4R/6R 1000 EU Stage IV/US Tier 4: Operating Instructions

4R/6R 1000 EU Stage IV/US Tier 4
Operating Instructions
Symbols
G WARNING
Warning notes make you aware of dangers
which could pose a threat to your health or
life, or to the health and life of others.
H Environmental note
Environmental notes provide you with infor-
mation on environmentally aware actions or
disposal.
! The purpose of material damage warnings

is to draw your attention to risks which
could lead to damage to your engine sys-
tem.
i These symbols indicate useful instruc-
tions or further information that could be
helpful to you.
X This symbol designates an instruc-
tion you must follow.
X Several consecutive symbols indi-
cate an instruction with several
steps.
(Y page) This symbol tells you where you
can find further information on a
topic.
YY This symbol indicates a warning or
an instruction that is continued on
the next page.
Display This text indicates an indicator in
the display.
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.
9345840981 É9345840981-ËÍ
2 Index
A D
AdBlue®/DEF Data card .............................................. 78
Consumption ................................... 47 DEF/AdBlue®
Gauge .............................................. 38 see AdBlue®/DEF service products
Important safety notes .................... 49 Description of the engine ................... 12
Refuelling ......................................... 49 Diagnostics connection ...................... 25
Service product ............................... 57 Diesel
ADM (FR (drive control) unit) ............. 12 Fuels ................................................ 56
Low outside temperatures ............... 56
B Refuelling ......................................... 48
Battery (vehicle) Dimensions .......................................... 79
Jump starting ................................... 69 Disposal of service products .............. 53
Bleeding the fuel system Driving mode
Bleeding the prefilter with a hand Idling speed ..................................... 36
pump ............................................... 67 Driving tips .......................................... 46
Braking
Continuous brake ............................ 35 E
Engine brake .................................... 36 Electronic engine control
Retarder ........................................... 36 see Engine management
Buzzer ................................................... 47 Electronic engine control unit ............ 36
Emergency gearshift
C Using the emergency switch ............ 37
Capacities ............................................ 81 Emergency running program ................ 7
Care products ...................................... 59 Engine
Charge current .................................... 36 Capacities ........................................ 81
Checking the fluid level ...................... 32 Cleaning ........................................... 59
Cleaning and care Data ................................................. 79
Engine cleaning ................................ 59 Data card ......................................... 78
High-pressure cleaning .................... 59 Data plate ........................................ 78
Notes on care .................................. 59 Modifying the power output ............... 7
Consumption Oil consumption ............................... 47
Operating data ................................. 80
AdBlue®/DEF .................................. 47
Rectifying faults ............................... 71
Fuel .................................................. 47
Running-in period ............................. 46
Oil (engine) ...................................... 47
Continuous brake Starting ............................................ 34
Stopping .......................................... 35
Important safety notes .................... 35
Coolant Engine brake ........................................ 36
Mixing ratio ...................................... 55 Engine data .......................................... 79
Service product ............................... 55 Engine data card .................................. 78
Topping up ....................................... 33 Engine description .............................. 12
Coolant additive .................................. 55 Engine idling speed ............................. 36
Correct use ............................................ 7 Engine management ........................... 18
Corrosion inhibitor/antifreeze Engine oil
agent .................................................... 55 Consumption ................................... 47
For winter operation ........................ 53
Mixing .............................................. 54
Index 3
Oil change ........................................ 54 O

Topping up ....................................... 54
Engine overview .................................. 13 Oil (engine)
Engine speed ....................................... 37 For winter operation ........................ 53
Oil change ........................................ 54
Exhaust gas aftertreatment ............... 20
Scope of use .................................... 54
Oil pressure ......................................... 37
F
Operating data ..................................... 80
Fuel Operating instructions
Additives .......................................... 57 General notes .................................... 9
Consumption ................................... 47 Operating safety .................................. 24
Diesel ............................................... 56 Operating safety and registration
Refuelling ......................................... 48 Changes in engine performance ........ 7
Fuel grade ............................................ 56 Implied warranty ................................ 7
Fuel system Operational monitoring ...................... 36
Automatic bleeding .......................... 67 Organisational measures ................... 25
Manual bleeding .............................. 67
Fuses P
Checking and replacing a safety
fuse .................................................. 68 Personnel ............................................. 25
Important safety notes .................... 68 Poly-V-belt
Replacing ......................................... 75
G Routing ............................................ 75
Preparing for starting operation
Gauge see Starting operation
AdBlue®/DEF .................................. 38 Protection of the environment ............. 6
Genuine Mercedes-Benz parts ............. 6
Q
H
Qualified specialist workshop .............. 9
High-pressure cleaning ....................... 59
R
I
Refuelling
Identification plate .............................. 78 AdBlue®/DEF .................................. 49
Idling speed Fuels ................................................ 48
Engine .............................................. 36 Requirements of the personnel ......... 25
Installation ........................................... 28 Rev counter .......................................... 37
Roadside Assistance ........................... 66
J Running the vehicle in ........................ 46
Jump-starting ....................................... 69
S
M Safety and emergency running pro-
Maintenance gram ....................................................... 7
Notes ............................................... 52 Safety precautions .............................. 24
Mercedes-Benz Service Centre Service products
see Qualified specialist workshop AdBlue®/DEF .................................. 57
Coolant ............................................ 55
4 Index
DEF/AdBlue® .................................. 57
Diesel fuel ........................................ 56
Disposal ........................................... 53
Disposing of AdBlue®/DEF .............. 58
Engine oil ......................................... 53
Fuel additives ................................... 57
General notes .................................. 53
Purity of AdBlue®/DEF .................... 59
Storing AdBlue®/DEF ...................... 58
Specialist workshop .............................. 9
Starting
see Starting (engine)
Starting (engine) .................................. 34
Stopping and switching off the
engine ................................................... 34
T
Technical data
Dimensions ...................................... 79
Filling capacities .............................. 81
Operating data ................................. 80
Weights ............................................ 79
Tightening torques .............................. 82
Transport .............................................. 28
W
Warning and indicator lamps
Electronics ....................................... 39
Engine, general ................................ 20
Warning buzzer .................................... 47
Weights ................................................ 79
Winter diesel ........................................ 56
Winter operation ................................. 50
5
Engine system ....................................... 6

Protection of the environment ............. 6
Introduction
Assembly equipment ............................ 6
Genuine Mercedes-Benz parts ............. 6
Modifying the engine output ................ 7
Safety/emergency running pro-
gram ....................................................... 7
Correct use ............................................ 7
Implied warranty ................................... 7
Stored data ............................................ 8
Qualified specialist workshop .............. 9
Further applicable documents ............. 9
6 Genuine Mercedes-Benz parts
Engine system Please contact any MTU or MTU-authorised

Mercedes-Benz Service Centre if you have
The 4R 1000 and 6R 1000 series of engines any questions about equipment and opera-
Introduction
only function as intended when used in con- tion (see addresses in the publication details
junction with the corresponding exhaust gas on the inside of the back cover).
aftertreatment unit. Therefore, in these Oper-
ating Instructions, the term "engine system"
refers to the engine and the exhaust gas after- Genuine Mercedes-Benz parts
treatment unit.
Daimler AG also supplies reconditioned
Protection of the environment assemblies and parts which are of the same
quality as new parts. For these, the same war-
H Environmental note ranty applies as for new parts.
Daimler AG has a declared policy of compre-
hensive environmental protection. If you use parts which have not been
approved by Mercedes-Benz, the operational
The objectives are to use the natural resour-
safety of the engine system may be jeopar-
ces which form the basis of our existence on
dised. This could lead to malfunctions in
this planet sparingly and in a manner which
safety-relevant systems. Use only genuine
takes the requirements of both nature and
Mercedes-Benz parts or parts of equal qual-
humanity into account.
ity. Only use parts that have been approved
You too can help to protect the environment for your engine type.
by operating your vehicle in an environmen-
Mercedes-Benz checks genuine Mercedes-
tally responsible manner.
Benz parts for:
Information and notes on driving in an envi- Rreliability
ronmentally responsible and fuel-saving man- Rsafety
ner can be found in the "Operating notes" Rsuitability
section (Y page 47).
Despite ongoing market research, Mercedes-
Benz is unable to assess other parts.
Assembly equipment Mercedes-Benz therefore accepts no respon-
sibility for the use of such parts in Mercedes-
Benz vehicles, even if they have been officially
These Operating Instructions describe all
approved or independently approved by a
models and all standard and optional equip-
testing centre.
ment available for your engine system at the
time of publication of the Operating Instruc- In Germany, certain parts are only officially
tions. Country-specific deviations are possi- approved for installation or modification if
ble. Note that your engine system may not be they comply with legal requirements. This
fitted with all features described. This also also applies to some other countries. All gen-
applies to safety-relevant systems and func- uine Mercedes-Benz parts meet the approval
tions. Therefore, the equipment on your requirements. The use of non-approved parts
engine system may differ from certain may invalidate the vehicle general operating
descriptions and illustrations. permit.
All of the components in your engine system
are listed in the data card of your engine sys-
tem. Data card (Y page 78).
Implied warranty 7
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 general automatically implemented after an appraisal
Introduction
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 39).
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 any play.
MTU or MTU-authorised Mercedes-Benz Ser- Rthe system switches to a suitable backup
vice Centre (Y page 9). function for the continued, albeit restric-
Always specify the assembly system ID num- ted, operation of the engine. This includes
ber (AGS ID), the engine number and the torque and engine speed limitation, for
number of the exhaust gas aftertreatment example, as well as road speed limitation or
unit when ordering genuine Mercedes-Benz constant emergency running speed.
parts. You can find the engine number on the
identification plate of your engine. You can
find the number of the exhaust gas aftertreat- Correct use
ment unit on the identification plate of the
exhaust gas aftertreatment control module The engine system may only be installed as
(ACM) (Y page 78). You can also find the contractually specified.
two numbers on the data card (Y page 78). The manufacturer of the end product is
responsible for the correct installation of the
engine and the exhaust gas aftertreatment
Modifying the engine output system in the overall system.
The engine and the exhaust gas aftertreat-
! Increased power could: ment system may not be modified. If the
Rchange emission levels engine is modified, Mercedes-Benz and MTU
do not accept responsibility for any damage
Rcause malfunctions arising as a result.
Rlead to consequential damage
Correct use of the engine system also
The operating safety of the engine cannot requires adherence to the instructions in
be guaranteed in all situations. these Operating Instructions. This also
Any tampering with the engine management requires compliance with the maintenance
system in order to increase the engine power intervals and the professional execution of
output will lead to a loss of warranty entitle- maintenance work. Please observe the Work-
ments. shop Information System (WIS) (Y page 9).
Safety/emergency running program Implied warranty
The engine is equipped with an electronic A well-developed network of MTU or MTU-

engine management system that monitors authorised Mercedes-Benz Service Centres is
the engine and the exhaust gas aftertreat- available to carry out maintenance work.
ment unit and has a self-diagnostic system.
Z
8 Stored data
These MTU or MTU-authorised Mercedes- If there are legal requirements on emission

Benz Service Centres: control, please note that:
Rhave special equipment and tools as well as Rmaintenance on the engines must be car-
Introduction
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 MTU or MTU-authorised Mercedes-Benz
ranty Service Centres are familiar with the relevant
Rcarry out all maintenance work expertly 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 MTU or MTU-authorised Mercedes-Benz Ser-
Please observe the instructions and recom- vice 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/
device. This is the only way to ensure that you Several of the electronic components in your
do not lose 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/device status messages and
an MTU or MTU-authorised Mercedes-Benz those of its individual components, e.g.
Service Centre. In particular, work relevant speed, deceleration in movement, acceler-
to safety or on safety-related systems must ator position
be carried out by a qualified specialist Rmalfunctions and defects in important sys-
workshop. tem components
Rthe vehicle/device reactions and operating
statuses in special driving situations
Rambient conditions, e.g. outside tempera-
ture
Further applicable documents 9
This data is exclusively technical in nature Further applicable documents

and can be used to:
Rassist in the detection and rectification of These operating instructions describe all
Introduction
faults and defects models and all standard and optional equip-
Ranalyse vehicle functions, e.g. after an acci- ment available for your engine system within
dent the scope of delivery of Daimler AG. The
installation of the engine system into the vehi-
The data cannot be used to trace the vehicle's
cle/device may require additional operating
movements.
instructions adapted to the vehicle/device
When you use one of the available services, and the appropriate use thereof. These addi-
technical information may be read from the tional operating instructions will be provided
event data memory and fault data memory. by the vehicle/device manufacturer (manu-
Services include, for example: facturer of the end product). The additional
Rrepair services operating instructions will describe, in partic-
Rservice
ular, the functions specific to the installation
processes
and operation, the use of such functions as
Rimplied warranty and guarantee cases
well as warning and control mechanisms.
Rquality assurance
To use the engine correctly, you also require
The information is read out by employees of the Maintenance Booklet.
the service network (including manufactur- For US-certified off-highway engines you also
ers) using special diagnostic testers. Further require the "Emission Warranty" supplement.
information is available there if required.
Always keep these documents together with
After a fault has been rectified, the informa- the engine, vehicle or device. These docu-
tion is deleted from the fault memory or is ments should be passed on to the new owner
continually overwritten. if you sell the engine, vehicle or device.
When carrying out maintenance work, you
Qualified specialist workshop require access to the Workshop Information
System (WIS) via the Internet. This access is
subject to a fee.
A qualified specialist workshop has the nec-
essary specialist knowledge, tools and quali- Current information on the system and prices
fications to carry out the work required on the can be found at this web address: http://
engine to a professional standard. This is par- service-parts.mercedes-benz.com. Click on
ticularly applicable to work relevant to safety. "EPC, WIS/ASRA" in the "Service and parts
information" tab and then on "WIS".
Observe the notes in the Maintenance Book-
let. You can log in by clicking on "Register" on the
right-hand side.
Always have the following maintenance work
carried out at a qualified specialist workshop:
Rwork relevant to safety
Rservice and maintenance work
Rrepair work
Rmodifications as well as installations and
conversions
Rwork on electronic components
Please consult an MTU or MTU-authorised
Mercedes-Benz partner.
Z
10
11
General information ............................ 12

Engine overview .................................. 13
Exhaust gas aftertreatment over-
view ...................................................... 17
Electronic engine management ......... 18
At a glance
BlueTec® exhaust gas aftertreat-
ment ..................................................... 20
Exhaust gas recirculation ................... 20
Warning and indicator lamps ............. 20
12 General information
General information
The engine is a four-stroke, water-cooled die-

sel engine with direct injection.
The engine is equipped with a common rail
At a glance
diesel injection system, cooled and regulated

exhaust gas recirculation and turbocharging
with charge-air pressure control.
Depending on the engine output, engine tur-
bocharging is either by means of single-stage
exhaust turbocharging or two stage exhaust
gas turbocharging with two sequential
exhaust gas turbochargers of differing dimen-
sions.
The valve gear has two camshafts at the top,
which are driven via a gearwheel drive.
The engine features a single-piece cylinder
head. In the cylinder head there are two inlet
valves and two exhaust valves per cylinder.
The valves are arranged symmetrically. The
symmetrical valve arrangement is optimal for
combustion.
The exhaust gas aftertreatment unit is char-
acterised by the following technologies:
Rselective catalytic reduction (SCR) with
ammonia slip catalytic converter
Rthe diesel oxidation catalytic converter
(DOC)
The engine brake is a decompression brake. It
has a controlled exhaust valve which gives it
high braking power. The engine brake is con-
trollable in steps or modulated.
Engine overview 13
Engine overview
At a glance
Engine overview: 4R 1000 with single-stage charging
: Exhaust gas recirculation positioner
; Rail
= Fuel filter
? External engine start/engine stop button
A High-pressure fuel pump
B Engine management control module (MCM)
C Dipstick
D Air compressor
E Power-steering pump
F Oil pan
G Charge-air pipe (cold)
14
At a glance Engine overview
Engine overview: 4R 1000 with single-stage charging

: Crankcase ventilation system
; Exhaust gas recirculation pipe (cold)
= Refrigerant compressor
? Coolant thermostat
A Combined oil filter/oil cooler module with coolant pump
B Oil pan
C Starter motor
D Exhaust pipe to exhaust gas aftertreatment unit
E Exhaust gas turbocharger
F Exhaust gas recirculation cooler
Engine overview 15
At a glance
Engine overview: 6R 1000 with two-stage charging
: Refrigerant compressor
; Exhaust gas recirculation positioner
= Rail
? Fuel filter
A External engine start/engine stop button
B Engine management control module (MCM)
C Dipstick
D Air compressor
E Power-steering pump
F Alternator
G Oil pan
16
At a glance Engine overview
Engine overview: 6R 1000 with two-stage charging

: Crankcase ventilation system
; Exhaust gas recirculation pipe (cold)
? Combined oil filter/oil cooler module with coolant pump
A Oil pan
B Starter motor
C Low pressure exhaust gas turbocharger
D Exhaust pipe to exhaust gas aftertreatment unit
E High pressure exhaust gas turbocharger
F Power take-off (PTO)
G Boost pressure positioner
H Exhaust gas recirculation cooler
Exhaust gas aftertreatment overview 17
Exhaust gas aftertreatment 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
18
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
Electronic engine management In addition to the engine, the exhaust gas

aftertreatment and the connection on the
The engine system is equipped with an elec- vehicle/device, the electronic engine man-
tronic engine management system which agement system also monitors itself.
comprises the following control units: Depending on the malfunctions/failures
REngine management control module which occur, warning and information dis-
(MCM) plays are activated (Y page 20). The mal-
function is stored in the fault memory and if
RDrive control system unit (CPC)
necessary a safety and emergency mode is
RExhaust gas aftertreatment control unit
automatically selected (Y page 36). If the
(ACM) electronic engine management control
The control units are connected in an elec- detects a fault, the fault code is stored in the
tronic network. Data is exchanged via CAN control units. It can then be read by a qualified
(Controller Area Network). specialist workshop (Y page 9) using a diag-
nostic tester.
Electronic engine management 19
Engine management control module Drive control system unit (CPC)

(MCM)
The drive control system unit (CPC) is instal-
The engine management control module led in a protected location in the vehicle/
(MCM) is located on the side of the engine. It device by the vehicle/device manufacturer. It
acts as an interface between the electric and acts as an interface between the electric and
At a glance
electronic components on the engine/vehi- electronic components on the vehicle/device
cle and the drive control system unit (CPC) on and the engine management control module
the vehicle. (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 serves to protect the nection.
engine, is 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 engine management control module REvaluation of start request

(MCM) controls the engine brake as The engine starting process is initiated
required by the drive control system unit once a corresponding start request is pres-
(CPC). ent (ignition lock or external engine start/
RFan regulation engine stop button).
In optional fan regulation, the solenoid
valve on the fan clutch is activated accord-
ing to coolant temperature. Exhaust gas aftertreatment control
unit (ACM)
RInstrument cluster display
The engine management control module The exhaust gas aftertreatment control mod-
(MCM) detects the oil level, engine oil tem- ule (ACM) is installed in a protected location
perature, oil pressure, coolant temperature in the vehicle/device by the vehicle/device
and the engine speed for the displays in the manufacturer. It regulates and controls the
instrument cluster. exhaust gas aftertreatment system.
20 Warning and indicator lamps
Functions of the exhaust gas aftertreatment Exhaust gas recirculation

control unit (ACM):
REvaluation of sensor signals Exhaust gas recirculation (EGR) serves pri-
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
serves to comply with emissions limits.
At a glance
via the CAN by the engine management

control module (MCM) and the control Exhaust gas is added to the fresh air being
units for the NOx sensors is also evaluated. drawn in or charged so that the concentration
RAdBlue®/DEF injection of oxygen in the combustion mixture is
reduced. Combustion deteriorates if the con-
Calculation of the required amount of centration of exhaust gas in the combustion
AdBlue®/DEF and supply of AdBlue®/DEF mixture is too high. The emission of soot par-
by actuation of the SCR delivery pump. ticles, carbon monoxide (CO) and hydrocar-
Injection by actuation of the AdBlue®/DEF bons (HC) increases. Conversely, the emis-
metering unit. sion of nitrogen oxides (NOx) would increase,
if the concentration of fresh or charged air
was too high.
BlueTec® exhaust gas aftertreatment
The exhaust gas aftertreatment system is Warning and indicator lamps

activated immediately after the engine is star-
Important safety notes
ted and remains activated during engine
operation. It ensures that the pollutant emis- If you ignore warning and indicator lamps, you
sions in the exhaust gas are reduced to the will not be able to recognise failures and mal-
limits stipulated in the emissions standard. functions in components or systems. Driv-
Exhaust gas treatment is carried out by: ing/braking characteristics may be different
and the operating and road safety of your
Rselective catalytic reduction (SCR) with
vehicle/device may be limited. Have the
ammonia slip catalytic converter
affected system checked and repaired at a
Rthe diesel oxidation catalytic converter
qualified specialist workshop. Always
(DOC) observe the warning and indicator lamps and
In order to ensure correct operation of the follow the corresponding corrective actions
exhaust gas aftertreatment system, only (Y page 39).
operate the engine/vehicle with the AdBlue®
reducing agent. AdBlue® is not refilled as part
of the maintenance work. You should there- Overview
fore top up the AdBlue® tank regularly your- The display format for indicator and warning
self. lights is vehicle-specific/device-specific.
Operating the vehicle or device without Please observe the information contained in
AdBlue® or with another medium that has not the device/vehicle operating instructions.
been approved by Mercedes-Benz or MTU The symbols listed below are examples and
invalidates the engine's operating permit or may differ from those symbols displayed in
certification. the vehicle/device.
In the event of a fault or warning, a warning
lamp or indicator lamp lights up automati-
cally. Depending on the priority of the fault or
Warning and indicator lamps 21
warning, the warning and indicator lamps

light up in different combinations.
The following warning and indicator lamps
may be available on the instrument panel:
Indicator Description
At a glance
lamp
red Engine stop
Ù Engine system malfunction

· Emissions-relevant malfunc-
tion of the exhaust gas after-
treatment system or
AdBlue®/DEF supply
(lit Torque operating restriction

constantly)
(flash- Torque and engine speed

ing) operating restriction
# Charge current
Ø AdBlue®/DEF reserve level
(optional)
5 Oil pressure too low (engine)
(optional)
4 Oil level too low or too high
(optional) (engine)
, Coolant level too low

(optional)
? Coolant temperature too
(optional) high
Ã Continuous brake active

(optional)
é Cruise control
(optional)
È Speed limiter
(optional)
I Power take-off engaged
(optional)
22
23
Operating safety ................................. 24

Safety precautions .............................. 24
Notes on electronic systems ............. 24
Staff qualifications .............................. 25
Organisational measures ................... 25
Safety
24 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-
ried out, this could result in malfunctions or trical system is switched off.
system failures. There is a risk of an accident. RIncorrect control unit-power supply
Always have the prescribed service/mainte- polarity (e.g. by connecting up the bat-
Safety
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 25
safety of the vehicle. There is an increased Staff qualifications

risk of an accident and injury.
Do not attempt to modify the wiring as well as G WARNING
electronic components or their software. If you do not have the prescribed service/
Always have work on electrical and electronic maintenance work or necessary repairs car-
components carried out at a qualified special- ried out, this could result in malfunctions or
ist workshop. system failures. There is a risk of an accident.
Always have the prescribed service/mainte-
Safety
The general operating permit for your vehi-
nance work as well as necessary repairs car-
cle/equipment could be rendered invalid if
ried out at a qualified specialist workshop.
you carry out modifications to electronic
components, their software or their wiring. The engine should only be operated, main-
tained and repaired by trained personnel who
have been briefed and authorised by the oper-
Electromagnetic compatibility ator. The prescribed minimum legal age for
The electromagnetic compatibility of the personnel carrying out maintenance and
engine system's components has been repair work must be observed.
checked and certified according to the cur-
rently valid version of Directive ECE-R 10.
Organisational measures
Diagnostics connection The operator must determine the responsi-

bilities for operation, maintenance and
The diagnostics connection is used for con-
repairs. Give the Operating Instructions and
necting diagnostic equipment at a qualified
the Maintenance Booklet to the personnel
specialist workshop.
that are charged with operating or carrying
G WARNING out work on the engine.
If you connect equipment to a diagnostics Instruct personnel on how to operate the
connection in the vehicle, it can affect the engine using the Operating Instructions.
operation of the vehicle systems. This may When doing so, put special emphasis on
affect the operating safety of the vehicle. safety-relevant information. This is particu-
There is a risk of an accident. larly important for personnel that only work
Do not connect any equipment to a diagnos- occasionally on the engine.
tics connection in the vehicle. Always keep the Operating Instructions and
the Maintenance Booklet readily accessible,
If the engine is switched off and devices con- in the area of engine operation.
nected to the diagnostics connection are In addition to the Operating Instructions,
being used, the starter battery can become other general, country-specific, legal and
discharged. other binding regulations on accident preven-
Connecting devices to the diagnostics con- tion and environmental protection must be
nection can, for example, cause the emis- adhered to.
sions monitoring information to be reset. As a Please also observe the information in the
result, there is a possibility that the vehicle/ additional operating instructions. These will
equipment will not fulfil the requirements of be provided by the device/vehicle manufac-
the next legally prescribed emissions test. turer.
Z
26
27
Transport ............................................. 28
Installation ........................................... 28
Transport, installation
28 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,
causing serious or even fatal injury.
Always make sure that:
Rthe engine is only lifted at the intended lift- Example: using a cross member
ing points/lifting lugs. The engine may only be lifted using a cross
Rthe engine is only lifted and transported in member with the chain/rope at 90° relative
the fitting position. to the horizontal engine.
Rropes/chains are always routed vertically.
Ronly parts which are typically in the original
scope of delivery are attached to the
engine.
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: belt-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.
! The engines are by default delivered filled

with oil. If the engine is transported at an
angle or on its side, oil could leak out. Only
transport the engine in the installation posi-
tion.
; Example: flywheel-side lifting point
! Do not stand on the engine or the exhaust
gas aftertreatment unit. They may other-
wise be damaged. Installation
The engine system may only be installed as

contractually specified.
Observe the sections "Correct use" (Y page 7)
and "Modifying the engine output" (Y page 7).
Installation 29
Daimler AG provides the vehicle manufac-

turer with comprehensive material, e.g. the
installation guideline, for initial installation.
The vehicle manufacturer must take this into
account. If the engine is fitted after repair
work, for example, the information in the
Workshop Information System (WIS) must be
observed (Y page 9).
Observe the sections "Qualified specialist
workshop" (Y page 9) and "Further applicable
documents" (Y page 9).
Please consult an MTU or MTU-authorised
Mercedes-Benz Service Centre if you have
any questions.
Z
30
31
Preparation for operation ................... 32

Starting and stopping the engine ...... 34
Switching the continuous brake on
and off .................................................. 35
Idling speed ......................................... 36
Operational monitoring ...................... 36
Displays ............................................... 37
Warning and indicator lamps ............. 39
Operating instructions ....................... 46
Refuelling ............................................. 48
Winter operation ................................. 50
Operation
32 Preparation for operation
Preparation for operation display of the engine oil level is therefore only
possible with the engine switched off and the
Engine with initial operation oil from ignition switched on.
the factory
X Park the vehicle/device on a level surface.
The engine is filled at the factory with an initial X Engage the parking brake.
operation oil. X Switch off the engine.
These high-quality engine oils are beneficial X Wait approximately five to ten minutes. If
to the running-in process. They also allow you you call up the oil level in the engine too
to make the first oil change in accordance early or while the engine is running, it is not
with the applicable oil change intervals. This available.
eliminates the need for special break-in oils
and the additional oil change otherwise Only use engine oil which has been approved
required. for the engine and which meets the specified
Operation
SAE classification (Y page 53).
Checking the engine oil level Checking the oil level with the dipstick
The engine is equipped with an electronic oil ! Do not add too much oil. If you add too
level detection system. much oil, the engine or the exhaust after-
If the engine is also equipped with a dipstick, treatment unit could be damaged. Drain or
this is subsidiary to the electronic oil level siphon off any excess oil.
measurement system. It is merely used for a Check the engine oil level on a regular basis,
general check to determine if there is oil in the e.g. before each journey or each time you
engine. refuel.
X Park the vehicle/device on a level surface.
Electronic oil level measurement – sys-
X Engage the parking brake.
tem description
X Switch off the engine.
The engine oil level sensor is installed in the X Wait approximately five to ten minutes.
oil pan for oil level measurement. The electri-
cal signals are detected in the engine man-
agement control module (MCM) and trans-
mitted to the drive control system control unit
(ADM) via the engine CAN.
Output can be displayed on a matrix display
when the engine is not running.
Checking the oil level electronically

Check the engine oil level on a regular basis,
e.g. before each journey or each time you
refuel.
Make sure that you also observe the notes in
the vehicle/device manufacturer's operating
instructions.
The current oil level in the engine is only dis-
played once the engine is switched off and
with the ignition switched on. An accurate
Preparation for operation 33
X Check the engine oil level with dipstick ;.

The oil level should be between the upper
and lower marks on dipstick ;.
X If necessary, use filler neck : to top up the
oil.
Only use engine oil which has been approved
for the engine and which meets the specified
SAE classification (Y page 53).
Checking the coolant level

Example: fuel prefilter on the chassis frame
X Check the coolant level as stated in the Function Page
Operation
vehicle/device operating instructions.
X Fill the cooling system if necessary. Only 1 Fuel prefilter
use coolant that has been approved for the
2 Drain plug
engine (Y page 55).
3 Inspection window
4 Manual fuel pump
Checking the fuel level
For checking the fuel level on the fuel gauge, 5 Bleed screw
see the vehicle operating instructions. Refuel
if necessary (Y page 56). If water has collected in inspection window
=, drain fuel prefilter : on the chassis
frame.
Checking the water level in the fuel Drain fuel prefilter : on the chassis frame
prefilter on the chassis frame when necessary; if there is a danger of frost,
do this on a regular basis.
Draining the fuel prefilter on the chassis
Dispose of the water-fuel mixture in an envi-
frame
ronmentally responsible manner.
RPlace a collector under drain plug ;.
RUnscrew drain plug ;.
RPress manual fuel pump ? and collect the
fuel/water mixture.
RTighten drain plug ;.
Checking the AdBlue®/DEF supply

For checking the AdBlue®/DEF supply on the
AdBlue®/DEF gauge, see the vehicle operat-
ing instructions. Refuel if necessary
(Y page 49).
Z
34 Starting and stopping the engine
Starting and stopping the engine Starting the engine with the key
Starting the engine ! After starting the engine, let it run at
engine idling speed until the oil pressure is
G WARNING displayed. If no oil pressure is displayed
Combustion engines emit poisonous exhaust after approximately 10 seconds, switch off
gases such as carbon monoxide. Inhaling the engine. Determine the cause. The oper-
these exhaust gases leads to poisoning. There ating safety of the engine is jeopardised.
is a risk of fatal injury. Therefore never leave
the engine running in enclosed spaces with-
out sufficient ventilation.
! If the oil pressure in the engine is too low,

a warning light lights up on the instrument
Operation
panel. The warning buzzer also sounds.

The operating safety of the engine is jeop-
ardised. Switch off the engine immediately.
! Do not pull away as soon as the engine
starts. Let the engine run in neutral for a
Example: ignition lock
short time after starting, until there is suf-
g To insert/remove the vehicle key
ficient engine oil pressure. Do not drive at
high engine speeds when the engine is 1 Steering wheel unlocked/radio position
cold. 2 Drive position (ignition)
This will prevent excessive wear and pos- 3 Start position
sible engine failure. X Secure the vehicle/device against rolling
Warm up the engine quickly by driving at away.
moderate engine speeds. Depending on the X Deactivate power take-off.
outside temperature, the engine will reach its X Shift into neutral.
operating temperature after approximately X To start the engine: turn the key in the
10 to 20 minutes (Y page 80). ignition lock to drive position 2.
You can utilise the full engine power output X Turn the key to start position 3 in the igni-
once the engine has reached its normal oper- tion lock. Do not depress the accelerator
ating temperature. pedal whilst doing so.
The display format for indicator and warning X When the engine has started, release the
lights is vehicle-specific/device-specific. key.
Please also observe the information in the The idling speed is controlled automati-
additional operating instructions. These will cally.
be provided by the vehicle/device manufac-
turer. i The engine idling speed is raised at very
low outside temperatures.
For additional safety, the electronic engine
X If the engine does not start immedi-
management system is equipped with a func-
ately: interrupt the starting procedure
tion that only allows the engine to be started
when the transmission is in neutral (vehicle- after no more than 30 seconds.
specific/device-specific). X Turn the key in the ignition lock back to the
stop at key position g.
Switching the continuous brake on and off 35
X Repeat the starting procedure after a wait- Rthe coolant or engine oil temperature
ing period of approximately 1 minute. rises steeply.
X If the engine fails to start: rectify the cause Rabnormal noises suddenly come from
of the poor starting characteristics the engine or exhaust gas turbocharger.
(Y page 71). X Park the vehicle/equipment.
X Observe the oil pressure gauge immedi-
X Secure the vehicle/device against rolling
ately after having started the engine. away.
X Shift the transmission into neutral/decou-
Starting the engine with the external ple the drive system.
engine start/engine stop button
Let the engine idle for approximately two
X To start the engine with the external minutes before switching off the engine if:
engine start/engine stop button:
Rthe coolant temperature is very high (over
Operation
(Y page 66).
100 †).
Rthe engine has been operated at full output.
Stopping the engine X To switch off the engine: turn the vehicle
key in the ignition lock back to the stop at
G WARNING position u.
When switching off the equipment or parking
the vehicle, make sure that the exhaust sys- i If you switch off the engine, the system
tem does not come into contact with com- may continue to run for a short while.
bustible objects, e.g. dry leaves, grass or Depending on the installation position,
other highly flammable materials. operating state and ambient temperature,
circulation of AdBlue®/DEF is necessary
G WARNING for ensuring cooling. To do this the
If you switch off the ignition while the vehicle AdBlue®/DEF delivery pump is actuated
is in motion, safety-relevant functions are during this period.
restricted or not available. This can affect the
power steering function and the brake boost- Switching off the engine with the exter-
ing effect, for example. You will then require nal engine start/engine stop button
considerably more force to steer and brake. X Switch off the engine with the external
There is a risk of an accident. engine start/engine stop button:
Do not switch off the ignition while the vehicle (Y page 66).
is in motion.
! Stop the engine immediately, paying Switching the continuous brake on

attention to the road and traffic conditions and off
if:
Rthe oil pressure falls or fluctuates signif-
G WARNING
icantly.
If you activate the continuous brake or shift to
Rthe power output or engine speed
a lower gear on a slippery road surface in
decreases and the position of the posi- order to increase the engine's braking effect,
tion sensor (accelerator) remains con- the drive wheels may lose traction. There is an
stant. increased risk of skidding and an accident.
Rheavy smoke is emitted from the
exhaust.
Z
36 Operational monitoring
Do not activate the continuous brake and do Retarder

not shift to a lower gear in order to increase
Operation of the retarder; see the vehicle/
the engine's braking effect on a slippery road
device Operating Instructions.
surface.
The engine brake and retarder are used as a

continuous brake. Idling speed
You can utilise the engine's braking effect,
After the engine has been started, idling
particularly on long downhill gradients if you:
speed is regulated automatically. The engine
Ractivate the continuous brake idling speed may differ in certain operating
Rshift to a lower gear in good time conditions depending on the engine or on
Slowly depress the brake pedal if the engine's vehicles with power take-off.
braking effect is insufficient when driving You can set the idling speed to between
Operation
downhill. approximately 600 and 800 rpm.

Vehicles without a retarder are equipped with The engine idling speed is raised at very low
only two brake stages. outside temperatures.
Operation of the continuous brake (see the You can set the speed to the working speed
vehicle/device operating instructions). via the electronic engine management sys-
The Ã indicator lamp in the instrument tem. This makes it possible to drive auxiliary
cluster is lit when the continuous brake is equipment such as pumps at their working
active. speed. For setting the working speed, see the
vehicle operating instructions.
When ABS (Anti-lock Braking System) inter-
venes, the continuous brake is switched off.
The Ã indicator lamp in the instrument
Operational monitoring
cluster remains on.
Charge current
Engine brake The charge current indicator lamp must go

out after the engine has started.
The effectiveness of the engine brake If the # indicator lamp does not go off or
depends on the engine speed. A high engine lights up when the engine is running, switch
speed results in more effective engine brak- off the engine. Searching for and eliminating
ing. the cause of the malfunction (Y page 71).
Observe the effective engine braking range
marked on the rev counter (Y page 37).
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-
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 71).
cle/device Operating Instructions).
Displays 37
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. When the final operating restriction (idling
Fault codes can be read by a qualified spe- speed and 20% of torque) has been reached,
cialist workshop using a diagnostic tester the push-button switch is deactivated.
(Y page 7).
Displays
Oil pressure
Rev counter
If the 1 indicator lamp does not go out or
if it lights up when the engine is running, ! If you exceed the maximum permissible
switch off the engine. Searching for and elim- engine speed, the warning tone sounds.
inating the cause of the malfunction You should not drive and change gear by
Operation
(Y page 71). the sound of the engine, but according to
the engine speed shown in the rev counter.
Avoid driving in the red overrevving range.
Operating restrictions This could lead to engine damage.
The electronic engine management system The engine speed display is the responsibility
monitors: of the vehicle manufacturer and is not nec-
Remissions-relevant malfunctions in the essarily supplied by Mercedes-Benz. Daimler
exhaust gas aftertreatment AG recommends that the vehicle manufac-
turer uses a rev counter divided by:
Rmalfunctions in the electronic monitoring
of the exhaust gas aftertreatment system Roperational efficiency
Rconsumption, level and quality of the Rengine braking range
AdBlue®/DEF reducing agent Rengine overrevving range
Rthe efficiency of the catalytic converter in General notes on the rev counter:
accordance with the permitted thresholds RKeep an eye on the rev counter while driv-
for nitric oxide emissions (NOx) ing and stay within the economical operat-
Operating restrictions in the form of torque ing range.
reduction and thus output and speed limita- In some situations it may make sense to
tion may occur. operate the engine outside the economical
engine speed range, e.g. on uphill gradients
or when overtaking.
Emergency switch for overriding RIf you run the engine within the economical
operating restrictions
engine speed range, you achieve low fuel
If an emissions-relevant malfunction in the consumption and reduced wear.
exhaust gas aftertreatment or the RIn engine braking mode, drive in the middle
AdBlue®/DEF supply is detected, this can engine speed range. The highest engine
cause an operating restriction (limitation of braking effect will be achieved just before
engine torque and engine speed). the red overrevving range.
In case of emergency a push-button switch RWhen driving downhill, make sure that the
can be operated to override the operating engine speed does not enter the overrev-
restriction. This means that full engine power ving range (marked red).
is available for a maximum of 30 minutes. This
Z
38 Displays
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
Operation
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 is operated without
AdBlue®/DEF. The legal consequence of this
is that the vehicle 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
panel. Top up the AdBlue®/DEF tank in good
time (Y page 49).
If the display is ignored and the AdBlue®/DEF
level drops further, engine torque and engine
speed may be reduced (Y page 36).
The engine torque can be limited to a maxi-
mum of 20% across the whole engine speed
range. The engine speed can be limited to
idling speed.

Warning and indicator lamps – causes/consequences and solutions
The display format for indicator and warning lights is vehicle-specific/device-specific. Please
observe the information contained in the device/vehicle operating instructions. The symbols
listed below are examples and may differ from those symbols displayed in the vehicle/device.
Depending on the priority of the fault or warning, the warning and indicator lamps light up in
different combinations.
Problem Possible causes/consequences and M Solutions

The r indicator A serious fault in the engine system has been detected.
Operation
lamp flashes red. X Immediately stop the vehicle/device while paying attention to
the traffic conditions and contact a qualified specialist work-
shop.
The Ù indicator Impermissible operating conditions have been detected in the

lamp lights up. engine system.
One of the following systems is malfunctioning:
REngine
REngine cooling
REngine management
RDiesel injection system
X If further indicator lamps are displayed, take the combination of

lamps (see below) into account when evaluating the cause.
X Have the systems checked at a qualified specialist workshop.
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 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
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 32).
X If this does not help, have the malfunction rectified at a qualified
Z

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
X Check the engine oil level (Y page 32).
The + indicator A malfunction in the coolant circuit has been detected. The coolant
Operation
lamp lights up. level is too low.

X Check coolant level.
The ? indicator A malfunction in the coolant circuit has been detected. The coolant
lamp lights up. temperature is too high.
X Check coolant level.
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.
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.
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.
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.
the power take-off is switched off.
Only vehicles/devices with the AdBlue®/DEF reserve warning light

If a malfunction is detected and the listed indicator lamps light up, a warning buzzer sounds for
approximately 5 seconds. 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 37).
Z

Indicator lamps Ø The AdBlue®/DEF level has dropped to approximately 7.5%.
and are lit and Reduced engine output is active. The engine torque is limited to a
· flashes. 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 Top up the AdBlue®/DEF tank immediately.
If you do not follow the instructions, an engine speed limitation

may be imposed.
The Ø indicator The AdBlue®/DEF level has dropped to approximately 5%. The
lamp is lit and · and reduction in engine output and limitation of the engine torque are
Operation
are flashing. 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.
If you do not observe the instructions, engine torque and engine

speed may be further reduced.
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.
The Ø, ·, The AdBlue®/DEF level has dropped to approximately 0%. The

and indicator reduction in engine output and limitation of the engine torque are
lamps are flashing. activated. The engine torque is limited to a maximum of 20%
to idling speed. The limitation takes effect by means of a ramp
function.
X Stop the vehicle/device, paying attention to road and traffic
conditions.

The · indicator An emissions-relevant malfunction in the exhaust gas aftertreat-
lamp lights up. ment system or in the AdBlue® supply has been detected.
X Have the exhaust gas aftertreatment system checked at a quali-
fied specialist workshop. Have the malfunction rectified imme-
diately. If you do not, engine output may be reduced and engine
speed may be limited.
If there are no malfunctions, the indicator lamp only goes out after
further test routines. The system check may involve several engine
starts, several hours or several journeys without a malfunction.
The indicator lamp You have not rectified an emissions-relevant malfunction that has
Operation
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 Drive carefully to the nearest qualified specialist workshop and
have the malfunction rectified immediately.
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. 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%
ramp function.
X Drive carefully to the nearest qualified specialist workshop and
have the malfunction rectified immediately.
may be imposed.
Z
The and · indi- You have not rectified an emissions-relevant malfunction that has
®
ing and lights up. AdBlue /DEF supply.
to idling speed.
shop.
Operation
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.
maximum of 20% across the whole engine speed range. The engine
speed is limited to idling speed.
conditions.
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.
Only vehicles/devices without the AdBlue®/DEF reserve warning light

If a malfunction is detected and the listed indicator lamps light up, a warning buzzer sounds for
approximately 5 seconds. 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 37).

The · indicator An emissions-relevant malfunction in the exhaust gas aftertreat-
lamp lights up. ment system or in the AdBlue®/DEF supply has been detected.
X If this does not help: have the exhaust gas aftertreatment sys-
tem checked at a qualified specialist workshop. Have the mal-
function rectified immediately. If you do not, engine output may
be reduced and engine speed may be limited.
If there are no malfunctions, the indicator lamp only goes out after
further test routines. The system check may involve several engine
starts, several hours or several journeys without a malfunction.
Operation
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.
maximum of 75% across the whole engine speed range. The limi-
tation will take effect the next time the engine is started.
may be imposed.
The · and indi- You have not rectified an emissions-relevant malfunction that has
ing. AdBlue®/DEF supply.
ramp function.
may be imposed.
Z
46 Operating instructions
The · and indi- You have not rectified an emissions-relevant malfunction that has
®
ing and lights up. AdBlue /DEF supply.
to idling speed.
Operation
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.
to idling speed.
conditions.
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.
Operating instructions Observe the following notes during the run-

ning-in period up to 2,000 km (30 operating
Running-in hours):
The running-in period of the engine has a sig- Ravoid subjecting the engine to full load.
nificant effect on the vehicle/equipment, Rrun in the engine with care, using differing
especially with regard to: speeds and engine revs.
Rservice
life Ravoid high engine speeds.
Roperatingsafety Rdo not drive at more than ¾ of the maxi-
Reconomy mum road speed for each gear.
Rchange gear in good time.
Operating instructions 47
Rdo not shift down to brake the vehicle. Fuel type

Rfor vehicles with automatic transmission, The fuel grade also affects fuel consumption.
do not depress the accelerator pedal Use of lower fuel grades and/or non-
beyond the point of resistance (kickdown). 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/equipment up to are filling the appropriate fuel grade
full output and increased engine speeds. (Y page 56).
Fuel consumption AdBlue®/DEF consumption

General notes AdBlue® consumption is between 2 and 4% of
Fuel consumption depends on: the fuel consumption, depending on engine
Operation
use.
Rthe machine version/vehicle version
Rthe operating conditions
Rthe attached equipment (e.g. hydraulic Engine oil consumption
pumps, mowers, etc.) After running-in the engine, oil consumption
Rmaintenance may reach 0.2% of the vehicle's fuel con-
Rdriving resistance sumption.
Ryour driving style More arduous operating conditions and
For these reasons, exact details about any increased distance covered could result in
single engine's fuel consumption cannot be engines exceeding this oil consumption
provided. value.
Machine version/vehicle version

Warning buzzer
The following components affect fuel con-
sumption: If the warning buzzer sounds and the 5
symbol on the instrument panel is displayed,
Rtyres (e.g. tyre pressure, tyre condition) the engine's operating safety is jeopardised.
Rbody type Do not pull away, or stop the vehicle as soon
Rdrive train (e.g. transmission ratio) as possible, paying attention to road and traf-
Radditional equipment (e.g. automatic cli- fic conditions. You could otherwise damage
mate control, auxiliary heating) the engine.
The warning buzzer sounds depending on the
Maintenance vehicle if:
Fuel consumption and assembly wear depend Ryou exceed the maximum permissible
on how often maintenance is carried out. Reg- engine speed.
ular maintenance increases safety and lowers Rthe engine speed or vehicle speed is too
fuel consumption. Keep to the maintenance high when changing gears.
intervals. Always have maintenance work car- Rthe coolant level is too low or the maximum
ried out at a qualified specialist workshop. permissible coolant temperature
Z
48 Refuelling
(Y page 80) is exceeded. The operating components in the exhaust system may over-
safety of the engine is jeopardised. heat unnoticed. There is a risk of fire.
Ran emissions-relevant fault is detected or Never refuel with petrol. Never add petrol to
there is an operating restriction due to an diesel fuel.
emissions-relevant malfunction.
! Only refuel using commercially available,
sulphur-free diesel fuel that complies with
Refuelling the following standards:
Fuels REN 590 as of 2010, et seq. (max. 0.001%
sulphur by weight) (10 ppm) or
Important safety notes RASTM D975 (max. 0.0015% sulphur by
G WARNING weight) (15 ppm).
Operation
Fuels are poisonous and hazardous to health. The following fuel types are not permitted:
There is a danger of injury. Rsulphurous fuel with a sulphur content
Do not swallow fuel or let it come into contact greater than 0.005% by weight (50 ppm)
with skin, eyes or clothing. Do not inhale fuel Rmarine diesel fuel
vapours. Keep fuels out of the reach of chil- Raviation turbine fuel
dren. Rheating oils
If you or others come into contact with fuel, Rfatty acid methyl ester FAME (bio-diesel
observe the following: fuel)
RWash the fuel off any affected areas of skin These fuel types cause irreversible damage
with water and soap immediately. to the engine and the exhaust gas after-
RIf you get fuel in your eyes, rinse them thor- treatment system, as well as also signifi-
oughly with clean water immediately. Seek cantly reducing the expected service life.
immediate medical attention.
! Do not use petrol to refuel vehicles with a
RIf fuel is swallowed, seek immediate medi-
diesel engine. Even small amounts of petrol
cal attention. Do not induce vomiting. result in damage to the fuel system and
RChange any clothing that has come into engine.
contact with fuel immediately.
! Do not switch on the ignition if you acci-
G WARNING dentally refuel with the wrong fuel. Other-
wise, the fuel will enter the fuel lines. Notify
Fuel is highly flammable. Improper handing of
a qualified specialist workshop and have
fuel creates a risk of fire and explosion.
the fuel tank and fuel lines drained com-
Avoid fire, naked flames, smoking and creat- pletely.
ing sparks under all circumstances. Switch off
the ignition and auxiliary heating before car- ! Do not add any special fuel additives to
rying out work to the fuel system. Always wear the diesel fuel.
protective gloves. Special fuel additives can lead to:
Rmalfunctions
G WARNING Rdamage to the catalytic converter
If you mix diesel fuel with petrol, the flash
Rengine damage
point of this fuel mixture is lower than that of
pure diesel fuel. When the engine is running, ! AdBlue®/DEF is not a fuel additive and
must not be added to the diesel tank. If
Refuelling 49
AdBlue®/DEF gets into the diesel tank, this If AdBlue®/DEF comes into contact with
could lead to engine damage. painted or aluminium surfaces when filling
the tank, rinse the affected area immedi-
! A higher fuel sulphur content accelerates
ately with plenty of water.
the ageing process of the engine oil and can
damage the engine and exhaust system. ! Do not mix additives to AdBlue®/DEF. Do
not dilute AdBlue®/DEF with tap water.
This could destroy the exhaust gas after-
If fuels are handled improperly, they pose a
treatment system.
danger to persons and the environment. Do
not allow fuels to run into the sewage system, ! Always close the AdBlue®/DEF tank
the surface waters, the ground water or into properly. Otherwise impurities may get into
the ground. the exhaust gas aftertreatment system and
damage it.
Operation
Please observe the additional information on
diesel fuels in the "Service products" section ! Make sure that you do not overfill the
(Y page 56). Using fuels which have not AdBlue®/DEF tank. Otherwise, the
been approved causes irreversible damage to AdBlue®/DEF tank could be damaged at
the engine and the exhaust gas aftertreat- very low temperatures.
ment system, as well as also significantly H Environmental note
reducing the expected service life.
Dispose of AdBlue®/DEF in an environmen-
Before filling the tank
! If you are using drums or canisters to When opening the AdBlue®/DEF tank, small
refuel the vehicle, you should filter the fuel amounts of ammonia vapours could escape.
before adding it. Ammonia vapours have a pungent smell and
This will prevent malfunctions in the fuel are particularly irritating to:
system due to contaminated fuel. Rskin
X Switch off the engine. Rmucous membranes
X Secure the vehicle/device against rolling Reyes
away. The vapours may cause a burning sensation in
X Observe the fuel grade (Y page 56). the eyes, nose and throat as well as irritation
Regularly check the fuel prefilter with heated of the throat and watering eyes.
water separator for condensation. Avoid inhaling ammonia vapours. Only fill the
AdBlue®/DEF tank in well-ventilated areas.
AdBlue®/DEF should not come into contact
AdBlue®/DEF with skin, eyes or clothing, and should not be
Important safety notes swallowed. Keep AdBlue®/DEF out of the
reach of children.
! Do not allow diesel fuel to run into the If you come into contact with AdBlue®/DEF,
AdBlue®/DEF tank. You could otherwise observe the following:
damage the exhaust gas aftertreatment
Rimmediately wash AdBlue®/DEF from your
system.
skin with water and soap.
! Only use AdBlue®/DEF in accordance Rif AdBlue®/DEF comes into contact with
with DIN 70070/ISO 22241. Do not use your eyes, rinse your eyes with clean water
any additives.
Z
50 Winter operation
immediately. Seek medical attention Jump-starting

immediately.
Rif you have swallowed AdBlue®/DEF,
G WARNING
immediately rinse your mouth with water The use of liquid or gaseous starting aids can
and drink plenty of water. Seek medical cause explosions. This may result in severe
attention immediately. injuries.
Rchange clothing that has come into contact
Do not use liquid or gaseous starting aids
such as ether or Startpilot to start the engine.
with AdBlue®/DEF immediately.
AdBlue®/DEF is not refilled as part of the
Batteries
maintenance work. Top up the tank regularly
during vehicle operation or at the latest when Always aim to achieve the full charge status.
the first event message is displayed on the You can do this by means of careful mainte-
electronic engine management system. nance and low electrical consumption. The
Operation
You will find further information on AdBlue®/ cold start capacity is reduced when it is very
DEF in the "Service products" section cold. For example, at -10 † it is only around
(Y page 57). 60% of the normal capacity.
Before filling the tank Diesel fuels

X Switch off the engine. Notes on diesel fuel at low temperatures
X Secure the vehicle/equipment against roll-
(Y page 56).
ing away.
Always fill the tank with at least 5 litres, as
smaller amounts could cause malfunctions.
Winter operation
Notes for winter operation
! At very low outside temperatures, make
sure that the engine oil added is of an
appropriate SAE classification. Using
engine oils that are not suitable for very low
outside temperatures may result in engine
damage.
Before the start of the cold season, make sure
that:
Rthe coolant contains sufficient antifreeze
(Y page 55)
Rthe fuel used is suitable for winter use
(Y page 56)
Rthe SAE class of the engine oil used is in
accordance with outside temperatures
(Y page 53).
51
General notes ...................................... 52

Service products ................................. 53
Cleaning and care ............................... 59
Maintenance
52 General notes
General notes H Environmental note

If circumstances require you to do some main-
G WARNING tenance work yourself, you must observe the
Before carrying out maintenance or repair environmental protection requirements.
work, you must read the relevant sections of When disposing of service products, e.g.
the technical documentation relating to main- engine oil, you must comply with the legal
tenance and repair measures, e.g. the Oper- requirements. This also concerns all parts,
ating Instructions and workshop information. e.g. filters, that have been in contact with ser-
In particular, first familiarise yourself with the vice products.
legal regulations, e.g. work safety and acci- Dispose of empty containers, cleaning cloths
dent prevention regulations. and care products in an environmentally
You could otherwise fail to recognise dangers responsible manner.
and injure yourself or others. Observe the instructions for care products.
Always have maintenance work carried out at Do not let the engine run longer than neces-
a qualified specialist workshop. sary when stationary.
Maintenance
G WARNING Like all technical equipment, the engine sys-

tem requires care and maintenance.
maintenance work or necessary repairs car- The scope and frequency of maintenance
ried out, this could result in malfunctions or work depends mainly on:
system failures. There is a risk of an accident. Rthe widely varying operating conditions.
Always have the prescribed service/mainte- Rthe service products used.
i All maintenance intervals and work refer
ried out at a qualified specialist workshop.
to genuine Mercedes-Benz parts. They also
refer to accessory parts and service prod-
G WARNING
ucts that have been expressly approved by
Limbs could be crushed or trapped if the Mercedes-Benz for the engine.
engine is started unintentionally during ser-
vice or maintenance work. There is a risk of Inspection and maintenance work requires
injury. special skills that cannot be acquired by read-
ing these Operating Instructions. Always have
Always secure the engine against uninten-
this work and maintenance work carried out
tional starting before carrying out mainte-
by a qualified specialist workshop.
nance or repair work.
Have any work that is carried out confirmed
G WARNING with an entry in the Maintenance Booklet.
This proof of regular maintenance is always
Cloths or other flammable materials left in the
required for any warranty claims.
engine compartment can ignite if they come
into contact with the exhaust system or parts Instructions and important information on
of the engine that heat up. There is a risk of carrying out maintenance work can be found
fire. After carrying out maintenance work, in the Workshop Information System (WIS) on
make sure that no extraneous flammable the Internet. Make sure that you have access
material is left in the engine compartment or to this information when carrying out main-
on the exhaust system. tenance work. Information on WIS (Y page 9).
Please also observe the maintenance instruc-
tions for special accessories.
Service products 53
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 9).
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)
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-
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
Maintenance
original container when using, storing and dis-
Centre (Y page 9).
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 Service Centre
(Y page 9).
Dispose of service products in an environ-
mentally-responsible manner. Engine oils
Service products are: Notes on engine oils

Rfuels (e.g. diesel) ! Engine oils other than those of the quality
Rlubricants (e.g. engine oil, transmission oil, specified in this Operator's Manual are not
grease) permitted.
Rcoolant, antifreeze Only use engine oils in accordance with
RAdBlue®/DEF, reducing agent in the Sheet No. 228.51, 228.31, 228.5 or 228.3 of
exhaust gas aftertreatment system the Mercedes-Benz Specifications for Service
Products.
Approved service products fulfil the highest
quality standards and are documented in the
Mercedes-Benz Specifications for Service
Products. For this reason, only use approved
service products for your engine system.
Z
54 Service products
Engine oils according to Sheet No. 228.51 Use only all-season oils.
and 228.5 have a higher quality standard and
have a favourable effect on:
Rlength of oil change intervals
Rengine wear
Rfuel consumption
Rexhaust emissions
Before delivery, the engine is filled with oil in
SAE class 5W-30 (Y page 32).
Check the vehicle assemblies for leaks regu-
larly. If fluid loss is identified, e.g. by oil drops
on the parking area, have the cause of the Engine oil SAE classes (viscosity)
fluid loss rectified at a qualified specialist X Select the SAE class (viscosity) of the
workshop. engine oil to suit the average outside tem-
peratures for the time of year.
Maintenance
Scope of application
Oil change intervals are dependent on the fol-
Multi-grade engine oils compliant with Sheet lowing:
No. 228.51, 228.31, 228.5 or 228.3 can be Rthe operating conditions of the vehicle
used all year round. Rthe grade of the engine oil used
Oil change The maximum oil change interval can only be
achieved by using engine oils of particularly
! If you mix engine oils with differing oil high quality in accordance with Sheet No.
grades, the change interval for the engine 228.51 and 228.5 of the Mercedes-Benz
oil is reduced in comparison to mixtures of Specifications for Service Products. The clas-
engine oil of identical grade. sification of oil change intervals is specified in
Therefore, only mix engine oils of differing the Maintenance Booklet.
grade in exceptional circumstances. To
prevent damage to the engine, the mainte- Adding/topping up the engine oil
nance intervals must be adjusted accord-
! There is a risk of damage to the catalytic
ingly.
converter or to the engine if too much oil is
! If the SAE class (viscosity) of the engine added. Have excess oil drained off.
oil used is not suitable for continually low When topping up, Mercedes-Benz recom-
outside temperatures below -20 †, this mends that you only use engine oil of the
could cause engine damage. same grade and SAE class as the oil filled at
The specified temperatures of the SAE the last oil change.
class always refer to freshly added oil. Check the oil level before topping up the
Engine oil ages during driving due to soot engine oil (Y page 32).
and fuel residue. This impairs the charac-
teristics of the engine oil, particularly at low Miscibility of engine oils
outside temperatures.
If the outside temperature is under -20 †, The benefits of high-quality engine oils are
Mercedes-Benz strongly recommends diminished if you mix them.
using engine oils of SAE class 5W-30 or
0W-30.
Service products 55
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
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-
Maintenance
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.
Only use approved corrosion inhibitor/anti-
freeze agents (Y page 81). Please note the
Coolant Mercedes-Benz Specifications for Service
Products (Y page 53). This prevents damage
G WARNING to the engine cooling system and engine.
The engine cooling system is under pressure, When renewing the coolant, ensure that it
particularly if the engine is warm. You could contains 50% corrosion inhibitor/antifreeze
be scalded by hot coolant spraying out when by volume. This corresponds to antifreeze
opening the cap. There is a danger of injury. protection down to Ò37 †.
Allow the engine to cool before opening the Do not exceed 55% by volume (antifreeze
cap. Wear gloves and protective eyewear down to approximately Ò45 †). The heat dis-
when opening. Slowly turn the cap half a turn sipation and antifreeze may otherwise be
to allow pressure to escape. negatively affected.
If there is a loss of coolant, do not top it up by
G WARNING using only water, but also add an approved
If antifreeze comes into contact with hot com- corrosion inhibitor/antifreeze agent.
ponents in the engine compartment, it may The water in the coolant must meet certain
ignite. There is a risk of fire and injury. requirements, which are often fulfilled by the
Let the engine cool down before you top up use of drinking water. The water must be
the antifreeze. Make sure that antifreeze is treated if its quality does not meet the
not spilled next to the filler neck. Thoroughly required standards.
clean the antifreeze from components before Please note the Mercedes-Benz Specifica-
starting the engine. tions for Service Products, Sheet No. 310.1.
A coolant that ensures anti-corrosion/anti- Mixtures with other corrosion inhibitors/anti-
freeze protection and other important pro- freeze agents are not permitted.
tective effects is filled at the factory.
Z
56 Service products
Diesel fuels The following fuel types are not permitted:

Rsulphurous fuel with a sulphur content
greater than 0.005% by weight (50 ppm)
G WARNING Rmarine diesel fuel
Fuel is highly flammable. Improper handing of Raviation turbine fuel
fuel creates a risk of fire and explosion. Rheating oils
Avoid fire, naked flames, smoking and creat- Rfatty acid methyl ester FAME (bio-diesel
ing sparks under all circumstances. Switch off fuel)
the engine and, if applicable, the auxiliary These fuel types cause irreversible damage
heating before refuelling. to the engine and the exhaust gas after-
treatment system, as well as also signifi-
G WARNING cantly reducing the expected service life.
Fuels are poisonous and hazardous to health.
There is a danger of injury. ! A higher fuel sulphur content accelerates
the ageing process of the engine oil and can
Do not swallow fuel or let it come into contact
Maintenance
damage the engine and exhaust system.

with skin, eyes or clothing. Do not inhale fuel
vapours. Keep fuels out of the reach of chil-
dren. Fuel grade
If you or others come into contact with fuel, i Certain countries have diesel fuel with
observe the following: varying sulphur contents. Diesel fuel with a
RWash the fuel off any affected areas of skin lower sulphur content is sold in certain
with water and soap immediately. countries under the name "Euro diesel".
RIf you get fuel in your eyes, rinse them thor- Information about current country-specific
oughly with clean water immediately. Seek sulphur contents can be obtained from any
immediate medical attention. MTU or MTU-authorised Mercedes-Benz Ser-
RIf fuel is swallowed, seek immediate medi- vice Centre (Y page 9).
cal attention. Do not induce vomiting. Water content
RChange any clothing that has come into
The maximum permissible water content at
contact with fuel immediately. the point of transfer between vehicle and
engine must not be greater than 200 mg/kg.
! If you are using drums or canisters to If the water content is higher, an additional
refuel the vehicle, you should filter the fuel water separator must be fitted on the chassis.
before filling.
If the engine is operated with increased
This prevents malfunctions in the fuel sys- amounts of dirt and water, an additional fuel
tem caused by contaminated fuel. prefilter with a water separator must be fitted
! Only refuel using commercially available, on the chassis.
sulphur-free diesel fuel that complies with
the following standards: Diesel fuels at low temperatures
REN 590 as of 2010, et seq. (max. 0.001%
G WARNING
sulphur by weight) (10 ppm) or
If you heat fuel system components, e.g. with
RASTM D975 (max. 0.0015% sulphur by
a hot-air gun or naked flame, these compo-
weight) (15 ppm). 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
Service products 57
engine is running. There is a risk of fire and AdBlue®/DEF

explosion.
Never heat fuel system components. Contact
a qualified specialist workshop to rectify the G WARNING
malfunction.
AdBlue®/DEF must not come into contact
At low outside temperatures, paraffin sepa- with skin, eyes or clothing.
ration may cause the flow properties of the RIf AdBlue®/DEF comes into contact with
diesel fuel to be insufficient. your eyes or skin, rinse affected areas with
To prevent operating problems, diesel fuel clean water immediately.
with improved flow properties is available in RIf AdBlue®/DEF is swallowed, immediately
the winter months. rinse your mouth out with a lot of clean
Winter diesel fuels are reliable down to out- water and drink plenty of water.
side temperatures of −22 † in Germany and RChange clothing that is soiled with
other Central European countries. You can AdBlue®/DEF immediately.
Maintenance
normally use winter diesel fuel without prob-
RIf allergic reactions occur, consult a doctor
lems at the outside temperatures expected in
immediately.
the country where it is on sale.
Keep AdBlue®/DEF out of the reach of chil-
Fuel additives dren.
! When necessary, use only approved fuel ! Only use AdBlue®/DEF in accordance
additives. with DIN 70070/ISO 22241. Do not use
There is otherwise a risk of impaired engine any additives.
performance or engine and catalytic con- If AdBlue®/DEF comes into contact with
verter damage. The use of appropriate fuel painted or aluminium surfaces when filling
additives is your responsibility. the tank, rinse the affected area immedi-
! Do not add any petrol or kerosene to die- ately with plenty of water.
sel fuel to improve its flow characteristics. The terms "Urea" and "DEF" (Diesel Exhaust
Petrol or kerosene impairs the lubricity of Fluid) are also used for "AdBlue®".
the diesel fuel. This can cause damage to If the AdBlue®/DEF tank is full of AdBlue®/
the injection system, for example. DEF, pressure compensation may occur when
For lower temperatures, the engine can be the tank lid is unscrewed. AdBlue®/DEF may
equipped with a fuel preheating system. This spill out. Therefore, open the AdBlue®/DEF
improves the flow characteristics of the die- tank lid carefully. If AdBlue®/DEF spills out,
sel fuel according to the output of the instal- immediately wash the affected area with
led heater. plenty of water.
Fuel additives used to improve flow charac- When opening the AdBlue®/DEF tank, small
teristics are flow improvers. amounts of ammonia vapours could escape.
Do not add flow improvers to winter diesel Ammonia vapours have a pungent smell and
fuel guaranteed to operate down to −22 †. are particularly irritating to:
The cold flow properties of the fuel may dete-
Rskin
riorate as a consequence of the flow
improver. Rmucous membranes
Reyes
Z
58 Service products
The vapours may cause a burning sensation in Low outside temperatures

the eyes, nose and throat as well as irritation
of the throat and watering eyes. AdBlue®/DEF freezes at a temperature of
approximately −11 † .
Avoid inhaling ammonia vapours. Only fill the
Depending on equipment and country, the
AdBlue®/DEF tank in well-ventilated areas.
AdBlue®/DEF supply system of the vehicle
AdBlue®/DEF should not come into contact may be heated; see the vehicle's Operating
with skin, eyes or clothing, and should not be Instructions. Winter operation is thus guar-
swallowed. Keep AdBlue® out of the reach of anteed at temperatures below −11 † .
children.
If you come into contact with AdBlue®/DEF, Additives, tap water
observe the following:
! Do not mix additives to AdBlue®/DEF. Do
Rimmediately wash AdBlue®/DEF from your
not dilute AdBlue®/DEF with tap water.
skin with water and soap. This could destroy the exhaust gas after-
Rif AdBlue®/DEF comes into contact with treatment system.
Maintenance
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
Rchange clothing that has come into contact Rcopper

with AdBlue®/DEF immediately. Rcopper alloys
Runalloyed steel
High outside temperatures Rgalvanised steel
G WARNING If AdBlue® is stored in these types of con-

tainer, constituents of these metals may
If the AdBlue®/DEF tank cap is opened at high
dissolve and damage the exhaust gas after-
temperatures, ammonia vapours may escape.
treatment beyond repair.
Ammonia vapours have a pungent odour and
particularly irritate: Only use containers made of the following
materials to store AdBlue®:
Rskin
RCr‑Nisteel in accordance with
Rmucous membranes
DIN EN 10 088-1/2/3
Reyes
RMo-Cr‑Ni steel in accordance with
The vapours may cause a burning sensation in
DIN EN 10 088-1/2/3
the eyes, nose and throat as well as irritation
RPolypropylene
of the throat and watering eyes.
RPolyethylene
Avoid inhaling ammonia vapours.
The chemical composition of AdBlue®/DEF Disposal

can break down if it heats up to 50 † over a
long period (e.g. as a result of direct sunlight H Environmental note
on the tank). This creates ammonia vapour. Dispose of AdBlue®/DEF in an environmen-
Cleaning and care 59
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
causing damage.
Ensure that AdBlue®/DEF is always pure to
Do not point the water jet at:
avoid malfunctions in the exhaust gas after-
Maintenance
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.
Cleaning the engine

Cleaning and care
! Observe the following notes when clean-
Notes on care ing the engine. This avoids malfunctions
and damage to the engine.
Regular care helps to maintain the value of
the engine. RWhen using high-pressure or steam
Mercedes-Benz recommends that you only cleaners, do not point the spray directly
use care products that have been approved at electrical components and electric
for Mercedes-Benz. You can obtain these cables.
care products from any MTU or MTU-author- RMake sure that no water enters the air
ised Mercedes-Benz Service Centre intake and ventilation openings.
(Y page 9). RTreat the engine with preservative
agents after it has been cleaned. When
doing so, protect the belt drive system
High-pressure cleaning from the preservative agent.
ROnly use wax-based protective agents
for engines that comply with
Only wash your vehicle at a wash bay
Sheet No. 385.4 of the Mercedes-Benz
designed for this purpose. Dispose of empty
Specifications for Service Products.
containers and used cleaning products in an
environmentally responsible manner. In addition, observe the notes in the "High-
pressure cleaning" section (Y page 59).
! When cleaning, never point the water jet
at the exhaust pipe. The system may oth-
erwise be damaged.
Z
60
61
General notes ...................................... 62

Decommissioning for up to 6
months ................................................. 62
Decommissioning for longer than
6 months .............................................. 63
Decommissioning
62 Decommissioning for up to 6 months
General notes RTop up the AdBlue®/DEF tank until it is full,

to prevent AdBlue®/DEF from crystallising.
Special measures are required to decommis- RDrain the water separator for the fuel sys-
sion the engine/vehicle. tem.
Information about batteries: if the engine/ Measures during decommissioning:
vehicle is to be out of use for longer than three
Decommissioning
weeks, disconnect the negative terminal on Start the engine at least once a month and
the battery. This prevents the batteries from leave it running for 15 - 30 minutes at approx-
being discharged by no-load current consum- imately 900 rpm.
ers. Depending on the vehicle equipment:
If the engine/vehicle is to be out of use for a Rwith the air-conditioning system switched
longer period, remove the batteries and store on
them in a dry and well-ventilated area. Rwith the heating activated
Recharge batteries every 3 months at the lat- Rwith the auxiliary heating switched on
est. The monthly engine start can be omitted if the
Ensure that there is adequate ventilation engine was operated with FAME-free fuel (B0
when recharging. Check the battery fluid lev- diesel fuel/without bio-diesel content1) and
els before and after charging and if necessary subsequently decommissioned.
correct them. For further information
The engine oil level and the coolant level must
(Y page 50).
be checked before every engine start. On
vehicles/devices with a water separator on
the fuel filter or fuel prefilter, additionally
Decommissioning for up to 6 months
drain the water separator, if necessary. Upon
starting and while the engine is running,
When decommissioning an engine/vehicle,
observe the oil pressure as well as the coolant
keep it in a covered, dry and well-ventilated
temperature.
area. The room temperature should not fall
below -10 †. Measures prior to recommissioning:
Measures prior to decommissioning: RFitand connect the battery.
RCheck that the electrical system is func-
RClean the engine/vehicle thoroughly.
tioning correctly.
RRemove any patches of corrosion from the
RCheck cables, hoses and lines for tears and
engine.
leaks.
RChange the engine oil and oil filter if the last
RCheck the engine oil level.
oil change was carried out more than
20,000 km (or around 300 operating hours) RCheck the oil level in the steering and
ago. hydrostatic fan drive.
Also change the engine oil and filter if the RCheck the coolant level and correct it, if
oil is more than 12 months old. necessary.
RCheck and adjust the level of coolant or RCheck AdBlue®/DEF level.
renew coolant. RCheck the fuel level.
RCheck and adjust the concentration of anti- RStart the engine and leave it running at
corrosion/antifreeze additives in the cool- medium engine speeds until it is at operat-
ant. ing temperature (coolant temperature).
While doing so, observe the indicators for
1 Further information can be obtained from any Mercedes Benz Service Centre.
Decommissioning for longer than 6 months 63
oil pressure, coolant temperature and oil

temperature.
RVehicles with auxiliary heating: activate the
auxiliary heating and check operation.
RCheck operation of the steering and
brakes.
Decommissioning
RCheck whether maintenance is due and if
necessary carry it out.
Decommissioning for longer than 6

months
If the vehicle is to be decommissioned for

longer than 6 months, further measures are
required. For more details, consult your MTU
or MTU-authorised Mercedes-Benz Service
Centre (Y page 9).
64
65
Important safety notes ....................... 66

Bleeding and draining the fuel sys-
tem ....................................................... 67
Electrical fuses .................................... 68
Jump-starting ....................................... 69
Troubleshooting .................................. 71
Troubleshooting
66 Important safety notes
Important safety notes When working on the vehicle, comply with all
safety regulations, such as operating instruc-
G WARNING tions, regulations concerning hazardous
materials, environmental protection meas-
ures, work safety and accident prevention
maintenance work or necessary repairs car-
regulations.
ried out, this could result in malfunctions or
system failures. There is a risk of an accident. Be aware of the road and traffic situation
when working on public roads and secure
Always have the prescribed service/mainte-
your position accordingly.
Troubleshooting
ried out at a qualified specialist workshop. Apart from careful operation and mainte-
nance of the engine it is also important that
G WARNING malfunctions be rectified in good time.
There are moving components in the engine You can rectify certain malfunctions yourself,
compartment. Certain components may con- (Y page 71).
tinue to move or suddenly move again even Have malfunctions that you cannot eliminate
after the ignition has been switched off, e.g. yourself rectified at a qualified specialist
the radiator fan. There is a risk of injury. workshop.
If you have to carry out work in the engine
compartment:
External engine start/engine stop
Rswitch off the ignition button
Rnever touch the dangerous areas surround-
ing moving components, e.g. the rotation
area of the fan
Rremove jewellery and watches
Rkeep items of clothing and hair, for exam-
ple, away from moving parts.
G WARNING
Limbs could be crushed or trapped if the
engine is started unintentionally during ser-
vice or maintenance work. There is a risk of
injury. You can start and stop the engine using the
Always secure the engine against uninten- external engine start/engine stop button.
tional starting before carrying out mainte- Before starting the engine
nance or repair work.
X Switch the ignition lock to the drive posi-
tion.
G WARNING
X Shift into neutral.
Certain engine components can become very
X Secure the vehicle against rolling away.
hot. There is a risk of injury when carrying out
work at the engine. X Deactivate power take-off.
Where possible, allow the engine to cool down Starting the engine
and only touch the components described
X Hold down external engine start/engine
below.
stop button : until the engine starts.
Bleeding and draining the fuel system 67
Starting the engine and increasing the When the engine is started, the battery must
engine speed have sufficient charge to bleed the fuel sys-
X Hold down external engine start/engine tem.
stop button : until the desired engine Bleed the heated fuel prefilter with water sep-
speed is achieved. arator on the vehicle before the fuel circuit on
The engine starts and runs at engine idling the engine is bled by the starter motor. Use
speed. the manual fuel pump integrated in the fuel
After about 3 seconds, the engine speed prefilter to do so.
increases. After releasing external engine
Troubleshooting
start/engine stop button :, the engine
continues to run at the currently set speed. Bleeding the fuel system without a
fuel prefilter on the chassis frame
The engine speed can be increased up to
the limiting speed. XTurn the key to the start position in the
X If the engine does not start immedi- ignition lock and hold it. Do not depress the
ately: interrupt the starting procedure accelerator pedal whilst doing so.
after no more than 30 seconds. i The starting procedure is automatically
X Turn the key in the ignition lock back to the cancelled after approximately 60 seconds.
stop at key position g. X Repeat the starting procedure after a wait-
X Repeat the starting procedure after a wait- ing period of approximately 1 minute.
ing period of approximately 1 minute. X If the engine starts normally, depress the
X If the engine fails to start: rectify the cause accelerator pedal several times.
of the poor starting characteristics The fuel system is completely bled.
(Y page 71).
X Observe the oil pressure gauge immedi-
ately after having started the engine. Bleeding the fuel system with a fuel
prefilter on the chassis frame
Stopping the engine
X Press external engine start/engine stop H Environmental note
button : again. Dispose of the water-fuel mixture in an envi-
ronmentally responsible manner.
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,
circulation of AdBlue®/DEF is necessary
for ensuring cooling. To do this the
AdBlue®/DEF delivery pump is actuated
during this period.
Bleeding and draining the fuel system
Bleeding, after refuelling a fuel system which Example: fuel prefilter on the chassis frame
has been run dry, is performed the next time If water has collected in inspection window
the engine is started. Automatic continuous =, drain fuel prefilter on chassis frame :
bleeding takes place in the filter.
Z
68 Electrical fuses
before bleeding. Drain fuel prefilter on chas- Electrical fuses

sis frame : regularly.
Draining the fuel prefilter on the chassis
frame G WARNING
X Place a collector under drain plug ;. If you manipulate, bridge or replace a faulty
X Turn drain plug ; open. fuse with a fuse of a higher amperage, the
X Press manual fuel pump ? and collect the
electric cables could be overloaded. This may
fuel/water mixture. result in a fire. There is a risk of an accident
and injury.
X Turn drain plug ; closed.
Troubleshooting
Always replace faulty fuses with specified new

Bleeding using the manual fuel pump of fuses of the correct amperage.
the fuel prefilter on the chassis frame
X Unscrew the fuel tank filler cap. The individual electrical circuits are protected
by safety fuses or automatic circuit-breakers.
X Place the collector underneath fuel prefil-
ter :. Blown fuses or defective automatic circuit-
breakers must be replaced by equivalent
X Unscrew bleed screw A.
fuses with the fuse ratings recommended in
X Press manual fuel pump ? repeatedly until the fuse allocation chart. Fuses with the same
the fuel escaping at bleed screw A is free fuse rating are the same colour.
of bubbles.
Further information is available from any MTU
X Tighten bleed screw A. or MTU-authorised Mercedes-Benz Service
i If there was no fuel in the fuel tank, press Centre (Y page 9).
manual fuel pump ? again until there is The vehicle-specific fuse allocation chart is
noticeable resistance. provided by the vehicle manufacturer.
i Then bleed the fuel circuit on the engine If the newly inserted fuse also blows, have the
as described under "Bleeding the fuel sys- cause traced and rectified at a qualified spe-
tem without a fuel prefilter on the chassis cialist workshop, e.g. a Mercedes-Benz Ser-
frame". vice Centre.
X Tighten the fuel tank filler cap. X If a circuit fails, switch off the consumer
X Turn the key to the start position in the equipment and switch the ignition lock to
ignition lock and hold it. Do not depress the position 0.
accelerator pedal whilst doing so.
i The starting procedure is automatically
cancelled after approximately 60 seconds. Checking and replacing a safety fuse
X Repeat the starting procedure after a wait- X Pull the fuse out of the module using the
ing period of approximately 1 minute. pliers and carry out a visual inspection.
X If the engine starts normally, depress the X If the fuse wire has melted, replace the
accelerator pedal several times. The fuel blown fuse with a spare fuse.
system is completely bled. X Switch on consumers and check that they
function correctly.
If the safety fuse burns out again, have the
electrical system checked at a qualified spe-
cialist workshop.
Jump-starting 69
Jump-starting Ronly have jump-starting provided by vehi-

cles with a 24 V system.
Important safety notes Ruse jump leads which are protected
G WARNING against polarity reversal and with a wire
cross section of approximately 35–
Comply with safety precautions and take pro-
tective measures when handling batteries. 50 mm2 and insulated terminal clamps.
Rif the outside temperature drops below
Risk of explosion
Ò10 †, a discharged battery could freeze.
Do not start the engine under these cir-
Troubleshooting
cumstances. Let the battery thaw out
Fire, naked flames and first.
smoking are prohibited
! Do not connect the negative terminal
when handling the battery.
clamp of the jump lead to the chassis
Avoid creating sparks.
frame. Otherwise, engine or transmission
Battery acid is caustic. components can be damaged.
Avoid contact with the skin,
eyes or clothing. ! When you remove the jump leads, let the
Wear suitable protective engine of the vehicle being jump-started
clothing, in particular idle. This avoids damage being caused to
gloves, an apron and a face the vehicle electronics.
mask.
Immediately rinse acid General notes
splashes off with clean
water. Consult a doctor if Observe the instructions relevant to safety
necessary. and protective measures when handling the
Wear eye protection. battery.
After jump-starting, have the batteries
checked at a qualified specialist workshop.
X Make sure that the vehicles are not touch-
Keep children away.
ing.
X Engage the parking brake.
X Switch off all electrical consumers.
Observe this Owner's Man-
X Turn the key to position 0 in the ignition
ual.
lock.
! Observe the following notes. You could

otherwise damage the battery or electronic
components in the vehicle:
Rdo not use a battery quick-charge unit for
jump-starting.
Rif you use a mobile battery charger (bat-
tery device with mains power stage),
remove the mains plug before jump-
starting.
Z
70 Jump-starting
Vehicles without a jump-starting con-

nection point
Troubleshooting
Connecting the jump lead

X Remove the battery compartment cover.
X First, connect the positive terminal clamp
of the jump lead to the positive terminal of
the other vehicle's battery and then to the
q positive terminal of the starter battery.
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.
Disconnecting the jump lead

X First, disconnect the negative terminal
clamps of the jump lead from the negative
terminals.
X Remove the positive terminal clamps of the
jump lead from the positive terminals.
Troubleshooting 71
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.
Always have the prescribed service/maintenance work as well as necessary repairs carried out
at a qualified specialist workshop.
Troubleshooting
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 9).
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.
The earth connection to the battery is loose.

X Tighten the cable on the terminal. If necessary, solder on a new
terminal.
The starter motor solenoid switch is faulty or the starter motor is

faulty.
X Have it checked at a qualified specialist workshop.
The engine does not The fuel tank is empty.

start or stalls again X Refill the fuel tank (Y page 48).
immediately.
The fuel filter is blocked.
X Replace the fuel filter element.
The fuel prefilter contains water.

X Drain the fuel prefilter.
The fuel prefilter is blocked.

X Replace the fuel filter element.
Z
72 Troubleshooting

Leaks or insufficient pressure in the low-pressure fuel circuit
X Check for leaks (visual check), replace the seals if necessary.
X Have the fuel pressure tested at a qualified specialist workshop.
Replace the seals.
Engine fails to start The fuel is not resistant to cold.

when the ambient tem- The flow properties of the diesel fuel are inadequate due to paraffin
Troubleshooting
perature is low. separation.

X Malfunctions resulting from paraffin separation can be correc-
ted by warming the entire fuel system, e.g. by parking the vehicle
in a heated area.
X Refuel with winter fuel (Y page 56).
The engine oil viscosity is incorrect.

X Alter the engine oil viscosity to the conditions of use
(Y page 54).
X If the engine does not start after another attempt, have the
cause traced and rectified at a qualified specialist workshop.
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.
Leaks or insufficient pressure in the low-pressure fuel circuit.

X Carry out a check for leaks (visual check).
X Have the fuel pressure tested at a qualified specialist workshop.
The engine is in emer- 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.
The engine surges, There is a malfunction in the fuel system.

vibrates or runs irregu- X Carry out a check for leaks (visual check).
larly. X Read out the control unit's fault memory.
The engine's output is The air filter is dirty or blocked.

poor (lack of power). X Replace the air filter element.
Troubleshooting 73

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

X Check the temperature sensor; replace if necessary. Check the
fan speed.
Troubleshooting
X Check the thermostat and replace as necessary. Consult a
qualified specialist workshop.
Malfunction in the fuel system (blocked, leaking).

X Visual inspection for leaks.
X Consult a qualified specialist workshop.
Poor fuel grade

X Use the specified type of fuel and fuel grade (Y page 56).
The charge-air system is leaking; the hose clip on the charge-air

hose is loose or damaged.
X Check the charge-air system for leaks.
X Check the charge-air pressure sensor and, if necessary, replace.
An operating restriction is activated due to an emissions-relevant

malfunction.
X Observe the notes on warning and indicator lamps (Y page 39).
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.
Fuel consumption is The cause must be established in a qualified specialist workshop.

too high. X Consult a qualified specialist workshop.
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.
Z
74 Troubleshooting

The poly-V-belt is damaged.
X Replace the poly-V-belt.
The fan does not switch on correctly.

The coolant radiator is dirty on the inside; the coolant radiator is

very dirty on the outside.
Troubleshooting
X Clean the coolant radiator.
The thermostat is faulty.

X Check and replace as necessary.
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.
The poly-V-belt is torn.

X Replace the poly-V-belt.
The alternator or sensor is faulty.

X Check the alternator or sensor.
The engine is "knock- The engine is misfiring.

ing". X Consult a qualified specialist workshop.
The engine is "knock- There is bearing damage.

ing". X Consult a qualified specialist workshop.
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 75

The turbine or compressor wheel is scraping the housing; there are
foreign objects in the compressor or turbine housing; bearings
have seized on the rotating parts.
X Have the exhaust gas turbocharger checked at a qualified spe-
cialist workshop.
The valve clearance is excessive.
Troubleshooting
X Check and adjust the valve clearance.
The poly-V-belt is slipping.

X Check that the poly-V-belt contact surfaces are not torn, dam-
aged, oily or glazed. Replace the poly-V-belt if necessary.
Replacing the poly-V-belt Belt profile

If the poly-V-belt is torn or shows damage
patterns, it must be replaced.
G WARNING
The tensioning device is spring-tensioned.
When it is loosened or tightened, there is a
risk of injury from crushing or entrapment in
pretensioned parts.
RAlways carry out work on the tensioning
device with extreme care.
RMake sure that the tool is handled cor-
rectly.
Poly-V-belt routing (engine without refrigerant

compressor)
: Coolant pump
; Guide pulley
= Alternator
? Crankshaft
A Tensioning pulley
Z
76 Troubleshooting
Fitting/removing poly-V-belts
X Insert the 15 mm socket, with the handle
and extension attached, into the tensioner.
X Swing back the tensioner.
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
Troubleshooting
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).
Poly-V-belt routing (engine with refrigerant com-
X Remove the spanner and check for correct
pressor)
: Coolant pump
seating of the poly-V-belt on the belt pul-
leys.
; Guide pulley
? Alternator
A Guide pulley
B Crankshaft
C Tensioning pulley
Poly-V-belt routing (engine with cooling system)

: Crankshaft
; Tensioning pulley
= Guide pulley
? Cooling system generator
77
Identification plates ............................ 78

Data card ............................................. 78
Engine data .......................................... 79
Technical data
78 Data card
Identification plates
Engine data plate
: Position Emission certification label (EPA

Certification)
Technical data
: Position of engine data plate (example)
Information on the engine data plate

The following data is contained on the engine
data plate in the form of numbers stamped
directly onto the crankcase:
Exhaust gas aftertreatment identifi-

cation plate
The exhaust gas aftertreatment identification
plate is located on the exhaust gas aftertreat-
ment control module (ACM).
Example: engine data plate
Information on the exhaust gas after-
: Manufacturer's name
treatment identification plate
; Engine model designation
= Type approval number The identification plate for the exhaust gas
aftertreatment unit contains the 14-digit
? Engine number
identification number (AGN ID number) of the
exhaust gas aftertreatment unit.
Emission certification label
In engines with the US TIER 4 emissions cer- Data card
tificate, the emission certification label (EPA
Certification) is located on the cylinder head The data card forms an integral part of the
cover. documents belonging to the engine and
should always be kept with the Maintenance
Booklet. It contains details about the design
Engine data 79
of the engine and the exhaust gas aftertreat-

ment system, including special features.
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.
The following is absolutely necessary when
procuring genuine Mercedes-Benz parts:
Rthe data card or
Technical data
Rthe complete engine number and the num-
ber of the exhaust gas aftertreatment unit.
Example: engine width and height

Engine data
R4 1000 R6 1000
Dimensions and weights
A = engine 948 mm 1070 mm
All data refers to the standard version of the length with
respective engine type. Deviations may fan
occur, depending on the engine equipment
and installation situation in the vehicle/ B = engine 885 mm 924 mm
device. width
C = engine 1033 mm 1068 mm
Dimensions height
Weights
Engine weight DIN 70020 - GZ
4R 1000 6R 1000
Single-stage charg- 499 kg 655 kg
ing
Dual-stage charging 510 kg 669 kg
Example: engine length

80 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 4R 1000 6R 1000
Assembly model series 933.91 935.91
Type In-line engine with exhaust gas recirculation and
charge-air pressure control
Combustion principle 4-stroke direct injection diesel
Number of cylinders 4 6
Technical data
Bore 110 mm 110 mm

Stroke 135 mm 135 mm
Engine capacity 5130 cm3 7700 cm3
Firing order 1 -3 -4 -2 1-5-3-6-2-4
Type of cooling system Forced circulation cooling
Engine, direction of Anti-clockwise (when looking at the flywheel)
rotation
Valve clear- Intake valve 0.30 mm +/- 0.05 mm 0.30 mm +/- 0.05 mm
ance
Exhaust valve 0.60 mm +/- 0.1 mm 0.60 mm +/- 0.1 mm
Engine brake when 0.15 mm 0.15 mm
using adjusting gauges
(0.6 mm) on both
exhaust valves
Starter Starter Electric Electric
motor
Voltage 24 V 24 V
Output 3.9 kW 3.9 kW
Cold-start limit Ò30 † (battery charging level 75%)
Alternator Voltage 24 V 24 V
Amperage 100 A 100 A
Operating data
Operating range of engine brake Approx. 1000 - 3000 rpm

Engine speed range of maximum engine torque Approx. 1200 - 1600 rpm
Engine data 81
Engine speed of maximum power output Approx. 2200 rpm

Idling speed Approx. 600 rpm
Oil pressure at idling speed Minimum 0.5 bar
Coolant temper- Normal operation Approx. 85 - 100 †
ature
Maximum permissible tempera- 105 †
ture of coolant (automatic tor-
que limitation up to
50 % from 103 †)
Technical data
Capacities and service products
Capacity approx- Service product

imately (Sheet No.2)
Engine with 4R 1000 17.5 l - 20.5 l Engine oil (Sheet No.
oil filter 228.3/.31/.5/.51)
(with stand- 6R 1000 24.5 l - 29.5 l
ard truck oil
pan)
Fuel system Diesel fuel tank3 Diesel fuels in accord-
ance with EN 590 as of
2010 or ASTM D975
(Sheet No. 131.0)
Exhaust gas AdBlue®/DEF tank3 AdBlue®/DEF in
aftertreat- accordance with ISO
ment sys- 22241 (Sheet No.
tem 352.1)
AdBlue®/DEF filter sealing - MB silicon grease
rings
Cooling sys- Amount of cool- 4R 1000 Approx. 11 l Antifreeze/corrosion
tem ant in the engine 6R 1000 Approx. 14 l inhibitor in accordance
with Sheet No. 325.5 or
Corrosion inhibitor/anti- Approx. 50% by premixed coolant in
freeze agent volume volume accordance with Sheet
down to –37 °C No. 326.5. Water qual-
ity in accordance with
Sheet No. 310.1
2 Mercedes-Benz Specifications for Service Products

3 Installation on the vehicle side; designed by the vehicle manufacturer.
82 Engine data
Capacity approx- Service product

imately (Sheet No.2)
Corrosion inhibitor/anti- Max. 55% by vol-
freeze volume ume
down to –45 °C
Engine com- Protective wax - Wax preservative in
partment accordance with Sheet
No. 385.4
Tightening torques
Technical data
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 4R 1000 and 6R 1000.
Engine Cylinder head cover screw on Light alloy 20 Nm

the rocker arm housing
(observe the tightening Thermoplastic 25 Nm
sequence for the cylinder
head cover)
Valve clearance setting Counternut on the rocker 30 Nm
arm adjustment screw
Engine brake setting Counternut on the rocker 27 Nm
arm adjustment screw
Screw of TDC inspection hole cap on the flywheel housing 30 Nm
Cranking device screw on the timing case 25 Nm
Fuel system Main fuel filter cap on the fuel filter module 25 Nm
Fuel prefilter cap on the fuel filter module 25 Nm
Oil circuit Drain plug on the oil pan M 16 x 1.5 35 Nm
(thermoplastic and light
alloy)
Oil filter cap on the oil/coolant module 50 Nm
Cooling system Silicate gel cartridge on the coolant pump 50 Nm
2 Mercedes-Benz Specifications for Service Products

Engine data 83
Exhaust gas Filter housing on the pump module 80 Nm

aftertreatment
Air dryer Granulate cartridge on the air dryer 15 Nm
Tightening sequence for the cylinder

head cover
The cylinder head cover screws must be tight-
ened in the correct tightening sequence in the
same order as described below.
Technical data
Tightening sequence for 4R 1000
Tightening sequence for 6R 1000

84
Publication details
Internet
Further information about MTU, Mercedes-

Benz and Daimler AG can be found online at:
www.mtu-online.com
www.mercedes-benz.com
www.daimler.com
Documentation team
Should you have any questions or sugges-

tions regarding this manual, you can reach
the technical documentation team at the fol-
lowing address:
Daimler AG, HPC: CAC, Customer Service,
70546 Stuttgart, Germany
©Daimler AG: not to be reprinted, translated
or otherwise reproduced, in whole or in part,

without written permission from Daimler AG.
Assembly manufacturer
Daimler AG
Mercedesstraße 137
70327 Stuttgart
Germany
As at 24.09.2014
É9345840981-ËÍ
9345840981
Order no. 6462 9859 02 Part no. 934 584 09 81 Edition 02-15

4R/6R 1000 EU Stage IV/US Tier 4: Operating Instructions

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4R/6R 1000 EU Stage IV/US Tier 4: Operating Instructions

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4R/6R 1000 EU Stage IV/US Tier 4

! The purpose of material damage warnings

Oil change ........................................ 54 O

Engine system ....................................... 6

Engine system Please contact any MTU or MTU-authorised

Safety/emergency running program Implied warranty

The engine is equipped with an electronic A well-developed network of MTU or MTU-

These MTU or MTU-authorised Mercedes- If there are legal requirements on emission

This data is exclusively technical in nature Further applicable documents

General information ............................ 12

The engine is a four-stroke, water-cooled die-

diesel injection system, cooled and regulated

Engine overview: 4R 1000 with single-stage charging

Engine overview: 6R 1000 with two-stage charging

Exhaust gas aftertreatment overview

Electronic engine management In addition to the engine, the exhaust gas

Engine management control module Drive control system unit (CPC)

The engine management control module REvaluation of start request

Functions of the exhaust gas aftertreatment Exhaust gas recirculation

via the CAN by the engine management

The exhaust gas aftertreatment system is Warning and indicator lamps

warning, the warning and indicator lamps

red Engine stop

Ù Engine system malfunction

(lit Torque operating restriction

(flash- Torque and engine speed

, Coolant level too low

Ã Continuous brake active

Operating safety ................................. 24

safety of the vehicle. There is an increased Staff qualifications

Diagnostics connection The operator must determine the responsi-

! The engines are by default delivered filled

The engine system may only be installed as

Daimler AG provides the vehicle manufac-

Preparation for operation ................... 32

SAE classification (Y page 53).

Checking the oil level electronically

X Check the engine oil level with dipstick ;.

Checking the coolant level

Checking the AdBlue®/DEF supply

! If the oil pressure in the engine is too low,

panel. The warning buzzer also sounds.

! Stop the engine immediately, paying Switching the continuous brake on

Do not activate the continuous brake and do Retarder

The engine brake and retarder are used as a

downhill. approximately 600 and 800 rpm.

Engine brake The charge current indicator lamp must go

RIdling speed is set automatically depending

AdBlue®/DEF indicator lamp for the

Warning and indicator lamps

Warning and indicator lamps

Problem Possible causes/consequences and M Solutions

The Ù indicator Impermissible operating conditions have been detected in the

X If further indicator lamps are displayed, take the combination of

Problem Possible causes/consequences and M Solutions

lamp lights up. level is too low.

Problem Possible causes/consequences and M Solutions

Only vehicles/devices with the AdBlue®/DEF reserve warning light

Problem Possible causes/consequences and M Solutions

If you do not follow the instructions, an engine speed limitation

are flashing. activated. The engine torque is limited to a maximum of 50%

If you do not observe the instructions, engine torque and engine

The Ø, ·, The AdBlue®/DEF level has dropped to approximately 0%. The