E532291 01E ECU8 SmartConnect

MTU_ValueService
Technical Documentation
Electronic Engine Governor

ECU8
Series 1600 Genset
Functional Description
E532291/01E
ECU8 2
Printed in Germany
© 2011 Copyright MTU Friedrichshafen GmbH
This publication, including all of its parts, is protected by copyright. All use requires the prior written approval of MTU
Friedrichshafen GmbH. This applies, in particular, to any reproduction, dissemination, editing, translation, microfilming and
storage and/or processing in electronic systems, including databases and online services. The instructions in the manual must
be observed to prevent malfunctions or damage during operation. The operating company must therefore make the manual
available to all maintenance and operating personnel involved.
Subject to technical changes.
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1 ........ General information ..................................................................................................................................... 6

1.1 General requirements ..................................................................................................................................... 6
1.1.1 General information .................................................................................................................................................. 6
1.1.2 Intended use ............................................................................................................................................................. 6
1.1.3 Modification or conversion ........................................................................................................................................ 6
1.1.4 Spare parts ............................................................................................................................................................... 6
1.2 Safety requirements for maintenance and repair work .................................................................................. 7
1.2.1 Safety requirements for startup ................................................................................................................................ 7
1.2.2 Safety requirements for operation ............................................................................................................................ 7
1.2.3 Engine operation ...................................................................................................................................................... 7
1.2.4 Maintenance and repair work ................................................................................................................................... 7
1.2.5 Welding .................................................................................................................................................................... 8
1.2.6 Force-fitting............................................................................................................................................................... 9
1.2.7 Working on electrical/electronic assemblies ............................................................................................................. 9
1.2.8 Working with laser equipment................................................................................................................................... 9
1.2.9 Operation of electrical equipment ........................................................................................................................... 10
1.3 Engine side and cylinder designations ......................................................................................................... 11
2 ........ Overview ...................................................................................................................................................... 12
2.1 MTU Engine Control Unit ECU8 ................................................................................................................... 12
2.1.1 Overview ................................................................................................................................................................ 12
2.1.1.1 System devices ................................................................................................................................................ 12
2.1.2 Design .................................................................................................................................................................... 13
2.2 Scope of delivery .......................................................................................................................................... 14
2.2.1 Basic MTU equipment ............................................................................................................................................ 14
2.2.1.1 Engine sensors/actuators ................................................................................................................................ 14
2.2.1.2 Engine wiring + injector wiring ......................................................................................................................... 14
2.2.1.3 Engine Control Unit ECU8 ............................................................................................................................... 14
2.2.1.4 Connecting cables between Engine Control Unit and system / power supply.................................................. 14
2.2.1.5 24V DC supply voltage .................................................................................................................................... 14
2.2.1.6 SmartConnect .................................................................................................................................................. 14
2.2.2 OEM parts .............................................................................................................................................................. 14
2.2.2.1 External sensors .............................................................................................................................................. 14
2.2.2.2 Connecting cables for external sensors ........................................................................................................... 14
2.3 Customer interface / user devices ................................................................................................................ 15
2.3.1 System overview / customer interface .................................................................................................................... 15
2.3.1.1 Display instruments ......................................................................................................................................... 15
2.3.2 Additional notes ...................................................................................................................................................... 16
2.3.2.1 Pushbuttons ..................................................................................................................................................... 16
2.3.2.2 Alarm indicator lamps ...................................................................................................................................... 16
2.3.2.3 Indicator lamp .................................................................................................................................................. 16
2.4 Diagnosis and tools ...................................................................................................................................... 17
2.4.1 Self-diagnosis ......................................................................................................................................................... 17
2.4.1.1 Flashing frequencies ........................................................................................................................................ 18
2.4.2 DiaSys .................................................................................................................................................................... 19
2.4.3 SmartConnect......................................................................................................................................................... 20
2.4.3.1 Functional description ...................................................................................................................................... 20
2.4.3.2 Description of SmartConnect hardware ........................................................................................................... 20
2.4.3.3 Overview of interfaces ..................................................................................................................................... 21
2.4.3.4 Settings ............................................................................................................................................................ 23
2.4.4 Engine Identification Label EIL ............................................................................................................................... 26
3 ........ Use and design ........................................................................................................................................... 27
3.1 Functions ...................................................................................................................................................... 27
3.2 Ignition (IGI) / emergency stop (ESI) function .............................................................................................. 28
3.2.1 Ignition Input (IGI TL15) .......................................................................................................................................... 28
3.2.2 Emergency Stop Input (ESI) ................................................................................................................................... 28
3.3 Installation on the engine ............................................................................................................................. 29
3.3.1 Specification ........................................................................................................................................................... 29
3.3.2 Mechanical design / installation location ................................................................................................................. 29
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3.4 Technical data of ECU8................................................................................................................................ 30

3.5 Connector plugs ........................................................................................................................................... 32
3.5.1 Connector X1 / connector to Engine Control Unit ECU8 ........................................................................................ 32
3.5.1.1 Connector pin assignment ............................................................................................................................... 32
3.5.2 Connector X2 / engine wiring harness .................................................................................................................... 35
3.5.2.1 Connector pin assignment ............................................................................................................................... 35
4 ........ Sensors ....................................................................................................................................................... 39
4.1 Sensor installation locations ......................................................................................................................... 39
4.1.1 Sensors on Series 1600 12V / Series 1600 10V engines ....................................................................................... 39
4.1.1.1 Top (plan view) Series 1600 12V ..................................................................................................................... 39
4.1.1.2 Driving end....................................................................................................................................................... 40
4.1.1.3 Right engine side ............................................................................................................................................. 41
4.1.1.4 Top, seen diagonally from driving end ............................................................................................................. 42
4.2 Sensors used................................................................................................................................................ 43
4.2.1 Sensor types........................................................................................................................................................... 43
4.2.1.1 Pressure sensors ............................................................................................................................................. 43
4.2.1.2 Use .................................................................................................................................................................. 44
4.2.2 Speed sensors........................................................................................................................................................ 49
4.2.2.1 Use .................................................................................................................................................................. 49
4.2.3 Temperature sensors ............................................................................................................................................. 52
4.2.4 External sensors ..................................................................................................................................................... 54
5 ........ Wiring........................................................................................................................................................... 55
5.1 Power supply ................................................................................................................................................ 55
5.1.1 Power supply .......................................................................................................................................................... 55
5.1.1.1 General information ......................................................................................................................................... 55
5.1.1.2 Example for power supply configuration (recommendation) ............................................................................ 57
5.1.1.3 Master switch ................................................................................................................................................... 57
5.1.1.4 Power circuit breakers ..................................................................................................................................... 57
5.1.1.5 Pushbutton S003 ............................................................................................................................................. 57
5.1.1.6 Emergency stop ............................................................................................................................................... 57
5.1.2 Grounding concept ................................................................................................................................................. 58
5.1.2.1 Grounding concept .......................................................................................................................................... 58
5.1.3 CAN bus ................................................................................................................................................................. 59
5.1.3.1 General information ......................................................................................................................................... 59
5.1.3.2 Cabling requirements ....................................................................................................................................... 59
5.1.3.3 Block diagram .................................................................................................................................................. 59
5.2 Engine wiring harnesses .............................................................................................................................. 61
5.2.1 Sensor wiring harness ............................................................................................................................................ 61
5.2.1.1 RB1600 10V (ten cylinder V engine) and RB1600 12V (twelve cylinder V engine).......................................... 61
5.2.1.2 Connectors XY39A1 ... XY39B2 ...................................................................................................................... 62
5.2.1.3 62
5.2.1.4 Connectors M8.1 / M8.2................................................................................................................................... 62
5.2.2 Injector wiring harness ............................................................................................................................................ 63
5.3 System cables .............................................................................................................................................. 64
5.3.1 System wiring harness ........................................................................................................................................... 64
6 ........ System inputs and outputs ....................................................................................................................... 65
6.1 Overview of channel assignment ................................................................................................................. 65
6.1.1 System side ............................................................................................................................................................ 65
7 ........ Functions .................................................................................................................................................... 66
7.1 ECU8 signals ................................................................................................................................................ 66
7.1.1 Engine side – System side ..................................................................................................................................... 66
7.1.1.1 General information about the parameters ...................................................................................................... 66
7.1.1.2 Supply .............................................................................................................................................................. 66
7.1.1.3 Schematic circuit diagram ................................................................................................................................ 66
7.1.1.4 Ignition input IGI............................................................................................................................................... 67
7.1.1.6 Emergency stop input ...................................................................................................................................... 68
7.1.1.7 Technical Data ................................................................................................................................................. 68
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7.1.2 Binary inputs DI 1 ... 8 ............................................................................................................................................ 69

7.1.2.1 Technical data ................................................................................................................................................. 69
7.1.2.2 Required settings ............................................................................................................................................. 69
7.1.2.4 DI1 - Engine stop ............................................................................................................................................. 69
7.1.2.5 DI 2 – Speed droop .......................................................................................................................................... 69
7.1.2.6 DI 3 – Increase idle speed / switch over frequency .......................................................................................... 70
7.1.2.7 DI 4 – Alarm reset ............................................................................................................................................ 70
7.1.2.8 DI 5 – Engine speed increase (speed up) ........................................................................................................ 70
7.1.2.9 DI 6 – Engine speed decrease (speed down) .................................................................................................. 70
7.1.2.10 DI 7 – Engine start ........................................................................................................................................... 70
7.1.2.11 DI 8 – Override ................................................................................................................................................ 70
7.1.3 Analog inputs AI 1 ... 2 ........................................................................................................................................... 71
7.1.3.1 Technical data ................................................................................................................................................. 71
7.1.3.4 AI 1 - Speed demand ....................................................................................................................................... 71
7.1.3.5 AI 2 – Torque request ...................................................................................................................................... 72
7.1.4 Frequency input FIP ............................................................................................................................................... 72
7.1.4.1 Channel specification / technical data .............................................................................................................. 72
7.1.5 Transistor outputs TOP 1 ... 4................................................................................................................................. 73
7.1.5.4 TOP 1 - Yellow alarm ....................................................................................................................................... 73
7.1.5.5 TOP 2 - Red alarm ........................................................................................................................................... 73
7.1.5.6 TOP 3 – Oil pressure too low (lube oil stop) .................................................................................................... 74
7.1.5.7 TOP 4 – Starter on ........................................................................................................................................... 74
7.1.6 Analog outputs AO 1 ... 2 ....................................................................................................................................... 74
7.1.6.4 AO 1 – Cooling temperature ............................................................................................................................ 74
7.1.6.5 AO 2 - Oil pressure .......................................................................................................................................... 75
7.1.7 CAN interfaces 1 ... 2 ............................................................................................................................................. 75
7.1.7.4 CAN 1 – PCS5 ................................................................................................................................................. 75
7.1.7.5 CAN 2 – J1939 ................................................................................................................................................ 76
8 ........ Fault message table ................................................................................................................................... 77
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1 General information
1.1 General requirements
1.1.1 General information
In addition to the instructions in this publication, all relevant country-specific legislation and other compulsory
regulations regarding accident prevention and environmental protection must be observed. This engine is a state-
of-the-art product and conforms with all the relevant specifications and regulations. In spite of this, the engine can
still constitute a danger to personnel and property in the event of:
 • Incorrect use
 • Operation, maintenance and repair by unqualified personnel
 • Modification or conversion
 • Noncompliance with safety instructions
1.1.2 Intended use
The engine is intended exclusively for the application specified in the contract or defined at the time of delivery. Any
other use is considered improper use. The engine manufacturer shall not accept liability for any resultant damage.
Responsibility shall be borne by the user alone in such instances.
Intended use also includes observation of the operating instructions and compliance with the maintenance and
repair specifications.
1.1.3 Modification or conversion
Unauthorized modification of the engine compromises safety.
MTU shall accept no liability or warranty claims whatsoever for any damage caused by unauthorized modification
or conversion.
1.1.4 Spare parts
Only genuine MTU spare parts may be used to replace components or assemblies.
The engine manufacturer refuses to accept any liability or warranty claims whatsoever in the event of damage
caused by the use of other spare parts.
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1.2 Safety requirements for maintenance and repair work

1.2.1 Safety requirements for startup
Before first using the product, it must be installed in accordance with the instructions and approved to MTU
specifications..
Whenever the device or system is taken into operation
 • All maintenance and repair work must have been completed
 • Any loose parts must have been removed from rotating machine components
 • All personnel must be clear of the danger zone represented by moving parts
Immediately after taking the device or system into operation, the control and display elements as well as the
monitoring, signaling and alarm systems must be tested to ensure satisfactory operation.
1.2.2 Safety requirements for operation
The emergency procedures must be practiced on a regular basis.
The operator must be familiar with the control and display elements.
The operator must know the effects of any action he/she performs.
The operator must proceed with the individual steps as specified in the documentation.
During operation, the display elements and monitoring assemblies must be supervised with respect to current
operating states, violation of limit values as well as warnings and alarm messages.
If a fault in the system is detected or signaled by the system
 • Report it to the person in charge
 • Evaluate the message
 • Take emergency action as required, e.g. emergency engine stop
1.2.3 Engine operation
Wear ear protectors when the engine is running!
Ventilate the engine room adequately!
Mop up any leaked or spilled fluids and lubricants immediately, or soak them up with a suitable bonding agent.
Exhaust gases produced by combustion engines are toxic. Inhaling exhaust gases is harmful to health.
Exhaust gas pipework must be leak-tight and routed to atmosphere.
Do not touch battery or alternator terminals or cables when the engine is running!
Inadequate protection of electrical components can lead to electric shocks and serious injuries.
Never undo water, oil, fuel, compressed-air or hydraulic oil lines when the engine is running!
1.2.4 Maintenance and repair work
Strict adherence to maintenance and repair instructions is a significant safety factor.
Never perform maintenance or repair work with the engine running unless expressly permitted to do so. Lock-out
and tag-out the engine to preclude undesired starting. Disconnect the battery when electric starters are used. Close
the main valve of the compressed air system and vent the compressed air line when pneumatic starters are used.
Affix a “Do Not Start” sign in the operating room or attach one to the control facility! Keep bystanders out of the
way!
Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools
required! Maintenance and repair work may only be carried out by authorized, qualified personnel.
Only use adequate, calibrated tools.
Never work on engines or components which are only suspended on lifting gear or cranes. Always support them
adequately before commencing maintenance or repair work.
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Ensure that all personnel is clear of the danger zone before cranking the engine. Ensure that all safety guards are
installed and all tools and loose parts have been removed from the engine after performing work.
Escaping pressurized fluids can penetrate clothing and skin and cause serious injury. Depressurize fluid and
lubricant systems and compressed air lines before commencing work!
Never bend fuel injection lines or install lines which have been subsequently bent. Keep fuel injection lines and
their connections scrupulously clean. Seal off all openings with caps and covers whenever lines are removed or
opened.
Avoid damaging fuel lines in the course of maintenance and repair work. When installing, tighten line unions to the
specified tightening torques and ensure that all fixtures and dampers are fitted properly.
Ensure that all fuel injection lines and pressurized oil lines have sufficient clearance to prevent contact with other
components. Never route fuel or oil lines in the vicinity of hot parts unless explicitly intended for installation in such
areas by design.
Elastomers (e.g. Viton sealing rings) are generally safe under normal working conditions. However, when exposed
to fire or temperatures
exceeding 300 °C, the material decomposes. Hydrogen flouride vapors are released as a result. Acid produced in
this way causes serious burning by skin contact. Never touch elastomer seals which appear to be charred or
resinous with your bare hands! Always wear protective gloves!
Beware of hot fluids in lines, pipes and chambers Risk of burning!
Observe the cooling-down period for components which have been heated up to facilitate assembly or disassembly
Risk of burning!
Do not touch hot parts of the compressor and exhaust gas system Risk of burning!
Take care when removing vent screws or plugs on the engine. Cover the screw or plug with a rag to prevent fluids
escaping under pressure. The risk of accidents increases if the engine was only shut down a short time ago and
the fluids are still hot.
Take care when draining hot fluids and lubricants. Risk of scalding!
Catch fluids and lubricants in a vessel, wipe up spilled fluids or use binder.
Ventilate the engine room well when changing engine oil or working on the fuel system!
Use safe stepladders and work platforms when working above head height.
Ensure that engine components are set down safely!
To avoid back injury, adults may only lift parts weighing between max. 10 kg and max. 30 kg depending on age and
sex, therefore:
 Use lifting gear or call for assistance.
 Ensure that all chains, hooks, slings etc. are tested and approved, have adequate lifting
capacity and that hooks are positioned correctly. Never subject lifting eyes to lateral pull.
Keep everything meticulously clean when performing maintenance and repair work on the machine. Ensure that no
loose parts are left in/on the machine after completing maintenance and repair work.
1.2.5 Welding
Welding is not permitted on the engine or attached auxiliary equipment!
Never use the engine as a ground terminal! This prevents the welding current passing through the engine and
burning bearings, sliding surfaces and tooth flanks which can lead to seizure and damage.
Never route welding cables over or near the wiring harnesses of MTU systems. The welding current can induce
interfering voltages in the wiring harnesses which may damage the electrical system.
The ground terminal of the welding equipment must not be connected further than 60 cm away from the welding
point.
Remove any parts (e.g. exhaust pipe) requiring welding from the engine beforehand.
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It is not necessary to disconnect plugs and connectors from the MTU electronic system in order to perform welding
providing that the power supply master switch is set to “Off” and the battery cables are disconnected from the
positive and negative terminals.
1.2.6 Force-fitting
Use only the jigs and fixtures specified in the work schedule and assembly instructions to force parts on and off.
Never exceed the maximum admissible forcing pressure of the respective jig when forcing parts on and off.
The HP lines used to force parts on and off hydraulically are tested to 3,800 bar.
Never bend or use force on pressurized lines!
Note the following points before commencing any forcing process:
 Vent the forcing jig, pumps and pipework system at the relevant points of the system (e.g. open vent plugs,
pump until bubble-free oil emerges, close vent plugs).
 Screw the jig on with the piston retracted when forcing parts on.
 Screw the jig on with the piston extended when forcing parts off.
Screw the spindle into the shaft end until sealed on forcing jigs featuring a central expansion pressure supply.
Ensure that all personnel stands well clear when force-fitting and removing components hydraulically. There is a
risk of the component suddenly freeing itself from the pressurized fixture when the system is still under pressure.
Check all jigs and fixtures at regular intervals prior to use (crack testing).
1.2.7 Working on electrical/electronic assemblies
Always obtain permission from the person in charge before commencing maintenance and repair work and before
switching off any parts of the electronic system required to conduct such work.
Switch off the power supply of the affected areas before commencing work on any assembly. Any work requiring a
power supply is explicitly described as such in the appropriate sections of the manual.
Gases emanating from the battery are explosive. Avoid sparks and naked flames. Avoid skin and clothing contact
with battery acid (electrolyte). Wear goggles. Never place tools on the battery. Check polarity before connecting the
battery. Escaping acid or bursting battery cases may cause injury if battery polarity is reversed.
Avoid damaging cabling when removing parts, and re-install avoiding any risk of damaging the cabling by sharp
edges, friction or contact with hot surfaces when the engine is running.
Never secure cabling to pipework bearing fluids!
On completion of maintenance and repair work, any cables that have been disconnected must be reconnected
properly and appropriately secured.
Always test function and operation of devices and systems following repair. Checking repaired components in
isolation without integrating them in the overall system is not sufficient.
Secure cables with suitable cable clamps where contact with mechanical parts presents a risk of chafing!
Do not use cable ties as these can be removed for purposes of maintenance and repair and then not replaced on
completion.
Store spare parts properly prior to replacement, i.e. protect them from moisture in particular. Package faulty
electronic components and assemblies properly for transport, i.e. protect them from moisture and impact and wrap
them in antistatic foil if necessary.
1.2.8 Working with laser equipment
Always wear special laser goggles when working with laser equipment!
Laser equipment is capable of generating extremely intense beams of light by stimulated emission in the visible,
infrared or ultraviolet spectral ranges. Laser beams may cause damage as a result of their photochemical, thermal
or optomechanical effects. First and foremost is the risk of irreparable eye damage.
Laser equipment must be equipped with safety features which ensure safe operation in accordance with their
respective class and intended use.
Only the following laser equipment may be used as a guide beam and for surveying work:
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 Category 1, 2 or 3A laser equipment

 Category 3B laser equipment operating in the visible wavelength range (400 nm to 700 nm) with a
maximum output of 5 mW and with a beam axis or area aligned such as to preclude any risk of eye injury.
1.2.9 Operation of electrical equipment
Certain parts of the electrical equipment are live in operation.
Noncompliance with the warning instructions given for this equipment may result in serious injury or damage to
property.
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1.3 Engine side and cylinder designations

The engine is always viewed from the driving end when designating its sides.
Cylinders are designated (in accordance with DIN ISO 1204 ) A on the left side of the engine and B on the right
side. The cylinders of each bank are numbered consecutively beginning with number 1 on the driving end of the
engine.
Consecutive numbers of other components also begin with number 1 at the driving end of the engine.
1 KGS = Free end 3 KS = Driving end

2 Right engine side 4 Left engine side
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2 Overview
2.1 MTU Engine Control Unit ECU8
2.1.1 Overview
X1 System wiring harness

X2 Engine wiring harness
KV Coolant inlet
KR Coolant outlet
Engine Control Unit ECU8 has been especially developed for Series 1600 and may be used in conjunction with 6R,
8V, 10V and 12V engines.
It is particularly suitable for use in offroad applications such as genset, C&I and rail.
The injector output stage is only suitable for Common Rail systems.
It has three adjustable power levels – Bootpeak/Boost/Hold Current.
The housing is mounted directly on the engine by means of absorbers.
A coolant circuit for water or fuel is provided in the housing for applications involving high ambient temperatures
and heavy soiling.
2.1.1.1 System devices
Basic equipment for genset applications
 ECU8
 SmartConnect
Engine Control Unit ECU8 has been tailored for use in conjunction with the Common Rail technology used in
Series 1600 engines.
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2.1.2 Design
Inductors
Sensors
Starter
Alternator
Features:
BATT Battery
SmartConnect ECU programming unit
X1 System wiring harness
X2 Engine wiring harness
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2.2 Scope of delivery

2.2.1 Basic MTU equipment
The following devices, assemblies and components are included in the basic scope:
2.2.1.1 Engine sensors/actuators
All sensors and actuators required to control the Engine Control Unit are mounted directly on the engine.
2.2.1.2 Engine wiring + injector wiring
Engine wiring harness to connect all sensors to Engine Control Unit ECU8
Connection of all injectors to Engine Control Unit ECU8 (via window gasket)
2.2.1.3 Engine Control Unit ECU8
Open-/closed-loop control and monitoring of the engine (mounted on the engine)
2.2.1.4 Connecting cables between Engine Control Unit and system / power supply
Connecting cable from connector X1 of Engine Control Unit ECU8 to a terminal strip.
The connecting cable is open-ended and is available in the following lengths:
 6m
 10 m
 15 m
 25 m
2.2.1.5 24V DC supply voltage
24V DC power for the Engine Control Unit is supplied via the terminal block, connecting cable W1 and connector
X1.
The starter, battery-charging generator and other consumers must be supplied by external cable connections.
2.2.1.6 SmartConnect
This device allows a number of settings to be changed with having to use a DiaSys dialog unit. It also indicates
ECU fault codes on a four-figure display.
2.2.2 OEM parts
The OEM must supply the following parts:
 Instrumentation, e.g. indicator lamps, display instruments for:
 Engine speed
 Lube oil pressure
 Lube oil temperature
 Coolant temperature
 Controls, e.g. pushbuttons for “Start”, “Stop”, “Override” etc.
 Cabling for 24V DC power supply of starter, battery-charging generator etc.
2.2.2.1 External sensors
External sensors are available as an option for:
 Coolant probe
 Level switch “Water in fuel prefilter”
 Pressure sensor “Oil filter differential pressure”
 Lube oil temperature
Signals from these sensors must be acquired and evaluated by the OEM.
2.2.2.2 Connecting cables for external sensors
Connection of all external sensors to the system shall be established by
OEM connectors for connecting cables to external sensors
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2.3 Customer interface / user devices

2.3.1 System overview / customer interface
OEM MTU
Display instruments (AO1, AO2) Series 1600 10V / 12V engine with ECU8
Check lamps (TOP1 – TOP4) Wiring harnesses X1, X2 (internal engine wiring harness)
External controllers (DiaSys) SmartConnect
Terminal block / control box (K1)
Battery (BATT)
Generator controller (GS)
All the necessary devices/parts for monitoring and control of the engine required by the user to operate the system
are part of the OEM scope of delivery.
2.3.1.1 Display instruments
2 outputs supplying engine operating values are provided for analog display instruments (AO1 / AO2). These may
be used for the following instruments as desired:
 Engine speed
 Coolant temperature
 Lube oil pressure
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2.3.2 Additional notes

The number of control and display instruments depends on the application engineering and configuration of the
OEM.
This also applies to the inscriptions and colors used and the arrangement of the controls and display instruments.
The functions of the controls and displays which may be connected are explained in the table below.
2.3.2.1 Pushbuttons
The following pushbuttons may be provided:
Chan Name Type PV Description/function
nel
DI1 ENGINE STOP Pushbutton 2.7001.800 Pressing the pushbutton trips the stopping sequence without switching off
the Engine Control Unit.
DI2 SWITCH SPEED Switch 2.1060.830 Switches between two speed droop settings.
DROOP
DI3 SWITCH 50/60HZ Switch 2.7003.800 Switches between two generator frequencies 50Hz and 60Hz.
DI4 ALARM RESET Pushbutton 2.8009.021 Pressing the pushbutton switches alarm signaling off. Pressing the
pushbutton acknowledges the alarm.
DI5 SPEED UP Pushbutton 2.1060.800 Pressing the pushbutton increases engine speed.
DI6 SPEED DOWN Pushbutton 2.1060.810 Pressing the pushbutton decreases engine speed.
DI7 START Pushbutton 2.1090.800 Pressing the pushbutton trips the automatic engine start sequence.
DI8 OVERRIDE Pushbutton 2.7002.800 Pressing the pushbutton temporarily bypasses the safety system.
2.3.2.2 Alarm indicator lamps

The alarm indicator lamps provide information about the operating state of the engine.
Channel Color Inscription Meaning/function
TOP1 Yellow YELLOW ALARM Summary alarm indicator lamp, lights up when a so-called “yellow alarm” has been
tripped, engine power may be reduced automatically.
TOP2 Red RED ALARM Summary alarm indicator lamp, lights up when a so-called “red alarm” has been tripped,
engine may be shut down automatically.
2.3.2.3 Indicator lamp

The indicator lamp provides information about the starting state of the engine
Channel Color Inscription Meaning/function
TOP3 Red LUBE OIL STOP Oil pressure too low
TOP4 Green Starter ON Activation of the starter
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2.4 Diagnosis and tools

2.4.1 Self-diagnosis
ECU8 features a diagnosis lamp to indicate a system malfunction to the operator on location.
Position of the diagnosis lamp on ECU8 (1)
1 Diagnosis lamp
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2.4.1.1 Flashing frequencies
1 Governor is ready for operation 4 External RAM faulty

2 Application loader is active 5 External flash memory faulty
3 Internal fault detected by ITS 6 No firmware
7 Application failed
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2.4.2 DiaSys
1 Laptop
2 CD-ROM with DiaSys 2.53 software (SP1 or higher)
The dialog system DiaSys® is available for more extensive fault diagnosis of the electronic system. It comprises a
laptop with the program DiaSys® 2.53 SP1 (or higher), a user dongle (hardkey) and a CAN interface.
The main purpose of the dialog system is to change ECU8 settings.
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ECU8 20
2.4.3 SmartConnect
2.4.3.1 Functional description
SmartConnect features:
1 DIP switches to change speed demand, frequency and droop settings
2 Four-figure display to indicate ECU fault numbers
3 Interface to connect DiaSys
SmartConnect comprises a unit equipped with connectors and a display and includes pre-programmed software.
2.4.3.2 Description of SmartConnect hardware
SmartConnect visualizes faults from the connected ECU which are transmitted on CAN1. It also allows specific
modes to be set for various applications using DIP switches.
It is possible to connect dialog systems (CAN1 and CAN2) via the additional DIASYS connector with a 24V supply
for dialog PCs. Software and parameters can be downloaded to the ECU via a USB flash stick (USB -> RS485).
Note: The USB interface and RS485 to the ECU are not active in SC1-01.
The figure below provides an overview of the interfaces and features of

SmartConnect SC1-01. The housing is designed for installation on a DIN rail.
DIASYS connector for dialog

with MTU Service
USB interface for
memory sticks
4-figure display
for fault indication
DIP switches for system

configuration setting CAN2 (J1939)
CAN1 (MTU internal)
RS485 –fast data communication
24V supply
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ECU8 21
The block circuit diagram shows the internal design of the SmartConnect. The main assembly is the NXP
microcontroller which realizes all functions.
The integral CAN repeater before the DiaSys interface means that the limitations presented by the approx. 1-2 m
long connecting cable no longer apply. A significantly longer cable can be connected here (up to 50 m).
Bus termination with the two 120 ohm resistors at the two CAN interfaces CAN1 and CAN2 can be configured, i.e.
these termination resistors must be removed from the two connectors if additional devices featuring CAN interfaces
are connected there.
2.4.3.3 Overview of interfaces

2.4.3.3.1 Alarms
Alarm number Zkp number German designation English designation
AL SmartConnect USB AL SmartConnect USB
696 2.0560.900
Error Error
AL SmartConnect RS485 AL SmartConnect RS485
697 2.0560.902
Error Error
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ECU8 22
2.4.3.3.2 Connector assignment of SC1-01
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ECU8 23
2.4.3.3.3 System image SC <-> ECU8
Switchgear cabinet
CAN terminating resistor

depending on bus conf.
In connector
System cable
Note: SmartConnect SC 1-01 must be protected by a 4 A fuse.
2.4.3.4 Settings
2.4.3.4.1 Summary of DIP switch functions
The SmartConnect unit is equipped with 6 DIP switches which allow ECU8 to be configured (there are a total of
eight switches, however the last two switches, 7 and 8, are only used internally by the SmartConnect).
The switch settings on the SmartConnect are transmitted cyclically to the ECU once per second in a message on
CAN1.
Changes to the switch settings only take effect after restarting the ECU.
The configurations which can be set with the switches are preset and cannot be changed. The figures below show
the assignment of the switches. Switch no. 6 has no function in the present SmartConnect version as CANopen is
not implemented as yet. In future, this switch will allow a choice between J1939 and CANopen for CAN2 as soon
as CANopen is available. J1939 only is used on CAN2 at the current time.
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ECU8 24
The figure below shows the assignment of the 8 DIP switches.
Used by TKE
Speed demand is set as follows:
Speed demand
The speed demand can be set using the three switches (i.e. 8 variants)
Switch default settings:
000 = 0 = ECU parameter default settings = Speed demand up/down direct
(variants 1 and 2 would thus be identical)
2.4.3.4.2 Summary of alarm display functions

The three-figure ECU fault numbers are shown on the display of the SmartConnect unit when it is running. The
ECU fault numbers run as a banner on the display. This means that all active faults in the ECU are displayed
consecutively at one-second intervals. “----” appears on the display of the SmartConnect unit for one second when
every active fault has been displayed once. This indicates that all faults have been displayed once and that the
fault numbers now appear again from the beginning.
“----” remains steady on the display if not fault numbers have been received from the ECU.
The ECU transmits the faults displayed on the SmartConnect unit via CAN1.
Fault code “F000” is indicated on the display if the SmartConnect unit fails to detect ECU8 on CAN1 (e.g. as the
cable has not been connected).
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ECU8 25
The following two fault numbers are assigned to the SmartConnect unit:
 Fault number 696 (USB faulty)
 Fault number 697 (RS485 faulty)
These two faults also run as a banner on the display and are written in the ECU8 fault memory. Should these faults
occur at the SmartConnect unit and no ECU8 is connected to CAN1, the SmartConnect displays fault number F050
instead of 696 in case of a USB fault and fault number F051 instead of 697.
The table below lists all alarms:
Alarm number on SC Alarms on SC
display when no display when ECU8
Description
ECU8 is detected on is connected to
the CAN1 bus CAN1 bus
This alarm appears on the SmartConnect display when no ECU8
F000
is detected on the Can1 bus.
AL SmartConnect USB Error This alarm is displayed when a
fault has occurred at the USB interface of the SmartConnect
F050 696 unit. This alarm is transmitted to ECU8 when one is connected
to the CAN1 bus. 696 then appears on the display. F050
appears on the display instead if ECU8 is not present.
AL SmartConnect RS485 Error. This alarm is displayed when a
fault has occurred at the RS485 interface of the SmartConnect
F051 697 unit. This alarm is transmitted to ECU8 when one is connected
to the CAN1 bus. 697 then appears on the display. F051
appears on the display instead if ECU8 is not present.
Three-figure fault code number from ECU8 depending on the
0001 – 0999
faults signaled in ECU8.
Currently free range of numbers for SmartConnect alarms when
F001 – F0049 no ECU8 is present on the CAN1 bus. These alarms are not
transmitted to the ECU.
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ECU8 26
2.4.4 Engine Identification Label EIL

The Engine Ident Label EIL is an electronic rating plate. It is attached to the engine, cannot be removed and is an
absolute necessity to operate the engine.
The EIL is connected to the ECU by a two-pin connector on the engine wiring harness. For trouble-free operation
ensure that the wiring between EIL and ECU is connected properly. Check the wiring if the “616 AL EIL Error”
fault message is signaled.
Furthermore, the EIL must be inspected periodically for visible damage or manipulation.
The EIL ensures that only the data record specifically programmed for the engine concerned can be used. The
engine is shut down after 15 minutes should it be necessary to use the ECU of another engine on the engine
concerned. The “615 AL EIL Protection” yellow alarm and the “454 SS Power Reduction Active” red alarm are
signaled during this period. This makes it possible to pinpoint or narrow down the cause of a fault by replacing with
an ECU from another engine.
In case of fault, a new ECU must be ordered from MTU including a valid data record for the engine concerned and
then installed.
Note: Manipulation of the EIL renders the warranty null and void. Furthermore, normal engine operation is
subsequently no longer possible.
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ECU8 27
3 Use and design

3.1 Functions
Central open- and closed-loop control unit of the engine

 Converts setpoint signals from the monitoring, control and remote control systems into signals to control the
engine
 Controls the injection system
 Controls other actuators on the engine
 Acquires sensor signals and evaluates engine operating states
 Monitors limit values for violation, initiates engine stop in case of inadmissible states/limit value violations if
necessary.
 Transmits fault messages to monitoring and control systems
 Downloads engine- and system-related configuration data.
 Self-monitoring ITS
 Diagnosis with dialog unit (laptop)
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ECU8 28
3.2 Ignition (IGI) / emergency stop (ESI) function

3.2.1 Ignition Input (IGI TL15)
The IGI input can be used for two functions:
1. ECU on/off when power supply is applied to the unit (TL 30).
2. Emergency stop function working on the “closed-circuit principle”
The input is connected to 24V (UBatt) if the function is not used.
The user can switch the unit on/off with the IGI input as follows:
 Input level = low to high - “wake”
The ECU is activated, the microcontroller boots up, executes its “start up” routine and keeps the power
stage “locked on”.
 Input level = low to high - “power down”
Deactivates the IOS (Injector Output Stage) for all cylinders. This state is stored and can only be reset by
the software. All data and alarms saved “Data Storage”. Internal supply voltages switched off.
The response of the ECU can be configured by the application software when the ESI has been activated (CAN
message, ...)
3.2.2 Emergency Stop Input (ESI)
Completely de-energizing the Engine Control Unit in order to initiate an emergency engine stop is INADMISSIBLE!
The ESI input is activated by a NO contact connected to UBatt (24V).
The input is not connected if the function is not used.
The ESI input immediately switches off the IOS (Injector Output Stage) by the hardware.
The engine is stopped immediately in this way. Engine data and alarms are then stored in the external flash
memory.
 Input level = low ->
The ECU detects this input state as a disruption when a 33kohm ±10% parallel resistor is connected. The
function can be programmed in the software.
 Input level = high ->
Deactivates the IOS (Injector Output Stage) for all cylinders. This state is stored and can only be reset by
the software. “Open-circuit principle”"
The response of the ECU can be configured by the software when the ESI has been activated (CAN message, ...)
Connection diagram and principle IGI / ESI function
ECU8 Engine Control Unit S1 Master switch

A Additional units IGI Ignition start
B Battery ESI Safety stop
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ECU8 29
3.3 Installation on the engine

3.3.1 Specification
Engine Control Unit ECU8 (ADEC) has been designed in regard of mechanical and thermal stress for mounting
directly on the engine (see technical data).
Ambient temperature –40°C to +80°C
Housing temperature range under extreme conditions with coolant flow (70°C media temperature) – 40°C to
+120°C
3.3.2 Mechanical design / installation location
Engine Control Unit ECU8 is mounted securely on the top of the engine towards the driving end on 10V and 12 V
engines and is easily accessible.
Off-engine installation is not possible.
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ECU8 30
3.4 Technical data of ECU8

Term Unit Value
Housing material AlSi10Mg
Dimensions (length x width mm 298 x 272 x 93
x height)
Draw-out clearance (height) mm 74
Weight (without cable kg 4.5
connection)
Installation position As desired
Operating voltage VDC 16.8V ...24V ...32V (normal operation, injection w/o power reduction)
14.4V ...16.8V (emergency operation, injection with power reduction)
Power consumption A 0.2 ... 18 (typ.)
33 max. at 24V (engine running)
10mA when IGI off (ignition off)
0.2A when IGI on (ignition on, engine off)
Thermal output w 45
Grounding Necessary, via grounding strip
EMC DIN ISO 7637-2 : 2002 (C&I International (SAEJ1113-13:2000))
DIN ISO 7637-3 : 1995 (C&I International)
DIN ISO11452-2 : 2000 (SAEJ1113-21 : 1998), (CE Classification)
EN 55011 : 2000 Curve A (CE Classification (industrial))
EN 55011 : 2000 Curve A (CE Classification (industrial) CISPR 11)
EN 55025 : 2003 (Vehicle, Marine (CISPR 11), SAEJ1113-41:2000)
EN 50121-3-2 : 2001 (Rail Curve A + 10dB)
EN 50155 (Rail)
EN 55025 : 2003 (C&I International (CISPR 25))
EN 61000-4-2 : 2001 (IEC 61000-4-2), (Marine classified / Rail)
EN 61000-4-4 : 2004 (IEC 61000-4-4), (Rail)
EN 61000-4 : 2006 (IEC 61000-4-4), (Rail)
EN 61000-4-5 : 2004 (IEC 61000-4-5), (Marine classified)
EN 61000-4-6 : 2001 (IEC 61000-4-6), (Marine classified)
EN 61000-4-17 : 2000 (Marine classified)
EN 61000-6-2 (CE industrial)
EN 13390 : 2000 (ISO13766), (C&I International)
IEC 60533 : 1990 (Marine classified (CISPR 16))
IEC 60533 : 1999 (Marine classified (CISPR 16))
ISO 10605 : 2001 (C&I International (SAEJ1113-13:2000))
Dielectric strength 10 m (IEC 60092-504)
Utest  50 VDC (ECU8 removed for testing)
500 VDC in accordance with EN 50155
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ECU8 31
Term Unit Value

ESD EN 61000-4-2 : 2001 (IEC 61000-4-2)
EN 50121-3-2, EN50155 Rail
IEC 60533 Civil Marine
EN 61000-6-2 CE industrial
ISO 10605 : 2001 (C&I International)
Operational ambient °C - 40 ... + 80 (up to 95°C max. 60 minutes, with air circulation at min.
temperature >2m/min)
Storage temperature range °C - 40 ... + 85
Housing temperature °C + 105 max. (cooling to below 75°C after 60 min)
Relative air humidity % 0 ... 95%, condensing
Degree of protection Plugs connected IP69K (IEC 60529, DIN 40050)
Open (plugs not connected) IP20
With connector caps IP54
Shock resistance ICE 600-2-32 drop test
ICE 68-2-27 (30g / 11ms)
Vibrostability ICE 60068-2-6 (requirements for the x/y/z axis 5Hz 2000Hz)
Electrical noise, ECU 4.7 grms at 5Hz ... 20Hz
housing 4.7 grms at 20Hz ... 150 Hz
4.7 grms at 150Hz ... 300 Hz
4.7 grms at 300Hz ... 1000 Hz
4.7 grms at 1000Hz ... 2000 Hz
Resistance to chemical EN 60271-1-3-5 (MTU requirements: EU standards, diesel fuel,
substances biodiesel, oil, coolant)
MTBF h 20000 (at an ambient temperature of 75°C
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ECU8 32
3.5 Connector plugs

3.5.1 Connector X1 / connector to Engine Control Unit ECU8
3.5.1.1 Connector pin assignment
Pin assignment X1 (system cable) 62 pole (6 x MCP2.8; 54 x MCP1.5)
Lock: Bayonet with multiple lugs
This connector is the interface to the system.

The table below describes the connector pin assignment of connector X1. The brief specification states the most
important characteristics of the channel concerned.
Designation Pin Signal type Brief specification

CAN1_P 1 CAN1_P_H 50V isolated
CAN1_P 2 CAN1_P_L
CAN1_P 5 CAN1_P_GND
CAN2_P 3 CAN2_P_H 50V isolated
CAN2_P 4 CAN2_P_L
CAN2_P 8 CAN2_P_GND
DI1 10 DI1_H <4V(<1.1mA) = low / >8V (>1.5mA) = high
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ECU8 33

DI1 9 DI1_L 50V isolated
I2 14 DI2_H <4V(<1.1mA) = low / >8V (>1.5mA) = high
DI6 29 DI6_L
AI1_2 41 AI_2_5V 5V / 24° ± 50V isolated to other potential
AI1 48 Al_U 0…10V (not isolated to AI2)
Al1 45 Al1_l 0…23.7mA (not isolated to AI2)
AI2 50 AI2_U 0…10V (not isolated to AI1)
AI2 49 AI2_UI 0…23.7mA (not isolated to AI1)
AI1_2 42 AI1_2_GND AI_GND ± 50V isolated to other potential
AO1 40 AO1_OUT 0…10V / 8mA
AO2 44 AO2_OUT 0…10V / 8mA
AOI_2_FIP 35 AOI1_2_FIP_GND GND
FIP 24 FIP_IN 0…5V or frequency input <xV low / >yV high I=?
TOP1 12 TOP1_OUT 24V / TOP1+…+TOP4 = 3A; max 1.5A source/sink
TOP1_2 15 TOP1_2_GND LGND (3A)
TOP3_4 16 TPO3_4_GND LGND (3A)
FO 48 FO_OUT 24V / 1.5A sink to LGND / < 500Hz
28 NC NC
28 NC NC
28 NC NC
IGI 32 IGI_24V 24V / 10mA (bridge to IGI_IN to disable IGI function)
IGI 31 IGI_IN <4V (2mA) = low / >8V (4mA) = high
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ECU8 34

ESI 36 ESI_IN <4V (2mA) = low / >8V (4mA) = high
ITS_OFF 39 ITS_OFF Connect this pin to FGND -> ITS disabled
ITS_OFF 43 FGND
6 NC NC
7 NC NC
47 NC NC
51 NC NC
52 NC NC
53 NC NC
54 NC NC
55 NC NC
56 NC NC
POWER 59 +24V 24V / 30A
POWER 58 +24V 24V / 30A
POWER 62 +24V 24V / 30A
POWER 57 +24V GND / 30A
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ECU8 35
3.5.2 Connector X2 / engine wiring harness

3.5.2.1 Connector pin assignment
Pin assignment of X2 (engine wiring harness) 92-pole (92 x MCP1.5)
Lock: Bayonet with multiple lugs
The engine sensors are connected to this connector.

The table below shows the connector pin assignment of connector X2. The brief specification states the most
important characteristics of the channel concerned.

ASI1 78 ASI1_H
ASI1 56 ASI1_L < 120mV = low / < 0mV = high
ASI2 77 ASI2_H
ASI2 55 ASI2_L < 120mV = low / < 0mV = high
CAN3_E 24 CAN3_E_GND
CAN3_E 1 CAN3_E_H 50V isolated
CAN3_E 2 CAN3_E_L
FI2 53 FI2_H <-482mV = low / > 586mV = high
FI2 75 FI2_L
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ECU8 36

FI1 54 FI1_H <-482mV = low / > 586mV = high
FI1 76 FI1_L
IO11 46 IO11_H 42V / 10A
IO11 23 IO11_L Bank 1
IO12 45 IO12_H 42V / 10A
IO21 44 IO21_H 42V / 10A
IO22 43 IO22_H 42V / 10A
IO31 42 IO31_H 42V / 10A
IO32 41 IO32_H 42V / 10A
IO41 40 IO41_H 42V / 10A
IO42 39 IO42_H 42V / 10A
IO51 38 IO51_H 42V / 10A
IO52 37 IO52_H 42V / 10A
IO61 36 IO61_H 42V / 10A
IO62 35 IO62_H 42V / 10A
LSI1 31 LSI1_13V_5V_T8 Supply 13V / 5V for LSI1 max 12mA / channel tracker 8
LSI1 10 LSI1_IN 0…5V / internal 47k5 pull down PI / pull up 3k32 LSI
LSI2 32 LSI1_13V_5V_T9 Supply 13V / 5V for LSI1 max 12mA / channel tracker 9
LSI2 33 LSI2_IN 0…5V / internal 47k5 pull down PI / pull up 3k32 LSI (Data IN /
OUT EI_module)
NSI1 11 NSI1_24V 24V / 0.5° / Rmin 16k for OL detection
NSI1 34 NSI1_IN 0…5V / internal 47k5 pull down PI / pull up LSI
NSI1 30 NSI1_GND GND
PHI1 73 PHI1_5V_T1 5v / 12mA / tracker T1
PHI1 52 PHI1_GND GND
PHI1 74 PHI1_IN 0…5V / internal 47k5 pull down
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ECU8 37

PHI2 71 PHI2_5V_T2 5v / 12mA / tracker T2
PHI2 51 PHI2_GND GND
PHI2 72 PHI2_IN 0…5V / internal 47k5 pull down
PI1 49 PI1_5V_T3 5v / 12mA / tracker T3
PI1 50 PI1_GND GND
PI1 70 PI1_IN 0…5V / internal 47k5 pull down
PI2 26 PI2_GND GND
PI3 27 PI3_GND GND
PI4 28 PI4_GND GND
PI5 8 PI5_5V_T3 5v / 12mA / tracker T7 for PI5..7 (48mA)
PI5 29 PI5_GND GND
PWM_CM1 91 PWM_CN1_GND LGND (50m ohm)
PWM_CM1 92 PWM_CN1_OUT 24V / 3A with current measurement (CM)
PWM_CM2 69 PWM_CN2_OUT 24V / 3A / < 500Hz
PWM_CM3 90 PWM_CN3_OUT 24V / 3A / < 500Hz
PWM1 65 PWM1_GND LGND
PWM1 88 PWM1_OUT 24V / 3A / < 500Hz
PWM2 66 PWM2_GND LGND
PWM2 89 PWM2_OUT 24V / 3A / < 500Hz
TI1 64 TI1_GND GND
TI1 87 TI1_IN 0…5V / internal 1k91 pull up to TI_BUF
TI2 63 TI2_GND GND
DFI2 62 DFI2_IN Internal 47k5 pull down / pull up 1.82k + diode -> 5V
DFI1 61 DFI1_IN Internal 47k5 pull down / pull up 1.82k + diode -> 5V
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ECU8 38

DFI1_2 60 DFI1_2_12v Supply for DFI1/2 (12V / 200mA)
PWM_CM4 58 PWM_CM4_GND LGND (50m ohm)
PWM_CM4 80 PWM_CM4_OUT 24V / 3A / < 500Hz
TO1 57 TO1_GND LGND
TO1 79 TO1_OUT 24V / 1.5A
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ECU8 39
4 Sensors
4.1 Sensor installation locations
4.1.1 Sensors on Series 1600 12V / Series 1600 10V engines
4.1.1.1 Top (plan view) Series 1600 12V
XY39A1 Injector connection A side 1 B6 Coolant temperature

XY39A2 Injector connection A side 2 B9 Charge-air temperature
XY39B1 Injector connection B side 1 B10 Charge-air pressure
XY39B2 Injector connection B side 2 B13 Crankshaft speed
X2 ECU connector engine wiring harness B16 Coolant pressure
B1 Camshaft speed B48.1 Fuel pressure A side
B5 Lube oil pressure B48.2 Fuel pressure B side
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ECU8 40
4.1.1.2 Driving end
XY39A1 Injector connection A side 1

XY39B1 Injector connection B side 1
B1 Camshaft speed
B13 Crankshaft speed
M8.1 Fuel pump HPP A
M8.2 Fuel pump HPP B
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ECU8 41
4.1.1.3 Right engine side

B1 Camshaft speed
X2 ECU8 connector engine wiring harness
B9 Charge-air temperature
B10 Charge-air pressure
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ECU8 42
4.1.1.4 Top, seen diagonally from driving end
B1 Camshaft speed
X1 ECU8 system cable plug connection
X2 ECU8 engine wiring harness plug connection
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ECU8 43
4.2 Sensors used

4.2.1 Sensor types
Various sensors are used to acquire the engine operating data:
 Pressure sensors
 Temperature sensors
 Speed sensors
The following information is provided for each of the sensors in the various sub-chapters
 Equipment identifier of the sensor (e.g. B5)
 Mechanical design
 Use (measurand)
 Block diagram
 Connector plug with pin assignment
4.2.1.1 Pressure sensors

Sensor B5, B16 (0 ... 10 bar)
mechanical design
Connections:
1 Supply voltage 3 Ventilation
2 Output voltage 4 Ground
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ECU8 44
4.2.1.2 Use
The sensor is used for:
 B5 Lube oil pressure
 B16 Coolant pressure
Block diagram
1 Supply voltage
2 Output voltage
4 Ground
Connector plug
B5 / B16 connector plug
Connector plug pin assignment

Pin no.: Signal:
1 Supply voltage +Ub : 5 VDC
2 Output voltage +Ua : 0.5 ... 4.5 VDC for 0 ... 10 bar
3 Ventilation
4 Ground / GND (not connected to the housing)
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ECU8 45
Sensor B10 (0 ... 4.5 bar)

mechanical design
1 Supply voltage
2 Output voltage
3 Ventilation
4 Ground
Use
B10 Charge-air pressure
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ECU8 46
Block diagram
1 Supply voltage
2 Output voltage
4 Ground
Connector plug
B10 Connector plug

Pin no.: Signal:
2 Output voltage +Ua : 0.5 ... 4.5 VDC for 0 ... 4.5 bar
3 Ventilation
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ECU8 47
Sensor B48.1, B48.2 (0 ... 2000 bar)

mechanical design
1 Ground / GND
2 Output
3 Supply voltage
Use
B48.1 High fuel pressure
B48.2 High fuel pressure
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ECU8 48
Block diagram
S Pressure sensor
ECU Engine Control Unit
1 Ground
2 Output voltage
3 Supply voltage
Connector plug

Pin no.: Signal:
2 Output voltage +Ua : 0.5 ... 4.5 VDC for 0 ... 2000 bar
4 Housing (ground)
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ECU8 49
4.2.2 Speed sensors

Sensor B1, B13 (ASI angular input)
mechanical design
1 Connection B
2 Connection A
4.2.2.1 Use
 B1 Camshaft speed
 B13 Crankshaft speed
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ECU8 50
Block diagram
S Sensor
ECU Engine Control Unit
ITS Fault detection OFFLINE
A Analog signal
B Analog signal
Connector plug
B1 Camshaft speed

Pin no.: Signal:
1 Black (analog signal)
2 Red (analog signal)
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ECU8 51
Connector plug

Pin no.: Signal:
1 Black (analog signal)
2 Red (analog signal)
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ECU8 52
4.2.3 Temperature sensors

Sensor B6, B9
mechanical design
Use
B6 Coolant temperature
Block diagram
1 Input
2 Ground / GND
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ECU8 53
Connector plugs
B6 Coolant temperature

Pin no.: Signal:
1 Pt 1000: 0° C: 1000 ... 100°C: 1385 
2 Ground / GND
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ECU8 54
4.2.4 External sensors

2 optional measuring points are provided for external measuring:
LSI1 Water in fuel prefilter
LSI2 Coolant level
Sensors
The sensors used are level monitors which switch to ground following a timeout on detecting violation of the
defined upper or lower level limits.
MTU can supply suitable sensors and connecting cables if desired.
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ECU8 55
5 Wiring
5.1 Power supply
5.1.1 Power supply
5.1.1.1 General information
Configuration of the power supply including the start button is the responsibility of the OEM.
This chapter therefore depicts straightforward power distribution wiring by way of recommendation only.
The following basic factors concerning the supply of power must be observed:
 Use a 2-pole master switch
 Protect all units separately with power circuit breakers
 Initiation of manual emergency stop, or by IGI, or by ESI (see chap. 7.1)
All these requirements are taken into consideration in the recommendations below. As a basic rule, all cable
connections must be established and distributed by means of terminal blocks.
The length of the supply cable from the battery to ECU8 must not exceed 25 m including the connection box.
6 pins (6x2.5mm2) are provided for the power supply in the connector (X1). The voltage drop between battery and
ECU8 for the 24V+ and GND line is load-dependent. Ensure that ECU8 has a minimum continuous voltage of 20V+
at the supply pins. The average ECU8 current depends on the number of engine cylinders, the speed and the
connected consumers.
Note: Take the additional voltage drop into account when a terminal box is interposed.
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ECU8 56
Example: Voltage drop for various cable lengths (Rcu and fuse taken into consideration):
Power consumption of Engine Control Unit ECU8 = Max. 33 A
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ECU8 57
5.1.1.2 Example for power supply configuration (recommendation)
BATT Power supply F001-3 Contactor S1 Master switch

ECU Engine Control Unit ECU8 GND Ground S3 START
5.1.1.3 Master switch

The supply voltage for the entire electronic engine management system is switched on and off by master switch
S001.
5.1.1.4 Power circuit breakers
Power circuit breakers are provided for the following areas:
F001 6A Input IGI_IN at Engine Control Unit : Ignition on Input DI. at Engine Control Unit
F002 25A Engine Control Unit supply voltage
F003 6A Pushbutton / START
5.1.1.5 Pushbutton S003
Pressing the pushbutton trips the start command. Input DI7. of the Engine Control Unit is connected to 24V DC.
5.1.1.6 Emergency stop
Completely de-energizing the Engine Control Unit in order to initiate an emergency engine stop is INADMISSIBLE.
Note: The event is recorded in an internal memory (counter) should the engine be shut down in this way
nevertheless. Alarm no. 549 “AL Power fail detected” is generated and written in the fault memory when the Engine
Control Unit is switched back on.
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ECU8 58
5.1.2 Grounding concept

The grounding concept envisages total isolation of generator ground and supply voltage ground.
5.1.2.1 Grounding concept
W01 System cable M Engine X1 System cable connector

W02 Engine wiring harness G Generator X2 Engine wiring harness connector
ECU Engine Control Unit ECU8 BATT Battery PE Ground connection
Warning: Supply voltage ground (- GND) must not be connected to generator ground at any point! The crossed-
out connection in the illustration must therefore never be established!
The following ground connections must be established:

 Cable -W01 / system connection: The shielding of the cable for connection to the system is connected on
the ECU side to the housing of the Engine Control Unit via connector X1 (factory-connected).
On the open end, the shielding must be connected to the housing in which the terminal block and the
customer controller are located (switchgear cabinet) (to be ensured by OEM).
 Cable -W02 / engine wiring harness: The shielding is connected to the housing of the Engine Control Unit
via the connector plugs of the engine wiring harness (factory-connected).
 The engine must be grounded by means of a ground strap (PE). Refer to the relevant MTN standard
“Grounding engines and systems” for details of execution, cross-sections etc..
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ECU8 59
5.1.3 CAN bus

5.1.3.1 General information
The CAN bus must be laid and connected carefully according to specifications in order to achieve the highest
possible signal-to-noise ratio and thus maximum reliability in operation.
Note: Failure of the CAN bus inevitably leads to serious restrictions even to the extent of total engine failure. CAN
bus execution is therefore central to ensuring reliability of the entire system!
5.1.3.2 Cabling requirements
The cabling used must have the following electrical properties at the least:
 Impedance Z: 120 (± 10%)
 Specific resistance rb: Max 50 /m at 20°C
 Specific signal delay tp: 5 ns/m
 Specific capacity between conductors cb: Max. 75 pF/m
 Specific capacity of conductors to shielding cs: Max. 110 pF/m
5.1.3.3 Block diagram
The figure is a schematic representation showing an example of CAN bus arrangement.
Terminal
block
OEM
SmartConnect
* Resistors may only be used at the ends of the bus.

Either at the terminal block or at the SmartConnect.
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ECU8 60
Pay attention to the following points when connecting the CAN bus:
 Termination resistor: One CAN bus termination resistor (120 ) must be connected at each end of the CAN
buses.
 The shielding of the bus cable (at the switchgear cabinet) must be connected to the housing/cable entry of
the switchgear cabinet.
The (twisted) bus cable does not have to be shielded inside the switchgear cabinet.
 CAN_GND connections: The connections must not be connected to the shielding, operating voltage ground
or vehicle ground!
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ECU8 61
5.2 Engine wiring harnesses

5.2.1 Sensor wiring harness
5.2.1.1 RB1600 10V (ten cylinder V engine) and RB1600 12V (twelve cylinder V engine)
B1 Camshaft speed B5 Lube oil pressure B6 Coolant temperature

B9 Charge-air temperature B10 Charge-air pressure B13 Crankshaft speed
B16 Coolant pressure B48.1 HP fuel A B48.2 HP fuel B
M8.1 Fuel pump HPP A M8.2 Fuel pump HPP B XY39A1 Injector connection A1
XY39A2 Injector connection A2 XY39B1 Injector connection B1 XY39B2 Injector connection B2
X2 ECU8 governor connector
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ECU8 62
5.2.1.2 Connectors XY39A1 ... XY39B2
The injector wiring harnesses are connected to connectors XY39A1 / XY39A2 / XY39B / 1XY39B2. The injector
wiring harness connections are in “window gasket” designed and are located in the cylinder heads.
5.2.1.3
5.2.1.4 Connectors M8.1 / M8.2
These connectors are used to connect:

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ECU8 63
5.2.2 Injector wiring harness

The wiring harness to connect the injectors is integrated in the cylinder heads (window gasket) and is installed in
the factory.
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ECU8 64
5.3 System cables

5.3.1 System wiring harness
Wiring harness W01 is provided to connect Engine Control Unit ECU8 to the higher-level controller and to the
power supply (terminal block). Wiring harness W01 is equipped with a 62-pole connector plug (X1) at one end. The
open end must be connected to a terminal block.
1 Connecting cable ECU8 W1
Cable W1 is assigned as follows: See chap. 3.2.1
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ECU8 65
6 System inputs and outputs

6.1 Overview of channel assignment
6.1.1 System side
Engine Control Unit ECU8 is assigned as follows on the system side:
Channel Assignment Default setting
POWER Power supply / 3x +24V / 3x GND = voltage to switch on Yes
the system (emergency stop by switching off the voltage)
IGI Ignition / Ubatt switch variant 1 emergency stop Yes
ESI Engine stop / emergency stop variant 2 emergency Not used
stop
DI1 Engine stop Yes, ground switching
DI2 Speed droop Yes
DI3 Idle / mode (fixed speed) or switching between 50/60Hz Idle / mode (fixed speed)
DI4 Alarm reset Yes
DI5 Speed up Yes
DI6 Speed down Yes
DI7 Start Yes
DI8 Override Yes
AI1 Speed demand (I) / Speed demand (U) Standard
AI2 Engine Torque / Demand (LSG) Standard
FIP Speed demand (5Hz/min-1) optional
AO1 Coolant temp. Yes
AO2 Lube oil pressure Yes
FO - -
TOP1 YELLOW alarm Yes
TOP12 RED alarm Yes
TOP3 Lube oil stop Yes
TOP4 Starter ON Yes
CAN_P1 PCS5 Yes
CAN_P2 J1939 Yes
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ECU8 66
7 Functions
7.1 ECU8 signals
7.1.1 Engine side – System side
The channels of the various inputs and outputs on Engine Control Unit ECU8 are divided into 2 groups.
Engine channels
System channels
All engine channels are connected to connector X2. All engine sensors and actuators are connected via this wiring
harness which is installed on the engine in the factory.
7.1.1.1 General information about the parameters
System channels are described in the sections below including the functions and parameters associated with them.
Parameters are set by creating a data record.
7.1.1.2 Supply
The supply is connected at connector X1 (system wiring harness)
7.1.1.3 Schematic circuit diagram
B Battery
+U Engine Control Unit operating voltage
RFS Indicator lamp “Ready for Start”
’ V Vehicle
X Battery master switch
E Emergency stop (NC contact)
-U GND
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ECU8 67
7.1.1.4 Ignition input IGI

Technical data
Control via:
Supply + 24 V DC, +Ubat
Channel specification:
 Voltage: 0 – 36 V DC
 Current Approx. 4.8 mA at 24 V DC / ~5k ohm
 Electrical isolation: No
+UBatt24 V DC operating voltage

PD Power driver disable
MPC MPC port
DC/DC DC/DC converter
IGI_24V Ignition / +Ubatt switch / emergency stop
IGI_IN Ignition
GND Ground
DS Data memory (data storage algorithm)
To deactivate the ignition function:

Insert a jumper between IGI_24V or +Ubat and IGI_IN.
Switch on ECU8 with ignition input IGI
1. +Ubat (24 V) power supply must be connected to ECU8.
2. IGI input level 0V (<4V) ->
>9V DC/DC converter is activated
> 11V blocked output stage can be enabled by the software.
Switching off ECU8 (with ignition input IGI)
The output amplifier for the injectors is switched off when the IGI input level is below the 4V threshold. Fuel is no
longer injected and the engine stops immediately.
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ECU8 68
7.1.1.6 Emergency stop input

The channel makes it possible to trip an emergency stop.
The ESI input is activated by a NO contact connected to UBatt (24V). The input is not connected if the function is
not used.
7.1.1.7 Technical Data
Control via:
Supply + 24 V DC, +Ubat
 Voltage: 0 – 36 V DC
 Current Approx. 4.8 mA at 24 V DC / ~5k ohm
 Electrical isolation: No
 Power disruption: Input voltage monitoring
+Batt 24 V DC operating voltage

Rol Input voltage monitoring (33kohm ± 10%)
ITS Fault detection (OFFLINE)
PD Power driver disable
MPC MPC port
DC/DC DC/DC converter
ESI_IN Ignition 4.8 mA at 24 V DC / ~ 5kohm ± 10% (12..32V at 33kohm ± 10%)
GND Ground
DS Data memory (data storage algorithm)
Detection of power disruption:

A switch or electronic controller must supply a 0.4 mA current (12 ... 32 V at 33kohm ± 10%) to ECU8 in order to
detect line disruption.
Emergency stop activation:
Activation of an emergency stop (Uin > 8 V) switches off fuel injection immediately -> the engine is stopped.
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ECU8 69
7.1.2 Binary inputs DI 1 ... 8

7.1.2.1 Technical data
Switches: External voltage or +Ubatt
Input voltage 0 ... 32 V DC
Low detection: Uin < 4 V
High detection: Uin > 8 V
Input impedance: 12.1 k ohm
Input filter (fg/-3dB): 19HZ
Scanning frequency: < 1ms
Electrical isolation: 50 V DC
Wire break monitoring: Current monitoring with ROL = 33 k ohm ± 10%
7.1.2.2 Required settings
 Open line = Wire break monitoring active
 Logic: “Active High” or “Active Low”
1 Resistor for wire break monitoring

2 Optocoupler
3 Inductive load (a free-wheeling diode must be provided for inductive loads.)
4 Voltage source
Note: Wire break monitoring is only possible when no load is connected in parallel to input DI1 ..8
7.1.2.4 DI1 - Engine stop

The engine stop signal is activated when this input is switched off. The signal is stored. until the engine has come
to a standstill.
Parameters:
 Wire break monitoring engine stop: (2.7001.804)
 Logic engine stop: (2.7001.805)
 Stop: stored: (2.7001.009)
7.1.2.5 DI 2 – Speed droop
This input can be used to change between the 50 Hz / 60 Hz frequencies in “genset” applications.
Parameters:
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ECU8 70
 Wire break monitoring speed droop (2.1060.834)

 Logic speed droop (2.1060.835)
7.1.2.6 DI 3 – Increase idle speed / switch over frequency
Activating this input raises idling speed to a predefined (adjustable) value.
Parameters:
 Wire break monitoring idle speed increase: (2.1060.844)
 Logic idle speed increase: (2.1060.845)
 Line break monitoring frequency switching: (2.7003.804)
 Logic frequency switching: (2.7003.805)
7.1.2.7 DI 4 – Alarm reset
Stored alarms are reset by activating this input.
Alarms are stored in YELLOW or RED sectors. Signaling remains unchanged until canceled with the “Alarm reset”
command.
Parameters:
 Line break monitoring alarm reset: (2.8009.804)
 Logic alarm reset: (2.8009.805)
7.1.2.8 DI 5 – Engine speed increase (speed up)
The engine speed can be increased between idling speed and rated speed (max. speed) when this input is
activated.
Parameters:
 Wire break monitoring idle speed increase: (2.1060.804)
 Logic engine speed increase: (2.1060.805)
7.1.2.9 DI 6 – Engine speed decrease (speed down)
The engine speed can be decreased from rated speed (max. speed) to idling speed when this input is activated.
Parameters:
 Wire break monitoring idle speed decrease: (2.1060.814)
 Logic engine speed decrease: (2.1060.815)
7.1.2.10 DI 7 – Engine start
Activating this input triggers the engine start program. The signal must be applied for the duration of the entire
starting sequence. The starting sequence is aborted if the signal is canceled.
Parameters:
 Wire break monitoring engine start: (2.1090.804)
 Logic engine start: (2.1090.805)
7.1.2.11 DI 8 – Override
The “Override” function is used to bypass a number of safety features. These would otherwise lead to power
reduction or emergency engine stop in case of limit value violation. Note: Internal performance maps cannot be
bypassed!
Parameters:
 Wire break monitoring override: (2.7002.804)
 Logic override: (2.7002.805)
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ECU8 71
7.1.3 Analog inputs AI 1 ... 2

7.1.3.1 Technical data
Channel specification
 Sensors: Current sources, voltage sources or potentiometers 1 ... 5 k ohm
 Power supply: 5 V ± 3% max. 50 mA
 Voltage input: 0 ... 10 V DC (max. 13 V), input impedance 100 k ohm, filter 200 Hz (fg/-3 dB)
 Current input: 0 ... 25 mA ± 2% (max. 25 mA), compliance voltage 4.5 V at 20 mA
 Fault detection voltage input: U > 10 V
 Fault detection current input: I < 4 mA, I >20 mA (overcurrent shutdown ~ 40 mA)
 Electrical isolation: 50 V DC
 Dielectric strength 36 V DC
 Configuration, voltage input / current input via connection
 Scaling
 Function
1. Control via current source

2. Control via resistance
3. Control via voltage source
4. Input amplifier
5. Supply voltage via potentiometer connection
7.1.3.4 AI 1 - Speed demand

The engine speed can be set between idling speed and rated speed (max. torque). This analog signal allows the
speed demand to be set to a certain value. Whereby: 4 mA / 0 V = Idling speed to 20 mA / 10 V = Rated speed.
Speed changes take place in stages along a speed ramp which can be programmed as an acceleration or
deceleration ramp.
Parameters:
 Configuration: (2.0280.039)
 Curves:
 Voltage: (2.0401.010)
 Current: (2.0401.012)
 Frequency: (2.0401.014)
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ECU8 72
7.1.3.5 AI 2 – Torque request

This signal is the torque demand in torque-controlled systems. For a fuel injection governor this is equivalent to
load demand in %.
Parameters:
 Configuration: (2.0287.039)
7.1.4 Frequency input FIP

7.1.4.1 Channel specification / technical data
 Sensor: analog 0 ...5 V DC
 Frequency input
 Input hysteresis: 2.2 V -> high / 0.6 V -> low
 Measuring range: 10 ... 1000 Hz at 50%
 Pull-up resistor: 3.3 k ohm after 5 V (adjustable)
 Input filter (fg / -3 dB): 14.5 kHz
 Fault detection: OFFLINE (IST) yes / ONLINE wire break via input voltage monitoring.
 Overvoltage protection: ± 36 V (Warning: Inductive load (a free-wheeling diode must be provided for
inductive loads.)
 0 ... 5 V DC input
 Input resistor: 47k5 PULL-DOWN (default setting)
 Measuring range: 0 V < U input / < 5 V absolute
 Measuring accuracy: ± 0.6% (0.4% absolute) / (without Sensor Worst Case / 95%)
 Input filter (fg / -3 dB): 19 Hz
 Resolution: 12 bit
 Electrical isolation: None
 Overvoltage protection: ± 36 V
 PULL-UP resistor on / off
1. Control via current source

2. Control via switch
3. Control via transistor switch:
4. Filter with fg 14.5 kHz
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ECU8 73
7.1.5 Transistor outputs TOP 1 ... 4

 Control of:
 Lamps
 Relays
 Digital inputs
 Channel specification
 Loads: 24 V DC consumers, valves
 DC output current: 1.4 A at 24 V On
 Output voltage without load: ~ 5 V (high switch) ~ 0 V (low switch)
 Switching frequency: Max. 2 Hz
 Load: Max. 140 mH inductive
 Short-circuit detection: Yes
 Wire break monitoring: Switched off, only with R_load < 25 k ohm
 Overvoltage protection: Up to 36 V (Warning: Inductive load (a free-wheeling diode must be provided for
inductive loads.)
 “Low Switch“ or “High Switch”
 Wire break monitoring on/off
1. Inductive load
2. Ohmic load
7.1.5.4 TOP 1 - Yellow alarm

This output switches as soon as a yellow alarm occurs. The output is briefly switched off and back on again when a
further alarm occurs.
Parameters:
 Active level: (2.1050.005)
 “Low Switch“ or “High Switch”: (2.1050.010)
7.1.5.5 TOP 2 - Red alarm
This output switches as soon as a red alarm occurs. The output is briefly switched off and back on again when a
further alarm occurs.
Parameters:
 Active level: (2.1050.006)
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ECU8 74

7.1.5.6 TOP 3 – Oil pressure too low (lube oil stop)
This output switches when the oil pressure falls below a minimum value (adjustable).
Parameters:
 Active level: (2.1050.007)
7.1.5.7 TOP 4 – Starter on
The output registers the internal starting sequence. The starter should engage with TOP4 is switched
Parameters:
 Active level: (2.1050.008)
7.1.6 Analog outputs AO 1 ... 2

 Control of:
 Display instruments
 Analog inputs
 Output current: 0 ... 8 mA at 10 V
 Output voltage: 0 … 10 V DC
 Output voltage without load: ~ 0 V
 Short-circuit current: ~ 18 mA
 Settling time: 11 ms at 0 ... 8 mA
 Wire break monitoring: No
 Overvoltage protection: Up to 36 V DC
None
7.1.6.4 AO 1 – Cooling temperature

This signal can be used to control a temperature gage and the cooling blower.
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ECU8 75
Parameters:
 Voltage output: Linear 0 ... 100% (12 bit) - > * 0 ... 9999 mV
7.1.6.5 AO 2 - Oil pressure
This signal can be used to control a pressure gage.
7.1.7 CAN interfaces 1 ... 2

 Channel type: Serial interface, Controller Area Network (CAN)
 Control of:
 CAN bus
 Analog inputs
 High-Speed CAN compatible with ISO 11898 (24 V)
 CAN specification: Version 2.0B / 11/29 bit bus structure (PCS-5 protocol)
 Max. data rate: 1 Mbit/s
 Max. bus length: 250 m
 Termination resistor: 120 ohm (to be provided in cable)
 Short-circuit detection / line disruption: By the CAN controller
 Electrical isolation: 50 V DC to ECU-GND and to CAN_1 / CAN_2
 Overvoltage protection: ± 36 V / 50 V DC / 12 kV ESD
Note: A 120 ohm termination resistor must by installed at both ends of the line!
none
CAN Controller Area Network DC Voltage direct current

GND Ground AC Voltage alternating current
ECU Engine governor
7.1.7.4 CAN 1 – PCS5

This CAN interface is used to connect the Engine Control Unit to other MTU or OEM units via the CAN bus. This is
the “redundant bus”.
This interface can only transmit, i.e. receive objects cannot be evaluated on this bus. All objects transmitted on
CAN 2 - J1939 (see below) are also transmitted here.
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ECU8 76
7.1.7.5 CAN 2 – J1939

This CAN interface is also used to connect the Engine Control Unit to other MTU or OEM units via the CAN bus.
This is the “default bus”.
Transmitting and receiving are both possible at this interface. The interface definition of the transmission and
receiving objects complies with the international SAE J1939 standard.
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ECU8 77
8 Fault message table
No. ZKP no. Name Description

Charge-air temperature too high (limit 1) ==> Check intercooler
5 2.0121.931 HI T-Charge Air
(Alarm configuration parameter, see PR 2.8008.100 for details)
Charge-air temperature too high (limit 2) ==> Check intercooler
6 2.0121.932 SS T-Charge Air
Lube oil pressure too low (limit value 1).
15 2.0100.921 LO P-Lube Oil
Lube oil pressure too low (limit value 2).
16 2.0100.922 SS P-Lube Oil
Engine overspeed (limit value 2).
30 2.2510.932 SS Engine Overspeed
Primary turbocharger speed too high (limit value 1).
31 2.3011.931 HI ETC1 Overspeed
Primary turbocharger speed too high (limit value 2).
32 2.3012.932 SS ETC1 Overspeed
Speed of 1st secondary turbocharger too high (limit value 1).
36 2.3013.931 HI ATL2 Overspeed
Speed of 1st secondary turbocharger too high (limit value 2).
37 2.3013.912 SS ATL2 Overspeed
Coolant pressure too low (limit value 1) ==> Check coolant circuit
57 2.0101.921 LO P-Coolant Idling speed not reached ==> Start terminated ==> Check for additional messages
Coolant pressure too low (limit 2) ==> Engine stop or limitation of injection quantity
58 2.0101.922 SS P-Coolant ==> check cooling circuit
Coolant temperature too high/ too low (limit 3).
59 2.0120.933 SS T-Coolant L3
Coolant temperature too high/ too low (limit 4).
60 2.0120.934 SS T-Coolant L4
Coolant temperature too high (limit 1) ==> Check coolant circuit
67 2.0120.931 HI T-Coolant
Coolant temperature too high (limit 2) ==> Check coolant circuit
68 2.0120.932 SS T-Coolant
Rail pressure gradient too low for start or too high for stop
81 1.8004.046 AL Rail Leakage (==> High-pressure system leaking, air in the system)
Rail pressure > setpoint value => DBR reduction, shift of start of injection delayed
82 2.0104.931 HI P-Fuel (Common Rail) (==> HP fuel control block stuck or wiring faulty)
Rail pressure < setpoint value => DBR reduction
83 2.0104.921 LO P-Fuel (Common Rail) (==> HP fuel control block faulty or leak in HP system)
Engine is stalled. The engine speed has fallen below the limit set by parameter
2.2500.027 in normal operation
89 2.2500.030 SS Engine Speed too Low Stalling in the absence of a stop request. Engine is stopped for safety reasons
when this occurs.
Idling speed not reached ==> Start terminated ==> Check for additional messages
90 2.1090.925 SS Idle Speed Not Reached
Runup speed not reached ==> Start terminated ==> Check for additional
SS Release Speed Not
91 2.1090.924 messages
Reached
Starter speed not reached ==> Start terminated ==> Starter does not turn or turns
92 2.1090.923 SS Starter Speed Not Reached too slowly
Preheating temperature too low (limit 2) ==> Coolant temperature for engine start
93 2.1090.922 SS T-Preheat too low ==> Engine start interlock
Preheating temperature too low (limit 1) ==> Coolant temperature for engine start
94 2.1090.921 LO T-Preheat too low
Priming fault.
95 2.1090.920 AL Prelubrication Fault
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ECU8 78

Consumption meter faulty.
102 1.8004.624 AL Fuel Cons. Counter Defect
Hour meter faulty.
104 1.8004.623 AL Eng Hours Counter Defect
S
118 2.0140.921 LO ECU Power Supply Voltage upply voltage too low (limit value 1) ==> Check batteries/generator
LOLO ECU Power Supply
119 2.0140.922 Supply voltage too low (limit value 2) ==> Check batteries/generator
Voltage
120 2.0140.931 HI ECU Power Supply Voltage Supply voltage too high (limit value 1) ==> Check batteries/generator
HIHI ECU Power Supply
121 2.0140.932 Supply voltage too high (limit value 2) ==> Check batteries/generator
Voltage
Electronics temperature too high (limit value 1).
122 2.0132.921 HI T-ECU
This alarm is raised if the average engine power over the last 24 hours exceeded
the value specified by PR1.1088.001.
141 1.1088.007 AL Power too high
This alarm is raised if the MCR was exceeded for longer than 1 hour in the last 12
142 1.1088.006 AL MCR exceeded 1 hour hours.
Connection to a node on CAN bus 1 lost. ==> Check devices connected to CAN
180 2.0500.680 AL CAN1 Node Lost
Connection to a node on CAN bus 2 lost. ==> Check devices connected to CAN
181 2.0500.681 AL CAN2 Node Lost
Incorrect CAN parameter values have been entered.
182 2.0500.682 AL CAN Wrong Parameters
A CAN mode has been selected in which communication is initialized with the help
of the PU data module. However, the required
183 2.0500.683 AL CAN No PU-Data PU data module is not present or is not valid.
==> Check devices connected to CAN
A programming fault occurred on attempting to copy a received PU data module to
184 2.0500.684 AL CAN PU-Data Flash Error the flash module. ==> Electronic Service
CAN controller 1 is in “Bus Off” state. => Automatic switching to CAN2.
==> Causes are e.g. short circuit, massive interference or baud rate
186 2.0500.686 AL CAN1 Bus Off
incompatibility.
CAN controller 1 has signaled a warning. ==> causes are e.g. lack of associated
nodes, minor interference or
187 2.0500.687 AL CAN1 Error Passive
temporary bus overload.
CAN controller 2 is in “Bus Off” state. => Automatic switching to CAN 1.
==> Causes are e.g. short circuit, massive interference or baud rate
188 2.0500.688 AL CAN2 Bus Off
incompatibility.
CAN controller 2 has signaled a warning. ==> causes are e.g. lack of associated
nodes, minor interference or
189 2.0500.689 AL CAN2 Error Passive
temporary bus overload.
Coolant temperature sensor faulty. ==> Short circuit or wiring damage
201 1.8004.570 SD T-Coolant ==> Check sensor and wiring (B6), replace as necessary.
Fuel temperature sensor faulty. ==> Short circuit or wiring damage
202 1.8004.572 SD T-Fuel ==> Check sensor and wiring (B33), replace as necessary.
Charge-air temperature sensor faulty. ==> Short circuit or wiring damage
203 1.8004.571 SD T-Charge Air ==> Check sensor and wiring (B9), replace as necessary.
Charge-air pressure sensor faulty. ==> Short circuit or wiring damage
==> Check sensor and wiring (B10), replace as necessary.
208 1.8004.566 SD P-Charge Air
E532291/01E 11-04 © MTU

ECU8 79

Lube oil sensor faulty. ==> Short circuit or wiring damage
211 1.8004.563 SD P-Lube Oil
Coolant pressure sensor faulty. ==> Short circuit or wiring damage

212 1.8004.564 SD P-Coolant ==> Check sensor and wiring (B16), replace as necessary.
Rail pressure sensor faulty. ==> High-pressure controller emergency operation
==> Short circuit or wiring damage
215 1.8004.567 SD P-HD
Lube oil temperature sensor faulty. ==> Short circuit or wiring damage
216 1.8004.575 SD T-Lube Oil
Intake air temperature sensor faulty. ==> Short circuit or wiring damage
219 1.8004.573 SD T-Intake Air
Engine stop due to faulty camshaft sensor (and, in the same operating cycle, prior
failure of the
AL Stop Camshaft Sensor crankshaft sensor).
229 1.8004.562
Defect Check sensor and wiring to connector B1, replace as necessary. Fault is rectified
following engine restart.
Crankshaft sensor faulty. ==> Short circuit or wiring damage
==> Check sensor and wiring (B13), replace as necessary. Fault is rectified
230 1.8004.498 SD Crankshaft Speed
Camshaft sensor faulty. ==> Short-circuit or wiring damage ==> Check sensor and
wiring (B1), replace as necessary.
231 1.8004.499 SD Camshaft Speed
Fault is rectified following engine restart.
Primary turbocharger speed sensor faulty. ==> Short circuit or wiring damage
232 1.3011.128 SD Charger 1 Speed ==> Check sensor and wiring (B44.1), replace as necessary.
Internal ECU faulty. ==> Electronic fault
245 2.8006.589 SD ECU Power Supply Voltage
Analog nominal speed setting faulty. ==> Short circuit or wiring damage
266 2.8006.586 SD Speed Demand ==> Check nominal speed sensor and wiring, replace as necessary.
Filtered analog load pulse signal not available.
269 2.8006.588 SD Loadp.Analog filt.
==> Check wiring, replace as necessary.
Frequency input faulty. ==> Short circuit or wiring damage
270 2.8006.590 SD Frequency Input
Short-circuit in injector wiring of cylinder A1. Result: Misfiring.
=> Rectify injector solenoid valve short circuit (positive to negative) (e.g. by
321 1.8004.520 AL Wiring Cylinder A1
replacing injector). Fault rectification: Every time engine is restarted.
E532291/01E 11-04 © MTU

ECU8 80

326 1.8004.525 AL Wiring Cylinder A6 => Rectify injector solenoid valve short circuit (positive to negative) (e.g. by
Short-circuit in injector wiring of cylinder B1. Result: Misfiring.

331 1.8004.530 AL Wiring Cylinder B1 => Rectify injector solenoid valve short circuit (positive to negative) (e.g. by




335 1.8004.534 AL Wiring Cylinder B5

336 1.8004.535 AL Wiring Cylinder B6

Disruption in injector wiring of cylinder A1. Result: Misfiring.
=> Check injector wiring for disruption or eliminate any disruption in the solenoid
valve (e.g. by
341 1.8004.540 AL Open Load Cylinder A1
replacing injector). Fault rectification: After every working cycle.

342 1.8004.541 AL Open Load Cylinder A2 valve (e.g. by
valve (e.g. by
346 1.8004.545 AL Open Load Cylinder A6
E532291/01E 11-04 © MTU

ECU8 81

Disruption in injector wiring of cylinder B1. Result: Misfiring.
351 1.8004.550 AL Open Load Cylinder B1 valve (e.g. by


353 1.8004.552 AL Open Load Cylinder B3
valve (e.g. by

354 1.8004.553 AL Open Load Cylinder B4
valve (e.g. by


Internal electronic fault (electronic defect possible -> Start ITS). If ITS diagnoses
“Electronics OK”, check
361 1.8004.496 AL Power Stage Low for additional fault messages (e.g. wiring faults).
If bit “1.1020.021” (Power Stage Failure: Stop Engine) is set, the engine is also
stopped in this case.
for additional fault messages (e.g. wiring faults).
362 1.8004.497 AL Power Stage High
363 1.8004.560 AL Stop Power Stage for additional fault messages (e.g. wiring faults).
Injector wiring fault. Engine stop possible via Protection Module. Possible causes:
1. Short circuit of injector positive connection of one or more injectors to ground.
365 1.8004.561 AL Stop MV-Wiring Ground
2. Short circuit of injector negative connection of one or more injectors to ground.
-> Check wiring, replace wiring harness as necessary.
Short circuit or open load at transistor output 1 (TO 1).
371 1.8004.634 AL Wiring TO 1
Short circuit or open load at transistor output 1, system side (TOP 1).
381 2.8006.638 AL Wiring TOP 1 (Alarm configuration parameter, see PR 2.8008.100 for details)
E532291/01E 11-04 © MTU

ECU8 82

382 2.8006.639 AL Wiring TOP 2 Short circuit or open load at transistor output 2, system side (TOP 2).
383 2.8006.640 AL Wiring TOP 3 Short circuit or open load at transistor output 3, system side (TOP 3).
Short circuit or open load at transistor output 4, system side (TOP 4).
384 2.8006.641 AL Wiring TOP 4
DBR/MCR function: MCR (Maximum Continuous Rate) exceeded.
390 1.1085.009 AL MCR exceeded
AL Open Load Emerg. Stop Open load at emergency stop input. ==> Wiring faulty or nor resistance at switch
408 2.8006.633
Input ESI (Alarm configuration parameter, see PR 2.8008.100 for details)
Injector voltage too low (limit value 1).
410 2.0141.921 LO U-PDU
Injector voltage too low (limit value 2).
411 2.0141.922 LOLO U-PDU
Injector voltage too high (limit value 1).
412 2.0141.931 HI U-PDU
Injector voltage too high (limit value 2).
413 2.0141.932 HIHI U-PDU
Rail pressure < setpoint value => DBR reduction
438 2.0116.921 LO P-Fuel 2 (Common Rail) (==> HP fuel control block faulty or leak in HP system)
Rail pressure > setpoint value => DBR reduction, shift of start of injection delayed
439 2.0116.931 HI P-Fuel 2 (Common Rail) (==> HP fuel control block stuck or wiring faulty)
Rail pressure gradient too low for start or too high for stop
441 1.8004.047 AL Rail 2 Leakage (==> High-pressure system leaking, air in the system)
Sensor fault at injector power driver unit. ==> Internal fault in ECU8. Replace
444 1.8004.578 SD U-PDU ECU8.
Ambient air pressure sensor faulty.
445 1.8004.580 SD P-Ambient Air
Rail pressure sensor faulty. ==> High-pressure controller emergency operation
446 1.8004.599 SD P-HD2
Charge-air pressure too high (limit value 1).
448 2.0103.931 HI P-Charge Air
Charge-air pressure too high (limit value 2).
449 2.0103.932 SS P-Charge Air
Input signal for idle/end torque faulty. ==> Short circuit or wiring damage
==> Check signal transmitter and wiring, replace as necessary. Fault is rectified
450 2.8006.592 SD Idle/End-Torque Input [%]
Power reduction activated.
454 2.7000.011 SS Power Reduction Active
Temperature sensor for ECU faulty. ==> Short circuit or wiring damage
470 1.8004.587 SD T-ECU ==> Check sensor and wiring, replace as necessary.
Engine stop as critical channels signal “Sensor Defect”.
472 2.8006.593 AL Stop SD
Open load or short circuit on frequency output (FO) channel.
474 2.8006.655 AL Wiring FO
Crash recorder initialization error.
476 1.8010.007 AL Crash Rec. Init. Error
Summary YELLOW alarm from the system.
478 2.8006.001 AL Comb. Alarm Yel (Plant)
Summary RED alarm from the system.
479 2.8006.002 AL Comb. Alarm Red (Plant)
External engine protection function active.
480 2.0291.921 AL Ext. Engine Protection
Override activated.
510 2.7002.010 AL Override applied
E532291/01E 11-04 © MTU

ECU8 83

Starter could not be engaged at POM. => New start attempt.
If the number of automatic starting attempts from PR 2.1090.134 Number of
515 2.1090.926 AL Starter Not Engaged Starting Attempts has been executed, starting procedure
is aborted. Check POM, starter and cabling.
This is the alarm from the Emergency Stop Counter function. ECU power was
AL Power Cut-Off
disconnected while the engine was still
549 2.7001.952 running. This could lead to possible overpressure in the high pressure system
detected
which might damage the engine.
Violation of the corrected MCR or DBR/MCR curve. Engine overload!
576 1.1075.083 AL ESCM Override
594 1.1301.900 AL L1 PRV Defect Yellow alarm pressure relief valve first rail.
595 1.1301.901 AL L2 PRV Defect Red alarm pressure relief valve first rail.
598 1.1302.900 AL L1 PRV Defect Yellow alarm pressure relief valve second rail.
599 1.1302.901 AL L2 PRV Defect Red alarm pressure relief valve second rail.
Open load or short circuit on PWM HP fuel control block channel.
610 1.1301.902 AL Wiring Suction Restrictor 1
Open load or short circuit on PWM HP fuel control block channel 2.
611 1.1302.902 AL Wiring Suction Restrictor 2
AL Wiring Pressure Control Open load or short circuit on PWM pressure regulating valve channel.
612 1.1301.903
Valve 1 (Alarm configuration parameter, see PR 2.8008.100 for details)
AL Wiring Pressure Control Open load or short circuit on PWM pressure regulating valve channel 2.
613 1.1302.903
Valve 2 (Alarm configuration parameter, see PR 2.8008.100 for details)
Alarm for Protection Module in response to faulty or manipulated EIL.
615 2.0610.951 AL EIL Protection
Alarm for faulty or manipulated EIL.
616 10.610.952 AL EIL Error
ECU configuration changed, switch power off / on
692 2.7003.901 AL ECU power off/on required (Alarm configuration parameter, see PR 2.8008.100 for details)
696 2.0560.901 AL SmartConnect USB Error (Alarm configuration parameter, see PR 2.8008.100 for details)
697 2.0560.903 AL SmartConnect RS485 Error (Alarm configuration parameter, see PR 2.8008.100 for details)
Channel signals open load or internal error
698 2.7001.904 AL SD Stop Button
Channel signals open load
700 2.1090.912 AL SD Start Button
701 2.1060.901 AL SD Up Button (Alarm configuration parameter, see PR 2.8008.100 for details)
702 2.1060.903 AL SD Down Button
AL SD Ext. Speed Demand Channel signals open load
703 2.1060.905
Switch (Alarm configuration parameter, see PR 2.8008.100 for details)
AL SD Speed Demand Channel signals open load or internal error
704 2.1060.907
Increase (Alarm configuration parameter, see PR 2.8008.100 for details)
705 2.1060.909 AL SD Binary Speed Limitation
706 2.1060.911 AL SD Droop 2 Switch
707 2.7003.903 AL SD Frequency Switch
709 2.7002.901 AL SD Override Button
710 2.8009.901 AL SD Alarm Reset
711 2.3000.901 AL SD Cylinder Cut Out
712 2.1050.901 AL SD Request BinOut Test
713 2.0291.901 AL SD Ext. Engine Protection
714 2.1090.914 AL SD Prelubrication Signal
715 2.1060.915 AL SD Ext. Increased Idle Bin (Alarm configuration parameter, see PR 2.8008.100 for details)
E532291/01E 11-04 © MTU

ECU8 84

AL SD Ext.Increased Idle
716 2.1060.917 Bin(Brake)
717 2.1080.901 AL SD Request Plant DBR
E532291/01E 11-04 © MTU

E532291 01E ECU8 SmartConnect

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E532291 01E ECU8 SmartConnect

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MTU_ValueService

Electronic Engine Governor

E532291/01E 11-04 © MTU

1 ........ General information ..................................................................................................................................... 6

E532291/01E 11-04 © MTU

3.4 Technical data of ECU8................................................................................................................................ 30

E532291/01E 11-04 © MTU

7.1.2 Binary inputs DI 1 ... 8 ............................................................................................................................................ 69

E532291/01E 11-04 © MTU

E532291/01E 11-04 © MTU

1.2 Safety requirements for maintenance and repair work

E532291/01E 11-04 © MTU

E532291/01E 11-04 © MTU

E532291/01E 11-04 © MTU

 Category 1, 2 or 3A laser equipment

E532291/01E 11-04 © MTU

1.3 Engine side and cylinder designations

1 KGS = Free end 3 KS = Driving end

E532291/01E 11-04 © MTU

X1 System wiring harness

E532291/01E 11-04 © MTU

E532291/01E 11-04 © MTU

2.2 Scope of delivery

E532291/01E 11-04 © MTU

2.3 Customer interface / user devices

E532291/01E 11-04 © MTU

2.3.2 Additional notes

2.3.2.2 Alarm indicator lamps

2.3.2.3 Indicator lamp

E532291/01E 11-04 © MTU

2.4 Diagnosis and tools

E532291/01E 11-04 © MTU

2.4.1.1 Flashing frequencies

1 Governor is ready for operation 4 External RAM faulty

E532291/01E 11-04 © MTU

E532291/01E 11-04 © MTU

The figure below provides an overview of the interfaces and features of

DIASYS connector for dialog

DIP switches for system

E532291/01E 11-04 © MTU

2.4.3.3 Overview of interfaces

E532291/01E 11-04 © MTU

2.4.3.3.2 Connector assignment of SC1-01

E532291/01E 11-04 © MTU

2.4.3.3.3 System image SC <-> ECU8

CAN terminating resistor

Note: SmartConnect SC 1-01 must be protected by a 4 A fuse.

E532291/01E 11-04 © MTU

The figure below shows the assignment of the 8 DIP switches.

Speed demand is set as follows:

2.4.3.4.2 Summary of alarm display functions

E532291/01E 11-04 © MTU

E532291/01E 11-04 © MTU

2.4.4 Engine Identification Label EIL

E532291/01E 11-04 © MTU

3 Use and design

Central open- and closed-loop control unit of the engine

E532291/01E 11-04 © MTU

3.2 Ignition (IGI) / emergency stop (ESI) function

ECU8 Engine Control Unit S1 Master switch

E532291/01E 11-04 © MTU

3.3 Installation on the engine

3.3.2 Mechanical design / installation location

E532291/01E 11-04 © MTU