1

Engine

Table of Contents Part 1

1.1 Introduction .......................................................................... 2
1.2 Safety .................................................................................. 3
1.2.1 Fuel (Diesel) .......................................................... 4
1.2.2 Radiator fluids and oils ............................................ 4
1.2.3 Prevention of fires ................................................... 5
1.2.4 Running in the engine ............................................. 7
1.2.5 Starting the engine ................................................. 7
1.2.6 Stopping the engine ................................................ 8
1.3 Engine identification .............................................................. 9
1.3.1 Type plate .............................................................. 9
1.3.2 Stamping ............................................................... 9
1.3.3 Type sticker .......................................................... 10
1.3.4 Type marking ........................................................ 11
1.4 Poly V-ribbed belt EU Stage IIIB and IIIA .............................. 12
1.5 Poly V-ribbed belt EU Stage IV ............................................ 13
1.6 Refuelling EU Stage IV, IIIB and IIIA ..................................... 16
1.6.1 Refilling without the refuelling/refilling pump ........... 16
1.6.2 Refilling using the refuelling/refilling pump .............. 16
1.6.3 Fuel refuelling pump (optional equipment) .............. 17
1.7 Changing the fuel filters ....................................................... 18
1.7.1 Fuel pre-filter EU Stage IIIB and IIIA ...................... 18
1.7.2 Fuel filter EU Stage IIIB and IIIA ............................ 18
1.7.3 Water separator filter EU Stage IV, IIIB and
IIIA ....................................................................... 20
1.7.4 Fuel pre-filter EU Stage IV ..................................... 21
1.7.5 Fuel filter EU Stage IV ........................................... 22
1.8 Fuel system bleeding EU Stage IIIB and IIIA ......................... 23
1.9 Engine oil requirements EU Stage IV, IIIB and IIIA ................ 25
1.10 Oil quantity and grade ......................................................... 26
1.11 Engine oil change and filter change EU Stage IIIB and
IIIA ..................................................................................... 27
1.12 Engine oil and filter change EU Stage IV .............................. 28
1.13 Radiator fluid quantity and grade ......................................... 30
1.14 Changing the air filter EU Stage IIIB and IIIA ........................ 31
1.15 Changing the air filters EU Stage IV ..................................... 32
1.16 Engine control unit (ECU) EU Stage IIIB and IIIA .................. 34
1.17 Engine control unit (ECU) EU Stage IV ................................ 35
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1.18 Engine sensors EU Stage IIIB and IIIA ................................. 36

1.19 Engine sensors EU Stage IV ............................................... 37
1.20 Valve clearance adjustment ................................................. 40
1.21 Exhaust gas purification system SCR EU Stage IV, IIIB ......... 40
1.21.1 General ................................................................ 40
1.21.2 Purifying exhaust gases ........................................ 40
1.21.3 Fuel (Diesel) ......................................................... 41
1.21.4 DEF additive (Diesel Exhaust Fluid) ....................... 42
1.21.5 Handling the additive ............................................ 42
1.21.6 Refilling the additive tank ...................................... 43
1.21.7 Display messages EU Stage IV ............................. 44
1.21.8 Decrease in engine power / torque caused by SCR
alarms EU Stage IV .............................................. 45
1.21.8.1 Operation in an exceptional situation when engine
speed / torque limitation is active EU Stage
IV ........................................................................ 51
1.21.9 SCR components EU Stage IIIB ............................ 53
1.21.10 SCR components EU Stage IV .............................. 57
1.21.11 Scheduled maintenance and tightening torques for
SCR EU Stage IIIB ............................................... 62
1.21.12 Cleaning the dosing unit EU Stage IIIB ................... 65
1.21.13 Scheduled maintenance and tightening torques for
SCR EU Stage IV ................................................. 68
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Dear Customer,

We thank you for the trust shown towards us by selecting a

PONSSE product.

The solutions used in PONSSE forest machines have been tested

in practice and therefore we believe that the forest machine is
well worth your trust. Because the forest machine will be operated
in very difficult conditions, it is of utmost importance that it will be
used and serviced in the correct way.

This engine Owner's Manual helps you in using the engine cor-
rectly and presents the maintenance measures required.

The actual repair actions are not included in this manual. Ponsse
Plc would, however, be pleased to provide you with information
about maintenance and to send a trained technician for your
assistance.

Due to the continuous development work, Ponsse Plc will retain

rights to make changes to Owner's Manuals without any prior
notification.

Familiarise yourself carefully with the forest machine construction

and its operating and service procedures before starting any
operations with the machine..

We wish you best of success!

Ponsse Plc

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1.1 Introduction
This engine Owner's Manual covers the aspects of safety,
operating instructions and maintenance.

This manual is intended as general instructions for PONSSE

forest machines equipped with engines of emission class EU
Stage IV, IIIB and IIIA.

For your engine's technical specifications, see the Technical

specifications section of the base machine's Owner's Manual.

Read and understand the Owner's Manual prepared by the

engine manufacturer before using the machine.

This manual should be stored with other manuals in the forest

machine.

Read and understand this engine Owner's Manual. In addi-

tion, read and understand the Owner's Manuals of the base
machine, crane and harvester head before starting the
machine.

Some photos or drawings in this manual represent details

that may differ from those of your engine. For example, some
guards and covers may have been removed for the sake of
clarity.

The development and design work carried out by the engine

manufacturer and Ponsse Plc may have caused changes in
the engine that are not included in this Owner's Manual. If
you have any questions concerning your engine or this
Instruction Manual, contact an authorised PONSSE service.

Read and understand the safety precautions listed in the

safety section before using the machine or before performing
lubrication, maintenance or repairs.

The engine's actual operating conditions may also reduce

service intervals. In extremely hard, dusty, wet or cold condi-
tions, more frequent maintenance, lubrication or cleaning
than those set out in the service programme may be needed.

Perform maintenance measures for the engine according

to the service programme set out in the base machine's
Owner's Manual.

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1.2 Safety
The engine may contain several warning signs. Read all
warning signs before starting to use the machine. Make sure
that all warning signs are readable.

Clean the warning signs or replace them if the words or pic-

tures are not readable.

Never work with the engine or use it if you have not under-
stood all of the Owner's Manual's instructions and warnings.

You are always responsible for following proper caution. Non-

compliance with instructions or warnings may lead to an
accident or death.

Always note the following before maintaining or repairing

the engine:

● Wear a protective helmet, goggles and other protective

equipment as required.
● Do not wear loose clothing or jewellery that may be
caught in engine controls or other parts.
● Make sure that all guards and covers are attached firmly
into place in the engine before starting any operations
with the machine.
● Keep the engine clean of foreign materials.
● Drain all liquids into a proper vessel. Dispose of fluids
and waste according to local regulations.
● Use all cleaning agents carefully.
● Inform the person responsible for the servicing/repairs
of the machine of all necessary repairs and maintenance
operations on the machine.
● Do not allow unauthorised persons to use the equipment.
● Make sure that all power sources are disconnected
before working with the engine.
● Do not touch any running engine parts.
● Allow the engine to cool down before performing any
maintenance measures.
● Release pressure slowly and carefully from the air,
hydraulic, lubrication, fuel or cooling systems before
removing lines, connectors etc..

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1.2.1 Fuel (Diesel)

Only commercially available sulphur-free fuel complying with
the following standards may be used:

● EN 590 (maximum sulphur content 0.001%) (10 ppm)

● ASTM D975 (maximum sulphur content 0.0015%) (15
ppm)

Never mix the additive with the fuel. If any fuel accesses the
additive tank or any additive accesses the fuel tank, the tanks
must be replaced before starting the engine.

Never use the same vessels for storing / transporting fuel

and additive. It is not enough that the tanks are cleaned
thoroughly!

1.2.2 Radiator fluids and oils

In Mercedes-Benz EU Stage IV engines, radiator fluids of
Mercedes-Benz classification 325.5 or 326.5 are used. Mix
radiator fluid of classification 325.5 with water at the ratio of
50% / 50%. Radiator liquid of classification 326.5 is ready to
use.

In Mercedes-Benz EU Stage IIIB and IIIA engines, radiator

fluids of Mercedes-Benz classification 325.0, 325.2 or 325.3
are used. Mix the radiator fluid with water at the ratio of 50%
/ 50%.

Hot radiator fluid or oil can cause serious burns.

● Remember that the radiator fluid is very hot at the

engine's operating temperature.
● The radiator fluid is pressurised.
● The radiator and all lines connected to heaters or the
engine contain hot radiator fluid.
● Check the radiator fluid level after the engine has
stopped and cooled down.
Make sure that the filling cap has cooled down before
removing it.
Release pressure by slowly and carefully removing the
radiator filling cap.

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● The cooling system's additive contains alkalis. Alkali

may cause personal injuries. Do not allow alkali to
access your skin, eyes or mouth.

Oils:

● Hot oil and hot lubrication parts may cause injuries.

● Do not allow hot oil to touch your skin.
● Prevent hot engine parts from touching your skin.

Pressurised liquid:

● The fuel circuit may be pressurised long after the engine

has been stopped.
● The pressure may cause hydraulic oil or an object to
discharge at great force unless the pressure is released
correctly.
● In order to prevent injuries, do not disassemble any
hydraulic components or parts until the pressure has
been released correctly.

1.2.3 Prevention of fires

All fuels, most lubricants and some radiator fluid mixtures
are flammable.

Flammable liquids leaking or spraying onto hot surfaces or

electrical components may start a fire. A fire may cause
personal injuries or property damage.

Determine whether the engine is used in an environment

which contains flammable gases that the engine can suck
into the system. Such gases may cause racing in the engine.
This may result in personal injuries or property or engine
damage.

Remove all flammable or conductive materials, such as fuel,

oil and waste, from the engine and its immediate surround-
ings. Carefully remove dust and debris also from the areas
surrounding the exhaust pipe and the pause heater (if
included in the machine accessories). If the pause heater
has not been used for a long time, monitor it with partic-
ular care when used for the first time!

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Do not allow flammable or conductive materials to accumulate

on the engine and, in particular, close to the turbocharger.

Store fuels and lubricants in their designated containers that

are inaccessible to unauthorised persons.

Store oily rags and flammable materials in protected contain-

ers.

Do not smoke in areas where flammable materials are stored.

Do not expose the engine to open flame. The exhaust sys-

tem's protective plates protect the exhaust system's hot
components from oil or fuel spraying as a result of a breakage
in lines, pipes or seals.

Do not weld lines or tanks that contain flammable liquids. Do

not flame-cut lines or tanks that contain flammable liquids.

Clean all such lines or tanks thoroughly using non-flammable

solvent before welding or flame-cutting.

Keep all wire harnesses in good condition. All electric cables

must be routed correctly and attached carefully.

Check all electric cables every day. Repair all loose or frayed
cables before starting the engine.

Do not bypass fuses and/or breakers.

Tighten all connections to the recommended torque. Any

leakage may start a fire.

Install oil and fuel filters correctly.

Remember that filter casings must be tightened to the correct

torque.

Be careful when refuelling.

Do not smoke when refuelling.

Do not refuel near open flame or sparks.

Always stop the engine before refuelling.

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1.2.4 Running in the engine

Careful running in of the engine has a positive effect on the
following matters, among others:

● Service life
● Fuel consumption

Observe the following instructions for running in for 50 hours

of operation:

● Do not load the engine by driving with too large a load

and high driving speed range.
● Drive the machien using various speed and engine
speed ranges.
● Avoid high engine speeds.

After 50 hours of operation, you can gradually increase the

engine power to full while increasing the engine speeds to
be suitable for normal working.

1.2.5 Starting the engine

Do not use aerosol-type starting aids, such as ether. They

can explode and cause injuries.

● If a warning sign is attached to the engine's starter switch

or controls, DO NOT START the engine. Contact the
person who installed the sign before starting the engine.
● All guards and covers must be in place if the engine is
started for maintenance.
● Be careful when working near rotating parts.
● Always start the engine as described in the Starting the
engine section of the Owner's Manual.

The engine's exhaust gases contain combustion products

that are hazardous to health. Start and run the engine only
in a properly ventilated area. If the engine is started in a
closed space, exhaust gases must be conducted outdoors.

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1.2.6 Stopping the engine

Stop the engine according to the instructions specified in the

Stopping the engine section of the Owner's Manual to prevent
the engine from overheating and its parts from wearing too
quickly.

● ONLY use the emergency push buttons in emergencies.

Do not use the emergency push button to stop the
engine under normal conditions.

DO NOT START the engine until the reason for the

emergency stop has been identified and the fault
repaired.

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1.3 Engine identification

1.3.1 Type plate

Location of the type plate:

The type plate of an EU Stage IV engine is located on the left side of the
engine block

1.3.2 Stamping
Location of the stamp:

The type number of EU Stage IIB and IIIA engines is stamped on the
right side of the engine block

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1.3.3 Type sticker

Location of the type sticker:

The type sticker of engines of Model Series 2015 is located in the

equipment bracket under the engine cover

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1.3.4 Type marking

1 Turbocharger
2 Intercooler
3 4 = 4 cylinders
34 = 4 cylinders
6 = 6 cylinders
26 = 6 cylinders
36 = 6 cylinders
4 900 series
5 Oil engine

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1.4 Poly V-ribbed belt EU Stage IIIB

and IIIA
1 Charging alternator
2 Guide roller
3 Water pump
4 Crankshaft
5 Tightening roller
6 Air conditioning compressor

Checking the condition of the poly V-ribbed belt:

● Check the condition of the poly V-ribbed belt regularly.

● Replace the belt if it is in a poor condition.
The belt may operate poorly if it is incorrectly installed,
worn, torn, frayed or dirty.
● Before replacing the poly V-ribbed belt, contact an
authorised PONSSE service for more detailed replace-
ment instructions.

The engine may overheat if the poly V-ribbed belt operates

incorrectly. In that case, the belt does not rotate the water
pump or alternator.

A poly V-ribbed belt in a poor condition may be torn, and the

entire belt or parts of it may come off the engine and cause
damage to those in the vicinity.

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1.5 Poly V-ribbed belt EU Stage IV

1 Charging alternator
2 Guide roller
3 Crankshaft
4 Tightening roller
5 Water pump
6 Guide roller
7 Air conditioning compressor

Checking the condition of the poly V-ribbed belt:

● Check the condition of the poly V-ribbed belt regularly.

● Replace the belt if it is in a poor condition.
The belt may operate poorly if it is incorrectly installed,
worn, torn, frayed or dirty.

The engine may overheat if the poly V-ribbed belt operates

incorrectly. In that case, the belt does not rotate the cooling
pump or alternator.

A poly V-ribbed belt in a poor condition may be torn, and the

entire belt or parts of it may come off the engine and cause
damage to those in the vicinity.

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Poly V-ribbed belt tighteness check EU Stage IV:

1 Alignment mark
2 Poly V-ribbed belt correct tightening range

● Check the tightness of the poly V-ribbed belt regularly,

both based on the marks on the tightening roller and
visually!
● Replace the poly V-ribbed belt if mark (1) is not within
tightness range (2). See the picture above!

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Poly V-ribbed belt replacement EU Stage IV:

1 8 mm screw
2 Tightening roller

1. Use a 15 mm wrench to turn the tightening roller (2)

downwards. If required, use an extension arm.
2. Lock the tightening roller loose using the 8 mm screw
(1). Remove the wrench from the tightening roller.
3. Replace the poly V-ribbed belt. Check the correct route
of the poly V-ribbed belt from the previous section.

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1.6 Refuelling EU Stage IV, IIIB and IIIA

The refuelling point is located in connection with the fuel tank.

See the base machine's Owner's Manual describing the exact

location of the refilling points.

1.6.1 Refilling without the refuelling/refilling

pump
Refilling fuel

1. Turn open the fuel tank cap.

2. Place the refilling nozzle into the refilling hole and start
refilling.
3. Refilling stops automatically when the tank is full if the
refilling nozzle is equipped with an automatic refilling
stoppage function.
4. Close the fuel tank cap.

1.6.2 Refilling using the refuelling/refilling

pump
Refilling fuel

1. Connect the refilling hose to the vacuum pump's quick

release coupling. Clean the strainer next to the quick
release coupling regularly (see Section 1.6.3).
2. Start the fuel feed by pressing the electric switch's
START button located on the side of the refuelling pump.
3. The pump stops refilling automatically when the tank is
full. If required, the refuelling pump can be stopped by
pressing the electric switch's STOP button.
4. Remove the hose and clean the refilling pump's quick
release coupling.

Fuel may flow out of the cap before the upper limit sensor
stops the refilling if the machine is not level when refilling or
if a highly-foaming fuel is used.

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1.6.3 Fuel refuelling pump (optional

equipment)
The strainer in the refuelling pump quick coupling prevents
dirt from entering the refuelling pump. Regular cleaning of
the refuelling pump's strainer affects the operation of the
pump.

1. Open the cover of the refuelling pump strainer.

2. Pull out the strainer and remove any dirt, for example,
by means of pressurised air. When cleaning the quick
coupling, make sure that the direction leading away from
the strainer is protected from dirt.
3. Set the strainer in place and close the cover.

When refuelling in dirty conditions, the refuelling pump

strainer must be cleaned more often.

17

1 Cover
2 Filter cartridge
3 Filter housing
4 Seal
Draining valve open
Draining valve closed
a Return hose from the engine
b To the fuel tank
5 Draining valve
6 Draining hose
1 Engine
1.7 Changing the fuel filters
1.7.1 Fuel pre-filter EU Stage IIIB and IIIA
Service comprises cleaning or changing
1. Clean the surroundings of the pre-filter and protect the
nearby hoses and pipes.
2. Open the filter cover (1). Clean the cover and the filter
cartridge (2). If the filter cartridge is dirty or damaged,
replace it with a new one.
3. Check the seal (4) and replace if needed.
4. Place the filter cartridge (2) on the filter cover (1) and
place the cover on the filter housing (3). Tighten the
cover. The tightening torque is 25 Nm.
1.7.2 Fuel filter EU Stage IIIB and IIIA
When servicing the fuel filter, cut off the fuel supply by the
fuel shut-off tap (13) in the water separator. The draining
valve (5) and the draining hose (6) are located on the right
hand side of the engine. The service is carried out via the
underbody protection plate.
1. Open the underbody protection plate.
2. Place a container under the draining hose.
3. Open the fuel line draining valve.
4. Open the filter cover (7) and lift it slightly.
5. Let the fuel drain into the vessel. This prevents possible
dirt on the edges of the filter entering into the filter
housing (11).
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Service comprises filter cartridge change:

1. Open the cover (7). Clean the cover and the sediment
bowl (8).
2. Change and lubricate the O-ring (9).
3. Change the filter cartridge (10).
4. Refit the sediment bowl, the filter cartridge and the seal.
5. Leave the cover (7) a few turns open.
7 Cap 6. Fill the filter housing with fuel by pumping the water
8 Sediment bowl separator's bleed pump until fuel starts to seep between
9 O-ring the threads.
10 Filter cartridge 7. Tighten the cover. The tightening torque is 25 Nm.
11 Filter housing
Note: Remember to close the draining valve (5) and open
the fuel shut-off tap when the service is finished.

When the filters have been changed, bleed the system by

using the pump in the water separator. Press the bleed pump
push button (12) until the button becomes stiff.

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1.7.3 Water separator filter EU Stage IV, IIIB

and IIIA
The water separator filter (14) is changed at the same time
as the fuel filter. If water collects in the water separator metal
bowl (15), the bowl can be drained via the water draining tap
(16).

12 Bleeding pump push button

13 Fuel shut-off tap
14 Water separator filter
15 Bowl
16 Water draining tap

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1.7.4 Fuel pre-filter EU Stage IV

1 Cover
2 Filter cartridge
3 Filter housing
4 O-ring
5 Pre-filter installation pin
6 Housing installation hole

Cleaning/replacement:

1. Clean the surroundings of the pre-filter and protect the

nearby hoses and pipes.
2. Open the filter cover (1). Clean the cover and the filter
cartridge (2). If the filter cartridge is dirty or damaged,
replace it with a new one.
3. Check the seal (4) and replace if needed.
4. Install the filter cartridge (2) on the filter cover (1) so that
the installation pin (5) goes into the filter cover hole (6).
Tighten the cover. The tightening torque is 25 Nm.

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1.7.5 Fuel filter EU Stage IV

When replacing the fuel filter, cut off the fuel supply by the
fuel shut-off tap in the water separator.

7 Cover
8 O-ring
9 Filter cartridge
10 Filter housing

Replacing the filter element:

1. Clean the surroundings of the filter cover from dirt and

debris.
2. Open the cover (7). Drain the fuel in the filter to the
housing.
Remove the filter cartridge (9) from the cover. Ensure
that no impurities can enter the filter housing.
3. Install a new filter element (9) in the cover, lubricate the
new O-ring (8) with fuel.
4. Install the cover and filter in the filter housing (10).
5. Note: Leave the cover (7) a few turns open.
6. Fill the filter housing with fuel by pumping the water
separator's bleed pump until fuel starts to seep between
the threads.
7. Tighten the cover. The tightening torque is 25 Nm.

Note: Remember to open the fuel shut-off tap when the ser-
vice is finished.

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When the filters have been changed, bleed the system by

using the pump in the water separator. Press the bleed pump
push button (12) until the button becomes stiff.

1.8 Fuel system bleeding EU Stage IIIB

and IIIA
Do not bleed the fuel system when the engine is hot. Beware
of high-pressure liquid leaks when working close to the
engine.

DO NOT USE THE STARTER MOTOR TO BLEED THE

FUEL SYSTEM. This can damage the starter motor.

EU Stage IV engines may not be purged as presented

below!

Usually, the fuel system bleeds itself automatically. Neverthe-

less, execute the bleeding procedure if:
1. You have run out of fuel while still working.
2. Injection pipes have been disconnected.
3. The filters have not been filled with fuel when changing
them.
4. There has been a leak in the fuel pipes.

12 Bleeding pump push button

13 Fuel shut-off tap
14 Water separator filter
15 Bowl
16 Water draining tap

23

Picture 2. Removing the engine
cover
1 Engine
Bleeding the fuel system:
1. Lift the machine's cabin and engine cover up.
2. Remove the engine cover on top of the engine's injection
pipes as shown in Picture 2.
3. Loosen all injection pipe nuts as shown in Picture 3.
4. Bleed the system by pumping the water separator's
bleeding pump push button (12) until only fuel comes
out of the injection pipes.
5. Close the injection pipe nuts you opened earlier.
6. Bleeding is now complete.
7. Start the engine.
8. If the engine does not start, contact an authorised
PONSSE service.
Do not try to start the engine for more than 30 seconds.
Exceeding 30 seconds can damage the starter motor.
Picture 3. Loosening the injection pipe nuts
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1.9 Engine oil requirements EU Stage

IV, IIIB and IIIA
The first fill oil in the engine is of quality grade SAE 5W-
30, 228.5.

If you need to add oil to the engine, use oil of the same SAE
and quality grade as used in the last oil change of the
engine.

0W - 30, 0W - 40
5W - 30, 5W - 40
10W - 30, 10W - 40, 10W - 50
15W - 30, 15W - 40, 15W - 50
20W - 40, 20W - 50

°F - 22 -4 + 14 + 32 + 50 + 68 + 86 °F

°C - 30 - 20 - 10 0 + 10 + 20 + 30 °C

Multigrade oils

Select the engine oil's SAE grade (viscosity) according to the

ambient temperature.

Engine oil viscosity Ambient temperature

20W-40, 20W-50 -5 °C – +30 °C or higher
15W-30, 15W-40, 15W-50 -15°C – +30 °C or higher
10W-30, 10W-40, 10W-50 -20 °C – +30 °C or higher
5W-30, 5W-40 -25 °C – +30 °C or higher
0W-30, 0W-40 -25 °C – +30 °C or higher

In Mercedes-Benz engines, SAE 5W-30 or SAE 0W-30

engine oil is recommended when the ambient temperature
falls below -20°C.

For further information, please contact an authorised

PONSSE service.

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1.10 Oil quantity and grade

Quantity approx- Qual-
Engine oil quantity / grade table
imately (l) ity
1. Engine 6 cylinders EU Stage IV engine max. 25 *) 1)

EU Stage IIIA engine (Model max. 28,5 *)

Series 2015)
EU Stage IIIA engine max. 29 *)
EU Stage IIIB engine max. 29 *)
2. Engine 4 cylinders EU Stage IV engine max. 17,5 *) 1)

EU Stage IIIA engine max. 16 *)

EU Stage IIIB engine max. 16 *)
1)
For engine oils pursuant to recommended Mercedes-Benz
classification 228.5 (228.3), see the Mercedes-Benz Mainten-
ance Booklet. The engines of PONSSE forest machines are
not equipped with diesel particulate filters, so classifications
228.3 and 228.5 are sufficient.

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1.11 Engine oil change and filter change

EU Stage IIIB and IIIA
1. Change the oil while it is still warm.
2. Open the oil filter cover (3), lift the cover a little bit and
wait until the filter casing is empty.
3. Remove the filter cartridge (7) and the cover (3). Ensure
that no impurities can enter the filter housing.
4. Place a suitable container under the draining hole plug
of the oil sump. Open the plug carefully and let the oil
drain out of the engine.
5. Change and lubricate the filter cover O-ring (6).
6. Install a new oil cartridge to the cover and ensure it is
properly installed.
7. Screw the cover onto the filter housing and tighten. The
tightening torque is 25 Nm.
8. Fit a new seal and refit the draining hole plug back to its
1 Fuel pre-filter
proper place (oil sump). Tighten. The tightening torque
2 Fuel filter
3 Oil filter (oil filter cover) is 80 Nm.
4 Dipstick 9. Add oil through the oil filler neck (5) until the engine oil
5 Oil filling level has reached the max mark on the dipstick (4).
10. Start the engine and let it run idle. Monitor the oil pres-
sure gauge.
11. Let the engine run idle until the oil pressure gauge shows
a reading. If the oil pressure gauge does not show any
pressure within 10 seconds, switch the engine off and
find out the reason.
12. Check the filter (3) and the oil draining hole for any leaks.
13. Switch off the engine. Recheck the oil level after
6 O-ring approximately five minutes. Add oil, if needed, to the
7 Filter cartridge max mark of the dipstick.

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1.12 Engine oil and filter change EU

Stage IV

1 Oil filter (oil filter cover)

2 Dipstick
3 Oil filling
4 Oil drain

1. Change the oil while it is still warm.

2. Open the oil filter cover (1), lift the cover slightly and wait
until the filter is empty.
3. Remove the filter cartridge (6) from the cover (1). Ensure
that no impurities can enter the filter housing.
4. Place a suitable container under the draining hole plug
of the oil sump (4). Open the plug carefully and let the
oil drain out of the engine.
5. Change and lubricate the filter cover O-ring (5) with oil.
6. Install a new filter to the cover and ensure it is properly
installed.
7. Screw the cover onto the filter housing and tighten. The
5 O-ring tightening torque is 50 Nm.
6 Filter cartridge 8. Fit a new seal to the draining hole plug and refit it back
to its proper place (oil sump). The tightening torque is
80 Nm.

28
 1 Engine

9. Add oil through the oil filler neck (3) until the engine oil
level has reached the max mark on the dipstick (2).
10. Start the engine and let it run idle. Monitor the oil pres-
sure gauge.
11. Let the engine run idle until the oil pressure gauge shows
a reading. If the oil pressure gauge does not show any
pressure within 10 seconds, switch the engine off and
find out the reason.
12. Check the filter cover (1) and oil draining hole (4) for any
leaks.
13. Switch off the engine. Recheck the oil level after
approximately five minutes. Add oil, if needed, to the
max mark of the dipstick (2).

29
 1 Engine

1.13 Radiator fluid quantity and grade

The first fill radiator fluid of machines with an EU Stage IV
engine is NESTE COOLANT LONGLIFE M or NESTE
COOLANT LONGLIFE BIO M of quality grade 325.5.

The first fill radiator fluid of machines with an EU Stage IIIB

or IIIA engine is NESTE XLC of quality grade 325.3.

If you need to add radiator fluid, use the same radiator fluid
as there currently is in the engine cooling system.

Quantity approx- Qual-

Radiator fluid quantity
imately (l) ity
1. Engine 6 cylinders EU Stage IV engine 20 + 20 1)

EU Stage IIIA engine 12 + 12 2)

EU Stage IIIB engine 12 + 12 2)

2. Engine 4 cylinders EU Stage IV engine 20 + 20 1)

EU Stage IIIA engine 12 + 12 2)

EU Stage IIIB engine 12 + 12 2)

1)
In Mercedes-Benz EU Stage IV engines, radiator fluids of
Mercedes-Benz classification 325.5 or 326.5 are used. Mix
radiator fluid of classification 325.5 with water at the ratio of
50% / 50%. Radiator liquid of classification 326.5 is ready to
use.
2)
In Mercedes-Benz EU Stage IIIB and IIIA engines, radiator
fluids of Mercedes-Benz classification 325.0, 325.2 or 325.3
are used. Mix the radiator fluid with water at the ratio of 50%
/ 50%.

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 1 Engine

1.14 Changing the air filter EU Stage IIIB

and IIIA

1 Cover
2 Main cartridge
3 Safety cartridge

1. Open the cover (1).

2. Pull the main cartridge out (2) from the housing.
3. Pull the safety cartridge (3) away. Replace it with a new
one and install it.
4. Change the main cartridge (2) and install it.
5. Close the cover (1).

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1.15 Changing the air filters EU Stage

IV

1 Air filter
2 Pre-filter valve
3 Pre-filter

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1. Switch off the engine. Make sure that the machine can-
not start moving.
2. Open the engine cover.
3. Remove the cover (4) by opening the catches.
4. Remove the pre-filter valve (2).
5. Pull the main cartridge out (5) from the housing. To
remove the cartridge, lift it diagonally upwards.
6. Clean the pre-filter pipeline (3) carefully using com-
pressed air. Note: At this stage, the safety cartridge
must be in place!
7. Pull the safety cartridge (6) away. Replace it with a new
one and install it. NOTE the guides; see the picture
below!
8. Change the main cartridge (5) and install it.
9. Close the cover (4) using the catches.
10. Install the pre-filter valve back into place.

4 Cover
5 Main cartridge
6 Safety cartridge

7 Alignment guide for the safety cartridge

8 Guide slot for the housing

When installing the safety cartridge into place, make sure

that the alignment guide (7) goes into the housing's guide
slot (8).

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1.16 Engine control unit (ECU) EU Stage

IIIB and IIIA
Engine control unit (ECU) connectors 2 and 3 must not be
removed when the main current is switched on.

1 Engine
2 Engine control unit (ECU) con-
nector from the engine to the
ECU 1
3 Engine control unit (ECU) con-
nector from the ECU to the VCU

The ECU connector is fitted to the engine with the connection

shown in the picture. To disconnect the connector, turn
the locking latch down, and the connector / harness comes
loose from the unit. Do not forcibly remove the connector.
See the picture below!

1 Connector closed
2 Connector in open position

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 1 Engine

1.17 Engine control unit (ECU) EU Stage

IV
Engine control unit (ECU) connectors 2 and 3 must not be
removed when the main current is switched on.

1 Engine
2 Engine control unit (ECU) connector from different engine functions to the ECU
3 Engine control unit (ECU) connector from the ECU to the VCU

In an EU Stage IV engine, the ECU connector need not be

removed during welding, for example!

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1.18 Engine sensors EU Stage IIIB and

IIIA

1 Oil temperature sensor

2 Oil pressure sensor
3 Fuel temperature sensor
4 Coolant temperature sensor
5 Boost pressure sensor and boost pressure temperature sensor
6 Camshaft angle sensor
7 Crankshaft angle sensor
8 Oil level sensor
9 Air pressure sensor in the engine control unit (ECU)

When the machine has an engine that meets the EU Stage

IIIB emission limits, see the exhaust gas purification system
sensors from SCR components EU Stage IIIB.

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1.19 Engine sensors EU Stage IV

1 B600 Crankshaft position sensor

2 B602 Fuel temperature sensor
3 B605 Oil temperature and level sensor
4 B616 Boost pressure sensor and boost pressure temperature sensor
5 B617 Charge air temperature sensor (EGR)
6 B622 Common rail pressure sensor

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7 B614 Temperature sensor, turbocharger housing

8 B604 Oil pressure sensor

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 1 Engine

9 B606 Coolant temperature sensor

When the machine has an engine that meets the EU Stage

IV emission limits, see the exhaust gas purification system
sensors from SCR components EU Stage IV.

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1.20 Valve clearance adjustment

See the valve clearance adjustment instructions from the
Mercedes-Benz Maintenance booklet supplied with the
machine.

1.21 Exhaust gas purification system SCR EU Stage IV, IIIB

1.21.1 General
In order to meet the EU Stage IV and IIIB requirements for
exhaust emissions of diesel engines, Ponsse Plc uses SCR
technology (Selective Catalytic Reduction) in its forest
machines. These requirements mean that the exhaust after-
treatment system of a forest machine engine must contain a
reliable NOx-level control system (NOx = nitrogen oxide).

The purpose of the NOx control system is to monitor:

● A sufficiently low level of NOx in exhaust gases

● The additive tank's level
● The quality of the additive
● System operations and any faults in it

If any faults are found in the exhaust after-treatment system:

● The control system notifies the driver of the faults

through indicator lights in the control panel and error
messages displayed on the Opti4G display. Error mes-
sages are described in more detail in Display messages
EU Stage IV and Decrease in engine power / torque
caused by SCR alarms EU Stage IV.

1.21.2 Purifying exhaust gases

The engine has been equipped with an exhaust gas purifica-
tion system which purifies exhaust emissions through an
additive solution. Mixed with compressed air, the additive is
sprayed into the exhaust system between the turbocharger
and the silencer equipped with an SCR catalyst. The catalyst
is used for reducing nitrogen oxide emissions. In addition,
machines equipped with EU Stage IV engines also contain

40
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an EGR exhaust gas circulation valve system which purifies

hazardous emissions from combustion gases.

1.21.3 Fuel (Diesel)

In order to guarantee the optimal operation of the SCR sys-
tem, as sulphur-free a fuel as possible must be used.

Only commercially available sulphur-free fuel complying with

the following standards may be used:

● EN 590 (maximum sulphur content 0.001%) (10 ppm)

● ASTM D975 (maximum sulphur content 0.0015%) (15
ppm)

Never mix the additive with the fuel. If any fuel accesses the
additive tank or any additive accesses the fuel tank, the tanks
must be replaced before starting the engine.

Never use the same vessels for storing / transporting fuel

and additive. It is not enough that the tanks are cleaned
thoroughly!

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1.21.4 DEF additive (Diesel Exhaust Fluid)

DEF additive refers to an additive solution used by SCR
technology.

For example, the additive is sold under the AdBlue® trade-

mark. It is a clear liquid which contains urea and distilled
water. It may have a slight odour of ammonia.

The additive's urea content is 32.5%. The additive must

meet the regulations of ISO 22241-1 or DIN 70070.

The urea solution's freezing point is -11°C and, therefore, it

should be stored in warm conditions.

Use suitable containers for the additive solution.

In addition to containers made of polypropylene or polyethyl-

ene, CR-Ni steel, Mo-Cr-Ni steel meeting the requirements
of DIN EN10088-1/2/3 are permitted materials in the storage
of the additive.

Containers made of aluminium, copper, copper alloys and

galvanised steel, for example, are absolutely prohibited.

1.21.5 Handling the additive

● Make sure that the additive is not in contact with your
skin, eyes or clothes.
● If any additive gets into the mouth, rinse the mouth well
and drink plenty of clean water. Contact a doctor.
● If any additive gets in the eyes, wash them carefully with
clean water and contact a doctor.
● If any additive gets on the skin, wash it with soap and
plenty of clean water. If required, contact a doctor.
● Do not allow the additive to come into contact with other
chemicals.
● The additive is a highly corroding substance. Avoid any
contact with metals.
● Do not allow children to have access to the additive.

If any additive is sprayed on hot objects (e.g. the exhaust

pipe), the additive may vaporise very quickly and cause a
dangerously strong steam blast!

42
 1 Engine

● When opening the additive tank's cap in high temperat-

ures, there is a danger of exposure to ammonia steam.
The steam has a pungent smell and irritates the skin,
mucous membranes and eyes.

The additive solution is a highly corrosive liquid that may

damage electrical conductors or hoses. If the additive can
drain onto connection cables and wires, clean them thor-
oughly. Damaged wires and hoses must be replaced before
starting to work.

● Dispose of the additive and empty packages according

to local environmental regulations.

1.21.6 Refilling the additive tank

The additive tank is located in the machine's left bumper case
and has a blue cap furnished with the text AdBlue. The tank
should always be refilled when refuelling.

Before refilling the additive tank, switch off the engine and
the main current. Make sure that the machine cannot move.

Pay special attention to the purity of the additive. No

foreign particles, snow or other debris may access the
additive tank. Do not use oily funnels or canisters for storing
or adding the additive.

The additive solution mixed with exhaust gases is not highly

dangerous but should be handled with care. If any solution
has been sprayed on the forest machine, rinse any splashes
with water and wipe the surfaces dry.

AdBlue® additive consumption is 2–4% of fuel consumption.

The additive solution's mixing ratio cannot be changed by

diluting it with water. Moreover, it cannot be replaced by any
other liquid that does not meet the ISO 22241-1 or DIN 70070
standard.

Never add the additive directly into the fuel tank. This may
damage the engine and fuel system.

43
 1 Engine

1.21.7 Display messages EU Stage IV

The tank's additive level can be checked from the Opti4G

display.

If there is a fault in the system, the error code will be activ-

ated.

In this case, the error code will be saved in the SCR system's
control unit, from where it cannot be deleted. By correcting
the fault, the error code will be deactivated but not removed
from the error log.

Through the error log, the authorities can check how long
the engine has been running while the fault has been active.

Faults that do not need to be corrected include:

● Empty additive tank

● NOx level exceeds the specified level
● NOx level cannot be monitored
● The quality of the additive

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 1 Engine

1.21.8 Decrease in engine power / torque

caused by SCR alarms EU Stage IV
SCR malfunction or quality of additive is poor:

Table 1. The engine's power / torque curve as a time function in case of an SCR malfunction + functionality of
indicator lights
1 Observing a fault
2 Warning
3 Torque (Nm) 100% -> 75%
4 Torque (Nm) 75% -> 50% and RPM 100% -> 60%
5 Torque (Nm) 50% -> 20% and RPM 60% -> 20%
6 Torque (Nm) 20% from normal, engine idling.
Y Torque / RPM (in percentage)
X Time (in minutes)

= Diesel engine alert light (yellow)

= Diesel engine warning light (red)

= SCR fault light

= General alarm light

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 1 Engine

Level of DEF additive too low:

Table 2. Engine power / torque curve as the level of DEF additive falls too low + functionality of indicator lights:
1 Warning, additive level 10% of maximum
2 Additive level decreases to approximately 7.5% of maximum -> Engine torque (Nm) 100% -> 75%
3 Additive level decreases to approximately 5% of maximum Torque (Nm) 75% -> 50% and RPM 100% ->
60%
4 Additive level decreases to approximately 2.5% of maximum Torque (Nm) 50% -> 20% and RPM 60% ->
20%
5 Additive level decreases to approximately 0% of maximum Torque (Nm) 20% of normal, engine idling.
Y Torque / RPM (in percentage)
X Additive level (in percentage)

= Diesel engine alert light (yellow)

= Diesel engine warning light (red)

= SCR fault light

= General alarm light

46
 1 Engine

NEW FAULT:

Table 2. A recurring fault

1 Fault 1
2 Fault 2

When a new fault occurs in the SCR system within 40 hours

of repairing the first fault:

The engine switches to idle and torque is dropped by 20%

from normal in 30 minutes!

47
 1 Engine

C Diesel engine alert light (yellow)

S Diesel engine warning light (red)
L SCR fault light
W General alarm light

Functionality of indicator lights for SCR alarms:Malfunc-

tion in the SCR system:

Indicator light operation: (W) blink- (L) lit (L) blink- (C) lit (S) lit (S) blink-
ing ing ing

Fault detected x x
Warning x x x
Engine torque 75% from normal x x x
Torque 50% from normal, 60% x x x
engine running speed
Torque 20% from normal, engine x x x x
switches to idle
Torque 20% from normal, engine x x x x
idling.

● (W) The general alarm light blinks, (C) engine alert light
is switched on and a message of malfunction in the SCR
system is displayed on the Opti display -> Fault detec-
ted.
● (W) The general alarm light blinks, (C) the engine alert
light is lit and (L) the SCR fault light is switched on->
Warning.
● (W) The general alarm light blinks, (C) the engine alert
light is lit and (L) the SCR fault light is lit-> Engine
torque decreases to 75% from normal.

48
 1 Engine

● (W) The general alarm light blinks, (C) the engine alert
light is lit and (L) the SCR fault light begins to blink ->
Engine torque 50% from normal, engine speed 60%.
● (W) The general alarm light blinks, (C) the engine alert
light is lit, (L) the SCR fault light blinks and (S) the engine
warning light is switched on -> Engine torque 20% from
normal, engine switches to idle.
● (W) The general alarm light blinks, (C) the engine alert
light is lit, (L) the SCR fault light blinks and (S) the engine
warning light starts to blink -> Engine torque 20% from
normal, engine switches to idle.

Functionality of indicator lights for SCR alarms when

the engine power and torque decrease: Additive volume:

Indicator light operation: (W) blink- (L) lit (L) blink- (C) lit (S) lit (S) blink-
ing ing ing

Warning, additive level 10% of x x

maximum
Additive level decreases to x x x
approximately 7.5% of max-
imum -> Engine torque (Nm)
100% -> 75%
Additive level decreases to x x x
approximately 5% of maximum
Torque (Nm) 75% -> 50% and
RPM 100% -> 60%
Additive level decreases to x x x x
approximately 2.5% of max-
imum Torque (Nm) 50% -> 20%
and RPM 60% -> 20%
Additive level decreases to x x x x
approximately 0% of maximum
Torque (Nm) 20% of normal,
engine idling.

● (W) The general alarm light blinks, (C) the engine alert
light is switched on and a message of the additive level
being 10% of maximum is displayed on the Opti display
-> Warning concerning additive level.
● (W) The general alarm light blinks, (C) the engine alert
light is lit and (L) the SCR fault light is switched on->

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 1 Engine

Additive level decreases to approximately 7.5% of

maximum -> Engine torque (Nm) 100% -> 75%.
● (W) The general alarm light blinks, (C) the engine alert
light is lit and (L) the SCR fault light begins to blink ->
Additive level decreases to approximately 5% of
maximum, Torque (Nm) 75% -> 50% and engine
speed (RPM) 100% -> 60%.
● (W) The general alarm light blinks, (C) the engine alert
light is lit, (L) the SCR fault light blinks and (S) the engine
warning light is switched on -> Additive level decreases
to approximately 2.5% of maximum, Torque (Nm)
50% -> 20% and engine speed (RPM) 60% -> 20%.
● (W) The general alarm light blinks, (C) the engine alert
light is lit, (L) the SCR fault light blinks and (S) the engine
stop light begins to blink -> Additive level decreases
to approximately 0% of maximum Torque (Nm) 20%
from normal, engine idling.

50
 1 Engine

1.21.8.1 Operation in an exceptional situation when

engine speed / torque limitation is active EU
Stage IV

During engine speed / torque limitation, the engine speed

and torque can be returned in exceptional cases to the
normal level by pressing the "Overdrive switch. Pressing
the switch gives more time to drive the machine to a safe
place for locating and repairing the fault.

Pressing the Overdrive switch returns the engine speed and

torque only for 30 minutes. In case of a repeated fault and
power is limited already during this period of 30 minutes,
pressing the switch only recovers the power for 10 minutes.

When the engine power limitation is in its last phase, i.e.

engine is idling and torque is 20% of normal, pressing
the Overdrive switch is of no use!

The location of the Overdrive switch in the machine is

presented in the pictures below:

"Overdrive" switch non-rotating

cabin

51
 1 Engine

"Overdrive" switch Scorpion

52
 1 Engine

1.21.9 SCR components EU Stage IIIB

The accurate location of components may vary depending
on the PONSSE machine model. However, the system's
operating principle is the same in all machine models.

53
 1 Engine

1 The pump unit pumps the additive solution to the dosing

unit using compressed air. The pump's filter cleans any
impurities contained by the additive.

2 The dosing unit mixes compressed air and the additive

into an aerosol, after which the mix is mixed with exhaust
gases through a nozzle. The unit is located above the tur-
bocharger on the side of the engine. The dosing unit contains
three sensors: A = pressure sensor, B = temperature sensor,
and C = compressed air sensor. With these sensors, the
system controls the volume of additive sprayed among
exhaust gases.

3 The heating valve circulates engine coolant within the

SCR lines. The heating valve keeps the additive tank, additive
lines and pump unit operational in a cold climate. The heating
valve is controlled using the engine control unit.

4 The additive tank (volume 25 l) is located in the machine's

left bumper case. The tank contains a temperature sensor
and additive level sensor.

5 Compressed air equipment. In addition to spraying the

additive, the SCR system requires compressed air for
cleaning the pump, nozzles and lines. These units are
cleaned when the engine is turned off. A = drier, B = com-
pressed air tank, and C = compressed air tank and pressure
reducing valve.

6 The control unit controls the SCR system's operations.

54
 1 Engine

7 The NOx sensor measures the volume of nitrogen oxides

in treated exhaust gases.

8 The intake air sensor measures air humidity and temper-

ature. It is located in the tube between the filter and turbochar-
ger.

11 The outdoor temperature sensor is located on the front

of the radiator under the engine cover. It measures the out-
door temperature.

55
 1 Engine

12 The SCR catalyst reduces nitrogen oxides into gaseous

nitrogen and water vapour.

The temperature sensors and the NOx control unit

measure the temperature of exhaust gases and their nitrogen
oxide level. The temperature sensors are located before and
after the SCR catalyst.

13 NOx sensor's control unit

9 Outgoing exhaust gas temperature sensor
10 Incoming exhaust gas temperature sensor

56
 1 Engine

1.21.10 SCR components EU Stage IV

The exact location of the components may vary depending
on the PONSSE machine model. However, the system's
operating principle is the same in all machine models.

57
 1 Engine

1 The pump unit pumps the additive solution to the dosing

unit. The pump's filter cleans any impurities contained by the
additive.

2 The dosing unit sprays the additive to the exhaust gas

using a nozzle. The dosing unit contains two sensors: the
pressure sensor and temperature sensor.
With these sensors, the system controls the volume of
additive sprayed among exhaust gases.

3 The heating valve circulates engine coolant within the

SCR lines. The heating valve keeps the additive tank, additive
lines and pump unit operational in a cold climate. The heating
valve is controlled using the engine control unit.

4 The additive tank (volume 29 l) is located in the machine's

left bumper case. The tank contains a temperature sensor
and additive level sensor.

58
 1 Engine

5 EGR valve. Exhaust gas recirculation valve. Located in

the exhaust manifold, the valve recirculates some exhaust
gases back into the engine's combustion chamber. The EGR
valve lowers the combustion chamber's temperature and
reduces nitrogen oxide (NOx) emissions. The EGR valve is
electrically controlled.

6 The control unit controls the SCR system's operations.

59
 1 Engine

7 The NOx sensor measures the volume of nitrogen oxides

in treated exhaust gases.

8 The temperature sensor measures the temperature of

outgoing exhaust gas.

60
 1 Engine

9 The temperature sensor measures the temperature of

exhaust gas conveyed to the catalyst.

10 The NOx sensor measures the volume of nitrogen oxides

in exhaust gases before the catalyst.

11 The outdoor temperature sensor is located on the front

of the radiator under the engine cover. It measures the out-
door temperature.

12 The EGR valve cooler cools down and circulates exhaust

gases to the EGR valve.

13 The SCR catalyst reduces nitrogen oxides into gaseous

nitrogen and water vapour.

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 1 Engine

1.21.11 Scheduled maintenance and tightening

torques for SCR EU Stage IIIB

Perform scheduled maintenance measures for the engine

according to the service programme set out in the base
machine's Owner's Manual.

VI = Visual inspection A = Adjustment C = Cleaning

I = Inspection T = Tightening V = Replacement

Item Service programme Notes:

Basic Complete
1. Pump filter V Filter casing's tightening torque
32 Nm
2. Pump pressurisation I, A 3.2 bar
3. Dryer V
4. Additive tank cleaning C Performed in connection with
every other Complete service

1. Pump filter replacement

Performed in connection with Complete scheduled service.

1. Turn the filter casing (2) so that it detaches from the

pump frame.
2. Pull the filter (1) out of the pump frame. Tightening torque
32 Nm.
3. When installing a new filter, also replace the O-rings (3).
Apply silicone to the O-rings to make installation easier.

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 1 Engine

2. Checking the pump pressure

Performed in connection with Complete scheduled service.

1. Remove the protective cup from the pump (1).

2. Attach the filling hose (3) to the valve in the additive
pump's pressure tank.
3. Check the pressure gauge reading (4). The pump's
correct pressure value is 3.2(±0.2) bar. If the pressure
value is not correct, the SCR equipment will not work
properly!
4. If required, increase or reduce the pressure.

Increasing pressure

1. Use the filling pump (5) to pump air until the pressure
value exceeds the provided pressure value by 0.2 bar,
i.e. the pressure is 3.4 bar. When the filling hose (3) is
disconnected from the valve, pressure in the pump's
1 Additive pump pressure tank will decrease by 0.2 bar.
2 Pressure release 2. Finally, refit the protective cup to the pressure tank's
3 Filling hose valve.
4 Pressure gauge
5 Filling pump (MB special tool) Reducing pressure

1. Lightly press the pressure release button (2) in order to

release air. Stop releasing air once the correct pressure
value has been reached.
2. Finally, refit the protective cup to the pressure tank's
valve.

The pressure should always be checked / adjusted before

the cold season in order to secure optimal system operations.
The correct air pressure protects the pump from freezing.

If the pump pressure has decreased by more than 0.2 bar

through regular operations, the pressure loss is normal.

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 1 Engine

3. Dryer

The compressed air system contains a dryer which removes

water from compressed air.

The dryer is changed in connection with Complete scheduled

service.

4. Additive tank cleaning

Performed in connection with every other Complete sched-

uled service. When working in dirty conditions or dirt gets
into the tank, the tank must be cleaned more frequently.

1. Detach the wires and hoses connected to the tank.

2. Remove the tank's fasteners and lift the tank out of the
bumper case.
3. Drain the solution out of the tank by pouring it into a
vessel resistant to the additive.
4. Rinse the tank using plenty of water! If required, you can
use a general cleaning agent.
5. Install the tank back into place in reverse order.

Never add fuel into the additive tank. If fuel gets into the tank,
the tank must be replaced!

64
 1 Engine

1.21.12 Cleaning the dosing unit EU Stage IIIB

Due to the composition of the DEF additive, precipitate may
accumulate in the dosing unit. In this case, the dosing unit
must be cleaned thoroughly using hot water. The unit is
cleaned according to the following instructions:

Location and removal of the dosing unit

1 Fastening screws
2 Electrical connectors
3 Nozzle
4 DEF additive connection
5 Connection for compressed air

The unit is located above the turbocharger on the right-hand

side of the engine. The dosing unit needs to be removed from
the machine for cleaning. It is removed as follows:

1. Drive the machine onto a level and even surface. Switch

off the main current. Make sure that the machine cannot
start moving under any circumstances.
2. Allow the machine to cool down before starting the fol-
lowing actions!
3. Open the engine cover. If required, tilt the cabin to the
upper position. See section Cabin and controls.
4. The dosing unit is the easiest to remove from the engine
room. See the adjacent picture.
5. Disconnect the unit's electrical connections (2), connec-
tion for compressed air (5) and DEF additive connection
(4).
6. Detach the nozzle (3) starting from the unit from the
nozzle end.

65
 1 Engine

7. Then, remove the three fastening screws (1) that fasten

the dosing unit to the side of the engine.
8. Remove the dosing unit and attach it firmly to, for
example, a vice.

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 1 Engine

Disassembly and cleaning of the dosing unit

1 Pressure sensor for com- B

pressed air
2 Compressed air frame
3 Diffusor + heating unit
4 O-ring
5 Line for the pressure sensor for
compressed air 2
6 Dosing unit frame 8
7 Fastening screws
8 Nozzle pipe for additive + com-
pressed air 1
A Additive
B Compressed air 4 3

6 7

1. Detach the nozzle pipe (8) from the frame (6).

2. Remove the fastening screws (7), and remove the
compressed air frame (2) from the dosing unit frame (6).
3. Remove the diffusor + heating unit (3) from the com-
pressed air frame.
4. Remove the pressure sensor (1) from the frame (6).
5. Clean / flush the removed parts thoroughly using hot
water. It is also possible to use compressed air.
6. Open and clean the line (5) to the compressed air
sensor very thoroughly. For example, use a bright
light to check that the line is open.
7. Check the condition of the O-rings (4), and replace them
if needed.
8. Assemble in reverse order.

The dosing unit may need to be cleaned when the machine

control system starts to display error messages related to
the SCR system's air pressure.

If the error messages do not disappear after cleaning the

dosing unit, contact an authorised PONSSE service.

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1.21.13 Scheduled maintenance and tightening

torques for SCR EU Stage IV

Perform scheduled maintenance measures for the engine

according to the service programme set out in the base
machine's Owner's Manual.

VI = Visual inspection A = Adjustment C = Cleaning

I = Inspection T = Tightening V = Replacement

Item Service programme Notes:

Basic Complete
1. Pump filter V Filter casing's tightening torque
32 Nm
2. Additive tank cleaning C Performed in connection with
every other Complete service

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1. Additive pump filter replacement

1 Filter
2 Filter casing
3 O-ring
4 Supply and return hoses
5 Heating tubes

Performed in connection with Complete scheduled service.

Wait for at least five minutes after shutting down the engine
before servicing the additive system.

The system is pressurised. Be careful when opening connect-

ors, etc. Always wear proper protective equipment.

1. The pump is under the front underbody protection plate

on the right-hand side of the engine.
2. Clamp the additive supply and return hoses (4) connec-
ted to the pump using hose clamps (DC000589543700)
to prevent the additive tank from draining. Note: Do not
clamp the additive line's heating pipes (5).
3. Turn the filter casing (2) so that it detaches from the
pump frame, spanner size 46 mm.
4. Pull the filter (1) out of the pump frame.
5. When installing a new filter, also replace the O-ring (3).
Lubricate the O-ring with MB silicone grease.

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 1 Engine

6. Turn the filter casing closed. The tightening torque is

32 Nm.

The system does not need to be bled after replacing the filter.
It bleeds itself automatically.

2. Additive tank cleaning

Performed in connection with every other Complete sched-

uled service. When working in dirty conditions or dirt gets
into the tank, the tank must be cleaned more frequently.

1. Detach the wires and hoses connected to the tank.

AdBlue lines should be closed using clamps.
2. Remove the tank's fasteners and lift the tank out of the
bumper case.
3. Drain the solution out of the tank by pouring it into a
vessel resistant to the additive.
4. Rinse the tank using plenty of water! If required, you can
use a general cleaning agent.
5. Install the tank back into place in reverse order.

Never add fuel into the additive tank. If fuel gets into the tank,
the tank must be replaced!

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