Professional Documents
Culture Documents
Order no. 6462 9837 02 Part no. 470 584 09 81 Edition 01-14
Symbols Imprint
G WARNING Internet
Warning notes make you aware dangers
which could pose a threat to your health or Further information about MTU, Mercedes-
life, or to the health and life of others. Benz and Daimler AG can be found on the
Internet at:
H Environmental note www.mtu-online.com
Environmental notes provide you with infor- www.mercedes-benz.com
mation on environmentally aware actions or www.daimler.com
disposal.
As at 28.08.2013
Welcome
Familiarise yourself with your engine system
and read the Operating Instructions before
you use the engine system. This will help you
to avoid endangering yourself or others.
The standard equipment and product descrip-
tion of your engine system may vary, depend-
ing on individual specifications. This is descri-
bed on the data card.
The engine systems are constantly updated
to be state of the art.
MTU/Mercedes-Benz reserves the right to
make changes to the following:
Rdesign
Requipment
Rtechnical features
Descriptions may therefore differ in individual
cases from your engine system.
4705840981 É4705840981$ËÍ
Contents 3
Operation ............................................. 27
Maintenance ........................................ 45
Decommissioning ............................... 55
Troubleshooting .................................. 57
A D
AdBlue®/DEF Data card .............................................. 70
Consumption ................................... 40 DEF/AdBlue®
Gauge .............................................. 33 see AdBlue®/DEF service products
Important safety notes .................... 42 Description of the engine ................... 12
Refuelling ......................................... 42 Diagnostics connection ...................... 23
Service product ............................... 51 Diesel
ADM (FR (drive control) unit) ............. 12 Fuels ................................................ 50
Low outside temperatures ............... 50
B Refuelling ......................................... 41
Battery (vehicle) Dimensions .......................................... 71
Jump starting ................................... 61 Disposal of service products .............. 47
Braking Driving mode
Continuous brake ............................ 31 Idling speed ..................................... 31
Engine brake .................................... 31 Driving tips .......................................... 39
Retarder ........................................... 31
Buzzer ................................................... 40 E
Electronic engine control
C see Engine management
Capacities ............................................ 73 Electronic engine control unit ............ 32
Care products ...................................... 53 Emergency gearshift
Charge current .................................... 32 Using the emergency switch ............ 32
Checking the fluid level ...................... 28 Emergency running program ................ 8
Cleaning and care Engine
Engine cleaning ................................ 53 Capacities ........................................ 73
High-pressure cleaning .................... 53 Cleaning ........................................... 53
Notes on care .................................. 53 Data ................................................. 70
Consumption Data card ......................................... 70
AdBlue®/DEF .................................. 40 Data plate ........................................ 70
Fuel .................................................. 40 Modifying the power output ............... 8
Oil (engine) ...................................... 40 Oil consumption ............................... 40
Continuous brake Operating data ................................. 73
Rectifying faults ............................... 63
Important safety notes .................... 31
Running-in period ............................. 39
Coolant
Starting ............................................ 29
Mixing ratio ...................................... 49
Stopping .......................................... 30
Service product ............................... 49
Engine brake ........................................ 31
Topping up ....................................... 29
Engine data .......................................... 70
Coolant additive .................................. 49
Engine data card .................................. 70
Correct use ............................................ 8
Corrosion inhibitor/antifreeze Engine description .............................. 12
agent .................................................... 49 Engine idling speed ............................. 31
Engine management ........................... 16
Engine oil
Consumption ................................... 40
For winter operation ........................ 47
Index 5
Mixing .............................................. 48 M
Oil change ........................................ 48
Topping up ....................................... 48 Maintenance
Engine overview .................................. 13 Notes ............................................... 46
Engine speed ....................................... 32 Mercedes-Benz Service Centre
Exhaust gas aftertreatment ............... 18 see Qualified specialist workshop
F O
H Q
I R
S
Safety and emergency running pro-
gram ....................................................... 8
Safety precautions .............................. 22
Service products
AdBlue®/DEF .................................. 51
Coolant ............................................ 49
DEF/AdBlue® .................................. 51
Diesel fuel ........................................ 50
Disposal ........................................... 47
Disposing of AdBlue®/DEF .............. 52
Engine oil ......................................... 47
Fuel additives ................................... 51
General notes .................................. 47
Purity of AdBlue®/DEF .................... 53
Storing AdBlue®/DEF ...................... 52
Specialist workshop ............................ 10
Starting
see Starting (engine)
Starting (engine) .................................. 29
Stopping and switching off the
engine ................................................... 29
T
Technical data
Dimensions ...................................... 70
Filling capacities .............................. 73
Operating data ................................. 73
Weights ............................................ 70
Tightening torques .............................. 74
Transport .............................................. 26
W
Warning and indicator lamps
Electronics ....................................... 34
Engine, general ................................ 18
Warning buzzer .................................... 40
Weights ................................................ 71
Winter diesel ........................................ 50
Winter operation ................................. 43
Introduction 7
Z
8 Introduction
This is the case if: If the electronic control system detects a mal-
Rthey result in a change to the vehicle type function, one of the following measures is
from that for which the vehicle's general automatically implemented after an appraisal
operating permit was granted of the malfunction:
Rthey pose a possible risk for road users Rfaults during operation are indicated by the
Rthey adversely affect the emission or noise corresponding warning lamp (Y page 32).
levels Rin conjunction with the electronic engine
You can find more information on recommen- management system, fault codes with addi-
ded conversion parts and accessories, as well tional information can be shown on a dis-
as permitted technical modifications at an play.
MTU or MTU-authorised Mercedes-Benz Ser- Rthe system switches to a suitable backup
vice Centre (Y page 10). function for the continued, albeit restric-
Always specify the engine number and the ted, operation of the engine. This includes
number of the exhaust gas aftertreatment torque and engine speed limitation, for
unit when ordering genuine Mercedes-Benz example, as well as road speed limitation or
parts. You can find the engine number on the constant emergency running speed.
identification plate of your engine. You can
find the number of the exhaust gas aftertreat-
ment unit on the identification plate of the Correct use
exhaust gas aftertreatment control module
(ACM) (Y page 70). You can also find the The engine system may only be installed as
two numbers on the data card (Y page 70). contractually specified.
The manufacturer of the end product is
responsible for the correct installation of the
Modifying the engine output engine and the exhaust gas aftertreatment
system in the overall system.
! Increased power could: The engine and the exhaust gas aftertreat-
Rchange emission levels ment system may not be modified. If the
engine is modified, Mercedes-Benz and MTU
Rcause malfunctions do not accept responsibility for any damage
Rlead to consequential damage arising as a result.
The operating safety of the engine cannot Correct use of the engine system also
be guaranteed in all situations. requires adherence to the instructions in
Any tampering with the engine management these Operating Instructions. This also
system in order to increase the engine power requires compliance with the maintenance
output will lead to a loss of warranty entitle- intervals and the professional execution of
ments. maintenance work. Please observe the Work-
shop Information System (WIS) (Y page 10).
Z
10 Introduction
At a glance
view ...................................................... 15
Electronic engine management ......... 16
Exhaust gas aftertreatment ............... 18
Exhaust gas recirculation .................. 18
Warning and indicator lamps ............. 18
12 General information
General information
Engine overview
At a glance
Engine overview: 6R 1100
: Rail
; Oil filter
= Fuel filter
? Manual fuel feed pump
A High-pressure fuel pump
B Power-steering pump
C External engine start/engine stop button
D Air compressor
E Engine management control module (MCM)
F Oil pan
G Coolant thermostat
H Charge-air pipe (cold)
I Coolant pump
14
At a glance Engine overview
At a glance
: NOx sensor on exhaust gas aftertreatment unit inlet
; AdBlue® treatment reactor
= Exhaust gas inlet from AdBlue® treatment reactor
? Position of identification plate
A Exhaust gas aftertreatment box
B Exhaust gas outlet
C Exhaust gas temperature sensor upstream of the SCR catalytic converter
D Pump module
E AdBlue®/DEF metering unit
F Exhaust gas temperature sensor upstream of the AdBlue® metering unit
16
At a glance Electronic engine management
: Mounting brackets
; Exhaust gas inlet from engine
= Exhaust gas aftertreatment control unit (ACM)
? NOx sensor at exhaust gas aftertreatment unit outlet
A Exhaust gas temperature sensor downstream of the SCR catalytic converter
At a glance
(MCM) is located on the side of the engine. It equipment by the vehicle/equipment manu-
acts as an interface between the electric and facturer. It acts as an interface between the
electronic components on the engine/equip- electric and electronic components on the
ment and the drive control system unit (CPC) vehicle/equipment and the engine manage-
on the vehicle. ment control module (MCM) on the engine.
The engine management control module The drive control system unit (CPC) has many
(MCM) has many functions: functions:
RInjection control of the Common Rail diesel RCalculation of torque demand
injection system The drive control system unit (CPC) regis-
The engine management control module ters the driver's requirements. For exam-
(MCM) calculates the optimum start and ple, the position of the accelerator is detec-
quantity of injection, taking the torque ted by the drive control system unit (CPC).
demand from the drive control system unit A torque requirement is calculated from
(CPC) into account. that and sent to the engine management
All of the data required for this, e.g. power control module (MCM) via the CAN con-
output or data which serve to protect the nection.
engine, are stored in the engine manage- In doing so, information and limitations
ment control module (MCM). from optionally connected control units
RRegulation of exhaust gas recirculation such as the gearbox control, retarder con-
(EGR) trol, ABS and ASR are taken into account.
The ratio between the mass of recirculated ROutput of displays and indicator signals
exhaust gas and the fresh air mass is pre- which are displayed in the instrument clus-
cisely regulated over the entire engine ter.
speed range. RMonitoring of coolant level, charge current
RCharge-air pressure control and air filter, for example
RControl of the engine brake RLegal speed limitation
The sensor signals of the directly connec- marily to reduce the amount of nitrogen oxide
ted sensors are evaluated. Data provided prior to exhaust gas aftertreatment. This
via the CAN by the engine management serves to comply with emissions limits.
control module (MCM) and the control Exhaust gas is added to the fresh air being
units for the NOx sensors are also evalu- drawn in or charged so that the concentration
ated. of oxygen in the combustion mixture is
RAdBlue®/DEF injection reduced. Combustion deteriorates if the con-
centration of exhaust gas in the combustion
Calculation of the required amount of mixture is too high. The emission of soot par-
AdBlue®/DEF and supply of AdBlue®/DEF ticles, carbon monoxide (CO) and hydrocar-
by actuation of the SCR delivery pump. bons (HC) increases. Conversely, the emis-
Injection by actuation of the AdBlue®/DEF sion of nitrogen oxides (NOx) would increase,
metering unit. if the concentration of fresh or charged air
was too high.
At a glance
may be available on the instrument panel:
Indicator Description
lamp
# Charge current
Ø AdBlue®/DEF reserve level
(optional)
5 Oil pressure too low (engine)
(optional)
4 Oil level too low (engine)
(optional)
, Coolant level too low
(optional)
? Coolant temperature too
(optional) high
Safety
Organisational measures ................... 23
22 Notes on electronic systems
Safety
Always have work on electrical and electronic ried out, this could result in malfunctions or
components carried out at a qualified special- system failures. There is a risk of an accident.
ist workshop. Always have the prescribed service/mainte-
nance work as well as necessary repairs car-
The general operating permit for your vehi-
ried out at a qualified specialist workshop.
cle/equipment could be rendered invalid if
you carry out modifications to electronic The engine should only be operated, main-
components, their software or their wiring. tained and repaired by trained personnel who
have been briefed and authorised by the oper-
ator. The prescribed minimum legal age for
Electromagnetic compatibility personnel carrying out maintenance and
The electromagnetic compatibility of the repair work must be observed.
engine system's components has been
checked and certified according to the cur-
rently valid version of Directive ECE-R 10. Organisational measures
Z
24
25
Transport ............................................. 26
Installation ........................................... 26
Transport, installation
26 Installation
Transport
G WARNING
If you do not lift the engine as described, the
lugs intended for the purpose may be torn out
or snap. This may be the case especially if the
maximum permissible lug load is exceeded.
The engine could then drop uncontrolled,
Transport, installation
Operation
Refuelling ............................................. 41
Winter operation ................................. 43
28 Preparation for operation
Preparation for operation possible with the engine switched off and the
ignition switched on.
Engine with initial operation oil from
X Park the vehicle/device on a level surface.
the factory
X Engage the parking brake.
The engine is filled at the factory with an initial X Switch off the engine.
operation oil.
X Wait approximately five to ten minutes. If
These high-quality engine oils are beneficial you call up the oil level in the engine too
to the running-in process. They also allow you early or while the engine is running, it is not
to make the first oil change in accordance available.
with the applicable oil change intervals. This
Only use engine oil which has been approved
Operation
X Check the engine oil level with dipstick ;. ! If the oil pressure in the engine is too low,
The oil level should be between the upper a warning light lights up on the instrument
and lower marks on dipstick ;. panel. The warning buzzer also sounds.
X If necessary, use filler neck : to top up the The operating safety of the engine is jeop-
oil. ardised. Switch off the engine immediately.
Only use engine oil which has been approved Do not pull away as soon as the engine starts.
for the engine and which meets the specified Do not subject the equipment to high loads
SAE classification (Y page 47). immediately. Let the engine run in neutral for
a short time after starting, until there is suf-
ficient engine oil pressure. Do not drive at
Operation
Checking the coolant level high engine speeds when the engine is cold.
X Check the coolant level as stated in the This will prevent excessive wear and possible
vehicle's/equipment's Operating Instruc- engine failure.
tions. Warm up the engine quickly by driving at
X Fill the cooling system if necessary. Only moderate engine speeds. Depending on the
use coolant that has been approved for the outside temperature, the engine will reach its
engine (Y page 49). operating temperature after around 10 to
20 minutes. Operating temperature
(Y page 73).
Checking the fuel level You can utilise the full engine power output
once the engine has reached its normal oper-
For checking the fuel level on the fuel gauge, ating temperature.
see the vehicle's Operating Instructions.
The display format for warning and indicator
Refuel if necessary (Y page 50).
lamps is vehicle-specific/equipment-spe-
cific. Observe the information contained in
the Operating Instructions for the vehicle/
Checking the AdBlue®/DEF supply equipment.
For checking the AdBlue®/DEF supply on the X Start the engine using the key in the ignition
AdBlue®/DEF gauge, see the vehicle's Oper- lock or the external engine start/engine
ating Instructions. Refuel if necessary stop button on the engine. Do not depress
(Y page 42). the accelerator or clutch pedal while doing
so.
For additional safety, the electronic engine
Starting and stopping the engine management system is equipped with a func-
Starting the engine tion that only allows the engine to be started
when the transmission is in neutral (vehicle/
G WARNING equipment-specific).
Combustion engines emit poisonous exhaust
gases such as carbon monoxide. Inhaling Starting the engine with the key
these exhaust gases leads to poisoning. There
is a risk of fatal injury. Therefore never leave ! After starting the engine, let it run at
the engine running in enclosed spaces with- engine idling speed until the oil pressure is
out sufficient ventilation. displayed. If no oil pressure is displayed
after approximately 10 seconds, switch off
the engine. Determine the cause. The oper-
ating safety of the engine is jeopardised.
Z
30 Starting and stopping the engine
X Park the vehicle/equipment. The engine brake and retarder are used as a
X Secure the vehicle/equipment against roll- continuous brake.
ing away. You can utilise the engine's braking effect,
X Shift the transmission into neutral/decou- particularly on long downhill gradients if you:
ple the drive system. Ractivate the continuous brake
Let the engine idle for approximately 2 Rshift to a lower gear in good time
minutes before switching off the engine if: Slowly depress the brake pedal if the engine's
Rthe coolant temperature is very high (over braking effect is insufficient when driving
100 †). downhill.
Rthe engine has been operated at full output. Vehicles without a retarder are equipped with
Operation
X To switch off the engine: turn the vehicle
only two brake stages.
key in the ignition lock back to the stop at Operation of the continuous brake; see the
position u. vehicle's Operating Instructions.
The à indicator lamp in the instrument
i If you switch off the engine, the system cluster is lit when the continuous brake is
may continue to run for a short while. active.
Depending on the installation position, When ABS (Anti-lock Braking System) inter-
operating state and ambient temperature, venes, the continuous brake is switched off.
circulation of AdBlue®/DEF is necessary The à indicator lamp in the instrument
for ensuring cooling. To do this the cluster remains on.
AdBlue®/DEF delivery pump is actuated
during this period.
Engine brake
Switching off the engine with the exter-
nal engine start/engine stop button The effectiveness of the engine brake
depends on the engine speed. A high engine
X To switch off the engine with the exter- speed results in more effective engine brak-
nal engine start/engine stop button: ing.
(Y page 58). Observe the effective engine braking range
marked on the rev counter (Y page 32).
At very low outside temperatures, the engine
Switching the continuous brake on brake has limited or no effect after the engine
and off has been started.
Operation of the engine brake; see the vehi-
G WARNING cle's Operating Instructions.
If you activate the continuous brake or shift to
a lower gear on a slippery road surface in
order to increase the engine's braking effect, Retarder
the drive wheels may lose traction. There is an
Operation of the retarder; see the vehicle's
increased risk of skidding and an accident.
Operating Instructions.
Do not activate the continuous brake and do
not shift to a lower gear in order to increase
the engine's braking effect on a slippery road Idling speed
surface.
After the engine has been started, idling
speed is regulated automatically. The engine
Z
32 Displays
idling speed may differ in certain operating switch off the engine. Searching for and elim-
conditions depending on the engine or on inating the cause of the malfunction
vehicles with power take-off. (Y page 63).
You can set the idling speed to between
approximately 600 and 800 rpm.
The engine idling speed is raised at very low Operating restrictions
outside temperatures or during regeneration The electronic engine management system
of the diesel particle filter. monitors:
You can set the speed to the working speed Remissions-relevant malfunctions in the
via the electronic engine management sys- exhaust gas aftertreatment
Operation
tem. This makes it possible to drive auxiliary Rmalfunctions in the electronic monitoring
equipment such as pumps at their working
of the exhaust gas aftertreatment system
speed. For setting the working speed, see the
Rconsumption, level and quality of the
vehicle's Operating Instructions.
AdBlue®/DEF reducing agent
Rthe efficiency of the catalytic converter in
Operational monitoring accordance with the permitted thresholds
for nitric oxide emissions (NOx)
Charge current
Operating restrictions in the form of torque
The charge current indicator lamp must go reduction and thus output and speed limita-
out after the engine has started. tion may occur.
If the # indicator lamp does not go off or
lights up when the engine is running, switch
off the engine. Searching for and eliminating Emergency switch for overriding the
the cause of the malfunction (Y page 63). operating restrictions
If an emissions-related malfunction of the
exhaust gas aftertreatment system or
Electronic engine management AdBlue®/DEF supply is detected, this can
The indicator and warning lamps must go out lead to operating restrictions (engine torque
after the engine has started. and engine speed limitation).
If an indicator lamp or warning lamp does not In emergencies, a push-button switch can be
go out, or if it lights up while the engine is operated to override the operating restric-
running, there is a malfunction in the elec- tion. This means that full engine power is
tronic engine management system. available for a maximum of 30 minutes. This
Each malfunction is stored in the system with emergency function by operating the switch
its own fault code. Temporary faults are also can be activated a maximum of three times.
stored. If the final operating restriction (idling speed
Fault codes can be read by a qualified spe- and 20% of torque) has been reached, the
cialist workshop using a diagnostic tester push-button switch is deactivated.
(Y page 8).
Displays
Oil pressure Rev counter
If the 1 indicator lamp does not go out or ! If you exceed the maximum permissible
if it lights up when the engine is running, engine speed, the warning tone sounds.
Displays 33
You should not drive and change gear by AdBlue®/DEF indicator lamp for the
the sound of the engine, but according to AdBlue®/DEF reserve level Ø.
the engine speed shown in the rev counter.
The AdBlue®/DEF reducing agent is required
Avoid driving in the red overrevving range. for reduction of engine emissions.
This could lead to engine damage.
The operating permit is invalidated if the vehi-
The engine speed display is the responsibility cle is operated without AdBlue®/DEF. The
of the vehicle manufacturer and is not nec- legal consequence of this is that the vehicle
essarily supplied by Mercedes-Benz. Daimler may no longer be operated on public roads.
AG recommends that the vehicle manufac-
If the AdBlue®/DEF level has sunk to approx-
turer uses a rev counter divided by:
imately 10 %, a warning lamp for the
Operation
Roperational efficiency AdBlue®/DEF reserve level lights up on the
Rengine braking range instrument panel. Top up the AdBlue®/DEF
Rengine overrevving range tank in good time (Y page 42).
General notes on the rev counter: If the gauge is ignored and the AdBlue®/DEF
RKeep an eye on the rev counter while driv- level drops further, engine torque and engine
ing and stay within the economical operat- speed may be reduced.
ing range. Engine torque may be limited to a maximum
In some situations it may make sense to of 20% across the whole engine speed range.
operate the engine outside the economical Engine speed may be limited to idling speed.
engine speed range, e.g. on uphill gradients
or when overtaking.
RIf you run the engine within the economical
engine speed range, you achieve low fuel
consumption and reduced wear.
RIn engine braking mode, drive in the middle
engine speed range. The highest engine
braking effect will be achieved just before
the red overrevving range.
RWhen driving downhill, make sure that the
engine speed does not enter the overrev-
ving range (marked red).
RIdling speed is set automatically depending
on the coolant temperature.
RWhen the vehicle is stationary, the engine is
running and the transmission is in neutral,
the engine increases throttle only slowly.
AdBlue®/DEF level
The AdBlue®/DEF gauge is the responsibility
of the vehicle manufacturer. It is not neces-
sarily supplied by Mercedes-Benz. Daimler
AG recommends that the vehicle manufac-
turer uses an AdBlue®/DEF gauge and an
Z
34 Warning and indicator lamps
The indicator lamp A serious fault in the engine system has been detected.
flashes red. X Immediately stop the vehicle/equipment while paying attention
to the traffic conditions and contact a qualified specialist work-
shop.
Operation
The Ø indicator The AdBlue®/DEF level has dropped to approximately 5%.
lamp is lit and · and Reduced engine output and engine speed limitation are active. The
are flashing. engine torque is limited to a maximum of 50% across the whole
engine speed range. The engine speed is limited to a maximum of
60%. The limitation takes effect by means of a ramp function.
X Adapt your driving/operating style.
X Top up the AdBlue®/DEF tank immediately.
The Ø and indi- The AdBlue®/DEF level has dropped to approximately 2.5%.
cator lamps are lit and Reduced engine output and engine speed limitation are active. The
· and are engine torque is limited to a maximum of 20% across the whole
flashing. engine 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.
Z
36 Warning and indicator lamps
The indicator lamp You have not rectified an emissions-relevant malfunction that has
lights up and · is been detected in the exhaust gas aftertreatment system or in the
flashing. AdBlue®/DEF supply.
Reduced engine output is active. The engine torque is limited to a
maximum 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 and
have the malfunction rectified immediately.
If you do not follow the instructions, engine speed may be limited.
The and · indi- You have not rectified an emissions-relevant malfunction that has
cator lamps are flash- been detected in the exhaust gas aftertreatment system or in the
ing. AdBlue®/DEF supply.
Reduced engine output and engine speed limitation are active. The
engine torque is limited to a maximum of 50% across the whole
engine speed range. The engine speed is limited to a maximum of
60%. 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 and
have the malfunction rectified immediately.
If you do not follow the instructions, further engine speed limita-
tion may be imposed.
Warning and indicator lamps 37
The and · indi- You have not rectified an emissions-relevant malfunction that has
cator lamps are flash- been detected in the exhaust gas aftertreatment system or in the
®
ing and lights up. AdBlue /DEF supply.
Reduced engine output and engine speed limitation are active. The
engine torque is limited to a maximum of 20% across the whole
engine 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-
Operation
shop.
The , · and You have not rectified an emissions-relevant malfunction that has
indicator lamps been detected in the exhaust gas aftertreatment system or in the
are flashing. AdBlue®/DEF supply.
Reduced engine output is active. The engine torque is limited to a
maximum of 20% across the whole engine speed range. The engine
speed is limited to idling speed.
X Stop the vehicle/equipment, paying attention to road and traffic
conditions.
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 available
again. If the system check does not detect any other faults, the indicator lamps go out after the
system's status indicator. The system check may involve several engine starts, several hours
or several journeys without a malfunction.
Z
38 Warning and indicator lamps
further test routines. The system check may involve several engine
starts, several hours or several journeys without a malfunction.
The · indicator You have not rectified an emissions-relevant malfunction that has
lamp is flashing and been detected in the exhaust gas aftertreatment system or in the
lights up. AdBlue®/DEF supply.
Reduced engine output is active. The engine torque is limited to a
maximum 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 the malfunction rectified at a qualified
specialist workshop.
If you do not follow the instructions, engine speed may be limited.
The · and indi- You have not rectified an emissions-relevant malfunction that has
cator lamps are flash- been detected in the exhaust gas aftertreatment system or in the
ing. AdBlue®/DEF supply.
Reduced engine output and engine speed limitation are active. The
engine torque is limited to a maximum of 50% across the whole
engine speed range. The engine speed is limited to a maximum of
60%. 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 the malfunction rectified at a qualified
specialist workshop.
If you do not follow the instructions, further engine speed limi-
tation may be imposed.
Operating instructions 39
The · and indi- You have not rectified an emissions-relevant malfunction that has
cator lamps are flash- been detected in the exhaust gas aftertreatment system or in the
®
ing and lights up. AdBlue /DEF supply.
Reduced engine output and engine speed limitation are active. The
engine torque is limited to a maximum of 20% across the whole
engine speed range. The engine speed is limited to idling speed.
X Adapt your driving/operating style.
X Top up the AdBlue®/DEF tank immediately.
Operation
X If this does not help: have the malfunction rectified at a qualified
specialist workshop.
The ·, and You have not rectified an emissions-relevant malfunction that has
indicator lamps been detected in the exhaust gas aftertreatment system or in the
are flashing. AdBlue®/DEF supply.
Reduced engine output and engine speed limitation are active. The
engine torque is limited to a maximum of 20% across the whole
engine speed range. The engine speed is limited to idling speed.
X Stop the vehicle/equipment, paying attention to road and traffic
conditions.
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 available
again. If the system check does not detect any other faults, the indicator lamps go out after the
system's status indicator. The system check may involve several engine starts, several hours
or several journeys without a malfunction.
Z
40 Operating instructions
Rmaintenance
Rdriving resistance More arduous operating conditions and
Ryour driving style increased distance covered could result in
engines exceeding this oil consumption
For these reasons, exact details about any
value.
single engine's fuel consumption cannot be
provided.
Warning buzzer
Machine version/vehicle version
If the warning buzzer sounds and the 5
The following components affect fuel con- symbol on the instrument panel is displayed,
sumption: the engine's operating safety is jeopardised.
Rtyres (e.g. tyre pressure, tyre condition) Do not pull away, or stop the vehicle as soon
Rbody type as possible, paying attention to road and traf-
Rdrive train (e.g. transmission ratio) fic conditions. You could otherwise damage
Radditional equipment (e.g. automatic cli-
the engine.
mate control, auxiliary heating) The warning buzzer sounds depending on the
vehicle if:
Maintenance Ryou exceed the maximum permissible
engine speed
The fuel consumption and assembly wear
Rthe engine speed or vehicle speed is too
depend on regular maintenance. Regular
maintenance increases safety and lowers fuel high when changing gears
consumption. Keep to the maintenance inter- Rthe coolant level is too low or the maximum
vals. Always have maintenance work carried permissible coolant temperature (approx-
out at a qualified specialist workshop. imately 115 †) is exceeded. The operating
safety of the engine is jeopardised.
Fuel type Ran emissions-relevant error is detected or
there is an operating restriction due to an
The fuel grade also affects fuel consumption.
emissions-relevant malfunction.
Use of lower fuel grades and/or non-
approved fuel additives will increase fuel con-
sumption. When refuelling, ensure that you
are filling the appropriate fuel grade
(Y page 50).
Refuelling 41
Operation
vapours. Keep fuels out of the reach of chil-
dren. Rmarine diesel fuel
If you or others come into contact with fuel, Raviation turbine fuel
observe the following: Rheating oils
RWash the fuel off any affected areas of skin Rfatty acid methyl ester FAME (bio-diesel
with water and soap immediately. fuel)
RIf you get fuel in your eyes, rinse them thor- These fuel types cause irreversible damage
oughly with clean water immediately. Seek to the engine and the exhaust gas after-
immediate medical attention. treatment system, as well as also signifi-
RIf fuel is swallowed, seek immediate medi-
cantly reducing the expected service life.
cal attention. Do not induce vomiting. ! Do not use petrol to refuel vehicles with a
RChange any clothing that has come into diesel engine. Even small amounts of petrol
contact with fuel immediately. result in damage to the fuel system and
engine.
G WARNING ! Do not switch on the ignition if you acci-
Fuel is highly flammable. Improper handing of dentally refuel with the wrong fuel. Other-
fuel creates a risk of fire and explosion. wise, the fuel will enter the fuel lines. Notify
Avoid fire, naked flames, smoking and creat- a qualified specialist workshop and have
ing sparks under all circumstances. Switch off the fuel tank and fuel lines drained com-
the ignition and auxiliary heating before car- pletely.
rying out work to the fuel system. Always wear
protective gloves. ! Do not add any special fuel additives to
the diesel fuel.
G WARNING Special fuel additives can lead to:
If you mix diesel fuel with petrol, the flash Rmalfunctions
point of this fuel mixture is lower than that of Rdamage to the catalytic converter
pure diesel fuel. When the engine is running, Rengine damage
components in the exhaust system may over-
heat unnoticed. There is a risk of fire. ! AdBlue®/DEF is not a fuel additive and
Never refuel with petrol. Never add petrol to must not be added to the diesel tank. If
diesel fuel. AdBlue®/DEF gets into the diesel tank, this
could lead to engine damage.
! A higher fuel sulphur content accelerates
the ageing process of the engine oil and can
damage the engine and exhaust system.
Z
42 Refuelling
with DIN 70070/ISO 22241. Do not use skin with water and soap.
any additives. Rif AdBlue®/DEF comes into contact with
If AdBlue®/DEF comes into contact with your eyes, rinse your eyes with clean water
painted or aluminium surfaces when filling immediately. Seek medical attention
the tank, rinse the affected area immedi- immediately.
ately with plenty of water. Rif you have swallowed AdBlue®/DEF,
! Do not mix additives to AdBlue®/DEF. Do immediately rinse your mouth with water
and drink plenty of water. Seek medical
not dilute AdBlue®/DEF with tap water.
attention immediately.
This could destroy the exhaust gas after-
Rchange clothing that has come into contact
treatment system.
with AdBlue®/DEF immediately.
Winter operation 43
Operation
X Switch off the engine. Notes on diesel fuel at low temperatures
X Secure the vehicle/equipment against roll- (Y page 50).
ing away.
Always fill the tank with at least 5 litres, as
smaller amounts could cause malfunctions.
Winter operation
Jump-starting
G WARNING
The use of liquid or gaseous starting aids can
cause explosions. This may result in severe
injuries.
Do not use liquid or gaseous starting aids
such as ether or Startpilot to start the engine.
Z
44
45
Maintenance
46 General notes
Always have maintenance work carried out at Do not let the engine run longer than neces-
a qualified specialist workshop. sary when stationary.
When working on the vehicle, comply with all Information about approved service products
safety regulations, such as operating instruc- is available from any MTU or MTU-authorised
tions, regulations concerning hazardous Mercedes-Benz Service Centre (Y page 10).
materials, environmental protection meas- You can recognise service products approved
ures, work safety and accident prevention by Mercedes-Benz by the following inscrip-
regulations. tion on the container:
RMB-Freigabe (e.g. MB-Freigabe 228.51)
Service products or
RMB-Approval (z. B. MB-Approval 228.51)
Important safety notes
Other labels and recommendations relating
G WARNING to the quality or indicating that the product
Service product can be poisonous and haz- meets a certain specification are not neces-
Maintenance
ardous to health. There is a risk of injury. sarily approved by Mercedes-Benz. Further
information is available from any MTU or
Observe the instructions on the respective
MTU-authorised Mercedes-Benz Service
original container when using, storing and dis-
Centre (Y page 10).
posing off service products. Always store ser-
vice products in the sealed original container. i Information about service products which
Always keep service products out of the reach have been tested by Mercedes-Benz and
of children. approved for your engine system can be
found in the Mercedes-Benz Specifications
! Special additives (except approved fuel for Service products on the Internet at:
additives) are neither required nor http://bevo.mercedes-benz.com/.
approved for use with approved service
products. Additives may cause damage to i The specification and availability of lubri-
major assemblies. Therefore, do not mix cants may vary. Individual lubricants may
any additives with service products. You no longer be available, especially for older
are responsible for the results of using fuel engines. Information is available from any
additives. MTU or MTU-authorised Mercedes-Benz
Service Centre (Y page 10).
H Environmental note
Dispose of service products in an environ-
mentally-responsible manner. Engine oils
Z
48 Service products
Engine oils according to Sheet No. 228.51 If the outside temperature is under -20 †,
and 228.5 have a higher quality standard and Mercedes-Benz strongly recommends
have a favourable effect on: using engine oils of SAE class 5W-30 or
Rlength of oil change intervals 0W-30.
Rengine wear Use only all-season oils.
Rfuel consumption
Rexhaust emissions
Engine oils are differentiated according to: The coolant is a mixture of water and corro-
Rengine oil brand sion inhibitor/antifreeze.
Rquality grade (Sheet No.) The corrosion inhibitor/antifreeze in the cool-
ant has the following properties:
RSAE viscosity class
Rheat transfer
If, in exceptional circumstances, the type of
engine oil currently used in the engine is not Ranti-corrosion protection
available, another mineral or synthetic engine Rcavitation protection (protection against
oil may be used. Make sure it is approved for pitting)
Mercedes-Benz. Rantifreeze protection
Please observe the following: if you top up Rraising the boiling point
with an engine oil of a lower quality, the main- Leave the coolant in the engine cooling sys-
tenance interval corresponding to the lower tem all year round – even in countries with
Maintenance
quality (Sheet No.) must be used. The main- high outside temperatures.
tenance interval is reduced. If you top up with
Check the corrosion inhibitor/antifreeze con-
an engine oil of a higher quality, the mainte-
centration in the coolant every six months.
nance interval is not altered.
Renew the coolant at the interval specified in
Observe the notes in the Maintenance Book-
the Maintenance Booklet.
let.
Use only approved corrosion inhibitor/anti-
freeze additives according to Sheet No.325.5
Coolant and 326.5. This prevents damage to the
engine cooling system and engine.
G WARNING When renewing the coolant, ensure that it
The engine cooling system is under pressure, contains 50% corrosion inhibitor/antifreeze
particularly if the engine is warm. You could by volume. This corresponds to antifreeze
be scalded by hot coolant spraying out when protection down to Ò37 †.
opening the cap. There is a danger of injury. Do not exceed 55% by volume (antifreeze
Allow the engine to cool before opening the down to approximately Ò45 †). The heat dis-
cap. Wear gloves and protective eyewear sipation and antifreeze may otherwise be
when opening. Slowly turn the cap half a turn negatively affected.
to allow pressure to escape. If there is a loss of coolant, do not top it up by
using only water, but also add an approved
G WARNING corrosion inhibitor/antifreeze agent.
If antifreeze comes into contact with hot com- The water in the coolant must meet certain
ponents in the engine compartment, it may requirements, which are often fulfilled by the
ignite. There is a risk of fire and injury. use of drinking water. The water must be
Let the engine cool down before you top up treated if its quality does not meet the
the antifreeze. Make sure that antifreeze is required standards.
not spilled next to the filler neck. Thoroughly Please note the Mercedes-Benz Specifica-
clean the antifreeze from components before tions for Service Products, Sheet No. 310.1.
starting the engine.
Mixtures with other corrosion inhibitors/anti-
A coolant that ensures anti-corrosion/anti- freeze agents are not permitted.
freeze protection and other important pro-
tective effects is filled at the factory.
Z
50 Service products
Maintenance
Fuel additives RChange clothing that is soiled with
Z
52 Service products
skin with water and soap. This could destroy the exhaust gas after-
Rif AdBlue®/DEF comes into contact with treatment system.
your eyes, rinse your eyes with clean water
immediately. Seek medical attention Storage
immediately.
Rif you have swallowed AdBlue®/DEF,
! Containers made of the following materi-
als are not suitable for the storage of
immediately rinse your mouth with water
AdBlue®/DEF:
and drink plenty of water. Seek medical
attention immediately. Raluminium
Observe laws and regulations on the disposal ! When using a high-pressure cleaner, keep
of AdBlue®/DEF in the country concerned. a minimum distance between the high-
pressure nozzle and the engine parts. Oth-
Purity erwise, parts of the engine may be dam-
aged.
! Impurities in AdBlue®/DEF, e.g. due to Observe the following minimum distances:
other service products, cleaning products
or dust, may lead to: Rabout 70 cm with round-spray jets
Rabout 30 cm with 25° flat-spray jets
Rincreased emission values
Rabout 30 cm with concentrated-power
Rdamage to the catalytic converter
jets
Rengine damage
Rmalfunctions in the exhaust gas after- ! Keep the water jet moving constantly
treatment system. while cleaning. In this way, you will avoid
Maintenance
causing damage.
Ensure that AdBlue®/DEF is always pure to
Do not point the water jet at:
avoid malfunctions in the exhaust gas after-
treatment system. Relectrical
components
If AdBlue®/DEF is pumped from the tank, e.g. Rplug connectors
during repairs, do not use this fluid to refill the Rseals
tank. Otherwise the purity of the fluid would Rhoses
no longer be guaranteed.
Z
54
55
Decommissioning
56 Decommissioning for longer than 6 months
Troubleshooting
58 Important safety notes
Where possible, allow the engine to cool down Starting the engine
and only touch the components described
X Press external engine start/engine stop
below.
button : until the engine starts.
When working on the vehicle, comply with all Starting the engine and increasing the
safety regulations, such as operating instruc- engine speed
tions, regulations concerning hazardous X Hold down external engine start/engine
materials, environmental protection meas-
stop button : until the desired engine
ures, work safety and accident prevention
speed is achieved.
regulations.
The engine starts and runs at engine idling
Be aware of the road and traffic situation speed.
when working on public roads and secure
After about 3 seconds, the engine speed
your position accordingly.
increases. After releasing external engine
Bleeding and draining the fuel system 59
start/engine stop button :, the engine Bleeding the fuel system without a
continues to run at the currently set speed. fuel prefilter on the chassis frame
The engine speed can be increased up to
Bleed the fuel system with the manual fuel
the limiting speed.
pump on the engine.
X If the engine does not start immedi-
ately: interrupt the starting procedure ! Do not bleed the fuel system with several
after no more than 30 seconds. starting procedures. You could otherwise
Troubleshooting
X Turn the key in the ignition lock back to the
damage the starter motor.
stop at key position g. X Switch the ignition lock to the drive posi-
X Repeat the starting procedure after a wait- tion.
ing period of approximately 1 minute. X Shift into neutral.
X If the engine fails to start: rectify the cause X Unscrew the fuel tank filler cap.
of the poor starting characteristics
(Y page 63).
X Observe the oil pressure gauge immedi-
ately after having started the engine.
Stopping the engine
X Press external engine start/engine stop
button : again.
i If you switch off the engine, the system
may continue to run for a short while.
Depending on the installation position,
operating state and ambient temperature, X Press handle of manual fuel pump : at the
circulation of AdBlue®/DEF is necessary main filter approx. 250 times in the space
for ensuring cooling. To do this the of approx. 3 minutes or until you feel sig-
AdBlue®/DEF delivery pump is actuated nificant resistance.
during this period. X Within approximately 5 seconds, press the
external engine start/engine stop and start
the engine.
Bleeding and draining the fuel system X If the engine starts, run the engine at
increased engine speed.
Bleeding, after refuelling a fuel system which X If the engine does not start, repeat the pro-
has been run dry, is performed manually by cedure.
means of a manual fuel pump. X Tighten the fuel tank filler cap.
Bleeding with a heated fuel prefilter with a
XTurn the key to the start position in the
water separator fitted on the chassis:
ignition lock and hold it. Do not depress the
X Bleed the heated fuel prefilter with water accelerator pedal whilst doing so.
separator fitted on the chassis before the i The starting procedure is automatically
fuel circuit on the engine is bled by the cancelled after approximately 40 seconds.
manual fuel pump at the main filter. Use the
hand pump integrated in the fuel prefilter to
do so.
Z
60 Electrical fuses
X Repeat the starting procedure after a wait- X Push hand pump ? repeatedly until the
ing period of approximately 1 minute. fuel escaping at bleed screw A is free of
X If the engine starts normally, depress the bubbles.
accelerator pedal several times. X Tighten bleed screw A.
The fuel system is completely bled. i If there was no fuel in the fuel tank, press
hand pump ? again until there is noticea-
ble resistance.
Troubleshooting
Troubleshooting
mation is available from any MTU or MTU- Avoid creating sparks.
authorised Mercedes-Benz Service Centre Battery acid is caustic.
(Y page 10). Avoid contact with the skin,
The fuse allocation chart is vehicle-specific eyes or clothing.
and is provided by the vehicle manufacturer. Wear suitable protective
If the newly inserted fuse also blows, have the clothing, in particular
cause traced and rectified at a qualified spe- gloves, an apron and a face
cialist workshop, e.g. a Mercedes-Benz Ser- mask.
vice Centre. Immediately rinse acid
splashes off with clean
X If a circuit fails, switch off the consumer
water. Consult a doctor if
equipment and switch the ignition lock to
necessary.
position 0.
Wear eye protection.
Z
62 Jump-starting
Troubleshooting
Engine problems
G WARNING
If you do not have the prescribed service/maintenance work or necessary repairs carried out, this
could result in malfunctions or system failures. There is a risk of an accident.
Troubleshooting
Always have the prescribed service/maintenance work as well as necessary repairs carried out
at 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 M Solutions
The drive pinion does The battery is not sufficiently charged.
not turn or turns too X Charge the battery.
slowly.
The connecting cable to the starter motor is loose.
X Tighten the cable on the terminal. If necessary, solder on a new
terminal.
Z
64 Troubleshooting
The engine stops inad- The power supply to the engine management (MCM) or the
vertently. exhaust gas aftertreatment (ACM) control modules is interrupted
or there is a short circuit in the wiring.
X Check the electrical fuses
X Have the power supply checked at a qualified specialist work-
shop.
The engine is in emer- There is an interruption to the control units' data flow.
gency running mode. X Check the connectors on the control units for secure seating
and corrosion.
X Read out the control unit's fault memory.
X Have it checked at a qualified specialist workshop.
Troubleshooting
X Check the temperature sensor; replace if necessary. Check the
fan speed.
X Check the thermostat and replace as necessary. Consult a
qualified specialist workshop.
There is an interruption There is an increased voltage drop to the control units (loose con-
in the tractive power. tact).
X Check the battery terminals on the battery and the connectors
on the control units for secure seating and corrosion.
The engine braking The cause must be established in a qualified specialist workshop.
effect is poor. X Consult a qualified specialist workshop.
The engine gets too hot There is not enough coolant in the cooling system.
(according to the cool- X Add and bleed the coolant.
ant temperature
gauge). The coolant temperature sensor or display is faulty.
X Replace the sensor or display.
Z
66 Troubleshooting
The radiator is dirty on the inside; the radiator is very dirty on the
outside.
X Clean the radiator.
Indicator lamps do not The lamps are faulty or the electrical cables are interrupted.
light up at IGNITION X Consult a qualified specialist workshop.
ON.
The charge current indi- The poly-V-belt is slipping.
cator lamp lights up X Check the belt tensioner function.
when the engine is run- X
Check that the poly-V-belt contact surfaces are not torn, dam-
ning.
aged, oily or glazed. Replace the poly-V-belt if necessary.
There are abnormal The air intake pipe and exhaust gas pipe are leaking, causing a
sounds. whistling noise.
X Rectify the cause of the leak and, if necessary, replace gaskets.
Troubleshooting 67
Troubleshooting
The valve clearance is excessive.
X Check and adjust the valve clearance.
Z
68
69
Technical data
70 Engine data
Data card
Technical data
Dimensions Weights
Technical data
6R 6R 6R
1100 1300 1500
A = engine 1290 1350 1400
length mm mm mm
B = engine 1120 1120 1120
width mm mm mm
C = engine 1100 1130 1150
height mm mm mm
72 Engine data
General data
All data refers to the standard version of the respective engine type. Data for other versions is
available on request.
Engine Engine type 6R 1100 6R 1300 6R 1500
Assembly model 470.907 471.919 473.905
series
Type In-line engine with exhaust gas recirculation and charge-air
pressure control
Technical data
Operating data
Technical data
ature
Maximum permissible tempera- 110 †
ture of coolant (automatic tor-
que limitation up to
50 % from 103 †)
Tightening torques
All threads on mechanical components and the corresponding contact surfaces must be clean,
smooth and coated with engine oil. Other lubricants lead to substantially different tightening
torques.
The tightening torques are the same for 6R 1100, 6R 1300 and 6R 1500. There is an exception
in the case of the cooling system: see the table.
Technical data
Air dryer Granulate cartridge on the air dryer 15 Nm
76
Symbols Imprint
G WARNING Internet
Warning notes make you aware dangers
which could pose a threat to your health or Further information about MTU, Mercedes-
life, or to the health and life of others. Benz and Daimler AG can be found on the
Internet at:
H Environmental note www.mtu-online.com
Environmental notes provide you with infor- www.mercedes-benz.com
mation on environmentally aware actions or www.daimler.com
disposal.
As at 28.08.2013
6R 1100/1300/1500
EU Stage IV/US TIER 4
Operating Instructions
É4705840981$ËÍ
4705840981
Order no. 6462 9837 02 Part no. 470 584 09 81 Edition 01-14