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6R 1100/1300/1500EU Stage IV/US TIER 4Operating Instructions

Order no. 6462 9837 02 Part no. 470 584 09 81 Edition 01-14

É4705840981$ËÍ4705840981

ImprintInternet

Further information about MTU, Mercedes-Benz and Daimler AG can be found on theInternet at:www.mtu-online.comwww.mercedes-benz.comwww.daimler.com

Documentation team

Should you have any questions or sugges-tions regarding this manual, you can reachthe technical documentation team at the fol-lowing address:Daimler AG, HPC: CAC, Customer Service,70546 Stuttgart, Germany©Daimler AG: not to be reprinted, translatedor otherwise reproduced, in whole or in part,without written permission from Daimler AG.

Equipment manufacturer

Daimler AGMercedesstraße 13770327 StuttgartGermany

SymbolsG WARNINGWarning notes make you aware dangerswhich could pose a threat to your health orlife, or to the health and life of others.

H Environmental noteEnvironmental notes provide you with infor-mation on environmentally aware actions ordisposal.

! The purpose ofmaterial damagewarningsis to draw your attention to risks whichcould lead to damage to your engine sys-tem.

i These symbols indicate useful instruc-tions or further information that could behelpful to you.

X This symbol designates an instruc-tion you must follow.

X Several consecutive symbols indi-cate an instruction with severalsteps.

(Y page) This symbol tells you where youcan find further information on atopic.

YY This symbol indicates a warning oran instruction that is continued onthe next page.

DisplayDisplay This text indicates an indicator inthe display.

As at 28.08.2013

WelcomeFamiliarise yourself with your engine systemand read the Operating Instructions beforeyou use the engine system. This will help youto avoid endangering yourself or others.The standard equipment and product descrip-tion of your engine systemmay vary, depend-ing on individual specifications. This is descri-bed on the data card.The engine systems are constantly updatedto be state of the art.MTU/Mercedes-Benz reserves the right tomake changes to the following:RdesignRequipmentRtechnical featuresDescriptionsmay therefore differ in individualcases from your engine system.

4705840981 É4705840981$ËÍ

Index ....................................................... 4

Introduction ........................................... 7

At a glance ........................................... 11

Safety ................................................... 21

Transport, installation ........................ 25

Operation ............................................. 27

Maintenance ........................................ 45

Decommissioning ............................... 55

Troubleshooting .................................. 57

Technical data ..................................... 69

Contents 3

AAdBlue®/DEF

Consumption ................................... 40Gauge .............................................. 33Important safety notes .................... 42Refuelling ......................................... 42Service product ............................... 51

ADM (FR (drive control) unit) ............. 12

BBattery (vehicle)

Jump starting ................................... 61Braking

Continuous brake ............................ 31Engine brake .................................... 31Retarder ........................................... 31

Buzzer ................................................... 40

CCapacities ............................................ 73Care products ...................................... 53Charge current .................................... 32Checking the fluid level ...................... 28Cleaning and care

Engine cleaning ................................ 53High-pressure cleaning .................... 53Notes on care .................................. 53

ConsumptionAdBlue®/DEF .................................. 40Fuel .................................................. 40Oil (engine) ...................................... 40

Continuous brakeImportant safety notes .................... 31

CoolantMixing ratio ...................................... 49Service product ............................... 49Topping up ....................................... 29

Coolant additive .................................. 49Correct use ............................................ 8Corrosion inhibitor/antifreezeagent .................................................... 49

DData card .............................................. 70DEF/AdBlue®

see AdBlue®/DEF service productsDescription of the engine ................... 12Diagnostics connection ...................... 23Diesel

Fuels ................................................ 50Low outside temperatures ............... 50Refuelling ......................................... 41

Dimensions .......................................... 71Disposal of service products .............. 47Driving mode

Idling speed ..................................... 31Driving tips .......................................... 39

EElectronic engine control

see Engine managementElectronic engine control unit ............ 32Emergency gearshift

Using the emergency switch ............ 32Emergency running program ................ 8Engine

Capacities ........................................ 73Cleaning ........................................... 53Data ................................................. 70Data card ......................................... 70Data plate ........................................ 70Modifying the power output ............... 8Oil consumption ............................... 40Operating data ................................. 73Rectifying faults ............................... 63Running-in period ............................. 39Starting ............................................ 29Stopping .......................................... 30

Engine brake ........................................ 31Engine data .......................................... 70Engine data card .................................. 70Engine description .............................. 12Engine idling speed ............................. 31Engine management ........................... 16Engine oil

Consumption ................................... 40For winter operation ........................ 47

4 Index

Mixing .............................................. 48Oil change ........................................ 48Topping up ....................................... 48

Engine overview .................................. 13Engine speed ....................................... 32Exhaust gas aftertreatment ............... 18

FFuel

Additives .......................................... 51Consumption ................................... 40Diesel ............................................... 50Refuelling ......................................... 41

Fuel filter with water separatordraining ............................................ 60

Fuel grade ............................................ 50Fuel system

Automatic bleeding .......................... 59Manual bleeding .............................. 59

FusesChecking and replacing a safetyfuse .................................................. 61Important safety notes .................... 60

GGauge

AdBlue®/DEF .................................. 33Genuine Mercedes-Benz parts ............. 7

HHigh-pressure cleaning ....................... 53

IIdentification plate .............................. 70Idling speed

Engine .............................................. 31Installation ........................................... 26

JJump-starting ....................................... 61

MMaintenance

Notes ............................................... 46Mercedes-Benz Service Centre

see Qualified specialist workshop

OOil (engine)

For winter operation ........................ 47Oil change ........................................ 48Scope of use .................................... 48

Oil pressure ......................................... 32Operating data ..................................... 73Operating instructions

General notes .................................. 10Operating safety .................................. 22Operating safety and registration

Changes in engine performance ........ 8Implied warranty ................................ 8

Operational monitoring ...................... 32Organisational measures ................... 23

PPersonnel ............................................. 23Preparing for starting operation

see Starting operationProtection of the environment ............. 7

QQualified specialist workshop ........... 10

RRefuelling

AdBlue®/DEF .................................. 42Fuels ................................................ 41

Requirements of the personnel ......... 23Rev counter .......................................... 32Roadside Assistance ........................... 58Running the vehicle in ........................ 39

Index 5

SSafety andemergency runningpro-gram ....................................................... 8Safety precautions .............................. 22Service products

AdBlue®/DEF .................................. 51Coolant ............................................ 49DEF/AdBlue® .................................. 51Diesel fuel ........................................ 50Disposal ........................................... 47Disposing of AdBlue®/DEF .............. 52Engine oil ......................................... 47Fuel additives ................................... 51General notes .................................. 47Purity of AdBlue®/DEF .................... 53Storing AdBlue®/DEF ...................... 52

Specialist workshop ............................ 10Starting

see Starting (engine)Starting (engine) .................................. 29Stopping and switching off theengine ................................................... 29

TTechnical data

Dimensions ...................................... 70Filling capacities .............................. 73Operating data ................................. 73Weights ............................................ 70

Tightening torques .............................. 74Transport .............................................. 26

WWarning and indicator lamps

Electronics ....................................... 34Engine, general ................................ 18

Warning buzzer .................................... 40Weights ................................................ 71Winter diesel ........................................ 50Winter operation ................................. 43

6 Index

Engine system

The 6R 1100, 6R 1300 and 6R 1500 series ofengines only function as intended when usedin conjunction with the correspondingexhaust gas aftertreatment unit. Therefore, inthese Operating Instructions, the term"engine system" refers to the engine and theexhaust gas aftertreatment unit.

Protection of the environment

H Environmental noteDaimler AG has a declared policy of compre-hensive environmental protection.The objectives are to use the natural resour-ces which form the basis of our existence onthis planet sparingly and in a manner whichtakes the requirements of both nature andhumanity into account.You too can help to protect the environmentby operating your vehicle in an environmen-tally responsible manner.

Information and notes on driving in an envi-ronmentally responsible and fuel-savingman-ner can be found in the "Operating notes"section (Y page 40).

Assembly equipment

These Operating Instructions describe allmodels and all standard and optional equip-ment available for your engine system at thetime of publication of the Operating Instruc-tions. Country-specific deviations are possi-ble. Note that your engine systemmay not befitted with all features described. This alsoapplies to safety-relevant systems and func-tions. Therefore, the equipment on yourengine system may differ from certaindescriptions and illustrations.All of the components in your engine systemare listed in the data card of your engine sys-tem. Data card (Y page 70).

Please contact an MTU or MTU-authorisedMercedes-Benz Service Centre if you haveany questions about the equipment or oper-ation.

Genuine Mercedes-Benz parts

H Environmental noteDaimler AG also supplies reconditionedassemblies and parts which are of the samequality as new parts. For these, the same war-ranty applies as for new parts.

If you use parts which have not beenapproved by Mercedes-Benz, the operationalsafety of the engine system may be jeopar-dised. This could lead to malfunctions insafety-relevant systems. Use only genuineMercedes-Benz parts or parts of equal qual-ity. Only use parts that have been approvedfor your engine type.Mercedes-Benz checks genuine Mercedes-Benz parts for:RreliabilityRsafetyRsuitabilityDespite ongoing market research, Mercedes-Benz is unable to assess other parts.Mercedes-Benz therefore accepts no respon-sibility for the use of such parts in Mercedes-Benz vehicles, even if they have been officiallyapproved or independently approved by atesting centre.In Germany, certain parts are only officiallyapproved for installation or modification ifthey comply with legal requirements. Thisalso applies to some other countries. All gen-uine Mercedes-Benz parts meet the approvalrequirements. The use of non-approved partsmay invalidate the vehicle's general operatingpermit.

Introduction 7

Z

This is the case if:Rthey result in a change to the vehicle typefrom that for which the vehicle's generaloperating permit was grantedRthey pose a possible risk for road usersRthey adversely affect the emission or noiselevels

You can find more information on recommen-ded conversion parts and accessories, as wellas permitted technical modifications at anMTU or MTU-authorised Mercedes-Benz Ser-vice Centre (Y page 10).Always specify the engine number and thenumber of the exhaust gas aftertreatmentunit when ordering genuine Mercedes-Benzparts. You can find the engine number on theidentification plate of your engine. You canfind the number of the exhaust gas aftertreat-ment unit on the identification plate of theexhaust gas aftertreatment control module(ACM) (Y page 70). You can also find thetwo numbers on the data card (Y page 70).

Modifying the engine output

! Increased power could:Rchange emission levelsRcause malfunctionsRlead to consequential damageThe operating safety of the engine cannotbe guaranteed in all situations.

Any tampering with the engine managementsystem in order to increase the engine poweroutput will lead to a loss of warranty entitle-ments.

Safety/emergency running program

The engine is equipped with an electronicengine management system that monitorsthe engine and the exhaust gas aftertreat-ment unit and has a self-diagnostic system.

If the electronic control systemdetects amal-function, one of the following measures isautomatically implemented after an appraisalof the malfunction:Rfaults during operation are indicated by thecorresponding warning lamp (Y page 32).Rin conjunction with the electronic enginemanagement system, fault codeswith addi-tional information can be shown on a dis-play.Rthe system switches to a suitable backupfunction for the continued, albeit restric-ted, operation of the engine. This includestorque and engine speed limitation, forexample, as well as road speed limitation orconstant emergency running speed.

Correct use

The engine system may only be installed ascontractually specified.The manufacturer of the end product isresponsible for the correct installation of theengine and the exhaust gas aftertreatmentsystem in the overall system.The engine and the exhaust gas aftertreat-ment system may not be modified. If theengine is modified, Mercedes-Benz and MTUdo not accept responsibility for any damagearising as a result.Correct use of the engine system alsorequires adherence to the instructions inthese Operating Instructions. This alsorequires compliance with the maintenanceintervals and the professional execution ofmaintenance work. Please observe the Work-shop Information System (WIS) (Y page 10).

Implied warranty

A well-developed network of MTU or MTU-authorisedMercedes-Benz Service Centres isavailable to carry out maintenance work.

8 Introduction

MTU or MTU-authorised Mercedes-Benz Ser-vice Centres:Rhave special equipment and tools aswell asspecialists who receive continuous trainingRguarantee that your engine system isrepaired and maintained thoroughly andexpertlyRcarry out all repairs related to implied war-rantyRcarry out all maintenance work expertlyRconfirm in the Maintenance Booklet thatthemaintenancework has been carried outat the required timeRhandle implied warranty claims that areadmissible according to the sales contract

Please observe the instructions and recom-mendations as well as the maintenance serv-ices in the Maintenance Booklet. Pleaseobserve these instructions even if you let athird party use and care for your vehicle/equipment. This is the only way to ensure thatyou do not lose your entitlements.If the prescribed maintenance work is notcarried out, claims can only be decided afterthe manufacturer has inspected the claim.During the implied warranty period, have theprescribed maintenance service for yourengine system carried out as follows:RregularlyRpunctuallyRat a qualified specialist workshop whichhas the necessary specialist knowledgeand tools to carry out the work requiredMercedes-Benz recommends that you useanMTU or MTU-authorised Mercedes-BenzService Centre. In particular, work relevantto safety or on safety-related systemsmustbe carried out at a qualified specialist work-shop.

If there are legal requirements on emissioncontrol, please note that:Rmaintenance on the engines must be car-ried out according to specific regulationsand using special measuring devicesRit is prohibited to modify or tamper withcomponents relevant to emissions

All MTU or MTU-authorised Mercedes-BenzService Centres are familiar with the relevantregulations.Maintenance work does not include repairwork. Issue a separate order for repair work.You can obtain further information on themaintenance of your engine system from anyMTU or MTU-authorised Mercedes-Benz Ser-vice Centre.

Stored data

Several of the electronic components in yourengine system contain data memories.These data memories temporarily or perma-nently store technical information about:Rthe engine system stateReventsRmalfunctionsIn general, this technical information docu-ments the state of a component, a module, asystem or the surroundings.This includes, for example:Roperating conditions of system compo-nents, e.g. fluid levelsRstatus messages for the vehicle/equip-ment and its individual components, e.g.speed, deceleration in movement, acceler-ator positionRmalfunctions and defects in important sys-tem componentsRthe reactions and operating statuses of thevehicle/equipment in special driving situa-tionsRambient conditions, e.g. outside tempera-ture

Introduction 9

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This data is exclusively technical in natureand can be used to:Rassist in the detection and rectification offaults and defectsRanalyse vehicle functions, e.g. after an acci-dent

The data cannot be used to trace the vehicle'smovements.When you use one of the available services,technical information may be read from theevent data memory and fault data memory.Services include, for example:Rrepair servicesRservice processesRimplied warranty and guarantee casesRquality assuranceThe information is read out by employees ofthe service network (including manufactur-ers) using special diagnostic testers. Furtherinformation is available there if required.After a fault has been rectified, the informa-tion is deleted from the fault memory or iscontinually overwritten.

Qualified specialist workshop

A qualified specialist workshop has the nec-essary specialist knowledge, tools and quali-fications to carry out the work required on theengine to a professional standard. This is par-ticularly applicable to work relevant to safety.Observe the notes in the Maintenance Book-let.Always have the following maintenance workcarried out at a qualified specialist workshop:Rwork relevant to safetyRservice and maintenance workRrepair workRmodifications as well as installations andconversionsRwork on electronic componentsPlease consult an MTU or MTU-authorisedMercedes-Benz partner.

Further applicable documents

To use the engine correctly, you require theMaintenance Booklet in addition to theseOperating Instructions.For US-certified engines you also require the"Emission Related Warranty" supplement.Always keep these documents together withthe engine/vehicle/equipment. These docu-ments should be passed on to the new ownerif you sell the engine/vehicle/device.When carrying out maintenance work, yourequire access to the Workshop InformationSystem (WIS) via the Internet. This access issubject to a fee.Current information on the system and pricescan be found at this web address: http://service-parts.mercedes-benz.com. Click on"EPC, WIS/ASRA" in the "Service and partsinformation" tab and then on "WIS".You can log in by clicking on "Register" on theright-hand side.

10 Introduction

General information ............................ 12Engine overview .................................. 13Exhaust gas aftertreatment over-view ...................................................... 15Electronic engine management ......... 16Exhaust gas aftertreatment ............... 18Exhaust gas recirculation .................. 18Warning and indicator lamps ............. 18

11

Ataglance

General information

The engine is a water-cooled four-stroke die-sel engine with direct injection.The engine is equipped with a Common Raildiesel injection system, cooled and regulatedexhaust gas recirculation and turbochargingwith charge-air pressure control.The valve gear has twin overhead camshaftswhich are gearwheel-driven.The engine has a single-part cylinder head. Inthe cylinder head there are two inlet valvesand two exhaust valves per cylinder. Thevalves are arranged symmetrically. The sym-metrical valve arrangement is optimal forcombustion .The exhaust gas aftertreatment unit is char-acterised by the following technologies:Rselective catalytic reduction (SCR) withammonia slip catalytic converterRthe diesel oxidation catalytic converter(DOC)

The engine brake is a decompression brake. Ithas a controlled exhaust valve which gives ithigh braking power. The engine brake can becontrolled stepwise or modulated.

Common Rail diesel injection systemThe engine is equipped with a diesel injectionsystem with an Amplified Pressure CommonRail System (APCRS) which reduces the fuelquantity required for combustion to a mini-mum. The advantage of this system is that thepressure in the rail and the high-pressurelines is relatively low. The fuel pressure isincreased as required in a second stageinside the injector, using a pressure amplifier.This has a particularly positive effect onmate-rial wear and tear and thus on componentdurability.

12 General informationAt

aglance

Engine overview

Engine overview: 6R 1100: Rail; Oil filter= Fuel filter? Manual fuel feed pumpA High-pressure fuel pumpB Power-steering pumpC External engine start/engine stop buttonD Air compressorE Engine management control module (MCM)F Oil panG Coolant thermostatH Charge-air pipe (cold)I Coolant pump

Engine overview 13

Ataglance

Engine overview: 6R 1100: Exhaust gas recirculation cooler; Exhaust gas recirculation pipe (cold)= Charge-air pipe (hot)? Refrigerant compressorA AlternatorB Fresh air intake from air filterC Crankcase ventilation systemD Starter motorE Exhaust gas turbocharger

14 Engine overviewAt

aglance

Exhaust gas aftertreatment overview

: NOx sensor on exhaust gas aftertreatment unit inlet; AdBlue® treatment reactor= Exhaust gas inlet from AdBlue® treatment reactor? Position of identification plateA Exhaust gas aftertreatment boxB Exhaust gas outletC Exhaust gas temperature sensor upstream of the SCR catalytic converterD Pump moduleE AdBlue®/DEF metering unitF Exhaust gas temperature sensor upstream of the AdBlue® metering unit

Exhaust gas aftertreatment overview 15

Ataglance

: Mounting brackets; Exhaust gas inlet from engine= Exhaust gas aftertreatment control unit (ACM)? NOx sensor at exhaust gas aftertreatment unit outletA Exhaust gas temperature sensor downstream of the SCR catalytic converter

Electronic engine management

The engine system is equipped with an elec-tronic engine management system whichcomprises the following control units:REngine management control module(MCM)RDrive control system unit (CPC)RExhaust gas aftertreatment control unit(ACM)

The control units are connected in an elec-tronic network. Data is exchanged via CAN(Controller Area Network).

In addition to the engine, the exhaust gasaftertreatment and the vehicle/equipment-side connection, the electronic engine man-agement system also monitors itself.Depending on the malfunctions/failureswhich occur, warning and information dis-plays are activated (Y page 18). The mal-function is stored in the fault memory and ifnecessary a safety and emergency mode isautomatically selected (Y page 32). If theelectronic engine management controldetects a fault, the fault code is stored in thecontrol units. It can then be read by a qualifiedspecialist workshop (Y page 10) using a diag-nostic tester.

16 Electronic engine managementAt

aglance

Engine management control module(MCM)The engine management control module(MCM) is located on the side of the engine. Itacts as an interface between the electric andelectronic components on the engine/equip-ment and the drive control system unit (CPC)on the vehicle.The engine management control module(MCM) has many functions:RInjection control of the Common Rail dieselinjection systemThe engine management control module(MCM) calculates the optimum start andquantity of injection, taking the torquedemand from the drive control system unit(CPC) into account.All of the data required for this, e.g. poweroutput or data which serve to protect theengine, are stored in the engine manage-ment control module (MCM).RRegulation of exhaust gas recirculation(EGR)The ratio between the mass of recirculatedexhaust gas and the fresh air mass is pre-cisely regulated over the entire enginespeed range.RCharge-air pressure controlRControl of the engine brakeThe engine management control module(MCM) controls the engine brake asrequired by the drive control system unit(CPC).RFan regulationIn optional fan regulation, the solenoidvalve on the fan clutch is activated accord-ing to coolant temperature.RInstrument cluster displayThe engine management control module(MCM) detects the oil level, engine oil tem-perature, oil pressure, coolant temperatureand the engine speed for the displays in theinstrument cluster.

Drive control system unit (CPC)The drive control system unit (CPC) is instal-led in a protected location in the vehicle/equipment by the vehicle/equipment manu-facturer. It acts as an interface between theelectric and electronic components on thevehicle/equipment and the engine manage-ment control module (MCM) on the engine.The drive control system unit (CPC) has manyfunctions:RCalculation of torque demandThe drive control system unit (CPC) regis-ters the driver's requirements. For exam-ple, the position of the accelerator is detec-ted by the drive control system unit (CPC).A torque requirement is calculated fromthat and sent to the engine managementcontrol module (MCM) via the CAN con-nection.In doing so, information and limitationsfrom optionally connected control unitssuch as the gearbox control, retarder con-trol, ABS and ASR are taken into account.ROutput of displays and indicator signalswhich are displayed in the instrument clus-ter.RMonitoring of coolant level, charge currentand air filter, for exampleRLegal speed limitationREvaluation of start requestThe engine starting process is initiatedonce a corresponding start request is pres-ent (ignition lock or external engine start/engine stop button).

Exhaust gas aftertreatment controlunit (ACM)The exhaust gas aftertreatment control unit(ACM) is installed in a protected location inthe vehicle/equipment by the vehicle/equip-ment manufacturer. It regulates and controlsthe exhaust gas aftertreatment system.

Electronic engine management 17

Ataglance

Functions of the exhaust gas aftertreatmentcontrol unit (ACM):REvaluation of sensor signalsThe sensor signals of the directly connec-ted sensors are evaluated. Data providedvia the CAN by the engine managementcontrol module (MCM) and the controlunits for the NOx sensors are also evalu-ated.RAdBlue®/DEF injectionCalculation of the required amount ofAdBlue®/DEF and supply of AdBlue®/DEFby actuation of the SCR delivery pump.Injection by actuation of the AdBlue®/DEFmetering unit.

Exhaust gas aftertreatment

The exhaust gas aftertreatment system isactivated immediately after the engine is star-ted and remains activated during engineoperation. It ensures that the pollutant emis-sions in the exhaust gas are reduced to thelimits stipulated in the emissions standard.Exhaust gas treatment is carried out by:Rselective catalytic reduction (SCR) withammonia slip catalytic converterRthe diesel oxidation catalytic converter(DOC)

In order to ensure correct operation of theexhaust gas aftertreatment system, onlyoperate the engine/vehicle with the AdBlue®reducing agent. AdBlue® is not refilled as partof the maintenance work. You should there-fore top up the AdBlue® tank regularly your-self.Operating the vehicle/equipment withoutAdBlue® or with another, non-Mercedes-Benzor non-MTU approved medium, invalidatesthe engine's operation certification/approval.

Exhaust gas recirculation

Exhaust gas recirculation (EGR) serves pri-marily to reduce the amount of nitrogen oxideprior to exhaust gas aftertreatment. Thisserves to comply with emissions limits.Exhaust gas is added to the fresh air beingdrawn in or charged so that the concentrationof oxygen in the combustion mixture isreduced. Combustion deteriorates if the con-centration of exhaust gas in the combustionmixture is too high. The emission of soot par-ticles, carbon monoxide (CO) and hydrocar-bons (HC) increases. Conversely, the emis-sion of nitrogen oxides (NOx) would increase,if the concentration of fresh or charged airwas too high.

Warning and indicator lamps

Important safety notesIf you ignorewarning and indicator lamps, youwill not be able to recognise failures and mal-functions in components or systems. Driv-ing/braking characteristics may be differentand the operating and road safety of yourvehicle/equipment may be limited. Have theaffected system checked and repaired at aqualified specialist workshop. Alwaysobserve the warning and indicator lamps andfollow the corresponding corrective actions(Y page 34).

OverviewThe display format for warning and indicatorlamps is vehicle-specific/equipment-spe-cific. Observe the information contained inthe Operating Instructions for the vehicle/equipment. The symbols listed below areexamples and may differ from those symbolsdisplayed in the vehicle/equipment.In the event of a fault or warning, a warninglamp or indicator lamp lights up automati-cally. Depending on the priority of the fault or

18 Warning and indicator lampsAt

aglance

warning, the warning and indicator lampslight up in different combinations.The following warning and indicator lampsmay be available on the instrument panel:

Indicatorlamp

Description

red Engine stop

Ù Engine system malfunction

· Emissions-relevant malfunc-tion of the exhaust gas after-treatment system orAdBlue®/DEF supply

(lit con-stantly)

Torque operating restriction

(flash-ing)

Torque and engine speedoperating restriction

# Charge current

Ø

(optional)AdBlue®/DEF reserve level

5

(optional)Oil pressure too low (engine)

4

(optional)Oil level too low (engine)

,

(optional)Coolant level too low

?

(optional)Coolant temperature toohigh

Ã

(optional)Continuous brake active

é

(optional)Cruise control

È

(optional)Speed limiter

I

(optional)Power take-off engaged

Warning and indicator lamps 19

Ataglance

Operating safety ................................. 22Safety precautions .............................. 22Notes on electronic systems ............. 22Staff qualifications ............................. 23Organisational measures ................... 23

21

Safety

Operating safety

G WARNINGIf you do not have the prescribed service/maintenance work or necessary repairs car-ried out, this could result in malfunctions orsystem failures. There is a risk of an accident.Always have the prescribed service/mainte-nance work as well as necessary repairs car-ried out at a qualified specialist workshop.

The operating safety of an engine systemdepends on its professional installation in theoverall system (e.g. the vehicle or workingmachinery). As the operator of the engine,you also affect its safe operation.Through compliance with the prescribedmaintenance intervals, you fulfil part of therequirements for safe operation of theengine.However, safe operation of the engine alsodepends upon its proper use and care. Thisincludes, for example, regularly checking theoil level.

Safety precautions

Damage to the engine can also lead to per-sonal injury. In order to avoid engine damage,the following safety precautions must beadhered to.ROnly start the engine when the batteriesare firmly attached.RDonot disconnect the batterieswhen theengine is running.RDo not use a rapid charger to start theengine.ROnly perform the jump-starting proce-dure with separate batteries.RNote, the battery terminals must be dis-connected when rapid charging the bat-teries.RObserve the operating instructions of therapid battery charger.

RPlease note, when carrying out electricwelding work, that the batteries must bedisconnected and both of the cables ("+"and "-") must be firmly attached to eachother.RThe control unit connectors may only beconnected/disconnected when the elec-trical system is switched off.RIncorrect control unit-power supplypolarity (e.g. by connecting up the bat-teries incorrectly) can cause irreparabledamage to the control units.RTighten diesel injection system connec-tions to the prescribed tightening torque.RIf temperatures above 80 † are to beexpected (e.g. in a drying oven), the con-trol unit on the engine must be removed.ROnly use the appropriate testing probeswhen taking measurements from electri-cal connectors (e.g. a Mercedes-Benzconnection set). Telephones and two-way radio devices that are not connectedto an external aerial can cause malfunc-tions in the electronics and thus endan-ger the operating safety of the engine.

Warning stickersIf you remove any warning stickers, you orothers could fail to recognise certain dangers.Various warning stickers are attached to theengine system. Their purpose is to make youand others aware of various risks.

Notes on electronic systems

Important safety notes

G WARNINGModifications to electronic components, theirsoftware as well as wiring could effect theirfunction and/or the operation of other net-worked components. This could in particularalso be the case for systems relevant tosafety. They might not function properly any

22 Notes on electronic systemsSafety

more and/or jeopardise the operationalsafety of the vehicle. There is an increasedrisk of an accident and injury.Do not attempt to modify the wiring as well aselectronic components or their software.Always have work on electrical and electroniccomponents carried out at a qualified special-ist workshop.

The general operating permit for your vehi-cle/equipment could be rendered invalid ifyou carry out modifications to electroniccomponents, their software or their wiring.

Electromagnetic compatibilityThe electromagnetic compatibility of theengine system's components has beenchecked and certified according to the cur-rently valid version of Directive ECE-R 10.

Diagnostics connectionThe diagnostics connection is used for con-necting diagnostic equipment at a qualifiedspecialist workshop.

G WARNINGIf you connect equipment to a diagnosticsconnection in the vehicle, it can affect theoperation of the vehicle systems. This mayaffect the operating safety of the vehicle.There is a risk of an accident.Do not connect any equipment to a diagnos-tics connection in the vehicle.

If the engine is switched off and devices con-nected to the diagnostics connection arebeing used, the starter battery can becomedischarged.Connecting devices to the diagnostics con-nection can, for example, cause the emis-sionsmonitoring information to be reset. As aresult, there is a possibility that the vehicle/equipment will not fulfil the requirements ofthe next legally prescribed emissions test.

Staff qualifications


The engine should only be operated, main-tained and repaired by trained personnel whohave been briefed and authorised by the oper-ator. The prescribed minimum legal age forpersonnel carrying out maintenance andrepair work must be observed.

Organisational measures

The operator must determine the responsi-bilities for operation, maintenance andrepairs. Give the Operating Instructions andthe Maintenance Booklet to the personnelthat are charged with operating or carryingout work on the engine.Instruct personnel on how to operate theengine using the Operating Instructions.When doing so, put special emphasis onsafety-relevant information. This is particu-larly important for personnel that only workoccasionally on the engine.Always keep the Operating Instructions andthe Maintenance Booklet readily accessible,in the area of engine operation.In addition to the Operating Instructions,other general, country-specific, legal andother binding regulations on accident preven-tion and environmental protection must beadhered to.

Organisational measures 23

Safety

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Transport ............................................. 26Installation ........................................... 26

25

Transport,installatio

n

Transport

G WARNINGIf you do not lift the engine as described, thelugs intended for the purpose may be torn outor snap. This may be the case especially if themaximum permissible lug load is exceeded.The engine could then drop uncontrolled,causing serious or even fatal injury.Always make sure that:Rthe engine is only lifted at the intended lift-ing points/lifting lugs.Rthe engine is only lifted and transported inthe fitting position.Rropes/chains are always routed vertically.Ronly parts which are typically in the originalscope of delivery are attached to theengine.

! The engines are by default delivered filledwith oil. If the engine is transported at anangle or on its side, oil could leak out. Onlytransport the engine in the installation posi-tion.

! Do not stand on the engine or the exhaustgas aftertreatment unit. They may other-wise be damaged.

Example: using a cross member

The engine may only be lifted using a crossmember with the chain/rope at 90° relativeto the horizontal engine.

Example: belt-side lifting point

Example: flywheel-side lifting points

Installation

The engine system may only be installed ascontractually specified.Observe the sections "Correct use" (Y page 8)and "Modifying the engine output" (Y page 8).Daimler AG provides the vehicle manufac-turer with comprehensive material, e.g. theinstallation guideline, for initial installation.The vehicle manufacturer must take this intoaccount. If the engine is fitted after repairwork, for example, the information in theWorkshop Information System (WIS) must beobserved (Y page 10).Observe the sections "Qualified specialistworkshop" (Y page 10) and "Further applica-ble documents" (Y page 10).Please consult an MTU or MTU-authorisedMercedes-Benz Service Centre (Y page 10) ifyou have any questions. .

26 InstallationTransport,installatio

n

Preparation for operation ................... 28Starting and stopping the engine ...... 29Switching the continuous brake onand off .................................................. 31Idling speed ......................................... 31Operational monitoring ...................... 32Displays ............................................... 32Warning and indicator lamps ............. 34Operating instructions ....................... 39Refuelling ............................................. 41Winter operation ................................. 43

27

Operation

Preparation for operation

Engine with initial operation oil fromthe factoryThe engine is filled at the factorywith an initialoperation oil.These high-quality engine oils are beneficialto the running-in process. They also allow youto make the first oil change in accordancewith the applicable oil change intervals. Thiseliminates the need for special break-in oilsand the additional oil change otherwiserequired.

Checking the engine oil levelThe engine is equipped with an electronic oillevel detection system.If the engine is also equipped with a dipstick,this is subsidiary to the electronic oil levelmeasurement system. It is merely used for ageneral check to determine if there is oil in theengine.

Electronic oil level measurement – sys-tem descriptionThe engine oil level sensor is installed in theoil pan for oil level measurement. The electri-cal signals are detected in the engine man-agement control module (MCM) and trans-mitted to the drive control systemcontrol unit(CPC) via the engine CAN.Output can be displayed on a matrix displaywhen the engine is not running.The engine oil level is not displayed while theengine is running.

Checking the oil level electronicallyCheck the engine oil level on a regular basis,e.g. before each journey or each time yourefuel.The current oil level in the engine is only dis-played once the engine is switched off andwith the ignition switched on. An accuratedisplay of the engine oil level is therefore only

possible with the engine switched off and theignition switched on.X Park the vehicle/device on a level surface.X Engage the parking brake.X Switch off the engine.X Wait approximately five to ten minutes. Ifyou call up the oil level in the engine tooearly or while the engine is running, it is notavailable.

Only use engine oil which has been approvedfor the engine and which meets the specifiedSAE classification (Y page 47).

Checking the oil level with the dipstick

! Do not add too much oil. If you add toomuch oil, the engine or the exhaust after-treatment unit could be damaged. Drain orsiphon off any excess oil.

Check the engine oil level on a regular basis,e.g. before each journey or each time yourefuel.X Park the vehicle/device on a level surface.X Engage the parking brake.X Switch off the engine.X Wait approximately five to ten minutes.

28 Preparation for operationOp

eration

X Check the engine oil level with dipstick;.The oil level should be between the upperand lower marks on dipstick;.

X If necessary, use filler neck: to top up theoil.

Only use engine oil which has been approvedfor the engine and which meets the specifiedSAE classification (Y page 47).

Checking the coolant levelX Check the coolant level as stated in thevehicle's/equipment's Operating Instruc-tions.

X Fill the cooling system if necessary. Onlyuse coolant that has been approved for theengine (Y page 49).

Checking the fuel levelFor checking the fuel level on the fuel gauge,see the vehicle's Operating Instructions.Refuel if necessary (Y page 50).

Checking the AdBlue®/DEF supplyFor checking the AdBlue®/DEF supply on theAdBlue®/DEF gauge, see the vehicle's Oper-ating Instructions. Refuel if necessary(Y page 42).

Starting and stopping the engine

Starting the engine

G WARNINGCombustion engines emit poisonous exhaustgases such as carbon monoxide. Inhalingthese exhaust gases leads to poisoning. Thereis a risk of fatal injury. Therefore never leavethe engine running in enclosed spaces with-out sufficient ventilation.

! If the oil pressure in the engine is too low,a warning light lights up on the instrumentpanel. The warning buzzer also sounds.The operating safety of the engine is jeop-ardised. Switch off the engine immediately.

Do not pull away as soon as the engine starts.Do not subject the equipment to high loadsimmediately. Let the engine run in neutral fora short time after starting, until there is suf-ficient engine oil pressure. Do not drive athigh engine speeds when the engine is cold.This will prevent excessive wear and possibleengine failure.Warm up the engine quickly by driving atmoderate engine speeds. Depending on theoutside temperature, the engine will reach itsoperating temperature after around 10 to20 minutes. Operating temperature(Y page 73).You can utilise the full engine power outputonce the engine has reached its normal oper-ating temperature.The display format for warning and indicatorlamps is vehicle-specific/equipment-spe-cific. Observe the information contained inthe Operating Instructions for the vehicle/equipment.X Start the engine using the key in the ignitionlock or the external engine start/enginestop button on the engine. Do not depressthe accelerator or clutch pedal while doingso.

For additional safety, the electronic enginemanagement system is equipped with a func-tion that only allows the engine to be startedwhen the transmission is in neutral (vehicle/equipment-specific).

Starting the engine with the key

! After starting the engine, let it run atengine idling speed until the oil pressure isdisplayed. If no oil pressure is displayedafter approximately 10 seconds, switch offthe engine. Determine the cause. The oper-ating safety of the engine is jeopardised.

Starting and stopping the engine 29

Operation

Z

Example: ignition lockg To insert/remove the vehicle key1 Steering wheel unlocked/radio position2 Drive position (ignition)3 Start positionX Secure the vehicle/equipment against roll-ing away.

X Deactivate power take-off.X Shift into neutral.X To start the engine: turn the key in theignition lock to drive position2.

X Turn the key to start position3 in the igni-tion lock. Do not depress the acceleratorpedal whilst doing so.

X When the engine has started, release thekey.The idling speed is controlled automati-cally.i The engine idling speed is raised at verylow outside temperatures or during regen-eration of the diesel particle filter.

X If the engine does not start immedi-ately: interrupt the starting procedureafter no more than 30 seconds.

X Turn the key in the ignition lock back to thestop at key positiong.

X Repeat the starting procedure after a wait-ing period of approximately 1 minute.

X If the engine fails to start: rectify the causeof the poor starting characteristics(Y page 63).

X Observe the oil pressure gauge immedi-ately after having started the engine.

Starting the engine with the externalengine start/engine stop buttonX To start the engine with the externalengine start/engine stop button:(Y page 58).

Stopping the engine

G WARNINGWhen switching off the equipment or parkingthe vehicle, make sure that the exhaust sys-tem does not come into contact with com-bustible objects, e.g. dry leaves, grass orother highly flammable materials.

G WARNINGIf you switch off the ignition while the vehicleis in motion, safety-relevant functions arerestricted or not available. This can affect thepower steering function and the brake boost-ing effect, for example. You will then requireconsiderably more force to steer and brake.There is a risk of an accident.Do not switch off the ignition while the vehicleis in motion.

! Stop the engine immediately, payingattention to the road and traffic conditionsif:Rthe oil pressure falls or fluctuates signif-icantly.Rthe power output or engine speeddecreases and the position of the posi-tion sensor (accelerator) remains con-stant.Rheavy smoke is emitted from theexhaust.Rthe coolant or engine oil temperaturerises steeply.Rabnormal noises suddenly come fromthe engine or exhaust gas turbocharger.

30 Starting and stopping the engineOp

eration

X Park the vehicle/equipment.X Secure the vehicle/equipment against roll-ing away.

X Shift the transmission into neutral/decou-ple the drive system.

Let the engine idle for approximately 2minutes before switching off the engine if:Rthe coolant temperature is very high (over100 †).Rthe engine has been operated at full output.X To switch off the engine: turn the vehiclekey in the ignition lock back to the stop atpositionu.

i If you switch off the engine, the systemmay continue to run for a short while.Depending on the installation position,operating state and ambient temperature,circulation of AdBlue®/DEF is necessaryfor ensuring cooling. To do this theAdBlue®/DEF delivery pump is actuatedduring this period.

Switching off the engine with the exter-nal engine start/engine stop buttonX To switch off the engine with the exter-nal engine start/engine stop button:(Y page 58).

Switching the continuous brake onand off

G WARNINGIf you activate the continuous brake or shift toa lower gear on a slippery road surface inorder to increase the engine's braking effect,the drive wheelsmay lose traction. There is anincreased risk of skidding and an accident.Do not activate the continuous brake and donot shift to a lower gear in order to increasethe engine's braking effect on a slippery roadsurface.

The engine brake and retarder are used as acontinuous brake.You can utilise the engine's braking effect,particularly on long downhill gradients if you:Ractivate the continuous brakeRshift to a lower gear in good timeSlowly depress the brake pedal if the engine'sbraking effect is insufficient when drivingdownhill.Vehicles without a retarder are equipped withonly two brake stages.Operation of the continuous brake; see thevehicle's Operating Instructions.TheÃ indicator lamp in the instrumentcluster is lit when the continuous brake isactive.When ABS (Anti-lock Braking System) inter-venes, the continuous brake is switched off.TheÃ indicator lamp in the instrumentcluster remains on.

Engine brakeThe effectiveness of the engine brakedepends on the engine speed. A high enginespeed results in more effective engine brak-ing.Observe the effective engine braking rangemarked on the rev counter (Y page 32).At very low outside temperatures, the enginebrake has limited or no effect after the enginehas been started.Operation of the engine brake; see the vehi-cle's Operating Instructions.

RetarderOperation of the retarder; see the vehicle'sOperating Instructions.

Idling speed

After the engine has been started, idlingspeed is regulated automatically. The engine

Idling speed 31

Operation

Z

idling speed may differ in certain operatingconditions depending on the engine or onvehicles with power take-off.You can set the idling speed to betweenapproximately 600 and 800 rpm.The engine idling speed is raised at very lowoutside temperatures or during regenerationof the diesel particle filter.You can set the speed to the working speedvia the electronic engine management sys-tem. This makes it possible to drive auxiliaryequipment such as pumps at their workingspeed. For setting the working speed, see thevehicle's Operating Instructions.

Operational monitoring

Charge currentThe charge current indicator lamp must goout after the engine has started.If the# indicator lamp does not go off orlights up when the engine is running, switchoff the engine. Searching for and eliminatingthe cause of the malfunction (Y page 63).

Electronic engine managementThe indicator and warning lamps must go outafter the engine has started.If an indicator lamp or warning lamp does notgo out, or if it lights up while the engine isrunning, there is a malfunction in the elec-tronic engine management system.Each malfunction is stored in the system withits own fault code. Temporary faults are alsostored.Fault codes can be read by a qualified spe-cialist workshop using a diagnostic tester(Y page 8).

Oil pressureIf the1 indicator lamp does not go out orif it lights up when the engine is running,

switch off the engine. Searching for and elim-inating the cause of the malfunction(Y page 63).

Operating restrictionsThe electronic engine management systemmonitors:Remissions-relevant malfunctions in theexhaust gas aftertreatmentRmalfunctions in the electronic monitoringof the exhaust gas aftertreatment systemRconsumption, level and quality of theAdBlue®/DEF reducing agentRthe efficiency of the catalytic converter inaccordance with the permitted thresholdsfor nitric oxide emissions (NOx)

Operating restrictions in the form of torquereduction and thus output and speed limita-tion may occur.

Emergency switch for overriding theoperating restrictionsIf an emissions-related malfunction of theexhaust gas aftertreatment system orAdBlue®/DEF supply is detected, this canlead to operating restrictions (engine torqueand engine speed limitation).In emergencies, a push-button switch can beoperated to override the operating restric-tion. This means that full engine power isavailable for a maximum of 30 minutes. Thisemergency function by operating the switchcan be activated a maximum of three times.If the final operating restriction (idling speedand 20% of torque) has been reached, thepush-button switch is deactivated.

Displays

Rev counter! If you exceed the maximum permissibleengine speed, the warning tone sounds.

32 DisplaysOp

eration

You should not drive and change gear bythe sound of the engine, but according tothe engine speed shown in the rev counter.Avoid driving in the red overrevving range.This could lead to engine damage.

The engine speed display is the responsibilityof the vehicle manufacturer and is not nec-essarily supplied by Mercedes-Benz. DaimlerAG recommends that the vehicle manufac-turer uses a rev counter divided by:Roperational efficiencyRengine braking rangeRengine overrevving rangeGeneral notes on the rev counter:RKeep an eye on the rev counter while driv-ing and stay within the economical operat-ing range.In some situations it may make sense tooperate the engine outside the economicalengine speed range, e.g. on uphill gradientsor when overtaking.RIf you run the engine within the economicalengine speed range, you achieve low fuelconsumption and reduced wear.RIn engine braking mode, drive in the middleengine speed range. The highest enginebraking effect will be achieved just beforethe red overrevving range.RWhen driving downhill, make sure that theengine speed does not enter the overrev-ving range (marked red).RIdling speed is set automatically dependingon the coolant temperature.RWhen the vehicle is stationary, the engine isrunning and the transmission is in neutral,the engine increases throttle only slowly.

AdBlue®/DEF levelThe AdBlue®/DEF gauge is the responsibilityof the vehicle manufacturer. It is not neces-sarily supplied by Mercedes-Benz. DaimlerAG recommends that the vehicle manufac-turer uses an AdBlue®/DEF gauge and an

AdBlue®/DEF indicator lamp for theAdBlue®/DEF reserve levelØ.The AdBlue®/DEF reducing agent is requiredfor reduction of engine emissions.The operating permit is invalidated if the vehi-cle is operated without AdBlue®/DEF. Thelegal consequence of this is that the vehiclemay no longer be operated on public roads.If the AdBlue®/DEF level has sunk to approx-imately 10%, a warning lamp for theAdBlue®/DEF reserve level lights up on theinstrument panel. Top up the AdBlue®/DEFtank in good time (Y page 42).If the gauge is ignored and the AdBlue®/DEFlevel drops further, engine torque and enginespeed may be reduced.Engine torque may be limited to a maximumof 20% across the whole engine speed range.Engine speed may be limited to idling speed.

Displays 33

Operation

Z

Warning and indicator lamps

Warning and indicator lamps - causes/consequences and solutions

Problem Possible causes/consequences andMM Solutions

The indicator lampflashes red.

A serious fault in the engine system has been detected.X Immediately stop the vehicle/equipment while paying attentionto the traffic conditions and contact a qualified specialist work-shop.

TheÙ indicatorlamp lights up.

Impermissible operating conditions have been detected in theengine system.One of the following systems is malfunctioning:REngineREngine coolingREngine managementRDiesel injection systemX If further indicator lamps are displayed, take the combination oflamps (see below) into account when evaluating the cause.

X Have the systems checked at a qualified specialist workshop.

Only vehicles/equipment with the AdBlue®/DEF reserve warning lightIf a malfunction is detected and the listed indicator lamps light up, a warning buzzer sounds forapproximately 5 seconds. In emergencies, operating restrictions (engine torque and enginespeed restrictions) can be temporarily overridden with the emergency switch (Y page 32).

34 Warning and indicator lampsOp

eration


Indicator lampsØand are lit and· flashes.

The AdBlue®/DEF level has dropped to approximately 7.5%.Reduced engine output is active. The engine torque is limited to amaximum of 75% across the whole engine speed range. The limi-tation takes effect by means of a ramp function.X Adapt your driving/operating style.X Top up the AdBlue®/DEF tank immediately.If you do not follow the instructions, the engine speed may belimited.

TheØ indicatorlamp is lit and· and

are flashing.

The AdBlue®/DEF level has dropped to approximately 5%.Reduced engine output and engine speed limitation are active. Theengine torque is limited to a maximum of 50% across the wholeengine speed range. The engine speed is limited to a maximum of60%. The limitation takes effect by means of a ramp function.X Adapt your driving/operating style.X Top up the AdBlue®/DEF tank immediately.If you do not observe the instructions, engine torque and enginespeed may be reduced further.

TheØ and indi-cator lamps are lit and· and areflashing.

The AdBlue®/DEF level has dropped to approximately 2.5%.Reduced engine output and engine speed limitation are active. Theengine torque is limited to a maximum of 20% across the wholeengine speed range. The engine speed is limited to idling speed.The limitation takes effect by means of a ramp function.X Adapt your driving/operating style.X Top up the AdBlue®/DEF tank immediately.

TheØ indicatorlamp lights up and·, andare flashing.

The AdBlue®/DEF level has dropped to approximately 0%.Reduced engine output and engine speed limitation are active. Theengine torque is limited to a maximum of 20% across the wholeengine speed range. The engine speed is limited to idling speed.The limitation takes effect by means of a ramp function.X Stop the vehicle/equipment, paying attention to road and trafficconditions.

X Top up the AdBlue®/DEF tank immediately.


Operation

Z


The· indicatorlamp lights up.

An emissions-relevant malfunction in the exhaust gas aftertreat-ment system or in the AdBlue®/DEF supply has been detected.X Have the exhaust gas aftertreatment system checked at a quali-fied specialist workshop. Have the malfunction rectified imme-diately. If you do not, engine output may be reduced and enginespeed may be limited.

If there are nomalfunctions, the indicator lamp only goes out afterfurther test routines. The systemcheckmay involve several enginestarts, several hours or several journeys without a malfunction.

The indicator lamplights up and· isflashing.

You have not rectified an emissions-relevant malfunction that hasbeen detected in the exhaust gas aftertreatment system or in theAdBlue®/DEF supply.Reduced engine output is active. The engine torque is limited to amaximum of 75% across the whole engine speed range. The limi-tation takes effect by means of a ramp function.X Adapt your driving/operating style.X Drive carefully to the nearest qualified specialist workshop andhave the malfunction rectified immediately.

If you do not follow the instructions, engine speed may be limited.

The and· indi-cator lamps are flash-ing.

You have not rectified an emissions-relevant malfunction that hasbeen detected in the exhaust gas aftertreatment system or in theAdBlue®/DEF supply.Reduced engine output and engine speed limitation are active. Theengine torque is limited to a maximum of 50% across the wholeengine speed range. The engine speed is limited to a maximum of60%. The limitation takes effect by means of a ramp function.X Adapt your driving/operating style.X Drive carefully to the nearest qualified specialist workshop andhave the malfunction rectified immediately.

If you do not follow the instructions, further engine speed limita-tion may be imposed.


eration


The and· indi-cator lamps are flash-ing and lights up.

You have not rectified an emissions-relevant malfunction that hasbeen detected in the exhaust gas aftertreatment system or in theAdBlue®/DEF supply.Reduced engine output and engine speed limitation are active. Theengine torque is limited to a maximum of 20% across the wholeengine speed range. The engine speed is limited to idling speed.X Adapt your driving/operating style.X Have the malfunction rectified immediately at a specialist work-shop.

The ,· andindicator lamps

are flashing.

You have not rectified an emissions-relevant malfunction that hasbeen detected in the exhaust gas aftertreatment system or in theAdBlue®/DEF supply.Reduced engine output is active. The engine torque is limited to amaximumof 20% across thewhole engine speed range. The enginespeed is limited to idling speed.X Stop the vehicle/equipment, paying attention to road and trafficconditions.

X Have the malfunction rectified immediately at a specialist work-shop.

When the AdBlue®/DEF tank is filled or the fault is rectified, full engine power will be availableagain. If the system check does not detect any other faults, the indicator lamps go out after thesystem's status indicator. The system check may involve several engine starts, several hoursor several journeys without a malfunction.

Only vehicles/equipment without the AdBlue®/DEF reserve warning lightIf a malfunction is detected and the listed indicator lamps light up, a warning buzzer sounds forapproximately 5 seconds. In emergencies, operating restrictions (engine torque and enginespeed restrictions) can be temporarily overridden with the emergency switch (Y page 32).


Operation

Z


The· indicatorlamp lights up.

An emissions-relevant malfunction in the exhaust gas aftertreat-ment system or in the AdBlue®/DEF supply has been detected.X Top up the AdBlue®/DEF tank immediately.X If this does not help: have the exhaust gas aftertreatment sys-tem checked at a qualified specialist workshop. Have the mal-function rectified immediately. If you do not, engine output maybe reduced and engine speed may be limited.

If there are nomalfunctions, the indicator lamp only goes out afterfurther test routines. The systemcheckmay involve several enginestarts, several hours or several journeys without a malfunction.

The· indicatorlamp is flashing and

lights up.

You have not rectified an emissions-relevant malfunction that hasbeen detected in the exhaust gas aftertreatment system or in theAdBlue®/DEF supply.Reduced engine output is active. The engine torque is limited to amaximum of 75% across the whole engine speed range. The limi-tation will take effect the next time the engine is started.X Adapt your driving/operating style.X Top up the AdBlue®/DEF tank immediately.X If this does not help: have themalfunction rectified at a qualifiedspecialist workshop.

If you do not follow the instructions, engine speed may be limited.

The· and indi-cator lamps are flash-ing.

You have not rectified an emissions-relevant malfunction that hasbeen detected in the exhaust gas aftertreatment system or in theAdBlue®/DEF supply.Reduced engine output and engine speed limitation are active. Theengine torque is limited to a maximum of 50% across the wholeengine speed range. The engine speed is limited to a maximum of60%. The limitation will take effect by means of a ramp function.X Adapt your driving/operating style.X Top up the AdBlue®/DEF tank immediately.X If this does not help: have themalfunction rectified at a qualifiedspecialist workshop.If you do not follow the instructions, further engine speed limi-tation may be imposed.


eration


The· and indi-cator lamps are flash-ing and lights up.

You have not rectified an emissions-relevant malfunction that hasbeen detected in the exhaust gas aftertreatment system or in theAdBlue®/DEF supply.Reduced engine output and engine speed limitation are active. Theengine torque is limited to a maximum of 20% across the wholeengine speed range. The engine speed is limited to idling speed.X Adapt your driving/operating style.X Top up the AdBlue®/DEF tank immediately.X If this does not help: have themalfunction rectified at a qualifiedspecialist workshop.

The·, andindicator lamps

are flashing.

You have not rectified an emissions-relevant malfunction that hasbeen detected in the exhaust gas aftertreatment system or in theAdBlue®/DEF supply.Reduced engine output and engine speed limitation are active. Theengine torque is limited to a maximum of 20% across the wholeengine speed range. The engine speed is limited to idling speed.X Stop the vehicle/equipment, paying attention to road and trafficconditions.

X Have the malfunction rectified at a specialist workshop.

When the AdBlue®/DEF tank is filled or the fault is rectified, full engine power will be availableagain. If the system check does not detect any other faults, the indicator lamps go out after thesystem's status indicator. The system check may involve several engine starts, several hoursor several journeys without a malfunction.

Operating instructions

Running-inThe running-in period of the engine has a sig-nificant effect on the vehicle/equipment,especially with regard to:Rservice lifeRoperating safetyReconomyObserve the following notes during the run-ning-in period up to 2000 km (30 operatinghours):Ravoid subjecting the engine to full load.Rrun in the engine with care, using differingspeeds and engine revs.

Ravoid high engine speeds.Rdo not drive at more than ¾ of the maxi-mum road speed for each gear.Rchange gear in good time.Rdo not shift down to brake the vehicle.Rfor vehicles with automatic transmission,do not depress the accelerator pedalbeyond the point of resistance (kickdown).

After 2,000 km (30 operating hours), you cangradually bring the vehicle/equipment up tofull output and increased engine speeds.

Operating instructions 39

Operation

Z

Fuel consumption

General notesFuel consumption depends on:Rthe machine version/vehicle versionRthe operating conditionsRthe attached equipment (e.g. hydraulicpumps, mowers, etc.)Rthe fuel type in useRmaintenanceRdriving resistanceRyour driving styleFor these reasons, exact details about anysingle engine's fuel consumption cannot beprovided.

Machine version/vehicle versionThe following components affect fuel con-sumption:Rtyres (e.g. tyre pressure, tyre condition)Rbody typeRdrive train (e.g. transmission ratio)Radditional equipment (e.g. automatic cli-mate control, auxiliary heating)

MaintenanceThe fuel consumption and assembly weardepend on regular maintenance. Regularmaintenance increases safety and lowers fuelconsumption. Keep to the maintenance inter-vals. Always have maintenance work carriedout at a qualified specialist workshop.

Fuel typeThe fuel grade also affects fuel consumption.Use of lower fuel grades and/or non-approved fuel additives will increase fuel con-sumption. When refuelling, ensure that youare filling the appropriate fuel grade(Y page 50).

AdBlue®/DEF consumptionAdBlue® consumption is between 2 and 4% ofthe fuel consumption, depending on engineuse.

Engine oil consumptionAfter running-in the engine, oil consumptionmay reach 0.2 % of the vehicle's fuel con-sumption.More arduous operating conditions andincreased distance covered could result inengines exceeding this oil consumptionvalue.

Warning buzzerIf the warning buzzer sounds and the5symbol on the instrument panel is displayed,the engine's operating safety is jeopardised.Do not pull away, or stop the vehicle as soonas possible, paying attention to road and traf-fic conditions. You could otherwise damagethe engine.The warning buzzer sounds depending on thevehicle if:Ryou exceed the maximum permissibleengine speedRthe engine speed or vehicle speed is toohigh when changing gearsRthe coolant level is too low or themaximumpermissible coolant temperature (approx-imately 115†) is exceeded. The operatingsafety of the engine is jeopardised.Ran emissions-relevant error is detected orthere is an operating restriction due to anemissions-relevant malfunction.

40 Operating instructionsOp

eration

Refuelling

Fuels


G WARNINGFuels are poisonous and hazardous to health.There is a danger of injury.Do not swallow fuel or let it come into contactwith skin, eyes or clothing. Do not inhale fuelvapours. Keep fuels out of the reach of chil-dren.If you or others come into contact with fuel,observe the following:RWash the fuel off any affected areas of skinwith water and soap immediately.RIf you get fuel in your eyes, rinse them thor-oughly with clean water immediately. Seekimmediate medical attention.RIf fuel is swallowed, seek immediate medi-cal attention. Do not induce vomiting.RChange any clothing that has come intocontact with fuel immediately.

G WARNINGFuel is highly flammable. Improper handing offuel creates a risk of fire and explosion.Avoid fire, naked flames, smoking and creat-ing sparks under all circumstances. Switch offthe ignition and auxiliary heating before car-rying outwork to the fuel system. Alwayswearprotective gloves.

G WARNINGIf you mix diesel fuel with petrol, the flashpoint of this fuel mixture is lower than that ofpure diesel fuel. When the engine is running,components in the exhaust system may over-heat unnoticed. There is a risk of fire.Never refuel with petrol. Never add petrol todiesel fuel.

! Only refuel using commercially available,sulphur-free diesel fuel that complies withthe following standards:REN 590 as of 2010, et seq. (max. 0.001%sulphur by weight) (10 ppm) orRASTM D975 (max. 0.0015% sulphur byweight) (15 ppm).

The following fuel types are not permitted:Rsulphurous fuel with a sulphur contentgreater than 0.005% by weight (50 ppm)Rmarine diesel fuelRaviation turbine fuelRheating oilsRfatty acid methyl ester FAME (bio-dieselfuel)

These fuel types cause irreversible damageto the engine and the exhaust gas after-treatment system, as well as also signifi-cantly reducing the expected service life.

! Do not use petrol to refuel vehicles with adiesel engine. Even small amounts of petrolresult in damage to the fuel system andengine.

! Do not switch on the ignition if you acci-dentally refuel with the wrong fuel. Other-wise, the fuel will enter the fuel lines. Notifya qualified specialist workshop and havethe fuel tank and fuel lines drained com-pletely.

! Do not add any special fuel additives tothe diesel fuel.Special fuel additives can lead to:RmalfunctionsRdamage to the catalytic converterRengine damage

! AdBlue®/DEF is not a fuel additive andmust not be added to the diesel tank. IfAdBlue®/DEF gets into the diesel tank, thiscould lead to engine damage.

! A higher fuel sulphur content acceleratesthe ageing process of the engine oil and candamage the engine and exhaust system.

Refuelling 41

Operation

Z

H Environmental noteIf fuels are handled improperly, they pose adanger to persons and the environment. Donot allow fuels to run into the sewage system,the surface waters, the ground water or intothe ground.

You will find further information on fuel in the"Service products" section (Y page 50).

Before filling the tank

! If you are using drums or canisters torefuel the vehicle, you should filter the fuelbefore adding it.This will prevent malfunctions in the fuelsystem due to contaminated fuel.

X Switch off the engine.X Secure the vehicle/equipment against roll-ing away.

X Observe the fuel grade (Y page 50).Regularly check the fuel prefilter with heatedwater separator for condensation.

AdBlue®/DEF


! Do not allow diesel fuel to run into theAdBlue®/DEF tank. You could otherwisedamage the exhaust gas aftertreatmentsystem.

! Only use AdBlue®/DEF in accordancewith DIN 70070/ISO 22241. Do not useany additives.If AdBlue®/DEF comes into contact withpainted or aluminium surfaces when fillingthe tank, rinse the affected area immedi-ately with plenty of water.

! Do not mix additives to AdBlue®/DEF. Donot dilute AdBlue®/DEF with tap water.This could destroy the exhaust gas after-treatment system.

! Always close the AdBlue®/DEF tankproperly. Otherwise impuritiesmay get intothe exhaust gas aftertreatment system anddamage it.

! Make sure that you do not overfill theAdBlue®/DEF tank. Otherwise, theAdBlue®/DEF tank could be damaged atvery low temperatures.

H Environmental noteDispose of AdBlue®/DEF in an environmen-tally responsible manner.

When opening the AdBlue®/DEF tank, smallamounts of ammonia vapours could escape.Ammonia vapours have a pungent smell andare particularly irritating to:RskinRmucous membranesReyesThe vapoursmay cause a burning sensation inthe eyes, nose and throat as well as irritationof the throat and watering eyes.Avoid inhaling ammonia vapours. Only fill theAdBlue®/DEF tank in well-ventilated areas.AdBlue®/DEF should not come into contactwith skin, eyes or clothing, and should not beswallowed. Keep AdBlue®/DEF out of thereach of children.If you come into contact with AdBlue®/DEF,observe the following:Rimmediately wash AdBlue®/DEF from yourskin with water and soap.Rif AdBlue®/DEF comes into contact withyour eyes, rinse your eyes with clean waterimmediately. Seek medical attentionimmediately.Rif you have swallowed AdBlue®/DEF,immediately rinse your mouth with waterand drink plenty of water. Seek medicalattention immediately.Rchange clothing that has come into contactwith AdBlue®/DEF immediately.

42 RefuellingOp

eration

AdBlue®/DEF is not refilled as part of themaintenance work. Top up the tank regularlyduring vehicle operation or at the latest whenthe first event message is displayed on theelectronic engine management system.You will find further information on AdBlue®/DEF in the "Service products" section(Y page 51).

Before filling the tankX Switch off the engine.X Secure the vehicle/equipment against roll-ing away.

Always fill the tank with at least 5 litres, assmaller amounts could cause malfunctions.

Winter operation

! At very low outside temperatures, makesure that the engine oil added is of anappropriate SAE classification. Usingengine oils that are not suitable for very lowoutside temperatures may result in enginedamage.

Before the start of the cold season,make surethat:Rthe coolant contains sufficient antifreeze(Y page 49)Rthe fuel used is suitable for winter use(Y page 50)Rthe SAE class of the engine oil used is inaccordance with outside temperatures(Y page 47).

Jump-starting

G WARNINGThe use of liquid or gaseous starting aids cancause explosions. This may result in severeinjuries.Do not use liquid or gaseous starting aidssuch as ether or Startpilot to start the engine.

BatteriesAlways aim to achieve the full charge status.You can do this by means of careful mainte-nance and low electrical consumption. Thecold start capacity is reduced when it is verycold. For example, at -10 † it is only around60 % of the normal capacity.

Diesel fuelsNotes on diesel fuel at low temperatures(Y page 50).

Winter operation 43

Operation

Z

General notes ...................................... 46Service products ................................. 47Cleaning and care ............................... 53

45

Maintenance

General notes

G WARNINGBefore carrying out maintenance or repairwork, you must read the relevant sections ofthe technical documentation relating to main-tenance and repair measures, e.g. the Oper-ating Instructions and workshop information.In particular, first familiarise yourself with thelegal regulations, e.g. work safety and acci-dent prevention regulations.You could otherwise fail to recognise dangersand injure yourself or others.Always have maintenance work carried out ata qualified specialist workshop.


G WARNINGLimbs could be crushed or trapped if theengine is started unintentionally during ser-vice or maintenance work. There is a risk ofinjury.Always secure the engine against uninten-tional starting before carrying out mainte-nance or repair work.

G WARNINGCloths or other flammablematerials left in theengine compartment can ignite if they comeinto contact with the exhaust system or partsof the engine that heat up. There is a risk offire. After carrying out maintenance work,make sure that no extraneous flammablematerial is left in the engine compartment oron the exhaust system.

H Environmental noteIf circumstances require you to do somemain-tenance work yourself, you must observe theenvironmental protection requirements.When disposing of service products, e.g.engine oil, you must comply with the legalrequirements. This also concerns all parts,e.g. filters, that have been in contact with ser-vice products.Dispose of empty containers, cleaning clothsand care products in an environmentallyresponsible manner.Observe the instructions for care products.Do not let the engine run longer than neces-sary when stationary.

Like all technical equipment, the engine sys-tem requires care and maintenance.The scope and frequency of maintenancework depends mainly on:Rthe widely varying operating conditions.Rthe service products used.

i All maintenance intervals and work referto genuine Mercedes-Benz parts. They alsorefer to accessory parts and service prod-ucts that have been expressly approved byMercedes-Benz for the engine.

Inspection and maintenance work requiresspecial skills that cannot be acquired by read-ing theseOperating Instructions. Always havethis work and maintenance work carried outby a qualified specialist workshop.Have any work that is carried out confirmedwith an entry in the Maintenance Booklet.This proof of regular maintenance is alwaysrequired for any warranty claims.Instructions and important information oncarrying out maintenance work can be foundin theWorkshop Information System (WIS) onthe Internet. Make sure that you have accessto this information when carrying out main-tenance work. Information on WIS(Y page 10).Please also observe themaintenance instruc-tions for special accessories.

46 General notesMaintenance

When working on the vehicle, comply with allsafety regulations, such as operating instruc-tions, regulations concerning hazardousmaterials, environmental protection meas-ures, work safety and accident preventionregulations.

Service products


G WARNINGService product can be poisonous and haz-ardous to health. There is a risk of injury.Observe the instructions on the respectiveoriginal container when using, storing and dis-posing off service products. Always store ser-vice products in the sealed original container.Always keep service products out of the reachof children.

! Special additives (except approved fueladditives) are neither required norapproved for use with approved serviceproducts. Additives may cause damage tomajor assemblies. Therefore, do not mixany additives with service products. Youare responsible for the results of using fueladditives.

H Environmental noteDispose of service products in an environ-mentally-responsible manner.

Service products are:Rfuels (e.g. diesel)Rlubricants (e.g. engine oil, transmission oil,grease)Rcoolant, antifreezeRAdBlue®/DEF, reducing agent in theexhaust gas aftertreatment system

Approved service products fulfil the highestquality standards and are documented in theMercedes-Benz Specifications for ServiceProducts. For this reason, only use approvedservice products for your engine system.

Information about approved service productsis available from any MTU or MTU-authorisedMercedes-Benz Service Centre (Y page 10).You can recognise service products approvedby Mercedes-Benz by the following inscrip-tion on the container:RMB-Freigabe (e.g. MB-Freigabe 228.51)orRMB-Approval (z.B. MB-Approval 228.51)Other labels and recommendations relatingto the quality or indicating that the productmeets a certain specification are not neces-sarily approved by Mercedes-Benz. Furtherinformation is available from any MTU orMTU-authorised Mercedes-Benz ServiceCentre (Y page 10).

i Information about service products whichhave been tested by Mercedes-Benz andapproved for your engine system can befound in the Mercedes-Benz Specificationsfor Service products on the Internet at:http://bevo.mercedes-benz.com/.

i The specification and availability of lubri-cants may vary. Individual lubricants mayno longer be available, especially for olderengines. Information is available from anyMTU or MTU-authorised Mercedes-BenzService Centre (Y page 10).

Engine oils

Notes on engine oils

! Engine oils other than those of the qualityspecified in this Operator's Manual are notpermitted.

Only use engine oils in accordance withSheet No. 228.51, 228.31, 228.5 or 228.3 oftheMercedes-Benz Specifications for ServiceProducts.

Service products 47

Maintenance

Z

Engine oils according to Sheet No. 228.51and 228.5 have a higher quality standard andhave a favourable effect on:Rlength of oil change intervalsRengine wearRfuel consumptionRexhaust emissions

i You can find information on the qualitygrade, e.g. Sheet No. 228.51, and the vis-cosity, e.g. SAE class 5W-30, from the des-ignation on the oil container.

Before delivery, the engine is filled with oil inSAE class 5W-30 (Y page 28).Check the vehicle assemblies for leaks regu-larly. If fluid loss is identified, e.g. by oil dropson the parking area, have the cause of thefluid loss rectified at a qualified specialistworkshop.

Scope of applicationMulti-grade engine oils compliant with SheetNo. 228.51, 228.31, 228.5 or 228.3 can beused all year round.

Oil change

! If you mix engine oils with differing oilgrades, the change interval for the engineoil is reduced in comparison to mixtures ofengine oil of identical grade.Therefore, only mix engine oils of differinggrade in exceptional circumstances. Toprevent damage to the engine, the mainte-nance intervals must be adjusted accord-ingly.

! If the SAE class (viscosity) of the engineoil used is not suitable for continually lowoutside temperatures below -20 †, thiscould cause engine damage.The specified temperatures of the SAEclass always refer to freshly added oil.Engine oil ages during driving due to sootand fuel residue. This impairs the charac-teristics of the engine oil, particularly at lowoutside temperatures.

If the outside temperature is under -20 †,Mercedes-Benz strongly recommendsusing engine oils of SAE class 5W-30 or0W-30.Use only all-season oils.

Engine oil SAE classes (viscosity)

Oil change intervals are dependent on the fol-lowing:Rthe operating conditions of the vehicleRthe grade of the engine oil usedThe maximum oil change interval can only beachieved by using engine oils of particularlyhigh quality in accordance with Sheet No.228.51 and 228.5 of the Mercedes-BenzSpecifications for Service Products. The clas-sification of oil change intervals is specified inthe Maintenance Booklet.

Adding/topping up the engine oil

! There is a risk of damage to the catalyticconverter or to the engine if too much oil isadded. Have excess oil drained off.

When topping up, Mercedes-Benz recom-mends that you only use engine oil of thesame grade and SAE class as the oil filled atthe last oil change.Check the oil level before topping up theengine oil (Y page 28).

Miscibility of engine oilsThe benefits of high-quality engine oils arediminished if you mix them.

48 Service productsMaintenance

Engine oils are differentiated according to:Rengine oil brandRquality grade (Sheet No.)RSAE viscosity classIf, in exceptional circumstances, the type ofengine oil currently used in the engine is notavailable, anothermineral or synthetic engineoil may be used. Make sure it is approved forMercedes-Benz.Please observe the following: if you top upwith an engine oil of a lower quality, the main-tenance interval corresponding to the lowerquality (Sheet No.) must be used. The main-tenance interval is reduced. If you top up withan engine oil of a higher quality, the mainte-nance interval is not altered.Observe the notes in the Maintenance Book-let.

Coolant

G WARNINGThe engine cooling system is under pressure,particularly if the engine is warm. You couldbe scalded by hot coolant spraying out whenopening the cap. There is a danger of injury.Allow the engine to cool before opening thecap. Wear gloves and protective eyewearwhen opening. Slowly turn the cap half a turnto allow pressure to escape.

G WARNINGIf antifreeze comes into contact with hot com-ponents in the engine compartment, it mayignite. There is a risk of fire and injury.Let the engine cool down before you top upthe antifreeze. Make sure that antifreeze isnot spilled next to the filler neck. Thoroughlyclean the antifreeze from components beforestarting the engine.

A coolant that ensures anti-corrosion/anti-freeze protection and other important pro-tective effects is filled at the factory.

The coolant is a mixture of water and corro-sion inhibitor/antifreeze.The corrosion inhibitor/antifreeze in the cool-ant has the following properties:Rheat transferRanti-corrosion protectionRcavitation protection (protection againstpitting)Rantifreeze protectionRraising the boiling pointLeave the coolant in the engine cooling sys-tem all year round – even in countries withhigh outside temperatures.Check the corrosion inhibitor/antifreeze con-centration in the coolant every six months.Renew the coolant at the interval specified inthe Maintenance Booklet.Use only approved corrosion inhibitor/anti-freeze additives according to Sheet No.325.5and 326.5. This prevents damage to theengine cooling system and engine.When renewing the coolant, ensure that itcontains 50% corrosion inhibitor/antifreezeby volume. This corresponds to antifreezeprotection down to Ò37 †.Do not exceed 55% by volume (antifreezedown to approximately Ò45 †). The heat dis-sipation and antifreeze may otherwise benegatively affected.If there is a loss of coolant, do not top it up byusing only water, but also add an approvedcorrosion inhibitor/antifreeze agent.The water in the coolant must meet certainrequirements, which are often fulfilled by theuse of drinking water. The water must betreated if its quality does not meet therequired standards.Please note the Mercedes-Benz Specifica-tions for Service Products, Sheet No. 310.1.Mixtures with other corrosion inhibitors/anti-freeze agents are not permitted.

Service products 49

Maintenance

Z

Diesel fuels


G WARNINGFuel is highly flammable. Improper handing offuel creates a risk of fire and explosion.Avoid fire, naked flames, smoking and creat-ing sparks under all circumstances. Switch offthe engine and, if applicable, the auxiliaryheating before refuelling.

G WARNINGFuels are poisonous and hazardous to health.There is a danger of injury.Do not swallow fuel or let it come into contactwith skin, eyes or clothing. Do not inhale fuelvapours. Keep fuels out of the reach of chil-dren.If you or others come into contact with fuel,observe the following:RWash the fuel off any affected areas of skinwith water and soap immediately.RIf you get fuel in your eyes, rinse them thor-oughly with clean water immediately. Seekimmediate medical attention.RIf fuel is swallowed, seek immediate medi-cal attention. Do not induce vomiting.RChange any clothing that has come intocontact with fuel immediately.

! Only refuel using commercially available,sulphur-free diesel fuel that complies withthe following standards:REN 590 as of 2010, et seq. (max. 0.001%sulphur by weight) (10 ppm) orRASTM D975 (max. 0.0015% sulphur byweight) (15 ppm).

The following fuel types are not permitted:Rsulphurous fuel with a sulphur contentgreater than 0.005% by weight (50 ppm)Rmarine diesel fuelRaviation turbine fuel

Rheating oilsRfatty acid methyl ester FAME (bio-dieselfuel)

These fuel types cause irreversible damageto the engine and the exhaust gas after-treatment system, as well as also signifi-cantly reducing the expected service life.

! A higher fuel sulphur content acceleratesthe ageing process of the engine oil and candamage the engine and exhaust system.

Fuel grade

i Certain countries have diesel fuel withvarying sulphur content. Diesel fuel withlow sulphur content is sold in certain coun-tries under the name "Euro diesel".

Information about current country-specificfuel sulphur contents can be obtained fromany MTU or MTU-authorised Mercedes-BenzService Centre (Y page 10).

Water contentThe maximum permissible water content atthe point of transfer between vehicle andengine must not be greater than 200 mg/kg.If the water content is higher, an additionalwater separatormust be fitted on the chassis.If the engine is operated with increasedamounts of dirt and water, an additional fuelprefilter with a water separator must be fittedon the chassis.

Diesel fuels at low temperatures

G WARNINGIf you heat fuel system components, e.g. witha hot-air gun or naked flame, these compo-nents could be damaged. This can cause fuelto escape and ignite. Depending on the typeof damage, fuel may also not escape until theengine is running. There is a risk of fire andexplosion.Never heat fuel system components. Contacta qualified specialist workshop to rectify themalfunction.


At low outside temperatures, paraffin sepa-ration may cause the flow properties of thediesel fuel to be insufficient.To prevent operating problems, diesel fuelwith improved flow properties is available inthe winter months.Winter diesel fuels are reliable down to out-side temperatures of −22 † in Germany andother Central European countries. You cannormally use winter diesel fuel without prob-lems at the outside temperatures expected inthe country where it is on sale.

Fuel additives

! Do not add any petrol or kerosene to die-sel fuel to improve its flow characteristics.Petrol or kerosene impairs the lubricity ofthe diesel fuel. This can cause damage tothe injection system, for example.

For lower temperatures, the engine can beequipped with a fuel preheating system. Thisimproves the flow characteristics of the die-sel fuel according to the output of the instal-led heater.Fuel additives used to improve flow charac-teristics are flow improvers.Do not add flow improvers to winter dieselfuel guaranteed to operate down to −22 †.The cold flow properties of the fuel may dete-riorate as a consequence of the flowimprover.

AdBlue®/DEF


G WARNINGAdBlue®/DEF must not come into contactwith skin, eyes or clothing.RIf AdBlue®/DEF comes into contact withyour eyes or skin, rinse affected areas withclean water immediately.RIf AdBlue®/DEF is swallowed, immediatelyrinse your mouth out with a lot of cleanwater and drink plenty of water.RChange clothing that is soiled withAdBlue®/DEF immediately.RIf allergic reactions occur, consult a doctorimmediately.

Keep AdBlue®/DEF out of the reach of chil-dren.

! Only use AdBlue®/DEF in accordancewith DIN 70070/ISO 22241. Do not useany additives.If AdBlue®/DEF comes into contact withpainted or aluminium surfaces when fillingthe tank, rinse the affected area immedi-ately with plenty of water.

The terms "Urea" and "DEF" (Diesel ExhaustFluid) are also used for "AdBlue®".If the AdBlue®/DEF tank is full of AdBlue®/DEF, pressure compensationmay occurwhenthe tank lid is unscrewed. AdBlue®/DEF mayspill out. Therefore, open the AdBlue®/DEFtank lid carefully. If AdBlue®/DEF spills out,immediately wash the affected area withplenty of water.When opening the AdBlue®/DEF tank, smallamounts of ammonia vapours could escape.Ammonia vapours have a pungent smell andare particularly irritating to:RskinRmucous membranesReyes

Service products 51

Maintenance

Z

The vapoursmay cause a burning sensation inthe eyes, nose and throat as well as irritationof the throat and watering eyes.Avoid inhaling ammonia vapours. Only fill theAdBlue®/DEF tank in well-ventilated areas.AdBlue®/DEF should not come into contactwith skin, eyes or clothing, and should not beswallowed. Keep AdBlue® out of the reach ofchildren.If you come into contact with AdBlue®/DEF,observe the following:Rimmediately wash AdBlue®/DEF from yourskin with water and soap.Rif AdBlue®/DEF comes into contact withyour eyes, rinse your eyes with clean waterimmediately. Seek medical attentionimmediately.Rif you have swallowed AdBlue®/DEF,immediately rinse your mouth with waterand drink plenty of water. Seek medicalattention immediately.Rchange clothing that has come into contactwith AdBlue®/DEF immediately.

High outside temperatures

G WARNINGIf the AdBlue®/DEF tank cap is opened at hightemperatures, ammonia vapoursmay escape.Ammonia vapours have a pungent odour andparticularly irritate:RskinRmucous membranesReyesThe vapoursmay cause a burning sensation inthe eyes, nose and throat as well as irritationof the throat and watering eyes.Avoid inhaling ammonia vapours.

The chemical composition of AdBlue®/DEFcan break down if it heats up to 50 † over along period (e.g. as a result of direct sunlighton the tank). This creates ammonia vapour.

Low outside temperatures

AdBlue®/DEF freezes at a temperature ofapproximately −11 † .Depending on equipment and country, theAdBlue®/DEF supply system of the vehiclemay be heated; see the vehicle's OperatingInstructions. Winter operation is thus guar-anteed at temperatures below −11 † .

Additives, tap water

! Do not mix additives to AdBlue®/DEF. Donot dilute AdBlue®/DEF with tap water.This could destroy the exhaust gas after-treatment system.

Storage

! Containers made of the following materi-als are not suitable for the storage ofAdBlue®/DEF:RaluminiumRcopperRcopper alloysRunalloyed steelRgalvanised steelIf AdBlue® is stored in these types of con-tainer, constituents of these metals maydissolve and damage the exhaust gas after-treatment beyond repair.

Only use containers made of the followingmaterials to store AdBlue®:RCr‑Ni steel in accordance withDIN EN 10 088-1/2/3RMo-Cr‑Ni steel in accordance withDIN EN 10 088-1/2/3RPolypropyleneRPolyethylene

Disposal

H Environmental noteDispose of AdBlue®/DEF in an environmen-tally responsible manner.


Observe laws and regulations on the disposalof AdBlue®/DEF in the country concerned.

Purity

! Impurities in AdBlue®/DEF, e.g. due toother service products, cleaning productsor dust, may lead to:Rincreased emission valuesRdamage to the catalytic converterRengine damageRmalfunctions in the exhaust gas after-treatment system.

Ensure that AdBlue®/DEF is always pure toavoid malfunctions in the exhaust gas after-treatment system.If AdBlue®/DEF is pumped from the tank, e.g.during repairs, do not use this fluid to refill thetank. Otherwise the purity of the fluid wouldno longer be guaranteed.

Cleaning and care

Notes on careRegular care helps to maintain the value ofthe engine.Mercedes-Benz recommends that you onlyuse care products that have been approvedfor Mercedes-Benz. You can obtain thesecare products from any MTU or MTU-author-ised Mercedes-Benz Service Centre(Y page 10).

High-pressure cleaning

H Environmental noteOnly wash your vehicle at a wash baydesigned for this purpose. Dispose of emptycontainers and used cleaning products in anenvironmentally responsible manner.

! When cleaning, never point the water jetat the exhaust pipe. The system may oth-erwise be damaged.

! When using a high-pressure cleaner, keepa minimum distance between the high-pressure nozzle and the engine parts. Oth-erwise, parts of the engine may be dam-aged.Observe the following minimum distances:Rabout 70 cm with round-spray jetsRabout 30 cm with 25° flat-spray jetsRabout 30 cm with concentrated-powerjets

! Keep the water jet moving constantlywhile cleaning. In this way, you will avoidcausing damage.Do not point the water jet at:Relectrical componentsRplug connectorsRsealsRhoses

Cleaning the engine! Observe the following notes when clean-ing the engine. This avoids malfunctionsand damage to the engine.RWhen using high-pressure or steamcleaners, do not point the spray directlyat electrical components and electriccables.RMake sure that no water enters the airintake and ventilation openings.RTreat the engine with preservativeagents after it has been cleaned. Whendoing so, protect the belt drive systemfrom the preservative agent.ROnly use wax-based protective agentsfor engines that comply withSheet No. 385.4 of the Mercedes-BenzSpecifications for Service Products.

In addition, observe the notes in the "High-pressure cleaning" section (Y page 53).

Cleaning and care 53

Maintenance

Z

General notes ...................................... 56Decommissioning for up to 6months ................................................. 56Decommissioning for longer than6 months .............................................. 56

55

Decommissioning

General notes

Special measures are required to decommis-sion the engine/vehicle.Information about batteries: if the engine/vehicle is to be out of use for longer than threeweeks, disconnect the negative terminal onthe battery. This prevents the batteries frombeing discharged by no-load current consum-ers.If the engine/vehicle is to be out of use for alonger period, remove the batteries and storethem in a dry and well-ventilated area.Recharge batteries every 3 months at the lat-est.Ensure that there is adequate ventilationwhen recharging. Check the battery fluid lev-els before and after charging and if necessarycorrect them. For further information(Y page 43).

Decommissioning for up to 6 months

When decommissioning an engine/vehicle,keep it in a covered, dry and well-ventilatedarea. The room temperature should not fallbelow -10 †.Measures prior to decommissioning:RClean the engine/vehicle thoroughly.RRemove any patches of corrosion from theengine.RChange the engine oil and oil filter if the lastoil change was carried out more than20,000 km (or around 300 operating hours)ago.Also change the engine oil and filter if theoil is more than 12 months old.RCheck and adjust the level of coolant orrenew coolant.RCheck and adjust the concentration of anti-corrosion/antifreeze additives in the cool-ant.

RTop up the AdBlue®/DEF tank until it is full,to prevent AdBlue®/DEF from crystallising.RDrain the water separator for the fuel sys-tem

Measures prior to recommissioning:RFit and connect the batteryRCheck that the electrical system is func-tioning correctly.RCheck cables, hoses and lines for tears andleaks.RCheck the engine oil level.RCheck the oil level in the steering andhydrostatic fan drive.RCheck the coolant level and correct it, ifnecessary.RCheck AdBlue®/DEF level.RCheck the fuel levelRStart the engine and leave it running atmedium engine speeds until it is at operat-ing temperature (coolant temperature).While doing so, observe the indicators foroil pressure, coolant temperature and oiltemperature.RVehicles with auxiliary heating: activate theauxiliary heating and check operation.RCheck operation of the steering andbrakes.RCheck whether maintenance is due and ifnecessary carry it out.

Decommissioning for longer than 6months

If the vehicle is to be decommissioned forlonger than 6 months, further measures arerequired. For more details, consult your MTUor MTU-authorised Mercedes-Benz ServiceCentre (Y page 10).

56 Decommissioning for longer than 6 monthsDe

commissioning

Important safety notes ....................... 58Bleeding and draining the fuel sys-tem ....................................................... 59Electrical fuses .................................... 60Jump-starting ...................................... 61Troubleshooting .................................. 63

57

Troubleshooting



G WARNINGThere are moving components in the enginecompartment. Certain components may con-tinue to move or suddenly move again evenafter the ignition has been switched off, e.g.the radiator fan. There is a risk of injury.If you have to carry out work in the enginecompartment:Rswitch off the ignitionRnever touch the dangerous areas surround-ing moving components, e.g. the rotationarea of the fanRremove jewellery and watchesRkeep items of clothing and hair, for exam-ple, away from moving parts.

G WARNINGCertain engine components can become veryhot. There is a risk of injury when carrying outwork at the engine.Where possible, allow the engine to cool downand only touch the components describedbelow.

When working on the vehicle, comply with allsafety regulations, such as operating instruc-tions, regulations concerning hazardousmaterials, environmental protection meas-ures, work safety and accident preventionregulations.Be aware of the road and traffic situationwhen working on public roads and secureyour position accordingly.

Apart from careful operation and mainte-nance of the engine it is also important thatmalfunctions be rectified in good time.You can rectify certain malfunctions yourself(Y page 34), (Y page 63).Have malfunctions that you cannot eliminateyourself rectified at a qualified specialistworkshop.

External engine start/engine stopbutton

You can start and switch off the engine usingthe external engine start/engine stop button.Before starting the engineX Switch the ignition lock to the drive posi-tion.

X Shift into neutral.X Secure the vehicle against rolling away.X Deactivate power take-off.Starting the engineX Press external engine start/engine stopbutton: until the engine starts.

Starting the engine and increasing theengine speedX Hold down external engine start/enginestop button: until the desired enginespeed is achieved.The engine starts and runs at engine idlingspeed.After about 3 seconds, the engine speedincreases. After releasing external engine

58 Important safety notesTroubleshooting

start/engine stop button:, the enginecontinues to run at the currently set speed.The engine speed can be increased up tothe limiting speed.

X If the engine does not start immedi-ately: interrupt the starting procedureafter no more than 30 seconds.

X Turn the key in the ignition lock back to thestop at key positiong.


X If the engine fails to start: rectify the causeof the poor starting characteristics(Y page 63).

X Observe the oil pressure gauge immedi-ately after having started the engine.

Stopping the engineX Press external engine start/engine stopbutton: again.

i If you switch off the engine, the systemmay continue to run for a short while.Depending on the installation position,operating state and ambient temperature,circulation of AdBlue®/DEF is necessaryfor ensuring cooling. To do this theAdBlue®/DEF delivery pump is actuatedduring this period.

Bleeding and draining the fuel system

Bleeding, after refuelling a fuel system whichhas been run dry, is performed manually bymeans of a manual fuel pump.Bleeding with a heated fuel prefilter with awater separator fitted on the chassis:X Bleed the heated fuel prefilter with waterseparator fitted on the chassis before thefuel circuit on the engine is bled by themanual fuel pump at themain filter. Use thehand pump integrated in the fuel prefilter todo so.

Bleeding the fuel system without afuel prefilter on the chassis frameBleed the fuel system with the manual fuelpump on the engine.

! Do not bleed the fuel system with severalstarting procedures. You could otherwisedamage the starter motor.

X Switch the ignition lock to the drive posi-tion.

X Shift into neutral.X Unscrew the fuel tank filler cap.

X Press handle of manual fuel pump: at themain filter approx. 250 times in the spaceof approx. 3 minutes or until you feel sig-nificant resistance.

X Within approximately 5 seconds, press theexternal engine start/engine stop and startthe engine.

X If the engine starts, run the engine atincreased engine speed.

X If the engine does not start, repeat the pro-cedure.

X Tighten the fuel tank filler cap.X Turn the key to the start position in theignition lock and hold it. Do not depress theaccelerator pedal whilst doing so.i The starting procedure is automaticallycancelled after approximately 40 seconds.

Bleeding and draining the fuel system 59

Troubleshooting

Z


X If the engine starts normally, depress theaccelerator pedal several times.The fuel system is completely bled.

Bleeding the fuel system with a fuelprefilter on the chassis frame

H Environmental noteDispose of the water-fuel mixture in an envi-ronmentally responsible manner.

Example: fuel prefilter on the chassis frame

If water has collected in inspection window=, drain fuel prefilter on chassis frame:before bleeding. Drain fuel prefilter on chas-sis frame: regularly.Draining the fuel prefilter on the chassisframeX Place a collector under drain plug;.X Turn drain plug; open.X Operate hand pump? and collect thefuel/water mixture.

X Turn drain plug; closed.Bleeding using the hand pump of the fuelprefilter on the chassis frameX Unscrew the fuel tank filler cap.X Place the collector underneath fuel prefil-ter:.

X Unscrew bleed screwA.

X Push hand pump? repeatedly until thefuel escaping at bleed screwA is free ofbubbles.

X Tighten bleed screwA.i If there was no fuel in the fuel tank, presshand pump? again until there is noticea-ble resistance.

i Then bleed the fuel circuit on the engineusing the hand pump at the main filter asdescribed in the "Bleeding the fuel systemwithout a fuel prefilter on the chassisframe" section.

Draining the fuel filter

X Place a collector under drain plug:.X Turn drain plug: open.X Collect and drain the fuel/water mixtureuntil pure fuel flows.

X Turn drain plug: closed.

Electrical fuses


G WARNINGIf you manipulate, bridge or replace a faultyfuse with a fuse of a higher amperage, theelectric cables could be overloaded. This mayresult in a fire. There is a risk of an accidentand injury.Always replace faulty fuseswith specified newfuses of the correct amperage.

60 Electrical fusesTroubleshooting

The individual electrical circuits are protectedby safety fuses or automatic circuit-breakers.Blown fuses or defective automatic circuit-breakers must be replaced by equivalentfuses with the fuse ratings recommended inthe fuse allocation chart. Fuseswith the samefuse rating are the same colour. Further infor-mation is available from any MTU or MTU-authorised Mercedes-Benz Service Centre(Y page 10).The fuse allocation chart is vehicle-specificand is provided by the vehicle manufacturer.If the newly inserted fuse also blows, have thecause traced and rectified at a qualified spe-cialist workshop, e.g. a Mercedes-Benz Ser-vice Centre.X If a circuit fails, switch off the consumerequipment and switch the ignition lock toposition 0.

Checking and replacing a safety fuseX Pull the fuse out of the module using thepliers and carry out a visual inspection.

X If the fuse wire has melted, replace theblown fuse with a spare fuse.

X Switch on consumers and check that theyfunction correctly.

If the safety fuse burns out again, have theelectrical system checked at a qualified spe-cialist workshop.

Jump-starting


G WARNINGComply with safety precautions and take pro-tective measures when handling batteries.

Risk of explosion

Fire, naked flames andsmoking are prohibitedwhen handling the battery.Avoid creating sparks.Battery acid is caustic.Avoid contact with the skin,eyes or clothing.Wear suitable protectiveclothing, in particulargloves, an apron and a facemask.Immediately rinse acidsplashes off with cleanwater. Consult a doctor ifnecessary.Wear eye protection.

Keep children away.

Observe this Owner's Man-ual.

! Observe the following notes. You couldotherwise damage the battery or electroniccomponents in the vehicle:Rdo not use a battery quick-charge unit forjump-starting.Rif you use a mobile battery charger (bat-tery device with mains power stage),remove the mains plug before jump-starting.Ronly have jump-starting provided by vehi-cles with a 24 V system.Ruse jump leads which are protectedagainst polarity reversal and with a wire

Jump-starting 61

Troubleshooting

Z

cross section of approximately 35–50 mm2 and insulated terminal clamps.Rif the outside temperature drops belowÒ10†, a discharged battery could freeze.Do not start the engine under these cir-cumstances. Let the battery thaw outfirst.

! Do not connect the negative terminalclamp of the jump lead to the chassisframe. Otherwise, engine or transmissioncomponents can be damaged.

! When you remove the jump leads, let theengine of the vehicle being jump-startedidle. This avoids damage being caused tothe vehicle electronics.

General notesObserve the instructions relevant to safetyand protective measures when handling thebattery.After jump-starting, have the batterieschecked at a qualified specialist workshop.X Make sure that the vehicles are not touch-ing.

X Engage the parking brake.X Switch off all electrical consumers.X Turn the key to position 0 in the ignitionlock.

Vehicles without a jump-starting con-nection point

Connecting the jump leadX Remove the battery compartment cover.X First, connect the positive terminal clampof the jump lead to the positive terminal ofthe other vehicle's battery and then to theq positive terminal of the starter battery.

X First, connect the negative terminal clampof the jump lead to the negative terminal ofthe other vehicle's battery and then to the± negative terminal of the starter battery.

X Assisting vehicle: run the engine at a highspeed.

X Start the engine and allow it to idle.Disconnecting the jump leadX First, disconnect the negative terminalclamps of the jump lead from the negativeterminals.

X Remove the positive terminal clamps of thejump lead from the positive terminals.

62 Jump-startingTroubleshooting

Troubleshooting

Engine problems

G WARNINGIf you do not have the prescribed service/maintenancework or necessary repairs carried out, thiscould result in malfunctions or system failures. There is a risk of an accident.Always have the prescribed service/maintenance work as well as necessary repairs carried outat a qualified specialist workshop.

Apart from careful operation and maintenance of the engine it is also important that malfunc-tions be rectified in good time. You can rectify certain faults yourself.Have malfunctions that you cannot eliminate yourself rectified at a qualified specialist work-shop (Y page 10).

Problem Possible causes/consequences and MM Solutions

The drive pinion doesnot turn or turns tooslowly.

The battery is not sufficiently charged.X Charge the battery.

The connecting cable to the starter motor is loose.X Tighten the cable on the terminal. If necessary, solder on a newterminal.

The earth connection to the battery is loose.X Tighten the cable on the terminal. If necessary, solder on a newterminal.

The starter motor solenoid switch is faulty or the starter motor isfaulty.X Have it checked at a qualified specialist workshop.

The engine does notstart or stalls againimmediately.

The fuel tank is empty.X Refill the fuel tank (Y page 41).

The fuel filter is blocked.X Replace the filter element.

The fuel prefilter contains water.X Drain the fuel prefilter.

The fuel prefilter is blocked.X Replace the filter element.

Troubleshooting 63

Troubleshooting

Z


Leaks or insufficient pressure in the low-pressure fuel circuitX Check for leaks (visual check), replace the seals if necessary.X Have the fuel pressure tested at a qualified specialist workshop.Replace the seals.

Engine fails to startwhen the ambient tem-perature is low.

The fuel is not resistant to cold.The flowproperties of the diesel fuel are inadequate due to paraffinseparation.X Malfunctions resulting from paraffin separation can be correc-ted bywarming the entire fuel system, e.g. by parking the vehiclein a heated area.

X Refuel with winter fuel (Y page 50).

The engine oil viscosity is incorrect.X Alter the engine oil viscosity to the conditions of use(Y page 48).

X If the engine does not start after another attempt, have thecause traced and rectified at a qualified specialist workshop.

The engine stops inad-vertently.

The power supply to the engine management (MCM) or theexhaust gas aftertreatment (ACM) control modules is interruptedor there is a short circuit in the wiring.X Check the electrical fusesX Have the power supply checked at a qualified specialist work-shop.

Leaks or insufficient pressure in the low-pressure fuel circuit.X Carry out a check for leaks (visual check).X Have the fuel pressure tested at a qualified specialist workshop.

The engine is in emer-gency running mode.

There is an interruption to the control units' data flow.X Check the connectors on the control units for secure seatingand corrosion.

X Read out the control unit's fault memory.X Have it checked at a qualified specialist workshop.

The engine surges,vibrates or runs irregu-larly.

There is a malfunction in the fuel system.X Carry out a check for leaks (visual check).X Read out the control unit's fault memory.X Have it checked at a qualified specialist workshop.

The engine's output ispoor (lack of power).

The air filter is dirty or blocked.X Replace the air filter element.

64 TroubleshootingTroubleshooting


The charge-air temperature is too high; the charge-air cooler orradiator is dirty on the exterior.X Clean the exterior of the charge-air cooler and radiator.

The coolant temperature is too high.X Check the temperature sensor; replace if necessary. Check thefan speed.

X Check the thermostat and replace as necessary. Consult aqualified specialist workshop.

Malfunction in the fuel system (blocked, leaking).X Visual inspection for leaksX Consult a qualified specialist workshop.

Poor fuel gradeX Use the specified type of fuel and fuel grade (Y page 50).

The charge-air system is leaking; the hose clip on the charge-airhose is loose or damaged.X Check the charge-air system for leaks.X Check the charge-air pressure sensor and, if necessary, replace.X Consult a qualified specialist workshop.

An operating restriction is activated due to an emissions-relevantmalfunction.X Observe information on the warning and indicator lamps(Y page 18).

There is an interruptionin the tractive power.

There is an increased voltage drop to the control units (loose con-tact).X Check the battery terminals on the battery and the connectorson the control units for secure seating and corrosion.

The engine brakingeffect is poor.

The cause must be established in a qualified specialist workshop.X Consult a qualified specialist workshop.

Fuel consumption istoo high.

The cause must be established in a qualified specialist workshop.X Consult a qualified specialist workshop.

The engine gets too hot(according to the cool-ant temperaturegauge).

There is not enough coolant in the cooling system.X Add and bleed the coolant.

The coolant temperature sensor or display is faulty.X Replace the sensor or display.

Troubleshooting 65

Troubleshooting

Z


The poly-V-belt is damaged.X Replace the poly-V-belt.

The fan does not switch on correctly.X Consult a qualified specialist workshop.

The radiator is dirty on the inside; the radiator is very dirty on theoutside.X Clean the radiator.

The thermostat is faulty.X Check and replace as necessary.X Consult a qualified specialist workshop.

Indicator lamps do notlight up at IGNITIONON.

The lamps are faulty or the electrical cables are interrupted.X Consult a qualified specialist workshop.

The charge current indi-cator lamp lights upwhen the engine is run-ning.

The poly-V-belt is slipping.X Check the belt tensioner function.X Check that the poly-V-belt contact surfaces are not torn, dam-aged, oily or glazed. Replace the poly-V-belt if necessary.

The poly-V-belt is torn.X Replace the poly-V-belt.

The alternator or sensor is faulty.X Check the alternator or sensor.X Consult a qualified specialist workshop.

The engine is "knock-ing".

The engine is misfiring.X Consult a qualified specialist workshop.

The engine is "knock-ing".

There is bearing damage.X Consult a qualified specialist workshop.

There are abnormalsounds.

The air intake pipe and exhaust gas pipe are leaking, causing awhistling noise.X Rectify the cause of the leak and, if necessary, replace gaskets.

66 TroubleshootingTroubleshooting


The turbine or compressorwheel is scraping the housing; there areforeign objects in the compressor or turbine housing; bearingshave seized on the rotating parts.X Have the exhaust gas turbocharger checked at a qualified spe-cialist workshop.

The valve clearance is excessive.X Check and adjust the valve clearance.

The poly-V-belt is slipping.X Check that the poly-V-belt contact surfaces are not torn, dam-aged, oily or glazed. Replace the poly-V-belt if necessary.

Troubleshooting 67

Troubleshooting

Z

Identification plates ............................ 70Data card ............................................. 70Engine data .......................................... 70

69

Technicaldata

Identification plates

Engine data plate

: Position of engine data plate

Information on the engine data plateThe following data is contained on the enginedata plate in the form of numbers stampeddirectly onto the crankcase:

Example: engine data plate: Manufacturer's name; Engine model designation= Engine number

Exhaust gas aftertreatment identifi-cation plateThe exhaust gas aftertreatment identificationplate is located on the exhaust gas aftertreat-ment control module (ACM).

Information on the exhaust gas after-treatment identification plateThe identification plate for the exhaust gasaftertreatment unit contains the 14-digitidentification number (AGN ID number) of theexhaust gas aftertreatment unit.

Data card

The data card forms an integral part of thedocuments belonging to the engine andshould always be kept with the MaintenanceBooklet. It contains details about the designof the engine and the exhaust gas aftertreat-ment system, including special features.Conversion parts on the engine systemwhichchange the scope of the engine delivered byMercedes-Benz should be reported toMercedes-Benz. Once the documentation(VeDoc) has been updated, an updated datacard is supplied. This helps to prevent incor-rect ordering of replacement parts.The following is absolutely necessary whenprocuring genuine Mercedes-Benz parts:Rthe data card orRthe complete engine number and the num-ber of the exhaust gas aftertreatment unit.

Engine data

Dimensions and weightsAll data refers to the standard version of therespective engine type. Deviations mayoccur, depending on the engine equipmentand installation situation in the vehicle/equipment.

70 Engine dataTechnicaldata

Dimensions

6R1100

6R1300

6R1500

A = enginelength

1290mm

1350mm

1400mm

B = enginewidth

1120mm

1120mm

1120mm

C = engineheight

1100mm

1130mm

1150mm

Weights

Engine weight DIN 70020 - GZ

6R 1100 950 kg

6R 1300 1083 kg

6R 1500 1235 kg

Engine data 71

Technicaldata

General dataAll data refers to the standard version of the respective engine type. Data for other versions isavailable on request.

Engine Engine type 6R 1100 6R 1300 6R 1500

Assembly modelseries

470.907 471.919 473.905

Type In-line engine with exhaust gas recirculation and charge-airpressure control

Combustion prin-ciple

4-stroke direct injection diesel

Number of cylin-ders

6 6 6

Bore 125 mm 132 mm 139 mm

Stroke 145 mm 156 mm 171 mm

Engine capacity 10,700 cm3 12,800 cm3 15,600 cm3

Firing order 1 - 5 - 3 - 6 - 2 - 4 1 - 5 - 3 - 6 - 2 - 4 1 - 5 - 3 - 6 - 2 - 4

Type of coolingsystem

Forced circulation cooling

Engine, directionof rotation

Anti-clockwise (when looking at the flywheel)

Valveclear-ance

Intake valve 0.40 mm+/- 0.05 mm

0.40 mm+/- 0.05 mm

0.40 mm+/- 0.05 mm

Exhaust valve 0.60 mm+/- 0.05 mm

0.60 mm+/- 0.05 mm

0.60 mm+/- 0.05 mm

Engine brake 4.6 mm+/- 0.05 mm

4.6 mm+/- 0.05 mm

4.6 mm+/- 0.05 mm

Startermotor

Starter Electric Electric Electric

Voltage 24 V 24 V 24 V

Output 7 kW 7 kW 7 kW

Cold-start limit Ò30 † (battery charging level 75%)

Alterna-tor

Voltage 24 V 24 V 24 V

Amperage 100 A 100 A 100 A


Operating data

Operating range of engine brake Approx. 1000 - 2300 rpm

Engine speed range of maximum engine torque Approx. 1100 rpm

Engine speed of maximum power output Approx. 1800 rpm

Idling speed Approx. 500 rpm

Oil pressure at idling speed Minimum 0.7 bar

Coolant temper-ature

Normal operation Approx. 85 - 95 †

Maximum permissible tempera-ture of coolant (automatic tor-que limitation up to50 % from 103 †)

110 †

Capacities and service products

Capacity approx-imately

Service product(Sheet No.1)

Engine withoil filter(with stand-ard truck oilpan)

6R 1100 Approx. 34/37 l Engine oil (Sheet228.51, 228.31, 228.5or 228.3)6R 1300 Approx. 39/40 l

6R 1500 Approx. 42 l

Fuel system Diesel fuel tank2 Diesel fuels in accord-ance with EN 590 orASTM D975 (Sheet131.0)

Exhaust gasaftertreat-ment sys-tem

AdBlue®/DEF tank AdBlue®/DEF in accord-ance with ISO 22241(Sheet No. 352.1)

AdBlue®/DEF filter seal-ing rings

- MB silicon grease

Coolingsystem

Amount ofcoolant inthe engine

6R 11006R 13006R 1500

Approx. 25 lApprox. 32 lApprox. 33 l

Antifreeze/corrosioninhibitor in accordancewith Sheet 325.5 or pre-mixed coolant in accord-ance with Sheet 326.5.

1 Mercedes-Benz Specifications for Service Products2 Fitted on the device/vehicle. Designed by device/vehicle manufacturer.

Engine data 73

Technicaldata

Capacity approx-imately

Service product(Sheet No.1)

Corrosion inhibitor/anti-freeze agent volumedown to –37 °C

Water quality in accord-ance with Sheet 310.1

Approximately 50% byvolume

Corrosion inhibitor/anti-freeze volume down to–45 °C

Max. 55% by volume

Enginecompart-ment

Protective wax - Wax preservative inaccordance with Sheet385.4

Tightening torquesAll threads onmechanical components and the corresponding contact surfacesmust be clean,smooth and coated with engine oil. Other lubricants lead to substantially different tighteningtorques.The tightening torques are the same for 6R 1100, 6R 1300 and 6R 1500. There is an exceptionin the case of the cooling system: see the table.

Engine Cylinder head cover screw with intermediate frame on cam-shaft housing

20 Nm

Valve clearance setting Counternut to the rocker armadjustment screw

50 Nm

Screw of TDC inspection hole cap on the flywheel housing 30 Nm

Cranking device screw on the timing case 30 Nm

Fuel system Main fuel filter cap on the fuel filter module 55 Nm

Fuel prefilter cap on the fuel filter module 15 Nm

Water separator Drain plug Tightenhand-tight

Oil circuit Drain plug without bayonetlock (thread screw)

M 20 x 1.5 65 Nm

M 22 x 1.5 70 Nm

M 26 x 1.5 85 Nm

Drain plug on the oil pan with bayonet lock (snap-in joint withspring pre-tension)

Tightenhand-tight

1 Mercedes-Benz Specifications for Service Products


Oil filter cap on the oil/coolant module 55 Nm

Cooling system6R 1100

Coolant drain plug on the oil/coolant module 70 Nm

Cooling system6R 13006R 1500

Drainage connection atcrankcase

M 18 x 1.5 30 Nm

Exhaust gasaftertreatment

Filter housing on the pump module 80 Nm

Air dryer Granulate cartridge on the air dryer 15 Nm

Engine data 75

Technicaldata

ImprintInternet

Further information about MTU, Mercedes-Benz and Daimler AG can be found on theInternet at:www.mtu-online.comwww.mercedes-benz.comwww.daimler.com

Documentation team

Should you have any questions or sugges-tions regarding this manual, you can reachthe technical documentation team at the fol-lowing address:Daimler AG, HPC: CAC, Customer Service,70546 Stuttgart, Germany©Daimler AG: not to be reprinted, translatedor otherwise reproduced, in whole or in part,without written permission from Daimler AG.

Equipment manufacturer

Daimler AGMercedesstraße 13770327 StuttgartGermany

SymbolsG WARNINGWarning notes make you aware dangerswhich could pose a threat to your health orlife, or to the health and life of others.

H Environmental noteEnvironmental notes provide you with infor-mation on environmentally aware actions ordisposal.

! The purpose ofmaterial damagewarningsis to draw your attention to risks whichcould lead to damage to your engine sys-tem.

i These symbols indicate useful instruc-tions or further information that could behelpful to you.

X This symbol designates an instruc-tion you must follow.

X Several consecutive symbols indi-cate an instruction with severalsteps.

(Y page) This symbol tells you where youcan find further information on atopic.

YY This symbol indicates a warning oran instruction that is continued onthe next page.

DisplayDisplay This text indicates an indicator inthe display.

As at 28.08.2013

6R 1100/1300/1500EU Stage IV/US TIER 4Operating Instructions

Order no. 6462 9837 02 Part no. 470 584 09 81 Edition 01-14

É4705840981$ËÍ4705840981

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