Technical Publication: Bluevision Engine Monitoring System Ecs-5 Application Marine

Technical Publication
BlueVision
Engine Monitoring System ECS-5
Application Marine
Installation and
Commissioning Instructions
E532191/00E
Printed in Germany
© 2006 Copyright MTU Friedrichshafen GmbH
Diese Veröffentlichung einschließlich aller ihrer Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen
schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Verbreitung, Bearbeitung, Übersetzung,
Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschließlich Datenbanken und Online-Diensten.
Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen Wartungs- und
Bedienungspersonal zur Verfügung zu stellen.
Änderungen bleiben vorbehalten.
Printed in Germany
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU
Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on electronic
systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation.
Subject to alterations and amendments.
Imprimé en Allemagne
Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU Friedrichshafen
GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches, la mémorisation et / ou le
traitement sur des systèmes électroniques, y compris les bases de données et les services en ligne.
Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à l’exploitant
de le mettre à la disposition du personnel chargé de l’entretien et de la conduite.
Modifications réservées.
Impreso en Alemania
Esta publicación se encuentra protegida, en toda su extensión, por los derechos de autor. Cualquier utilización de la misma, así como su
reproducción, difusión, transformación, traducción, microfilmación, grabación y/o procesamiento en sistemas electrónicos, entre los que se incluyen
bancos de datos y servicios en línea, precisa de la autorización previa de MTU Friedrichshafen GmbH.
El manual debe tenerse presente para evitar fallos o daños durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposición del personal
de mantenimiento y de servicio.
Nos reservamos el derecho de introducir modificaciones.
Stampato in Germania
Questa pubblicazione è protetta dal diritto d’autore in tutte le sue parti. Ciascun impiego o utilizzo, con particolare riguardo alla riproduzione, alla
diffusione, alla modifica, alla traduzione, all’archiviazione in microfilm e alla memorizzazione o all’elaborazione in sistemi elettronici, comprese
banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen GmbH.
II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall’utente al personale addetto alla
manutenzione e alla condotta.
Con riserva di modifiche.
Impresso na Alemanha
A presente publicação, inclusive todas as suas partes, está protegida pelo direito autoral. Qualquer aproveitamento ou uso exige a autorização
prévia e por escrito da MTU Friedrichshafen GmbH. Isto diz respeito em particular à reprodução, divulgação, tratamento, tradução, microfilmagem, e
a memorização e/ou processamento em sistemas eletrônicos, inclusive bancos de dados e serviços on-line.
Para evitar falhas ou danos durante a operação, os dizeres do manual devem ser respeitados. Quem explora o equipamento economicamente
consequentemente deve colocá-lo à disposição do respetivo pessoal da conservação, e à dispositção dos operadores.
Salvo alterações.
Table of Contents 01
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03
1.1 General provisions ....................................................... 03
1.2 Personnel and organizational prerequisites .................................. 04
1.3 Safety requirements for maintenance and repair work .......................... 05
1.4 Fluids and lubricants, fire prevention and environmental protection .............. 08
1.5 Conventions for safety warnings in the text .................................. 10
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1.1 Cable routes and openings between all installation locations – Check . . . . . . . . . 11
2.1.2 Cable routing between installation locations for Series 2000 unit-pump system,
non-classifiable system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1.3 Cable routing between installation locations for Series 2000 CR, non-classifiable
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.4 Cable routing between installation locations for Series 4000, non-classifiable
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.5 Cable routing between installation locations for Series 2000 unit-pump system,
classifiable system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1.6 Cable routing between installation locations for Series 2000 CR, classifiable
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.1.7 Cable routing between installation locations for Series 4000, classifiable
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2 Mechanical Installation (all Series, basic and extended scope) .................. 24
2.2.1 LOP – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.2.2 Installing terminal box X010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3 Mechanical Installation (all Series, extended scope only) . . . . . . . . . . . . . . . . . . . . . . . 27
2.3.1 MEU – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.4 Mechanical Installation (all Series, depending on Trolling option) . . . . . . . . . . . . . . . . 29
2.4.1 GCU – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.5 Mechanical Installation (Series 4000 only, optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.5.1 Priming Pump Controller PPC – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.6 Electrical Installation (all Series, basic and extended scope) . . . . . . . . . . . . . . . . . . . . 32
2.6.1 LOP – Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.6.2 Fuel prefilter level sensors – Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.7 Electrical Installation (Series-dependent, basic and extended scope) . . . . . . . . . . . . . 36
2.7.1 Connecting engine governor ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.7.2 Engine Control Unit ECU 7 – Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.7.3 Starter and battery-charging generator – Connection on BR 2000 . . . . . . . . . . . . 38
2.7.4 Starter and battery-charging generator – Connection on BR 4000 . . . . . . . . . . . . 41
2.7.5 Barring gear limit switch – Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.8 Electrical Installation (Series-dependent, extended scope only) . . . . . . . . . . . . . . . . . . 47
2.8.1 Engine Monitoring Unit EMU 1 – Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.8.2 Engine Monitoring Unit EMU 7 – Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.8.3 MEU – Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
E532191/00E 05-06 © MTU

02 Table of Contents
2.9 Electrical Installation (all Series, depending on equipment and options) . . . . . . . . . . . 52

2.9.1 HSK cable bushing – Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.9.2 Terminal strip – Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.9.3 Terminal box X010 – Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.9.4 GCU connection – Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.9.5 Connecting GCU 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.9.6 Connecting GCU 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.9.7 GCU – Pin assignment for third-party gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.10 Electrical Installation (Series 4000 only, optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.10.1 Priming Pump Controller PPC – Connection (single phase) . . . . . . . . . . . . . . . . . 65
2.10.2 Priming Pump Controller PPC – Connection (three phases) . . . . . . . . . . . . . . . . 67
3 Initial Operation ............................................................... 69
3.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.1.1 Checks prior to startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.1.2 LOP power supply – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.1.3 Operating voltage – Initial connection (basic scope) . . . . . . . . . . . . . . . . . . . . . . 73
3.1.4 Operating voltage – Initial connection (extended scope) . . . . . . . . . . . . . . . . . . . 75
3.2 Tests .................................................................. 77
3.2.1 LOP – Initial engine startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.2.2 Gearbox – Engagement/disengagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.2.3 Engine speed – Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4 Supplementary Technical Information ............................................. 81
4.1 LOP – Fuses and jumpers ................................................. 81
4.2 GCU – Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.3 MEU – Fuses and jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.4 Supply voltage distribution (basic scope) .................................... 86
4.5 Supply voltage distribution (extended scope) ................................. 88
4.6 Power consumption specifications – Engine room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5 Annex ....................................................................... 91
5.1 Conversion tables ....................................................... 91
5.2 Abbreviations ........................................................... 97
5.3 Index .................................................................. 99
E532191/00E 05-06 © MTU

Safety 03
1 Safety
1.1 General provisions

General
All relevant national laws and regulations concerning accident prevention and environmental protection
shall be observed in addition to the information provided in this manual. This state-of-the-art engine
has been designed to meet all applicable laws and regulations. The engine may nevertheless
present a risk of injury or damage in the following cases:
• Improper or non-intended use
• Operation, maintenance and repair by unqualified personnel
• Changes or modifications
• Failure to comply with safety instructions
Intended use
The engine is intended solely for use in accordance with contractual agreements and the purpose envisaged for
it on delivery. Any other use shall be considered non-intended. The engine manufacturer accepts no liability
whatsoever for resultant damage or injury in such case. The user shall be held fully responsible.
Furthermore, intended use extends to include compliance with the operating instructions and strict
adherence to servicing and maintenance recommendations.
Changes or modifications
Unauthorized modifications to the engine represent a safety risk.
MTU accepts no liability whatsoever for damage or injury resulting from unauthorized changes or
modifications and refuses to accept warranty claims in such case.
Spare parts
Use genuine MTU spare parts only when replacing components or assemblies. The engine
manufacturer accepts no liability whatsoever for damage or injury resulting from the use of other
spare parts and the warranty shall be voided in such case.
E532191/00E 05-06 © MTU

04 Safety
1.2 Personnel and organizational prerequisites

Personnel requirements
All work on the engine shall be carried out by trained and qualified personnel only.
Observe minimum legal age requirements.
Define the responsibilities of operating, maintenance and repair personnel.
Organizational measures
Hand over this manual to operating, maintenance, repair and transport personnel.
Keep it handy in the vicinity of the engine such that it is accessible to operating, maintenance,
repair and transport personnel at all times.
Use the manual as a basis for instructing personnel on engine operation and repair with an
emphasis on explaining safety-relevant instructions.
This is particularly important in the case of personnel which only occasionally performs work on or
around the engine. Instruction should be repeated for this personnel.
Working clothes and safety wear
Always wear appropriate safety clothing when carrying out work.
Put on additional safety wear as dictated by the nature of the work, e.g. safety goggles, gloves, helmet, apron!
Working clothes must be close-fitting to prevent them getting caught on rotating or protruding parts.
Do not wear jewelry (rings, chains, etc.).
E532191/00E 05-06 © MTU

Safety 05
1.3 Safety requirements for maintenance and repair work

Safety requirements for initial 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 controls and displays as well as the
monitoring, signaling and alarm systems must be tested for proper operation.
Safety requirements for operation
The emergency procedures must be practiced on a regular basis.
The operator must be familiar with the controls and displays.
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 instruments 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
• inform the person in charge
• evaluate the message
• take appropriate emergency action, e.g. stop the engine
Engine operation
When the engine is running, always wear ear protectors.
Ensure that the engine room is well ventilated.
Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binder.
Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a health
hazard. The exhaust pipework must be free of leaks and discharge the gases to atmosphere.
During engine operation, do not touch battery terminals, generator terminals or cables.
Inadequate protection of electrical components can lead to electric shocks and serious injuries.
When the engine is running, never release coolant, oil, fuel, compressed air or hydraulic lines.
Maintenance and repair
Strict adherence to the maintenance and repair schedule is an essential safety factor.
Never carry out maintenance and repair work with the engine running unless expressly instructed to do so.
Lock-out/tag-out the engine to preclude undesired starting. Disconnect the battery when electrical starters are fitted.
Close the main valve on the compressed-air system and vent the compressed-air line when air starters are fitted. Post
the "Do Not Start" sign in the operating room or affix it to the controlling device! Persons not involved must keep clear.
Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools
required. Have maintenance and repair work carried out by qualified and authorized personnel only.
Use only proper, calibrated tools.
Do not work on engines or components which are only held by lifting equipment or crane. Support
appropriately according to regulations before commencing maintenance or repair work.
Before barring the engine, make sure that nobody is standing in the danger zone. After completing
work on the engine, check that all protective devices/safety guards have been installed and that
all tools and loose parts have been removed from the engine.
Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Before
starting work, relieve pressure in systems and compressed-air lines which are to be opened.
Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage fuel lines during maintenance and repair work. To tighten the connections when installing
the lines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly.
E532191/00E 05-06 © MTU

06 Safety
Ensure that all fuel injection lines and pressurized oil lines have sufficient distance to other
components to avoid contact with them. Do not place fuel or oil lines near hot components,
except when necessary for design reasons during installation.
Elastomers (e.g. "Viton" sealing rings) are stable under normal operating conditions. The material decomposes
when exposed to fire or temperatures exceeding 300 °C. Hydrogen fluoride vapors are released in this
case. The resulting acid leads to serious burning if it contacts the skin. Do not touch elastomeric seals
if they have carbonized or resinous appearance. Wear protective gloves!
Take care with hot fluids in lines, pipes and chambers ⇒ Risk of injury!
Note cooling period for components which are heated for installation or removal ⇒ Risk of injury!
Never touch hot parts of the compressor and exhaust system ⇒ Risk of burning!
Take special care when removing ventilation or plug screws from engine. In order to avoid discharge
of highly pressurized liquids, hold a cloth over the screw or plug. It is even more dangerous if the
engine has recently been shut down, as the liquids can still be hot.
Take special care when draining hot fluids. ⇒ Risk of injury!
When draining, collect fluids in a suitable container, mop up any spilt fluids or wipe or soak them with a suitable binder.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.
When working high on the engine, always use suitable ladders and work platforms. Make
sure components are placed on stable surfaces.
In order to prevent back injuries when lifting heavy components adults, depending on age and sex,
should only lift weights between max. 10 kg and 30 kg, therefore:
• Use lifting gear or seek assistance.
• Ensure that all chains, hooks, slings, etc. are tested and authorized, are sufficiently strong and that
hooks are correctly positioned. Lifting eyes must not be unevenly loaded.
Welding work
Never carry out welding work on the engine or engine-mounted units.
Never use the engine as a ground connection. This prevents the welding current passing through
the engine resulting in burnt/scorched bearings, sliding surfaces and tooth flanks which may
lead to bearing seizure and/or other material damage.
Never route the welding lead over or near the wiring harnesses of MTU systems. The welding current may
induce interference in the wiring harnesses which could damage the electrical system.
The welding unit ground connection must not be more than 60 cm from the weld point.
If components (e.g. exhaust manifold) are to be welded, they must be removed from the engine.
It is not necessary to remove the connector and the connections when carrying out welding operation
on MTU electronics if the master switch for power supply is switched from "ON" to "OFF" and the wire
is disconnected from the negative and positive poles on the battery.
Hydraulic installation and removal
Only the hydraulic installation and removal equipment specified in the work schedule and
in the assembly instructions must be used.
The max. permissible push-on pressure specified for the equipment must not be exceeded.
The H.P. lines for hydraulic installation and removal are tested with 3800 bar.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the system
to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle
into shaft end until correct sealing is achieved.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed. As long as the system is under pressure, there is the risk that the
component to be installed/removed may be suddenly released from the pressure connection.
Before use, the tools must be checked at regular intervals (crack test).
E532191/00E 05-06 © MTU

Safety 07
Working on electrical/electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and repair
work or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies. Any measures requiring a power
supply are expressly defined as such at the appropriate place in the manual.
Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery
acids to come in contact with skin or clothing. Wear protective goggles. Do not place tools on the
battery. Before connecting the cable to the battery, check battery polarity. Battery pole reversal may lead
to injury through the sudden discharge of acid or bursting of the battery body.
Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is
not damaged by contact with sharp objects, by rubbing against other component or by a hot surface.
Do not secure wiring to fluid-carrying lines.
On completion of the maintenance and repair work, any cables which have become loose
must be correctly connected and secured.
On completion of all repair work, the component and system must be subjected to a function check.
Separate testing of the repaired component without system integration is insufficient.
If wires are installed beside mechanical components and there is a risk of chafing, use
cable clamps to properly support the wires.
For this purpose, no cable binders must be used as, during maintenance and / or repair work,
the binders can be removed but not installed a second time.
Spare parts shall be properly stored prior to replacement, i.e. particularly protected against moisture. Defective
electronic components and assemblies must be suitably packed when dispatched for repair, i.e. particularly
protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment
When working with laser equipment, always wear special laser-protection goggles.
Laser equipment can generate extremely intensive, concentrated radiation by the effect of stimulated emission
in the range of visible light or in the infrared or ultraviolet spectral range. The photochemical, thermal and
optomechanical effects of the laser can cause damage. The main danger is irreparable damage to the eyes.
Laser equipment must be fitted with the protective devices necessary for safe
operation according to type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be used:
• Laser devices of classes 1, 2 or 3A,
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a
maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.
Operation of electrical equipment
When operating electrical equipment, certain components of this equipment are live.
Noncompliance with the warning instructions given for this equipment may result in
serious injury or damage to property.
E532191/00E 05-06 © MTU

08 Safety
1.4 Fluids and lubricants, fire prevention and

environmental protection
Fire prevention
Clean up spilt or leaked fuel immediately, even small amounts of fuel on hot parts may cause a
fire, so keep the engine clean at all times. Never leave fluid-soaked rags lying on the engine. Do
not store flammable materials in the vicinity of the engine.
Do not perform welding work on pipes and parts bearing oil or fuel! Clean with a non-flammable agent prior to welding.
Connect the ground cable last and disconnect it first when starting the engine from an external power
source. Connect the ground cable of the external power source to the ground cable of the engine or to the
ground terminal of the starter to prevent sparking in the vicinity of the battery.
Keep suitable extinguishants (fire extinguishers) on hand and practice their usage.
Noise
Noise may increase the risk of accident as it may impair the perception of audible signals,
warning cries or other sounds indicating a hazard.
Wear ear protectors (muffs, plugs, caps) when working in environments with sound
pressure levels exceeding 85 dB(A)!
Environmental protection
Dispose of used fluids, lubricants and filters in accordance with the applicable regulations.
Manipulation of the injection or control systems may affect the performance of the engine and exhaust gas
emission to the extent that statutory environmental protection regulations are violated.
Use fuels of the prescribed quality only in order to meet emission limits.
VAwS regulations (ordinance on installations handling water-polluting substances) apply in Germany, i.e.
work may only be carried out by specialist companies (MTU is a specialist company).
Consumables and expedients
Only use consumables which have been tested and approved by MTU.
Store consumables and expedients in suitable and correctly labelled receptacles! Observe the
safety regulations which apply to the product when handling fluids and lubricants and other chemical
substances. Take care when handling hot, very cold or corrosive substances. Avoid sources of
ignition when handling inflammable substances, do not smoke!
Lead
• Avoid skin contact with lead or lead-bearing pastes, do not inhale lead vapors.
• Avoid creating lead dust!
• Switch on extractors!
• Wash your hands following contact with lead or lead-bearing substances!
Acids and alkaline solutions
• Wear goggles or a face shield, gloves and protective clothing when working with acids and alkaline solutions.
• Remove contaminated clothing immediately in case of acid or alkali burns!
• Rinse injuries with copious amounts of water!
• Irrigate eyes immediately with an eye wash bottle or clean tap water!
Paints and lacquers
• Ensure good ventilation when painting outside spraying stands equipped with extractors. Ensure
that neighboring workplaces are not adversely affected!
• No naked flames!
• No smoking!
• Observe fire prevention regulations!
• Wear a face mask to preclude inhalation of paint and solvent vapors!
Liquid nitrogen
• Store only small quantities of liquid nitrogen in regulation vessels (without sealed cap).
• Avoid contact (eyes, hands). Frostbite, even to the extent of necrosis of affected
parts of the body, may otherwise result.
E532191/00E 05-06 © MTU

Safety 09
• Wear protective clothing, gloves, closed footwear and goggles!

• Ensure good room ventilation. Suffocation ensues when nitrogen levels in the air rise above 88%.
• Avoid jolting or jarring vessels, valves and fittings or workpieces!
Compressed air
Compressed air is air compressed at overpressure and stored in a pressure vessel from where it may be withdrawn.
Air pressure is indicated on pressure gauges (manometers) which must be fitted on pressure
vessels and also on the compressed-air lines.
Observe the following special safety precautions when dealing with compressed air:
• Check the pressure level in the compressed-air system or pressure vessel!
• Any connected equipment or devices must either be designed to withstand this pressure or, should their
admissible pressure be lower, pressure reduction and safety valves (set to the admissible pressure)
must be integrated in between. Hose couplings and unions must be securely tightened!
• Wear goggles when blasting out workpieces or blowing away swarf!
• It is advisable to fit a guard (e.g. rubber) at the mouth of the air nozzle to minimize flying
particles and afford protection against eye injuries.
• Shut-off compressed-air lines before disconnecting pneumatic equipment from the supply
line or before changing equipment and tools!
• Improper use of compressed air, e.g. to force out flammable liquids (hazard classes AI,
AII and B), represents an "explosion hazard"!
• Blowing compressed air into thin-walled receptacles (e.g. made of sheet metal, plastic, glass) for
purposes of drying or checking for leakage represents a "bursting hazard"!
• Never blow dirt off clothing when worn!
Used oil
Used oils may contain combustion residues which are detrimental to health.
Apply barrier cream to your hands!
Wash your hands after coming into contact with used oil!
E532191/00E 05-06 © MTU

10 Safety
1.5 Conventions for safety warnings in the text

In the event of immediate danger.
Consequences: Death or serious injury.
DANGER • Preventive measures
In the event of possibly dangerous situations.
Consequences: Death or serious injury.
WARNING • Preventive measures
In the event of dangerous situations.
Consequences: Slight injury or material damage.
CAUTION • Preventive measures
Note: This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which
begin with one of the signal words listed above depending on the degree of hazard seriousness.
Safety warnings
1. Read and familiarize yourself with all safety warnings before starting up or repairing the product!
2. Pass on all safety warnings to operating, maintenance, repair and transport personnel!
E532191/00E 05-06 © MTU

Installation 11
2 Installation
2.1 Preparation
2.1.1 Cable routes and openings between all installation locations – Check
Defining cable routes
1. Define the cable route between engine room and main control stand 1.
2. Define the cable route between main control stand 1 and main control stand 2 (if applicable).
3. Define the cable route between main control stand 1 and slave control stand 1 (if applicable).
4. Define the cable route between main control stand 1 and slave control stand 2 (if applicable).
5. Define the cable routes between the control units and the positions in the console where the MTU BlueLine
devices are to be located.
Checking cable routes

1. Check that the minimum opening diameters (see figure) through one or more partition walls over the course
of these routes are no smaller than the dimensions specified below.
1.1. Between LOS / LOP and machinery or engine room: min. 200 mm
1.2. Between machinery or engine room and main control stand 1 (PIM 4): min. 100 mm
1.3. Between main control stand 1 (PIM 4) and main control stand 1 (console front panel): min. 60 mm
1.4. Between main control stand 1 (PIM 4) and slave control stand 1: min. 60 mm
1.5. Between main control stand 1 (PIM 4) and slave control stand 2: min. 60 mm
1.6. Between main control stand 1 (PIM 4) and main control stand 2 (PIM 4): min. 100 mm
1.7. Between main control stand 2 (PIM 4) and main control stand 2 (console front panel): min. 60 mm
2. Change the cable route (check new cable lengths!) or increase the size of the openings if these specifications
are not met.
E532191/00E 05-06 © MTU

12 Installation
2.1.2 Cable routing between installation locations for Series 2000

unit-pump system, non-classifiable system
Preconditions
• Cable openings provided.
• Devices not yet installed.
• Cable trays etc. installed.
• Cables are long enough to allow their plugs to be connected once the devices have been installed.
Cable routing, general information
1. Route asymmetrical cables in the right direction. Connector numbers commencing with X are provided on
stickers on the connectors or cable ends and are used in the descriptions below to facilitate this.
2. Route cables neatly! Edges over which cables are routed must be suitably blunted (edge protectors, anti-kink
sleeve over cable etc.).
3. Secure all cables by appropriate means (cable clamps, cable ties etc.) at suitable points on the vessel.
1 Engine 2 Gearbox 3 Trolling unit (option)
Cables to engine on Series 2000 M60, M70, M90, M91

1. Check that relevant engine sensors/actuators are connected to ECU 4 (X2) by cable W002.
3. Route cable W037 between X010 (X4) and the barring gear limit switches.
4. Route cable W014 between X010 (X2) and battery-charging generator.
5. Route cable W014.1 between X010 (X2) and starter.
6. Route cable W014.3 (if applicable) between X010 (X2) and battery-charging generator.
E532191/00E 05-06 © MTU

Installation 13
Routing cables to gearbox and fuel system

1. Route cable W022 between GCU (X2) and gearbox.
2. Route cable W011.1 and W011.2 between LOP (X11) and fuel prefilter.
Routing cables between ECS devices on Series 2000 M60, M70, M90, M91
1. Route cable W001 between LOP (X1) and ECU 4 (X1).
3. Route cable W002.1 between LOP (X2) and X010 (X1).
4. Route cable W013 between LOP (X13) and GCU (X1).
Routing cables to main control stand and power supply

1. Route cable W004 between LOP (X4) and CCP 1 (X4.2).
2. Route cable W007 from battery installation location to LOP (X7).
Routing cables for options

1. For Trolling option: Route cable W023.1 from battery installation location to GCU (X3). Route attached cable
W023.2 from GCU (X3) further to trolling unit.
2. For optional additional signals (external start interlock, external heat exchanger, exhaust back pressure): Route
cable W010.x between LOP (X10) and relevant signal source.
E532191/00E 05-06 © MTU

14 Installation
2.1.3 Cable routing between installation locations for Series

2000 CR, non-classifiable system
Preconditions
1 Engine 2 Gearbox 3 Trolling unit (option)

E532191/00E 05-06 © MTU

Installation 15



E532191/00E 05-06 © MTU

16 Installation

4000, non-classifiable system
Preconditions
1 Engine 3 Trolling unit (option)

2 Gearbox 4 Oil priming pump
Cables to engine on Series 4000 M60, M61, M70, M71, M90

5. Route cable W014.1 between X010 (X2) and starter “B”.
E532191/00E 05-06 © MTU

Installation 17
6. If second starter installed: Route cable W014.2 between X010 (X2) and starter “A”.

Routing cables between ECS devices on Series 4000 M60, M61, M70, M71, M90

Routing cables for optional oil priming pump

1. Route cable W017 from AC voltage connection location to PPC (X2).
2. Route cable W014.7 between X010 (X3) and PPC (X1).
3. Route cable W018 between PPC (X3) and oil priming pump.
Routing cables for additional options

E532191/00E 05-06 © MTU

18 Installation
2.1.5 Cable routing between installation locations for Series 2000

unit-pump system, classifiable system
Preconditions

2 Gearbox 4 Shaft speed sensor

3. Check that relevant engine sensors are connected to EMU 1 (X12) by cable W012.
E532191/00E 05-06 © MTU

Installation 19

Routing cables to gearbox, shaft and fuel system

1. Route cable W043 between MEU (X2) and gearbox (X15).
2. Route cable W042 between MEU (X3) and shaft speed sensor (X27).
4. Route cable W013 between LOP (X13) and MEU (X1).
5. Route cable W044 between MEU (X13) and GCU (X1).
7. Route cable W041 between MEU (X6) and EMU 1 (X11).

2. Route cable W051 between MEU (X8) and CCP 1 (X8.2).
5. Route cable W040 from battery installation location to MEU (X7).

E532191/00E 05-06 © MTU

20 Installation

2000 CR, classifiable system
Preconditions


E532191/00E 05-06 © MTU

Installation 21




E532191/00E 05-06 © MTU

22 Installation

4000, classifiable system
Preconditions
1 Engine 3 Trolling unit (option) 5 Oil priming pump

Cables to engine on Series 4000 M60, M61, M70, M71, M90

6. Route cable W014.1 between X010 (X2) and starter “B”.
E532191/00E 05-06 © MTU

Installation 23
7. If second starter installed: Route cable W014.2 between X010 (X2) and starter “A”.

Routing cables between ECS devices on Series 4000 M60, M61, M70, M71, M90

Routing cables for optional oil priming pump

1. Route cable W017 from AC voltage connection location to PPC (X2).
2. Route cable W014.7 between X010 (X3) and PPC (X1).
3. Route cable W018 between PPC (X3) and oil priming pump.
Routing cables for additional options

E532191/00E 05-06 © MTU

24 Installation
2.2 Mechanical Installation (all Series, basic and extended

scope)
2.2.1 LOP – Installation
Preconditions
• The Local Operating Panel should be located in the engine room in the immediate vicinity of the engine.
Ensure that adequate space is available in front of and next to the housing.
• Position the Local Operating Panels of the power trains such that it is obvious which Local Operating Panel
controls which power train.
• The Local Operating Panel can be installed in extremely confined engine rooms provided that it can still be
operated properly.
• If the Local Operating Panel LOP features a display it must be installed in an easily accessible location in the
engine room. A wide range of control functions and detailed information about the operating states of the
engines and the overall electronic system are provided here.
• Allow space for disconnection! Ensure that adequate space is left at the bottom and at the sides to allow
disconnection. Leave at least 200 mm of space on each side between the two bores on the right and left and
any bordering wall. The space between the two bores at the bottom and a floor must be at least 300 mm.
• The Local Operating Panel must be easy to open at the front when mounted in the installation location.
Making bores
Note: Installation of the Local Operating Panel
as described here applies to the Local
Operating Panel LOP and the Local
Operating Panel LOP with display.
1. Mark out the four mounting bores for the Local

Operating Panel LOP on the designated wall in
accordance with the drilling pattern. The tolerance
is ± 0.5 mm.
2. Drill bores with a diameter of 8 mm.
Installing LOP
1. Hold the Local Operating Panel LOP against the wall and insert bolts through the mounting brackets and the
bores in the wall.
2. Screw a nut with a plain washer and a spring washer on the other side of each of the four bolts and tighten by
hand.
3. Tighten the bolts. Ensure that the Local Operating Panel LOP is aligned horizontally in so doing.
E532191/00E 05-06 © MTU

Installation 25
Fitting grounding cable

1. Route a cable with a cross-section of at least 2.5
mm2 to the grounding point.
2. Fit a terminal ring (diameter 6 mm) on the device
end.
3. Secure the terminal ring at the grounding stud
on the device as shown in the figure: Nut (1) --
spring washer (2) -- washer (3) -- terminal ring (4)
-- grounding stud (5) -- housing (6)
4. Secure the grounding cable such as to establish
an electrical connection at the common grounding
point (specifics vary from case to case).
E532191/00E 05-06 © MTU

26 Installation
2.2.2 Installing terminal box X010
Preconditions
• Terminal box X010 can be positioned such that the precut wiring harnesses W014 from the battery-charging
generator and the starter(s) reach up to the terminal box.
• Terminal box X010 can be positioned such that the precut wiring harness W002 from the LOP reaches up to
the terminal box.
• Sufficient clearance to walls and other devices next to the terminal box is available (→ illustration): Left-hand
side (up to A) ≥ 115 mm; lower side (up to B) ≥ 156 mm; right-hand side (up to C) ≥ 108 mm.
• Free access to the screws of the cover must be provided after installation of the housing.
Making the bores
1. Mark out the four mounting bores for the terminal
box on the designated wall in accordance with the
drilling pattern. Tolerance: ±0.5 mm.
Installing X010
1. Remove the cover on the terminal box.
2. Insert a bolt through one of the mounting bores.
3. Push the bolt through the bore in the wall.
4. Fit a plain washer, a spring washer and a nut on the other side.
5. Tighten nut by hand.
6. Fit three more bolts in the same way.
7. Tighten all bolts. Ensure that the terminal box is aligned horizontally.
8. Screw the cover back on loosely.
Fitting the grounding cable

1. Route a cable with a cross-section of at least 2.5 mm2 to the grounding point.
2. Fit wire-end ferrules on the device end.
3. Undo both bolts on the ground strap, slide the grounding cable underneath.
4. Tighten the bolts firmly.
5. Check cable for firm seating.
6. Secure the grounding cable such as to establish an electrical connection at the common grounding point
(specifics vary from case to case).
E532191/00E 05-06 © MTU

Installation 27
2.3 Mechanical Installation (all Series, extended scope only)
2.3.1 MEU – Installation
Preconditions
• The intended installation location affords adequate space around the housing (draw-out clearance): Distance
between the two bores on the right and any adjoining wall is at least 180 mm. Distance between the two bores
at the bottom and any adjoining wall is at least 255 mm.
• The front panel of the MEU must be easy to open at the front following installation.
• Monitoring Extension Units MEU for several power trains can be positioned such that it is easy to determine
which MEU is associated with which power train.
Making the bores
1. Mark out the four mounting bores for the MEU on
the designated wall in accordance with the drilling
pattern. Tolerance is ±0.3 mm.
Installing MEU
1. Hold Monitoring Extension Unit MEU against the wall and insert screws through the lugs and the bores
in the wall.
2. Screw a nut with washer and spring washer onto each of the four screws from the other side and tighten
hand-tight.
3. Tighten the screws. Ensure that MEU is aligned horizontally.
E532191/00E 05-06 © MTU

28 Installation

Note: Figure shows example. The grounding stud
is located on the right side of the housing
between the lower connector sockets.

mm2 to the ground connection.
2. Fit a ring terminal with a diameter of 6 mm onto
the device end.
3. Secure the ring terminal on the grounding stud of
the device as shown in the figure: Nut (1) -- Spring
washer (2) -- Washer (3) -- Ring terminal (4) --
Grounding stud (5) -- Housing (6)
an electrical connection at the common ground
connection (specifics vary from case to case).
E532191/00E 05-06 © MTU

Installation 29
2.4 Mechanical Installation (all Series, depending on Trolling

option)
2.4.1 GCU – Installation
Preconditions
• The Gear Control Unit must be located in the engine room in the immediate vicinity of the gearbox. Ensure that
adequate space is available in front of and next to the housing.
• Position the Gear Control Units such that it is perfectly clear which Gear Control Unit controls which power train.
• Allow space for disconnection! Ensure that adequate space is left at the bottom and at the sides to allow
disconnection. Leave at least 200 mm of space on each side between the two bores on the right and left and
any bordering wall. The space between the two bores at the bottom and a floor must be at least 300 mm.
• The front panel of the Gear Control Unit must be easy to open at the front.
Making bores
Note: The installation procedure described here
applies to GCU 2, GCU 3 and GCU 6.
1. Mark out the four mounting bores for the Gear

Control Unit on the designated wall in accordance
with the drilling pattern. Tolerance: ± 0.5 mm.
Installing GCU
1. Hold the Gear Control Unit GCU against the wall and fit the bolts.
2. Tighten the bolts. Ensure that Gear Control Unit GCU is aligned horizontally.
E532191/00E 05-06 © MTU

30 Installation
Fitting grounding cable

mm2 to the grounding point.
2. Fit a ring terminal (4) with a diameter of 6 mm onto
the cable.
3. Fit the ring terminal (4) over the grounding stud (5)
on the device (6).
4. Fit a plain washer (3) and a spring washer (2) over
the grounding stud (5).
5. Tighten the nut (1).
an electrical connection at the common grounding
point (specifics vary from case to case).
E532191/00E 05-06 © MTU

Installation 31
2.5 Mechanical Installation (Series 4000 only, optional)
2.5.1 Priming Pump Controller PPC – Installation
Preconditions
• Space to next wall or other device below the housing at least 150 mm.
• At least 20 mm space on left and right.
• Front door of PPC can be opened at front when installed.
Making the bores
1. Mark out the four mounting bores for the housing
on the designated wall in accordance with the
drilling pattern, tolerance ±0.5.
Installing PPC
1. Open housing door.
2. Insert a screw through one of the mounting bores.
3. Push the screw through the bore in the wall.
4. Fit washer, spring washer and nut on other side and tighten fingertight.
5. Proceed with other screws in the same way.
6. Align housing horizontally.
7. Tighten screws.
8. Close door.
1. Route a cable with a cross-section of at least 2.5 mm 2 to the ground connection.
2. Fit wire-tip sleeve on device end.
3. Undo ground strap screws, slide grounding cable under and tighten screws.
4. Secure grounding cable to common ground connection.
E532191/00E 05-06 © MTU

32 Installation
2.6 Electrical Installation (all Series, basic and extended scope)
2.6.1 LOP – Connection
Preconditions
• Cables properly routed
• Cables long enough
Connectors on LOP
1. Remove cap covering connector socket X1.

2. Plug connector X1 of cable W001 into connector socket X1.
8. Plug connector X2 of cable W002.1 into connector socket X2.
12. Plug connector X11 of cable W011 into connector socket X11. Check polarity! The connector has two cables
(W011.1 and W011.2) for the two “Water in fuel prefilter” sensors.
E532191/00E 05-06 © MTU

Installation 33
Power supply
Note: MTU recommends equipping each power train with two battery banks respectively (see fig.). The
second battery bank may have less power as it only serves for emergency supply of the electronic
system in case the starter batteries are flat. This increases the operational reliability of the electronic
system.
1. Connect the negative terminals of both battery banks to the same ground potential, i.e. interconnect the two
battery banks with a suitably thick cable (3). The ground potential in the engine room and on the control
stands must be the same!
2. Ensure that fuses are installed in all feeder lines between the connection points and the MTU cable (two-pole
power circuit breakers in both ground and positive paths). Cable connection at the batteries is represented
schematically, this largely depends on conditions on-board.
3. Secure the MTU cable appropriately in the vicinity of the connection points and cut to size.
4. Strip the outer sheath of the cable back approx. 500 mm.
5. Route the four individual cores to their respective connection points and cut to size:
5.1. Brown — Positive terminal main supply +24V DC (1)
5.2. Black — Negative terminal main supply ground (1)
5.3. Blue — Positive terminal emergency supply (second battery bank, if applicable) (2)
5.4. Black — Negative terminal emergency supply (second battery bank ground, if applicable) (2)
6. Dress the four individual cores with terminal rings which fit the battery terminals.
7. Connect the four individual cores to the battery terminals.
8. Route cable W007 from the battery banks to connector socket X7 on the LOP but do not plug in connector
X7 yet.
E532191/00E 05-06 © MTU

34 Installation
Vessels equipped with just one main battery bank for each power train
1. Connect the two cables for + 24 V (brown and blue) together to the supply of this one battery bank (figure
note A).
2. Connect the two cables for ground (both black) together to the ground of this one battery bank (figure note A).
E532191/00E 05-06 © MTU

Installation 35
2.6.2 Fuel prefilter level sensors – Connection
Preconditions
Connecting “Water in fuel prefilter” level sensors
Note: Installations with double prefilters have two sensors. The two sensors are connected in the same way.
1. Lead cable W011.1 (coming from Local Operating Panel LOP) to the connector an of sensor F070. Lead the
other cable W011.2 (coming from Local Operating Panel LOP) to the connector an of sensor F070.2.
2. Remove the connector at the filter.
3. Route the cable through the connector housing.
4. Strip the outer cable sheath back approx. 3 cm.
5. Strip back the three cores and connect to the connector as follows:
5.1. Core no. 1: +24 V DC supply to connector pin A
5.2. Core no. 2: Ground supply to connector pin B
5.3. Core no. 3: Signal to connector pin C
6. Assemble the connector.
7. Plug the connector into the fuel prefilter and tighten the union nut.
E532191/00E 05-06 © MTU

36 Installation
2.7 Electrical Installation (Series-dependent, basic and

extended scope)
2.7.1 Connecting engine governor ECU
Preconditions
• Cables are properly routed.
• Cables are long enough.
Special tools
Designation / Use Part No. Qty.
Connector pliers 0135315483 1
Loose contact at plug connections.

Risk of malfunctions in engine operation!
CAUTION • Ensure that bayonet union nuts engage completely.
Connecting ECU
1. Remove covers (3) from sockets (1, 2).
2. Plug connector X1 into socket X1.
4. Route the cables up away from the engine.
5. Turn bayonet union nuts on connectors (4)
clockwise with connector pliers (5) until firmly
engaged (do not tighten by hand!).
E532191/00E 05-06 © MTU

Installation 37
2.7.2 Engine Control Unit ECU 7 – Connection
Preconditions
Connecting ECU
1. Remove cable clamps (6).
2. Plug connector X1 (1) into socket X1 (4) and
engage clip.
engage clip.
4. Route the cable away over the Engine Control Unit.
5. Secure cable (5) with cable clamps (6).
6. Screw in screws (8) with washers (7) and tighten.
E532191/00E 05-06 © MTU

38 Installation
2.7.3 Starter and battery-charging generator – Connection on BR 2000
Preconditions
• Cable cross-sections as specified
Wiring fires due to short-circuits.

Damage to components, major material damage!
CAUTION • Ensure that connections do not come into contact with each other.
• When making connections, make sure that polarity of connections is correct.
Cable cross-section specifications for cabling between starter and battery (→ Technical sales
documentation for engine)
Connecting the starter – Bosch, Prestolite
Note: The starter (B) is located at the bottom of the engine. The starter relay is located on top of the starter.
1. Route one cable (+U_BAT) with an adequate cross-section from the battery positive terminal to starter B.
2. Fit a cable ring for an M12 stud (terminal 30) to the +U_BAT cable.
3. Route one cable (GND_BAT) with an adequate cross-section from the battery negative terminal to starter B.
4. Fit a cable ring for an M10 stud (terminal 31) to the GND_BAT cable.
5. Lead cable W014.1 to starter B.
E532191/00E 05-06 © MTU

Installation 39
6. Prepare cable (W014.1):

6.1. Cut cable to size and strip the insulation back approx. 100 mm.
6.2. Core 1: Fit a cable ring for an M12 stud (terminal 30).
7. Insulate all crimp connections with heat-shrinkable hose (red for “+”, blue or black for “–”).
8. Connect all cables as illustrated. Check arrangement of nuts and washers on the stud (see below).
9. Secure all cables at suitable points with cable clamps/ties.
Connecting the starter – Delco Remy

Note: Connection is principally the same as for
the Bosch/Prestolite starter.
1. Refer to the table for deviant connection

designations.
Starter connection assignment, Bosch/Prestolite – Delco Remy
Standard designation Terminal designation Terminal designation Function

Bosch, Prestolite Delco Remy
30 30 BAT Direct input from battery

positive
30b 30b MTR/2 Battery positive input, 2nd

starter
31 31 G Battery ground
45 45 MTR/1 Output at separate starter

relay, input at starter (main
current)
50 50 S Starter control
2. Connect the starter as described under

“Connecting starter B – Bosch, Prestolite”.
E532191/00E 05-06 © MTU

40 Installation
Connecting the battery-charging generator

Note: Connection of the battery-charging generator depends largely on the conditions on board. Refer to the
MTU “Wiring diagram” for additional information.
1. Route a cable from the positive terminal of the battery which is to be charged to the battery-charging generator
and connect it to terminal “B+” (fitting spade lugs, cable rings etc. as required).
2. Route a cable from the negative terminal of the battery which is to be charged to the battery-charging generator
and connect it to terminal “B–” (fitting spade lugs, cable rings etc. as required).
3. Lead cable W014 to the battery-charging generator and secure it at the strain reliever.
4. Connect cable W014:
4.1. Cut the cable to size and strip the insulation back approx. 100 mm.
4.2. Connect core 1 to terminal “D+” on the battery-charging generator (fitting spade lugs, cable rings
etc. as required).
4.3. Connect core 2 to terminal “W” on the battery-charging generator (fitting spade lugs, cable rings etc. as
required).
5. Applicable to application“Battery-charging generator does not charge starter battery” only:
5.1. If a connecting cable is fitted between the starter (terminals 30, 31) and battery-charging generator
(terminals B+, B–) on delivery: Disconnect or cut the cable and insulate the ends.
5.2. Lead cable W014.3 to the battery-charging generator and secure it at the strain reliever.
5.3. Cut cable W014.3 to size and strip the insulation back.
5.4. Connect cable W014.3 to terminal “B+” (fitting spade lugs, cable rings etc. as required).
Connecting batteries
1. Fit suitable connections to the cables connected to the positive terminals of the batteries.
2. Fit suitable connections to the cables connected to the negative terminals of the batteries.
3. Connect the cables to the battery terminals.
Arrangement of parts on a stud

1. Fit cables and washers on the stud in the order
shown in the figure.
2. Tighten nut (1) countering the locknut (9) in so
doing.
1 Nut
2 Spring washer
3 Washer
4 Cable ring with thin cable
5 Cable ring with thick cable
6 Cable ring with additional thick cable
7 Washer
8 Stud
9 Locknut
E532191/00E 05-06 © MTU

Installation 41
2.7.4 Starter and battery-charging generator – Connection on BR 4000
Preconditions
• Cable cross-sections as specified
Wiring fires due to short-circuits.

Damage to components, major material damage!
CAUTION • Ensure that connections do not come into contact with each other.
• When making connections, make sure that polarity of connections is correct.
Cable cross-section specifications for cabling between starter and battery (→ Technical sales
documentation for engine)
Engine with two starters (A and B) – Bosch, Prestolite
Note: Applicable for two starters, type Bosch/Prestolite. Starters A and B are located on the right and left at
the bottom of the engine. The starter relays are located on top of the starters to which they are assigned.
1. Route one cable (+U_BAT) with an adequate cross-section from the battery positive terminal to starter A.
3. Route two cables (GND_BAT) with an adequate cross-section from the battery negative terminal to the starters.
4. Fit a cable ring for an M10 stud (terminal 31) to both GND_BAT cables.
5. Route two cables with an adequate cross-section from starter A to starter B.
E532191/00E 05-06 © MTU

42 Installation
6. Fit cable rings for an M12 stud (terminals 30, 30b and 45) to both ends of these cables.
8. Prepare cable W014.1:
9. Lead cable W014.2 to starter A.
10. Prepare cable W014.2:
Engine with one starter – Bosch, Prestolite
Note: Applicable for one starter, type Bosch/Prestolite. The starter (B) is located at the bottom of the engine.
The starter relay is located on top of the starter.
1. Route one cable (+U_BAT) with an adequate cross-section from the battery positive terminal to starter B.
E532191/00E 05-06 © MTU

Installation 43
3. Route one cable (GND_BAT) with an adequate cross-section from the battery negative terminal to starter B.
4. Fit a cable ring for an M10 stud (terminal 31) to the GND_BAT cable.
6. Prepare cable (W014.1):
Engine with two starters (A and B) – Delco Remy
Note: Applicable for two starters, type Delco Remy. Connection is principally the same as for Bosch/Prestolite
starters.
1. FIRST REMOVE THE METAL JUMPER BETWEEN THE MTR/1 AND MTR/2 CONNECTIONS ON STARTER
A!
E532191/00E 05-06 © MTU

44 Installation
2. Connect the starters as described under “Two starters (A and B) – Bosch, Prestolite”. Refer to the table
below for details of deviant connection designations.
Starter connection assignment, Bosch/Prestolite – Delco Remy
Standard designation Terminal designation Terminal designation Function

Bosch, Prestolite Delco Remy
30 30 BAT Direct input from battery

positive
30b 30b MTR/2 Battery positive input, 2nd

starter
31 31 G Battery ground
45 45 MTR/1 Output at separate starter

relay, input at starter (main
current)
50 50 S Starter control
Engine with one starter – Delco Remy

Note: Applicable when only one Delco Remy type starter (B) is installed. Connection is principally the same
as for the Bosch/Prestolite starter.
1. Deviant connection designations (→ Table Starter connection assignment, Bosch/Prestolite – Delco Remy
on page 44).
2. Connect the starter as described under “Connecting starter B – Bosch, Prestolite”.
Connecting the battery-charging generator

Note: Connection of the battery-charging generator depends largely on the conditions on board. Refer to the
MTU “Wiring diagram” for additional information.
1. Route a cable from the positive terminal of the battery which is to be charged to the battery-charging generator
and connect it to terminal “+” (fitting spade lugs, cable rings etc. as required).
2. Route a cable from the negative terminal of the battery which is to be charged to the battery-charging generator
and connect it to terminal “–” (fitting spade lugs, cable rings etc. as required).
3. Lead cable W014 to the battery-charging generator and secure it at the strain reliever.
4. Connect cable W014:
4.1. Cut the cable to size and strip the insulation back approx. 100 mm.
4.2. Insulate core 2, it is not connected.
4.3. Connect core 1 to terminal 61 on the battery-charging generator (fitting spade lugs, cable rings etc. as
required).
5. Applicable to application“Battery-charging generator does not charge starter battery” only:
5.1. Lead cable W014.3 to the battery-charging generator and secure it at the strain reliever.
5.2. Cut cable W014.3 to size and strip the insulation back.
5.3. Connect cable W014.3 to terminal “+” (fitting spade lugs, cable rings etc. as required).
Connecting batteries
1. Fit suitable connections to the cables connected to the positive terminals of the batteries.
2. Fit suitable connections to the cables connected to the negative terminals of the batteries.
3. Connect the cables to the battery terminals.
E532191/00E 05-06 © MTU

Installation 45
Arrangement of parts on a stud

1. Fit cables and washers on the stud in the order
shown in the figure.
2. Tighten nut (1) countering the locknut (9) in so
doing.
1 Nut
2 Spring washer
3 Washer
4 Cable ring with thin cable
5 Cable ring with thick cable
6 Cable ring with additional thick cable
7 Washer
8 Stud
9 Locknut
E532191/00E 05-06 © MTU

46 Installation
2.7.5 Barring gear limit switch – Connection
Preconditions
Limit switch with screw cable entry on Series 2000,
unit-pump system
1. Lead cable W014.2 to the limit switch (2) on the
barring gear.
2. Strip back cable insulation.
3. Remove cover on limit switch.
4. Route the cable through the cable entry (1)
(→ Page 52).
5. Strip back both cores and connect to the switch
as follows:
Core No. Signal Connect to
1 Switch COM S037 -- terminal 0
2 Switch NC S037 -- terminal 2
6. Install cover on limit switch.
Limit switch with plug connection on Series 4000

1. Lead cable W037 to connector X037 on the engine. Connector X037 is located at the bottom on the ECU
mounting plate.
2. Plug in the cable at connector X037 and engage the bayonet lock.
E532191/00E 05-06 © MTU

Installation 47
2.8 Electrical Installation (Series-dependent, extended scope

only)
2.8.1 Engine Monitoring Unit EMU 1 – Connection
Preconditions
• Cables properly routed.
• Cables long enough.
Special tools
Connector pliers 0135315483 1
Loose contact at plug connections.

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

X12 (1).
4. Turn the bayonet union nuts (4) on the connectors
clockwise with connector pliers (3) until they
engage. Do not tighten by hand!
5. Route cables up away from the engine.
E532191/00E 05-06 © MTU

48 Installation
2.8.2 Engine Monitoring Unit EMU 7 – Connection
Preconditions
Connecting EMU 7
Note: The cable to the engine may already be
connected on delivery. Omit the associated
activities in this case.
1. Unscrew cable clamps (8).

engage clip.
engage clip.
4. Secure cable (1) on device with cable clamps (8)
as shown.
5. Insert screws (2) with washers (3) into the
appropriate bores (6) and tighten.
6. Secure connected cables at suitable points on the
engine.
E532191/00E 05-06 © MTU

Installation 49
2.8.3 MEU – Connection
Preconditions
Connectors on MEU

2. Plug connector X5 of cable W022 into connector socket X5 and engage the retainer.
E532191/00E 05-06 © MTU

50 Installation
Power supply
Note: MTU recommends equipping each power train with two battery banks respectively (see fig.). The
second battery bank may have less power as it only serves for emergency supply of the electronic
system in case the starter batteries are flat. This increases the operational reliability of the electronic
system.
1. Connect the negative terminals of both battery banks to the same ground potential, i.e. interconnect the two
battery banks with a suitably thick cable (3). The ground potential in the engine room and on the control
stands must be the same!
2. Ensure that fuses are installed in all feeder lines between the connection points and the MTU cable (two-pole
power circuit breakers in both ground and positive paths). Cable connection at the batteries is represented
schematically, this largely depends on conditions on-board. Power is generally distributed via a main
switchboard.
3. Secure the MTU cable appropriately in the vicinity of the connection points and cut to size.
4. Strip the outer sheath of the cable back approx. 500 mm.
5. Route the four individual cores to their respective connection points and cut to size:
5.1. Brown — Positive terminal main supply +24V DC (1)
5.2. Black — Negative terminal main supply ground (1)
5.3. Blue — Positive terminal emergency supply (second battery bank, if applicable) (2)
5.4. Black — Negative terminal emergency supply (second battery bank ground, if applicable) (2)
6. Dress the four individual cores with terminal rings which fit the battery terminals.
7. Connect the four individual cores to the battery terminals.
8. Route cable W040 from the battery banks to connector socket X7 on the MEU but do not plug in connector
X7 yet.
E532191/00E 05-06 © MTU

Installation 51
Vessels equipped with just one main battery bank for each power train
1. Connect the two cables for + 24 V (brown and blue) together to the supply of this one battery bank (figure
note A).
2. Connect the two cables for ground (both black) together to the ground of this one battery bank (figure note A).
E532191/00E 05-06 © MTU

52 Installation
2.9 Electrical Installation (all Series, depending on equipment

and options)
2.9.1 HSK cable bushing – Preparation
Preconditions
Stripping the cables
1. Slide the bushing (5) over the cable.
2. Remove enough outer sheath of the cable such
that it still reaches into the screw element (4) as
far as possible.
Installing the cables

1. Slide the plastic insert (2) over the shielding braid.
2. Fold the shielding braid (1) back over the O-ring (3) of the plastic insert (2).
3. Cut off superfluous shielding braid.
4. Insert the individual wires through the screw element (4).
5. Slide the cable with the plastic insert (2) and the union (5) into the screw element (4) as far as it will go.
6. Tighten the union (5) firmly.
E532191/00E 05-06 © MTU

Installation 53
2.9.2 Terminal strip – Preparation
Preconditions
Cutting individual wires to length
1. Determine the terminal to which the wire concerned
is to be connected (see connection or wiring
diagram).
2. Cut each wire to the suitable length.
Connecting the cables

1. Strip approx 8 mm of insulation off the first wire to be connected.
2. Do not fit wire-end ferrules.
3. Determine the terminal to which this wire is to be connected (see connection or wiring diagram).
4. Press the actuator tool (1) firmly into the square hole (4) in the direction indicated by the arrow; move the
inscription tag (5) to one side if necessary.
5. Insert the wire (2) into the corresponding round hole (3).
6. Pull out the actuator tool.
7. Connect up all the other wires in the same way.
Final steps
1. Bundle the individual wires suitably using cable tie(s).
2. Remove all foreign bodies (bits of cable, bits of cable tie etc.) from the housing.
3. Subsequently check that all connections have been established correctly and are firmly seated.
E532191/00E 05-06 © MTU

54 Installation
2.9.3 Terminal box X010 – Connection
Preconditions
For all Series 2000 and 4000 engines: Local Operating Panel LOP, starter and battery-charging generator
Note: Connection as described here applies to the most common application:
• Electric starting
• Battery-charging generator charges starter battery
• No emergency air-shutoff flap fitted
Refer to the MTU wiring diagram for details of other applications(e.g. air starting).

4. Plug connector X2 on cables W014, W014.1 etc. into connector socket X2.
Series 2000 unit-pump system and 4000 engines only: Barring gear limit switch
3. Plug connector X37 of cable W037 in at barring gear limit switches S037.1/S037.2.
E532191/00E 05-06 © MTU

Installation 55
Series 4000 engines only, option: Priming Pump Controller PPC

Option: Battery-charging generator does not charge starter battery

Note: The following steps are necessary for the LOP signal “Charging check” if the battery-charging generator
charges a battery other than the starter battery.
1. Undo the screws on the terminal box cover.

2. Open the terminal box.
3. Remove the jumper between terminal 2 and terminal 9 at the terminal strip.
4. Lead cable W014.3 to the terminal box from the right and cut to size (approx. 30 cm of cable are required
inside the terminal box).
5. Insert cable W014.3 into the terminal box via the corresponding HSK cable gland (→ Page 52)).
6. Strip cable cores back 8 mm.
7. Connect cable W014.3 cores to terminal 9 (→ Page 53).
8. Fit the cover on the terminal box.
9. Tighten the screws on the terminal box cover.
10. Applicable to special starter-battery/charging generator combinations only (→ MTU wiring diagram):
Disconnect or cut the connecting cables between starter and battery-charging generator fitted by MTU.
Assignment of terminal strip X010 in terminal box X010
Core No. Signal Connector /Pin No. on X010
X010–1 +U BAT terminal 30 (battery supply) X1–1 X2–a1
X010–2 X1–2 X2–e6
X010–3 Starter A terminal 50 (starter control starter X1–3 X2–a2

A)
X010–4 X1–4 X2–d3
X010–5 GND_BAT, terminal 31 (battery ground) X1–5 X2–e3
X010–6 Starter A terminal 45 (starter A engaged) X1–6 X2–e1
X010–7 Barring gear switch +24V X1–7 X4–1
X010–8 Barring gear switch signal (barring gear X1–8 X4–2

mounted = +24V)
X010–9 Common battery bank for starter and X1–9 —

electronics:
+U_BAT, terminal 30 (battery supply)
For separate battery banks for starter and
electronics: +U_BAT_SERVICE, terminal
30 of battery for electronics supply
X010–10 Charging check, battery-charging X1–10 X2–e4

generator terminal 61 (D+)
X010–11 Spare (cable to battery-charging generator, - X2–e5

not assigned)
X010–12 Starter terminal 45 (starter B engaged) X1–12 X2–d4
X010–13 Starter B terminal 50 (starter control starter X1–13 X2–b1

A)
X010–14 X1–14
E532191/00E 05-06 © MTU

56 Installation
Core No. Signal Connector /Pin No. on X010
X010–15 +24 V supply for PPC control section X1–15 X3–1
X010–16 GND (ground for PPC control section) X1–16 X3–2
X010–17
X010–18 Control signal priming on X1–17 X3–3
X010–19
X010–20 Engine running (engine speed > 300 rpm X1–18 —

= +24V)
X010–21 Feedback, oil priming pump running X1–19 X3–4
X010–22 Feedback oil priming pump fault (pump X1–20 X3–5

safety switch tripped)
X010–23 Emergency air-shutoff flap solenoid +24 X1–21 —

VDC*
X010–24 Emergency air-shutoff flap solenoid GND* X1–22 —
X010–25 Emergency air-shutoff flap limit switch X1–23 —

COM*
X010–26 Emergency air-shutoff flap limit switch NC* X1–24 —
X010–27 Emergency air-shutoff flap limit switch NO* X1–11 —
X010–28 — – —
X010–29 — – —
X010–30 - – —
Note: Pin numbers and signals marked * are not used at present.
E532191/00E 05-06 © MTU

Installation 57
2.9.4 GCU connection – Variants
BlueVision – Basic scope

Without trolling
Connecting Gear Control Unit GCU 6 to Local Operating Panel LOP (→ Page 60)
With trolling
Connecting Gear Control Unit GCU 3 to Local Operating Panel LOP (→ Page 58)
BlueVision – Extended scope

Without trolling
Connect Gear Control Unit GCU 6 to Monitoring Extension Unit MEU
Compared to connecting GCU 6 to Local Operating Panel LOP (→ Page 60) the following
differences must be taken into account:
• Cable W044 from GCU socket X1 does not lead to the LOP, but to socket X13 on the MEU.
• Cable W022 from GCU socket X2 does not lead to the gearbox, but to socket X5 on the MEU.
With trolling
Connect Gear Control Unit GCU 3 to Monitoring Extension Unit MEU
Compared to connecting GCU 3 to Local Operating Panel LOP (→ Page 58) the following
differences must be taken into account:
• Cable W044 from GCU socket X1 does not lead to the LOP, but to socket X13 on the MEU.
• Cable W022 from GCU socket X2 does not lead to the gearbox, but to socket X5 on the MEU.
E532191/00E 05-06 © MTU

58 Installation
2.9.5 Connecting GCU 3
Preconditions
Connectors on GCU
Note: The figure shows connection of GCU 3 to LOP 6 as an example.
1. Remove protective cover from connector socket X1 on GCU.

2. Plug connector X1 of cable W013 into connector socket X1 on the Gear Control Unit (1).
7. Engage all connector locking levers.
E532191/00E 05-06 © MTU

Installation 59
Connecting the gearbox trolling device

Note: Only a schematic representation of cable connection at the battery is shown as this varies greatly
depending on the specifics of the vessel. Two-pole power circuit-breakers must be provided both in the
ground and positive circuits between the connection terminals and the MTU cables.
1. Secure the MTU cable in the vicinity of the battery and cut to a suitable length.
2. Route the two individual wires (2) of cable W023.1 to the power supply connecting points (3) and cut to
a suitable length.
2.1. Blue or brown — positive terminal
2.2. Black — Negative terminal
3. Fit cable lugs which fit the connecting points to the individual wires.
4. Connect both individual wires to the supply voltage terminals.
5. Route two individual wires (5) of cable W023.2 to the trolling device and cut to a suitable length.
6. Pinpoint the corresponding connections on the trolling device (terminal strip, sensors, actuators).
7. Gain access to the connection points.
8. Connect the individual wires to the connecting points in accordance with the MTU “Wiring diagram”.
Connecting to gearboxes with connector sockets

1. Pinpoint the connector socket on the gearbox.
2. Plug connector X5 (4) of cable W022 into the connector socket on the gearbox.
3. Engage connector lock if applicable.
Connecting to gearboxes with terminal strips

Note: An open-ended cable W022 without any connector (4) is supplied for some gearboxes.
1. Access the terminal strip on the gearbox.

2. Connect the individual wires of cable W022 to the terminal strip (→ MTU “Wiring diagram”) (→ Gearbox
documentation)
3. Fix the wires and secure the terminal strip (depending on design).
Connecting to third-party gearboxes (not MTU scope of supply)

Note: An open-ended cable is supplied for gearbox types unknown to MTU. In such cases, it is the
responsibility of the Yard to determine how to connect up the gearbox on the basis of the gearbox
documentation.
1. Pinpoint and access connections on the gearbox (terminal strip, sensors, actuators).
2. Connect the individual wires to the connection points. Assignment of the wires: (→ Page 62)
Note: A connector to which additional Yard signals must be applied is delivered loose.
3. Connect signal cable/wires to connector X5. Assignment of the pins: (→ Page 62)
4. Assemble connector X5.
5. Secure cabling.
6. Connect connector X5 to socket X5 on the Gear Control Unit (1).
E532191/00E 05-06 © MTU

60 Installation
2.9.6 Connecting GCU 6
Preconditions
• Cables routed correctly
• Cables sufficiently long
Connectors on GCU
Note: The illustration shows the connection of GCU 6 to LOP 6 as an example.
1. Remove protective cover of socket X1 on GCU.

2. Plug connector X1 of cable W013 into socket X1 of gearbox control (1).
3. Remove protective cover of socket X2 on GCU.
4. Plug connector X2 of cable W022 into socket X2 of gearbox control (1).
5. Secure all connector latches.
Connecting to gearboxes with connector sockets
1. Locate the connector socket on the gearbox.
2. Plug connector X5 (4) of cable W022 into gearbox socket.
3. Secure connector latch if applicable.
E532191/00E 05-06 © MTU

Installation 61
Connecting to gearboxes with terminal board

Note: An open-ended cable W022 without connector (4) is supplied for some gearboxes.
1. Gain access to terminal board on gearbox.

2. Position individual leads of cable W022 on terminal board (→ MTU drawing "Wiring diagram") (→ Gearbox
documentation)
3. Secure cable and terminal board (depending on design).
Connecting to third-party gearboxes (not MTU scope of supply)

Note: If MTU has no information on the type of gearbox used, an open-ended cable is supplied. In such
cases, it is the responsibility of the yard to determine how to connect the gearbox on the basis of
the gearbox documentation.
1. Locate and gain access to the gearbox connections (terminal board, sensors, actuators).
2. Connect the individual leads to the connection points. Assignment of the wires: (→ Page 62)
Note: A loose connector X5 is supplied to which further yard-side signals must be applied.
3. Connect signal cable/leads to connector X5. Assignment of the pins: (→ Page 62)
4. Assemble connector X5.
5. Secure cable.
6. Connect connector X5 to socket X5 in gearbox control (1).
E532191/00E 05-06 © MTU

62 Installation
2.9.7 GCU – Pin assignment for third-party gearbox
Cable W022
The individual wires of cable W022 are assigned as follows:
Core No. Signal Meaning
1 Enginewise rotation setting (+24 Voltage applied: Valve is activated

VDC)
2 Enginewise rotation setting (GND)
3 Gearbox neutral setting (+24 VDC) Depending on gearbox type:

• Not used
4 Gearbox neutral setting (GND) • Switched by disengagement
enable
• Always energized by
disengagement enable
5 Contrarotation setting (+24 VDC) Voltage applied: Valve is activated
6 Contrarotation setting (GND)
7 Output voltage (+24 VDC) for On gearboxes with limit switches

“Gearbox engaged in enginewise
rotation” limit switch
8 Input “Gearbox engaged in +24 V DC equivalent to engaged

enginewise rotation”

“Gearbox disengaged” limit switch
10 Input “Gearbox disengaged” +24 V DC equivalent to disengaged

“Gearbox engaged in contrarotation”
pressure switch
12 Input “Gearbox engaged in +24 V DC equivalent to engaged

contrarotation”

“Electrical control” limit switch
14 Input “Electrical control” +24 V DC equivalent to electrical

control
15 Input gearbox control oil pressure 4 mA ... 20 mA 0 bar ... 30 bar

(+24 VDC)
16 Input gearbox control oil pressure
17 Not assigned
18 Input gearbox lube oil pressure (+24 4 mA ... 20 mA 0 bar ... 10 bar
VDC)
19 Input gearbox lube oil pressure
20 Not assigned
E532191/00E 05-06 © MTU

Installation 63
Core No. Signal Meaning
21 Input gearbox oil temperature Pt1000 0 °C 120 °C
22 Input gearbox oil temperature
23 Input (pressure switch) gearbox oil Switching signal for “gearbox oil
pressure before filter filter clogged”
24 Input (pressure switch) gearbox oil Switching signal for “gearbox oil
pressure before filter filter clogged”
25 Not assigned
26 Not assigned
27 Not assigned
28 Not assigned
— Shield
E532191/00E 05-06 © MTU

64 Installation
Connector X5
Connector socket X5 is provided on the Gear Control Unit GCU to connect Yard signals. A separate connector to
which these signals may be connected is supplied for this socket. The pins of connector X5 are assigned as follows:
Pin No. Signal Comments
1 Output voltage +24 VDC For “Engagement interlock” signal
2 Engagement interlock input +24 VDC equivalent to “Interlock”

setting
3 Output voltage +24 VDC For “Disengagement” signal
4 Disengagement input +24 VDC equivalent to “Disengage”

setting
5 Output voltage +24 VDC For “Trolling active/Alarm interlock”

signal
6 GND Ground
7 Trolling active/Alarm interlock input +24 VDC equivalent to/means active
8 Trolling active/Alarm interlock input 0 VDC equivalent to/means active
9* Input voltage +24 VDC_Ext. Reserved for two-speed gearbox
10* Input voltage GND_Ext. Reserved for two-speed gearbox
11* 2-speed manual setting output Reserved for two-speed gearbox
12* 2-speed manual setting output 2nd Reserved for two-speed gearbox
gear
13* Output voltage GND_Ext. Reserved for two-speed gearbox
14* Output voltage +24 VDC_Ext. Reserved for two-speed gearbox

feedback
15* Output voltage GND Reserved for two-speed gearbox

feedback
16* 2-speed manual input +24 VDC equivalent to/means

manual
17* 2-speed manual input 0 VDC equivalent to/means manual
18* 2-speed manual setting input 2nd +24 VDC equivalent to/means 2nd
gear gear
19* 2-speed manual setting input 2nd 0 VDC equivalent to/means 2nd
gear gear
Pin numbers marked * and the associated signals are currently not used and are intended for future applications.
E532191/00E 05-06 © MTU

Installation 65
2.10 Electrical Installation (Series 4000 only, optional)
2.10.1 Priming Pump Controller PPC – Connection (single phase)
Preconditions
Connector on PPC device

Note: The supply connection of cables W017 and W018 is represented schematically in the figure. It depends
largely on conditions on-board.
1. Remove cap covering connector socket X1 on PPC.

E532191/00E 05-06 © MTU

66 Installation
Connecting the pump and the supply voltage

1. Connect individual cores of cable W017 to the supply voltage of the oil priming pump.
1.1. Install two-pole power circuit breakers in all lines between the connection points and the MTU cable.
1.2. Prepare the cores:
• Core 1: L1
• Core 2: not used, insulate
• Core 4: Neutral conductor
• Core yellow/green: Housing ground
2. Connect individual cores of cable W018 to the oil priming pump:
• Core 1: V1/Z2
• Core 4: U2
E532191/00E 05-06 © MTU

Installation 67
2.10.2 Priming Pump Controller PPC – Connection (three phases)
Preconditions
Connector on PPC device

Note: The supply connection of cables W017 and W018 is represented schematically in the figure. It depends
largely on conditions on-board.

E532191/00E 05-06 © MTU

68 Installation
Connecting the pump and the supply voltage

1. Connect individual cores of cable W017 to the supply voltage of the oil priming pump.
1.1. Install two-pole power circuit breakers in all lines between the connection points and the MTU cable.
1.2. Prepare the cores:
• Core 1: L1
• Core 2: L2
• Core 3: L3
• Core 4: N, not used, insulate
2. Connect individual cores of cable W018 to the oil priming pump:
• Core 1: V1
• Core 2: U1
• Core 3: W1
• Core 4: N, not used, insulate
E532191/00E 05-06 © MTU

Initial Operation 69
3 Initial Operation
3.1 Preparation
3.1.1 Checks prior to startup

Checking system installation
Note: Before switching on the operating voltage for the first time: Carry out the tasks listed below for each
power train!
1. Check that all plug connectors are correctly connected at the Local Operating Panel LOP and that the
retainers are engaged.
2. Check that the plug connectors are correctly connected at the Gear Control Unit GCU and that the retainers
are engaged.
3. For extended scope: Check that the plug connectors are correctly connected at the MEU and that the
retainers are engaged.
4. Check that the plug connectors are correctly connected at terminal box X010 and that the retainers are
engaged.
5. If cables are routed through the cable bushing on terminal box X010: Check that all cables are properly
installed in the cable bushing and that the individual cores are correctly connected in the terminal box.
6. If Priming Pump Controller PPC is installed: Check that the plug connectors are correctly connected at the
PPC and that the retainers are engaged.
7. For Engine Control Unit ECU 4: Check that the plug connectors are correctly connected at the ECU and
that the union nuts are tight.
8. For Engine Control Unit ECU 7: Check that the plug connectors are correctly connected at the ECU and
that the retainers are engaged.
9. For extended monitoring with EMU 1: Check that the plug connectors are correctly connected at the EMU and
that the union nuts are tight.
10. For extended monitoring with EMU 7: Check that the plug connectors are correctly connected at the EMU and
that the retainers are engaged.
11. Check that all cables are correctly connected at the starter; ensure that cables, spade lugs etc. are not
touching each other.
12. Depending on gearbox design: Check that the connector or the cables is/are properly connected at the gearbox.
13. For extended monitoring: Check that the shaft speed sensor is correctly connected.
14. Check that the engine and all electronic devices in the engine room are properly connected to ground.
15. Check that the cables on the engine (to ECU, EMU and starter) have been suitably secured. These cables
must not hang loose at any point.
16. Check that all cables are suitably secured at appropriate points on the vessel.
17. Ensure that cables are never routed over sharp edges unless suitably protected against chafing.
18. Ensure that none of the cables can be sheared through when doors or flaps etc. are closed.
19. Check that all cables have been routed such as to ensure legibility of connector and cable designations.
Checking fuses and jumpers

1. Check fuses and jumpers in the LOP (→ Page 81).
2. Check fuses and jumpers in the GCU (→ Page 84).
3. For extended scope only: Check fuses and jumpers in the MEU (→ Page 85).
Checking external supply voltage of the system

1. Check that all battery cables are properly connected and cannot cause short circuiting.
2. Check external LOP power supply (→ Page 71).
3. Check external MEU power supply. Proceed in the same way as for checking the power supply at the LOP
(→ Page 71).
E532191/00E 05-06 © MTU

70 Initial Operation
Checking supply voltage distribution in the system

1. Prepare multimeter for voltage measuring:
1.1. Connect test leads to appropriate sockets.
1.2. Plug on test prods.
1.3. Set voltage measuring range to min. 30 V.
2. Check at the fuses and connectors on the individual devices to ensure that the supply voltage is applied and
is within the tolerated range:
• Basic scope (→ Page 86)
• Extended scope (→ Page 88)
E532191/00E 05-06 © MTU

3.1.2 LOP power supply – Check
Preconditions
• Supply voltage available.
Special tools
Multimeter 0005362539 1
Test prod, black 0005385130 1
Test prod, red 0005385230 1
Checking ship-side LOP power supply

Note: Appearance of the LOP cover may differ
from the figure.
1. Switch off ship-side supply voltage.

2. Unclip retainer (1) for connector X7 (2).
3. Disconnect connector X7 from Local Operating
Panel.
4. Prepare multimeter for voltage measuring:
4.1. Connect test leads to appropriate sockets.
4.2. Plug on test prods.
4.3. Set voltage measuring range to min. 30 V
5. Switch on ship-side main supply voltage.

6. Measure voltage between pins 1a (+) (1) and
2a (-) (4) on the Harting connector: It must be
between 19.5 V and 30 V.
7. Measure voltage between pins 1b (+) (2) and
2b (-) (3) on the Harting connector: No voltage
applied here.
8. Switch off ship-side main supply voltage.
9. Switch on ship-side emergency supply voltage.
10. Measure voltage between pins 1b (+) (2) and
2b (-) (3) on the Harting connector: It must be
between 19.5 V and 30 V.
11. Measure voltage between pins 1a (+) (1) and
2a (-) (4) on the Harting connector: No voltage
applied here.
12. Switch off ship-side emergency supply voltage.
13. Rectify any faults as necessary:
Item Diagnosis Action
Connector X07 Main supply and emergency supply Correct cabling. (→ Installation and
mixed up. Initial Operation)
E532191/00E 05-06 © MTU

Item Diagnosis Action
Voltage measured violates tolerated Check ship-side power supply.

range.
Main supply missing. Check cabling.

Check ship-side power supply
connection.
Emergency supply missing. Check cabling.

Check ship-side power supply
connection.
14. Plug connector X7 into connector socket X7 (2).

15. Engage retainer (1).
16. Switch on ship-side supply voltage.
E532191/00E 05-06 © MTU

3.1.3 Operating voltage – Initial connection (basic scope)

Pump overheating.
Damage to component!
CAUTION • Do not exceed operating time limit.
Carry our pre-startup checks (→ Page 69).
Preparation at LOP
Note: The operating voltage is applied to the various devices step-by-step.
1. Disconnect connector X5 of cable W005 to ECU.

2. Disconnect connector X13 of cable W013 to GCU.
3. Plug connector X7 of cable W007 into connector socket X7 and engage retainer.
4. Open the front panel on the LOP.
Connecting ECS operating voltage step-by-step

1. Switch on ship-side ECS-5 supply voltage.
Result: Operating voltage is applied to Local Operating Panel LOP (and terminal box X010) only.
2. Observe the Local Operating Panel LOP closely!
• Make sure that none of the components get hot or otherwise react unusually.
• Check that display on printed circuit board MPU 29 works.
• Wait until the display in the front panel has booted up and the start page is displayed.
• Providing that no inadmissible operating states are indicated on the Local Operating Panel, the
• Gear Control Unit GCU
• Engine Control Unit ECU
can be taken into operation:
3. Switch off ship-side ECS-5 supply voltage.
4. Plug cable W013 leading to the GCU into LOP connector X13 and engage the retainer.
5. Open the front panel on the GCU.
Result: Operating voltage is also applied to Gear Control Unit GCU.
7. Keep observing Local Operating Panel LOP.
• No excessively high current should flow despite GCU being connected. Fuse F69 must not trip.
8. Observe the Gear Control Unit GCU closely!
9. Close the front panel on the GCU.
11. Plug cable W005 leading to the ECU into LOP connector X5 and engage the retainer.
Result: Operating voltage is applied to all ECS-5 devices.
• No excessively high current should flow despite ECU being connected. Fuse F67 must not trip.
14. Close the front panel on the LOP.
15. Switch off ship-side ECS-5 supply voltage if necessary.
Connecting optional oil priming pump operating voltage

1. Switch on the pump supply voltage (AC voltage).
2. Turn the rotary switch on the Priming Pump Controller PPC to “Manual”.
3. Ensure that the pump is running and that the motor protection switch does not trip. Do not exceed the
admissible ON time.
E532191/00E 05-06 © MTU

4. Turn the rotary switch on the Priming Pump Controller PPC to “Automatic”.
5. Switch of the pump AC voltage if necessary.
E532191/00E 05-06 © MTU

3.1.4 Operating voltage – Initial connection (extended scope)

Pump overheating.
Damage to component!
CAUTION • Do not exceed operating time limit.
Carry our pre-startup checks (→ Page 69).
Preparation at LOP
Note: The operating voltage is applied to the various devices step-by-step.
1. Disconnect connector X5 of cable W005 to ECU.

2. Disconnect connector X13 of cable W013 to MEU.
3. Plug connector X7 of cable W007 into connector socket X7 and engage retainer.
4. Open the front panel on the LOP.
Preparation at MEU
1. Disconnect connector X6 of cable W041 to EMU.
2. Disconnect connector X13 of cable W044 to GCU.
3. Open the front panel on the MEU.
Connecting ECS operating voltage step-by-step

Result: Operating voltage is applied to Local Operating Panel LOP (and terminal box X010) only.
• Wait until the display in the front panel has booted up and the start page is displayed.
• Providing that no inadmissible operating states are indicated on the Local Operating Panel, the
• Gear Control Unit GCU
• Monitoring Extension Unit MEU
• Engine Monitoring Unit EMU
• Engine Control Unit ECU
can be taken into operation:
4. Plug cable W013 leading to the MEU into LOP connector X13 and engage the retainer.
5. Plug cable W044 leading to the GCU into MEU connector X13 and engage the retainer.
6. Open the front panel on the GCU.
Result: Operating voltage is also applied to Gear Control Unit GCU.
8. Keep observing Local Operating Panel LOP.
• No excessively high current should flow despite GCU being connected. Fuse F69 must not trip.
9. Observe the Gear Control Unit GCU closely!
10. Close the front panel on the GCU.
12. Plug connector X7 of cable W040 into connector socket X7 on the MEU and engage retainer.
Result: Operating voltage is also applied to the MEU.
14. Observe Monitoring Extension Unit MEU closely!
• Fuse F2 must not trip.
E532191/00E 05-06 © MTU

16. Plug connector X6 of cable W041 into connector socket X6 on the MEU and engage retainer.
Result: Operating voltage is also applied to the EMU.
18. Keep observing MEU.
• No excessively high current should flow despite EMU being connected. Fuse F3 must not trip.
19. Close the front panel on the MEU.
21. Plug cable W005 leading to the ECU into LOP connector X5 and engage the retainer.
Result: Operating voltage is applied to all ECS-5 devices.
• No excessively high current should flow despite ECU being connected. Fuse F67 must not trip.
24. Close the front panel on the LOP.
25. Switch off ship-side ECS-5 supply voltage if necessary.
Connecting optional oil priming pump operating voltage

1. Switch on the pump supply voltage (AC voltage).
2. Turn the rotary switch on the Priming Pump Controller PPC to “Manual”.
3. Ensure that the pump is running and that the motor protection switch does not trip. Do not exceed the
admissible ON time.
4. Turn the rotary switch on the Priming Pump Controller PPC to “Automatic”.
5. Switch of the pump AC voltage if necessary.
E532191/00E 05-06 © MTU

3.2 Tests
3.2.1 LOP – Initial engine startup
Preconditions
• All mechanical connection and installation work completed.
• All installation work on the gearbox completed as specified in the gearbox documentation.
• Operator familiar with all emergency operating procedures (engine and gearbox).
• Gearbox not permanently engaged by emergency actuation.
• Engine/gearbox supplied with lube oil, coolant and fuel.
• Ensure that all personnel is clear of the danger zone around the propeller/shaft; remove the propeller if
necessary: (the shaft still turns.)
• When starting up in water note that the vessel starts moving when the gear is engaged. The drive shaft flanges
must be disconnected to prevent this.
Unguarded rotating and moving engine components.

Risk of serious injury – danger to life!
DANGER • Take special care when working on a running engine.
Engine noise above 85 dB (A).

Risk of damage to hearing!
WARNING • Wear ear protectors.
Engine damage due to wrong actions.

Major material damage!
CAUTION • Ensure engine is ready for operation before starting. See engine documentation.
Preparation
1. Switch on the engine control system for the power train of the engine which is to be started.
2. If the remote control system is switched on: Set all propulsion control levers of the power train concerned
to neutral.
3. When an oil priming pump is fitted: Set selector switch on PPC to AUTO.
4. Open a graphic screen page displaying engine speed (e.g. Page “Propulsion”) on the LOP display.
Activating Local mode and canceling manual start interlock

1. Press illuminated pushbutton LOCAL OPERATION.
Result:
• Illuminated pushbutton LOCAL OPERATION lights up green.
• Local mode is activated.
2. Press illuminated pushbutton READY FOR OPERATION.
Result:
• Illuminated pushbutton READY FOR OPERATION lights up green.
• Manual start interlock is canceled.
• The engine is ready for starting providing that no start interlock is active in the system.
E532191/00E 05-06 © MTU

Starting the engine

Note: The automatic starting sequence can be canceled at any time by pressing illuminated pushbutton STOP.
1. Press illuminated pushbutton START briefly.

Result:
• Illuminated pushbutton START lights up white.
• Automatic starting sequence is executed.
• When an oil priming pump is fitted: Pump is switched on automatically.
• Increasing engine speed is indicated by the bar chart on the display.
• On completion of the automatic starting sequence:
• The engine runs at idling speed.
• Illuminated pushbutton START goes out.
• The power train is ready for engagement.
2. Observe the engine operating data on the display.
E532191/00E 05-06 © MTU

3.2.2 Gearbox – Engagement/disengagement
Preconditions
• ECS-5 of the power train is switched on.
• Local mode is activated: Illuminated pushbutton LOCAL OPERATION lights up green.
• Gearbox is disengaged: Illuminated pushbutton CLUTCH NEUTRAL lights up green (for “Engagement”
procedure only).
• Gearbox is engaged: Illuminated pushbutton CLUTCH NEUTRAL is dark (for “Disengagement” procedure only).
• Engine speed in engagement/disengagement window.
Vessel is sailing blind.

In Local Operation mode, the propulsion plant is controlled from the engine room.
DANGER Risk of accidents!
• Only execute vessel movements on the instructions of a person who has visual contact
with the area outside the vessel.
Engaging a reversing gearbox at the LOP (FPP propulsion)

1. Make contact with the control stand.
2. Press one of the following pushbuttons depending on the desired direction of thrust:
• CLUTCH AHEAD
• CLUTCH ASTERN
Result:
• The gearbox is engaged in accordance with the input signal.
• The gearbox state is indicated on the display.
• The selected illuminated pushbutton lights up green when the gearbox is engaged.
Disengaging a reversing gearbox at the LOP

1. Reduce engine speed to idling (→ Page 80).
2. Press illuminated pushbutton CLUTCH NEUTRAL
Result:
• The gearbox is disengaged.
• Illuminated pushbutton CLUTCH AHEAD or CLUTCH NEUTRAL goes out when the gearbox is disengaged.
• The illuminated pushbutton CLUTCH NEUTRAL lights up green when the gearbox is disengaged.
Engaging a reduction gearbox at the LOP (CPP or Waterjet propulsion)

1. Make contact with the control stand.
2. Press illuminated pushbutton CLUTCH IN
Result:
• The gearbox is engaged.
• The illuminated pushbutton CLUTCH IN lights up green when the gearbox is engaged.
Disengaging a reduction gearbox at the LOP

1. Reduce engine speed to idling (→ Page 80).
2. Press illuminated pushbutton CLUTCH OUT
Result:
• The gearbox is disengaged.
• The illuminated pushbutton CLUTCH OUT lights up green when the gearbox is disengaged.
E532191/00E 05-06 © MTU

3.2.3 Engine speed – Adjustment
Preconditions
• ECS-5 of the power train is switched on.
• Local mode is activated: Illuminated pushbutton LOCAL OPERATION lights up green.
• Power train is switched ready for operation: Illuminated pushbutton READY FOR OPERATION lights up green
Adjusting engine speed at the LOP
1. Press and hold down one of the following illuminated pushbuttons as required:
• Illuminated pushbutton ENGINE SPEED INCREASE
• Illuminated pushbutton ENGINE SPEED DECREASE
Result:
• The selected illuminated pushbutton lights up white when pressed.
• The engine speed increases or decreases.
• The currently changing engine speed is indicated on the LOP display.
2. Release the illuminated pushbutton when the desired engine speed has been reached.
Result: The engine speed remains constant.
E532191/00E 05-06 © MTU

Supplementary Technical Information 81
4 Supplementary Technical Information
4.1 LOP – Fuses and jumpers
Fuses
13 fuses are provided in Local Operating Panel LOP to protect the supply voltages for
• the assemblies of the ECS-5 subsystem installed in the Local Operating Panel,
• the devices associated with the ECS-5 subsystem connected to the Local Operating Panel,
E532191/00E 05-06 © MTU

• other connected devices as applicable.
Item. Designation Rating Protection of
On printed circuit board LMB 3
1 F1 4A External dialog unit (CAN dialog) at connector socket X8
5 F67 20 A Engine Control Unit ECU
3 F69 4A BlueLine: Gear Control Unit GCU

BlueVision, basic scope: Gear Control Unit GCU
BlueVision, extended scope: Gear Control Unit GCU and Engine
Monitoring Unit EMU
2 F70 15 A Local Operating Panel LOP supply;

All I/O printed circuit board in the Local Operating Panel (slots 1 ... 8)
4 F71 4A Externally connectable safety system (not for BlueLine)
6 F72 15 A Spare
7 F73 20 A Spare
8 F74 4A Spare
9 F75 4A Spare
On printed circuit board PSB
10 F1 15 A MCS control stand supply (not for BlueVision)
11 F2 15 A RCS control stand supply (not for BlueVision)
Underside of LMB 3
12 F5 30 A Starter
13 F6 30 A Starter
E532191/00E 05-06 © MTU

Jumpers
There are four jumper banks for 9 jumpers respectively on motherboard LMB 3 in the Local Operating Panel.
Item. Designation Intended position Meaning
1 ST3A All jumpers inserted • BlueLine: Without EMU

• BlueVision, basic scope: Without EMU
• BlueVision, extended scope: EMU is not set
by LOP jumpers.
2 ST3B No jumper inserted With EMU
3 ST4A No jumper inserted Without GCU
4 ST4B All jumpers inserted With GCU
E532191/00E 05-06 © MTU

4.2 GCU – Jumpers
Jumpers
On motherboard
7 JP 6 (5-pole jumper bar) Inserted CAN bus devices
6 JP 5 (9-pole jumper bar) Inserted
On printed circuit board MIB 1 (GCU 3 only)
1 1.JP 1, JP 2, JP 3 and JP 4 All inserted Trolling unit

2.JP 9. JP 10, JP 11, JP 12
3.JP 17, JP 18
4.JP 19a, JP 20a, JP 21a, JP 22a
E532191/00E 05-06 © MTU

4.3 MEU – Fuses and jumpers
Fuses
Item. Designation Rating Protection of
On printed circuit board LMB
1 F2 5A Supply of SAM in MEU
2 F3 5A Supply of Gear Control Unit GCU
Jumpers
1 JP1 ... JP4 Not inserted EMU fitted
2 JP5 ... JP8 Not inserted GCU fitted
3 JP9 ... JP12 As desired External supply, SAM slots 2, 3
4 JP13 Inserted MEU is not in stand-alone operation
5 JP14 ... JP17 As desired Relevant for MEU in stand-alone operation

only
E532191/00E 05-06 © MTU

4.4 Supply voltage distribution (basic scope)
Designation Rating Meaning
Devices and assemblies
LOP – Local Operating Panel
ECU – Engine Control Unit (installed on engine)
GCU – Gearbox Control Unit
SiSy – External safety system (not for BlueVision)
AlSy – Alarm system (integrated in LOP)
CAN Dia – External CAN dialog unit
Voltages
+Ub 24 V Redundant external supply voltage
+Umain 24 V +Ub main supply
+Uemerg 24 V +Ub emergency supply
+Uint 24 V Internal supply voltage
E532191/00E 05-06 © MTU

LOP fuses on printed circuit board LMB
F1 4A Supply for externally connected CAN dialog unit
F67 20 A Supply for Engine Control Unit ECU and externally

connected CAN dialog unit
F69 4A Supply for GCU
F70 15 A Supply for internal alarm system AlSy
F71 3A Supply for external safety system
LOP fuses on printed circuit board PSB
F1 15 A Control stand output circuit supply (not used for

BlueVision)

BlueVision)
The +Ub supply voltage for all ECS-5 devices is applied at Local Operating Panel LOP.
The +Ub supply voltage comprises a main supply +Umain and an emergency supply +Uemerg. Both voltages are
connected to the Local Operating Panel where they are combined to form the internal supply voltage +Uint. The
overall system can thus be immediately supplied with a second voltage should one of the voltages fail.
The ground potentials of the two supply voltages (+Umain and +Uemerg) are interconnected.
The supply voltages of the LOP assemblies and the connected assemblies are derived from the internal
+Uint voltage in the LOP. These voltages are individually protected in the LOP.
E532191/00E 05-06 © MTU

4.5 Supply voltage distribution (extended scope)
Devices and assemblies
LOP – Local Operating Panel
ECU – Engine Control Unit (installed on engine)
EMU – Engine Monitoring Unit (installed on engine)
GCU – Gearbox Control Unit
MEU – Monitoring Extension Unit
SAM – Service and Automation Module
SiSy – External safety system (not for BlueVision)
AlSy – Alarm system (integrated in LOP)
CAN Dia – External CAN dialog unit
Voltages
+Ub 24 V Redundant external supply voltage
E532191/00E 05-06 © MTU

+Umain 24 V +Ub main supply
+Uemerg 24 V +Ub emergency supply
+Uint 24 V Internal supply voltage
LOP fuses

BlueVision)

BlueVision)
F67 20 A Supply for Engine Control Unit ECU and externally

connected CAN dialog unit
F69 4A Supply for GCU
F70 15 A Supply for internal alarm system AlSy
F71 3A Supply for external safety system
F1 4A Supply for externally connected CAN dialog unit
MEU fuses
F2 5A Supply for SAM
F2 5A Supply for EMU
MEU relays
K1.1 – Changeover contact for SAM supply
K1.2 – Changeover contact for EMU supply
The +Ub supply voltage for all ECS-5 devices is separate for LOP and MEU.
The +Ub supply voltage comprises a main supply +Umain and an emergency supply +Uemerg. Both voltages are
connected to the Local Operating Panel where they are combined to form the internal supply voltage +Uint. The
overall system can thus be immediately supplied with a second voltage should one of the voltages fail.
The ground potentials of the two supply voltages (+Umain and +Uemerg) are interconnected.
The supply voltages of the LOP assemblies and the connected assemblies are derived from the internal
+Uint voltage in the LOP. These voltages are individually protected.
The supply voltage for the GCU is looped through the MEU and simultaneously serves as switching
voltage for the internal +Uint supply voltage of the MEU.
The supply voltages of the SAM and the connected EMU are derived from +Uint in the
MEU. These voltages are individually protected.
E532191/00E 05-06 © MTU

4.6 Power consumption specifications – Engine room

Power consumption from LOP power supply
Device/assembly Minimum consumption (A) Maximum consumption (A)
LOP internal 1.5 2.5
ECU 4 0.3 17
ECU 7 0.2 24
GCU internal 0.5 1.0
Solenoid valves gearbox 1.0 2.0
X010 Negligible Negligible
PPC (from 24 VDC) Negligible Negligible
Total LOP, 3.3 22.5

Series 2000 unit-pump system or
4000
Total LOP, 3.2 29.5

Series 2000 CR
Power consumption from MEU power supply
Device/assembly Minimum consumption (A) Maximum consumption (A)
MEU internal 0.5 1.0
EMU 1 0.2 2.2
EMU 7 0.1 5.5
Total MEU, 0.7 3.2

Series 2000 unit-pump system or
4000
Total MEU, 0.6 6.5

Series 2000 CR
Power consumption from trolling unit power supply

Consumption specifications are approximate values.
Manufacturer, type Minimum consumption (A) Maximum consumption (A)
ZF PWM 0.8 1.2
ZF EST-59 2 2
Reintjes G-ADS 0.5 1
E532191/00E 05-06 © MTU

Annex 91
5 Annex
5.1 Conversion tables
Length
Unit A multiplied by factor = Unit B
in 25.4 = mm
ft 0.3048 =m
yd 0.9144 =m
stat. mile 1.609 = km

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

mm 0.3937 = in
m 3.281 = ft
km 0.6215 = stat. mile
Area
in2 645.16 = mm2
ft2 0.0929 = m2
yd2 0.8361 = m2
stat. mile2 2.5889 = km2

mm2 0.00155 = in2
m2 10.7643 = ft2
m2 1.1960 = yd2
km2 0.3863 stat. mile2
E532191/00E 05-06 © MTU

92 Annex
Volume
in3 16387 = mm3
ft3 0.02832 = m3
yd3 0.7646 = m3
gallon (U.S.) 3.787 = dm3
gallon (UK) 4.546 = dm3

cm3 0.06102 = in3
m3 35.31 = ft3
dm3 0.2642 = gallon (U.S.)
dm3 0.22 = gallon (UK)
Velocity
ft/s 0.3048 = m/s
stat. mile/h (mph) 1.609 = km/h
knot (UK) 1.852 = km/h
Unit B multiplied by factor = Unit B
m/s 3.281 = ft/s
km/h 0.6215 = stat. mile/h (mph)
km/h 0.54 = knot (UK)
E532191/00E 05-06 © MTU

Annex 93
Mass
lb 0.4536 = kg
oz 28.35 =g
ton 1.016 =t

g 0.03527 = oz
kg 2.205 = lb
t 0.9843 = ton
Force
lb 0.4536 = kp
lb 4.4483 =N
kp 2.205 = lb
N 0.101972 = kp
kp 9.80665 =N
Density
lb s2/ft4 515.4 = kg/m3
kg/m3 0.00194 = lb s2/ft4
E532191/00E 05-06 © MTU

94 Annex
Torque
ft lb 1.3563 = Nm
Nm 0.7373 = ft lb
Pressure
lb/sq in (psi) 703.1 = kp/m2 (mm WS)
lb/sq in (psi) 0.06895 = bar
lb/sq ft 47.883 = Pa
in QS 0.03386 = bar
in QS 345.3 = kp/m2
atm 760 = mm QS
atm 1.0133 = bar
atm 10332 = kp/m2 (mm WS)
atm 1.0332 = kp/cm2 (at)
atm 14.696 = lb/sq in
bar 14.503 = lb/sq in
Mass moment of inertia

ft lb s2 1.3563 = kg m2
kg m2 0.7373 = ft lb s2
E532191/00E 05-06 © MTU

Annex 95
Energy
ft lb 1.356 =J
kcal 4186.8 =J
BTU 1055 =J
CHU 1899 =J
J 0.7376 = ft lb
J 0.0002389 = kcal
J 0.0009479 = BTU
J 0.00052656 = CHU
Power
PS 0.7355 = kW
HP 0.7457 = kW
BTU/s 1.055 = kW
kcal/h 1.163 =W
HP 550 = ft lb/s
kW 1.36 = PS
kW 1.341 = HP
kW 0.9479 = BTU/s
W 0.8598 = kcal/h
ft lb/s 0.0018 = HP
E532191/00E 05-06 © MTU

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

K
x°R = 5/4x °C = (5/4x) + 273.15 K = (9/4x) + 32 °F
Fuel consumption
mile/gal (U.S.) 0.4251 = km/l
gal/mile (U.S.) 2.3527 = l/km
km/l 2.3527 = mile/gal (U.S.)
l/km 0.4251 = gal/mile (U.S.)
E532191/00E 05-06 © MTU

Annex 97
5.2 Abbreviations
Abbrevia- Meaning Explanation

tion
AL Alarm Alarm (general)
ANSI American National Standards Institute Umbrella organization administering and coordinating
U.S. standards
ATL Abgasturbolader Exhaust turbocharger
BR Baureihe Series
CAN Controller Area Network Data bus system, bus standard
CPP Controllable Pitch Propeller
DIN Deutsches Institut für Normung e. V. German Standardization Organization, at the same
time identifier of German standards ("Deutsche
Industrie-Norm")
DIS Display unit
DL Default Lost Alarm: Default CAN bus failure
ECS Engine Control System
ECU Engine Control Unit Engine governor
EDM Engine Data Module
EMU Engine Monitoring Unit
FL Fluids and Lubricants Specifications MTU publication No. A01061/..
FPP Fixed Pitch Propeller
GCU Gear Control Unit
GMU Gear Monitoring Unit
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
HT High Temperature
ICFN ISO - Continuous rating - Fuel stop power Power specification in accordance with DIN-ISO 3046-7
- Net
IDM Interface Data Module Memory module for interface data
IMO International Maritime Organisation
ISO International Organization for

Standardization
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
LCD Liquid Crystal Display, Liquid Crystal

Device
LCU Local Control Unit LOP subassembly
E532191/00E 05-06 © MTU

98 Annex
Abbrevia- Meaning Explanation

tion
LED Light Emitting Diode
LMU Local Monitoring Unit LOP subassembly
LO Low Alarm: Measured value lower than 1st minimum limit
LOLO Low Low Alarm: Measured value lower than 2nd minimum limit
LOP Local Operating Panel
LOS Local Operating Station
MCD Marine Control Drive
MCS Monitoring and Control System
MG Message
MPU Microprocessor Unit, Microprocessing

Unit
OT Oberer Totpunkt Top dead center
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel Control panel
PCU Propeller Control Unit
PIM Peripheral Interface Module
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAE Society of Automotive Engineers U.S. standardization organization
SAM Service and Automation Module
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps
SPC Spare Parts Catalog
SS Safety System Indicated alarm is initiated by the safety system
SSK Schnellschlussklappe(n) Emergency-air shutoff flap(s)
T-xyz Temperature-xyz Temperature measuring point xyz
TC Tools Catalog
TD Transmitter Deviation Alarm: Sensor comparison fault
UT Unterer Totpunkt Bottom dead center
VS Voith Schneider Voith-Schneider drive
WJ Water Jet Waterjet drive
E532191/00E 05-06 © MTU

Annex 99
5.3 Index
A Priming Pump Controller PPC –
Abbreviations ......................... 97 Connection (three phases) . . . . . . . . . . 67
Electrical Installation (Series-dependent, basic
and extended scope) . . . . . . . . . . . . . . . . . . . 36
B Barring gear limit switch – Connec
Barring gear limit switch – Connection ...... 46 tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Connecting engine governor ECU . . . . 36
Engine Control Unit ECU 7 –
C Connection . . . . . . . . . . . . . . . . . . . . . . 37
Cable routes and openings between all Starter and battery-charging generator –
installation locations – Check . . . . . . . . . . . . . 11 Connection on BR 2000 . . . . . . . . . . . . 38
Cable routing between installation locations for Starter and battery-charging generator –
Series 2000 CR, classifiable system . . . . . . . . 20 Connection on BR 4000 . . . . . . . . . . . . 41
Cable routing between installation locations for Electrical Installation (Series-dependent,
Series 2000 CR, non-classifiable system . . . . 14 extended scope only) . . . . . . . . . . . . . . . . . . . 47
Cable routing between installation locations Engine Monitoring Unit EMU 1 –
for Series 2000 unit-pump system, classifiable Connection . . . . . . . . . . . . . . . . . . . . . . 47
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Engine Monitoring Unit EMU 7 –
Connection . . . . . . . . . . . . . . . . . . . . . . 48
Cable routing between installation locations for
MEU – Connection . . . . . . . . . . . . . . . . 49
Series 2000 unit-pump system, non-classifiable
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine Control Unit ECU 7 – Connection . . . . 37
Cable routing between installation locations for Engine Monitoring Unit EMU 1 – Connec
Series 4000, classifiable system . . . . . . . . . . . 22 tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Cable routing between installation locations for Engine Monitoring Unit EMU 7 – Connec
Series 4000, non-classifiable system . . . . . . . 16 tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Checks prior to startup . . . . . . . . . . . . . . . . . . 69 Engine speed – Adjustment . . . . . . . . . . . . . . 80
Connecting engine governor ECU . . . . . . . . . 36
Connecting GCU 3 . . . . . . . . . . . . . . . . . . . . . 58 F
Connecting GCU 6 . . . . . . . . . . . . . . . . . . . . . 60 Fluids and lubricants, fire prevention and
Conventions for safety warnings in the text . . . 10 environmental protection . . . . . . . . . . . . . . . . . 08
Conversion tables . . . . . . . . . . . . . . . . . . . . . . 91 Fuel prefilter level sensors – Connection . . . . 35
E G
Electrical Installation (all Series, basic and GCU – Installation . . . . . . . . . . . . . . . . . . . . . . 29
extended scope) . . . . . . . . . . . . . . . . . . . . . . . 32 GCU – Jumpers . . . . . . . . . . . . . . . . . . . . . . . 84
Fuel prefilter level sensors – GCU – Pin assignment for third-party
Connection . . . . . . . . . . . . . . . . . . . . . . 35 gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
LOP – Connection . . . . . . . . . . . . . . . . 32 GCU connection – Variants . . . . . . . . . . . . . . . 57
Electrical Installation (all Series, depending on Gearbox – Engagement/disengagement . . . . 79
equipment and options) . . . . . . . . . . . . . . . . . 52
Connecting GCU 3 . . . . . . . . . . . . . . . . 58 General provisions . . . . . . . . . . . . . . . . . . . . . 03
Connecting GCU 6 . . . . . . . . . . . . . . . . 60
GCU – Pin assignment for third-party H
gearbox . . . . . . . . . . . . . . . . . . . . . . . . . 62
HSK cable bushing – Preparation . . . . . . . . . . 52
GCU connection – Variants . . . . . . . . . . 57
HSK cable bushing – Preparation . . . . . 52
Terminal box X010 – Connection . . . . . 54 I
Terminal strip – Preparation . . . . . . . . . 53 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Electrical Installation (Series 4000 only, Installing terminal box X010 . . . . . . . . . . . . . . 26
optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Priming Pump Controller PPC –
Connection (single phase) . . . . . . . . . . 65 L
LOP – Connection ..................... 32
E532191/00E 05-06 © MTU

100 Annex
LOP – Fuses and jumpers . . . . . . . . . . . . . . . 81 Cable routing between installation

LOP – Initial engine startup . . . . . . . . . . . . . . . 77 locations for Series 2000 unit-pump
system, classifiable system . . . . . . . . . . 18
LOP – Installation . . . . . . . . . . . . . . . . . . . . . . 24
Cable routing between installation
LOP power supply – Check . . . . . . . . . . . . . . 71 locations for Series 2000 unit-pump
system, non-classifiable system . . . . . . 12
M Cable routing between installation
locations for Series 4000, classifiable
Mechanical Installation (all Series, basic and system . . . . . . . . . . . . . . . . . . . . . . . . . 22
extended scope) . . . . . . . . . . . . . . . . . . . . . . . 24 Cable routing between installation
Installing terminal box X010 . . . . . . . . . 26 locations for Series 4000, non-classifiable
LOP – Installation . . . . . . . . . . . . . . . . . 24 system . . . . . . . . . . . . . . . . . . . . . . . . . 16
Mechanical Installation (all Series, depending Checks prior to startup . . . . . . . . . . . . . 69
on Trolling option) . . . . . . . . . . . . . . . . . . . . . . 29 LOP power supply – Check . . . . . . . . . 71
GCU – Installation . . . . . . . . . . . . . . . . . 29 Operating voltage – Initial connection
Mechanical Installation (all Series, extended (basic scope) . . . . . . . . . . . . . . . . . . . . 73
scope only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Operating voltage – Initial connection
MEU – Installation . . . . . . . . . . . . . . . . . 27 (extended scope) . . . . . . . . . . . . . . . . . 75
Mechanical Installation (Series 4000 only, Priming Pump Controller PPC – Connection
optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 (single phase) . . . . . . . . . . . . . . . . . . . . . . . . . 65
Priming Pump Controller PPC – Priming Pump Controller PPC – Connection
Installation . . . . . . . . . . . . . . . . . . . . . . 31 (three phases) . . . . . . . . . . . . . . . . . . . . . . . . . 67
MEU – Connection . . . . . . . . . . . . . . . . . . . . . 49 Priming Pump Controller PPC – Installa
MEU – Fuses and jumpers . . . . . . . . . . . . . . . 85 tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
MEU – Installation . . . . . . . . . . . . . . . . . . . . . . 27
S
O Safety requirements for maintenance and repair
Operating voltage – Initial connection (basic work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05
scope) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Starter and battery-charging generator –
Operating voltage – Initial connection (extended Connection on BR 2000 . . . . . . . . . . . . . . . . . 38
scope) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Starter and battery-charging generator –
Connection on BR 4000 . . . . . . . . . . . . . . . . . 41
Supply voltage distribution (basic scope) . . . . 86
P
Supply voltage distribution (extended
Personnel and organizational prerequi
scope) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
sites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04
Power consumption specifications – Engine
room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 T
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . 11, Terminal box X010 – Connection . . . . . . . . . . 54
69 Terminal strip – Preparation . . . . . . . . . . . . . . 53
Cable routes and openings between all Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
installation locations – Check . . . . . . . . 11 Engine speed – Adjustment . . . . . . . . . 80
Cable routing between installation Gearbox – Engagement/disengage
locations for Series 2000 CR, classifiable ment . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
system . . . . . . . . . . . . . . . . . . . . . . . . . 20 LOP – Initial engine startup . . . . . . . . . . 77
Cable routing between installation
locations for Series 2000 CR,
non-classifiable system . . . . . . . . . . . . . 14
E532191/00E 05-06 © MTU

Technical Publication: Bluevision Engine Monitoring System Ecs-5 Application Marine

Uploaded by

Copyright:

Available Formats

Technical Publication: Bluevision Engine Monitoring System Ecs-5 Application Marine

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Technical Publication: Bluevision Engine Monitoring System Ecs-5 Application Marine

Uploaded by

Copyright:

Available Formats

Technical Publication

E532191/00E 05-06 © MTU

2.9 Electrical Installation (all Series, depending on equipment and options) . . . . . . . . . . . 52

E532191/00E 05-06 © MTU

1.1 General provisions

E532191/00E 05-06 © MTU

1.2 Personnel and organizational prerequisites

E532191/00E 05-06 © MTU

1.3 Safety requirements for maintenance and repair work

E532191/00E 05-06 © MTU

E532191/00E 05-06 © MTU

Working on electrical/electronic assemblies

E532191/00E 05-06 © MTU

1.4 Fluids and lubricants, fire prevention and

E532191/00E 05-06 © MTU

• Wear protective clothing, gloves, closed footwear and goggles!

E532191/00E 05-06 © MTU

1.5 Conventions for safety warnings in the text

E532191/00E 05-06 © MTU

Checking cable routes

E532191/00E 05-06 © MTU

2.1.2 Cable routing between installation locations for Series 2000

1 Engine 2 Gearbox 3 Trolling unit (option)

Cables to engine on Series 2000 M60, M70, M90, M91

E532191/00E 05-06 © MTU

Routing cables to gearbox and fuel system

Routing cables to main control stand and power supply

Routing cables for options

E532191/00E 05-06 © MTU

2.1.3 Cable routing between installation locations for Series

1 Engine 2 Gearbox 3 Trolling unit (option)

Cables to engine on Series 2000 M72, M73, M92, M93

E532191/00E 05-06 © MTU

Routing cables to gearbox and fuel system

Routing cables to main control stand and power supply

Routing cables for options

E532191/00E 05-06 © MTU

2.1.4 Cable routing between installation locations for Series

1 Engine 3 Trolling unit (option)

Cables to engine on Series 4000 M60, M61, M70, M71, M90

E532191/00E 05-06 © MTU

Routing cables to gearbox and fuel system

Routing cables to main control stand and power supply

Routing cables for optional oil priming pump

Routing cables for additional options

E532191/00E 05-06 © MTU

2.1.5 Cable routing between installation locations for Series 2000

1 Engine 3 Trolling unit (option)

Cables to engine on Series 2000 M60, M70, M90, M91

E532191/00E 05-06 © MTU

6. Route cable W014.1 between X010 (X2) and starter.

Routing cables to gearbox, shaft and fuel system

Routing cables to main control stand and power supply

Routing cables for options

E532191/00E 05-06 © MTU

2.1.6 Cable routing between installation locations for Series

1 Engine 3 Trolling unit (option)

Cables to engine on Series 2000 M72, M73, M92, M93

E532191/00E 05-06 © MTU