Sách Engine Control Unit Type ECU 4 BR 4000 Marine applications

Documentation

Part 1, 3, 4, 5
Engine Control Unit
Type ECU 4
BR 4000
Marine applications
- Structure and function
- Maintenance and repair (Plant personnel)
- Maintenance and repair (Service personnel)
- Illustrated parts catalog

Table of contents
Table of contents I
Abbreviations VI .
General information about documentation VIII
1 Structure and function 2 .
1.1 Use and structure 2 .
1.1.1 Use 2 .
1.1.2 Structure of Engine Control Unit ECU 4 4
1.1.2.1 External structure 4 .
1.1.2.2 Internal structure 6 .
1.1.2.3 Attachment of Engine Control Unit ECU 4 to the engine 8
1.2 Functions of Engine Control Unit ECU 4 9 .
1.2.1 Engine governing/control 9
1.2.2 Software 10 .
1.2.3 Speed/injection governing 11 .
1.2.4 Common Rail injection system 12
1.2.5 Angle measuring/determining control timing 13
1.2.6 Adjustable speed droop 14 .
1.2.7 Power limitation (fuel flow) 15 .
1.2.7.1 Dynamic fuel flow limitation 15
1.2.7.2 Fixed fuel flow limitation 15 .
1.2.7.3 Control of fuel flow during engine starting 15
1.2.7.4 Speed limitation 15
1.2.8 Nominal speed value handling 16
1.2.9 Recirculating ETC control 17
1.2.10 Cylinder cutout 18 .
1.3 Start and stop functions 18 .
1.3.1 Engine start 18
1.3.2 Emergency engine start 19 .
1.3.3 Engine stop 19
1.3.4 Emergency engine stop 20 .
1.3.5 Safety system override 20
1.4 Engine monitoring 21
1.4.1 Engine protection system 21
1.4.2 Integral Test System (ITS) 22 .
1.4.2.1 Monitoring the electronics of Engine Control Unit ECU 4 23 .
1.4.2.2 Monitoring the sensors/actuators 23 .
1.4.2.3 Monitoring bus communication 23 .
1.5 Status and fault displays 24 .
1.6 Communication and system integration via CAN bus 25
1.7 Inputs/outputs of Engine Control Unit ECU 4 25 .
1.7.1 Inputs on the plant side 25
1.7.1.1 Assignment of inputs on the plant side 25 .
1.7.1.2 Input specifications 26 .
1.7.2 Inputs on the engine side 28
1.7.2.1 Assignment of inputs on the engine side 28 .
1.7.2.2 Input specifications 29 .
1.7.3 Outputs on the plant side 35
1.7.3.1 Assignment of outputs on the plant side 35 .
1.7.3.2 Output specifications 36
1.7.4 Outputs on the engine side 38 .
1.7.4.1 Assignment of outputs on the engine side 38
1.7.4.2 Output specifications 39
1.7.5 Bus connections 42
1.7.5.1 Serial interface RS232 42
1.7.5.2 CAN bus interface 43
1.8 Technical data 44
2 Operation 47 .
(Not applicable)
3 Maintenance and repair (Plant personnel) 51 .
3.1 Safety requirements 51 .
3.2 Maintenance 53 .
3.2.1 General notes 53
3.2.2 Maintenance work 56
3.2.2.1 Maintenance intervals 56 .
3.2.2.2 Task summary for scheduled maintenance work 56
3.2.3 Task overview -- visual inspection 57 .
3.2.3.1 Checking firm seating of all connectors 58
3.2.3.2 Checking firm seating of cables 59 .
3.2.3.3 Checking screwed sensor connections for leaks 60
3.2.3.4 Checking cables 61
3.2.4 Task overview -- cleaning 62
3.2.4.1 Cleaning Engine Control Unit ECU 4 63
3.2.4.2 Cleaning connectors 64
3.3 Troubleshooting 65
3.3.1 Faults without fault code display 65
3.3.2 Faults with fault code display 68 .
3.3.3 Faults indicated by LEDs 87
3.4 Repair 88 .
3.4.1 Replacing Engine Control Unit ECU 4 88 .
3.4.1.1 Removing the housing of Engine Control Unit ECU 4 from the engine 90 .
3.4.1.2 Removing the cover of Engine Control Unit ECU 4 92
3.4.1.3 Transferring the memory modules of Engine Control Unit ECU 4 93
3.4.1.4 Fitting the cover of Engine Control Unit ECU 4 95
3.4.1.5 Mounting the housing of Engine Control Unit ECU 4 on the engine 96
3.4.2 Replacing the fusible cutout in ECU 4 98 .
3.4.2.1 Removing the cover of Engine Control Unit ECU 4 when mounted on the
engine 99 .
3.4.2.2 Replacing the fusible cutout 100
3.4.2.3 Fitting the cover of Engine Control Unit ECU 4 when mounted on the engine101
4 Maintenance and repair (Service personnel) 105 .
4.1 Safety requirements 105 .
4.2 Maintenance 107 .
4.2.1 General notes 107
4.2.2 Maintenance work 107
4.3 Troubleshooting 107
4.3.1 Faults with fault code display 107 .
4.4 Repair 113 .
4.4.1 Replacing data module IDM 113
4.4.1.1 Removing the cover of Engine Control Unit ECU 4 115
4.4.1.2 Replacing Interface Data Module IDM 116 .
4.4.1.3 Fitting the cover of Engine Control Unit ECU 4 when mounted on the engine118
4.4.2 Replacing data module EDM 119 .
4.4.2.1 Removing the cover of Engine Control Unit ECU 4 120
4.4.2.2 Replacing Engine Data Module EDM 120
4.4.2.3 Fitting the cover of Engine Control Unit ECU 4 122
4.5 Metrological tests 122 .
4.5.1 Testing the CAN bus 122
4.5.1.1 CAN bus short-circuit test 123
4.5.1.2 Checking and repairing shielding 125 .

5 Illustrated parts catalog 128
5.1 Introduction 128
5.2 Drawings and tables 131
5.3 Cross-reference list 135 .
Appendix 137 .
Connector pin assignment 139 .
Input circuitry of the ECU channels 153