OM 457 LA BlueTec® / OM 457 LAOM 460 LA BlueTec® / OM 460 LAOperating Instructions

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

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

! Notes on material damage alert you todangers that could lead to damage to yourvehicle.

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

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

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

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

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

Display This text indicates an indicator inthe display.

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

4605843681 É4605843681ÇËÍ

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

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

At a glance ........................................... 13

Safety ................................................... 29

Transport, installation ........................ 33

Operation ............................................. 37

Maintenance ........................................ 63

Decommissioning ............................... 75

Troubleshooting .................................. 79

Technical data ..................................... 93

Contents 3

AAdBlue®/DEF

Components .................................... 18Consumption ................................... 58Gauge .............................................. 45Important safety notes .................... 60Refuelling ......................................... 60Service product ............................... 71

ADM (FR (drive control) unit) ............. 14

BBattery (vehicle)

Jump starting ................................... 83Bio-diesel fuel

see FAME fatty acid methyl ester fuelBleeding the fuel prefilter with themanual fuel pump ............................... 83BlueTec®

Sensors ............................................ 18Braking

Continuous brake ............................ 41Engine brake .................................... 41Retarder ........................................... 42

CCapacities ............................................ 98Care products ...................................... 72Charge current .................................... 42Checking the fluid level ...................... 38Cleaning and care

Engine cleaning ................................ 73High-pressure cleaning .................... 72Notes on care .................................. 72

Cold-start aid ....................................... 61Consumption

AdBlue®/DEF .................................. 58Fuel .................................................. 58Oil (engine) ...................................... 58

Continuous brakeImportant safety notes .................... 41

CoolantMixing ratio ...................................... 68Service product ............................... 68Topping up ....................................... 39

Coolant additive .................................. 68

Correct use ............................................ 8Corrosion inhibitor/antifreezeagent .................................................... 68

DData card .............................................. 94DEF/AdBlue®

see AdBlue®/DEF service productsDescription of the engine ................... 14Diagnostics connection ...................... 31Diesel

Fuels ................................................ 68Low outside temperatures ............... 70Refuelling ......................................... 59Sulphur content table ...................... 69

Dimensions .......................................... 95Disposal of service products .............. 65Driving mode

Idling speed ..................................... 42Driving tips .......................................... 58

EElectronic engine control

see Engine managementElectronic engine control unit ............ 42Emergency gearshift

Using the emergency switch ............ 44Emergency running program ................ 8Engine

Capacities ........................................ 98Cleaning ........................................... 72Data ................................................. 95Data card ......................................... 94Data plate ........................................ 94Modifying the power output ............... 8Oil consumption ............................... 58Operating data ................................. 97Rectifying faults ............................... 86Running-in period ............................. 58Starting ............................................ 39Stopping .......................................... 40

Engine brake ........................................ 41Engine data .......................................... 95Engine data card .................................. 94Engine description .............................. 14Engine idling speed ............................. 42

4 Index

Engine management ........................... 19Engine management control unit ...... 20Engine model designation .................. 94Engine oil

Consumption ................................... 58For winter operation ........................ 65Mixing .............................................. 67Oil change ........................................ 66Topping up ....................................... 67

Engine overview .................................. 15Engine speed ....................................... 44Exhaust gas aftertreatment ............... 21Exhaust gas aftertreatment con-trol unit ................................................ 21

FFR (drive control) unit

see ADMFuel

Additives .......................................... 70Consumption ................................... 58Diesel ............................................... 68FAME fatty acid methyl ester fuel .... 70Refuelling ......................................... 59Sulphur content table ...................... 69

Fuel grade ............................................ 69Fuel prefilter

Draining ........................................... 82Fuel system

Automatic bleeding .......................... 81Manual bleeding .............................. 81

FusesChecking and replacing a safetyfuse .................................................. 83Important safety notes .................... 83

GGauge

AdBlue®/DEF .................................. 45Genuine Mercedes-Benz parts ............. 7Getting started .................................... 80

HHigh-pressure cleaning ....................... 72

IIdentification plate .............................. 94Idling speed

Engine .............................................. 42Indicator and warning lamps

BlueTec® exhaust gas aftertreat-ment ................................................ 24

Installation ........................................... 34Instrument cluster

Warning and indicator lamps ........... 23

JJump-starting ....................................... 83

MMaintenance

Notes ............................................... 64Mercedes-Benz Service Centre

see Qualified specialist workshopMR control unit

see Engine management control unit

OOil (engine)

For winter operation ........................ 65Oil change ........................................ 66Scope of use .................................... 66

Oil pressure ......................................... 42Operating data ..................................... 97Operating instructions

General notes .................................. 10Operating restriction

Off-highway ...................................... 26On-highway ...................................... 24

Operating safety .................................. 30Operating safety and registration

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

Operational monitoring ...................... 42Organisational measures ................... 31Overview, sensors ............................... 17

PPersonnel ............................................. 31

Index 5

Poly-V-beltReplacing ......................................... 90Routing ............................................ 90

Preparing for starting operationsee Starting operation

Protection of the environment ............. 7

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

RRefuelling

AdBlue®/DEF .................................. 60Fuels ................................................ 59

Requirements of the personnel ......... 31Rev counter .......................................... 44Roadside Assistance ........................... 80Running the vehicle in ........................ 58

SSafety and emergency running pro-gram ....................................................... 8Safety precautions .............................. 30SCR frame module

see Exhaust gas aftertreatmentcontrol unit

Service productsAdBlue®/DEF .................................. 71Coolant ............................................ 68DEF/AdBlue® .................................. 71Diesel fuel ........................................ 68Disposal ........................................... 65Disposing of AdBlue®/DEF .............. 72Engine oil ......................................... 65FAME fatty acid methyl ester fuel .... 70Fuel additives ................................... 70General notes .................................. 65Purity of AdBlue®/DEF .................... 72Storing AdBlue®/DEF ...................... 72

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

see Starting (engine)Starting (engine) .................................. 39Stopping and switching off theengine ................................................... 39

Sulphur content of fuel ....................... 69

TTechnical data

Dimensions ...................................... 95Filling capacities .............................. 98Operating data ................................. 97Weights ............................................ 95

Tightening torques .............................. 99Torque reduction ................................. 43Transport .............................................. 34

WWarning and indicator lamps

Electronics ....................................... 46Weights ................................................ 96Winter diesel ........................................ 70Winter operation ................................. 61

6 Index

Engine system

The OM 457-460 LA BlueTec® series ofengines only function as intended when usedin conjunction with the correspondingexhaust gas aftertreatment unit. Therefore, inthese Operating Instructions, the term"engine system" refers to the engine and theexhaust gas aftertreatment unit.

Protection of the environment

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

Information and notes on driving in an envi-ronmentally responsible and fuel-saving man-ner can be found in the "Operating notes"section (Y page 58).

Assembly equipment

These Operating Instructions describe allmodels and all standard and optional equip-ment available for your engine system at thetime of publication of the Operating Instruc-tions. Country-specific deviations are possi-ble. Note that your engine system may not befitted with all features described. This alsoapplies to safety-relevant systems and func-tions. Therefore, the equipment on yourengine system may differ from certaindescriptions and illustrations.All of the components in your engine systemare listed in the data card of your engine sys-tem. Data card (Y page 94).

Please contact a Mercedes-Benz, MTU orMTU-authorised Mercedes-Benz ServiceCentre if you have any questions about equip-ment or operation (see addresses in the pub-lication details on the rear inside cover).RMercedes-Benz recommends, for on-high-

way applications, that you use a Mercedes-Benz Service Centre.RMTU recommends, for off-highway applica-

tions, an MTU partner or MTU-authorisedMercedes‑Benz partner.

Genuine Mercedes-Benz parts

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

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

Introduction 7

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requirements. The use of non-approved partsmay invalidate the vehicle's general operatingpermit.This is the case if:Rthey result in a change to the vehicle type

from that for which the vehicle's generaloperating permit was grantedRthey pose a possible risk for road usersRthey adversely affect the emission or noise

levelsYou can find more information on recommen-ded conversion parts and accessories, as wellas permitted technical modifications at anyMercedes-Benz, MTU or MTU-authorisedMercedes-Benz Service Centre (Y page 10).Always state the engine number when order-ing genuine Mercedes-Benz parts. You canfind the engine number on the identificationplate of your engine. You can also find thenumbers on the data card (Y page 94).

Modifying the engine output

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

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

Safety/emergency running program

The engine is equipped with an electronicengine management system that monitorsthe engine and has a self-diagnostic system.

If the electronic control system detects a mal-function, one of the following measures isautomatically implemented after an appraisalof the malfunction:Rfaults during operation are indicated by the

corresponding warning lamp (Y page 46).Rin conjunction with the electronic engine

management system, fault codes with addi-tional information can be shown on a dis-play.Rthe system switches to a suitable backup

function for the continued, albeit restric-ted, operation of the engine. This includestorque and engine speed limitation, forexample, as well as road speed limitation orconstant emergency running speed.

Correct use

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

Implied warranty

A well-developed network of Mercedes-Benz,MTU and MTU-authorised Mercedes-BenzService Centres is available to carry out main-tenance work.

8 Introduction

These Mercedes-Benz and MTU or MTU-authorised Mercedes-Benz Service Centres:Rhave special equipment and tools as well as

specialists who receive continuous trainingRguarantee that your engine system is

repaired and maintained thoroughly andexpertlyRcarry out all repairs related to implied war-

rantyRcarry out all maintenance work expertlyRconfirm in the Maintenance Booklet that

the maintenance work has been carried outat the required timeRhandle implied warranty claims that are

admissible according to the sales contractPlease observe the instructions and recom-mendations as well as the maintenance serv-ices in the Maintenance Booklet. Pleaseobserve these instructions even if you let athird party use and care for your vehicle. Thisis the only way to ensure that you do not loseyour entitlements.If the prescribed maintenance work is notcarried out, claims can only be decided afterthe manufacturer has inspected the claim.During the implied warranty period, have theprescribed maintenance service for yourengine system carried out as follows:RregularlyRpunctuallyRat a qualified specialist workshop which

has the necessary specialist knowledgeand tools to carry out the work requiredMercedes-Benz recommends that you usea Mercedes-Benz, MTU or MTU-authorisedMercedes-Benz Service Centre. In particu-lar, work relevant to safety or on safety-related systems must be carried out by aqualified specialist workshop.

If there are legal requirements on emissioncontrol, please note that:Rmaintenance on the engines must be car-

ried out according to specific regulationsand using special measuring devicesRit is prohibited to modify or tamper with

components relevant to emissionsAll Mercedes-Benz and MTU or MTU-author-ised Mercedes-Benz Service Centres arefamiliar with the relevant regulations.Maintenance work does not include repairwork. Issue a separate order for repair work.You can obtain further information on themaintenance of your engine system from anyMercedes-Benz, MTU or MTU-authorisedMercedes-Benz Service Centre.

Stored data

Several of the electronic components in yourengine system contain data memories.These data memories temporarily or perma-nently store technical information about:Rthe engine system stateReventsRmalfunctionsIn general, this technical information docu-ments the state of a component, a module, asystem or the surroundings.This includes, for example:Roperating conditions of system compo-

nents, e.g. fluid levelsRthe vehicle's status messages and those of

its individual components, e.g. speed,deceleration in movement, acceleratorpositionRmalfunctions and defects in important sys-

tem componentsRthe vehicle's reactions and operating sta-

tuses in special driving situationsRambient conditions, e.g. outside tempera-

ture

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This data is exclusively technical in natureand can be used to:Rassist in the detection and rectification of

faults and defectsRanalyse vehicle functions, e.g. after an acci-

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

Qualified specialist workshop

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

conversionsRwork on electronic components

RMercedes-Benz recommends, for on-high-way applications, that you use a Mercedes-Benz Service Centre.RMTU recommends, for off-highway applica-

tions, an MTU partner or MTU-authorisedMercedes‑Benz partner.

Further applicable documents

These Operating Instructions describe allmodels, as well as all standard and optionalequipment of your engine system which arepart of the scope of delivery of Daimler AG.The installation of the engine system into thevehicle/device may require additional oper-ating instructions adapted to the vehicle/device and the appropriate use thereof. Theseadditional operating instructions will be pro-vided by the vehicle/device manufacturer.The additional operating instructions willdescribe, in particular, the functions specificto the installation and operation, the use ofsuch functions as well as warning and controlmechanisms.To use the engine correctly, you also requirethe Maintenance Booklet.For US-certified off-highway engines you alsorequire the "Emission Warranty" supplement.Please also observe the information con-tained in the vehicle or the equipment oper-ating instructions (manufacturer of the endproduct). Always keep these documentstogether with the engine, vehicle or equip-ment. These documents should be passed onto the new owner if you sell the engine, vehi-cle or equipment.When carrying out maintenance work, yourequire access to the Workshop InformationSystem (WIS) via the Internet. This access issubject to a fee.Current information on the system and pricescan be found at this web address: http://service-parts.mercedes-benz.com. Click on"EPC, WIS/ASRA" in the "Service and partsinformation" tab and then on "WIS".

10 Introduction

You can log in by clicking on "Register" on theright-hand side.

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General information ............................ 14Engine overview .................................. 15Sensors overview ................................ 17Electronic engine management ......... 19BlueTec® exhaust gas aftertreat-ment ..................................................... 21Warning and indicator lamps ............. 23

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General information

The engine is a four-stroke, water-cooled die-sel engine with direct injection.The six cylinders are arranged in a row. Eachcylinder has two inlet and two outlet valves.Each cylinder has its own fuel injection pump(unit pump) with a short high-pressure fuelinjection line to the multi-hole nozzle at thecentre of the combustion chamber. The unitpumps sit directly in the crankcase and aredriven by the camshaft.The engine is equipped with exhaust gas tur-bocharger and intercooler as standard. Theengine may include an engine brake (airbrakeand constantly open throttle) as optionalequipment.It is a low-emission engine. Start of injection,injection duration and injection quantity arecontrolled entirely electronically.

BlueTEC® exhaust gas aftertreatmentThe engines meet the requirements of therelevant emissions level and are correspond-ingly certified. Compliance with emissionslaws and regulations is a condition of theoperating permit for the vehicle/equipment.The BlueTEC® exhaust gas aftertreatmentunit is characterised by the following tech-nologies:Rselective catalytic reduction (SCR) with

ammonia slip catalytic converterRthe diesel oxidation catalytic converter

(DOC)Engines with BlueTEC® exhaust gas after-treatment must be operated with AdBlue® orDEF in order to meet the emissions laws andregulations. The operating permit is invalida-ted if the vehicle/equipment is operatedwithout AdBlue®/DEF. Failure to useAdBlue® or DEF during operation may be astatutory or regulatory offence in certaincountries. Special concessions grantedeither at the time of purchase or to reduce

operating costs of the vehicle/equipment,e.g. reduced taxes or tolls, may also be ren-dered retroactively invalid. This may be thecase in the country of registration. Or also inanother country where you operate the vehi-cle/equipment.

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Engine overview

: Poly-V-belt; Fuel pump= Thermostat housing? Fuel filterA Oil filterB Cylinder head coverC Start/Stop buttonD Charge-air distributorE Charge-air pipe from the charge-air coolerF Crankcase ventilation systemG Engine control unit (MR)H Air compressorI Power-steering pumpJ DipstickK Engine oil filler neck

Engine overview 15

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: Alternator; Starter motor= Exhaust gas turbocharger? Exhaust manifoldA Coolant pumpB Poly V-belt tensioning device

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Sensors overview

Sensors, general

: Engine oil pressure and temperature sensor; Charge-air pressure/temperature sensor= Camshaft position sensor (on camshaft gear)? Crankshaft position sensor (on flywheel)A Coolant temperature sensorB Engine oil level sensorC Fuel temperature sensor

Sensors overview 17

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AdBlue®/DEF components

BlueTec® sensors, overview: NOX sensor; Metering unit= Exhaust aftertreatment unit? Temperature and humidity sensor (air filter, clean air side)A Valve preheating, AdBlue®/DEF systemB Exhaust gas temperature sensor (inlet)C Exhaust gas temperature sensor (outlet)D Exhaust gas aftertreatment control unitE Supply unitF AdBlue®/DEF filterG AdBlue®/DEF tank

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BlueTec® sensors and test connection on the metering unit: AdBlue®/DEF pressure sensor; AdBlue®/DEF temperature sensor= Pressure sensor for compressed air? Metering unit test connectionA Metering unit heaterB Metering valve

Electronic engine management

The engine system is equipped with an elec-tronic engine management system whichcomprises the following control units:Rengine control unit (MR)Rdrive control unit (ADM)Rexhaust gas aftertreatment control unit

(only for engines with BlueTec® exhaustgas aftertreatment)

The electronic engine management systemmonitors:

Rthe engineRthe exhaust gas aftertreatment in the case

of BlueTec®

Rand, as well as the connection to the vehi-cle or the device, it also monitors itself.

Depending on the malfunctions or failureswhich occur, warning and information dis-plays are activated (Y page 23). The mal-function is stored in the fault memory and ifnecessary a safety and emergency mode isautomatically selected (Y page 42). If theelectronic engine management control

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detects a fault, the fault code is stored in thecontrol units. It can then be read by a qualifiedspecialist workshop (Y page 10) using a diag-nostic tester.

Engine management control unit (MR)(engine-mounted)

The engine management control unit (MR) ison the side of the engine.

Example: engine management control unit (MR)

The engine management control unit (MR)processes values from the drive control unit(ADM). These are, for example, the position ofthe accelerator pedal sensor, the enginebrake or engine start/stop, etc.These values are analysed together with datafrom the engine sensors. They are comparedwith the charts or characteristic curvesstored in the engine management control unit(MR).Data from the sensors derives from informa-tion such as:Rcharge-air pressure and charge-air temper-

atureRcoolant temperatureRfuel temperatureRoil pressure

Start of injection, injection duration and injec-tion quantity are calculated on this basis andthe unit pumps are controlled via the solenoidvalve accordingly.If BlueTec® exhaust gas aftertreatment isavailable, the associated sensors are alsoanalysed and the AdBlue®/DEF dosage iscontrolled.

i To obtain a replacement engine manage-ment control unit (MR), you will require allthe data on the control unit type plate.

Control unit type plate: Data record; Certification no.= Engine number? Equipment code

Drive control unit (ADM)The drive control unit (ADM) is installed in aprotected location in the vehicle/device bythe vehicle/device manufacturer. It acts asan interface between the electric and elec-tronic components on the vehicle/deviceside and the engine management controlmodule (MR) on the engine side.The engine can be adapted to the variousoperation-specific requirements using thedrive control unit (ADM).

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Example: drive control unit (ADM)

The drive control unit (ADM) has many func-tions:RCalculation of torque demand

The drive control unit (ADM) registers thedriver's requirements. For example, theposition of the accelerator is detected bythe drive control unit (ADM). A torquerequirement is calculated from that andsent to the engine management controlmodule (MR) via the CAN connection.In doing so, information and limitationsfrom optionally connected control unitssuch as the gearbox control, retarder con-trol, ABS and ASR are taken into account.ROutput of displays and indicator signals

which are displayed in the instrument clus-ter.RMonitoring of coolant level, charge current

and air filter, for exampleRLegal speed limitationREvaluation of start request

The engine starting process is initiatedonce a corresponding start request is pres-ent (ignition lock or external engine start/engine stop button).

Exhaust gas aftertreatment controlunit (on the frame)

Exhaust gas aftertreatment control unit

The exhaust gas aftertreatment control unitreads signals and transmits them via the CANline to the engine management (MR) controlunit.The following signals are read:Rtemperature sensor upstream of the SCR

catalytic converterRtemperature sensor downstream of the

SCR catalytic converterRNOx sensor downstream of the SCR cata-

lytic converterRpressure and temperature sensor for the

fluid level and temperature in the AdBlue®/DEF tankRsensor for humidity and intake air temper-

atureIf the electronic engine management controldetects a fault, the fault code is stored in thecontrol units.

BlueTec® exhaust gas aftertreatment

The exhaust gas aftertreatment system isactivated immediately after the engine is star-ted and remains activated during engineoperation. It ensures that the pollutant emis-sions in the exhaust gas are reduced to thelimits stipulated in the emissions standard.

BlueTec® exhaust gas aftertreatment 21

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Exhaust gas treatment is carried out by:Rselective catalytic reduction (SCR) with

ammonia slip catalytic converterRthe diesel oxidation catalytic converter

(DOC)In order to ensure correct operation of theBlueTec® exhaust gas aftertreatment system,only operate the engine, vehicle or devicewith AdBlue®/DEF reducing agent. AdBlue®/DEF is not refilled as part of the maintenancework. You should therefore top up theAdBlue®/DEF tank regularly.Mercedes-Benz recommends that you use aMercedes-Benz or MTU Service Centre.BlueTec® technology is one part of the enginehomologation that requires certification.Operating the engine, vehicle or device with-out AdBlue®/DEF or with another mediumthat has not been approved by Daimler inva-lidates the engine's operating permit or cer-tification.

Continuous brakeIf increased braking power is required, theengine can be equipped with a brake valvedownstream from the exhaust gas turbo-charger in conjunction with constant throttlevalves. The brake valve uses exhaust backpressure to increase braking power. The con-stant throttle valves bring about a reductionof the compression pressure in the powerstroke (third stroke), whilst the compression(second stroke) is not significantly affected.The constant throttle valve is an additionalvalve in the cylinder head. When open, theconstant throttle valve establishes a connec-tion between the combustion chamber andexhaust port.

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Warning and indicator lamps

Important safety notes

Important safety notesIf you ignore warning and indicator lamps, you will not be able to recognise failures and mal-functions in components or systems. The driving and braking characteristics may change andthe road and operating safety of your vehicle or equipment may be restricted. Have the affec-ted system checked and repaired at a qualified specialist workshop. Always observe thewarning and indicator lamps and follow the corresponding corrective actions (Y page 46).

OverviewThe indicator and warning lamp display is designed for the specific vehicle or equipment.Please also observe the information in the additional operating instructions. These will beprovided by the vehicle/device manufacturer. The symbols listed below are examples only andtheir appearance may differ in the vehicle or on the equipment. In the event of a fault orwarning, a warning lamp or indicator lamp lights up automatically. Depending on the priority ofthe fault or warning, the warning and indicator lamps light up in different combinations. Thefollowing warning and indicator lamps may be available on the instrument panel:

On-highway version without BlueTec®1

The following warning and indicator lamps may be available on the instrument panel:

Indicator lamp Description

r red2 Engine stop

Ù Engine system malfunction

# Charge current

%

(optional)Cold-start aid

5

(optional)Oil pressure too low (engine)

4

(optional)Oil level too low (engine)

,

(optional)Coolant level too low

?

(optional)Coolant temperature too high

1 On-highway: vehicles with operating permit2 In addition, an acoustic warning signal may sound.

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Indicator lamp Description

Ã

(optional)Continuous brake active

é

(optional)Cruise control

È

(optional)Speed limiter

I

(optional)Power take-off engaged

On-highway version1 with BlueTec®

The following warning and indicator lamps may be available on the instrument panel:

Indicator lamp Description

r red2 Engine stop

Ù Engine system malfunction

; Engine diagnostics MIL

s (lit constantly) Torque operating restriction

# Charge current

%

(optional)Cold-start aid

Ø

(optional)AdBlue®/DEF reserve level

5

(optional)Oil pressure too low (engine)

4

(optional)Oil level too low (engine)

,

(optional)Coolant level too low

?

(optional)Coolant temperature too high

1 On-highway: vehicles with operating permit2 In addition, an acoustic warning signal may sound.

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Indicator lamp Description

Ã

(optional)Continuous brake active

é

(optional)Cruise control

È

(optional)Speed limiter

I

(optional)Power take-off engaged

Off-highway version3 without BlueTec®

The following warning and indicator lamps may be available on the instrument panel:

Indicator lamp Description

r red2 Engine stop

Ù Engine system malfunction

# Charge current

%

(optional)Cold-start aid

5

(optional)Oil pressure too low (engine)

4

(optional)Oil level too low (engine)

,

(optional)Coolant level too low

?

(optional)Coolant temperature too high

Ã

(optional)Continuous brake active

é

(optional)Cruise control

3 Off-highway: devices/vehicles2 In addition, an acoustic warning signal may sound.

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Indicator lamp Description

È

(optional)Speed limiter

I

(optional)Power take-off engaged

Off-highway version3 with BlueTec®

The following warning and indicator lamps may be available on the instrument panel:

Indicator lamp Description

r red2 Engine stop

Ù Engine system malfunction

· Emissions-relevant malfunction of the exhaust gas aftertreat-ment system or AdBlue®/DEF supply

s (lit constantly) Torque operating restriction

s (flashing) Torque and engine speed operating restriction

# Charge current

%

(optional)Cold-start aid

Ø

(optional)AdBlue®/DEF reserve level

5

(optional)Oil pressure too low (engine)

4

(optional)Oil level too low (engine)

,

(optional)Coolant level too low

?

(optional)Coolant temperature too high

Ã

(optional)Continuous brake active

3 Off-highway: devices/vehicles2 In addition, an acoustic warning signal may sound.

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Indicator lamp Description

é

(optional)Cruise control

È

(optional)Speed limiter

I

(optional)Power take-off engaged

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Operating safety ................................. 30Safety precautions .............................. 30Notes on electronic systems ............. 30Staff qualifications .............................. 31Organisational measures ................... 31

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Operating safety

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

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

Safety precautions

Damage to the engine can also lead to per-sonal injury. In order to avoid engine damage,the following safety precautions must beadhered to.ROnly start the engine when the batteries

are firmly attached.RDo not disconnect the batteries when the

engine is running.RDo not use a rapid charger to start the

engine.ROnly perform the jump-starting proce-

dure with separate batteries.RNote, the battery terminals must be dis-

connected when rapid charging the bat-teries.RObserve the operating instructions of the

rapid battery charger.

RPlease note that the "+" and "-" terminalson the batteries must be disconnectedwhen carrying out electric welding work.RThe control unit connectors may only be

connected/disconnected when the elec-trical system is switched off.RIncorrect control unit-power supply

polarity (e.g. by connecting up the bat-teries incorrectly) can cause irreparabledamage to the control units.RTighten diesel injection system connec-

tions to the prescribed tightening torque.RIf temperatures above 80 † are to be

expected (e.g. in a drying oven), the con-trol unit on the engine must be removed.ROnly use the appropriate testing probes

when taking measurements from electri-cal connectors (e.g. a Mercedes-Benzconnection set). Telephones and two-way radio devices that are not connectedto an external aerial can cause malfunc-tions in the electronics and thus endan-ger the operating safety of the engine.

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

Notes on electronic systems

Important safety notes

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

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

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

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

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

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

If the engine is switched off and devices con-nected to the diagnostics connection arebeing used, the starter battery can becomedischarged.

Staff qualifications

G WARNINGIf you do not have the prescribed service/maintenance work or necessary repairs car-

ried out, this could result in malfunctions orsystem failures. There is a risk of an accident.Always have the prescribed service/mainte-nance work as well as necessary repairs car-ried out at a qualified specialist workshop.

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

Organisational measures

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

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Transport ............................................. 34Installation ........................................... 34

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Transport

G WARNINGIf you do not lift the engine as described, thelugs intended for the purpose may be torn outor snap. This may be the case especially if themaximum permissible lug load is exceeded.The engine could then drop uncontrolled,causing serious or even fatal injury.Always make sure that:Rthe engine is only lifted at the intended lift-

ing points/lifting lugs.Rthe engine is only lifted and transported in

the fitting position.Rropes/chains are always routed vertically.Ronly parts which are typically in the original

scope of delivery are attached to theengine.

G WARNINGIf you lift the engine at unsuitable points and/or using unsuitable lifting gear, it may:Rwork loose and fall offRswing uncontrollably as a result of a change

in the centre of gravity.There is a risk of injury.Lift the engine only at the lifting points provi-ded using suitable lifting gear. Make sure thatthere is nobody in the danger zone when rais-ing and lowering the engine.

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

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

Example: using a cross member

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

Example: flywheel-side lifting point

Example: belt-side lifting point

Installation

The engine system may only be installed ascontractually specified.Observe the sections "Correct use" (Y page 8)and "Modifying the engine output" (Y page 8).

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Daimler AG provides the vehicle manufac-turer with comprehensive material, e.g. theinstallation guideline, for initial installation.The vehicle manufacturer must take this intoaccount. If the engine is fitted after repairwork, for example, the information in theWorkshop Information System (WIS) must beobserved (Y page 10).Observe the sections "Qualified specialistworkshop" (Y page 10) and "Further applica-ble documents" (Y page 10).Please consult a Mercedes-Benz, MTU orMTU-authorised Mercedes-Benz ServiceCentre if you have any questions.

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Preparation for operation ................... 38Starting and stopping the engine ...... 39Switching the continuous brake onand off .................................................. 41Idling speed ......................................... 42Operational monitoring ...................... 42Displays ............................................... 44Warning and indicator lamps ............. 46Operating instructions ....................... 58Refuelling ............................................. 59Winter operation ................................. 61

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Preparation for operation

Engine with initial operation oil fromthe factory

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

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

Electronic oil level measurement – sys-tem descriptionThe engine oil level sensor is installed in theoil pan for oil level measurement. The electri-cal signals are detected in the engine control(MR) control unit and transmitted to the adap-tation module (ADM) via the engine CAN.Output can be displayed on a matrix displaywhen the engine is not running.The engine oil level is not displayed while theengine is running.

Checking the oil level electronicallyCheck the engine oil level on a regular basis,e.g. every week or each time you refuel.The current oil level in the engine is only dis-played once the engine is switched off andwith the ignition switched on. An accuratedisplay of the engine oil level is therefore onlypossible with the engine switched off and theignition switched on.

X Park the vehicle/device on a level surface.X Engage the parking brake.X Switch off the engine.X Wait approximately five to ten minutes. If

you call up the oil level in the engine tooearly or while the engine is running, it is notavailable.

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

Only use engine oil which has been approvedfor the engine and which meets the specifiedSAE classification (Y page 65).

Checking the oil level with the dipstick

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

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

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

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

Only use engine oil which has been approvedfor the engine and which meets the specifiedSAE classification (Y page 65).

Checking the coolant levelX Check the coolant level as stated in the

vehicle's/device's operating instructions.X Fill the cooling system if necessary. Only

use coolant that has been approved for theengine (Y page 68).

Checking the fuel levelFor checking the fuel level on the fuel gauge,see the vehicle's operating instructions.Refuel if necessary (Y page 68).

Checking the AdBlue®/DEF supplyFor checking the AdBlue®/DEF supply on theAdBlue®/DEF gauge, see the vehicle's oper-ating instructions. Refuel if necessary(Y page 60).

Starting and stopping the engine

Starting the engine

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

! If the oil pressure in the engine is too low,a warning light lights up on the instrumentpanel. The warning buzzer also sounds.

The operating safety of the engine is jeop-ardised. Switch off the engine immediately.

! Do not pull away as soon as the enginestarts. Let the engine run in neutral for ashort time after starting, until there is suf-ficient engine oil pressure. Do not drive athigh engine speeds when the engine iscold.This will prevent excessive wear and pos-sible engine failure.

Warm up the engine quickly by driving atmoderate engine speeds. Depending on theoutside temperature, the engine will reach itsoperating temperature after approximately10 to 20 minutes (Y page 97).You can utilise the full engine power outputonce the engine has reached its normal oper-ating temperature.The display format for indicator and warninglights is vehicle-specific/device-specific.Please also observe the information in theadditional operating instructions. These willbe provided by the vehicle/device manufac-turer.X Start the engine using the key in the ignition

lock or the external engine start/enginestop button on the engine. Do not depressthe accelerator or clutch pedal while doingso.

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

Starting the engine with the key

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

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

ing away.X Deactivate power take-off.X Shift the transmission to neutral or engage

neutral on the equipment.X To start the engine: turn the key in the

ignition lock to drive position 2.X Vehicles/equipment with a hot-water aux-

iliary heater: preheat the engine at outsidetemperatures below −20 † before starting.

X Vehicles/equipment with cold-start aid:wait until the % indicator lamp in theinstrument cluster goes out.

X Turn the key to start position 3 in the igni-tion lock. Do not depress the acceleratorpedal whilst doing so. For equipment, keepthe idling function active.

X When the engine has started, release thekey.The idling speed is controlled automati-cally.

i The engine idling speed is raised at verylow outside temperatures.

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

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

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

X If the engine fails to start: rectify the causeof the poor starting characteristics(Y page 86).

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

Starting the engine with the externalengine start/engine stop buttonX To start the engine with the external

engine start/engine stop button:(Y page 80).

Stopping the engine

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

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

! Stop the engine immediately, payingattention to the road and traffic conditionsif:Rthe oil pressure falls or fluctuates signif-

icantly.Rthe power output or engine speed

decreases and the position of the posi-tion sensor (accelerator) remains con-stant.Rheavy smoke is emitted from the

exhaust.

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Rthe coolant or engine oil temperaturerises steeply.Rabnormal noises suddenly come from

the engine or exhaust gas turbocharger.X Park the vehicle/equipment.X Secure the vehicle/equipment against roll-

ing away.X Shift the transmission into neutral/decou-

ple the drive system.Let the engine idle for approximately twominutes before switching off the engine if:Rthe coolant temperature is very high (over

90 †).Rthe engine has been operated at full output.X To switch off the engine: turn the vehicle

key in the ignition lock back to the stop atposition u.

i When you switch off the engine, BlueTec®

exhaust gas aftertreatment automaticallyflushes the exhaust system with fresh air.Residues of AdBlue®/DEF on the meteringunit or the injection nozzle might otherwiseimpair the function of BlueTec® exhaustgas aftertreatment. Depending on theengine's previous operating load, BlueTec®

exhaust gas aftertreatment may flush theexhaust system several times.When BlueTec® exhaust gas aftertreatmentflushes the exhaust system, an air valve isactivated. You may then hear a hissingsound. This hissing sound does not indicatea leak in the compressed-air system.

Switching off the engine with the exter-nal engine start/engine stop buttonX Switch off the engine with the external

engine start/engine stop button:(Y page 80).

Switching the continuous brake onand off

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

! If the continuous brake is deactivated andthe à indicator lamp in the instrumentcluster does not go out, have the continu-ous brake checked at a qualified specialistworkshop.

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

Engine brakeThe effectiveness of the engine brakedepends on the engine speed. A high engine

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speed results in more effective engine brak-ing.Observe the effective engine braking rangemarked on the rev counter (Y page 44).The maximum permissible engine speed isrestricted if necessary, depending on thevehicle/device application.Observe the vehicle/device OperatingInstructions.At very low outside temperatures, the enginebrake has limited or no effect after the enginehas been started.Operation of the engine brake (see the vehi-cle/device Operating Instructions).

RetarderOperation of the retarder; see the vehicle/device Operating Instructions.

Idling speed

After the engine has been started, idlingspeed is regulated automatically. The engineidling speed may differ in certain operatingconditions depending on the engine or onvehicles with power take-off.The engine idling speed is raised at very lowoutside temperatures.You can set the speed to the working speedvia the electronic engine management sys-tem. This makes it possible to drive auxiliaryequipment such as pumps at their workingspeed. For setting the working speed, see thevehicle's operating instructions.

Operational monitoring

Charge currentThe charge current indicator lamp must goout after the engine has started.If the # indicator lamp does not go off orlights up when the engine is running, switch

off the engine. Searching for and eliminatingthe cause of the malfunction (Y page 86).

Electronic engine managementThe indicator and warning lamps must go outafter the engine has started.If an indicator lamp or warning lamp does notgo out, or if it lights up while the engine isrunning, there is a malfunction in the elec-tronic engine management system.Searching for and eliminating the cause of themalfunction (Y page 86).Each malfunction is stored in the system withits own fault code. Temporary faults are alsostored.Fault codes can be read by a qualified spe-cialist workshop using a diagnostic tester(Y page 8).

Oil pressureIf the 1 indicator lamp does not go out orif it lights up when the engine is running,switch off the engine. Searching for and elim-inating the cause of the malfunction(Y page 86).

Operating restrictions for on-highwayapplications with BlueTec®

The electronic engine management systemmonitors:Remissions-relevant malfunctions in the

exhaust gas aftertreatmentRmalfunctions in the electronic monitoring

of the exhaust gas aftertreatment systemRconsumption, level and quality of the

AdBlue®/DEF reducing agentRthe efficiency of the catalytic converter in

accordance with the permitted thresholdsfor nitric oxide emissions (NOx)

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Operating restrictions may occur in the formof torque reduction, thus also limiting outputand speed.The degree of torque reduction depends onthe vehicle category:Rvehicles above 7.5 t: torque reduction by

approximately 40%Rvehicles below 7.5 t: torque reduction by

approximately 25%

Operating restrictions for off-highwayengines with BlueTec®

The electronic engine management systemmonitors:Remissions-relevant malfunctions in the

exhaust gas aftertreatmentRmalfunctions in the electronic monitoring

of the exhaust gas aftertreatment systemRconsumption, level and quality of the

AdBlue®/DEF reducing agentRthe efficiency of the catalytic converter in

accordance with the permitted thresholdsfor nitric oxide emissions (NOx)

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

Minor operating restrictionThe available torque is reduced to roughly80% of the maximum torque.

Reduction in output during minor operating restric-tion

Major operating restrictionThe transition between a minor and a majoroperating restriction is achieved by a gradualreduction in engine speed and torque.RThe engine torque is linearly reduced to

20% of the nominal value.RAt the same time, the engine speed is

slowly reduced to 1000 rpm.

Types of operating restriction

AdBlue®/DEF level low

Insufficient AdBlue®/DEF remaining; warning andlength of operating restriction period (example dis-play)A Acknowledged faultB Minor operating restrictionC Speed/torque reductionD Major operating restriction

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AdBlue®/DEF quality not OK/fault inthe monitoring system

Poor AdBlue®/DEF quality and misuse; warningand length of operating restriction period (exampledisplay)A Acknowledged faultB Minor operating restrictionC Speed/torque reductionD Major operating restriction

Repeated violationsIn the event of repeated violations, the peri-ods for the operating restriction system areshortened. When a fault is eliminated (forexample the NOx sensor is replaced or recon-nected), the operating restrictions are reset.Normal operation can be resumed.

Recurring fault (example display)a Regular operating restrictionb Operating restriction after first recurrence

of faultc Operating restriction after second recur-

rence of fault

Emergency switch for overridingoperating restrictions

If an emissions-relevant malfunction in theexhaust gas aftertreatment or theAdBlue®/DEF supply is detected, this cancause an operating restriction (limitation ofengine torque and engine speed).In case of emergency a push-button switchcan be operated to override the operatingrestriction. This means that full engine poweris available for a maximum of 30 minutes. Thisemergency function by operating the switchcan be activated a maximum of three times.When the final operating restriction (idlingspeed and 20% of torque) has been reached,the push-button switch is deactivated.

Deleting the fault memoryA fault stored in the fault memory because ofthe operating restriction system cannot bedeleted with a conventional reading device.Faults can only be deleted using the Daimler/MTU maintenance system.

Displays

Rev counter! If you exceed the maximum permissible

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

The engine speed display is the responsibilityof the vehicle manufacturer and is not nec-essarily supplied by Mercedes-Benz. DaimlerAG recommends that the vehicle manufac-turer uses a rev counter divided by:Roperational efficiencyRengine braking rangeRengine overrevving range

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General notes on the rev counter:RKeep an eye on the rev counter while driv-

ing and stay within the economical operat-ing range.In some situations it may make sense tooperate the engine outside the economicalengine speed range, e.g. on uphill gradientsor when overtaking.RIf you run the engine within the economical

engine speed range, you achieve low fuelconsumption and reduced wear.RIn engine braking mode, drive in the middle

engine speed range. The highest enginebraking effect will be achieved just beforethe red overrevving range.RWhen driving downhill, make sure that the

engine speed does not enter the overrev-ving range (marked red).RIdling speed is set automatically depending

on the coolant temperature.RWhen the vehicle is stationary, the engine is

running and the transmission is in neutral,the engine increases throttle only slowly.

AdBlue®/DEF levelThe AdBlue®/DEF gauge is the responsibilityof the vehicle manufacturer. It is not neces-sarily supplied by Mercedes-Benz. DaimlerAG recommends that the vehicle manufac-turer uses an AdBlue®/DEF gauge and anAdBlue®/DEF indicator lamp for theAdBlue®/DEF reserve level Ø.The AdBlue®/DEF reducing agent is requiredfor reduction of engine emissions.The MOT approval/operating permit is inva-lidated if the vehicle/equipment is operatedwithout AdBlue®/DEF. The legal conse-quence of this is that the vehicle/equipmentmay no longer be operated on public roads.If the AdBlue®/DEF level has sunk to approx-imately 10%, a warning lamp for the AdBlue®/DEF reserve level lights up on the instrument

panel. Top up the AdBlue®/DEF tank in goodtime (Y page 60).If the display is ignored and the AdBlue®/DEFlevel drops further, engine torque and enginespeed may be reduced (Y page 42).

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Warning and indicator lamps

Warning and indicator lamps – causes/consequences and solutions

Warning and indicator lamps for on-highway applications

Problem Possible causes/consequences and M Solutions

The r indicatorlamp flashes red.

A serious fault in the engine system has been detected.X Immediately stop the vehicle/device while paying attention to

the traffic conditions and contact a qualified specialist work-shop.

The Ù indicatorlamp lights up.

Impermissible operating conditions have been detected in theengine system.One of the following systems is malfunctioning:REngineREngine coolingREngine managementRDiesel injection systemX If further indicator lamps are displayed, take the combination of

lamps (see below) into account when evaluating the cause.X Have the systems checked at a qualified specialist workshop.

The # indicatorlamp lights up.

A malfunction has been detected in the electric power supply.X If there are no malfunctions, the indicator lamp goes out after

the engine is started.X If the indicator lamp does not go out or if it lights up when the

engine is running, search for the cause of the malfunction andhave it repaired at a qualified specialist workshop.

The % indicatorlamp lights up.

After you have switched the ignition lock to the drive position, theindicator lamp indicates the status of the cold-start aid(Y page 61).X If there are no malfunctions, the indicator lamp goes out after

the cold start aid has been switched off.

The 1 indicatorlamp lights up.

A malfunction was detected in the supply of engine lubricating oil.X If there are no malfunctions, the indicator lamp goes out after

the engine is started.X If the indicator lamp does not go off or lights up when the engine

is running, switch off the engine.X Check the engine oil level (Y page 38).X If this does not help, have the malfunction rectified at a qualified

specialist workshop.

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Problem Possible causes/consequences and M Solutions

The 2 indicatorlamp lights up.

A malfunction was detected in the supply of engine lubricating oil.The engine oil level is too low.X If there are no malfunctions, the indicator lamp goes out after

the engine is started.X If the indicator lamp does not go off or lights up when the engine

is running, switch off the engine.X Check the engine oil level (Y page 38).X If this does not help, have the malfunction rectified at a qualified

specialist workshop.

The + indicatorlamp lights up.

A malfunction in the coolant circuit has been detected. The coolantlevel is too low.X If there are no malfunctions, the indicator lamp goes out after

the engine is started.X If the indicator lamp does not go off or lights up when the engine

is running, switch off the engine.X Check coolant level.X If this does not help, have the malfunction rectified at a qualified

specialist workshop.

The ? indicatorlamp lights up.

A malfunction in the coolant circuit has been detected. The coolanttemperature is too high.X If there are no malfunctions, the indicator lamp goes out after

the engine is started.X If the indicator lamp does not go off or lights up when the engine

is running, switch off the engine.X Check coolant level.X If this does not help, have the malfunction rectified at a qualified

specialist workshop.If you do not observe the instructions, engine performance andtorque may be limited.

The w indicatorlamp lights up.

The indicator lamp shows the status of the continuous brake.X The indicator lamp lights up after activation of the continuous

brake.X Observe the information contained in the operating instructions

of the device/vehicle.X If the indicator lamp does not go out after deactivation or if it

lights up permanently, there is a malfunction.X Have the malfunction rectified immediately at a specialist work-

shop.

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Problem Possible causes/consequences and M Solutions

The = indicatorlamp lights up.

The indicator lamp shows the status of the cruise control function.X The indicator lamp lights up after activation of cruise control.X Observe the information contained in the operating instructions

of the device/vehicle.

The È indicatorlamp lights up.

The indicator lamp shows the status of the variable speed limiter.X The indicator lamp lights up after a speed limit was activated by

the speed limiter.X The active speed limit is shown in the vehicle/device display.X Observe the information contained in the operating instructions

of the device/vehicle.

The È indicatorlamp flashes.

The indicator lamp shows that the speed set by the speed limiterhas been exceeded.X The maximum speed (speed limit) set by the speed limiter is

being exceeded by more than 3 km/h. If necessary, reducespeed by adaptive braking.

X The speed limit set by the speed limiter was temporarily deac-tivated by kickdown and may be exceeded. By briefly switchingto idle throttle position, the set speed limit is reactivated.

X Observe the information contained in the operating instructionsof the device/vehicle.

The I indicatorlamp lights up.

The indicator lamp shows the status of the power take-off.X The indicator lamp lights up after engaging power take-off.X If there are no malfunctions, the indicator lamp goes out after

the power take-off is switched off.X Observe the information contained in the operating instructions

of the device/vehicle.

Additional information for vehicles/devices with BlueTec®/DEF

Problem Possible causes/consequences and M Solutions

The Ø indicatorlamp lights up.

The AdBlue®/DEF reserve level has been reached.X Top up the AdBlue®/DEF tank.

The ; indicatorlamp flashes when theignition is ON.

After you have switched the ignition lock into the drive position,the indicator lamp indicates the status of the European On-BoardDiagnosis (OBD) by means of a sequence of flashes.X If there are no malfunctions, the indicator lamp goes out after

the engine is started.

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Problem Possible causes/consequences and M Solutions

The ; indicatorlamp lights up.

An emissions-relevant fault has been detected.X If further indicator lamps are displayed, take the combination of

lamps (see below) into account when evaluating the cause.X Have the exhaust gas aftertreatment system checked at a quali-

fied specialist workshop.The operating permit is invalidated if you continue to use the vehi-cle.If there are no malfunctions, the indicator lamp only goes out afterfurther test routines. The system check may involve several enginestarts, several hours or several journeys without a malfunction.

The s indicatorlamp lights up.

An emissions-relevant fault has been detected.X An operating restriction is active. The engine torque is tempo-

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

lamps (see below) into account when evaluating the cause.

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

Warning and indicator lamps for off-highway engines

Problem Possible causes/consequences and M Solutions

The r indicatorlamp flashes red.

A serious fault in the engine system has been detected.X Immediately stop the vehicle/device while paying attention to

the traffic conditions and contact a qualified specialist work-shop.

The Ù indicatorlamp lights up.

Impermissible operating conditions have been detected in theengine system.One of the following systems is malfunctioning:REngineREngine coolingREngine managementRDiesel injection systemX If further indicator lamps are displayed, take the combination of

lamps (see below) into account when evaluating the cause.X Have the systems checked at a qualified specialist workshop.

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Problem Possible causes/consequences and M Solutions

The # indicatorlamp lights up.

A malfunction has been detected in the electric power supply.X If there are no malfunctions, the indicator lamp goes out after

the engine is started.X If the indicator lamp does not go out or if it lights up when the

engine is running, search for the cause of the malfunction andhave it repaired at a qualified specialist workshop.

The % indicatorlamp lights up.

After you have switched the ignition lock to the drive position, theindicator lamp indicates the status of the cold-start aid(Y page 61).X If there are no malfunctions, the indicator lamp goes out after

the cold start aid has been switched off.

The 1 indicatorlamp lights up.

A malfunction was detected in the supply of engine lubricating oil.X If there are no malfunctions, the indicator lamp goes out after

the engine is started.X If the indicator lamp does not go off or lights up when the engine

is running, switch off the engine.X Check the engine oil level (Y page 38).X If this does not help, have the malfunction rectified at a qualified

specialist workshop.

The 2 indicatorlamp lights up.

A malfunction was detected in the supply of engine lubricating oil.The engine oil level is too low.X If there are no malfunctions, the indicator lamp goes out after

the engine is started.X If the indicator lamp does not go off or lights up when the engine

is running, switch off the engine.X Check the engine oil level (Y page 38).X If this does not help, have the malfunction rectified at a qualified

specialist workshop.

The + indicatorlamp lights up.

A malfunction in the coolant circuit has been detected. The coolantlevel is too low.X If there are no malfunctions, the indicator lamp goes out after

the engine is started.X If the indicator lamp does not go off or lights up when the engine

is running, switch off the engine.X Check coolant level.X If this does not help, have the malfunction rectified at a qualified

specialist workshop.

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Problem Possible causes/consequences and M Solutions

The ? indicatorlamp lights up.

A malfunction in the coolant circuit has been detected. The coolanttemperature is too high.X If there are no malfunctions, the indicator lamp goes out after

the engine is started.X If the indicator lamp does not go off or lights up when the engine

is running, switch off the engine.X Check coolant level.X If this does not help, have the malfunction rectified at a qualified

specialist workshop.If you do not observe the instructions, engine performance andtorque may be limited.

The w indicatorlamp lights up.

The indicator lamp shows the status of the continuous brake.X The indicator lamp lights up after activation of the continuous

brake.X Observe the information contained in the operating instructions

of the device/vehicle.X If the indicator lamp does not go out after deactivation or if it

lights up permanently, there is a malfunction.X Have the malfunction rectified immediately at a specialist work-

shop.

The = indicatorlamp lights up.

The indicator lamp shows the status of the cruise control function.X The indicator lamp lights up after activation of cruise control.X Observe the information contained in the operating instructions

of the device/vehicle.

The È indicatorlamp lights up.

The indicator lamp shows the status of the variable speed limiter.X The indicator lamp lights up after a speed limit was activated by

the speed limiter.X The active speed limit is shown in the vehicle/device display.X Observe the information contained in the operating instructions

of the device/vehicle.

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Problem Possible causes/consequences and M Solutions

The È indicatorlamp flashes.

The indicator lamp shows that the speed set by the speed limiterhas been exceeded.X The maximum speed (speed limit) set by the speed limiter is

being exceeded by more than 3 km/h. If necessary, reducespeed by adaptive braking.

X The speed limit set by the speed limiter was temporarily deac-tivated by kickdown and may be exceeded. By briefly switchingto idle throttle position, the set speed limit is reactivated.

X Observe the information contained in the operating instructionsof the device/vehicle.

The I indicatorlamp lights up.

The indicator lamp shows the status of the power take-off.X The indicator lamp lights up after engaging power take-off.X If there are no malfunctions, the indicator lamp goes out after

the power take-off is switched off.X Observe the information contained in the operating instructions

of the device/vehicle.

Additional information for vehicles/devices with BlueTec®

Problem Possible causes/consequences and M Solutions

The Ø indicatorlamp lights up.

The AdBlue®/DEF reserve level has been reached.X Top up the AdBlue®/DEF tank.

The s indicatorlamp lights up.

An emissions-relevant fault has been detected.X An operating restriction is active. The engine torque is tempo-

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

lamps (see below) into account when evaluating the cause.

The s indicatorlamp flashes.

An emissions-relevant fault has been detected.X An operating restriction is active. The engine torque is tempo-

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

lamps (see below) into account when evaluating the cause.

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Problem Possible causes/consequences and M Solutions

The · indicatorlamp lights up.

An emissions-relevant malfunction in the exhaust gas aftertreat-ment system or in the AdBlue®/DEF supply has been detected.X Top up the AdBlue®/DEF tank immediately.X If this does not help: have the exhaust gas aftertreatment sys-

tem checked at a qualified specialist workshop. Have the mal-function rectified immediately. If you do not, engine output maybe reduced and engine speed may be limited.

If there are no malfunctions, the indicator lamp only goes out afterfurther test routines. The system check may involve several enginestarts, several hours or several journeys without a malfunction.If further indicator lamps are displayed, take the combination oflamps (see below) into account when evaluating the cause.

The · indicatorlamp flashes, the sindicator lamp lightsup.

You have not rectified an emissions-relevant malfunction that hasbeen detected in the exhaust gas aftertreatment system or in theAdBlue®/DEF supply. Reduced engine output is active. The enginetorque is temporarily limited to a maximum of 80% across theentire engine speed range. The effect of the limitation is linear. Ifyou do not observe the instructions, engine torque may be furtherlimited to a maximum of 50%.X Adapt your driving/operating style.X Top up the AdBlue®/DEF tank immediately.X If this does not help, have the malfunction rectified at a qualified

specialist workshop.If you do not observe the instructions, engine performance andalso engine speed may be limited.

The · and sindicator lamps areflashing.

You have not rectified an emissions-relevant malfunction that hasbeen detected in the exhaust gas aftertreatment system or in theAdBlue®/DEF supply.The reduction in engine output and limitation of the engine torqueare activated. The engine torque is limited to a maximum of 20%across the whole engine speed range. The engine speed is limitedto a maximum of 1000 rpm.X Adapt your driving/operating style.X Top up the AdBlue®/DEF tank immediately.X If this does not help, have the malfunction rectified at a qualified

specialist workshop.

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The · and Ùindicator lamps are lit.

An emissions-relevant malfunction in the exhaust gas aftertreat-ment system or in the AdBlue®/DEF supply has been detected.X Have the exhaust gas aftertreatment system checked at a quali-

fied specialist workshop. Have the malfunction rectified imme-diately. If you do not, engine output may be reduced and enginespeed may be limited.

If there are no malfunctions, the indicator lamp only goes out afterfurther test routines. The system check may involve several enginestarts, several hours or several journeys without a malfunction.

The · indicatorlamp flashes, the Ùand s indicatorlamps light up.

You have not rectified an emissions-relevant malfunction that hasbeen detected in the exhaust gas aftertreatment system or in theAdBlue®/DEF supply.The reduction in engine output and limitation of the engine torqueare activated. The engine torque is temporarily limited to a maxi-mum of 80% across the entire engine speed range. The effect ofthe limitation is linear. If you do not observe the instructions,engine torque may be further limited to a maximum of 50%.X Adapt your driving/operating style.X Have the malfunction rectified immediately at a specialist work-

shop.If you do not observe the instructions, engine performance andalso engine speed may be limited.

The · and sindicator lamps flash,the Ù indicatorlamp lights up.

You have not rectified an emissions-relevant malfunction that hasbeen detected in the exhaust gas aftertreatment system or in theAdBlue®/DEF supply.The reduction in engine output and limitation of the engine torqueare activated. The engine torque is limited to a maximum of 20%across the whole engine speed range. The engine speed is limitedto a maximum of 1000 rpm.X Adapt your driving/operating style.X Have the malfunction rectified immediately at a specialist work-

shop.

In the event of an emergency, operating restrictions (limitation of the engine torque and enginespeed) can be temporarily overridden with the emergency switch (Y page 44). When theAdBlue®/DEF tank is filled or the fault is rectified, full engine power will be available again. Ifthe system check does not detect any other faults, the indicator lamps go out after the sys-tem's status indicator. The system check may involve several engine starts, several hours orseveral journeys without a malfunction.

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Only vehicles/devices with the AdBlue®/DEF reserve warning lightIf a malfunction is detected and the listed indicator lamps light up, a warning buzzer sounds forapproximately 5 seconds. In the event of an emergency, operating restrictions (limitation of theengine torque and engine speed) can be temporarily overridden with the emergency switch(Y page 44).

Problem Possible causes/consequences and M Solutions

Indicator lamps Øand are lit and· flashes.

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

The Ø indicatorlamp is lit and · and

are flashing.

The AdBlue®/DEF level has dropped to approximately 5%. Thereduction in engine output and limitation of the engine torque areactivated. The engine torque is limited to a maximum of 50%across the whole engine speed range. The engine speed is limitedto a maximum of 60%. The limitation takes effect by means of aramp function.X Adapt your driving/operating style.X Top up the AdBlue®/DEF tank immediately.

If you do not observe the instructions, engine torque and enginespeed may be further reduced.

The Ø and indi-cator lamps are lit and· and areflashing.

The AdBlue®/DEF level has dropped to approximately 2.5%. Thereduction in engine output and limitation of the engine torque areactivated. The engine torque is limited to a maximum of 20%across the whole engine speed range. The engine speed is limitedto idling speed. The limitation takes effect by means of a rampfunction.X Adapt your driving/operating style.X Top up the AdBlue®/DEF tank immediately.

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The Ø indicatorlamp lights up and·, and are flashing.

The AdBlue®/DEF level has dropped to approximately 0%. Thereduction in engine output and limitation of the engine torque areactivated. The engine torque is limited to a maximum of 20%across the whole engine speed range. The engine speed is limitedto idling speed. The limitation takes effect by means of a rampfunction.X Stop the vehicle/device, paying attention to road and traffic

conditions.X Top up the AdBlue®/DEF tank immediately.

The · indicatorlamp lights up.

An emissions-relevant malfunction in the exhaust gas aftertreat-ment system or in the AdBlue® supply has been detected.X Have the exhaust gas aftertreatment system checked at a quali-

fied specialist workshop. Have the malfunction rectified imme-diately. If you do not, engine output may be reduced and enginespeed may be limited.

If there are no malfunctions, the indicator lamp only goes out afterfurther test routines. The system check may involve several enginestarts, several hours or several journeys without a malfunction.

The indicator lamplights up and · isflashing.

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

have the malfunction rectified immediately.If you do not follow the instructions, an engine speed limitationmay be imposed.

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Problem Possible causes/consequences and M Solutions

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

You have not rectified an emissions-relevant malfunction that hasbeen detected in the exhaust gas aftertreatment system or in theAdBlue®/DEF supply.The reduction in engine output and limitation of the engine torqueare activated. The engine torque is limited to a maximum of 50%across the whole engine speed range. The engine speed is limitedto a maximum of 60%. The limitation takes effect by means of aramp function.X Adapt your driving/operating style.X Drive carefully to the nearest qualified specialist workshop and

have the malfunction rectified immediately.If you do not follow the instructions, an engine speed limitationmay be imposed.

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

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

shop.

The , · andindicator lamps

are flashing.

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

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

shop.

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

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Operating instructions

Running-in

Vehicles/devicesObserve the vehicle/device manufacturer'srunning-in notes.The running-in period of the engine has a sig-nificant effect on the vehicle, especially withregard to:Rservice lifeRoperating safetyReconomyObserve the following notes during the run-ning-in period up to 2,000 km (30 operatinghours):Ravoid subjecting the engine to full load.Rrun in the engine with care, using differing

speeds and engine revs.Ravoid high engine speeds.Rdo not drive at more than ¾ of the maxi-

mum road speed for each gear.Rchange gear in good time.Rdo not shift down to brake the vehicle.Rfor vehicles with automatic transmission,

do not depress the accelerator pedalbeyond the point of resistance (kickdown).

After 2,000 km (30 operating hours), you cangradually bring the vehicle up to full roadspeed and increase engine speeds.

Fuel consumption

General notesFuel consumption depends on:Rthe type of fuel used (diesel fuel, fatty acid

methyl ester FAME fuel)Rthe machine version/vehicle versionRthe operating modeRthe operating conditionsRthe attached equipment (e.g. hydraulic

pumps, mowers, etc.)Rmaintenance

Rdriving resistanceRyour driving styleFor these reasons, exact details about anysingle engine's fuel consumption cannot beprovided.

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

mate control, auxiliary heating)

MaintenanceFuel consumption and assembly wear dependon how often maintenance is carried out. Reg-ular maintenance increases safety and lowersfuel consumption. Keep to the maintenanceintervals. Always have maintenance work car-ried out at a qualified specialist workshop.

Fuel typeThe fuel grade also affects fuel consumption.Use of lower fuel grades and/or non-approved fuel additives will increase fuel con-sumption. When refuelling, ensure that youare filling the appropriate fuel grade(Y page 68).

AdBlue®/DEF consumptionAdBlue®/DEF consumption is between 3 and6% of the fuel consumption, depending onengine use.

Engine oil consumptionAfter running-in the engine, oil consumptionmay reach 0.5% of the vehicle's fuel con-sumption.

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More arduous operating conditions andincreased distance covered could result inengines exceeding this oil consumptionvalue.

Warning buzzerIf the warning buzzer sounds and the 1symbol on the instrument panel is displayed,the engine's operating safety is jeopardised.Do not pull away, or stop the vehicle as soonas possible, paying attention to road and traf-fic conditions. You could otherwise damagethe engine. The warning buzzer soundsdepending on the vehicle if:Ryou exceed the maximum permissible

engine speed.Rthe engine speed or vehicle speed is too

high when changing gears.Rthe coolant level is too low or the maximum

permissible coolant temperature (about100 °C) is exceeded. The operating safetyof the engine is jeopardised.Ran emissions-relevant fault is detected or

there is an operating restriction due to anemissions-relevant malfunction.

Refuelling

Fuels

Important safety notes

G WARNINGFuels are poisonous and hazardous to health.There is a danger of injury.Do not swallow fuel or let it come into contactwith skin, eyes or clothing. Do not inhale fuelvapours. Keep fuels out of the reach of chil-dren.

If you or others come into contact with fuel,observe the following:RWash the fuel off any affected areas of skin

with water and soap immediately.RIf you get fuel in your eyes, rinse them thor-

oughly with clean water immediately. Seekimmediate medical attention.RIf fuel is swallowed, seek immediate medi-

cal attention. Do not induce vomiting.RChange any clothing that has come into

contact with fuel immediately.

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

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

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

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

! Do not add any special fuel additives tothe diesel fuel.

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Special fuel additives can lead to:RmalfunctionsRdamage to the catalytic converterRengine damage

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

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

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

Only refuel using approved fuels which arecommercially available. Please note theapproved fuel grade in the "Service products"section (Y page 68). Using fuels which havenot been approved causes irreversible dam-age to the engine and the exhaust gas after-treatment system, as well as also significantlyreducing the expected service life.

Before filling the tank

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

X Switch off the engine.X Secure the vehicle/device against rolling

away.X Switch off the auxiliary heating.X Observe the fuel grade (Y page 68).Regularly check the fuel prefilter with heatedwater separator for condensation.

AdBlue®/DEF

Important safety notes

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

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

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

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

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

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

When opening the AdBlue®/DEF tank, smallamounts of ammonia vapours could escape.Ammonia vapours have a pungent smell andare particularly irritating to:RskinRmucous membranesReyesThe vapours may cause a burning sensation inthe eyes, nose and throat as well as irritationof the throat and watering eyes.Avoid inhaling ammonia vapours. Only fill theAdBlue®/DEF tank in well-ventilated areas.

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AdBlue®/DEF should not come into contactwith skin, eyes or clothing, and should not beswallowed. Keep AdBlue®/DEF out of thereach of children.If you come into contact with AdBlue®/DEF,observe the following:Rimmediately wash AdBlue®/DEF from your

skin with water and soap.Rif AdBlue®/DEF comes into contact with

your eyes, rinse your eyes with clean waterimmediately. Seek medical attentionimmediately.Rif you have swallowed AdBlue®/DEF,

immediately rinse your mouth with waterand drink plenty of water. Seek medicalattention immediately.Rchange clothing that has come into contact

with AdBlue®/DEF immediately.AdBlue®/DEF is not refilled as part of themaintenance work. Top up the tank regularlyduring vehicle operation or at the latest whenthe first event message is displayed on theelectronic engine management system.You will find further information on AdBlue®/DEF in the "Service products" section(Y page 71).

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

ing away.X Switch off the auxiliary heating.Always fill the tank with at least 5 litres, assmaller amounts could cause malfunctions.

Winter operation

Notes for winter operation! At very low outside temperatures, make

sure that the engine oil added is of anappropriate SAE classification. Usingengine oils that are not suitable for very low

outside temperatures may result in enginedamage.

Before the start of the cold season, make surethat:Rthe coolant contains sufficient antifreeze

(Y page 68)Rthe fuel used is suitable for winter use

(Y page 68)Rthe SAE class of the engine oil used is in

accordance with outside temperatures(Y page 65).

Jump-starting

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

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

Diesel fuelsNotes on diesel fuel at low temperatures(Y page 70).

Cold-start aidThe cold-start aid makes it easier to start theengine at low outside temperatures(below–15 †). It is activated when the out-side temperature falls below –4 †.

H Environmental noteAt outside temperatures below approximatelyÒ4 †, the cold-start aid minimises pollutantemissions (after the engine is started). In addi-tion, it reduces the load on the starter motor

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and batteries and enables the engine to bestarted more rapidly. For this reason, onlystart the engine once the % indicator lampin the status area of the on-board computerhas gone out.

X To activate the cold-start aid: turn thevehicle key to the drive position in the igni-tion lock.The % indicator lamp lights up in theinstrument panel.

X After the % indicator lamp goes out,start the engine within 30 seconds.

The cold-start aid is automatically deactiva-ted if:Rthe engine is not started within 30 seconds

of the % indicator lamp going out.Rthe engine is started when the % indi-

cator lamp is lit.Rthe coolant temperature reaches around

0 † while the engine is running.At a coolant temperature above approx-imately -4 †, the % indicator lamp goesout after approximately 2 seconds (functioncheck). At a coolant temperature belowapproximately -4 †, the % indicator lampgoes out after approximately 20 seconds.Have the cold-start aid checked and repairedonly at a qualified specialist workshop.Mercedes-Benz recommends that you use aMercedes-Benz, MTU or MTU-authorisedMercedes-Benz Service Centre (Y page 10).Work relevant to safety or on safety-relatedsystems must be carried out at a qualifiedspecialist workshop.

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General notes ...................................... 64Service products ................................. 65Cleaning and care ............................... 72

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General notes

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

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

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

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

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

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

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

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

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

Service products

Important safety notes

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

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

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

Service products are:Rfuels (e.g. diesel)Rlubricants (e.g. engine oil, transmission oil,

grease)Rcoolant, antifreezeRAdBlue®/DEF, reducing agent in the

exhaust gas aftertreatment systemApproved service products fulfil the highestquality standards and are documented in theMercedes-Benz Specifications for ServiceProducts. For this reason, only use approvedservice products for your vehicle. Information

about approved service products is availablefrom any Mercedes-Benz Service Centre(Y page 10).You can recognise service products approvedby Mercedes-Benz by the following inscrip-tion on the container:RMB-Freigabe (e.g. MB-Freigabe 228.51)

orRMB-Approval (z. B. MB-Approval 228.51)Other labels and recommendations relatingto the quality or indicating that the productmeets a certain specification are not neces-sarily approved by Mercedes-Benz. Furtherinformation is available from any Mercedes-Benz, MTU or MTU-authorised Mercedes-Benz Service Centre (Y page 10).

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

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

Engine oils

Notes on engine oils

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

Only use engine oils that comply with theMercedes-Benz Specifications for ServiceProducts.

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The following engine oils are approved:RSheet No. 228.5 / 228.3 / 228.1 standard

quality multi-grade engine oilsRSheet No. 228.51 / 228.31 low-ash multi-

grade engine oilsRSheet No. 228.0 / 228.2 standard quality

single-grade engine oils (exceptional cir-cumstances)

Mercedes-Benz particularly recommendsengine oils that comply with Sheet no. 228.5of the Mercedes-Benz Specifications for Ser-vice Products.These engine oils are of a high standard ofquality and have a beneficial effect on:Rlength of oil change intervalsRengine wearRfuel consumptionRexhaust emissionsThe maximum interval for oil change is onlyachieved with engine oils of a particularly highquality grade.Check the vehicle assemblies for leaks regu-larly. If fluid loss is identified, e.g. by oil dropson the parking area, have the cause of thefluid loss rectified at a qualified specialistworkshop.

Scope of application

For engines with BlueTec® exhaust gas after-treatment and operation with diesel fuel, onlyuse multi-grade engine oils compliant withSheet Nos. 228.5, 228.51, 228.3 and 228.31or, in exceptional cases, single-grade engineoils compliant with Sheet No. 228.2.For engines without BlueTec® exhaust gasaftertreatment, multi-grade oils compliantwith Sheet No. 228.1 and, in exceptionalcases, single-grade oils compliant with SheetNo. 228.0 / 228.2 can also be used.For operation with FAME fatty acid methylester fuel (bio-diesel fuel), use only engine oilscompliant with Sheet Nos. 228.5, 228.51,228.3 and 228.31 (Y page 70).

This is also required for a mixture of conven-tional diesel fuels and FAME fatty acid methylester fuels (bio-diesel fuel).Multi-grade engine oils compliant with SheetNos. 228.5, 228.51, 228.3, 228.31 and228.1 can be used all year round. Dependingon the fuel quality (fuel sulphur content orFAME fatty acid methyl ester fuel), the oilchange intervals may be shortened. Fordetails, see the Maintenance Booklet.Single-grade engine oils only cover an SAE(viscosity) classification for certain tempera-ture ranges. Change the engine oil to an SAEclass suitable for the time of year and therespective outside temperatures.The use of low-ash engine oils is permittedbut only necessary on engines with a dieselparticle filter. The use of low-ash engine oilscompliant with Sheet No. 228.51 and 228.31is however only approved in conjunction withlow-sulphur diesel fuel (less than 50 ppm,0.005% by weight) (Y page 69).

Oil change

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

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

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using engine oils of SAE class 5W-30 or0W-30.Use only all-season oils.

! If you do not use oil for all-year-roundoperation in your engine, change theengine oil right at the beginning of the coldseason. Use only an approved engine oil inthe specified SAE classification.

Engine oil SAE classes (viscosity): Single-grade engine oils; Multi-grade engine oilsOil change intervals are dependent on the fol-lowing:Rthe operating conditions of the vehicleRthe grade of the engine oil usedRthe fuel grade (sulphur content)Rthe fuel type, e.g. FAME fatty acid methyl

ester fuelFor more details, see the Maintenance Book-let.The maximum oil change interval can only beachieved by using engine oils of particularlyhigh quality in accordance with Sheet No.228.51 and 228.5 of the Mercedes-BenzSpecifications for Service Products. The clas-sification of oil change intervals is specified inthe Maintenance Booklet.

H Environmental noteIf you operate your vehicle using FAME fattyacid methyl ester fuel (bio-diesel), special pre-cautions must be taken and national specifi-cations complied with when disposing ofengine oils. Information is available from anyMercedes-Benz or MTU Service Centre.

Adding/topping up the engine oil

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

When topping up, Mercedes-Benz recom-mends that you only use engine oil of thesame grade and SAE class as the oil filled atthe last oil change.Check the oil level before topping up theengine oil (Y page 38).

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

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Coolant

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

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

A coolant that ensures anti-corrosion/anti-freeze protection and other important pro-tective effects is filled at the factory.The coolant is a mixture of water and corro-sion inhibitor/antifreeze.The corrosion inhibitor/antifreeze in the cool-ant has the following properties:Rheat transferRanti-corrosion protectionRcavitation protection (protection against

pitting)Rantifreeze protectionRraising the boiling pointLeave the coolant in the engine cooling sys-tem all year round – even in countries withhigh outside temperatures.Check the corrosion inhibitor/antifreeze con-centration in the coolant every six months.Renew the coolant at the interval specified inthe Maintenance Booklet.Only use approved corrosion inhibitor/anti-freeze agents. Please note the Mercedes-Benz Specifications for Service Products

(Y page 65). This prevents damage to theengine cooling system and engine.When renewing the coolant, ensure that itcontains 50% corrosion inhibitor/antifreezeby volume. This corresponds to antifreezeprotection down to Ò37 †.Do not exceed 55% by volume (antifreezedown to approximately Ò45 †). The heat dis-sipation and antifreeze may otherwise benegatively affected.If there is a loss of coolant, do not top it up byusing only water, but also add an approvedcorrosion inhibitor/antifreeze agent.The water in the coolant must meet certainrequirements, which are often fulfilled by theuse of drinking water. The water must betreated if its quality does not meet therequired standards.Please note the Mercedes-Benz Specifica-tions for Service Products, Sheet No. 310.1.Mixtures with other corrosion inhibitors/anti-freeze agents are not permitted.

Diesel fuels

Important safety notes

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

G WARNINGFuels are poisonous and hazardous to health.There is a danger of injury.Do not swallow fuel or let it come into contactwith skin, eyes or clothing. Do not inhale fuelvapours. Keep fuels out of the reach of chil-dren.

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If you or others come into contact with fuel,observe the following:RWash the fuel off any affected areas of skin

with water and soap immediately.RIf you get fuel in your eyes, rinse them thor-

oughly with clean water immediately. Seekimmediate medical attention.RIf fuel is swallowed, seek immediate medi-

cal attention. Do not induce vomiting.RChange any clothing that has come into

contact with fuel immediately.

! If you are using drums or canisters torefuel the engine/vehicle/equipment, youshould filter the fuel before filling.This prevents malfunctions in the fuel sys-tem caused by contaminated fuel.

The following fuel types are not permitted:Rmarine diesel fuelRaviation turbine fuelRheating oils

Fuel grade

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

Fuel sulphur content! A higher fuel sulphur content accelerates

the ageing process of the engine oil and candamage the engine and exhaust system.

! Vehicles with BlueTec® exhaust gas aftertreatment:Only standardised fuels with a maximumsulphur content of 0.05% (500 ppm) byweight are permissible. However,Mercedes-Benz only recommends fuel thatcomplies with the European standard EN590 as of 2005, et seq. (max. 0.005%(50 ppm) sulphur by weight). The use offuels with a sulphur content higher than0.005% (50 ppm) by weight reduces the life

expectancy of the engine and exhaust sys-tem.

! Vehicles without BlueTec® exhaust gas aftertreatment: Only commercially available fuels whichcomply with the European standard EN 590or comparable national fuel standards arepermitted. Mercedes-Benz recommendsfuels with a low sulphur content. The use offuels with a high sulphur content reducesthe lifespan of the engine and the exhaustsystem. For operation with a high sulphurcontent > 0.05% by weight (500 ppm), themaintenance intervals for the engine oiland filter must be reduced.

For details, see the Maintenance Booklet.

i Even if the maintenance intervals arereduced, operation with fuel with a highersulphur content will lead to increasedengine wear, especially on the fuel injec-tors.

Information about current country-specificfuel sulphur contents can be obtained fromany Mercedes-Benz, MTU or MTU-authorisedMercedes-Benz Service Centre (Y page 10).You can find a table of fuel sulphur contents inspecific countries in the Mercedes-BenzSpecifications for Service Products, Sheet136.2 at http://bevo.mercedes-benz.com.The maintenance intervals for engine oil andfilter replacement must be adapted depend-ing on the fuel grade used. The higher the sul-phur content in diesel fuel, the shorter themaintenance intervals for engine oil and filterreplacement. Observe the notes in the Main-tenance Booklet.

Water contentIf the engine is operated with increasedamounts of dirt and water, an additional fuelprefilter with a water separator must be fittedon the chassis.

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Diesel fuels at low temperatures

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

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

Fuel additives

! When necessary, use only approved fueladditives.There is otherwise a risk of impaired engineperformance or engine and catalytic con-verter damage. The use of appropriate fueladditives is your responsibility.

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

For lower temperatures, the engine can beequipped with a fuel preheating system. Thisimproves the flow characteristics of the die-sel fuel according to the output of the instal-led heater.Fuel additives used to improve flow charac-teristics are flow improvers.

Do not add flow improvers to winter dieselfuel guaranteed to operate down to −22 †.The cold flow properties of the fuel may dete-riorate as a consequence of the flowimprover.

Fatty acid methyl ester (FAME) fuel(bio-diesel)

General notesOperate your engine using pure FAME fattyacid methyl ester fuel in compliance withDIN EN 14214. You can also operate yourengine using a mixture of conventional dieselfuel and FAME fatty acid methyl ester fuel.This also applies to engines with exhaust gasaftertreatment.Observe the specifications in accordancewith Sheet no. 135.0 of the Mercedes-BenzSpecifications for Service Products for oper-ation with FAME fatty acid methyl ester fuel.Operating the vehicle with FAME fatty acidmethyl ester fuel results in:Rhigher fuel consumptionRreduced engine power outputRincreased white smoke after a cold startRreduced maintenance intervals

Low outside temperaturesFAME fatty acid methyl ester fuel compliantwith DIN EN 14214 can be used reliably atoutside temperatures down to −20 †.If you add a flow improver to the FAME fattyacid methyl ester fuel, the fuel's resistance tolow temperatures does not change.For lower temperatures, the engine can beequipped with a fuel preheating system. Thisimproves the flow characteristics of the FAMEfatty acid methyl ester fuel according to theheat output installed.

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AdBlue®/DEF

Important safety notes

G WARNINGAdBlue®/DEF must not come into contactwith skin, eyes or clothing.RIf AdBlue®/DEF comes into contact with

your eyes or skin, rinse affected areas withclean water immediately.RIf AdBlue®/DEF is swallowed, immediately

rinse your mouth out with a lot of cleanwater and drink plenty of water.RChange clothing that is soiled with

AdBlue®/DEF immediately.RIf allergic reactions occur, consult a doctor

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

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

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

The vapours may cause a burning sensation inthe eyes, nose and throat as well as irritationof the throat and watering eyes.Avoid inhaling ammonia vapours. Only fill theAdBlue®/DEF tank in well-ventilated areas.AdBlue®/DEF should not come into contactwith skin, eyes or clothing, and should not beswallowed. Keep AdBlue® out of the reach ofchildren.If you come into contact with AdBlue®/DEF,observe the following:Rimmediately wash AdBlue®/DEF from your

skin with water and soap.Rif AdBlue®/DEF comes into contact with

your eyes, rinse your eyes with clean waterimmediately. Seek medical attentionimmediately.Rif you have swallowed AdBlue®/DEF,

immediately rinse your mouth with waterand drink plenty of water. Seek medicalattention immediately.Rchange clothing that has come into contact

with AdBlue®/DEF immediately.

High outside temperatures

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

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

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Low outside temperatures

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

Additives, tap water

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

Storage

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

Only use containers made of the followingmaterials to store AdBlue®:RCr‑Ni steel in accordance with

DIN EN 10 088-1/2/3RMo-Cr‑Ni steel in accordance with

DIN EN 10 088-1/2/3RPolypropyleneRPolyethylene

Disposal

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

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

Purity

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

treatment system.

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

Cleaning and care

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

High-pressure cleaning

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

! The exhaust gas aftertreatment systemmay only be cleaned when it is cool. Thesensors can otherwise be damaged.

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

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

jets

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

Cleaning the engine! Observe the following notes when clean-

ing the engine. This avoids malfunctionsand damage to the engine.RWhen using high-pressure or steam

cleaners, do not point the spray directlyat electrical components and electriccables.RMake sure that no water enters the air

intake and ventilation openings.RTreat the engine with preservative

agents after it has been cleaned. Whendoing so, protect the belt drive systemfrom the preservative agent.ROnly use wax-based protective agents

for engines that comply withSheet No. 385.4 of the Mercedes-BenzSpecifications for Service Products.

In addition, observe the notes in the "High-pressure cleaning" section (Y page 72).

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74

General notes ...................................... 76Decommissioning for up to 6months ................................................. 76Decommissioning for up to 12months ................................................. 76

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General notes

Decommissioned engines are engines thatare not operated for over a month.Special measures are required to decommis-sion the engine/vehicle.Information about batteries: if the engine/vehicle is to be out of use for longer than threeweeks, disconnect the negative terminal onthe battery. This prevents the batteries frombeing discharged by no-load current consum-ers.If the engine/vehicle is to be out of use for alonger period, remove the batteries and storethem in a dry and well-ventilated area.Recharge batteries every 3 months at the lat-est.Ensure that there is adequate ventilationwhen recharging. Check the battery fluid lev-els before and after charging and if necessarycorrect them. For further information(Y page 61).

Decommissioning for up to 6 months

When decommissioning an engine/vehicle,keep it in a covered, dry and well-ventilatedarea. The room temperature should not fallbelow -10 †.Measures prior to decommissioning:RClean the engine/vehicle thoroughly.RRemove any patches of corrosion from the

engine.RChange the engine oil and oil filter if the last

oil change was carried out more than20,000 km (or around 300 operating hours)ago.Also change the engine oil and filter if theoil is more than 12 months old.RCheck and adjust the level of coolant or

renew coolant.RCheck and adjust the concentration of anti-

corrosion/antifreeze additives in the cool-ant.

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

tem.Engine/vehicle/equipment run on FAME (Fatty Acid Methyl Ester) bio-diesel fuel

Before decommissioning, operate the enginewith at least two fuel tanks of diesel fuel.Decommissioning with FAME fatty acidmethyl ester (bio-diesel fuel) is not permitted. Measures prior to recommissioning:RFit and connect the battery.RCheck that the electrical system is func-

tioning correctly.RCheck cables, hoses and lines for tears and

leaks.RCheck the engine oil level.RCheck the oil level in the steering and

hydrostatic fan drive.RCheck the coolant level and correct it, if

necessary.RCheck AdBlue®/DEF level.RCheck the fuel level.RStart the engine and leave it running at

medium engine speeds until it is at operat-ing temperature (coolant temperature).While doing so, observe the indicators foroil pressure, coolant temperature and oiltemperature.RVehicles with auxiliary heating: activate the

auxiliary heating and check operation.RCheck operation of the steering and

brakes.RCheck whether maintenance is due and if

necessary carry it out.

Decommissioning for up to 12months

Carry out all measures in "Decommissioningfor up to 6 months". In addition, the enginemust be started at least every three months.Warm up the engine at medium engine

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speeds and allow it to run for approximately30 minutes at operating temperature.Before recommissioning, carry out the pre-scribed maintenance work, see the Mainte-nance Booklet.

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Important safety notes ....................... 80External engine start/engine stopbutton ................................................... 80Bleeding and draining the fuel sys-tem ....................................................... 81Electrical fuses .................................... 83Jump-starting ....................................... 83Troubleshooting .................................. 86

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Important safety notes

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

G WARNINGThere are moving components in the enginecompartment. Certain components may con-tinue to move or suddenly move again evenafter the ignition has been switched off, e.g.the radiator fan. There is a risk of injury.If you have to carry out work in the enginecompartment:Rswitch off the ignitionRnever touch the dangerous areas surround-

ing moving components, e.g. the rotationarea of the fanRremove jewellery and watchesRkeep items of clothing and hair, for exam-

ple, away from moving parts.

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

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

Apart from careful operation and mainte-nance of the engine it is also important thatmalfunctions be rectified in good time.You can rectify certain malfunctions yourself,(Y page 86).Have malfunctions that you cannot eliminateyourself rectified at a qualified specialistworkshop.

External engine start/engine stopbutton

Switch off the engine with the external enginestart/engine stop button:The safety functions of the electronic enginemanagement system only allow the engine tobe started when the transmission is in neutralor equipment is not being driven (disen-gaged).Observe the information contained in theequipment's/vehicle's Operating Instruc-tions.Before starting the engineX Switch the ignition lock to the drive posi-

tion.X Shift into neutral.X Secure the vehicle against rolling away.X Deactivate power take-off.

Engine with one button

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X To start the engine: press Start/Stop but-ton :.The engine starts and runs at engine idlingspeed.

X To start the engine and increase the engine speed: press and hold Start/Stopbutton :.The engine starts and runs at engine idlingspeed. After about three seconds, theengine speed increases.

X Hold down Start/Stop button : until thedesired engine speed is reached.After releasing Start/Stop button :, theengine continues to run at the currently setspeed. The engine speed can be increasedup to the limiting speed.

X To stop the engine: press Start/Stop but-ton : again.The engine switches off.

Engine with two buttons

X To start the engine: press start button ;.The engine starts and runs at engine idlingspeed.

X To increase the engine speed: while theengine is running, press start button ;again and hold it down until the desiredengine speed is reached.After releasing start button ;, the enginecontinues to run at the currently set speed.The engine speed can be increased up tothe limiting speed.

X To stop the engine: while the engine isrunning, press stop button =.The engine switches off.

X To turn the engine over without starting it: press and hold start button ; and stopbutton = at the same time.The engine turns over without starting.

X Release start button ; and stop button=.The engine remains at a standstill.

Bleeding and draining the fuel system

When the engine is started, the battery musthave sufficient charge to bleed the fuel sys-tem.Bleeding with a heated fuel prefilter with awater separator fitted on the chassis:X Bleed the fuel prefilter with water separator

on the chassis before bleeding the fuel cir-cuit on the engine side (Y page 83).

Bleeding the fuel system without afuel prefilter on the chassis frame

! Do not bleed the fuel system by operatingthe starter motor for an extended period oftime. You could otherwise damage thestarter motor.

X Turn the key to the start position in theignition lock and hold it. Do not depress theaccelerator pedal whilst doing so.

i Stop the starting procedure after approx-imately 30 seconds.

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

The fuel system is bled automatically.

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Bleeding the fuel system using themanual fuel pump

Fuel system on crankcase (left side of engine): Manual fuel pump; Control unitX Press manual fuel pump : on control

unit ; repeatedly (about 100 times), untilyou hear the overflow valve open.

Automatic bleeding! Do not bleed the fuel system by operating

the starter motor for an extended period oftime. You could otherwise damage thestarter motor.

X Turn the starter motor for up to 30 secondswithout interruption until the engine is run-ning smoothly. The fuel system is automat-ically bled when the tank is empty.

Bleeding the fuel system with a fuelprefilter on the chassis frame

Fuel prefilter overview

Example: fuel prefilter: Manual fuel pump; Vent valve= Shutoff valve? Filter housingA Water separator with inspection windowB Water release valveIf water has collected in inspection windowA, drain the fuel prefilter before bleeding.

Draining the fuel prefilter

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

Drain the fuel prefilter regularly.X Place a collector under water release valveB.

X On vehicles with fuel prefilter at tank level:close shutoff valve =.

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X Open water release valve B.X Press manual fuel pump : and collect the

fuel/water mixture.X Close water release valve B.X On vehicles with fuel prefilter at tank level:

open shutoff valve =.X Start the engine and allow it to run for about

one minute.The fuel system is bled automatically.

X Check the fuel system for leaks.

Bleeding the fuel prefilter with the man-ual fuel pumpThe fuel prefilter must only be bled when:Rthe fuel tank is empty orRthe fuel filter has been replaced.X Unscrew the fuel tank filler cap.X Place the collector underneath the fuel pre-

filter.X Open shutoff valve = fully.X Open bleed nipple ;.X Press manual fuel pump : repeatedly until

the escaping fuel is free of bubbles ;. Donot continue to pump.

X Close bleed nipple ;.X Close the fuel tank filler cap.X Start the engine.The fuel system is bled automatically.

! Do not continue to press the fuel handpump after the engine has started. Thiscould otherwise damage the hand pump.

Electrical fuses

Important safety notes

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

Always replace faulty fuses with specified newfuses of the correct amperage.

The individual electrical circuits are protectedby safety fuses or automatic circuit-breakers.Blown fuses or defective automatic circuit-breakers must be replaced by equivalentfuses with the fuse ratings recommended inthe fuse allocation chart. Fuses with the samefuse rating are the same colour.Further information is available from anyMercedes-Benz, MTU or MTU-authorisedMercedes-Benz Service Centre (Y page 10).The vehicle-specific fuse allocation chart isprovided by the vehicle manufacturer.If the newly inserted fuse also blows, have thecause traced and rectified at a qualified spe-cialist workshop, e.g. a Mercedes-Benz Ser-vice Centre.X If a circuit fails, switch off the consumer

equipment and switch the ignition lock toposition 0.

Checking and replacing a safety fuseX Pull the fuse out of the module using the

pliers and carry out a visual inspection.X If the fuse wire has melted, replace the

blown fuse with a spare fuse.X Switch on consumers and check that they

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

Jump-starting

Important safety notes

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

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Risk of explosion

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

Keep children away.

Observe this Owner's Man-ual.

! Observe the following notes. You couldotherwise damage the battery or electroniccomponents in the vehicle:Rdo not use a battery quick-charge unit 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.Rif the outside temperature drops belowÒ10 †, a discharged battery could freeze.Do not start the engine under these cir-cumstances. Let the battery thaw outfirst.

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

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

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

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

lock.

Vehicles without a jump-starting con-nection point

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Connecting the jump leadX Remove the battery compartment cover.X First, connect the positive terminal clamp

of the jump lead to the positive terminal ofthe other vehicle's battery and then to theq positive terminal of the starter battery.

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

X Assisting vehicle: run the engine at a highspeed.

X Start the engine and allow it to idle.Disconnecting the jump leadX First, disconnect the negative terminal

clamps of the jump lead from the negativeterminals.

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

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Troubleshooting

Engine problems

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

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

Problem Possible causes/consequences and M Solutions

The drive pinion doesnot turn or turns tooslowly.

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

The connecting cable to the starter motor is loose.X Tighten the cable on the terminal. If necessary, solder on a 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 isfaulty.X Have it checked at a qualified specialist workshop.

The engine does notstart or stalls againimmediately.

The fuel tank is empty.X Refill the fuel tank (Y page 59).

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

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

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

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Problem Possible causes/consequences and M Solutions

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

Replace the seals.

The engine does notstart correctly.

There is a malfunction in the engine control unit.X Read out the MR (engine control) unit; have it checked at a

qualified specialist workshop.

There are leaks or there is insufficient pressure in the low-pressurefuel circuit.X Carry out a check for leaks (visual check).X Have the pressure tested at a qualified specialist workshop.

The engine stops inad-vertently.

The MR (engine control) unit is faulty (total failure).X Consult a qualified specialist workshop.

The power supply to the MR and ADM control units is interruptedor there is a short circuit in the wiring.X Have the power supply checked at a qualified specialist work-

shop.

There are leaks or there is insufficient pressure in the low-pressurefuel circuit or the fuel pump drive is faulty.X Check for leaks (visual check).X Have the fuel pressure tested at a qualified specialist workshop.

The engine is in emer-gency running mode.

There is an interruption in the data flow of the MR and ADM controlunits.X Read out the control unit's fault memory.X Have it checked at a qualified specialist workshop.

The engine surges,vibrates or runs irregu-larly.

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

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

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

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

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Problem Possible causes/consequences and M Solutions

The coolant temperature is too high.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 gradeX Use the specified type of fuel and fuel grade (Y page 68).

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

An operating restriction is activated due to an emissions-relevantmalfunction.X Observe the notes on warning and indicator lamps (Y page 23).

There is an interruptionin the tractive power.

There is an increased voltage drop to the MR and ADM control unit(loose contact).X Check the battery terminals and the connectors on the MR and

ADM control unit for secure seating and corrosion.

The engine brakingeffect is poor.

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

Fuel consumption istoo high.

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

The engine cuts off tooearly (maximum enginespeed cannot bereached).

The engine management (MR) control unit is faulty or parameter-ised incorrectly.X Consult a qualified specialist workshop.

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

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

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

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Problem Possible causes/consequences and M Solutions

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

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

The coolant radiator is dirty on the inside; the coolant radiator isvery dirty on the outside.X Clean the coolant radiator.

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

Indicator lamps do notlight up at IGNITIONON.

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

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

The poly-V-belt is slipping.X Check the belt tensioner function.X Check that the poly-V-belt contact surfaces are not torn, dam-

aged, oily or glazed. Replace the poly-V-belt if necessary.

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

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

The engine emits blacksmoke.

The air filter is heavily contaminated.X Replace the air filter element.

The engine brake is faulty.X Consult a qualified specialist workshop.

The exhaust gas turbocharger is faulty.X Carry out a visual inspection.X Consult a qualified specialist workshop.

Misfiring; the fuel injector is faulty.X Consult a qualified specialist workshop.

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Problem Possible causes/consequences and M Solutions

The exhaust fumes areblue.

The oil level in the engine is too high; the crankcase ventilationsystem is faulty; engine oil has entered the combustion chamber.X Adjust the oil level correctly.X Have the crankcase ventilation system checked at a qualified

specialist workshop.

The exhaust fumes arewhite.

Coolant is entering the combustion chamber.X Have a pressure loss test carried out at a qualified specialist

workshop.

The engine is "knock-ing".

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

The engine is "knock-ing".

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

There are abnormalsounds.

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

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

cialist workshop.

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

The poly-V-belt is slipping.X Check that the poly-V-belt contact surfaces are not torn, dam-

aged, oily or glazed. Replace the poly-V-belt if necessary.

Indicator lamp forcharge current lightsup.

The poly-V-belt is slipping.X Check that the poly-V-belt contact surfaces are not torn, dam-

aged, oily or glazed. Replace the poly-V-belt if necessary.

Replacing the poly-V-beltIf the poly-V-belt is torn or shows damagepatterns, it must be replaced.

G WARNINGThe tensioning device is spring-tensioned.When it is loosened or tightened, there is arisk of injury from crushing or entrapment inpretensioned parts.

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RAlways carry out work on the tensioningdevice with extreme care.RMake sure that the tool is handled cor-

rectly.

Belt profile

: Alternator; Guide pulley= Coolant pump? Crankshaft belt pulleyA Tensioning pulleyB Guide pulleyRouting

: Example: tensioning direction

Fitting/removing poly-V-beltsX Insert the 15 mm socket, with the handle

and extension attached, into the tensioner.X Swing the tensioning pulley down and

remove the poly-V-belt.X Swing back the tensioner.X Check that both the tensioner and the belt

pulley are in fault-free condition. Check forsuch defects as worn bearings in the ten-sioner, tensioning pulley and guide pulleysand for wear of the tooth profile on the beltpulleys.

X Replace faulty parts.X Route the new poly-V-belt over all belt pul-

leys except the tensioning pulley (observethe poly-V-belt routing shown in the illus-tration).

X Swing the tensioning pulley down using thelever, lay the poly-V-belt over the tension-ing pulley and allow the tensioning pulley toswing back.

X Remove the spanner and check for correctseating of the poly-V-belt on the belt pul-leys.

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92

Engine data plate ................................ 94Information on the engine dataplate ..................................................... 94Engine model designation .................. 94Data card ............................................. 94Engine data .......................................... 95

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Engine data plate

The engine data plate is located on the left-hand side of the engine underneath theStart/Stop button or Start/Stop buttons. Theengine data plate data is stamped into thecrankcase.

Information on the engine data plate

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

Example: engine data plate for road vehicles (on-highway engine): Manufacturer's name; Engine model designation= Engine number

Example: engine data plate for non-road vehicles(off-highway engine): Manufacturer's name; Engine model designation= Type approval number? Engine number

Engine model designation

Example: engine model designation

OM 460 L E

OM Oil engine (die-sel)

460 Engine type

L Intercooler

E Exhaust gas tur-bocharger

Data card

The engine data card forms an integral part ofthe documents belonging to the engine andshould always be kept together with the Main-tenance Booklet. It contains details about thedesign of the engine, including special fea-tures.The engine data card must be presented orthe complete engine number must be speci-fied for the procurement of genuineMercedes-Benz parts.

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Engine data card

The engine data card describes the scope ofdelivery from the Mercedes-Benz factory.Conversion parts on the engine system whichchange the scope of the engine delivered byMercedes-Benz should be reported toMercedes-Benz. Once the documentation(VeDoc) has been updated, an updated datacard is supplied. This helps to prevent incor-rect ordering of replacement parts.In order to prevent incorrect ordering ofreplacement parts, the Mercedes-Benzreplacement parts service must also beinformed.

Engine data

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

Dimensions

OM 457 LA OM 460 LA

A = enginelength

1320 mm 1320 mm

B = enginewidth

750 mm 793 mm

C = engineheight

1115 mm 1144 mm

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Weights

OM 457 LA OM 460 LA

Dry enginemaximum

930 kg 930 kg

Wet enginemaximum

980 kg 980 kg

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

Engine Engine type OM 457 LA OM 460 LA

Assembly model series 457.9 458.9

Type Turbocharged in-line engine with intercooler

Combustion principle 4-stroke direct injection diesel

Number of cylinders 6 6

Bore 128 mm 128 mm

Stroke 155 mm 166 mm

Engine capacity 11,970 cm3 12,820 cm3

Type of cooling system Forced circulation cooling

Engine, direction ofrotation

Anti-clockwise (when looking at the flywheel)

Valve clear-ance

Intake valve 0.40 mm 0.40 mm

Exhaust valve 0.60 mm 0.60 mm

Startermotor

Starter Electric Electric

Voltage 24 V 24 V

Output 7.0 kW 7.0 kW

Battery Voltage 12/24 V 12/24 V

Cold-discharge testcurrent

Maximum 700 A Maximum 700 A

Cold start ability Down to maximum Ò20 † (battery charge level 75%)

Alternator Voltage 28 V 28 V

Amperage 35/80 A 35/80 A

Operating data

Engine type OM 457 LA (457.95.) OM 460 LA (458.99.)

Rated engine speed 1800 rpm 1800 rpm

Effective engine speed range 2000 rpm 2000 rpm

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Idling speed Approximately500 to 550 rpm

Approximately500 to 550 rpm

Engine brake permissible up to 2300 rpm 2300 rpm

Engine speed limiter (emergencyrunning mode)

1300 rpm 1300 rpm

Oil pres-sure

At idling speed Minimum 0.5 bar Minimum 0.5 bar

At nominal enginespeed

Minimum 2.5 bar Minimum 2.5 bar

Coolanttempera-ture

Normal operation Approximately 80-95 † Approximately 80-95 †

Maximum permissi-ble coolant tempera-ture

100 † 100 †

Capacities and service products

Capacityapprox-imately

Service product (SheetNo.4)

Engine with oilfilter (withstandard truckoil pan)

OM 457 LA (457.9) 37 l - 39 l For all engines:Engine oil (Sheet No.228.2/.3/.31/.5/.51)For engines without Blue-Tec®, also:Engine oil (Sheet No.228.0/.1)

OM 460 LA (458.9) 37 l - 39 l

Fuel system Diesel fuel tank5 - Diesel fuels in accordancewith EN 590 or ASTM D975(Sheet No. 131.0)

Vehicle operation withfatty acid methyl ester

- Fatty acid methyl ester fuel inaccordance with DIN EN14214 (Sheet No. 135.0)

Exhaust gasaftertreatmentsystem

AdBlue®/DEF5 - AdBlue®/DEF in accordancewith ISO 22241 (Sheet No.352.1)

AdBlue®/DEF filter seal-ing rings

- MB silicon grease

4 Mercedes-Benz Specifications for Service Products5 Installation on the vehicle side; designed by the vehicle manufacturer.

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Capacityapprox-imately

Service product (SheetNo.4)

Cooling system Amount of coolant in theengine

15 l Antifreeze/corrosion inhibi-tor in accordance with SheetNo. 325.0/2/3/5 and waterquality in accordance withSheet No. 310.1 or premixedcoolant in accordance withSheet No. 326.0/2/3/5.

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

Approx. 50%by volume

Corrosion inhibitor/anti-freeze volumedown to –45 °C

Approx. 55%by volume

Coolant additive (coolantwithout antifreeze protec-tion)

- Coolant additive and waterquality in accordance withSheet No. 310.1, 312.0

Engine compart-ment

Protective wax - Wax preservative (Sheet No.385.4)

Engine brake Heat-resistant lubricant - Heat-resistant lubricant (partnumber A000 989 76 51)

Tightening torquesAll threads on mechanical components and the corresponding contact surfaces must be clean,smooth and coated with engine oil. Other lubricants lead to substantially different tighteningtorques.

Engine Cylinder head cover Light alloy (with oil filler cap) 25 Nm

Plastic (without oil filler cap) 20 Nm

Valve clearance setting Counternut on the rockerarm adjustment screw

50 Nm

Inspection hole cap on the timing case 25 Nm

Flywheel housing rotation device 25 Nm

Charge-air distributor at cylinder head 30 Nm

Fuel system Cap on the fuel filter housing 25 Nm

Oil circuit Drain plug on the oil pan M 18 x 1.5 50 Nm

M 20 x 1.5 70 Nm

M 22 x 1.5 80 Nm

4 Mercedes-Benz Specifications for Service Products

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M 26 x 1.5 90 Nm

Oil filter cap on the oil filter housing 40 Nm

Cooling system Coolant drain screw On the crankcase 60 Nm

On the radiator 2 Nm

Exhaust gasaftertreatment

Filter bowl on the AdBlue®/DEF pump module 32 Nm

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ImprintInternet

You will find further information aboutMercedes-Benz engines, Daimler and Tog-num AG on the Internet at:www.mercedes-benz.comwww.daimler.comwww.mtu-online.com

Documentation team

Should you have any questions or sugges-tions regarding this manual, you can reachthe technical documentation team at the fol-lowing address:Daimler AG, HPC: CAC, Customer Service,70546 Stuttgart, Germany© Daimler AG: reprinting, translation andreproduction, even in part, is forbidden with-out written permission.

As at 29.08.2014

Order no. 6462 9852 02 Part no. 460 584 36 81 Edition 01-15

É4605843681ÇËÍ4605843681