Professional Documents
Culture Documents
Om 457 La Bluetec / Om 457 La Om 460 La Bluetec / Om 460 La: Operating Instructions
Om 457 La Bluetec / Om 457 La Om 460 La Bluetec / Om 460 La: Operating Instructions
H Environmental note
Environmental notes provide you with infor-
mation on environmentally aware actions or
disposal.
4605843681 É4605843681ÇËÍ
Contents 3
Operation ............................................. 37
Maintenance ........................................ 63
Decommissioning ............................... 75
Troubleshooting .................................. 79
F M
FR (drive control) unit Maintenance
see ADM Notes ............................................... 64
Fuel Mercedes-Benz Service Centre
Additives .......................................... 70 see Qualified specialist workshop
Consumption ................................... 58 MR control unit
Diesel ............................................... 68 see Engine management control unit
FAME fatty acid methyl ester fuel .... 70
Refuelling ......................................... 59 O
Sulphur content table ...................... 69
Fuel grade ............................................ 69 Oil (engine)
Fuel prefilter For winter operation ........................ 65
Draining ........................................... 82 Oil change ........................................ 66
Fuel system Scope of use .................................... 66
Automatic bleeding .......................... 81 Oil pressure ......................................... 42
Manual bleeding .............................. 81 Operating data ..................................... 97
Fuses Operating instructions
Checking and replacing a safety General notes .................................. 10
fuse .................................................. 83 Operating restriction
Important safety notes .................... 83 Off-highway ...................................... 26
On-highway ...................................... 24
G Operating safety .................................. 30
Operating safety and registration
Gauge Changes in engine performance ........ 8
AdBlue®/DEF .................................. 45 Implied warranty ................................ 8
Genuine Mercedes-Benz parts ............. 7 Operational monitoring ...................... 42
Getting started .................................... 80 Organisational measures ................... 31
Overview, sensors ............................... 17
H
High-pressure cleaning ....................... 72 P
Personnel ............................................. 31
6 Index
S
Safety and emergency running pro-
gram ....................................................... 8
Safety precautions .............................. 30
SCR frame module
see Exhaust gas aftertreatment
control unit
Service products
AdBlue®/DEF .................................. 71
Coolant ............................................ 68
DEF/AdBlue® .................................. 71
Diesel fuel ........................................ 68
Disposal ........................................... 65
Disposing of AdBlue®/DEF .............. 72
Engine oil ......................................... 65
FAME fatty acid methyl ester fuel .... 70
Fuel additives ................................... 70
General notes .................................. 65
Purity of AdBlue®/DEF .................... 72
Storing AdBlue®/DEF ...................... 72
Specialist workshop ............................ 10
Starting
see Starting (engine)
Starting (engine) .................................. 39
Stopping and switching off the
engine ................................................... 39
Introduction 7
Z
8 Introduction
requirements. The use of non-approved parts If the electronic control system detects a mal-
may invalidate the vehicle's general operating function, one of the following measures is
permit. automatically implemented after an appraisal
This is the case if: of the malfunction:
Rthey result in a change to the vehicle type Rfaults during operation are indicated by the
from that for which the vehicle's general corresponding warning lamp (Y page 46).
operating permit was granted Rin conjunction with the electronic engine
Rthey pose a possible risk for road users management system, fault codes with addi-
Rthey adversely affect the emission or noise tional information can be shown on a dis-
levels play.
Rthe system switches to a suitable backup
You can find more information on recommen-
ded conversion parts and accessories, as well function for the continued, albeit restric-
as permitted technical modifications at any ted, operation of the engine. This includes
Mercedes-Benz, MTU or MTU-authorised torque and engine speed limitation, for
Mercedes-Benz Service Centre (Y page 10). example, as well as road speed limitation or
constant emergency running speed.
Always state the engine number when order-
ing genuine Mercedes-Benz parts. You can
find the engine number on the identification Correct use
plate of your engine. You can also find the
numbers on the data card (Y page 94).
The engine system may only be installed as
contractually specified.
Modifying the engine output The manufacturer of the end product is
responsible for the correct installation of the
! Increased power could: engine and the exhaust gas aftertreatment
system in the overall system.
Rchange emission levels The engine and the exhaust gas aftertreat-
Rcause malfunctions ment system may not be modified. If the
Rlead to consequential damage engine is modified, Mercedes-Benz and MTU
The operating safety of the engine cannot do not accept responsibility for any damage
be guaranteed in all situations. arising as a result.
Any tampering with the engine management Correct use of the engine system also
system in order to increase the engine power requires adherence to the instructions in
output will lead to a loss of warranty entitle- these Operating Instructions. This also
ments. requires compliance with the maintenance
intervals and the professional execution of
maintenance work. Please observe the Work-
Safety/emergency running program shop Information System (WIS) (Y page 10).
These Mercedes-Benz and MTU or MTU- If there are legal requirements on emission
authorised Mercedes-Benz Service Centres: control, please note that:
Rhave special equipment and tools as well as Rmaintenance on the engines must be car-
specialists who receive continuous training ried out according to specific regulations
Rguarantee that your engine system is and using special measuring devices
repaired and maintained thoroughly and Rit is prohibited to modify or tamper with
expertly components relevant to emissions
Rcarry out all repairs related to implied war- All Mercedes-Benz and MTU or MTU-author-
ranty ised Mercedes-Benz Service Centres are
Rcarry out all maintenance work expertly familiar with the relevant regulations.
Rconfirm in the Maintenance Booklet that Maintenance work does not include repair
the maintenance work has been carried out work. Issue a separate order for repair work.
at the required time You can obtain further information on the
Rhandle implied warranty claims that are maintenance of your engine system from any
admissible according to the sales contract Mercedes-Benz, MTU or MTU-authorised
Please observe the instructions and recom- Mercedes-Benz Service Centre.
mendations as well as the maintenance serv-
ices in the Maintenance Booklet. Please
observe these instructions even if you let a Stored data
third party use and care for your vehicle. This
is the only way to ensure that you do not lose Several of the electronic components in your
your entitlements. engine system contain data memories.
If the prescribed maintenance work is not These data memories temporarily or perma-
carried out, claims can only be decided after nently store technical information about:
the manufacturer has inspected the claim. Rthe engine system state
During the implied warranty period, have the Revents
prescribed maintenance service for your Rmalfunctions
engine system carried out as follows: In general, this technical information docu-
Rregularly ments the state of a component, a module, a
Rpunctually system or the surroundings.
Rat a qualified specialist workshop which This includes, for example:
has the necessary specialist knowledge Roperating conditions of system compo-
and tools to carry out the work required nents, e.g. fluid levels
Mercedes-Benz recommends that you use Rthe vehicle's status messages and those of
a Mercedes-Benz, MTU or MTU-authorised its individual components, e.g. speed,
Mercedes-Benz Service Centre. In particu- deceleration in movement, accelerator
lar, work relevant to safety or on safety- position
related systems must be carried out by a Rmalfunctions and defects in important sys-
qualified specialist workshop. tem components
Rthe vehicle's reactions and operating sta-
tuses in special driving situations
Rambient conditions, e.g. outside tempera-
ture
Z
10 Introduction
Ranalyse vehicle functions, e.g. after an acci- tions, an MTU partner or MTU-authorised
dent Mercedes‑Benz partner.
The data cannot be used to trace the vehicle's
movements. Further applicable documents
When you use one of the available services,
technical information may be read from the These Operating Instructions describe all
event data memory and fault data memory. models, as well as all standard and optional
Services include, for example: equipment of your engine system which are
Rrepair services part of the scope of delivery of Daimler AG.
Rservice
The installation of the engine system into the
processes
vehicle/device may require additional oper-
Rimplied warranty and guarantee cases
ating instructions adapted to the vehicle/
Rquality assurance device and the appropriate use thereof. These
The information is read out by employees of additional operating instructions will be pro-
the service network (including manufactur- vided by the vehicle/device manufacturer.
ers) using special diagnostic testers. Further The additional operating instructions will
information is available there if required. describe, in particular, the functions specific
After a fault has been rectified, the informa- to the installation and operation, the use of
tion is deleted from the fault memory or is such functions as well as warning and control
continually overwritten. mechanisms.
To use the engine correctly, you also require
the Maintenance Booklet.
Qualified specialist workshop For US-certified off-highway engines you also
require the "Emission Warranty" supplement.
A qualified specialist workshop has the nec- Please also observe the information con-
essary specialist knowledge, tools and quali- tained in the vehicle or the equipment oper-
fications to carry out the work required on the ating instructions (manufacturer of the end
engine to a professional standard. This is par- product). Always keep these documents
ticularly applicable to work relevant to safety. together with the engine, vehicle or equip-
Observe the notes in the Maintenance Book- ment. These documents should be passed on
let. to the new owner if you sell the engine, vehi-
Always have the following maintenance work cle or equipment.
carried out at a qualified specialist workshop: When carrying out maintenance work, you
Rwork relevant to safety require access to the Workshop Information
Rservice and maintenance work System (WIS) via the Internet. This access is
subject to a fee.
Rrepair work
Current information on the system and prices
Rmodifications as well as installations and
can be found at this web address: http://
conversions
service-parts.mercedes-benz.com. Click on
Rwork on electronic components
"EPC, WIS/ASRA" in the "Service and parts
information" tab and then on "WIS".
Introduction 11
Z
12
13
At a glance
Sensors overview ................................ 17
Electronic engine management ......... 19
BlueTec® exhaust gas aftertreat-
ment ..................................................... 21
Warning and indicator lamps ............. 23
14 General information
sel engine with direct injection. case in the country of registration. Or also in
The six cylinders are arranged in a row. Each another country where you operate the vehi-
cylinder has two inlet and two outlet valves. cle/equipment.
Each cylinder has its own fuel injection pump
(unit pump) with a short high-pressure fuel
injection line to the multi-hole nozzle at the
centre of the combustion chamber. The unit
pumps sit directly in the crankcase and are
driven by the camshaft.
The engine is equipped with exhaust gas tur-
bocharger and intercooler as standard. The
engine may include an engine brake (airbrake
and constantly open throttle) as optional
equipment.
It is a low-emission engine. Start of injection,
injection duration and injection quantity are
controlled entirely electronically.
Engine overview
At a glance
: Poly-V-belt
; Fuel pump
= Thermostat housing
? Fuel filter
A Oil filter
B Cylinder head cover
C Start/Stop button
D Charge-air distributor
E Charge-air pipe from the charge-air cooler
F Crankcase ventilation system
G Engine control unit (MR)
H Air compressor
I Power-steering pump
J Dipstick
K Engine oil filler neck
16
At a glance Engine overview
: Alternator
; Starter motor
= Exhaust gas turbocharger
? Exhaust manifold
A Coolant pump
B Poly V-belt tensioning device
Sensors overview 17
Sensors overview
Sensors, general
At a glance
: Engine oil pressure and temperature sensor
; Charge-air pressure/temperature sensor
= Camshaft position sensor (on camshaft gear)
? Crankshaft position sensor (on flywheel)
A Coolant temperature sensor
B Engine oil level sensor
C Fuel temperature sensor
18 Sensors overview
AdBlue®/DEF components
At a glance
At a glance
BlueTec® sensors and test connection on the metering unit
: AdBlue®/DEF pressure sensor
; AdBlue®/DEF temperature sensor
= Pressure sensor for compressed air
? Metering unit test connection
A Metering unit heater
B Metering valve
detects a fault, the fault code is stored in the Start of injection, injection duration and injec-
control units. It can then be read by a qualified tion quantity are calculated on this basis and
specialist workshop (Y page 10) using a diag- the unit pumps are controlled via the solenoid
At a glance
At a glance
Example: drive control unit (ADM)
The drive control unit (ADM) has many func-
tions: Exhaust gas aftertreatment control unit
RCalculation of torque demand The exhaust gas aftertreatment control unit
The drive control unit (ADM) registers the reads signals and transmits them via the CAN
driver's requirements. For example, the line to the engine management (MR) control
position of the accelerator is detected by unit.
the drive control unit (ADM). A torque The following signals are read:
requirement is calculated from that and
Rtemperature sensor upstream of the SCR
sent to the engine management control
module (MR) via the CAN connection. catalytic converter
Rtemperature sensor downstream of the
In doing so, information and limitations
from optionally connected control units SCR catalytic converter
such as the gearbox control, retarder con- RNOx sensor downstream of the SCR cata-
trol, ABS and ASR are taken into account. lytic converter
ROutput of displays and indicator signals Rpressure and temperature sensor for the
which are displayed in the instrument clus- fluid level and temperature in the AdBlue®/
ter. DEF tank
RMonitoring of coolant level, charge current Rsensor for humidity and intake air temper-
and air filter, for example ature
RLegal speed limitation If the electronic engine management control
REvaluation of start request detects a fault, the fault code is stored in the
control units.
The engine starting process is initiated
once a corresponding start request is pres-
ent (ignition lock or external engine start/
engine stop button). BlueTec® exhaust gas aftertreatment
Continuous brake
If increased braking power is required, the
engine can be equipped with a brake valve
downstream from the exhaust gas turbo-
charger in conjunction with constant throttle
valves. The brake valve uses exhaust back
pressure to increase braking power. The con-
stant throttle valves bring about a reduction
of the compression pressure in the power
stroke (third stroke), whilst the compression
(second stroke) is not significantly affected.
The constant throttle valve is an additional
valve in the cylinder head. When open, the
constant throttle valve establishes a connec-
tion between the combustion chamber and
exhaust port.
Warning and indicator lamps 23
At a glance
Important safety notes
If you ignore warning and indicator lamps, you will not be able to recognise failures and mal-
functions in components or systems. The driving and braking characteristics may change and
the road and operating safety of your vehicle or equipment may be restricted. Have the affec-
ted system checked and repaired at a qualified specialist workshop. Always observe the
warning and indicator lamps and follow the corresponding corrective actions (Y page 46).
Overview
The indicator and warning lamp display is designed for the specific vehicle or equipment.
Please also observe the information in the additional operating instructions. These will be
provided by the vehicle/device manufacturer. The symbols listed below are examples only and
their appearance may differ in the vehicle or on the equipment. In the event of a fault or
warning, a warning lamp or indicator lamp lights up automatically. Depending on the priority of
the fault or warning, the warning and indicator lamps light up in different combinations. The
following warning and indicator lamps may be available on the instrument panel:
(optional)
é Cruise control
(optional)
È Speed limiter
(optional)
I Power take-off engaged
(optional)
At a glance
(optional)
é Cruise control
(optional)
È Speed limiter
(optional)
I Power take-off engaged
(optional)
3 Off-highway: devices/vehicles
2 In addition, an acoustic warning signal may sound.
26 Warning and indicator lamps
(optional)
I Power take-off engaged
(optional)
3 Off-highway: devices/vehicles
2 In addition, an acoustic warning signal may sound.
Warning and indicator lamps 27
At a glance
(optional)
È Speed limiter
(optional)
I Power take-off engaged
(optional)
28
29
Safety
Organisational measures ................... 31
30 Notes on electronic systems
Operating safety RPlease note that the "+" and "-" terminals
on the batteries must be disconnected
G WARNING when carrying out electric welding work.
RThe control unit connectors may only be
If you do not have the prescribed service/
maintenance work or necessary repairs car- connected/disconnected when the elec-
trical system is switched off.
Safety
Always have the prescribed service/mainte- polarity (e.g. by connecting up the bat-
nance work as well as necessary repairs car- teries incorrectly) can cause irreparable
ried out at a qualified specialist workshop. damage to the control units.
RTighten diesel injection system connec-
The operating safety of an engine system tions to the prescribed tightening torque.
depends on its professional installation in the RIftemperatures above 80 † are to be
overall system (e.g. the vehicle or working
expected (e.g. in a drying oven), the con-
machinery). As the operator of the engine,
trol unit on the engine must be removed.
you also affect its safe operation.
ROnly use the appropriate testing probes
Through compliance with the prescribed
when taking measurements from electri-
maintenance intervals, you fulfil part of the
cal connectors (e.g. a Mercedes-Benz
requirements for safe operation of the
connection set). Telephones and two-
engine.
way radio devices that are not connected
However, safe operation of the engine also to an external aerial can cause malfunc-
depends upon its proper use and care. This tions in the electronics and thus endan-
includes, for example, regularly checking the ger the operating safety of the engine.
oil level.
Warning stickers
Safety precautions
If you remove any warning stickers, you or
Damage to the engine can also lead to per- others could fail to recognise certain dangers.
sonal injury. In order to avoid engine damage, Various warning stickers are attached to the
the following safety precautions must be engine system. Their purpose is to make you
adhered to. and others aware of various risks.
ROnly start the engine when the batteries
are firmly attached. Notes on electronic systems
RDo not disconnect the batteries when the
engine is running. Important safety notes
RDo not use a rapid charger to start the
G WARNING
engine.
Modifications to electronic components, their
ROnly perform the jump-starting proce-
software as well as wiring could affect their
dure with separate batteries. function and/or the operation of other net-
RNote, the battery terminals must be dis- worked components. This could in particular
connected when rapid charging the bat- also be the case for systems relevant to
teries. safety. They might not function properly any-
RObserve the operating instructions of the more and/or jeopardise the operational
rapid battery charger.
Organisational measures 31
safety of the vehicle. There is an increased ried out, this could result in malfunctions or
risk of an accident and injury. system failures. There is a risk of an accident.
Do not attempt to modify the wiring as well as Always have the prescribed service/mainte-
electronic components or their software. nance work as well as necessary repairs car-
Always have work on electrical and electronic ried out at a qualified specialist workshop.
Safety
components carried out at a qualified special-
ist workshop. The engine should only be operated, main-
tained and repaired by trained personnel who
The general operating permit for your vehi- have been briefed and authorised by the oper-
cle/equipment could be rendered invalid if ator. The prescribed minimum legal age for
you carry out modifications to electronic personnel carrying out maintenance and
components, their software or their wiring. repair work must be observed.
Staff qualifications
G WARNING
If you do not have the prescribed service/
maintenance work or necessary repairs car-
Z
32
33
Transport ............................................. 34
Installation ........................................... 34
Transport, installation
34 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
G WARNING
If you lift the engine at unsuitable points and/
or using unsuitable lifting gear, it may:
Rwork loose and fall off
Rswing uncontrollably as a result of a change
in the centre of gravity. Example: flywheel-side lifting point
There is a risk of injury.
Lift the engine only at the lifting points provi-
ded using suitable lifting gear. Make sure that
there is nobody in the danger zone when rais-
ing and lowering the engine.
Transport, installation
Observe the sections "Qualified specialist
workshop" (Y page 10) and "Further applica-
ble documents" (Y page 10).
Please consult a Mercedes-Benz, MTU or
MTU-authorised Mercedes-Benz Service
Centre if you have any questions.
Z
36
37
Operation
Refuelling ............................................. 59
Winter operation ................................. 61
38 Preparation for operation
X Check the engine oil level with dipstick :. The operating safety of the engine is jeop-
The oil level should be between the upper ardised. Switch off the engine immediately.
and lower marks on dipstick :.
! Do not pull away as soon as the engine
X If necessary, use filler neck ; to top up the
starts. Let the engine run in neutral for a
oil. short time after starting, until there is suf-
Only use engine oil which has been approved ficient engine oil pressure. Do not drive at
for the engine and which meets the specified high engine speeds when the engine is
SAE classification (Y page 65). cold.
This will prevent excessive wear and pos-
sible engine failure.
Operation
Checking the coolant level
Warm up the engine quickly by driving at
X Check the coolant level as stated in the moderate engine speeds. Depending on the
vehicle's/device's operating instructions. outside temperature, the engine will reach its
X Fill the cooling system if necessary. Only operating temperature after approximately
use coolant that has been approved for the 10 to 20 minutes (Y page 97).
engine (Y page 68). You can utilise the full engine power output
once the engine has reached its normal oper-
ating temperature.
Checking the fuel level The display format for indicator and warning
For checking the fuel level on the fuel gauge, lights is vehicle-specific/device-specific.
see the vehicle's operating instructions. Please also observe the information in the
Refuel if necessary (Y page 68). additional operating instructions. These will
be provided by the vehicle/device manufac-
turer.
Checking the AdBlue®/DEF supply X Start the engine using the key in the ignition
lock or the external engine start/engine
For checking the AdBlue®/DEF supply on the stop button on the engine. Do not depress
AdBlue®/DEF gauge, see the vehicle's oper- the accelerator or clutch pedal while doing
ating instructions. Refuel if necessary so.
(Y page 60).
For additional safety, the electronic engine
management system is equipped with a func-
tion that only allows the engine to be started
Starting and stopping the engine
when the transmission is in neutral (vehicle-
Starting the engine specific/device-specific).
Z
40 Starting and stopping the engine
Operation
not shift to a lower gear in order to increase
minutes before switching off the engine if:
the engine's braking effect on a slippery road
Rthe coolant temperature is very high (over surface.
90 †).
Rthe engine has been operated at full output. ! If the continuous brake is deactivated and
the à indicator lamp in the instrument
X To switch off the engine: turn the vehicle
cluster does not go out, have the continu-
key in the ignition lock back to the stop at
ous brake checked at a qualified specialist
position u.
workshop.
i When you switch off the engine, BlueTec® The engine brake and retarder are used as a
exhaust gas aftertreatment automatically continuous brake.
flushes the exhaust system with fresh air. You can utilise the engine's braking effect,
Residues of AdBlue®/DEF on the metering particularly on long downhill gradients if you:
unit or the injection nozzle might otherwise
Ractivate the continuous brake
impair the function of BlueTec® exhaust
Rshift to a lower gear in good time
gas aftertreatment. Depending on the
engine's previous operating load, BlueTec® Slowly depress the brake pedal if the engine's
exhaust gas aftertreatment may flush the braking effect is insufficient when driving
exhaust system several times. downhill.
When BlueTec® exhaust gas aftertreatment Vehicles without a retarder are equipped with
flushes the exhaust system, an air valve is only two brake stages.
activated. You may then hear a hissing Operation of the continuous brake (see the
sound. This hissing sound does not indicate vehicle/device operating instructions).
a leak in the compressed-air system. The à indicator lamp in the instrument
cluster is lit when the continuous brake is
Switching off the engine with the exter- active.
nal engine start/engine stop button When ABS (Anti-lock Braking System) inter-
X Switch off the engine with the external venes, the continuous brake is switched off.
engine start/engine stop button: The à indicator lamp in the instrument
(Y page 80). cluster remains on.
Engine brake
The effectiveness of the engine brake
depends on the engine speed. A high engine
Z
42 Operational monitoring
speed results in more effective engine brak- off the engine. Searching for and eliminating
ing. the cause of the malfunction (Y page 86).
Observe the effective engine braking range
marked on the rev counter (Y page 44).
The maximum permissible engine speed is Electronic engine management
restricted if necessary, depending on the The indicator and warning lamps must go out
vehicle/device application. after the engine has started.
Observe the vehicle/device Operating If an indicator lamp or warning lamp does not
Instructions. go out, or if it lights up while the engine is
At very low outside temperatures, the engine running, there is a malfunction in the elec-
Operation
brake has limited or no effect after the engine tronic engine management system.
has been started. Searching for and eliminating the cause of the
Operation of the engine brake (see the vehi- malfunction (Y page 86).
cle/device Operating Instructions). Each malfunction is stored in the system with
its own fault code. Temporary faults are also
stored.
Retarder Fault codes can be read by a qualified spe-
Operation of the retarder; see the vehicle/ cialist workshop using a diagnostic tester
device Operating Instructions. (Y page 8).
Operation
Types of operating restriction
Operating restrictions for off-highway
engines with BlueTec® AdBlue®/DEF level low
The electronic engine management system
monitors:
Remissions-relevant malfunctions in the
exhaust gas aftertreatment
Rmalfunctions in the electronic monitoring
of the exhaust gas aftertreatment system
Rconsumption, level and quality of the
AdBlue®/DEF reducing agent
Rthe efficiency of the catalytic converter in
accordance with the permitted thresholds
for nitric oxide emissions (NOx) Insufficient AdBlue®/DEF remaining; warning and
length of operating restriction period (example dis-
Operating restrictions in the form of torque play)
reduction and thus output and speed limita- A Acknowledged fault
tion may occur.
B Minor operating restriction
Minor operating restriction C Speed/torque reduction
D Major operating restriction
The available torque is reduced to roughly
80% of the maximum torque.
Z
44 Displays
General notes on the rev counter: panel. Top up the AdBlue®/DEF tank in good
RKeep an eye on the rev counter while driv- time (Y page 60).
ing and stay within the economical operat- If the display is ignored and the AdBlue®/DEF
ing range. level drops further, engine torque and engine
In some situations it may make sense to speed may be reduced (Y page 42).
operate the engine outside the economical
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
Operation
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
AdBlue®/DEF indicator lamp for the
AdBlue®/DEF reserve level Ø.
The AdBlue®/DEF reducing agent is required
for reduction of engine emissions.
The MOT approval/operating permit is inva-
lidated if the vehicle/equipment is operated
without AdBlue®/DEF. The legal conse-
quence of this is that the vehicle/equipment
may no longer be operated on public roads.
If the AdBlue®/DEF level has sunk to approx-
imately 10%, a warning lamp for the AdBlue®/
DEF reserve level lights up on the instrument
Z
46 Warning and indicator lamps
The # indicator A malfunction has been detected in the electric power supply.
lamp lights up. X If there are no malfunctions, the indicator lamp goes out after
the engine is started.
X If the indicator lamp does not go out or if it lights up when the
engine is running, search for the cause of the malfunction and
have it repaired at a qualified specialist workshop.
The % indicator After you have switched the ignition lock to the drive position, the
lamp lights up. indicator lamp indicates the status of the cold-start aid
(Y page 61).
X If there are no malfunctions, the indicator lamp goes out after
the cold start aid has been switched off.
The 1 indicator A malfunction was detected in the supply of engine lubricating oil.
lamp lights up. X If there are no malfunctions, the indicator lamp goes out after
the engine is started.
X If the indicator lamp does not go off or lights up when the engine
is running, switch off the engine.
X Check the engine oil level (Y page 38).
X If this does not help, have the malfunction rectified at a qualified
specialist workshop.
Warning and indicator lamps 47
Operation
specialist workshop.
The + indicator A malfunction in the coolant circuit has been detected. The coolant
lamp lights up. level is too low.
X If there are no malfunctions, the indicator lamp goes out after
the engine is started.
X If the indicator lamp does not go off or lights up when the engine
is running, switch off the engine.
X Check coolant level.
X If this does not help, have the malfunction rectified at a qualified
specialist workshop.
The ? indicator A malfunction in the coolant circuit has been detected. The coolant
lamp lights up. temperature is too high.
X If there are no malfunctions, the indicator lamp goes out after
the engine is started.
X If the indicator lamp does not go off or lights up when the engine
is running, switch off the engine.
X Check coolant level.
X If this does not help, have the malfunction rectified at a qualified
specialist workshop.
If you do not observe the instructions, engine performance and
torque may be limited.
The w indicator The indicator lamp shows the status of the continuous brake.
lamp lights up. X The indicator lamp lights up after activation of the continuous
brake.
X Observe the information contained in the operating instructions
of the device/vehicle.
X If the indicator lamp does not go out after deactivation or if it
lights up permanently, there is a malfunction.
X Have the malfunction rectified immediately at a specialist work-
shop.
Z
48 Warning and indicator lamps
The È indicator The indicator lamp shows the status of the variable speed limiter.
lamp lights up. X The indicator lamp lights up after a speed limit was activated by
the speed limiter.
Operation
The È indicator The indicator lamp shows that the speed set by the speed limiter
lamp flashes. has been exceeded.
X The maximum speed (speed limit) set by the speed limiter is
being exceeded by more than 3 km/h. If necessary, reduce
speed by adaptive braking.
X The speed limit set by the speed limiter was temporarily deac-
tivated by kickdown and may be exceeded. By briefly switching
to idle throttle position, the set speed limit is reactivated.
X Observe the information contained in the operating instructions
of the device/vehicle.
The I indicator The indicator lamp shows the status of the power take-off.
lamp lights up. X The indicator lamp lights up after engaging power take-off.
X If there are no malfunctions, the indicator lamp goes out after
the power take-off is switched off.
X Observe the information contained in the operating instructions
of the device/vehicle.
The ; indicator After you have switched the ignition lock into the drive position,
lamp flashes when the the indicator lamp indicates the status of the European On-Board
ignition is ON. Diagnosis (OBD) by means of a sequence of flashes.
X If there are no malfunctions, the indicator lamp goes out after
the engine is started.
Warning and indicator lamps 49
Operation
further test routines. The system check may involve several engine
starts, several hours or several journeys without a malfunction.
The s indicator An emissions-relevant fault has been detected.
lamp lights up. X An operating restriction is active. The engine torque is tempo-
rarily limited.
X If further indicator lamps are displayed, take the combination of
lamps (see below) into account when evaluating the cause.
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
50 Warning and indicator lamps
The % indicator After you have switched the ignition lock to the drive position, the
lamp lights up. indicator lamp indicates the status of the cold-start aid
Operation
(Y page 61).
X If there are no malfunctions, the indicator lamp goes out after
the cold start aid has been switched off.
The 1 indicator A malfunction was detected in the supply of engine lubricating oil.
lamp lights up. X If there are no malfunctions, the indicator lamp goes out after
the engine is started.
X If the indicator lamp does not go off or lights up when the engine
is running, switch off the engine.
X Check the engine oil level (Y page 38).
X If this does not help, have the malfunction rectified at a qualified
specialist workshop.
The 2 indicator A malfunction was detected in the supply of engine lubricating oil.
lamp lights up. The engine oil level is too low.
X If there are no malfunctions, the indicator lamp goes out after
the engine is started.
X If the indicator lamp does not go off or lights up when the engine
is running, switch off the engine.
X Check the engine oil level (Y page 38).
X If this does not help, have the malfunction rectified at a qualified
specialist workshop.
The + indicator A malfunction in the coolant circuit has been detected. The coolant
lamp lights up. level is too low.
X If there are no malfunctions, the indicator lamp goes out after
the engine is started.
X If the indicator lamp does not go off or lights up when the engine
is running, switch off the engine.
X Check coolant level.
X If this does not help, have the malfunction rectified at a qualified
specialist workshop.
Warning and indicator lamps 51
Operation
specialist workshop.
If you do not observe the instructions, engine performance and
torque may be limited.
The w indicator The indicator lamp shows the status of the continuous brake.
lamp lights up. X The indicator lamp lights up after activation of the continuous
brake.
X Observe the information contained in the operating instructions
of the device/vehicle.
X If the indicator lamp does not go out after deactivation or if it
lights up permanently, there is a malfunction.
X Have the malfunction rectified immediately at a specialist work-
shop.
The = indicator The indicator lamp shows the status of the cruise control function.
lamp lights up. X The indicator lamp lights up after activation of cruise control.
X Observe the information contained in the operating instructions
of the device/vehicle.
The È indicator The indicator lamp shows the status of the variable speed limiter.
lamp lights up. X The indicator lamp lights up after a speed limit was activated by
the speed limiter.
X The active speed limit is shown in the vehicle/device display.
X Observe the information contained in the operating instructions
of the device/vehicle.
Z
52 Warning and indicator lamps
The I indicator The indicator lamp shows the status of the power take-off.
lamp lights up. X The indicator lamp lights up after engaging power take-off.
X If there are no malfunctions, the indicator lamp goes out after
the power take-off is switched off.
X Observe the information contained in the operating instructions
of the device/vehicle.
Operation
further test routines. The system check may involve several engine
starts, several hours or several journeys without a malfunction.
If further indicator lamps are displayed, take the combination of
lamps (see below) into account when evaluating the cause.
The · indicator You have not rectified an emissions-relevant malfunction that has
lamp flashes, the s been detected in the exhaust gas aftertreatment system or in the
indicator lamp lights AdBlue®/DEF supply. Reduced engine output is active. The engine
up. torque is temporarily limited to a maximum of 80% across the
entire engine speed range. The effect of the limitation is linear. If
you do not observe the instructions, engine torque may be further
limited to a maximum of 50%.
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 observe the instructions, engine performance and
also engine speed may be limited.
The · and s You have not rectified an emissions-relevant malfunction that has
indicator lamps are been detected in the exhaust gas aftertreatment system or in the
flashing. AdBlue®/DEF supply.
The reduction in engine output and limitation of the engine torque
are activated. The engine torque is limited to a maximum of 20%
across the whole engine speed range. The engine speed is limited
to a maximum of 1000 rpm.
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.
Z
54 Warning and indicator lamps
In the event of an emergency, operating restrictions (limitation of the engine torque and engine
speed) can be temporarily overridden with the emergency switch (Y page 44). 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 sys-
tem's status indicator. The system check may involve several engine starts, several hours or
several journeys without a malfunction.
Warning and indicator lamps 55
Operation
tation 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%. The
cator lamps are lit and reduction in engine output and limitation of the engine torque are
· and are activated. The engine torque is limited to a maximum of 20%
flashing. across the whole 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
56 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, an engine speed limitation
may be imposed.
Warning and indicator lamps 57
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.
The reduction in engine output and limitation of the engine torque
are activated. 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.
Operation
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, an engine speed limitation
may be imposed.
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.
The reduction in engine output and limitation of the engine torque
are activated. 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-
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/device, 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
58 Operating instructions
Rservice life
Roperating safety Rbody type
Reconomy Rdrive train (e.g. transmission ratio)
Observe the following notes during the run- Radditional equipment (e.g. automatic cli-
ning-in period up to 2,000 km (30 operating mate control, auxiliary heating)
hours):
Ravoid
Maintenance
subjecting the engine to full load.
Rrun in the engine with care, using differing Fuel consumption and assembly wear depend
speeds and engine revs. on how often maintenance is carried out. Reg-
Ravoid high engine speeds. ular maintenance increases safety and lowers
Rdo not drive at more than ¾ of the maxi-
fuel consumption. Keep to the maintenance
intervals. Always have maintenance work car-
mum road speed for each gear.
ried out at a qualified specialist workshop.
Rchange gear in good time.
Rdo not shift down to brake the vehicle. Fuel type
Rfor vehicles with automatic transmission,
do not depress the accelerator pedal The fuel grade also affects fuel consumption.
beyond the point of resistance (kickdown). Use of lower fuel grades and/or non-
approved fuel additives will increase fuel con-
After 2,000 km (30 operating hours), you can sumption. When refuelling, ensure that you
gradually bring the vehicle up to full road are filling the appropriate fuel grade
speed and increase engine speeds. (Y page 68).
Fuel consumption
AdBlue®/DEF consumption
General notes AdBlue®/DEF consumption is between 3 and
Fuel consumption depends on: 6% of the fuel consumption, depending on
Rthe
engine use.
type of fuel used (diesel fuel, fatty acid
methyl ester FAME fuel)
Rthe machine version/vehicle version
Engine oil consumption
Rthe operating mode
After running-in the engine, oil consumption
Rthe operating conditions
may reach 0.5% of the vehicle's fuel con-
Rthe attached equipment (e.g. hydraulic sumption.
pumps, mowers, etc.)
Rmaintenance
Refuelling 59
More arduous operating conditions and If you or others come into contact with fuel,
increased distance covered could result in observe the following:
engines exceeding this oil consumption
RWash the fuel off any affected areas of skin
value.
with water and soap immediately.
RIf you get fuel in your eyes, rinse them thor-
Warning buzzer
oughly with clean water immediately. Seek
If the warning buzzer sounds and the 1 immediate medical attention.
symbol on the instrument panel is displayed, RIf fuel is swallowed, seek immediate medi-
the engine's operating safety is jeopardised. cal attention. Do not induce vomiting.
Do not pull away, or stop the vehicle as soon RChange any clothing that has come into
Operation
as possible, paying attention to road and traf-
contact with fuel immediately.
fic conditions. You could otherwise damage
the engine. The warning buzzer sounds
G WARNING
depending on the vehicle if:
Fuel is highly flammable. Improper handing of
Ryou exceed the maximum permissible
fuel creates a risk of fire and explosion.
engine speed.
Avoid fire, naked flames, smoking and creat-
Rthe engine speed or vehicle speed is too
ing sparks under all circumstances. Switch off
high when changing gears.
the ignition and auxiliary heating before car-
Rthe coolant level is too low or the maximum
rying out work to the fuel system. Always wear
permissible coolant temperature (about protective gloves.
100 °C) is exceeded. The operating safety
of the engine is jeopardised. G WARNING
Ran emissions-relevant fault is detected or
If you mix diesel fuel with petrol, the flash
there is an operating restriction due to an point of this fuel mixture is lower than that of
emissions-relevant malfunction. pure diesel fuel. When the engine is running,
components in the exhaust system may over-
heat unnoticed. There is a risk of fire.
Refuelling
Never refuel with petrol. Never add petrol to
Fuels diesel fuel.
Z
60 Refuelling
AdBlue®/DEF should not come into contact outside temperatures may result in engine
with skin, eyes or clothing, and should not be damage.
swallowed. Keep AdBlue®/DEF out of the Before the start of the cold season, make sure
reach of children. that:
If you come into contact with AdBlue®/DEF, Rthe coolant contains sufficient antifreeze
observe the following: (Y page 68)
Rimmediately wash AdBlue®/DEF from your Rthe fuel used is suitable for winter use
skin with water and soap. (Y page 68)
Rif AdBlue®/DEF comes into contact with Rthe SAE class of the engine oil used is in
your eyes, rinse your eyes with clean water accordance with outside temperatures
Operation
immediately. Seek medical attention (Y page 65).
immediately.
Rif you have swallowed AdBlue®/DEF, Jump-starting
immediately rinse your mouth with water
G WARNING
and drink plenty of water. Seek medical
attention immediately. The use of liquid or gaseous starting aids can
cause explosions. This may result in severe
Rchange clothing that has come into contact
injuries.
with AdBlue®/DEF immediately.
Do not use liquid or gaseous starting aids
AdBlue®/DEF is not refilled as part of the such as ether or Startpilot to start the engine.
maintenance work. Top up the tank regularly
during vehicle operation or at the latest when
Batteries
the first event message is displayed on the
electronic engine management system. Always aim to achieve the full charge status.
You will find further information on AdBlue®/ You can do this by means of careful mainte-
DEF in the "Service products" section nance and low electrical consumption. The
(Y page 71). cold start capacity is reduced when it is very
cold. For example, at -10 † it is only around
Before filling the tank 60% of the normal capacity.
Z
62 Winter operation
Maintenance
64 General notes
When working on the vehicle, comply with all about approved service products is available
safety regulations, such as operating instruc- from any Mercedes-Benz Service Centre
tions, regulations concerning hazardous (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 Mercedes-
Observe the instructions on the respective
Benz, MTU or MTU-authorised Mercedes-
original container when using, storing and dis-
Benz Service 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. Mercedes-Benz, MTU or MTU-authorised
Service Centre (Y page 10).
H Environmental note
Dispose of service products in an environ-
mentally-responsible manner. Engine oils
Z
66 Service products
The following engine oils are approved: This is also required for a mixture of conven-
RSheet No. 228.5 / 228.3 / 228.1 standard tional diesel fuels and FAME fatty acid methyl
quality multi-grade engine oils ester fuels (bio-diesel fuel).
RSheet No. 228.51 / 228.31 low-ash multi- Multi-grade engine oils compliant with Sheet
grade engine oils Nos. 228.5, 228.51, 228.3, 228.31 and
228.1 can be used all year round. Depending
RSheet No. 228.0 / 228.2 standard quality
on the fuel quality (fuel sulphur content or
single-grade engine oils (exceptional cir-
FAME fatty acid methyl ester fuel), the oil
cumstances)
change intervals may be shortened. For
Mercedes-Benz particularly recommends details, see the Maintenance Booklet.
engine oils that comply with Sheet no. 228.5
Single-grade engine oils only cover an SAE
of the Mercedes-Benz Specifications for Ser-
(viscosity) classification for certain tempera-
vice Products.
ture ranges. Change the engine oil to an SAE
Maintenance
These engine oils are of a high standard of class suitable for the time of year and the
quality and have a beneficial effect on: respective outside temperatures.
Rlength of oil change intervals The use of low-ash engine oils is permitted
Rengine wear but only necessary on engines with a diesel
Rfuel consumption particle filter. The use of low-ash engine oils
Rexhaust emissions
compliant with Sheet No. 228.51 and 228.31
is however only approved in conjunction with
The maximum interval for oil change is only low-sulphur diesel fuel (less than 50 ppm,
achieved with engine oils of a particularly high 0.005% by weight) (Y page 69).
quality grade.
Check the vehicle assemblies for leaks regu- Oil change
larly. If fluid loss is identified, e.g. by oil drops
on the parking area, have the cause of the ! If you mix engine oils with differing oil
fluid loss rectified at a qualified specialist grades, the change interval for the engine
workshop. oil is reduced in comparison to mixtures of
engine oil of identical grade.
Scope of application Therefore, only mix engine oils of differing
grade in exceptional circumstances. To
For engines with BlueTec® exhaust gas after- prevent damage to the engine, the mainte-
treatment and operation with diesel fuel, only nance intervals must be adjusted accord-
use multi-grade engine oils compliant with ingly.
Sheet Nos. 228.5, 228.51, 228.3 and 228.31
or, in exceptional cases, single-grade engine ! If the SAE class (viscosity) of the engine
oils compliant with Sheet No. 228.2. oil used is not suitable for continually low
outside temperatures below -20 †, this
For engines without BlueTec® exhaust gas
could cause engine damage.
aftertreatment, multi-grade oils compliant
with Sheet No. 228.1 and, in exceptional The specified temperatures of the SAE
cases, single-grade oils compliant with Sheet class always refer to freshly added oil.
No. 228.0 / 228.2 can also be used. Engine oil ages during driving due to soot
and fuel residue. This impairs the charac-
For operation with FAME fatty acid methyl
teristics of the engine oil, particularly at low
ester fuel (bio-diesel fuel), use only engine oils
outside temperatures.
compliant with Sheet Nos. 228.5, 228.51,
228.3 and 228.31 (Y page 70). If the outside temperature is under -20 †,
Mercedes-Benz strongly recommends
Service products 67
Maintenance
When topping up, Mercedes-Benz recom-
mends that you only use engine oil of the
same grade and SAE class as the oil filled at
the last oil change.
Check the oil level before topping up the
engine oil (Y page 38).
Z
68 Service products
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.
Diesel fuels
The coolant is a mixture of water and corro-
sion inhibitor/antifreeze. Important safety notes
The corrosion inhibitor/antifreeze in the cool-
ant has the following properties: G WARNING
Fuel is highly flammable. Improper handing of
Rheat transfer
fuel creates a risk of fire and explosion.
Ranti-corrosion protection
Avoid fire, naked flames, smoking and creat-
Rcavitation protection (protection against
ing sparks under all circumstances. Switch off
pitting) the engine and, if applicable, the auxiliary
Rantifreeze protection heating before refuelling.
Rraising the boiling point
Leave the coolant in the engine cooling sys- G WARNING
tem all year round – even in countries with Fuels are poisonous and hazardous to health.
high outside temperatures. There is a danger of injury.
Check the corrosion inhibitor/antifreeze con- Do not swallow fuel or let it come into contact
centration in the coolant every six months. with skin, eyes or clothing. Do not inhale fuel
Renew the coolant at the interval specified in vapours. Keep fuels out of the reach of chil-
the Maintenance Booklet. dren.
Only use approved corrosion inhibitor/anti-
freeze agents. Please note the Mercedes-
Benz Specifications for Service Products
Service products 69
If you or others come into contact with fuel, expectancy of the engine and exhaust sys-
observe the following: tem.
RWash the fuel off any affected areas of skin ! Vehicles without BlueTec® exhaust
with water and soap immediately. gas aftertreatment:
RIf you get fuel in your eyes, rinse them thor- Only commercially available fuels which
oughly with clean water immediately. Seek comply with the European standard EN 590
immediate medical attention. or comparable national fuel standards are
RIf fuel is swallowed, seek immediate medi- permitted. Mercedes-Benz recommends
cal attention. Do not induce vomiting. fuels with a low sulphur content. The use of
RChange any clothing that has come into fuels with a high sulphur content reduces
contact with fuel immediately. the lifespan of the engine and the exhaust
system. For operation with a high sulphur
content > 0.05% by weight (500 ppm), the
Maintenance
! If you are using drums or canisters to
refuel the engine/vehicle/equipment, you maintenance intervals for the engine oil
should filter the fuel before filling. and filter must be reduced.
This prevents malfunctions in the fuel sys- For details, see the Maintenance Booklet.
tem caused by contaminated fuel.
i Even if the maintenance intervals are
The following fuel types are not permitted: reduced, operation with fuel with a higher
Rmarine diesel fuel sulphur content will lead to increased
Raviation turbine fuel
engine wear, especially on the fuel injec-
tors.
Rheating oils
Information about current country-specific
Fuel grade fuel sulphur contents can be obtained from
any Mercedes-Benz, MTU or MTU-authorised
i Certain countries have diesel fuel with Mercedes-Benz Service Centre (Y page 10).
varying sulphur content. Diesel fuel with You can find a table of fuel sulphur contents in
low sulphur content is sold in certain coun- specific countries in the Mercedes-Benz
tries under the name "Euro diesel". Specifications for Service Products, Sheet
Fuel sulphur content 136.2 at http://bevo.mercedes-benz.com.
! A higher fuel sulphur content accelerates The maintenance intervals for engine oil and
the ageing process of the engine oil and can filter replacement must be adapted depend-
damage the engine and exhaust system. ing on the fuel grade used. The higher the sul-
phur content in diesel fuel, the shorter the
! Vehicles with BlueTec® exhaust gas maintenance intervals for engine oil and filter
aftertreatment: replacement. Observe the notes in the Main-
Only standardised fuels with a maximum tenance Booklet.
sulphur content of 0.05% (500 ppm) by
Water content
weight are permissible. However,
Mercedes-Benz only recommends fuel that If the engine is operated with increased
complies with the European standard EN amounts of dirt and water, an additional fuel
590 as of 2005, et seq. (max. 0.005% prefilter with a water separator must be fitted
(50 ppm) sulphur by weight). The use of on the chassis.
fuels with a sulphur content higher than
0.005% (50 ppm) by weight reduces the life
Z
70 Service products
Diesel fuels at low temperatures Do not add flow improvers to winter diesel
fuel guaranteed to operate down to −22 †.
G WARNING The cold flow properties of the fuel may dete-
If you heat fuel system components, e.g. with riorate as a consequence of the flow
a hot-air gun or naked flame, these compo- improver.
nents could be damaged. This can cause fuel
to escape and ignite. Depending on the type
of damage, fuel may also not escape until the Fatty acid methyl ester (FAME) fuel
engine is running. There is a risk of fire and (bio-diesel)
explosion.
Never heat fuel system components. Contact
General notes
a qualified specialist workshop to rectify the Operate your engine using pure FAME fatty
malfunction. acid methyl ester fuel in compliance with
Maintenance
Maintenance
RChange clothing that is soiled with
skin with water and soap.
AdBlue®/DEF immediately. Rif AdBlue®/DEF comes into contact with
RIf allergic reactions occur, consult a doctor
your eyes, rinse your eyes with clean water
immediately.
immediately. Seek medical attention
immediately.
Keep AdBlue®/DEF out of the reach of chil-
Rif you have swallowed AdBlue®/DEF,
dren.
immediately rinse your mouth with water
! Only use AdBlue®/DEF in accordance and drink plenty of water. Seek medical
with DIN 70070/ISO 22241. Do not use attention immediately.
any additives. Rchange clothing that has come into contact
Z
72 Cleaning and care
Maintenance
jets
! Keep the water jet moving constantly
while cleaning. In this way, you will avoid
causing damage.
Do not point the water jet at:
Relectrical
components
Rplug connectors
Rseals
Rhoses
Z
74
75
Decommissioning
76 Decommissioning for up to 12 months
Recharge batteries every 3 months at the lat- RCheck cables, hoses and lines for tears and
est. leaks.
Ensure that there is adequate ventilation RCheck the engine oil level.
when recharging. Check the battery fluid lev- RCheck the oil level in the steering and
els before and after charging and if necessary hydrostatic fan drive.
correct them. For further information RCheck the coolant level and correct it, if
(Y page 61). necessary.
RCheck AdBlue®/DEF level.
Decommissioning
78
79
Troubleshooting
Jump-starting ....................................... 83
Troubleshooting .................................. 86
80 External engine start/engine stop button
X To start the engine: press Start/Stop but- X To stop the engine: while the engine is
ton :. running, press stop button =.
The engine starts and runs at engine idling The engine switches off.
speed. X To turn the engine over without starting
X To start the engine and increase the it: press and hold start button ; and stop
engine speed: press and hold Start/Stop button = at the same time.
button :. The engine turns over without starting.
Troubleshooting
The engine starts and runs at engine idling X Release start button ; and stop button
speed. After about three seconds, the =.
engine speed increases. The engine remains at a standstill.
X Hold down Start/Stop button : until the
desired engine speed is reached.
After releasing Start/Stop button :, the Bleeding and draining the fuel system
engine continues to run at the currently set
speed. The engine speed can be increased When the engine is started, the battery must
up to the limiting speed. have sufficient charge to bleed the fuel sys-
X To stop the engine: press Start/Stop but- tem.
ton : again. Bleeding with a heated fuel prefilter with a
The engine switches off. water separator fitted on the chassis:
X Bleed the fuel prefilter with water separator
on the chassis before bleeding the fuel cir-
Engine with two buttons
cuit on the engine side (Y page 83).
Z
82 Bleeding and draining the fuel system
Bleeding the fuel system using the Bleeding the fuel system with a fuel
manual fuel pump prefilter on the chassis frame
Fuel prefilter overview
Troubleshooting
Automatic bleeding
! Do not bleed the fuel system by operating
the starter motor for an extended period of
time. You could otherwise damage the Example: fuel prefilter
starter motor. : Manual fuel pump
X
; Vent valve
Turn the starter motor for up to 30 seconds
without interruption until the engine is run- = Shutoff valve
ning smoothly. The fuel system is automat- ? Filter housing
ically bled when the tank is empty. A Water separator with inspection window
B Water release valve
If water has collected in inspection window
A, drain the fuel prefilter before bleeding.
X Open water release valve B. Always replace faulty fuses with specified new
X Press manual fuel pump : and collect the fuses of the correct amperage.
fuel/water mixture.
X Close water release valve B.
The individual electrical circuits are protected
by safety fuses or automatic circuit-breakers.
X On vehicles with fuel prefilter at tank level:
open shutoff valve =. Blown fuses or defective automatic circuit-
breakers must be replaced by equivalent
Troubleshooting
X Start the engine and allow it to run for about
fuses with the fuse ratings recommended in
one minute.
the fuse allocation chart. Fuses with the same
The fuel system is bled automatically.
fuse rating are the same colour.
X Check the fuel system for leaks.
Further information is available from any
Mercedes-Benz, MTU or MTU-authorised
Bleeding the fuel prefilter with the man- Mercedes-Benz Service Centre (Y page 10).
ual fuel pump The vehicle-specific fuse allocation chart is
The fuel prefilter must only be bled when: provided by the vehicle manufacturer.
Rthe fuel tank is empty or If the newly inserted fuse also blows, have the
Rthe fuel filter has been replaced. cause traced and rectified at a qualified spe-
cialist workshop, e.g. a Mercedes-Benz Ser-
X Unscrew the fuel tank filler cap.
vice Centre.
X Place the collector underneath the fuel pre-
X If a circuit fails, switch off the consumer
filter.
equipment and switch the ignition lock to
X Open shutoff valve = fully.
position 0.
X Open bleed nipple ;.
X Press manual fuel pump : repeatedly until
the escaping fuel is free of bubbles ;. Do Checking and replacing a safety fuse
not continue to pump.
X Pull the fuse out of the module using the
X Close bleed nipple ;.
pliers and carry out a visual inspection.
X Close the fuel tank filler cap.
X If the fuse wire has melted, replace the
X Start the engine. blown fuse with a spare fuse.
The fuel system is bled automatically. X Switch on consumers and check that they
function correctly.
! Do not continue to press the fuel hand
pump after the engine has started. This If the safety fuse burns out again, have the
could otherwise damage the hand pump. electrical system checked at a qualified spe-
cialist workshop.
Electrical fuses
Jump-starting
Important safety notes
Important safety notes
G WARNING
If you manipulate, bridge or replace a faulty G WARNING
fuse with a fuse of a higher amperage, the Comply with safety precautions and take pro-
electric cables could be overloaded. This may tective measures when handling batteries.
result in a fire. There is a risk of an accident
and injury.
Z
84 Jump-starting
Troubleshooting
X First, connect the negative terminal clamp
of the jump lead to the negative terminal of
the other vehicle's battery and then to the
± negative terminal of the starter battery.
X Assisting vehicle: run the engine at a high
speed.
X Start the engine and allow it to idle.
Z
86 Troubleshooting
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.
Troubleshooting
The engine does not There is a malfunction in the engine control unit.
start correctly. X Read out the MR (engine control) unit; have it checked at a
qualified specialist workshop.
The engine stops inad- The MR (engine control) unit is faulty (total failure).
vertently. X Consult a qualified specialist workshop.
The engine is in emer- There is an interruption in the data flow of the MR and ADM control
gency running mode. units.
X Read out the control unit's fault memory.
X Have it checked at a qualified specialist workshop.
Z
88 Troubleshooting
There is an interruption There is an increased voltage drop to the MR and ADM control unit
in the tractive power. (loose contact).
X Check the battery terminals and the connectors on the MR and
ADM control unit 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 cuts off too The engine management (MR) control unit is faulty or parameter-
early (maximum engine ised incorrectly.
speed cannot be X Consult a qualified specialist workshop.
reached).
The engine gets too hot There is not enough coolant in the coolant circuit.
(according to the cool- X Add coolant and bleed the system.
ant temperature
gauge). The coolant temperature sensor or display is faulty.
X Replace the sensor or display.
Troubleshooting 89
Troubleshooting
The coolant radiator is dirty on the inside; the coolant radiator is
very dirty on the outside.
X Clean the coolant 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.
Z
90 Troubleshooting
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
X Check that both the tensioner and the belt
pulley are in fault-free condition. Check for
such defects as worn bearings in the ten-
sioner, tensioning pulley and guide pulleys
and for wear of the tooth profile on the belt
pulleys.
X Replace faulty parts.
X Route the new poly-V-belt over all belt pul-
leys except the tensioning pulley (observe
the poly-V-belt routing shown in the illus-
tration).
X Swing the tensioning pulley down using the
lever, lay the poly-V-belt over the tension-
ing pulley and allow the tensioning pulley to
swing back.
X Remove the spanner and check for correct
: Alternator
seating of the poly-V-belt on the belt pul-
; Guide pulley
leys.
= Coolant pump
? Crankshaft belt pulley
A Tensioning pulley
B Guide pulley
Routing
Z
92
93
Technical data
94 Data card
Data card
Dimensions
Technical data
Engine data card
The engine data card describes the scope of
delivery from the Mercedes-Benz factory.
Conversion parts on the engine system which
change the scope of the engine delivered by
Mercedes-Benz should be reported to
Mercedes-Benz. Once the documentation
(VeDoc) has been updated, an updated data
card is supplied. This helps to prevent incor-
rect ordering of replacement parts.
In order to prevent incorrect ordering of
replacement parts, the Mercedes-Benz
replacement parts service must also be
informed.
Engine data
Dimensions and weights OM 457 LA OM 460 LA
All data refers to the standard version of the A = engine 1320 mm 1320 mm
respective engine type. Deviations may length
occur, depending on the engine equipment
and installation situation in the vehicle/ B = engine 750 mm 793 mm
device. width
C = engine 1115 mm 1144 mm
height
96 Engine data
Weights
OM 457 LA OM 460 LA
Dry engine 930 kg 930 kg
maximum
Wet engine 980 kg 980 kg
maximum
Technical data
Engine data 97
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 OM 457 LA OM 460 LA
Assembly model series 457.9 458.9
Type Turbocharged in-line engine with intercooler
Combustion principle 4-stroke direct injection diesel
Technical data
Number of cylinders 6 6
Bore 128 mm 128 mm
Stroke 155 mm 166 mm
Engine capacity 11,970 cm3 12,820 cm3
Type of cooling system Forced circulation cooling
Engine, direction of Anti-clockwise (when looking at the flywheel)
rotation
Valve clear- Intake valve 0.40 mm 0.40 mm
ance
Exhaust valve 0.60 mm 0.60 mm
Starter Starter Electric Electric
motor
Voltage 24 V 24 V
Output 7.0 kW 7.0 kW
Battery Voltage 12/24 V 12/24 V
Cold-discharge test Maximum 700 A Maximum 700 A
current
Cold start ability Down to maximum Ò20 † (battery charge level 75%)
Alternator Voltage 28 V 28 V
Amperage 35/80 A 35/80 A
Operating data
Technical data
Corrosion inhibitor/anti-
freeze volume by volume
down to –45 °C
Coolant additive (coolant - Coolant additive and water
without antifreeze protec- quality in accordance with
tion) Sheet No. 310.1, 312.0
Engine compart- Protective wax - Wax preservative (Sheet No.
ment 385.4)
Engine brake Heat-resistant lubricant - Heat-resistant lubricant (part
number A000 989 76 51)
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.
Engine Cylinder head cover Light alloy (with oil filler cap) 25 Nm
Plastic (without oil filler cap) 20 Nm
Valve clearance setting Counternut on the rocker 50 Nm
arm adjustment screw
Inspection hole cap on the timing case 25 Nm
Flywheel housing rotation device 25 Nm
Charge-air distributor at cylinder head 30 Nm
Fuel system Cap on the fuel filter housing 25 Nm
Oil circuit Drain plug on the oil pan M 18 x 1.5 50 Nm
M 20 x 1.5 70 Nm
M 22 x 1.5 80 Nm
M 26 x 1.5 90 Nm
Oil filter cap on the oil filter housing 40 Nm
Cooling system Coolant drain screw On the crankcase 60 Nm
On the radiator 2 Nm
Exhaust gas Filter bowl on the AdBlue®/DEF pump module 32 Nm
aftertreatment
Technical data
Imprint
Internet
Documentation team
As at 29.08.2014
É4605843681ÇËÍ
4605843681
Order no. 6462 9852 02 Part no. 460 584 36 81 Edition 01-15