MTU 4r6r1000

4R/6R 1000 EU Stage IV/US TIER 4
Operating Instructions
É9345843771)ËÍ
9345843771
Order no. 6462 9839 02 Part no. 934 584 37 71 Edition 01-14
Symbols Imprint
G WARNING Internet
Warning notes make you aware dangers
which could pose a threat to your health or Further information about MTU, Mercedes-
life, or to the health and life of others. Benz and Daimler AG can be found on the
Internet at:
H Environmental note www.mtu-online.com
Environmental notes provide you with infor- www.mercedes-benz.com
mation on environmentally aware actions or www.daimler.com
disposal.
! The purpose of material damage warnings Documentation team

is to draw your attention to risks which
could lead to damage to your engine sys- Should you have any questions or sugges-
tem. tions regarding this manual, you can reach
i These symbols indicate useful instruc- the technical documentation team at the fol-
tions or further information that could be lowing address:
helpful to you. Daimler AG, HPC: CAC, Customer Service,
X This symbol designates an instruc- 70546 Stuttgart, Germany
©Daimler AG: not to be reprinted, translated
tion you must follow.
X Several consecutive symbols indi- or otherwise reproduced, in whole or in part,
cate an instruction with several without written permission from Daimler AG.
steps.
(Y page) This symbol tells you where you
Equipment manufacturer
can find further information on a
topic.
Daimler AG
YY This symbol indicates a warning or
Mercedesstraße 137
an instruction that is continued on
the next page. 70327 Stuttgart
Display This text indicates an indicator in Germany
the display.
As at 21.10.2013
Welcome
Familiarise yourself with your engine system
and read the Operating Instructions before
you use the engine system. This will help you
to avoid endangering yourself or others.
The standard equipment and product descrip-
tion of your engine system may vary, depend-
ing on individual specifications. This is descri-
bed on the data card.
The engine systems are constantly updated
to be state of the art.
MTU/Mercedes-Benz reserves the right to
make changes to the following:
Rdesign
Requipment
Rtechnical features
Descriptions may therefore differ in individual
cases from your engine system.
9345843771 É9345843771)ËÍ
Contents 3
Index ....................................................... 4 At a glance ........................................... 11
Introduction ........................................... 7 Safety ................................................... 23
Transport, installation ........................ 27
Operation ............................................. 29
Maintenance ........................................ 47
Decommissioning ............................... 57
Troubleshooting .................................. 59
Technical data ..................................... 71

4 Index
A D
AdBlue®/DEF Data card .............................................. 72
Consumption ................................... 42 DEF/AdBlue®
Gauge .............................................. 35 see AdBlue®/DEF service products
Important safety notes .................... 44 Description of the engine ................... 12
Refuelling ......................................... 44 Diagnostics connection ...................... 25
Service product ............................... 53 Diesel
ADM (FR (drive control) unit) ............. 12 Fuels ................................................ 52
Low outside temperatures ............... 52
B Refuelling ......................................... 43
Battery (vehicle) Dimensions .......................................... 73
Jump starting ................................... 62 Disposal of service products .............. 49
Braking Driving mode
Continuous brake ............................ 33 Idling speed ..................................... 33
Engine brake .................................... 33 Driving tips .......................................... 41
Retarder ........................................... 33
Buzzer ................................................... 42 E
Electronic engine control
C see Engine management
Capacities ............................................ 75 Electronic engine control unit ............ 34
Care products ...................................... 55 Emergency gearshift
Charge current .................................... 34 Using the emergency switch ............ 34
Checking the fluid level ...................... 30 Emergency running program ................ 8
Cleaning and care Engine
Engine cleaning ................................ 55 Capacities ........................................ 75
High-pressure cleaning .................... 55 Cleaning ........................................... 55
Notes on care .................................. 55 Data ................................................. 72
Consumption Data card ......................................... 72
AdBlue®/DEF .................................. 42 Data plate ........................................ 72
Fuel .................................................. 42 Modifying the power output ............... 8
Oil (engine) ...................................... 42 Oil consumption ............................... 42
Continuous brake Operating data ................................. 74
Rectifying faults ............................... 65
Important safety notes .................... 33
Running-in period ............................. 41
Coolant
Starting ............................................ 31
Mixing ratio ...................................... 51
Stopping .......................................... 32
Service product ............................... 51
Engine brake ........................................ 33
Topping up ....................................... 31
Engine data .......................................... 72
Coolant additive .................................. 51
Engine data card .................................. 72
Correct use ............................................ 8
Corrosion inhibitor/antifreeze Engine description .............................. 12
agent .................................................... 51 Engine idling speed ............................. 33
Engine management ........................... 18
Engine oil
Consumption ................................... 42
For winter operation ........................ 49
Index 5
Mixing .............................................. 50 O
Oil change ........................................ 50
Topping up ....................................... 50 Oil (engine)
Engine overview .................................. 13 For winter operation ........................ 49
Engine speed ....................................... 35 Oil change ........................................ 50
Exhaust gas aftertreatment ............... 20 Scope of use .................................... 50
Oil pressure ......................................... 34
Operating data ..................................... 74
F
Operating instructions
Fuel General notes .................................. 10
Additives .......................................... 53 Operating safety .................................. 24
Consumption ................................... 42 Operating safety and registration
Diesel ............................................... 52 Changes in engine performance ........ 8
Refuelling ......................................... 43 Implied warranty ................................ 8
Fuel grade ............................................ 52 Operational monitoring ...................... 34
Fuel system Organisational measures ................... 25
Automatic bleeding .......................... 61
Manual bleeding .............................. 61 P
Fuses
Checking and replacing a safety Personnel ............................................. 25
fuse .................................................. 62 Preparing for starting operation
Important safety notes .................... 62 see Starting operation
Protection of the environment ............. 7
G
Q
Gauge
AdBlue®/DEF .................................. 35 Qualified specialist workshop ........... 10
Genuine Mercedes-Benz parts ............. 7
R
H Refuelling
High-pressure cleaning ....................... 55 AdBlue®/DEF .................................. 44
Fuels ................................................ 43
I Requirements of the personnel ......... 25
Rev counter .......................................... 35
Identification plate .............................. 72 Roadside Assistance ........................... 60
Idling speed Running the vehicle in ........................ 41
Engine .............................................. 33
Installation ........................................... 28 S
J Safety and emergency running pro-
gram ....................................................... 8
Jump-starting ....................................... 62 Safety precautions .............................. 24
Service products
M AdBlue®/DEF .................................. 53
Maintenance Coolant ............................................ 51
Notes ............................................... 48 DEF/AdBlue® .................................. 53
Mercedes-Benz Service Centre Diesel fuel ........................................ 52
see Qualified specialist workshop Disposal ........................................... 49
6 Index
Disposing of AdBlue®/DEF .............. 54

Engine oil ......................................... 49
Fuel additives ................................... 53
General notes .................................. 49
Purity of AdBlue®/DEF .................... 55
Storing AdBlue®/DEF ...................... 54
Specialist workshop ............................ 10
Starting
see Starting (engine)
Starting (engine) .................................. 31
Stopping and switching off the
engine ................................................... 31
T
Technical data
Dimensions ...................................... 72
Filling capacities .............................. 75
Operating data ................................. 74
Weights ............................................ 72
Tightening torques .............................. 76
Transport .............................................. 28
W
Warning and indicator lamps
Electronics ....................................... 36
Engine, general ................................ 20
Warning buzzer .................................... 42
Weights ................................................ 73
Winter diesel ........................................ 52
Winter operation ................................. 45
Introduction 7
Engine system Please contact an MTU or MTU-authorised

Mercedes-Benz Service Centre if you have
The 4R 1000 and 6R 1000 series of engines any questions about the equipment or oper-
only function as intended when used in con- ation.
junction with the corresponding exhaust gas
aftertreatment unit. Therefore, in these Oper-
ating Instructions, the term "engine system" Genuine Mercedes-Benz parts
refers to the engine and the exhaust gas after-
treatment unit. H Environmental note
Daimler AG also supplies reconditioned
assemblies and parts which are of the same
Protection of the environment quality as new parts. For these, the same war-
ranty applies as for new parts.
H Environmental note
Daimler AG has a declared policy of compre- If you use parts which have not been
hensive environmental protection. approved by Mercedes-Benz, the operational
safety of the engine system may be jeopar-
The objectives are to use the natural resour-
dised. This could lead to malfunctions in
ces which form the basis of our existence on
safety-relevant systems. Use only genuine
this planet sparingly and in a manner which
Mercedes-Benz parts or parts of equal qual-
takes the requirements of both nature and
ity. Only use parts that have been approved
humanity into account.
for your engine type.
You too can help to protect the environment
Mercedes-Benz checks genuine Mercedes-
by operating your vehicle in an environmen-
Benz parts for:
tally responsible manner.
Rreliability
Information and notes on driving in an envi- Rsafety
ronmentally responsible and fuel-saving man- Rsuitability
ner can be found in the "Operating notes"
Despite ongoing market research, Mercedes-
section (Y page 42).
Benz is unable to assess other parts.
Mercedes-Benz therefore accepts no respon-
Assembly equipment sibility for the use of such parts in Mercedes-
Benz vehicles, even if they have been officially
approved or independently approved by a
These Operating Instructions describe all
testing centre.
models and all standard and optional equip-
ment available for your engine system at the In Germany, certain parts are only officially
time of publication of the Operating Instruc- approved for installation or modification if
tions. Country-specific deviations are possi- they comply with legal requirements. This
ble. Note that your engine system may not be also applies to some other countries. All gen-
fitted with all features described. This also uine Mercedes-Benz parts meet the approval
applies to safety-relevant systems and func- requirements. The use of non-approved parts
tions. Therefore, the equipment on your may invalidate the vehicle's general operating
engine system may differ from certain permit.
descriptions and illustrations.
All of the components in your engine system
are listed in the data card of your engine sys-
tem. Data card (Y page 72).
Z
8 Introduction
This is the case if: If the electronic control system detects a mal-
Rthey result in a change to the vehicle type function, one of the following measures is
from that for which the vehicle's general automatically implemented after an appraisal
operating permit was granted of the malfunction:
Rthey pose a possible risk for road users Rfaults during operation are indicated by the
Rthey adversely affect the emission or noise corresponding warning lamp (Y page 34).
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 a play.
Mercedes-Benz or MTU Service Centre Rthe system switches to a suitable backup
(Y page 10). function for the continued, albeit restric-
Always specify the engine number and the ted, operation of the engine. This includes
number of the exhaust gas aftertreatment torque and engine speed limitation, for
unit when ordering genuine Mercedes-Benz example, as well as road speed limitation or
parts. You can find the engine number on the constant emergency running speed.
identification plate of your engine. You can
find the number of the exhaust gas aftertreat-
ment unit on the identification plate of the Correct use
exhaust gas aftertreatment control module
(ACM) (Y page 72). You can also find the The engine system may only be installed as
two numbers on the data card (Y page 72). contractually specified.
The manufacturer of the end product is
responsible for the correct installation of the
Modifying the engine output engine and the exhaust gas aftertreatment
system in the overall system.
! Increased power could: The engine and the exhaust gas aftertreat-
Rchange emission levels ment system may not be modified. If the
engine is modified, Mercedes-Benz and MTU
Rcause malfunctions do not accept responsibility for any damage
Rlead to consequential damage arising as a result.
The operating safety of the engine cannot Correct use of the engine system also
be guaranteed in all situations. requires adherence to the instructions in
Any tampering with the engine management these Operating Instructions. This also
system in order to increase the engine power requires compliance with the maintenance
output will lead to a loss of warranty entitle- intervals and the professional execution of
ments. maintenance work. Please observe the Work-
shop Information System (WIS) (Y page 10).
Safety/emergency running program

Implied warranty
The engine is equipped with an electronic
engine management system that monitors A well-developed network of Mercedes-Benz
the engine and the exhaust gas aftertreat- Service Centres is available to carry out main-
ment unit and has a self-diagnostic system. tenance work.
Introduction 9
Mercedes-Benz Service Centres: If there are legal requirements on emission

Rhave special equipment and tools as well as control, please note that:
specialists who receive continuous training Rmaintenance on the engines must be car-
Rguarantee that your engine system is ried out according to specific regulations
repaired and maintained thoroughly and and using special measuring devices
expertly Rit is prohibited to modify or tamper with
Rcarry out all repairs related to implied war- components relevant to emissions
ranty All Mercedes-Benz Service Centres are famil-
Rcarry out all maintenance work expertly iar with the relevant regulations.
Rconfirm in the Maintenance Booklet that Maintenance work does not include repair
the maintenance work has been carried out work. Issue a separate order for repair work.
at the required time You can obtain further information on the
Rhandle implied warranty claims that are maintenance of your engine system from any
admissible according to the sales contract Mercedes-Benz Service Centre.
Please observe the instructions and recom-
mendations as well as the maintenance serv-
ices in the Maintenance Booklet. Please Stored data
observe these instructions even if you let a
third party use and care for your vehicle/ Several of the electronic components in your
device. This is the only way to ensure that you engine system contain data memories.
do not lose your entitlements. These data memories temporarily or perma-
If the prescribed maintenance work is not nently store technical information about:
carried out, claims can only be decided after Rthe engine system state
the manufacturer has inspected the claim. Revents
During the implied warranty period, have the Rmalfunctions
prescribed maintenance service for your In general, this technical information docu-
engine system carried out as follows: ments the state of a component, a module, a
Rregularly system or the surroundings.
Rpunctually This includes, for example:
Rat a qualified specialist workshop which Roperating conditions of system compo-
has the necessary specialist knowledge nents, e.g. fluid levels
and tools to carry out the work required Rstatus messages for the vehicle/equip-
Mercedes-Benz recommends that you use ment and its individual components, e.g.
a Mercedes-Benz Service Centre for this speed, deceleration in movement, acceler-
purpose. In particular, work relevant to ator position
safety or on safety-related systems must Rmalfunctions and defects in important sys-
be carried out at a qualified specialist work- tem components
shop.
Rthe reactions and operating statuses of the
vehicle/equipment in special driving situa-
tions
Rambient conditions, e.g. outside tempera-
ture
Z
10 Introduction
This data is exclusively technical in nature Further applicable documents

and can be used to:
Rassist in the detection and rectification of To use the engine correctly, you require the
faults and defects Maintenance Booklet in addition to these
Ranalyse vehicle functions, e.g. after an acci- Operating Instructions.
dent For US-certified engines you also require the
The data cannot be used to trace the vehicle's "Emission Related Warranty" supplement.
movements. Always keep these documents together with
When you use one of the available services, the engine/vehicle/equipment. These docu-
technical information may be read from the ments should be passed on to the new owner
event data memory and fault data memory. if you sell the engine/vehicle/device.
Services include, for example: When carrying out maintenance work, you
require access to the Workshop Information
Rrepair services System (WIS) via the Internet. This access is
Rservice processes subject to a fee.
Rimplied warranty and guarantee cases Current information on the system and prices
Rquality assurance can be found at this web address: http://
The information is read out by employees of service-parts.mercedes-benz.com. Click on
the service network (including manufactur- "EPC, WIS/ASRA" in the "Service and parts
ers) using special diagnostic testers. Further information" tab and then on "WIS".
information is available there if required. You can log in by clicking on "Register" on the
After a fault has been rectified, the informa- right-hand side.
tion is deleted from the fault memory or is
continually overwritten.
Qualified specialist workshop
A qualified specialist workshop has the nec-

essary specialist knowledge, tools and quali-
fications to carry out the work required on the
engine to a professional standard. This is par-
ticularly applicable to work relevant to safety.
Observe the notes in the Maintenance Book-
let.
Always have the following maintenance 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.
11
General information ............................ 12

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

At a glance
sel engine with direct injection.

The engine is equipped with a Common Rail
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 twin overhead camshafts
which are gearwheel-driven.
The engine has a single-part cylinder head. In
the cylinder head there are two inlet valves
and two exhaust valves per cylinder. The
valves are arranged symmetrically. The sym-
metrical 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 can be
controlled stepwise 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)
= Refrigerant compressor
? 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 vehicle/equipment-
The engine system is equipped with an elec- side connection, 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 34). 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 10) 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-
At a glance
The engine management control module led in a protected location in the vehicle/
(MCM) is located on the side of the engine. It equipment by the vehicle/equipment manu-
acts as an interface between the electric and facturer. It acts as an interface between the
electronic components on the engine/equip- electric and electronic components on the
ment and the drive control system unit (CPC) vehicle/equipment and the engine manage-
on the vehicle. ment control module (MCM) on the engine.
The engine management control module The drive control system unit (CPC) has many
(MCM) has many functions: functions:
RInjection control of the Common Rail diesel RCalculation of torque demand
injection system The drive control system unit (CPC) regis-
The engine management control module ters the driver's requirements. For exam-
(MCM) calculates the optimum start and ple, the position of the accelerator is detec-
quantity of injection, taking the torque ted by the drive control system unit (CPC).
demand from the drive control system unit A torque requirement is calculated from
(CPC) into account. that and sent to the engine management
All of the data required for this, e.g. power control module (MCM) via the CAN con-
output or data which serve to protect the nection.
engine, are stored in the engine manage- In doing so, information and limitations
ment control module (MCM). from optionally connected control units
RRegulation of exhaust gas recirculation such as the gearbox control, retarder con-
(EGR) trol, ABS and ASR are taken into account.
The ratio between the mass of recirculated ROutput of displays and indicator signals
exhaust gas and the fresh air mass is pre- which are displayed in the instrument clus-
cisely regulated over the entire engine ter.
speed range. RMonitoring of coolant level, charge current
RCharge-air pressure control and air filter, for example
RControl of the engine brake RLegal speed limitation
The 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 unit
(MCM) detects the oil level, engine oil tem- (ACM) is installed in a protected location in
perature, oil pressure, coolant temperature the vehicle/equipment by the vehicle/equip-
and the engine speed for the displays in the ment manufacturer. It regulates and controls
instrument cluster. the 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-
At a glance
The sensor signals of the directly connec- marily to reduce the amount of nitrogen oxide
ted sensors are evaluated. Data provided prior to exhaust gas aftertreatment. This
via the CAN by the engine management serves to comply with emissions limits.
control module (MCM) and the control Exhaust gas is added to the fresh air being
units for the NOx sensors are also evalu- drawn in or charged so that the concentration
ated. of oxygen in the combustion mixture is
RAdBlue®/DEF injection reduced. Combustion deteriorates if the con-
centration of exhaust gas in the combustion
Calculation of the required amount of mixture is too high. The emission of soot par-
AdBlue®/DEF and supply of AdBlue®/DEF ticles, carbon monoxide (CO) and hydrocar-
by actuation of the SCR delivery pump. bons (HC) increases. Conversely, the emis-
Injection by actuation of the AdBlue®/DEF sion of nitrogen oxides (NOx) would increase,
metering unit. if the concentration of fresh or charged air
was too high.
Exhaust gas aftertreatment

The exhaust gas aftertreatment system is
activated immediately after the engine is star- Important safety notes
ted and remains activated during engine If you ignore warning and indicator lamps, you
operation. It ensures that the pollutant emis- will not be able to recognise failures and mal-
sions in the exhaust gas are reduced to the functions in components or systems. Driv-
limits stipulated in the emissions standard. ing/braking characteristics may be different
Exhaust gas treatment is carried out by: and the operating and road safety of your
Rselective
vehicle/equipment may be limited. Have the
catalytic reduction (SCR) with
affected system checked and repaired at a
ammonia slip catalytic converter
qualified specialist workshop. Always
Rthe diesel oxidation catalytic converter
observe the warning and indicator lamps and
(DOC) follow the corresponding corrective actions
In order to ensure correct operation of the (Y page 36).
exhaust gas aftertreatment system, only
operate the engine/vehicle with the AdBlue®
reducing agent. AdBlue® is not refilled as part Overview
of the maintenance work. You should there-
The display format for warning and indicator
fore top up the AdBlue® tank regularly your- lamps is vehicle-specific/equipment-spe-
self. cific. Observe the information contained in
Operating the vehicle/equipment without the Operating Instructions for the vehicle/
AdBlue® or with another, non-Mercedes-Benz equipment. The symbols listed below are
or non-MTU approved medium, invalidates examples and may differ from those symbols
the engine's operation certification/ displayed in the vehicle/equipment.
approval. 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
At a glance
may be available on the instrument panel:
Indicator Description
lamp
red Engine stop
Ù Engine system malfunction

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

stantly)
(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 (engine)
(optional)
, 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
Safety
Organisational measures ................... 25
24 Notes on electronic systems
Operating safety RPlease note, when carrying out electric

welding work, that the batteries must be
G WARNING disconnected and both of the cables ("+"
and "-") must be firmly attached to each
If you do not have the prescribed service/
other.
maintenance work or necessary repairs car-
RThe control unit connectors may only be
Safety
ried out, this could result in malfunctions or

system failures. There is a risk of an accident. connected/disconnected when the elec-
trical system is switched off.
Always have the prescribed service/mainte-
RIncorrect control unit-power supply
nance work as well as necessary repairs car-
ried out at a qualified specialist workshop. polarity (e.g. by connecting up the bat-
teries incorrectly) can cause irreparable
The operating safety of an engine system damage to the control units.
depends on its professional installation in the RTighten diesel injection system connec-
overall system (e.g. the vehicle or working tions to the prescribed tightening torque.
machinery). As the operator of the engine, RIftemperatures above 80 † are to be
you also affect its safe operation.
expected (e.g. in a drying oven), the con-
Through compliance with the prescribed trol unit on the engine must be removed.
maintenance intervals, you fulfil part of the ROnly use the appropriate testing probes
requirements for safe operation of the
when taking measurements from electri-
engine.
cal connectors (e.g. a Mercedes-Benz
However, safe operation of the engine also connection set). Telephones and two-
depends upon its proper use and care. This way radio devices that are not connected
includes, for example, regularly checking the to an external aerial can cause malfunc-
oil level. tions in the electronics and thus endan-
ger the operating safety of the engine.
Safety precautions
Warning stickers
Damage to the engine can also lead to per-
sonal injury. In order to avoid engine damage, If you remove any warning stickers, you or
the following safety precautions must be others could fail to recognise certain dangers.
adhered to. Various warning stickers are attached to the
engine system. Their purpose is to make you
ROnly start the engine when the batteries
and others aware of various risks.
are firmly attached.
RDo not disconnect the batteries when the
engine is running. Notes on electronic systems
RDo not use a rapid charger to start the
engine. Important safety notes
ROnly perform the jump-starting proce- G WARNING
dure with separate batteries. Modifications to electronic components, their
RNote, the battery terminals must be dis- software as well as wiring could effect their
connected when rapid charging the bat- function and/or the operation of other net-
teries. worked components. This could in particular
RObserve the operating instructions of the also be the case for systems relevant to
rapid battery charger. safety. They might not function properly any
Organisational measures 25
more and/or jeopardise the operational Staff qualifications

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

Diagnostics connection bilities for operation, maintenance and
repairs. Give the Operating Instructions and
The diagnostics connection is used for con-
the Maintenance Booklet to the personnel
necting diagnostic equipment at a qualified
that are charged with operating or carrying
specialist workshop.
out work on the engine.
G WARNING Instruct personnel on how to operate the
If you connect equipment to a diagnostics engine using the Operating Instructions.
connection in the vehicle, it can affect the When doing so, put special emphasis on
operation of the vehicle systems. This may safety-relevant information. This is particu-
affect the operating safety of the vehicle. larly important for personnel that only work
There is a risk of an accident. occasionally on the engine.
Do not connect any equipment to a diagnos- Always keep the Operating Instructions and
tics connection in the vehicle. the Maintenance Booklet readily accessible,
in the area of engine operation.
If the engine is switched off and devices con- In addition to the Operating Instructions,
nected to the diagnostics connection are other general, country-specific, legal and
being used, the starter battery can become other binding regulations on accident preven-
discharged. tion and environmental protection must be
Connecting devices to the diagnostics con- adhered to.
nection can, for example, cause the emis-
sions monitoring information to be reset. As a
result, there is a possibility that the vehicle/
equipment will not fulfil the requirements of
the next legally prescribed emissions test.
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,
Transport, installation
causing serious or even fatal injury.

Always make sure that:
Rthe engine is only lifted at the intended lift- : Example: belt-side lifting point
ing points/lifting lugs.
Rthe engine is only lifted and transported in
the fitting position.
Rropes/chains are always routed vertically.
Ronly parts which are typically in the original
scope of delivery are attached to 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 ; Example: flywheel-side lifting point
transport the engine in the installation posi-
tion.
! Do not stand on the engine or the exhaust Installation
gas aftertreatment unit. They may other-
wise be damaged. The engine system may only be installed as
contractually specified.
Observe the sections "Correct use" (Y page 8)
and "Modifying the engine output" (Y page 8).
Daimler AG provides the vehicle manufac-
turer with comprehensive material, e.g. 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 10).
Example: using a cross member Observe the sections "Qualified specialist
The engine may only be lifted using a cross workshop" (Y page 10) and "Further applica-
member with the chain/rope at 90° relative ble documents" (Y page 10).
to the horizontal engine. Please consult an MTU or MTU-authorised
Mercedes-Benz Service Centre (Y page 10) if
you have any questions. .
29
Preparation for operation ................... 30

Starting and stopping the engine ...... 31
Switching the continuous brake on
and off .................................................. 33
Idling speed ......................................... 33
Operational monitoring ...................... 34
Displays ............................................... 35
Warning and indicator lamps ............. 36
Operating instructions ....................... 41
Operation
Refuelling ............................................. 43
Winter operation ................................. 45
30 Preparation for operation
Preparation for operation possible with the engine switched off and the
ignition switched on.
Engine with initial operation oil from
X Park the vehicle/device on a level surface.
the factory
X Engage the parking brake.
The engine is filled at the factory with an initial X Switch off the engine.
operation oil.
X Wait approximately 5 to 10 minutes. If you
These high-quality engine oils are beneficial call up the oil level in the engine too early or
to the running-in process. They also allow you while the engine is running, it is not availa-
to make the first oil change in accordance ble.
with the applicable oil change intervals. This
Only use engine oil which has been approved
Operation
eliminates the need for special break-in oils

and the additional oil change otherwise for the engine and which meets the specified
required. SAE classification (Y page 49).
Checking the oil level with the dipstick

Checking the engine oil level ! Do not add too much oil. If you add too
The engine is equipped with an electronic oil much oil, the engine or the exhaust after-
level detection system. treatment unit could be damaged. Drain or
If the engine is also equipped with a dipstick, siphon off any excess oil.
this is subsidiary to the electronic oil level Check the engine oil level on a regular basis,
measurement system. It is merely used for a e.g. before each journey or each time you
general check to determine if there is oil in the refuel.
engine. X Park the vehicle/device on a level surface.
Electronic oil level measurement – sys-
X Switch off the engine.
tem description
X Wait approximately 5 to 10 minutes.
The engine oil level sensor is installed in the
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
(CPC) via the engine CAN.
Output can be displayed on a matrix display
when the engine is not running.
The engine oil level is not displayed while the
engine is 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.
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
display of the engine oil level is therefore only
Starting and stopping the engine 31
X Check the engine oil level with dipstick ;. ! If the oil pressure in the engine is too low,
The oil level should be between the upper a warning light lights up on the instrument
and lower marks on dipstick ;. panel. The warning buzzer also sounds.
X If necessary, use filler neck : to top up the The operating safety of the engine is jeop-
oil. ardised. Switch off the engine immediately.
Only use engine oil which has been approved Do not pull away as soon as the engine starts.
for the engine and which meets the specified Do not subject the equipment to high loads
SAE classification (Y page 49). immediately. Let the engine run in neutral for
a short time after starting, until there is suf-
ficient engine oil pressure. Do not drive at
Operation
Checking the coolant level high engine speeds when the engine is cold.
X Check the coolant level as stated in the This will prevent excessive wear and possible
vehicle's/equipment's Operating Instruc- engine failure.
tions. Warm up the engine quickly by driving at
X Fill the cooling system if necessary. Only moderate engine speeds. Depending on the
use coolant that has been approved for the outside temperature, the engine will reach its
engine (Y page 51). operating temperature after around 10 to
20 minutes. Operating temperature
(Y page 74).
Checking the fuel level You can utilise the full engine power output
once the engine has reached its normal oper-
For checking the fuel level on the fuel gauge, ating temperature.
see the vehicle's Operating Instructions.
The display format for warning and indicator
Refuel if necessary (Y page 52).
lamps is vehicle-specific/equipment-spe-
cific. Observe the information contained in
the Operating Instructions for the vehicle/
Checking the AdBlue®/DEF supply equipment.
For checking the AdBlue®/DEF supply on the X Start the engine using the key in the ignition
AdBlue®/DEF gauge, see the vehicle's Oper- lock or the external engine start/engine
ating Instructions. Refuel if necessary stop button on the engine. Do not depress
(Y page 44). the accelerator or clutch pedal while doing
so.
For additional safety, the electronic engine
Starting and stopping the engine management system is equipped with a func-
Starting the engine tion that only allows the engine to be started
when the transmission is in neutral (vehicle/
G WARNING equipment-specific).
Combustion engines emit poisonous exhaust
gases such as carbon monoxide. Inhaling Starting the engine with the key
these exhaust gases leads to poisoning. There
is a risk of fatal injury. Therefore never leave ! After starting the engine, let it run at
the engine running in enclosed spaces with- engine idling speed until the oil pressure is
out sufficient ventilation. displayed. If no oil pressure is displayed
after approximately 10 seconds, switch off
the engine. Determine the cause. The oper-
ating safety of the engine is jeopardised.
Z
32 Starting and stopping the engine
Starting the engine with the external

engine start/engine stop button
X To start the engine with the external
engine start/engine stop button:
(Y page 60).
Stopping the engine

G WARNING
Operation
Example: ignition lock When switching off the equipment or parking

g To insert/remove the vehicle key the vehicle, make sure that the exhaust sys-
tem does not come into contact with com-
1 Steering wheel unlocked/radio position
bustible objects, e.g. dry leaves, grass or
2 Drive position (ignition)
other highly flammable materials.
3 Start position
X Secure the vehicle/equipment against roll- G WARNING
ing away. If you switch off the ignition while the vehicle
X Deactivate power take-off. is in motion, safety-relevant functions are
X Shift into neutral. restricted or not available. This can affect the
power steering function and the brake boost-
X To start the engine: turn the key in the
ing effect, for example. You will then require
ignition lock to drive position 2.
considerably more force to steer and brake.
X Turn the key to start position 3 in the igni-
There is a risk of an accident.
tion lock. Do not depress the accelerator
Do not switch off the ignition while the vehicle
pedal whilst doing so.
is in motion.
X When the engine has started, release the
key. ! Stop the engine immediately, paying
The idling speed is controlled automati- attention to the road and traffic conditions
cally. if:
i The engine idling speed is raised at very Rthe oil pressure falls or fluctuates signif-
low outside temperatures or during regen- icantly.
eration of the diesel particle filter. Rthe power output or engine speed
X If the engine does not start immedi- decreases and the position of the posi-
ately: interrupt the starting procedure tion sensor (accelerator) remains con-
after no more than 30 seconds. stant.
X Turn the key in the ignition lock back to the Rheavy smoke is emitted from the
stop at key position g. exhaust.
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 65).
X Observe the oil pressure gauge immedi-
ately after having started the engine.
Idling speed 33
X Park the vehicle/equipment. The engine brake and retarder are used as a
X Secure the vehicle/equipment against roll- continuous brake.
ing away. You can utilise the engine's braking effect,
X Shift the transmission into neutral/decou- particularly on long downhill gradients if you:
ple the drive system. Ractivate the continuous brake
Let the engine idle for approximately 2 Rshift to a lower gear in good time
minutes before switching off the engine if: Slowly depress the brake pedal if the engine's
Rthe coolant temperature is very high (over braking effect is insufficient when driving
100 †). downhill.
Rthe engine has been operated at full output. Vehicles without a retarder are equipped with
Operation
X To switch off the engine: turn the vehicle
only two brake stages.
key in the ignition lock back to the stop at Operation of the continuous brake; see the
position u. vehicle's Operating Instructions.
The Ã indicator lamp in the instrument
i If you switch off the engine, the system cluster is lit when the continuous brake is
may continue to run for a short while. active.
Depending on the installation position, When ABS (Anti-lock Braking System) inter-
operating state and ambient temperature, venes, the continuous brake is switched off.
circulation of AdBlue®/DEF is necessary The Ã indicator lamp in the instrument
for ensuring cooling. To do this the cluster remains on.
AdBlue®/DEF delivery pump is actuated
during this period.
Engine brake
Switching off the engine with the exter-
nal engine start/engine stop button The effectiveness of the engine brake
depends on the engine speed. A high engine
X To switch off the engine with the exter- speed results in more effective engine brak-
nal engine start/engine stop button: ing.
(Y page 60). Observe the effective engine braking range
marked on the rev counter (Y page 35).
At very low outside temperatures, the engine
Switching the continuous brake on brake has limited or no effect after the engine
and off has been started.
Operation of the engine brake; see the vehi-
G WARNING cle's Operating Instructions.
If you activate the continuous brake or shift to
a lower gear on a slippery road surface in
order to increase the engine's braking effect, Retarder
the drive wheels may lose traction. There is an
Operation of the retarder; see the vehicle's
increased risk of skidding and an accident.
Operating Instructions.
Do not activate the continuous brake and do
not shift to a lower gear in order to increase
the engine's braking effect on a slippery road Idling speed
surface.
After the engine has been started, idling
speed is regulated automatically. The engine
Z
34 Operational monitoring
idling speed may differ in certain operating Oil pressure

conditions depending on the engine or on
vehicles with power take-off. If the 1 indicator lamp does not go out or
if it lights up when the engine is running,
The engine idling speed for the 6R1000
switch off the engine. Searching for and elim-
engine can be set between approximately
inating the cause of the malfunction
600 and 800 rpm. For the 4R 1000 engine,
(Y page 65).
the engine idling speed can be set between
approximately 680 rpm and 800 rpm.
The engine idling speed is raised at very low Operating restrictions
outside temperatures or during regeneration
The electronic engine management system
Operation
of the diesel particle filter.

monitors:
You can set the speed to the working speed
via the electronic engine management sys- Remissions-relevant malfunctions in the
tem. This makes it possible to drive auxiliary exhaust gas aftertreatment
equipment such as pumps at their working Rmalfunctions in the electronic monitoring
speed. For setting the working speed, see the of the exhaust gas aftertreatment system
vehicle's Operating Instructions. Rconsumption, level and quality of the
AdBlue®/DEF reducing agent
Rthe efficiency of the catalytic converter in
Operational monitoring
accordance with the permitted thresholds
Charge current for nitric oxide emissions (NOx)
The charge current indicator lamp must go Operating restrictions in the form of torque
out after the engine has started. reduction and thus output and speed limita-
tion may occur.
If the # indicator lamp does not go off or
lights up when the engine is running, switch
off the engine. Searching for and eliminating Emergency switch for overriding the
the cause of the malfunction (Y page 65). operating restrictions
If an emissions-related malfunction of the
Electronic engine management exhaust gas aftertreatment system or
AdBlue®/DEF supply is detected, this can
The indicator and warning lamps must go out
lead to operating restrictions (engine torque
after the engine has started.
and engine speed limitation).
If an indicator lamp or warning lamp does not
In emergencies, a push-button switch can be
go out, or if it lights up while the engine is
operated to override the operating restric-
running, there is a malfunction in the elec-
tion. This means that full engine power is
tronic engine management system.
available for a maximum of 30 minutes. This
Each malfunction is stored in the system with emergency function by operating the switch
its own fault code. Temporary faults are also can be activated a maximum of three times.
stored.
If the final operating restriction (idling speed
Fault codes can be read by a qualified spe- and 20% of torque) has been reached, the
cialist workshop using a diagnostic tester push-button switch is deactivated.
(Y page 8).
Displays 35
Displays AdBlue®/DEF level

Rev counter The AdBlue®/DEF gauge is the responsibility
of the vehicle manufacturer. It is not neces-
! If you exceed the maximum permissible
sarily supplied by Mercedes-Benz. Daimler
engine speed, the warning tone sounds.
AG recommends that the vehicle manufac-
You should not drive and change gear by turer uses an AdBlue®/DEF gauge and an
the sound of the engine, but according to
AdBlue®/DEF indicator lamp for the
the engine speed shown in the rev counter.
AdBlue®/DEF reserve level Ø.
Avoid driving in the red overrevving range.
This could lead to engine damage. The AdBlue®/DEF reducing agent is required
Operation
for reduction of engine emissions.
The engine speed display is the responsibility
The operating permit is invalidated if the vehi-
of the vehicle manufacturer and is not nec-
essarily supplied by Mercedes-Benz. Daimler cle is operated without AdBlue®/DEF. The
AG recommends that the vehicle manufac- legal consequence of this is that the vehicle
turer uses a rev counter divided by: may no longer be operated on public roads.
If the AdBlue®/DEF level has sunk to approx-
Roperational efficiency
imately 10 %, a warning lamp for the
Rengine braking range AdBlue®/DEF reserve level lights up on the
Rengine overrevving range
instrument panel. Top up the AdBlue®/DEF
General notes on the rev counter: tank in good time (Y page 44).
RKeep an eye on the rev counter while driv- If the gauge is ignored and the AdBlue®/DEF
ing and stay within the economical operat- level drops further, engine torque and engine
ing range. speed may be reduced.
In some situations it may make sense to Engine torque may be limited to a maximum
operate the engine outside the economical of 20% across the whole engine speed range.
engine speed range, e.g. on uphill gradients Engine speed may be limited to idling speed.
or when overtaking.
RIf you run the engine within the economical
engine speed range, you achieve low fuel
consumption and reduced wear.
RIn engine braking mode, drive in the middle
engine speed range. The highest engine
braking effect will be achieved just before
the red overrevving range.
RWhen driving downhill, make sure that the
engine speed does not enter the overrev-
ving range (marked red).
RIdling speed is set automatically depending
on the coolant temperature.
RWhen the vehicle is stationary, the engine is
running and the transmission is in neutral,
the engine increases throttle only slowly.
Z

Warning and indicator lamps - causes/consequences and solutions
Problem Possible causes/consequences and M Solutions
The indicator lamp A serious fault in the engine system has been detected.
flashes red. X Immediately stop the vehicle/equipment while paying attention
to the traffic conditions and contact a qualified specialist work-
shop.
The Ù indicator Impermissible operating conditions have been detected in the

Operation
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.
Only vehicles/equipment 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 emergencies, operating restrictions (engine torque and engine
speed restrictions) can be temporarily overridden with the emergency switch (Y page 34).

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, the engine speed may be

limited.
Operation
The Ø indicator The AdBlue®/DEF level has dropped to approximately 5%.
lamp is lit and · and Reduced engine output and engine speed limitation are active. The
are flashing. engine torque is limited to a maximum of 50% across the whole
engine speed range. The engine speed is limited to a maximum of
60%. The limitation takes effect by means of a ramp function.
If you do not observe the instructions, engine torque and engine

speed may be reduced further.
The Ø and indi- The AdBlue®/DEF level has dropped to approximately 2.5%.
cator lamps are lit and Reduced engine output and engine speed limitation are active. The
· and are engine torque is limited to a maximum of 20% across the whole
flashing. engine speed range. The engine speed is limited to idling speed.
The limitation takes effect by means of a ramp function.
The Ø indicator The AdBlue®/DEF level has dropped to approximately 0%.

lamp lights up and Reduced engine output and engine speed limitation are active. The
·, and engine torque is limited to a maximum of 20% across the whole
are flashing. engine speed range. The engine speed is limited to idling speed.
The limitation takes effect by means of a ramp function.
X Stop the vehicle/equipment, paying attention to road and traffic
conditions.
Z

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 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
Operation
starts, several hours or several journeys without a malfunction.
The indicator lamp You have not rectified an emissions-relevant malfunction that has
lights up and · is been detected in the exhaust gas aftertreatment system or in the
flashing. AdBlue®/DEF supply.
Reduced engine output is active. The engine torque is limited to a
maximum of 75% across the whole engine speed range. The limi-
tation takes effect by means of a ramp function.
X Drive carefully to the nearest qualified specialist workshop and
have the malfunction rectified immediately.
If you do not follow the instructions, engine speed may be limited.
The and · indi- You have not rectified an emissions-relevant malfunction that has
cator lamps are flash- been detected in the exhaust gas aftertreatment system or in the
ing. AdBlue®/DEF supply.
Reduced engine output and engine speed limitation are active. The
engine torque is limited to a maximum of 50% across the whole
60%. The limitation takes effect by means of a ramp function.
X Drive carefully to the nearest qualified specialist workshop and
have the malfunction rectified immediately.
If you do not follow the instructions, further engine speed limita-
tion may be imposed.
The and · indi- You have not rectified an emissions-relevant malfunction that has
®
ing and lights up. AdBlue /DEF supply.
engine speed range. The engine speed is limited to idling speed.
X Have the malfunction rectified immediately at a specialist work-
Operation
shop.
The , · and You have not rectified an emissions-relevant malfunction that has
indicator lamps been detected in the exhaust gas aftertreatment system or in the
are flashing. AdBlue®/DEF supply.
maximum of 20% across the whole engine speed range. The engine
speed is limited to idling speed.
conditions.
X Have the malfunction rectified immediately at a specialist work-
shop.
When the AdBlue®/DEF tank is filled or the fault is rectified, full engine power will be available
again. If the system check does not detect any other faults, the indicator lamps go out after the
system's status indicator. The system check may involve several engine starts, several hours
or several journeys without a malfunction.
Only vehicles/equipment 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 emergencies, operating restrictions (engine torque and engine
speed restrictions) can be temporarily overridden with the emergency switch (Y page 34).
Z

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
Operation
further test routines. The system check may involve several engine
starts, several hours or several journeys without a malfunction.
The · indicator You have not rectified an emissions-relevant malfunction that has
lamp is flashing and been detected in the exhaust gas aftertreatment system or in the
lights up. AdBlue®/DEF supply.
maximum of 75% across the whole engine speed range. The limi-
tation will take effect the next time the engine is started.
X If this does not help: have the malfunction rectified at a qualified
If you do not follow the instructions, engine speed may be limited.
The · and indi- You have not rectified an emissions-relevant malfunction that has
ing. AdBlue®/DEF supply.
60%. The limitation will take effect by means of a ramp function.
If you do not follow the instructions, further engine speed limi-
tation may be imposed.
Operating instructions 41
The · and indi- You have not rectified an emissions-relevant malfunction that has
®
ing and lights up. AdBlue /DEF supply.
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.
conditions.
X Have the malfunction rectified at a specialist workshop.
When the AdBlue®/DEF tank is filled or the fault is rectified, full engine power will be available
again. If the system check does not detect any other faults, the indicator lamps go out after the
system's status indicator. The system check may involve several engine starts, several hours
or several journeys without a malfunction.
Operating instructions Ravoid high engine speeds.

Rdo not drive at more than ¾ of the maxi-
Running-in mum road speed for each gear.
The running-in period of the engine has a sig- Rchange gear in good time.
nificant effect on the vehicle/equipment, Rdo not shift down to brake the vehicle.
especially with regard to: Rfor vehicles with automatic transmission,
Rservice life do not depress the accelerator pedal
Roperating safety beyond the point of resistance (kickdown).
Reconomy After 2,000 km (30 operating hours), you can
Observe the following notes during the run- gradually bring the vehicle/equipment up to
ning-in period up to 2000 km (30 operating full output and increased engine speeds.
hours):
Ravoid subjecting the engine to full load.
Rrun in the engine with care, using differing
speeds and engine revs.
Z
42 Operating instructions
Fuel consumption AdBlue®/DEF consumption

General notes AdBlue® consumption is between 2 and 4% of
the fuel consumption, depending on engine
Fuel consumption depends on:
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
Rthe fuel type in use may reach 0.2 % of the vehicle's fuel con-
sumption.
Operation
Rmaintenance
Rdriving resistance More arduous operating conditions and
Ryour driving style increased distance covered could result in
engines exceeding this oil consumption
For these reasons, exact details about any
value.
single engine's fuel consumption cannot be
provided.
Warning buzzer
Machine version/vehicle version
If the warning buzzer sounds and the 5
The following components affect fuel con- symbol on the instrument panel is displayed,
sumption: the engine's operating safety is jeopardised.
Rtyres (e.g. tyre pressure, tyre condition) Do not pull away, or stop the vehicle as soon
Rbody type as possible, paying attention to road and traf-
Rdrive train (e.g. transmission ratio) fic conditions. You could otherwise damage
Radditional equipment (e.g. automatic cli-
the engine.
mate control, auxiliary heating) The warning buzzer sounds depending on the
vehicle if:
Maintenance Ryou exceed the maximum permissible
engine speed
The fuel consumption and assembly wear
Rthe engine speed or vehicle speed is too
depend on regular maintenance. Regular
maintenance increases safety and lowers fuel high when changing gears
consumption. Keep to the maintenance inter- Rthe coolant level is too low or the maximum
vals. Always have maintenance work carried permissible coolant temperature (approx-
out at a qualified specialist workshop. imately 112 †) is exceeded. The operating
safety of the engine is jeopardised.
Fuel type Ran emissions-relevant error is detected or
there is an operating restriction due to an
The fuel grade also affects fuel consumption.
emissions-relevant malfunction.
Use of lower fuel grades and/or non-
approved fuel additives will increase fuel con-
sumption. When refuelling, ensure that you
are filling the appropriate fuel grade
(Y page 52).
Refuelling 43
Refuelling ! Only refuel using commercially available,

sulphur-free diesel fuel that complies with
Fuels the following standards:
Important safety notes REN 590 as of 2010, et seq. (max. 0.001%
sulphur by weight) (10 ppm) or
G WARNING RASTM D975 (max. 0.0015% sulphur by
Fuels are poisonous and hazardous to health. weight) (15 ppm).
There is a danger of injury.
The following fuel types are not permitted:
Do not swallow fuel or let it come into contact
Rsulphurous fuel with a sulphur content
with skin, eyes or clothing. Do not inhale fuel
greater than 0.005% by weight (50 ppm)
Operation
vapours. Keep fuels out of the reach of chil-
dren. Rmarine diesel fuel
If you or others come into contact with fuel, Raviation turbine fuel
observe the following: Rheating oils
RWash the fuel off any affected areas of skin Rfatty acid methyl ester FAME (bio-diesel
with water and soap immediately. fuel)
RIf you get fuel in your eyes, rinse them thor- These fuel types cause irreversible damage
oughly with clean water immediately. Seek to the engine and the exhaust gas after-
immediate medical attention. treatment system, as well as also signifi-
RIf fuel is swallowed, seek immediate medi-
cantly reducing the expected service life.
cal attention. Do not induce vomiting. ! Do not use petrol to refuel vehicles with a
RChange any clothing that has come into diesel engine. Even small amounts of petrol
contact with fuel immediately. result in damage to the fuel system and
engine.
G WARNING ! Do not switch on the ignition if you acci-
Fuel is highly flammable. Improper handing of dentally refuel with the wrong fuel. Other-
fuel creates a risk of fire and explosion. wise, the fuel will enter the fuel lines. Notify
Avoid fire, naked flames, smoking and creat- a qualified specialist workshop and have
ing sparks under all circumstances. Switch off the fuel tank and fuel lines drained com-
the ignition and auxiliary heating before car- pletely.
rying out work to the fuel system. Always wear
protective gloves. ! Do not add any special fuel additives to
the diesel fuel.
G WARNING Special fuel additives can lead to:
If you mix diesel fuel with petrol, the flash Rmalfunctions
point of this fuel mixture is lower than that of Rdamage to the catalytic converter
pure diesel fuel. When the engine is running, Rengine damage
components in the exhaust system may over-
heat unnoticed. There is a risk of fire. ! AdBlue®/DEF is not a fuel additive and
Never refuel with petrol. Never add petrol to must not be added to the diesel tank. If
diesel fuel. AdBlue®/DEF gets into the diesel tank, this
could lead to engine damage.
! A higher fuel sulphur content accelerates
the ageing process of the engine oil and can
damage the engine and exhaust system.
Z
44 Refuelling
H Environmental note ! Always close the AdBlue®/DEF tank

If fuels are handled improperly, they pose a properly. Otherwise impurities may get into
danger to persons and the environment. Do the exhaust gas aftertreatment system and
not allow fuels to run into the sewage system, damage it.
the surface waters, the ground water or into ! Make sure that you do not overfill the
the ground. AdBlue®/DEF tank. Otherwise, the
You will find further information on fuel in the AdBlue®/DEF tank could be damaged at
"Service products" section (Y page 52). very low temperatures.
Before filling the tank
Operation
Dispose of AdBlue®/DEF in an environmen-

! If you are using drums or canisters to tally responsible manner.
refuel the vehicle, you should filter the fuel
before adding it. When opening the AdBlue®/DEF tank, small
amounts of ammonia vapours could escape.
This will prevent malfunctions in the fuel
system due to contaminated fuel. Ammonia vapours have a pungent smell and
are particularly irritating to:
X Switch off the engine.
Rskin
X Secure the vehicle/equipment against roll-
Rmucous membranes
ing away.
Reyes
X Observe the fuel grade (Y page 52).
The vapours may cause a burning sensation in
Regularly check the fuel prefilter with heated
the eyes, nose and throat as well as irritation
water separator for condensation.
of the throat and watering eyes.
Avoid inhaling ammonia vapours. Only fill the
AdBlue®/DEF AdBlue®/DEF tank in well-ventilated areas.
AdBlue®/DEF should not come into contact
Important safety notes with skin, eyes or clothing, and should not be
! Do not allow diesel fuel to run into the swallowed. Keep AdBlue®/DEF out of the
AdBlue®/DEF tank. You could otherwise reach of children.
damage the exhaust gas aftertreatment If you come into contact with AdBlue®/DEF,
system. observe the following:
! Only use AdBlue®/DEF in accordance Rimmediately wash AdBlue®/DEF from your
with DIN 70070/ISO 22241. Do not use skin with water and soap.
any additives. Rif AdBlue®/DEF comes into contact with
If AdBlue®/DEF comes into contact with your eyes, rinse your eyes with clean water
painted or aluminium surfaces when filling immediately. Seek medical attention
the tank, rinse the affected area immedi- immediately.
ately with plenty of water. Rif you have swallowed AdBlue®/DEF,
! Do not mix additives to AdBlue®/DEF. Do immediately rinse your mouth with water
and drink plenty of water. Seek medical
not dilute AdBlue®/DEF with tap water.
attention immediately.
This could destroy the exhaust gas after-
Rchange clothing that has come into contact
treatment system.
with AdBlue®/DEF immediately.
Winter operation 45
AdBlue®/DEF is not refilled as part of the Batteries

maintenance work. Top up the tank regularly
Always aim to achieve the full charge status.
during vehicle operation or at the latest when
You can do this by means of careful mainte-
the first event message is displayed on the
nance and low electrical consumption. The
electronic engine management system.
cold start capacity is reduced when it is very
You will find further information on AdBlue®/ cold. For example, at -10 † it is only around
DEF in the "Service products" section 60 % of the normal capacity.
(Y page 53).
Before filling the tank Diesel fuels
Operation
X Switch off the engine. Notes on diesel fuel at low temperatures
X Secure the vehicle/equipment against roll- (Y page 52).
ing away.
Always fill the tank with at least 5 litres, as
smaller amounts could cause malfunctions.
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 51)
Rthe fuel used is suitable for winter use
(Y page 52)
Rthe SAE class of the engine oil used is in
accordance with outside temperatures
(Y page 49).
Jump-starting
G WARNING
The use of liquid or gaseous starting aids can
cause explosions. This may result in severe
injuries.
Do not use liquid or gaseous starting aids
such as ether or Startpilot to start the engine.
Z
46
47
General notes ...................................... 48

Service products ................................. 49
Cleaning and care ............................... 55
Maintenance
48 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.
Observe the instructions for care products.
Maintenance
and injure yourself or others.

Always have maintenance work carried out at Do not let the engine run longer than neces-
a qualified specialist workshop. sary when stationary.
G WARNING Like all technical equipment, the engine sys-

tem requires care and maintenance.
If you do not have the prescribed service/
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
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 10).
Please also observe the maintenance instruc-
tions for special accessories.
Service products 49
When working on the vehicle, comply with all Information about approved service products
safety regulations, such as operating instruc- is available from any MTU or MTU-authorised
tions, regulations concerning hazardous Mercedes-Benz Service Centre (Y page 10).
materials, environmental protection meas- You can recognise service products approved
ures, work safety and accident prevention by Mercedes-Benz by the following inscrip-
regulations. tion on the container:
RMB-Freigabe (e.g. MB-Freigabe 228.51)
Service products or
RMB-Approval (z. B. MB-Approval 228.51)
Important safety notes
Other labels and recommendations relating
G WARNING to the quality or indicating that the product
Service product can be poisonous and haz- meets a certain specification are not neces-
Maintenance
ardous to health. There is a risk of injury. sarily approved by Mercedes-Benz. Further
information is available from any MTU or
Observe the instructions on the respective
MTU-authorised Mercedes-Benz Service
original container when using, storing and dis-
Centre (Y page 10).
posing off service products. Always store ser-
vice products in the sealed original container. i Information about service products which
Always keep service products out of the reach have been tested by Mercedes-Benz and
of children. approved for your engine system can be
found in the Mercedes-Benz Specifications
! Special additives (except approved fuel for Service products on the Internet at:
additives) are neither required nor http://bevo.mercedes-benz.com/.
approved for use with approved service
products. Additives may cause damage to i The specification and availability of lubri-
major assemblies. Therefore, do not mix cants may vary. Individual lubricants may
any additives with service products. You no longer be available, especially for older
are responsible for the results of using fuel engines. Information is available from any
additives. MTU or MTU-authorised Mercedes-Benz
Service Centre (Y page 10).
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
50 Service products
Engine oils according to Sheet No. 228.51 If the outside temperature is under -20 †,
and 228.5 have a higher quality standard and Mercedes-Benz strongly recommends
have a favourable effect on: using engine oils of SAE class 5W-30 or
Rlength of oil change intervals 0W-30.
Rengine wear Use only all-season oils.
Rfuel consumption
Rexhaust emissions
i You can find information on the quality

grade, e.g. Sheet No. 228.51, and the vis-
cosity, e.g. SAE class 5W-30, from the des-
ignation on the oil container.
Before delivery, the engine is filled with oil in
Maintenance
SAE class 5W-30 (Y page 30).

Check the vehicle assemblies for leaks regu-
larly. If fluid loss is identified, e.g. by oil drops Engine oil SAE classes (viscosity)
on the parking area, have the cause of the
fluid loss rectified at a qualified specialist Oil change intervals are dependent on the fol-
workshop. lowing:
Rthe operating conditions of the vehicle
Scope of application Rthe grade of the engine oil used
Multi-grade engine oils compliant with Sheet The maximum oil change interval can only be
Nos. 228.51, 228.31, 228.5 or 228.3 can be achieved by using engine oils of particularly
used all year round. high quality in accordance with Sheet No.
228.51 and 228.5 of the Mercedes-Benz
Oil change Specifications for Service Products. The clas-
sification of oil change intervals is specified in
! If you mix engine oils with differing oil the Maintenance Booklet.
grades, the change interval for the engine
oil is reduced in comparison to mixtures of Adding/topping up the engine oil
engine oil of identical grade.
Therefore, only mix engine oils of differing ! There is a risk of damage to the catalytic
grade in exceptional circumstances. To converter or to the engine if too much oil is
prevent damage to the engine, the mainte- added. Have excess oil drained off.
nance intervals must be adjusted accord- When topping up, Mercedes-Benz recom-
ingly. mends that you only use engine oil of the
same grade and SAE class as the oil filled at
! If the SAE class (viscosity) of the engine
the last oil change.
oil used is not suitable for continually low
outside temperatures below -20 †, this Check the oil level before topping up the
could cause engine damage. engine oil (Y page 30).
The specified temperatures of the SAE
Miscibility of engine oils
class always refer to freshly added oil.
Engine oil ages during driving due to soot The benefits of high-quality engine oils are
and fuel residue. This impairs the charac- diminished if you mix them.
teristics of the engine oil, particularly at low
outside temperatures.
Service products 51
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 must be adapted to the lower tem all year round – even in countries with
Maintenance
quality (Sheet No.). The maintenance interval high outside temperatures.
is reduced. If you top up with an engine oil of
Check the corrosion inhibitor/antifreeze con-
a higher quality, the maintenance interval is
centration in the coolant every six months.
not altered.
Renew the coolant at the interval specified in
Observe the notes in the Maintenance Book-
the Maintenance Booklet.
let.
Use only approved corrosion inhibitor/anti-
freeze additives according to Sheet No.325.5
Coolant and 326.5. This prevents damage to the
engine cooling system and engine.
G WARNING When renewing the coolant, ensure that it
The engine cooling system is under pressure, contains 50% corrosion inhibitor/antifreeze
particularly if the engine is warm. You could by volume. This corresponds to antifreeze
be scalded by hot coolant spraying out when protection down to Ò37 †.
opening the cap. There is a danger of injury. Do not exceed 55% by volume (antifreeze
Allow the engine to cool before opening the down to approximately Ò45 †). The heat dis-
cap. Wear gloves and protective eyewear sipation and antifreeze may otherwise be
when opening. Slowly turn the cap half a turn negatively affected.
to allow pressure to escape. If there is a loss of coolant, do not top it up by
using only water, but also add an approved
G WARNING corrosion inhibitor/antifreeze agent.
If antifreeze comes into contact with hot com- The water in the coolant must meet certain
ponents in the engine compartment, it may requirements, which are often fulfilled by the
ignite. There is a risk of fire and injury. use of drinking water. The water must be
Let the engine cool down before you top up treated if its quality does not meet the
the antifreeze. Make sure that antifreeze is required standards.
not spilled next to the filler neck. Thoroughly Please note the Mercedes-Benz Specifica-
clean the antifreeze from components before tions for Service Products, Sheet No. 310.1.
starting the engine.
Mixtures with other corrosion inhibitors/anti-
A coolant that ensures anti-corrosion/antifreeze agents are not permitted.
freeze protection and other important pro-
tective effects is filled at the factory.
Z
52 Service products
Diesel fuels Rheating oils

Rfatty acid methyl ester FAME (bio-diesel
Important safety notes fuel)
G WARNING These fuel types cause irreversible damage
Fuel is highly flammable. Improper handing of to the engine and the exhaust gas after-
fuel creates a risk of fire and explosion. treatment system, as well as also signifi-
cantly reducing the expected service life.
Avoid fire, naked flames, smoking and creat-
ing sparks under all circumstances. Switch off ! A higher fuel sulphur content accelerates
the engine and, if applicable, the auxiliary the ageing process of the engine oil and can
heating before refuelling. damage the engine and exhaust system.
G WARNING Fuel grade

Maintenance
Fuels are poisonous and hazardous to health.

i Certain countries have diesel fuel with
There is a danger of injury.
varying sulphur content. Diesel fuel with
Do not swallow fuel or let it come into contact low sulphur content is sold in certain coun-
with skin, eyes or clothing. Do not inhale fuel tries under the name "Euro diesel".
vapours. Keep fuels out of the reach of chil-
dren. Information about current country-specific
fuel sulphur contents can be obtained from
If you or others come into contact with fuel,
any MTU or MTU-authorised Mercedes-Benz
observe the following:
Service Centre (Y page 10).
RWash the fuel off any affected areas of skin
with water and soap immediately. Water content
RIf you get fuel in your eyes, rinse them thor- The maximum permissible water content at
oughly with clean water immediately. Seek the point of transfer between vehicle and
immediate medical attention. engine must not be greater than 200 mg/kg.
RIf fuel is swallowed, seek immediate medi-
If the water content is higher, an additional
water separator must be fitted on the chassis.
cal attention. Do not induce vomiting.
RChange any clothing that has come into
If the engine is operated with increased
amounts of dirt and water, an additional fuel
contact with fuel immediately.
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
The following fuel types are not permitted: to escape and ignite. Depending on the type
Rsulphurous
of damage, fuel may also not escape until the
fuel with a sulphur content
engine is running. There is a risk of fire and
greater than 0.005% by weight (50 ppm)
explosion.
Rmarine diesel fuel
Never heat fuel system components. Contact
Raviation turbine fuel
a qualified specialist workshop to rectify the
malfunction.
Service products 53
At low outside temperatures, paraffin sepa- AdBlue®/DEF

ration may cause the flow properties of the
diesel fuel to be insufficient. Important safety notes
To prevent operating problems, diesel fuel
G WARNING
with improved flow properties is available in
the winter months. AdBlue®/DEF must not come into contact
with skin, eyes or clothing.
Winter diesel fuels are reliable down to out-
side temperatures of −22 † in Germany and RIf AdBlue®/DEF comes into contact with
other Central European countries. You can your eyes or skin, rinse affected areas with
normally use winter diesel fuel without prob- clean water immediately.
lems at the outside temperatures expected in RIf AdBlue®/DEF is swallowed, immediately
the country where it is on sale. rinse your mouth out with a lot of clean
water and drink plenty of water.
Maintenance
Fuel additives RChange clothing that is soiled with
! Do not add any petrol or kerosene to die- AdBlue®/DEF immediately.

sel fuel to improve its flow characteristics. RIf allergic reactions occur, consult a doctor
Petrol or kerosene impairs the lubricity of immediately.
the diesel fuel. This can cause damage to Keep AdBlue®/DEF out of the reach of chil-
the injection system, for example. dren.
For lower temperatures, the engine can be
equipped with a fuel preheating system. This ! Only use AdBlue®/DEF in accordance
improves the flow characteristics of the die- with DIN 70070/ISO 22241. Do not use
sel fuel according to the output of the instal- any additives.
led heater. If AdBlue®/DEF comes into contact with
Fuel additives used to improve flow charac- painted or aluminium surfaces when filling
teristics are flow improvers. the tank, rinse the affected area immedi-
Do not add flow improvers to winter diesel ately with plenty of water.
fuel guaranteed to operate down to −22 †. The terms "Urea" and "DEF" (Diesel Exhaust
The cold flow properties of the fuel may dete- Fluid) are also used for "AdBlue®".
riorate as a consequence of the flow
If the AdBlue®/DEF tank is full of AdBlue®/
improver.
DEF, pressure compensation may occur when
the tank lid is unscrewed. AdBlue®/DEF may
spill out. Therefore, open the AdBlue®/DEF
tank lid carefully. If AdBlue®/DEF spills out,
immediately wash the affected area with
plenty of water.
When opening the AdBlue®/DEF tank, small
amounts of ammonia vapours could escape.
Ammonia vapours have a pungent smell and
are particularly irritating to:
Rskin
Rmucous membranes
Reyes
Z
54 Service products
The vapours may cause a burning sensation in Low outside temperatures

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.
Maintenance
skin with water and soap. This could destroy the exhaust gas after-
Rif AdBlue®/DEF comes into contact with treatment system.
your eyes, rinse your eyes with clean water
immediately. Seek medical attention Storage
immediately.
Rif you have swallowed AdBlue®/DEF,
! Containers made of the following materi-
als are not suitable for the storage of
immediately rinse your mouth with water
AdBlue®/DEF:
and drink plenty of water. Seek medical
attention immediately. Raluminium
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
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-
tally responsible manner.
Cleaning and care 55
Observe laws and regulations on the disposal ! When using a high-pressure cleaner, keep
of AdBlue®/DEF in the country concerned. a minimum distance between the high-
pressure nozzle and the engine parts. Oth-
Purity erwise, parts of the engine may be dam-
aged.
! Impurities in AdBlue®/DEF, e.g. due to Observe the following minimum distances:
other service products, cleaning products
or dust, may lead to: Rabout 70 cm with round-spray jets
Rabout 30 cm with 25° flat-spray jets
Rincreased emission values
Rabout 30 cm with concentrated-power
Rdamage to the catalytic converter
jets
Rengine damage
Rmalfunctions in the exhaust gas after- ! Keep the water jet moving constantly
treatment system. while cleaning. In this way, you will avoid
Maintenance
causing damage.
Ensure that AdBlue®/DEF is always pure to
Do not point the water jet at:
avoid malfunctions in the exhaust gas after-
treatment system. Relectrical
components
If AdBlue®/DEF is pumped from the tank, e.g. Rplug connectors
during repairs, do not use this fluid to refill the Rseals
tank. Otherwise the purity of the fluid would Rhoses
no longer be guaranteed.
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 Mercedes-Benz or RMake sure that no water enters the air
MTU Service Centre (Y page 10). intake and ventilation openings.
RTreat the engine with preservative
agents after it has been cleaned. When
High-pressure cleaning doing so, protect the belt drive system
from the preservative agent.
ROnly use wax-based protective agents
Only wash your vehicle at a wash bay
for engines that comply with
designed for this purpose. Dispose of empty
Sheet No. 385.4 of the Mercedes-Benz
containers and used cleaning products in an
Specifications for Service Products.
environmentally responsible manner.
In addition, observe the notes in the "High-
! When cleaning, never point the water jet pressure cleaning" section (Y page 55).
at the exhaust pipe. The system may oth-
erwise be damaged.
Z
56
57
General notes ...................................... 58

Decommissioning for up to 6
months ................................................. 58
Decommissioning for longer than
6 months .............................................. 58
Decommissioning
58 Decommissioning for longer than 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 prior to recommissioning:
vehicle is to be out of use for longer than three RFit and connect the battery
weeks, disconnect the negative terminal on
RCheck that the electrical system is func-
the battery. This prevents the batteries from
being discharged by no-load current consum- tioning correctly.
ers. RCheck cables, hoses and lines for tears and
If the engine/vehicle is to be out of use for a leaks.

longer period, remove the batteries and store RCheck the engine oil level.
them in a dry and well-ventilated area. RCheck the oil level in the steering and
Recharge batteries every 3 months at the lat- hydrostatic fan drive.
est. RCheck the coolant level and correct it, if
Decommissioning
Ensure that there is adequate ventilation necessary.

when recharging. Check the battery fluid lev- RCheck AdBlue®/DEF level.
els before and after charging and if necessary RCheck the fuel level
correct them. For further information RStart the engine and leave it running at
(Y page 45).
medium engine speeds until it is at operat-
ing temperature (coolant temperature).
While doing so, observe the indicators for
Decommissioning for up to 6 months
oil pressure, coolant temperature and oil
temperature.
When decommissioning an engine/vehicle,
RVehicles with auxiliary heating: activate the
keep it in a covered, dry and well-ventilated
area. The room temperature should not fall auxiliary heating and check operation.
below -10 †. RCheck operation of the steering and
Measures prior to decommissioning: brakes.

RCheck whether maintenance is due and if
RClean the engine/vehicle thoroughly.
necessary carry it out.
RRemove any patches of corrosion from the
engine.
RChange the engine oil and oil filter if the last Decommissioning for longer than 6
oil change was carried out more than months
20,000 km (or around 300 operating hours)
ago. If the vehicle is to be decommissioned for
Also change the engine oil and filter if the longer than 6 months, further measures are
oil is more than 12 months old. required. For more details, consult your MTU
RCheck and adjust the level of coolant or or MTU-authorised Mercedes-Benz Service
renew coolant. Centre (Y page 10).
RCheck and adjust the concentration of anti-
corrosion/antifreeze additives in the cool-
ant.
59
Important safety notes ....................... 60

Bleeding and draining the fuel sys-
tem ....................................................... 61
Electrical fuses .................................... 62
Jump-starting ...................................... 62
Troubleshooting .................................. 65
Troubleshooting
60 Important safety notes
Important safety notes Apart from careful operation and mainte-

nance of the engine it is also important that
G WARNING malfunctions be rectified in good time.
If you do not have the prescribed service/ You can rectify certain malfunctions yourself
maintenance work or necessary repairs car- (Y page 36), (Y page 65).
ried out, this could result in malfunctions or Have malfunctions that you cannot eliminate
system failures. There is a risk of an accident. yourself rectified at a qualified specialist
Troubleshooting
Always have the prescribed service/mainte- workshop.

External engine start/engine stop
G WARNING button
There are moving components in the engine
compartment. Certain components may con-
tinue to move or suddenly move again even
after the ignition has been switched off, e.g.
the radiator fan. There is a risk of injury.
If you have to carry out work in the engine
compartment:
Rswitch off the ignition
Rnever touch the dangerous areas surround-
ing moving components, e.g. the rotation
area of the fan You can start and switch off the engine using
Rremove jewellery and watches the external engine start/engine stop button.
Rkeep items of clothing and hair, for exam- Before starting the engine
ple, away from moving parts.
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 Press external engine start/engine stop
below.
button : until the engine starts.
When working on the vehicle, comply with all Starting the engine and increasing the
safety regulations, such as operating instruc- engine speed
tions, regulations concerning hazardous X Hold down external engine start/engine
materials, environmental protection meas-
stop button : until the desired engine
ures, work safety and accident prevention
speed is achieved.
regulations.
The engine starts and runs at engine idling
Be aware of the road and traffic situation speed.
when working on public roads and secure
After about 3 seconds, the engine speed
your position accordingly.
increases. After releasing external engine
Bleeding and draining the fuel system 61
start/engine stop button :, the engine Bleeding the fuel system without a
continues to run at the currently set speed. fuel prefilter on the chassis frame
The engine speed can be increased up to XTurn the key to the start position in the
the limiting speed.
ignition lock and hold it. Do not depress the
X If the engine does not start immedi-
accelerator pedal whilst doing so.
ately: interrupt the starting procedure
i The starting procedure is automatically
after no more than 30 seconds.
Troubleshooting
cancelled after approximately 60 seconds.
X Turn the key in the ignition lock back to the
X Repeat the starting procedure after a wait-
stop at key position g.
ing period of approximately 1 minute.
X Repeat the starting procedure after a wait-
X If the engine starts normally, depress the
ing period of approximately 1 minute.
accelerator pedal several times.
X If the engine fails to start: rectify the cause
The fuel system is completely bled.
of the poor starting characteristics
(Y page 65).
X Observe the oil pressure gauge immedi-
Bleeding the fuel system with a fuel
ately after having started the engine. prefilter on the chassis frame
Stopping the engine
X Press external engine start/engine stop
Dispose of the water-fuel mixture in an envi-
button : again.
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

Example: fuel prefilter on the chassis frame
Bleeding, after refuelling a fuel system which
If water has collected in inspection window
has been run dry, is performed the next time
=, drain fuel prefilter on chassis frame :
the engine is started. Automatic continuous
before bleeding. Drain fuel prefilter on chas-
bleeding takes place in the filter.
sis frame : regularly.
When the engine is started, the battery must
Draining the fuel prefilter on the chassis
have sufficient charge to bleed the fuel sys-
frame
tem.
X Place a collector under drain plug ;.
X Turn drain plug ; open.
X Operate hand pump ? and collect the
fuel/water mixture.
X Turn drain plug ; closed.
Z
62 Jump-starting
Bleeding using the hand pump of the fuel fuse rating are the same colour. Further infor-
prefilter on the chassis frame mation is available from any MTU or MTU-
X Unscrew the fuel tank filler cap. authorised Mercedes-Benz Service Centre
(Y page 10).
X Place the collector underneath fuel prefil-
ter :. The fuse allocation chart is vehicle-specific
and is provided by the vehicle manufacturer.
X Unscrew bleed screw A.
If the newly inserted fuse also blows, have the
Troubleshooting
X Push hand pump ? repeatedly until the

cause traced and rectified at a qualified spe-
fuel escaping at bleed screw A is free of
cialist workshop, e.g. a Mercedes-Benz Ser-
bubbles.
vice Centre.
X Tighten bleed screw A.
X If a circuit fails, switch off the consumer
i If there was no fuel in the fuel tank, press equipment and switch the ignition lock to
hand pump ? again until there is noticea- position 0.
ble resistance.
X Tighten the fuel tank filler cap.
X Turn the key to the start position in the Checking and replacing a safety fuse
ignition lock and hold it. Do not depress the
X Pull the fuse out of the module using the
accelerator pedal whilst doing so.
pliers and carry out a visual inspection.
i The starting procedure is automatically X If the fuse wire has melted, replace the
cancelled after approximately 60 seconds.
blown fuse with a spare fuse.
X Repeat the starting procedure after a wait- X Switch on consumers and check that they
ing period of approximately 1 minute. function correctly.
X If the engine starts normally, depress the
If the safety fuse burns out again, have the
accelerator pedal several times. The fuel
electrical system checked at a qualified spe-
system is completely bled.
cialist workshop.
Electrical fuses Jump-starting

Important safety notes Important safety notes
G WARNING G WARNING
If you manipulate, bridge or replace a faulty Comply with safety precautions and take pro-
fuse with a fuse of a higher amperage, the tective measures when handling batteries.
electric cables could be overloaded. This may
Risk of explosion
result in a fire. There is a risk of an accident
and injury.
Always replace faulty fuses with specified new
fuses of the correct amperage. Fire, naked flames and
smoking are prohibited
The individual electrical circuits are protected when handling the battery.
by safety fuses or automatic circuit-breakers. Avoid creating sparks.
Blown fuses or defective automatic circuit- Battery acid is caustic.
breakers must be replaced by equivalent Avoid contact with the skin,
fuses with the fuse ratings recommended in eyes or clothing.
the fuse allocation chart. Fuses with the same
Jump-starting 63
Wear suitable protective ! When you remove the jump leads, let the
clothing, in particular engine of the vehicle being jump-started
gloves, an apron and a face idle. This avoids damage being caused to
mask. the vehicle electronics.
Immediately rinse acid
splashes off with clean
water. Consult a doctor if General notes
Troubleshooting
necessary. Observe the instructions relevant to safety
Wear eye protection. and protective measures when handling the
battery.
After jump-starting, have the batteries
checked at a qualified specialist workshop.
Keep children away.
X Make sure that the vehicles are not touch-
ing.
Observe this Owner's Man-
X Switch off all electrical consumers.
ual.
X Turn the key to position 0 in the ignition
lock.
! Observe the following notes. You could

otherwise damage the battery or electronic Vehicles without a jump-starting con-
components in the vehicle: nection point
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.
Ronly have jump-starting provided by vehi-
cles with a 24 V system.
Ruse jump leads which are protected
against polarity reversal and with a wire
cross section of approximately 35–
50 mm2 and insulated terminal clamps. Connecting the jump lead
Rif the outside temperature drops below X Remove the battery compartment cover.
Ò10 †, a discharged battery could freeze. X First, connect the positive terminal clamp
Do not start the engine under these cir- of the jump lead to the positive terminal of
cumstances. Let the battery thaw out the other vehicle's battery and then to the
first. q positive terminal of the starter battery.
! Do not connect the negative terminal X First, connect the negative terminal clamp
clamp of the jump lead to the chassis of the jump lead to the negative terminal of
frame. Otherwise, engine or transmission the other vehicle's battery and then to the
components can be damaged. ± negative terminal of the starter battery.
Z
64 Jump-starting
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
Troubleshooting
terminals.
X Remove the positive terminal clamps of the
jump lead from the positive terminals.
Troubleshooting 65
Troubleshooting
Engine problems
G WARNING
If you do not have the prescribed service/maintenance work or necessary repairs carried out, this
could result in malfunctions or system failures. There is a risk of an accident.
Troubleshooting
Always have the prescribed service/maintenance work as well as necessary repairs carried out
at a qualified specialist workshop.
Apart from careful operation and maintenance of the engine it is also important that malfunc-
tions be rectified in good time. You can rectify certain faults yourself.
Have malfunctions that you cannot eliminate yourself rectified at a qualified specialist work-
shop (Y page 10).
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 43).
immediately.
The fuel filter is blocked.
X Replace the filter element.
The fuel prefilter contains water.

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

X Replace the filter element.
Z
66 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.
Troubleshooting
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
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 52).
The engine oil viscosity is incorrect.

X Alter the engine oil viscosity to the conditions of use
(Y page 50).
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 67

The charge-air temperature is too high; the charge-air cooler or
radiator is dirty on the exterior.
X Clean the exterior of the charge-air cooler and radiator.
The coolant temperature is too high.
Troubleshooting
X Check the temperature sensor; replace if necessary. Check the
fan speed.
X Check the thermostat and replace as necessary. Consult a
qualified specialist workshop.
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 52).
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 information on the warning and indicator lamps
(Y page 20).
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 cooling system.
(according to the cool- X Add and bleed the coolant.
ant temperature
gauge). The coolant temperature sensor or display is faulty.
X Replace the sensor or display.
Z
68 Troubleshooting

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

Troubleshooting
The radiator is dirty on the inside; the radiator is very dirty on the
outside.
X Clean the 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 69

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.
Troubleshooting
The valve clearance is excessive.
X Check and adjust the valve clearance.
The poly-V-belt is slipping.

X Check that the poly-V-belt contact surfaces are not torn, dam-
aged, oily or glazed. Replace the poly-V-belt if necessary.
Z
70
71
Identification plates ............................ 72

Data card ............................................. 72
Engine data .......................................... 72
Technical data
72 Engine data
Identification plates Information on the exhaust gas after-

treatment identification plate
Engine data plate
The identification plate for the exhaust gas
aftertreatment unit contains the 14-digit
identification number (AGN ID number) of the
exhaust gas aftertreatment unit.
Data card
Technical data
The data card forms an integral part of the

documents belonging to the engine and
should always be kept with the Maintenance
Booklet. It contains details about the design
: Position of engine data plate (example)
of the engine and the exhaust gas aftertreat-
ment system, including special features.
Information on the engine data plate
Conversion parts on the engine system which
The following data is contained on the engine change the scope of the engine delivered by
data plate in the form of numbers stamped Mercedes-Benz should be reported to
directly onto the crankcase: 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
Rthe complete engine number and the num-
ber of the exhaust gas aftertreatment unit.
Example: engine data plate

Engine data
: Manufacturer's name Dimensions and weights
; Engine model designation
All data refers to the standard version of the
= Engine number
respective engine type. Deviations may
occur, depending on the engine equipment
and installation situation in the vehicle/
Exhaust gas aftertreatment identifi- equipment.
cation plate
The exhaust gas aftertreatment identification
plate is located on the exhaust gas aftertreat-
ment control module (ACM).
Engine data 73
Dimensions Weights
Engine weight DIN 70020 - GZ1
4R 1000 6R 1000
Single stage charging - -
Two stage charging - -
Technical data
Example: engine length
Example: engine width and height
R4 1000 R6 1000
A = engine 917 mm 1070 mm
length with
fan
B = engine 840 mm 1050 mm
width
C = engine 1025 mm 1050 mm
height
1 Data not available at the time of going to print.

74 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
Technical data
Number of cylinders 4 6
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
adjusting gauges
(0.6 mm) are used on
the exhaust valve
Starter Starter Electric Electric
motor
Voltage 24 V 24 V
Output 3.9 kW 5.5 kW
Cold-start limit Ò30 † (battery charging level 75%)
Alternator Voltage 24 V 24 V
Amperage 100 A 150 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 75
Engine speed of maximum power output Approx. 2200 rpm

4R 1000 idling speed Approx. 680 rpm
6R 1000 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-
Technical data
que limitation up to
50 % from 103 †)
Capacities and service products
Capacity approx- Service product

imately (Sheet No.2)
Engine with 4R 1000 Approx. 20.5 l Engine oil (Sheet
oil filter 228.51, 228.31, 228.5
(with stand- 6R 1000 Approx. 27.0 l or 228.3)
ard truck oil
pan)
Fuel system Diesel fuel tank3 Diesel fuels in accord-
ance with EN 590 or
ASTM D975 (Sheet
131.0)
Exhaust gas AdBlue®/DEF tank 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. 21 l Antifreeze/corrosion
tem ant in the engine 6R 1000 Approx. 23.5 l inhibitor in accordance
with Sheet 325.5 or pre-
Corrosion inhibitor/anti- Approx. 50% by mixed coolant in
freeze agent volume volume accordance with Sheet
down to –37 °C 326.5. Water quality in
accordance with Sheet
310.1
2 Mercedes-Benz Specifications for Service Products

3 Fitted on the vehicle. Designed by vehicle manufacturer.
76 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
385.4
Technical data
Tightening torques
All threads on mechanical components and the corresponding contact surfaces must be clean,
smooth and coated with engine oil. Other lubricants lead to substantially different tightening
torques.
The tightening torques are the same for 4R 1000 and 6R 1000.
Engine Cylinder head cover screw on Light alloy 20 Nm

the rocker arm housing
(observe the tightening Plastic 25 Nm
sequence for the cylinder
head cover)
Valve clearance setting Counternut on the rocker 50 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 15 Nm
Oil circuit Drain plug on the oil pan M 16 x 1.5 35 Nm
(plastic)
Oil filter cap on the oil/coolant module 50 Nm
Cooling system Silicate gel cartridge on the coolant pump 50 Nm
Exhaust gas Filter housing on the pump module 80 Nm
aftertreatment
Air dryer Granulate cartridge on the air dryer 15 Nm
2 Mercedes-Benz Specifications for Service Products

Engine data 77
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

78
79
80
Symbols Imprint
G WARNING Internet
Warning notes make you aware dangers
which could pose a threat to your health or Further information about MTU, Mercedes-
life, or to the health and life of others. Benz and Daimler AG can be found on the
Internet at:
H Environmental note www.mtu-online.com
Environmental notes provide you with infor- www.mercedes-benz.com
mation on environmentally aware actions or www.daimler.com
disposal.
! The purpose of material damage warnings Documentation team

is to draw your attention to risks which
could lead to damage to your engine sys- Should you have any questions or sugges-
tem. tions regarding this manual, you can reach
i These symbols indicate useful instruc- the technical documentation team at the fol-
tions or further information that could be lowing address:
helpful to you. Daimler AG, HPC: CAC, Customer Service,
X This symbol designates an instruc- 70546 Stuttgart, Germany
©Daimler AG: not to be reprinted, translated
tion you must follow.
X Several consecutive symbols indi- or otherwise reproduced, in whole or in part,
cate an instruction with several without written permission from Daimler AG.
steps.
(Y page) This symbol tells you where you
Equipment manufacturer
can find further information on a
topic.
Daimler AG
YY This symbol indicates a warning or
Mercedesstraße 137
an instruction that is continued on
the next page. 70327 Stuttgart
Display This text indicates an indicator in Germany
the display.
As at 21.10.2013
4R/6R 1000 EU Stage IV/US TIER 4
Operating Instructions
É9345843771)ËÍ
9345843771
Order no. 6462 9839 02 Part no. 934 584 37 71 Edition 01-14

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

! The purpose of material damage warnings Documentation team

Index ....................................................... 4 At a glance ........................................... 11

Introduction ........................................... 7 Safety ................................................... 23

Transport, installation ........................ 27

Technical data ..................................... 71

Disposing of AdBlue®/DEF .............. 54

Engine system Please contact an MTU or MTU-authorised

Safety/emergency running program

Mercedes-Benz Service Centres: If there are legal requirements on emission

This data is exclusively technical in nature Further applicable documents

Qualified specialist workshop

A qualified specialist workshop has the nec-

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

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

sel engine with direct injection.

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

Exhaust gas aftertreatment

warning, the warning and indicator lamps

red Engine stop

Ù Engine system malfunction

(lit con- Torque operating restriction

(flash- Torque and engine speed

Ã Continuous brake active

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

Operating safety RPlease note, when carrying out electric

ried out, this could result in malfunctions or

more and/or jeopardise the operational Staff qualifications

The operator must determine the responsi-

causing serious or even fatal injury.

! The engines are by default delivered filled

Preparation for operation ................... 30

eliminates the need for special break-in oils

Checking the oil level with the dipstick

Checking the oil level electronically

Starting the engine with the external

Stopping the engine

Example: ignition lock When switching off the equipment or parking

idling speed may differ in certain operating Oil pressure

of the diesel particle filter.

Displays AdBlue®/DEF level

Warning and indicator lamps

Problem Possible causes/consequences and M Solutions

The Ù indicator Impermissible operating conditions have been detected in the

lamp lights up. engine system.

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

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

Problem Possible causes/consequences and M Solutions

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

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

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

Problem Possible causes/consequences and M Solutions