÁ
tion due to redun-
dancy
ÁÁÁÁ
105 OP HOURS2 NOT VALID
Operating hours coun- Replace the IDM at the Part 4
ter in IDM invalid next scheduled mainte-
(Interface Data nance interval if the
ter remains in opera-
tion due to redun-
dancy
Error recorder 1 in Replace the EDM at the Part 4
106 ERR REC1 NOT VALID
EDM invalid (Engine next scheduled mainte-
Faults still recorded
due to redundancy
>>
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Part 3
code
>>
ÁÁÁÁ
107 ERR REC2 NOT VALID
Error recorder 2 in Replace the IDM at the Part 4
IDM invalid (Interface next scheduled mainte-
Faults still recorded
due to redundancy
118 L1 SUPPLY VOLT. LOW Limit value 1 supply Check the operating vol-
voltage too low tage of the engine
management system
with the ship’s voltmeter
(if available) Ship’s docu-
mentation
119 L2 SUPPLY VOLT. LOW Limit value 2 supply Check the operating vol-
voltage too low tage of the engine
management system
with the ship’s voltmeter
(if available) Ship’s docu-
mentation
120 L1 SUPPLY VOLT. HIGH Limit value 1 operating Check the operating vol-
voltage too high tage of the engine
management system
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ with the ship’s voltmeter
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ (if available) Ship’s docu-
mentation
121 L2 SUPPLY VOLT. HIGH Limit value 2 operating Check the operating vol-
voltage too high tage of the engine
management system
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ with the ship’s voltmeter
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ (if available) Ship’s docu-
mentation
The engine has been
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ shut down
>>
E 531 685 / 01 E – 08.98 –

Part 3
code
>>
ÁÁÁÁ
122 L1 T-ELECTRONIC
Limit value 1 internal 1. Ensure that the
housing temperature engine room is well
ventilated
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1. Ship’s
ÁÁÁÁ
docu-
mentation
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 2. Reduce power of the 2. E 531 687
ÁÁÁÁ
134 15V POS ECU DEFECT
Internal +15 VDC
engine(s)
Replace Engine Control T-P-ECU-0003

voltage missing Unit ECU 4 Page 88
Engine stopped auto-

matically
136 15V NEG ECU DEFECT Internal –15 VDC Replace Engine Control T-P-ECU-0003
voltage missing Unit ECU 4 Page 88

matically
137 L1 5V BUFFER TEST Pressure sensor Check cabling and A-P-ECU-0008

supply voltage faulty pressure sensors Page 61
A-P-ECU-0010
Page 60
138 SENSOR POWER DEFECT Pressure sensor Check cabling and A-P-ECU-0008
supply voltage faulty pressure sensors Page 61
A-P-ECU-0010
Page 60
139 L1 TE BUFFER TEST Temperature sensor Check cabling and A-P-ECU-0008

supply voltage faulty temperature sensors Page 61
140 TE BUF. ECU DEFECT Temperature sensor Check cabling and A-P-ECU-0008
supply voltage faulty temperature sensors Page 61
142 BANK1 ECU DEFECT Power amplifier for Replace Engine Control T-P-ECU-0003
solenoid valve activa- Unit ECU 4 Page 88
tion on bank 1 faulty
>>
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Part 3
code
>>
144 BANK2 ECU DEFECT Power amplifier for Replace Engine Control T-P-ECU-0003
solenoid valve activa- Unit ECU 4 Page 88
tion on bank 2 faulty
145 15V_GOOD ECU DEFECT Power supply faulty Replace Engine Control T-P-ECU-0003
Unit ECU 4 Page 88
ÁÁÁÁ
matically
146 L1 AD-TEST1 SUPPLY Internal electronic fault Replace Engine Control T-P-ECU-0003
Unit ECU 4 Page 88
matically
ÁÁÁÁ
147 AD TEST1 ECU DEFECT
Internal electronic fault Replace Engine Control T-P-ECU-0003
Unit ECU 4 Page 88
matically
148 L1 AD-TEST2 SUPPLY
Unit ECU 4 Page 88
matically
149 AD TEST2 ECU DEFECT Internal electronic fault Replace Engine Control T-P-ECU-0003
Unit ECU 4 Page 88
matically
ÁÁÁÁ
150 L1 AD-TEST3 SUPPLY
ÁÁÁÁ
matically
Unit ECU 4 Page 88
ÁÁÁÁ
ÁÁÁÁ
151 AD TEST3 ECU DEFECT ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Unit ECU 4 Page 88
matically
>>
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Part 3
code
>>
ÁÁÁÁ
170 MI MODULE FAIL
At least one module in No activity required if Fault no. 171
the maintenance indi- this fault does not occur
cator is faulty simultaneously with fault
no. 171, otherwise see
fault no. 171
171 MI NOT ACTIVE Maintenance indicator 1. Reload configuration Part 4
no longer active data
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
2. Replace EEPROMs
ÁÁÁÁ
172 TBO EXPIRED
Time between engine General engine over- –
overhaul expired haul by MTU
ÁÁÁÁ
173 MODULE WRITE LIMIT
Maintenance indicator Save all EEPROM data, Part 4
ÁÁÁÁ
EEPROM write limit
reached
use new EEPROMs and
restore saved data
180 CAN1 NODE LOST At least one node 1. Check CAN 1 (bus) T-P-ECU-0001
(station) on CAN 1 Page 57
monitored by Engine 2. Check nodes
Control Unit ECU 4 is
3. Rectify any interrup-
missing
tion
4. Replace faulty unit

as necessary
181 CAN2 NODE LOST At least one node 1. Check CAN 2 (bus) T-P-ECU-0001
(station) on CAN 2 Page 57
monitored by Engine 2. Check nodes
Control Unit ECU 4 is
3. Rectify any interrup-
missing
tion
4. Replace faulty unit

as necessary
>>
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Part 3
code
>>
ÁÁÁÁ
183 CAN NO PU-DATA
Configuration data Download configuration
must be used to initia- data using Backup Data
lize communication, Module BDM
however, there is no
valid configuration E 531 718
data module
ÁÁÁÁ
184 CAN PU-DATA EE-FAIL
One or both 1. Repeat procedure Part 4
EEPROMs could not
be completely pro- 2. Replace EEPROMs
grammed during confi-
guration data down-
load
185 CAN LESS MAILBOXES
186 CAN1 BUS OFF CAN1 in bus off state, 1. Check CAN bus for Part 4
there is either a short- short-circuits and
circuit on the bus or rectify as necessary
severe interference
caused by magnetic 2. Locate faults and
fields rectify as necessary,
improve shielding as
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ required
ÁÁÁÁ
187
ÁÁÁÁ
CAN1 ERROR PASSIVE
CAN1 in error passive
state, minor interfe-
1. Check that at least
one CAN station is
Part 4
rence on the bus or a available and check
CAN station is missing wiring as necessary
ÁÁÁÁ
2. Locate faults and
rectify as necessary,
required
188 CAN2 BUS OFF CAN2 in bus off state, 1. Check CAN bus for Part 4
there is either a short- short-circuits and
ÁÁÁÁ
circuit on the bus or
ÁÁÁÁÁÁÁÁÁ
severe interference
rectify as necessary
caused by magnetic 2. Locate faults and
fields
required
>>
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code
>>
ÁÁÁÁ
189 CAN2 ERROR PASSIVE
CAN2 in error passive 1. Check that at least Part 4
state, minor interfe- one CAN station is
rence on the bus or a available and check
CAN station is missing cabling as necessary
2. Locate faults and
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ required
201 SD T-COOLANT Coolant temperature 1. Check cabling, parti-
sensor fault cularly connectors,
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ and repair as neces-
sary
Ship’s docu-
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 2. Replace sensor B06 mentation
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ on the engine
ÁÁÁÁ
202 SD T-FUEL
Fuel temperature 1. Check cabling, parti- A-P-ECU-0008
sensor fault cularly connectors, Page 61
and repair as neces-
sary
2. Replace sensor B33
on the engine
ÁÁÁÁ
203 SD T-CHARGE AIR
Charge air tempera- 1. Check cabling, parti- A-P-ECU-0008
ture sensor fault cularly connectors, Page 61
sary
2. Replace sensor on
the engine
206 SD T-EXHAUST A Exhaust temperature 1. Check cabling, parti- A-P-ECU-0008

sensor fault engine cularly connectors, Page 61
side A and repair as neces-
sary
the engine
>>
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Part 3
code
>>
207 SD T-EXHAUST B Exhaust temperature 1. Check cabling, parti- A-P-ECU-0008

sensor fault engine cularly connectors, Page 61
side B and repair as neces-
sary
the engine
208 SD P-CHARGE AIR Charge air pressure 1. Check cabling, parti- A-P-ECU-0008
sary
the engine
ÁÁÁÁ
211 SD P-LUBE OIL
Lube oil pressure sen- 1. Check cabling, parti- A-P-ECU-0008
sor fault cularly connectors, Page 61
sary
the engine
ÁÁÁÁ
212 SD P-COOLANT Coolant pressure sen- 1. Check cabling, parti- A-P-ECU-0008
sor fault cularly connectors, Page 61
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ sary
ÁÁÁÁ
the engine
ÁÁÁÁ
214 SD P-CRANKCASE Crankcase pressure 1. Check cabling, parti- A-P-ECU-0008
ÁÁÁÁ
the engine
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ >>
E 531 685 / 01 E – 08.98 –

Part 3
code
>>
ÁÁÁÁ
215 SD P-RAIL FUEL
Common Rail fuel 1. Check cabling, parti- A-P-ECU-0008
pressure sensor fault cularly connectors, Page 61
sary
the engine
ÁÁÁÁ
216 SD T-LUBE OIL ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Lube oil temperature 1. Check cabling, parti- A-P-ECU-0008
sary
the engine
ÁÁÁÁ
219 SD T-INTAKE AIR
Charge air tempera- 1. Check cabling, parti- A-P-ECU-0008
ture sensor fault cularly connectors, Page 61
sary
the engine
ÁÁÁÁ
220 SD COOLANT LEVEL Coolant level 1 sensor 1. Check cabling, parti- A-P-ECU-0008
fault cularly connectors, Page 61
ÁÁÁÁ
the engine
ÁÁÁÁ
ÁÁÁÁ
221
ÁÁÁÁÁÁÁÁÁ
SD P-OILFILTER DIFF.
ÁÁÁÁÁÁÁÁÁ
Differential lube oil 1. Check cabling, parti- A-P-ECU-0008
pressure sensor fault cularly connectors, Page 61
sary
the engine
>>
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Part 3
code
>>
222 SD LEVEL LEAKAGEFUEL Leakage fuel sensor 1. Check cabling, parti- A-P-ECU-0008
sary
the engine
ÁÁÁÁ
230 SD CRANKSHAFT SPEED
Crankshaft angle 1. Check cabling, parti- A-P-ECU-0008
speed sensor fault cularly connectors, Page 61
sary
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
the engine
ÁÁÁÁ
231 SD CAMSHAFT SPEED
Camshaft angle speed 1. Check cabling, parti- A-P-ECU-0008
sary
the engine
ÁÁÁÁ
232 SD CHARGER SPEED 1 Charger speed 1 1. Check cabling, parti- A-P-ECU-0008
ÁÁÁÁ
2. Replace sensor B44
on the engine
ÁÁÁÁ
240 SD P-FUEL Fuel pressure sensor 1. Check cabling, parti- A-P-ECU-0008
ÁÁÁÁ
the engine
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ >>
E 531 685 / 01 E – 08.98 –

Part 3
code
>>
ÁÁÁÁ
245 SD POWER SUPPLY
Operating voltage Replace Engine Control T-P-ECU-0003
ÁÁÁÁ
246 SD T-ELECTRONIC
sensor fault
Electronic temperature
Unit ECU 4 Page 88
Replace Engine Control T-P-ECU-0003

measuring sensor Unit ECU 4 Page 88
fault
ÁÁÁÁ
249 SD CAN STOP
CAN stop signal sen- Check MCS-5 commu- Relevant Moni-
sor fault nication toring and Con-
trol System
MCS-5 docu-
mentation
250 SD CAN SPEED DEMAND CAN speed demand Check control lever or Relevant Re-
sensor fault or no PCS-5 communication mote Control
ÁÁÁÁ
communication with
RCS
System RCS-5
documentation
ÁÁÁÁ
251 SD CAN UP/DOWN
No data from Periphe- Check control lever or Relevant Re-
ral Interface Module PCS-5 communication mote Control
PIM System
RCS 5 docu-
RCS-5 docu
252 SD CAN NOTCH POS. No data from Periphe- Check control lever or mentation
ral Interface Module PCS-5 communication (e.g. RCS-5
PIM on the CAN bus FPP/B))
ÁÁÁÁ
253
ÁÁÁÁ
SD CAN OVERRIDE
No override signal
from MCS on the CAN
Check control lever or
PCS-5 communication
bus
ÁÁÁÁ
254
ÁÁÁÁ
SD CAN TEST OVERSP
No “Test overspeed”
signal on the CAN bus
Check control lever or
PCS-5 communication
ÁÁÁÁ
255 SD CAN ENGAGE SIGNAL
No “Engage” signal on Check control lever or
the CAN bus PCS-5 communication
>>
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Part 3
code
>>
ÁÁÁÁ
256 SD CAN CYL. CUTOUT
No “Cylinder cutout” Check control lever or Relevant Re-
signal on the CAN bus PCS-5 communication mote Control
System
257 SD CAN LOCAL No “Local mode” Check control lever or
RCS-5 docu-
signal on the CAN bus PCS-5 communication mentation
No “RCS engage” Check control lever or
(e.g. RCS-5
258 SD CAN RCS ENGAGE S.
FPP/B)
signal on the CAN bus PCS-5 communication
259 SD CAN RCS CYL.CUT. No “RCS cylinder Check control lever or
cutout” signal on the PCS-5 communication
ÁÁÁÁ
260 SD 15V POS SUPPLY
ÁÁÁÁÁÁÁÁÁ
CAN bus
Internal fault in Engine Replace Engine Control T-P-ECU-0003

Control Unit ECU 4; Unit ECU 4 Page 88
sensor fault +15 VDC
261 SD 15V NEG SUPPLY Internal fault in Engine Replace Engine Control T-P-ECU-0003
Control Unit ECU 4; Unit ECU 4 Page 88
sensor fault –15 VDC
262 SD 5V BUFFER TEST Internal fault in Engine Replace Engine Control T-P-ECU-0003
Control Unit ECU 4 Unit ECU 4 Page 88
263 SD TE BUFFER TEST Internal fault in Engine Replace Engine Control T-P-ECU-0003
264 SD BANK 1 TEST Internal fault in Engine Replace Engine Control T-P-ECU-0003
265 SD BANK 2 TEST Internal fault in Engine Replace Engine Control T-P-ECU-0003
266 SD SPEED DEMAND AN. External transmitter Check control lever and
for analog speed control lever wiring
demand faulty
E 531 616
>>
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code
>>
267 SD SP.DEM.TEST BENCH External transmitter Check potentiometer Special docu-

for test bench analog and wiring mentation for
speed demand faulty test bench
270 SD SPEED DEMAND FI1 Nominal speed fre- Check command unit Special docu-
quency demand signal and wiring and repair mentation for
faulty test bench
ÁÁÁÁ
279 SD CAN RES TRIP FUEL
CAN signal daily con- Check MCS-5 commu- Relevant Moni-
sumption display sen- nication toring and Con-
sor faulty trol System
MCS-5 docu-
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ mentation
CAN signal for alarm Check MCS-5 commu- Relevant Moni-
280 SD CAN ALARM RESET
reset sensor faulty nication toring and Con-
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ trol System
MCS-5 docu-
mentation
284 SD CAN LAMP TEST CAN signal for lamp Check MCS-5 commu- Relevant Moni-
test sensor faulty nication toring and Con-
trol System
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ MCS-5 docu-
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ mentation
ÁÁÁÁ
301
ÁÁÁÁ
TIMING BANK1 MV1
Timing Bank 1
solenoid valve 1
Replace injector con-
cerned if the fault mes-
Part 4
: sage is received perma-
: :
nently
310
TIMING BANK1 MV10 Timing Bank 1
solenoid valve 10
311 TIMING BANK2 MV1 Timing Bank 2 Replace injector con- Part 4
solenoid valve 1 cerned if the fault mes-
sage is received perma-
: : : nently
ÁÁÁÁ
ÁÁÁÁ
320 TIMING BANK2 MV10 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Timing Bank 2
solenoid valve 10
ÁÁÁÁ
321 WIRING BANK1 MV1
Wiring Bank 1 Check solenoid valve Part 4
solenoid valve 1
ÁÁÁÁ
:
ÁÁÁÁ
:
ÁÁÁÁÁÁÁÁÁ
:
ÁÁÁÁÁÁÁÁÁ
330 WIRING BANK1 MV10 Wiring Bank 1
solenoid valve 10
>>
– 08.98 – E 531 685 / 01 E

Part 3
code
>>
ÁÁÁÁ
331 WIRING BANK2 MV1
Wiring Bank 2 Check solenoid valve Part 4
solenoid valve 1
ÁÁÁÁ
:
ÁÁÁÁ
:
ÁÁÁÁÁÁÁÁÁ
:
ÁÁÁÁÁÁÁÁÁ
Wiring Bank 2
340 WIRING BANK2 MV10 solenoid valve 10
341 OPEN_LOAD BANK1 MV1 Open Load Bank 1 Check solenoid valve Part 4
solenoid valve 1
ÁÁÁÁ
ÁÁÁÁ
: : ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
: ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
350 OPEN_LOAD BANK1 MV10 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Open Load Bank 1
solenoid valve 10
ÁÁÁÁ
351 OPEN_LOAD BANK2 MV1
Open Load Bank 2 Check solenoid valve Part 4
ÁÁÁÁ
ÁÁÁÁ
: :
solenoid valve 1
:
ÁÁÁÁ
ÁÁÁÁ
360 OPEN_LOAD BANK2 MV10
Open Load Bank 2
solenoid valve 10
361 POWER STAGE FAIL 1 Fault in solenoid valve 1. Check solenoid valve A-P-ECU-0008
power stage bank 1 wiring Page 61
2. Replace Engine T-P-ECU-0003
Control Unit ECU 4 Page 88
362 POWER STAGE FAIL 2 Fault in solenoid valve 1. Check solenoid valve A-P-ECU-0008
power stage bank 2 wiring Page 61
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 2. Replace Engine T-P-ECU-0003
363 STOP POWER STAGE 1 Automatic engine stop 1. Check solenoid valve A-P-ECU-0008
due to fault in solenoid wiring Page 61
valve power stage
bank 1 2. Replace Engine T-P-ECU-0003
364 STOP POWER STAGE 2 Automatic engine stop 1. Check solenoid valve A-P-ECU-0008
due to fault in solenoid wiring Page 61
valve power stage
bank 2 2. Replace Engine T-P-ECU-0003
>>
E 531 685 / 01 E – 08.98 –

Part 3
code
>>
365 STOP MV-WIRING Automatic engine stop Check solenoid valve

due to faulty solenoid wiring
valve wiring
ÁÁÁÁ
ÁÁÁÁ
371
ÁÁÁÁÁÁÁÁÁ
TRAN.OUT1 ENGINE DEF
ÁÁÁÁÁÁÁÁÁ
Binary transistor out-
put engine 1 faulty
1. Check charger valve/ A-P-ECU-0008
wiring and repair as Page 61
ÁÁÁÁ
necessary
2. Replace Engine
T-P-ECU-0003
372 TRAN.OUT2 ENGINE DEF Binary transistor out- 1. Check recirculation A-P-ECU-0008
put engine 2 faulty valve/wiring and Page 61
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
replace as neces-
sary
T-P-ECU-0003
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 2. Replace Engine Page 88
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Control Unit ECU 4
ÁÁÁÁ
381 TRAN.OUT1 PLANT DEF
Binary transistor out- Check wiring to plant A-P-ECU-0008
put plant 1 faulty Page 61
ÁÁÁÁ
:
ÁÁÁÁ
:
ÁÁÁÁÁÁÁÁÁ
:
ÁÁÁÁÁÁÁÁÁ
386 TRAN.OUT6 PLANT DEF Binary transistor out-
put plant 6 faulty
– 08.98 – E 531 685 / 01 E

Part 3
3.3.3 Faults indicated by LEDs
The following voltages are monitored on the printed circuit board in Engine Control Unit
ECU 4:
y +24 VDC supply voltage
y +15 VDC (internal)
y --15 VDC (internal)
y +5 VDC (internal)
Faulty supply voltages are also indicated by fault codes (providing that Engine
Control Unit ECU is still operating) (see chap. 3.3.2). The following fault code
numbers are relevant: 118 ¤ 121, 133 ¤ 138, 145, 245 and 260 ¤ 262.
The state of the processor is indicated by:

y RESET/STOP
The processor system is RESET to a defined state. The engine is shut down.
Replace Engine Control Unit ECU 4 if one of the internal supply voltages is missing (the
corresponding LED is dark in this case). This also applies when the processor automati-
cally assumes the RESET/STOP state when the entire PCS-5 is switched off and back on
again.
Replacement of Engine Control Unit ECU 4 is described under task

T-P-ECU-0003.
E 531 685 / 01 E -- 08.98 --

Part 3
3.4 Repair
The repair work listed in the table is explained in the chapters below.
No. Task Quali- Dura- Task ID Page Remarks

ficat. tion
(appr.)
1 Replacing Engine PP 0.5 h T-P-ECU-0003 88 --
Control Unit ECU 4
2 Replacing the fusible PP 0.2 h T-P-ECU-0004 98 --

cutout in ECU 4
3.4.1 Replacing Engine Control Unit ECU 4

Required assemblies
y Replacement Engine Control Unit ECU 4 assembly
Recommended tools
y Set of double open-end wrenches
y Phillips screwdriver
Requirements


activities
y Engine Control Unit ECU 4 documentation, document no. E 531 685
-- 08.98 -- E 531 685 / 01 E

Part 3
Additional information
y The two memory modules must be transferred from the old Engine
Control Unit ECU 4 to the new one. Engine operation is otherwise not
possible.
1. Remove the housing of Engine Control Unit ECU 4 A-P-ECU-0004

from the engine Page 90
2. Remove the cover on Engine Control Unit ECU 4 A-P-ECU-0006
Page 92
3. Transferring the memory modules from A-P-ECU-0011
Engine Control Unit ECU 4 Page 93
4. Fitting the cover of Engine Control Unit ECU 4 A-P-ECU-0007
Page 95
5. Mounting the housing of Engine Control Unit ECU 4 A-P-ECU-0005
on the engine Page 96
E 531 685 / 01 E -- 08.98 --

Part 3
3.4.1.1 Removing the housing of Engine Control Unit ECU 4 from the engine
Engine Control Unit ECU 4 (35/1) is

2
located at one end of the engine (auxiliary
1 3 PTO end). It is bolted to the engine on two
10
brackets (35/4 and 35/8) with three cable
shock absorbers (35/3). The two adapter
plates (35/2 and 35/7) connect the hou-
4 sing of Engine Control Unit ECU 4 to the
cable shock absorbers.
Proceed as follows to remove Engine

Control Unit ECU 4:
1. Disconnect the connectors (35/5) on

the side one after the other:
2. Turn the bayonet nut (35/6) on the
connector counterclockwise
3. Pull the connector off the housing
4. Disconnect all connectors on Engine
Control Unit ECU 4 in the same way
5. Unscrew and remove the two hex-
head bolts (35/9 and 36/1) which con-
8 nect the housing of Engine Control
Unit ECU 4 (35/1) to the lower adapter
7 6 5
3 9 plate (bracket 35/7) (the hex-head
bolts are screwed into the back of the
Fig. 35 : Engine Control Unit ECU 4 on the housing of Engine Control Unit ECU 4)
engine
-- 08.98 -- E 531 685 / 01 E

Part 3
Hold the housing of Engine Control Unit ECU 4 to prevent it

falling down when the second bolt at the top is unscrewed.
CAUTION
6. Unscrew and remove the two hex-

2 head bolts (35/10 and 36/2) which
connect the housing of Engine Control
Unit ECU 4 to the upper adapter plate
(plate 35/2) (the hex-head bolts are
also screwed into the back of the hou-
sing of Engine Control Unit ECU 4)
7. Now remove the housing of Engine
Control Unit ECU 4 (36/3) from the
engine
8. Close off the connector sockets using
(plastic) covering caps (36/4) when
the housing of Engine Control Unit
ECU 4 is not mounted on the engine,
and until the connectors are plugged
back in, to prevent the ingress of dirt
4
3
1
Fig. 36 : Engine Control Unit ECU 4 dismoun-

ted
E 531 685 / 01 E -- 08.98 --

Part 3
3.4.1.2 Removing the cover of Engine Control Unit ECU 4

1. Place Engine Control Unit ECU 4 on a

flat surface with the sockets facing to-
wards you
2. The cover is secured on the housing
of Engine Control Unit ECU 4 with ten
Phillips screws. Undo them one after
the other using a Phillips screwdriver
3. One plain washer and one spring
washer are provided under each
screw; take care not to lose these
parts or drop them inside the housing
Fig. 37 : Unscrewing the cover
4. Pull the cover off; take care not to

damage the seal (sticking to the cover
etc.)
Fig. 38 : Removing the cover
-- 08.98 -- E 531 685 / 01 E

Part 3
3.4.1.3 Transferring the memory modules of Engine Control Unit ECU 4

The two data modules (engine data and

program memory EDM, 39/1 and interface
data module IDM, 39/2) must first be
removed from the old ECU. Proceed as
follows:
1. Take hold of the roughened surfaces

on data module MEM 6-01 (39/1) with
finger and thumb and pull it off printed
circuit board ECB 4-01 without twisting
2. Press the two levers on the snap-in
clips on the rear data module MEM 7
(39/2) together in the direction indi-
cated by the arrows with thumb and
2 forefinger
1
3. Pull the data module off out of its
socket
4. Remove the two (unprogrammed!)
data modules from the new ECU in
the same way
5. Transfer the two data modules from
the old ECU 4 to the new one; pro-
ceed as described in steps 6. through
8.
Fig. 39 : Data modules in Engine Control Unit

ECU 4
E 531 685 / 01 E -- 08.98 --

Part 3
3 Check polarity!
1
There is a mark
(40/4) indicating pin 1
on interface data
4 CAUTION module IDM and its
socket; these two
marks must be
1
aligned
6. Press the rear data module (40/3) into

the socket on printed circuit board
ECB 4-01 (40/2) until the clips (40/1)
snap into place
7. Place the front data module MEM 6-01
4 (41/1) on the two connector strips on
printed circuit board ECB 4-01 (41/2)
2
Fig. 40 : Inserting interface data module IDM

(MEM 7)
Check polarity!
If data module MEM
6-01 (41/1) is inser-
ted the wrong way
2 CAUTION round, it cannot be
1 pressed into the con-
3 nector strips. Turn it
round through 180 in
this case.
The module will be
destroyed if it is
forced in.
8. Carefully press data module MEM

6-01 (41/1) into the connector strips
as far as it will go
4
Fig. 41 : Inserting engine data and program

memory module EDM (MEM 6-01)
-- 08.98 -- E 531 685 / 01 E

Part 3
3.4.1.4 Fitting the cover of Engine Control Unit ECU 4

1. Check that the sealing cord is not

damaged, otherwise replace it
2. Ensure that the seal is firmly seated in
the groove in the housing
3. Fit the cover onto the housing of
Engine Control Unit ECU 4 making
sure it is positioned correctly; fit the
cover on the housing such that the
connector designations face the same
side as the connectors
Fig. 42 : Fitting the cover
4. Screw the ten screws together with

2 4
their plain and spring washers into the
threaded bores and tighten by hand
5. Tighten diagonally-opposed screws
one after the other (see example in
fig. 43, first screw (43/1), then screw
(43/2), then proceed with screw (43/3)
and screw (43/4), etc.)
1
3
Fig. 43 : Screwing down the cover
E 531 685 / 01 E -- 08.98 --

Part 3
3.4.1.5 Mounting the housing of Engine Control Unit ECU 4 on the engine
1. Place the Engine Control Unit on the

2 adapter plate (plate 44/5 and bracket
44/4)
2. Screw the two hex-head bolts (44/2)
through the plate (44/5) into the hou-
sing of Engine Control Unit ECU 4 by
hand
3. Screw the two hex-head bolts (44/1)
5
through the bracket (44/4) into the
housing of Engine Control Unit ECU 4
by hand
4. Tighten all four bolts with a suitable
open-end wrench
3
4 1
Fig. 44 : Engine Control Unit ECU 4 dismoun-

ted
-- 08.98 -- E 531 685 / 01 E

Part 3
5. Connect up the first connector plug

(45/1) of a cable harness to the
appropriate connector socket (45/2)
on Engine Control Unit ECU 4
6. Turn the bayonet union nuts (45/4)
clockwise until they lock into place
using connector pliers (45/3)
Do not tighten by
hand!
4
Tightening bayonet
union nuts by hand is
CAUTION not sufficient. There
is a risk that the lock
will not engage pro-
perly and that the
connector will come
2 loose during engine
operation. Always
1
use connector
3 pliers to turn the
union nuts!
Fig. 45 : Engine Control Unit ECU 4 on the
engine
E 531 685 / 01 E -- 08.98 --

Part 3
3.4.2 Replacing the fusible cutout in ECU 4

Required assemblies
y Spare fuse
Recommended tools
y Phillips screwdriver
y Engine Control Unit ECU 4 documentation, document no. E 531 685
Requirements

activities
Additional information
y Replace the fusible cutout with one of the same electrical rating (30 A)
only
1. Opening the housing by removing the cover A-P-ECU-0006,

Page 99
2. Replacing the fusible cutout A-P-ECU-0003

Page 100
3. Closing the housing by fitting the cover A-P-ECU-0007
Page 101
-- 08.98 -- E 531 685 / 01 E

Part 3
3.4.2.1 Removing the cover of Engine Control Unit ECU 4 when mounted on the
engine
The fusible cutout of the Engine Control

Unit is located on printed circuit board
ECB 4-01 inside Engine Control Unit
ECU 4. Replace as follows:
1. The cover is attached to the housing

of Engine Control Unit ECU 4 by ten
Phillips screws. Unscrew them one
after the other with a Phillips screw-
driver
2. There is a plain washer and a spring
washer under each screw. Take care
not to lose them or drop them into the
housing on removal
Fig. 46 : Removing the cover
Hold the cover on Engine Control Unit ECU 4 to prevent it falling

off when you undo the last screw.
CAUTION
3. Remove the cover; take care not to

damage the seal (sticking to the cover
etc.)
E 531 685 / 01 E -- 08.98 --

Part 3
3.4.2.2 Replacing the fusible cutout

1. The fusible cutout is located on the

right-hand side of printed circuit board
ECB 4-01 (see fig. 47); It can be
pulled out by hand
Always ensure that

fusible cutouts are
replaced by ones with
CAUTION the same electrical
rating. Electronic
assemblies may
otherwise be des-
troyed or fire may
break out.
Fig. 47 : Position of the fusible cutout
2. Check that the fusible cutout has actu-

ally blown by inspecting the wire
(48/3)
3 3. Insert a new fusible cutout (48/1)
(30 A) as shown in fig. 48 pressing it
into the socket (48/2) as far as it will
go
2
1
Fig. 48 : Replacing the fusible cutout
-- 08.98 -- E 531 685 / 01 E

Part 3
3.4.2.3 Fitting the cover of Engine Control Unit ECU 4 when mounted on the
engine
1. Check the cord seal for damage and

replace it if necessary
2 2. Ensure that the seal is properly seated
in the groove in the housing
3. Fit the cover onto the housing of
Engine Control Unit ECU 4 making
sure that it is positioned correctly; fit
the cover on the housing such that the
connector designations face the same
3
side as the connectors
2
4. Screw the ten screws with their plain
and spring washers into the threaded
bores and tighten by hand
4 5. Tighten diagonally-opposed screws
one after the other (see example in
fig. 49, first screw (49/1), then screw
(49/2), then screw (49/3) and screw
(49/4), etc.)
1
Fig. 49 : Fitting the cover
E 531 685 / 01 E -- 08.98 --

Part 3
-- 08.98 -- E 531 685 / 01 E

Part 4
Part 4

(Service personnel)
E 531 685 / 01 E -- 08.98 --

Part 4
-- 08.98 -- E 531 685 / 01 E

Part 4
4 Maintenance and repair (Service personnel)
4.1 Safety requirements
IMPORTANT
These safety requirements shall be read and observed by all
personnel involved in operation, care, maintenance or repair of the
products concerned.
Furthermore, the following shall be observed:

y The safety requirements (if provided) in other relevant MTU manuals
y Warning and safety notes and operating and limit values attached to the
products as required
y National accident prevention and safety standards
y Appropriate regulations usual in the industry
y 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 531 685 / 01 E -- 08.98 --

Part 4
Safety requirements for maintenance and repair

Maintenance and repair work shall be performed exactly and on schedule to ensure
constant readiness and reliability of the product.
Authorization must be obtained from the commanding officer prior to commencing mainte-
nance and repair work and switching off parts of the electronic system required for this.
Prior to working on assemblies, the power supply of the appropriate areas must be
switched off and secured against unauthorized switching on.
Any measures requiring power supply are expressly defined as such at the appropriate
place in the manual.
Maintenance and repair work shall be performed in accordance with the instructions in the
manual by authorized personnel.
Suitable tools, special MTU tools if necessary, shall be used for maintenance and repair
work.
Genuine spare parts only may be used to replace defective components or assemblies.
The manufacturer is in no way responsible for damage caused by using other spare parts.
The manufacturer’s guarantee is also voided in such cases.
The manufacturer shall not be held responsible if unauthorized changes or modifications
are made to the product and the guarantee shall be voided.
Spare parts shall be properly stored prior to replacement, i.e. particularly protected
against moisture. Defective electronic components and assemblies must be suitably
packed when despatched for repair, i.e. particularly protected against moisture and impact
and wrapped in antistatic foil if necessary.
Inform the MTU service department or its representative in case of damage which cannot
be rectified by plant personnel.
On completion of maintenance and repair work, ensure that no superfluous parts (tools
etc.) remain inside the device or system.
On completion of all repair work, the system must be subjected to a function check. Sepa-
rate testing of the repaired component without system integration is insufficient.
When working on the engine, suitable measures shall be taken to prevent accidental start-
ing.
-- 08.98 -- E 531 685 / 01 E

Part 4
4.2 Maintenance
4.2.1 General notes
This chapter explains work required on Engine Control Unit ECU 4 to maintain operational
readiness. This work cannot always be performed without using testing and measuring
equipment.
4.2.2 Maintenance work
The maintenance work on Engine Control Unit ECU 4 predominantly involves visual
checks which are described in part 3 of this manual.
System failure
If the following work is not performed in accordance with the

instructions, failure of Engine Control Unit ECU 4 or failure of the
CAUTION entire PCS-5 system may result.
If faults are detected, the fault cause can be pinpointed and the fault rectified in accor-
dance with the instructions contained in the following chapters.
4.3 Troubleshooting
4.3.1 Faults with fault code display
The fault code display and the structure of the fault codes are described in part 3 of this
manual (chap. 3.3.2). The following table lists those fault codes which require rectification
by trained service personnel only.
E 531 685 / 01 E -- 08.98 --

Part 4
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Fault
Fault text Fault description Rectification See
ÁÁÁÁ ÁÁÁÁÁÁ
code
030 ENGINE OVERSPEED Engine overspeeding 1. Alarm reset
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 2. Attempt restarting
ÁÁÁÁ
ÁÁÁÁÁÁ
when the engine
has come to a
standstill
2. Check additional
ÁÁÁÁ ÁÁÁÁÁÁ
fault messages if
the engine does not
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
start
4. Inform specialist
personnel if fault
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ persists
ÁÁÁÁ
100 EDM NOT VALID
Faulty engine data EDM must be replaced T-P-ECU-0402
ÁÁÁÁ
ÁÁÁÁÁÁÁÁ
Data Module, ÁÁÁÁÁÁ
checksum (Engine
ÁÁÁÁÁÁ
at the next scheduled
maintenance interval if
Page 119
EEPROM1) the fault persists
Engine control pos-
IDM
101 IDM NOT VALID Interface data check- Replace the IDM at the T-P-ECU-0401
sum faulty (Interface next scheduled mainte- Page 113
ÁÁÁÁ
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
EEPROM2)
ÁÁÁÁÁÁ
Engine control pos-
fault persists
ÁÁÁÁ
EDM
ÁÁÁÁ
104
ÁÁÁÁ
OP HOURS1 NOT VALID

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E531685 - 01 (MDEC For BR4000)

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Engine Control Unit

Quality assurance in design/development,

-- Guideline 73/23/EEC -- Low voltage guideline -- dated

-- Guideline 89/336/EEC -- Guideline on electromagnetic

CE conformity is influenced if the product is installed incorrectly, an assembly or system is

1 Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

E 531 685 / 01 E -- 08.98 --

Table of contents (cont.)

1.3.3 Engine stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.3.4 Emergency engine stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.3.5 Safety system override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.4 Engine monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.4.1 Engine protection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.4.2 Integral Test System (ITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.5 Status and fault displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.6 Communication and system integration via CAN bus . . . . . . . . . . . . . . . . . . 25

1.7 Inputs/outputs of Engine Control Unit ECU 4 . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.7.1 Inputs on the plant side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.7.2 Inputs on the engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.7.3 Outputs on the plant side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1.7.4 Outputs on the engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

1.7.5 Bus connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

-- 08.98 -- E 531 685 / 01 E

Table of contents (cont.)

1.8 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3 Maintenance and repair (Plant personnel) . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.1 Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.2.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.2.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3.2.3 Task overview -- visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3.2.4 Task overview -- cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

3.3.1 Faults without fault code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

3.3.2 Faults with fault code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3.3.3 Faults indicated by LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

3.4.1 Replacing Engine Control Unit ECU 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

E 531 685 / 01 E -- 08.98 --

Table of contents (cont.)

3.4.1.4 Fitting the cover of Engine Control Unit ECU 4 . . . . . . . . . . . . . . . . . . . . . . . . 95

3.4.2 Replacing the fusible cutout in ECU 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

4 Maintenance and repair (Service personnel) . . . . . . . . . . . . . . . . . . . . . . . 105

4.1 Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

4.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

4.2.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

4.2.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

4.3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

4.3.1 Faults with fault code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

4.4 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

4.4.1 Replacing data module IDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

4.4.2 Replacing data module EDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

4.5 Metrological tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

4.5.1 Testing the CAN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

-- 08.98 -- E 531 685 / 01 E

Table of contents (cont.)

5 Illustrated parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

5.2 Drawings and tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

5.3 Cross-reference list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Connector pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Input circuitry of the ECU channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

E 531 685 / 01 E -- 08.98 --

BR Baureihe, series (in this case engine series)

CAN Controller Area Network (bus designation)

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