MTU 20 V 4000 G23 Instructions d'exploitation

Operating InstructionsDiesel engine20 V 4000 G23 with 6 exhaust turbochargers20 V 4000 G43 with 6 exhaust turbochargers20 V 4000 G63 with 6 exhaust tu

Installing guard plates and enginemounting brackets (if applicable)on driving end (KS)Note: Always use the screws supplied with the orremoved from the

524 – SS Engine Overspeed Mid ValZKP-Number: 20.480.089Limit value 2Cause Corrective actionAverage engine overspeed valuefrom three sources is too hig

530 – SS P-Lube Oil Red2ZKP-Number: 20.480.295Limit value 2Cause Corrective actionSecond redundant lube-oilpressure too high.u Check oil level, top up

551 – SS Engine Overspeed CamshaftZKP-Number: 22.510.933Limit value 2Cause Corrective actionCamshaft overspeed. 1. Acknowledge alarm.2. Attempt to res

579 – AL MD CAN Request Idle SpeedZKP-Number: 21.063.511Cause Corrective actionMD forced idle demand => nodefailure (node 3,4 or 5)u580 – AL MD CAN

6 Task Description6.1 Engine6.1.1 Engine – Barring manuallyPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare parts

6.1.2 Engine – Barring with starting systemDANGERUnguarded rotating and moving engine components.Risk of serious injury – danger to life!• before barr

6.1.3 Engine – Test runDANGERUnguarded rotating and moving engine components.Risk of serious injury – danger to life!• Before barring or starting the

6.2 Cylinder Liner6.2.1 Cylinder liner – Endoscopic examinationPreconditions☑ Engine is stopped and starting disabledSpecial tools, Material, Spare pa

Final steps1. Install injector (→ Page 120).2. Install cylinder head cover (→ Page 117).108 | Task Description | MS150093/01E 2012-06TIM-ID: 000000001

6.2.2 Cylinder liner – Instructions and comments on endoscopic and visualexaminationTerms used for endoscopic examinationUse the terms listed below to

1.5 Explosion hazard when removing inspection port cover onengineDANGERExplosion hazard due to oil vapors.Risk of serious injury – danger to life!• Al

Findings MeasureBurn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they runover the whole ring-travel area (TDC/BDC),

6.3 Crankcase Breather6.3.1 Crankcase breather – Oil mist fine separator replacementPreconditions☑ Engine is stopped and starting disabled.Special too

6.4 Valve Drive6.4.1 Valve gear – LubricationPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation /

6.4.2 Valve clearance – Check and adjustmentPreconditions☑ Engine is stopped and starting disabled.☑ Engine coolant temperature is max. 40 °C.☑ Valves

4. Rotate crankshaft with barring device in di‐rection of engine rotation until TDC-A1marking and pointer are aligned.Diagram for 8V engines (twocrank

Diagram for 16V engines (twocrankshaft positions)1 Cylinder A1 is in firing TDC2 Cylinder A1 is in overlap TDCI Inlet valveX Exhaust valveDiagram for

Adjusting valve clearance1. Release locknut (1).2. Insert feeler gauge between valve bridgeand rocker arm.3. Use Allen key to set adjusting screw (2)

6.4.3 Cylinder head cover – Removal and installationPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesigna

6.5 Injection Pump / HP Pump6.5.1 HP pump – Filling with engine oilPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spa

6.6 Injection Valve / Injector6.6.1 Injector – ReplacementSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Injector(→ Spare Parts Ca

1.6 Safety regulations for maintenance and repair workSafety regulations for maintenance and repair workHave maintenance and repair work carried out b

6.6.2 Injector – Removal and installationPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use

2. Remove HP fuel line (4).3. Remove return line (5).Note: The injector accumulator will be emptiedwhen removing the adapter.4. Remove adapter (3).5.

Installing injector1. Remove plug before installing the injec‐tor. (Do not remove the plug from the HPline before installing the adapter.)2. Coat inje

9. Coat screw head mating face (2) andthread with engine oil.10. Fit hold-down clamp (1) in the correct position and use torque wrench to tighten scre

18. Mount double-walled HP line (5) and use torque wrench to tighten to the specified torque. Tighteningsequence:1 Adapter (4)2 Rail (6)Name Size Type

6.7 Fuel System6.7.1 Fuel system – VentingPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use

6.8 Fuel Filter6.8.1 Fuel filter – ReplacementPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation /

6.8.2 Fuel prefilter cleaningPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Part No. Qty

6.8.3 Fuel prefilter – Differential pressure gauge check and adjustmentDANGERUnguarded rotating and moving engine components.Risk of serious injury –

6.8.4 Fuel prefilter – DrainingPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Part No. Q

Welding workNever carry out welding work on the assembly, system, or engine-mounted units. Cover the engine whenwelding in its vicinity.Do not use the

6.8.5 Fuel prefilter ‒ FlushingSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.FuelGasket(→ Spare Parts Catalog)DANGERUnguarded rot

2. Open threaded vent plug (5) of filter to beflushed.3. Unlock drain valve (6) by pressing valvetoggle, open it and drain fuel.Result: Fuel flows fro

6.8.6 Fuel prefilter – Filter element replacementPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignatio

2. Open threaded vent plug (5) of contaminat‐ed filter.3. Unlock drain valve (6) by pressing toggleand open it.4. Drain water and dirt from filter.5.

6.9 Charge-Air Cooling6.9.1 Intercooler – Checking condensate drain for coolant discharge andobstructionsDANGERUnguarded rotating and moving engine co

6.10 Air Filter6.10.1 Air filter – ReplacementSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Air filter(→ Spare Parts Catalog)Air

6.10.2 Air filter – CheckSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Air filter(→ Spare Parts Catalog)Air filter – Check1. Chec

6.10.3 Air filter – Removal and installationPreconditions☑ Engine is stopped and starting disabled.Removing and installing air filter1. Release clamp

6.11 Air Intake6.11.1 Contamination indicator – Signal ring position check (optional)Preconditions☑ Engine is stopped and starting disabled.Checking s

6.12 Starting Equipment6.12.1 Air starter – Manual operationDANGERUnguarded rotating and moving engine components.Risk of serious injury – danger to l

For conducting light-beam procedures and measurement work, only the following laser devices must beused:• Laser devices of classes 1, 2 or 3A.• Laser

6.13 Lube Oil System, Lube Oil Circuit6.13.1 Engine oil – ChangePreconditions☑ Engine is stopped and starting disabled.☑ Engine is at operating temper

Draining residual oil fromequipment carrier (only withunscheduled engine oil change)1. Provide a suitable container in which to col‐lect the engine oi

6.13.2 Engine oil level – CheckPreconditions☑ Engine shut down and starting disabled.Checking oil level prior to enginestart1. Withdraw oil dipstick f

6.13.3 Engine oil – Sample extraction and analysisPreconditions☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.Special tools, Ma

6.14 Oil Filtration / Cooling6.14.1 Engine oil filter – ReplacementPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spa

6.14.2 Centrifugal oil filter – Cleaning and filter sleeve replacementPreconditions☑ Engine is stopped and starting disabled.Special tools, Material,

Centrifugal oil filter cleaning andfilter sleeve replacement1. Remove clamp (14).2. Release cover screw (2) and take off cov‐er (1).3. Carefully lift

6.15 Coolant Circuit, General, High-Temperature Circuit6.15.1 Engine coolant – Level checkPreconditions☑ Engine is stopped and starting disabled.☑ MTU

6.15.2 Engine coolant – ChangeSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.CoolantEngine coolant – Change1. Drain engine coolant

6.15.3 Engine coolant – DrainingPreconditions☑ Engine is stopped and starting disabled.WARNINGCoolant is hot and under pressure.Risk of injury and sca

1.7 Auxiliary materials, fluids and lubricants, fire prevention andenvironmental protectionFire preventionRectify any fuel or oil leaks immediately; e

6.15.4 Engine coolant – FillingPreconditions☑ Engine is stopped and starting disabled.☑ MTU Fluids and Lubricants Specifications (A001061/..) are avai

Filling coolant with pump1. Connect appropriate pump with hose to thedrain valve of the engine coolant pump (ar‐row).2. Open venting point at distribu

Alternatively: Filling coolantthrough filler neck1. Open venting point at distributor (arrow).2. Fill in coolant in expansion tank via fillerneck unti

6.15.5 Engine coolant pump – Relief bore checkDANGERUnguarded rotating and moving engine components.Risk of serious injury – danger to life!• Take spe

6.15.6 Engine coolant – Sample extraction and analysisPreconditions☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.Special tools

6.16 Low-Temperature Circuit6.16.1 Charge-air coolant – Level checkPreconditions☑ Engine is stopped and starting disabled.☑ MTU Fluids and Lubricants

6.16.2 Charge-air coolant – ChangeSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.CoolantCharge-air coolant – Change1. Drain charge

6.16.3 Charge-air coolant – DrainingPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Part

6.16.4 Charge-air coolant – FillingPreconditions☑ Engine is stopped and starting disabled.☑ MTU Fluids and Lubricants Specifications (A001061/..) are

Filling coolant with pump1. Connect a suitable pump with a hose to thedrain valve (arrowed).2. Undo the vent line union at the distributorpiece (arrow

Lead• When working with lead or lead-containing compounds, avoid direct contact to the skin and do notinhale lead vapors.• Adopt suitable measures to

Alternatively: Filling coolantthrough filler neck1. Undo the vent line union at the distributorpiece (arrowed).2. Fill in coolant in expansion tank vi

6.16.5 Charge-air coolant pump – Relief bore checkDANGERUnguarded rotating and moving engine components.Risk of serious injury – danger to life!• Take

6.17 Belt Drive6.17.1 Drive belt – Condition checkPreconditions☑ Engine is stopped and starting disabled.☑ Guard is removed.Drive belt – Condition che

6.18 Battery-Charging Generator6.18.1 Battery-charging generator drive – Drive belt tension adjustmentPreconditions☑ Engine is stopped and starting di

6.18.2 Battery-charging generator drive – Drive belt replacementPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare

6.19 Wiring (General) for Engine/Gearbox/Unit6.19.1 Engine wiring – CheckPreconditions☑ Engine is stopped and starting disabled.Special tools, Materia

6.20 Engine Mounting / Support6.20.1 Engine mounting – CheckEngine mounting – CheckItem Findings ActionVisually inspect mounts. • Damage• Brittleness•

6.21 Accessories for (Electronic) Engine Governor / ControlSystem6.21.1 CDC parameters – Reset with DiaSys®Preconditions☑ Engine is stopped and starti

6.21.2 Engine governor and connectors – CleaningPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation

6.21.3 Engine governor – Checking plug-in connectionsPreconditions☑ Engine is stopped and starting disabled.Note: Always use test connectors to enter

1.8 Conventions for safety instructions in the textDANGERIn the event of immediate danger.Consequences: Death or serious injury• Remedial actionWARNIN

6.21.4 ECU 7 engine governor – Removal and installationPreconditions☑ Engine is stopped and starting disabled.CAUTIONWrong engine governor installed.E

7 Appendix A7.1 AbbreviationsAbbreviation Meaning ExplanationA/D Analog/Digital Transformer: transforms sensor voltages intonumeric valuesADEC Advance

Abbreviation Meaning ExplanationEGR Exhaust Gas RecirculationEMU Engine Monitoring UnitETK Ersatzteilkatalog Spare Parts Catalog (SPC)EUI Electronic U

Abbreviation Meaning ExplanationSAE Society of Automotive Engineers U.S. standardization organizationSD Sensor Defect Alarm: Sensor failureSEL Stop En

7.2 MTU contacts/service partnersServiceOur worldwide sales network with its subsidiaries, sales offices, representatives and customer servicecenters

8 Appendix B8.1 Special ToolsBarring devicePart No.: F6555766Qty.:Used in:1 6.1.1 Engine – Barring manually (→ Page 104)Box wrench socket, 24 mmPart N

Installation/removal toolPart No.: F6789889Qty.:Used in:1 6.6.2 Injector – Removal and installation (→ Page 120)Milling cutterPart No.: F30452739Qty.:

Ratchet with extensionPart No.: F30006212Qty.:Used in:1 6.1.1 Engine – Barring manually (→ Page 104)Rigid endoscopePart No.: Y20097353Qty.:Used in:1 6

Torque wrench, 10-60 NmPart No.: F30510423Qty.:Used in:1 1.4 Crankshaft transport locking device (→ Page 8)Torque wrench, 10-60 NmPart No.: F30452769Q

Torque wrench, 60-320 NmPart No.: F30047446Qty.:Used in:1 1.4 Crankshaft transport locking device (→ Page 8)Torque wrench, 60-320 NmPart No.: F3045276

2 Product Summary2.1 Engine Layout010 Crankcase and add-oncomponents020 Gear train030 Running gear040 Cylinder head050 Valve gear070 Fuel system (high

8.2 Index20 V 4000 Gx3 engine data: Continuous operation 3D,optimized fuel consumption  2720 V 4000 Gx3 engine data: Continuous operation 3D,optimized

Fuel– prefilter  – Flushing  130Fuel filter – Replacement 126Fuel prefilter– Differential pressure gauge  – Check and adjustment  128– Draining  129–

2.2 Overview of sensors, actuators and injectors1 Temperature sensorsfor single exhaust gasB4.1 to B4.10 (engineside A)2 Sensor B34 (P-Fuel afterfilte

Printed in Germany© 2012 Copyright MTU Friedrichshafen GmbHThis Publication is protected by copyright and may not be used in any way whether in whole

1 B50 (P crankcase)2 B05.3 (P lube oil beforefilter)3 B05 (P lube oil after fil‐ter)4 B33 (T fuel, rail)5 B07 (T lube oil)6 B01 (N camshaft)7 B48 (P f

1 Temperature sensorsfor single exhaust gasB4.11 to B4.20 (engineside B)2 B16 (P coolant)3 B10 (P charge air)4 B09 (T charge air)The injectors (Y39.11

1 B13 (N crankshaft)22 | Product Summary | MS150093/01E 2012-06TIM-ID: 0000019859 - 001

2.3 Engine – Main dimensionsEngine – Main dimensionsLength (A) approx. 3560 mmWidth (B) approx. 1660 mmHeight (C) approx. 2163 mmMS150093/01E 2012-06

2.4 Firing orderFiring orderNum‐ber ofcylin‐dersFiring order8V A1-B4-A4-A2-B3-A3-B2-B112V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B116 V A1-A7-B4-B6-A4-B8-A2

2.5 Final compression pressureFinal compression pressureFinal compression pressure at 120 rpm 24 bar to 28 barMS150093/01E 2012-06 | Product Summary |

2.6 Engine side and cylinder designationsEngine sides are always designated as viewed from the driving end (KS).The cylinders of the left engine side

2.7 20V 4000 Gx3 engine data: Continuous operation, variable3B, optimized fuel consumptionExplanation:DL Ref. value: Continuous powerBL Ref. value: Fu

Number of cylinders 20 20 20 20 20Exhaust gas over‐pressure30 30 30 30 30Exhaust gas over‐pressure, max.A mbar 85 85 85 85 85MODEL-RELATED DATA (basic

COOLANT SYSTEM (LT circuit)Number of cylin‐ders20 20 20 20 20Coolant tempera‐ture before inter‐cooler (at engine in‐let inlet from cool‐ing system)A °

Table of Contents1 Safety1.1 General conditions 51.2 Personnel and organizational requirements 61.3 Transport 71.4 Crankshaft transport locking device

GENERAL OPERATING DATANumber of cylin‐ders20 20 20 20 20Cold start capabili‐ty: Air temperature(w/o start aid, w/opreheating) - (caseA)R °C 10 10 10 1

ACOUSTICSNumber of cylin‐ders20 20 20 20 20Engine surfacenoise with attenuat‐ed intake noise (fil‐ter) - DL (free-fieldsound power levelLp, 1 m distan

2.8 20V 4000 Gx3 engine data: Continuous operation, variable3B, optimized exhaust emissions ("TA-Luft")Explanation:DL Ref. value: Continuous

Number of cylinders 20 20 20Compression ratio 16.4 16.4 16.4Inlet valves per cylinder 2 2 2Exhaust valves per cylinder 2 2 2COMBUSTION AIR / EXHAUST G

GENERAL OPERATING DATANumber of cylinders 20 20 20Cold start capability: Air temperature (w/o start aid,w/o preheating) - (case A)R °C 10 10 10Coolant

2.9 20 V 4000 Gx3 engine data: Standby operation 3D,optimized fuel consumption, 6ETCExplanation:DL Ref. value: Continuous powerBL Ref. value: Fuel sto

MODEL-RELATED DATA (basic design)Number of cylin‐ders20 20 20 20 20 20Number of cylin‐ders20 20 20 20 20 20Cylinder arrange‐ment: V-angleDegrees 90 90

COOLANT SYSTEM (LT circuit)Number of cylin‐ders20 20 20 20 20 20Coolant tempera‐ture before inter‐cooler (at engineinlet inlet fromcooling system)A °C

FUEL SYSTEMNumber of cylin‐ders20 20 20 20 20 20Fuel pressure atengine inlet con‐nection, min.(when engine isstarting)L bar -0.1 -0.1 -0.1 -0.1 -0.1 -

Number of cylin‐ders20 20 20 20 20 20Oil pan capacityat dipstick mark“min.” (standardoil system) (op‐tion: max. operat‐ing inclinations)L Liters 245 2

6.8 Fuel Filter 1266.8.1 Fuel filter – Replacement 1266.8.2 Fuel prefilter cleaning 1276.8.3 Fuel prefilter – Differential pressure gaugecheck and adj

3 Operation3.1 Putting the engine into operation after extended out-of-service periods (>3 months)Preconditions☑ Engine is stopped and starting dis

3.2 Putting the engine into operation after scheduled out-of-service-periodPreconditions☑ Engine is stopped and starting disabled.Putting the engine i

3.3 Start engine in manual mode (testing mode)Preconditions☑ Generator (if provided) not connected to network.☑ External start interlock is not activa

3.4 Safety system – OverrideCAUTIONSafety functions and engine shutdown alarms will be disregarded.Serious damage to plant!• Initiate emergency start

3.5 Operational checksDANGERUnguarded rotating and moving engine components.Risk of serious injury – danger to life!• Take special care when working o

3.6 Starting the engine in emergency situations (override mode)CAUTIONSafety functions and engine shutdown alarms will be disregarded.Serious damage t

3.7 Stop engine in manual mode (testing mode)Preconditions☑ Generator (if provided) not connected to network.☑ Engine is running in manual mode.CAUTIO

3.8 Emergency stopCAUTIONAn emergency stop causes extreme stress to the engine.Risk of overheating, damage to components!• Initiate emergency stop onl

3.9 After stopping the engine – Engine remains ready foroperationAfter stopping the engineItem ActionEngine/generator/pumpcontrolSelect operating mode

3.10 After stopping the engine – putting the engine out of servicePreconditions☑ MTU Fluids and Lubricants Specifications (A001061/..) is available.Af

1 Safety1.1 General conditionsGeneralIn addition to the instructions in this publication, the applicable country-specific legislation and other com‐pu

3.11 Plant cleaningPreconditions☑ Engine is stopped and starting disabled.☑ Operating voltage is not present.Special tools, Material, Spare partsDesig

4 Maintenance4.1 Maintenance task reference table [QL1]The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. T

5 Troubleshooting5.1 TroubleshootingEngine does not turn when starter is actuatedComponent Probable cause TaskBattery Low or defective Charge or repla

Engine does not reach nominal speedComponent Probable cause TaskFuel supply Fuel prefilter clogged Replace (→ Page 132).Easy-change fuel filter clogge

Exhaust gas blueComponent Probable cause TaskEngine oil Too much engine oil in the engine Drain engine oil (→ Page 140).Oil separator of crankcase bre

5.2 Engine governor ADEC (ECU 7) for Series 4000 gensetengines – Fault messages003 – HI T-FuelZKP-Number: 2.0122.931Limit value 1Cause Corrective acti

010 – SS T-Coolant IntercoolerZKP-Number: 2.0124.932Limit value 2Cause Corrective actionCoolant temperature inintercooler too high; engineshutdown.u R

022 – SS T-Exhaust BZKP-Number: 2.0127.932Limit value 2Cause Corrective actionExhaust gas temperature (B-side) too high; engine shutdown.1. Check cabl

030 – SS Engine SpeedZKP-Number: 2.2510.932Limit value 2Cause Corrective actionReduced fuel injection. 1. Acknowledge alarm.2. Attempt to restart engi

037 – SS ETC 2 OverspeedZKP-Number: 2.3013.912Limit value 2Cause Corrective actionSpeed of first secondaryturbocharger too high.1. Reduce power.2. Con

1.2 Personnel and organizational requirementsPersonnel requirementsAll work on the engine shall be carried out by trained and qualified personnel only

057 – LO P-CoolantZKP-Number: 2.0101.921Limit value 1Cause Corrective actionCoolant pressure too low. u Check coolant circuit.058 – SS P-CoolantZKP-Nu

064 – SS P-CrankcaseZKP-Number: 2.0106.932Limit value 2Cause Corrective actionCrankcase pressure too high;engine shutdown.1. Replace oil separator ele

081 – AL Rail LeakageZKP-Number: 1.8004.046Cause Corrective actionPressure gradient in common railtoo low during engine start or toohigh during engine

090 – SS Starter Speed Not ReachedZKP-Number: 2.1090.925Cause Corrective actionIdling speed was not attained. u Contact Service.091 – SS Release Speed

102 – AL Consumption Meter FaultyZKP-Number: 1.8004.624Cause Corrective actionconsumption meter faulty. u Contact Service.104 – AL Eng Hours Counter D

122 – HI T-ECUZKP-Number: 2.0132.921Limit value 1Cause Corrective actionElectronic unit temperature toohigh.1. Reduce power.2. Improve engine room ven

180 – AL CAN1 Node LostZKP-Number: 2.0500.680Cause Corrective actionConnection to one node on CANbus 1 failed.u Contact Service.181 – AL CAN2 Node Los

187 – AL CAN1 Error PassiveZKP-Number: 2.0500.687Cause Corrective actionCAN controller 1 has signaled awarning.1. Inspect CAN bus for short circuit an

203 – SD T-Charge AirZKP-Number: 1.8004.571Cause Corrective actionCharge-air temperature sensorfaulty; short circuit or wire break.u Check sensor and

211 – SD P-Lube OilZKP-Number: 1.8004.563Cause Corrective actionLube-oil pressure sensor faulty;short circuit or wire break.u Check sensor and cabling

1.3 TransportTransportAlways use the lifting eyes on the engine and generator/gearbox when transporting gensets.Always use the lifting eyes on the eng

219 – SD T-Intake AirZKP-Number: 1.8004.573Cause Corrective actionIntake air temperature sensorfaulty; short circuit or wire break.u Check sensor and

228 – SD P-Fuel before FilterZKP-Number: 18.004.595Cause Corrective actionFuel pressure sensor faulty;short circuit or wire break.u Check sensor and c

239 – SD P-Diff FuelZKP-Number: 18.004.598Cause Corrective actionFuel differential pressure sensorfaulty.This alarm occurs only incombination with the

266 – SD Speed DemandZKP-Number: 2.8006.586Cause Corrective actionAnalog speed demand signalfaulty; short circuit or wire break.1. Check cabling.2. Ch

303 – AL Timing Cylinder A3ZKP-Number: 1.8004.502Cause Corrective actionTime-of-flight measuring fault ofinjector: time-of flight measuredvalue extrem

308 – AL Timing Cylinder A8ZKP-Number: 1.8004.507Cause Corrective actionTime-of-flight measuring fault ofinjector: time-of flight measuredvalue extrem

313 – AL Timing Cylinder B3ZKP-Number: 1.8004.512Cause Corrective actionTime-of-flight measuring fault ofinjector: time-of flight measuredvalue extrem

318 – AL Timing Cylinder B8ZKP-Number: 1.8004.517Cause Corrective actionTime-of-flight measuring fault ofinjector: time-of flight measuredvalue extrem

324 – AL Wiring Cylinder A4ZKP-Number: 1.8004.523Cause Corrective actionCabling fault in injector cabling tocylinder. Result: misfiring.1. Check solen

331 – AL Wiring Cylinder B1ZKP-Number: 1.8004.530Cause Corrective actionCabling fault in injector cabling tocylinder. Result: misfiring.1. Check solen

1.4 Crankshaft transport locking deviceSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Torque wrench, 10-60 NmF30510423 1Torque wre

338 – AL Wiring Cylinder B8ZKP-Number: 1.8004.537Cause Corrective actionCabling fault in injector cabling tocylinder. Result: misfiring.1. Check solen

345 – AL Open Load Cylinder A5ZKP-Number: 1.8004.544Cause Corrective actionDisruption fault in injector cablingto cylinder. Result: misfiring.1. Check

352 – AL Open Load Cylinder B2ZKP-Number: 1.8004.551Cause Corrective actionDisruption fault in injector cablingto cylinder. Result: misfiring.1. Check

359 – AL Open Load Cylinder B9ZKP-Number: 1.8004.558Cause Corrective actionDisruption fault in injector cablingto cylinder. Result: misfiring.1. Check

365 – AL Stop MV-Wiring GroundZKP-Number: 1.8004.561Cause Corrective actionInjector cabling fault. If bit“1.1020.021” (Power StageFailure: stop engine

381 – AL Wiring TOP 1ZKP-Number: 2.8006.638Cause Corrective actionShort circuit or wire break ontransistor output, plant-side 1(TOP 1).u Check cabling

393 – SS T-Coolant RedZKP-Number: 2.0129.932Limit value 2Cause Corrective actionRedundant coolant temperaturereading too high; engineshutdown.1. Check

401 – AL Open Load Digital Input 2ZKP-Number: 2.8006.626Cause Corrective actionOpen circuit at digital input 2;cabling faulty or no resistanceacross t

407 – AL Open Load Digital Input 8ZKP-Number: 2.8006.632Cause Corrective actionOpen circuit at digital input 8;cabling faulty or no resistanceacross t

413 – HIHI U-PDUZKP-Number: 2.0141.932Limit value 2Cause Corrective actionInjector voltage too high. 1. Check cabling.2. Check power supply.3. Contact

Fitting the transport locking deviceon driving end (KS)Note: Attach plates (2) only to the upper part of the openings.1. Secure the two plates (2) wit

420 – AL L1 Aux 1ZKP-Number: 2.0160.921Limit value 1Cause Corrective actionInput signal of Aux 1 hasexceeded/not attained limit value1, depending on c

434 – HI T-Coolant before EngineZKP-Number: 20.173.931Limit value 1Cause Corrective actionCoolant temperature too high. u Check coolant circuit.435 –

448 – HI P-Charge AirZKP-Number: 2.0103.931Limit value 1Cause Corrective actionCharge-air pressure too high. u Contact Service.449 – SS P-Charge AirZK

460 – HI T-Exhaust EMUZKP-Number: 2.8006.652Limit value 1Cause Corrective actionEMU exhaust gas temperaturevalue too high.1. Check cabling.2. Contact

469 – SD AUX 1ZKP-Number: 1.8004.590Cause Corrective actionAnalog input signal for Aux 1faulty; short circuit or wire break.u Check signal transmitter

475 – AL CR Trigger Engine StopZKP-Number: 1.8010.009Cause Corrective actionTripped by crash recordertriggering due to engineshutdown.u Determine and

483 – SD T-Exhaust DZKP-Number: 18.004.597Cause Corrective actionExhaust temperature sensor onA-side faulty; short circuit or wirebreak.u Check sensor

489 – SS ETC3 OverspeedZKP-Number: 23.014.932Limit value 2Cause Corrective actionSpeed of second secondaryturbocharger too high.u Reduce power.490 – H

501 – AL Wiring POM Starter 2ZKP-Number: 14.500.901Cause Corrective actionA wiring fault was detected in theconnection of starter 2 of theCPM. The roo

508 – AL Wrong POM-IDZKP-Number: 14.500.908Cause Corrective actionPOM transmits a different ID No.than expected.u Check POM wiring harness.510 – AL Ov