MTU 4R 1000 series Operating Instructions Manual
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MTU 4R 1000 series Operating Instructions Manual

Eu stage iv/us tier 4
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4R/6R 1000 EU Stage IV/US Tier 4
Operating Instructions

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  • Page 1 4R/6R 1000 EU Stage IV/US Tier 4 Operating Instructions...
  • Page 2 Symbols WARNING Warning notes make you aware of dangers which could pose a threat to your health or life, or to the health and life of others. Environmental note Environmental notes provide you with infor- mation on environmentally aware actions or disposal.
  • Page 3 This is descri- bed on the data card. The engine systems are constantly updated to be state of the art. MTU/Mercedes-Benz reserves the right to make changes to the following: design equipment technical features Descriptions may therefore differ in individual cases from your engine system.

  • Page 4: Table Of Contents

    Index ® Data card ..........78 AdBlue /DEF ® Consumption ........47 DEF/AdBlue Gauge ..........38 ® see AdBlue /DEF service products Important safety notes ....49 Description of the engine ....12 Refuelling ......... 49 Diagnostics connection ...... 25 Service product .......
  • Page 5 Index Oil change ........54 Topping up ........54 Oil (engine) Engine overview ........13 For winter operation ......53 Engine speed ........37 Oil change ........54 Exhaust gas aftertreatment ....20 Scope of use ........54 Oil pressure ......... 37 Operating data ........
  • Page 6 Index ® DEF/AdBlue ........57 Diesel fuel ........56 Disposal ........... 53 ® Disposing of AdBlue /DEF ....58 Engine oil ......... 53 Fuel additives ........57 General notes ........53 ® Purity of AdBlue /DEF ....59 ® Storing AdBlue /DEF ......
  • Page 7 Engine system ........6 Protection of the environment ..... 6 Assembly equipment ......6 Genuine Mercedes-Benz parts ..... 6 Modifying the engine output ....7 Safety/emergency running pro- gram ............7 Correct use ..........7 Implied warranty ........7 Stored data ..........8 Qualified specialist workshop ....

  • Page 8: Genuine Mercedes-Benz Parts

    Genuine Mercedes-Benz parts Please contact any MTU or MTU-authorised Engine system Mercedes-Benz Service Centre if you have any questions about equipment and opera- The 4R 1000 and 6R 1000 series of engines tion (see addresses in the publication details only function as intended when used in con- on the inside of the back cover).

  • Page 9: Correct Use

    Information System (WIS) ( page 9). ments. Implied warranty Safety/emergency running program A well-developed network of MTU or MTU- The engine is equipped with an electronic authorised Mercedes-Benz Service Centres is engine management system that monitors available to carry out maintenance work.

  • Page 10: Stored Data

    Stored data These MTU or MTU-authorised Mercedes- If there are legal requirements on emission Benz Service Centres: control, please note that: have special equipment and tools as well as maintenance on the engines must be car- specialists who receive continuous training...

  • Page 11: Qualified Specialist Workshop

    Always have the following maintenance work carried out at a qualified specialist workshop: work relevant to safety service and maintenance work repair work modifications as well as installations and conversions work on electronic components Please consult an MTU or MTU-authorised Mercedes-Benz partner.
  • Page 13 General information ......12 Engine overview ........13 Exhaust gas aftertreatment over- view ............17 Electronic engine management ..18 ® BlueTec exhaust gas aftertreat- ment ............. 20 Exhaust gas recirculation ....20 Warning and indicator lamps ..... 20...

  • Page 14: General Information

    General information General information The engine is a four-stroke, water-cooled die- sel engine with direct injection. The engine is equipped with a common rail diesel injection system, cooled and regulated exhaust gas recirculation and turbocharging with charge-air pressure control. Depending on the engine output, engine tur- bocharging is either by means of single-stage exhaust turbocharging or two stage exhaust gas turbocharging with two sequential...

  • Page 15: Engine Overview

    Engine overview Engine overview Engine overview: 4R 1000 with single-stage charging Exhaust gas recirculation positioner Rail Fuel filter External engine start/engine stop button High-pressure fuel pump Engine management control module (MCM) Dipstick Air compressor Power-steering pump Oil pan Charge-air pipe (cold)
  • Page 16 Engine overview Engine overview: 4R 1000 with single-stage charging Crankcase ventilation system Exhaust gas recirculation pipe (cold) Refrigerant compressor Coolant thermostat Combined oil filter/oil cooler module with coolant pump Oil pan Starter motor Exhaust pipe to exhaust gas aftertreatment unit Exhaust gas turbocharger Exhaust gas recirculation cooler...
  • Page 17 Engine overview Engine overview: 6R 1000 with two-stage charging Refrigerant compressor Exhaust gas recirculation positioner Rail Fuel filter External engine start/engine stop button Engine management control module (MCM) Dipstick Air compressor Power-steering pump Alternator Oil pan...
  • Page 18 Engine overview Engine overview: 6R 1000 with two-stage charging Crankcase ventilation system Exhaust gas recirculation pipe (cold) Refrigerant compressor Combined oil filter/oil cooler module with coolant pump Oil pan Starter motor Low pressure exhaust gas turbocharger Exhaust pipe to exhaust gas aftertreatment unit High pressure exhaust gas turbocharger Power take-off (PTO) Boost pressure positioner...

  • Page 19: Exhaust Gas Aftertreatment Overview

    Exhaust gas aftertreatment overview Exhaust gas aftertreatment overview NOx sensor on exhaust gas aftertreatment unit inlet ® AdBlue treatment reactor ® Exhaust gas inlet from AdBlue treatment reactor Position of identification plate Exhaust gas aftertreatment box Exhaust gas outlet Exhaust gas temperature sensor upstream of the SCR catalytic converter Pump module ®...

  • Page 20: Electronic Engine Management

    Electronic engine management Mounting brackets Exhaust gas inlet from engine Exhaust gas aftertreatment control unit (ACM) NOx sensor at exhaust gas aftertreatment unit outlet Exhaust gas temperature sensor downstream of the SCR catalytic converter In addition to the engine, the exhaust gas Electronic engine management aftertreatment and the connection on the vehicle/device, the electronic engine man-...
  • Page 21 Electronic engine management Engine management control module Drive control system unit (CPC) (MCM) The drive control system unit (CPC) is instal- The engine management control module led in a protected location in the vehicle/ (MCM) is located on the side of the engine. It device by the vehicle/device manufacturer.

  • Page 22: Bluetec ® Exhaust Gas Aftertreatment

    ® AdBlue or with another medium that has not the device/vehicle operating instructions. been approved by Mercedes-Benz or MTU The symbols listed below are examples and invalidates the engine's operating permit or may differ from those symbols displayed in certification.
  • Page 23 Warning and indicator lamps warning, the warning and indicator lamps light up in different combinations. The following warning and indicator lamps may be available on the instrument panel: Indicator Description lamp Engine stop Engine system malfunction Ù Emissions-relevant malfunc- · tion of the exhaust gas after- treatment system or ®...
  • Page 25 Operating safety ......... 24 Safety precautions ......24 Notes on electronic systems ..... 24 Staff qualifications ......25 Organisational measures ....25...

  • Page 26: Operating Safety

    Notes on electronic systems Please note that the "+" and "-" terminals Operating safety on the batteries must be disconnected when carrying out electric welding work. WARNING The control unit connectors may only be If you do not have the prescribed service/ connected/disconnected when the elec- maintenance work or necessary repairs car- trical system is switched off.

  • Page 27: Diagnostics Connection

    Organisational measures Staff qualifications safety of the vehicle. There is an increased risk of an accident and injury. WARNING Do not attempt to modify the wiring as well as electronic components or their software. If you do not have the prescribed service/ Always have work on electrical and electronic maintenance work or necessary repairs car- components carried out at a qualified special-...
  • Page 29 Transport ..........28 Installation ........... 28...

  • Page 30: Installation

    Installation Transport WARNING If you do not lift the engine as described, the lugs intended for the purpose may be torn out or snap. This may be the case especially if the maximum permissible lug load is exceeded. The engine could then drop uncontrolled, causing serious or even fatal injury.
  • Page 31 Workshop Information System (WIS) must be observed ( page 9). Observe the sections "Qualified specialist workshop" ( page 9) and "Further applicable documents" ( page 9). Please consult an MTU or MTU-authorised Mercedes-Benz Service Centre if you have any questions.
  • Page 33 Preparation for operation ....32 Starting and stopping the engine ..34 Switching the continuous brake on and off ..........35 Idling speed ......... 36 Operational monitoring ...... 36 Displays ..........37 Warning and indicator lamps ..... 39 Operating instructions ....... 46 Refuelling ..........

  • Page 34: Preparation For Operation

    Preparation for operation display of the engine oil level is therefore only Preparation for operation possible with the engine switched off and the Engine with initial operation oil from ignition switched on. the factory Park the vehicle/device on a level surface. The engine is filled at the factory with an initial Engage the parking brake.
  • Page 35 Preparation for operation Check the engine oil level with dipstick ;. The oil level should be between the upper and lower marks on dipstick ;. If necessary, use filler neck : to top up the oil. Only use engine oil which has been approved for the engine and which meets the specified SAE classification ( page 53).

  • Page 36: Starting And Stopping The Engine

    Starting and stopping the engine Starting the engine with the key Starting and stopping the engine ! After starting the engine, let it run at Starting the engine engine idling speed until the oil pressure is WARNING displayed. If no oil pressure is displayed after approximately 10 seconds, switch off Combustion engines emit poisonous exhaust the engine.

  • Page 37: Switching The Continuous Brake On And Off

    Switching the continuous brake on and off Repeat the starting procedure after a wait- the coolant or engine oil temperature ing period of approximately 1 minute. rises steeply. If the engine fails to start: rectify the cause abnormal noises suddenly come from of the poor starting characteristics the engine or exhaust gas turbocharger.

  • Page 38: Idling Speed

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

  • Page 39: Displays

    Displays Each malfunction is stored in the system with emergency function by operating the switch its own fault code. Temporary faults are also can be activated a maximum of three times. stored. When the final operating restriction (idling Fault codes can be read by a qualified spe- speed and 20% of torque) has been reached, cialist workshop using a diagnostic tester the push-button switch is deactivated.

  • Page 40: Gauge

    Displays Idling speed is set automatically depending on the coolant temperature. When the vehicle is stationary, the engine is running and the transmission is in neutral, the engine increases throttle only slowly. ® AdBlue /DEF level ® The AdBlue /DEF gauge is the responsibility of the vehicle manufacturer.

  • Page 41: Warning And Indicator Lamps

    Warning and indicator lamps Warning and indicator lamps Warning and indicator lamps – causes/consequences and solutions The display format for indicator and warning lights is vehicle-specific/device-specific. Please observe the information contained in the device/vehicle operating instructions. The symbols listed below are examples and may differ from those symbols displayed in the vehicle/device. Depending on the priority of the fault or warning, the warning and indicator lamps light up in different combinations.
  • Page 42 Warning and indicator lamps Problem Possible causes/consequences and M Solutions The 2 indicator A malfunction was detected in the supply of engine lubricating oil. lamp lights up. The engine oil level is too low. If there are no malfunctions, the indicator lamp goes out after the engine is started.
  • Page 43 Warning and indicator lamps Problem Possible causes/consequences and M Solutions The = indicator The indicator lamp shows the status of the cruise control function. lamp lights up. The indicator lamp lights up after activation of cruise control. Observe the information contained in the operating instructions of the device/vehicle.
  • Page 44 Warning and indicator lamps Problem Possible causes/consequences and M Solutions Indicator lamps Ø ® The AdBlue /DEF level has dropped to approximately 7.5%. Reduced engine output is active. The engine torque is limited to a are lit and maximum of 75% across the whole engine speed range. The limi- ·...
  • Page 45 Warning and indicator lamps Problem Possible causes/consequences and M Solutions The · indicator An emissions-relevant malfunction in the exhaust gas aftertreat- lamp lights up. ® ment system or in the AdBlue supply has been detected. Have the exhaust gas aftertreatment system checked at a quali- fied specialist workshop.
  • Page 46 Warning and indicator lamps Problem Possible causes/consequences and M Solutions You have not rectified an emissions-relevant malfunction that has and · indi- been detected in the exhaust gas aftertreatment system or in the cator lamps are flash- ® AdBlue /DEF supply. ing and lights up.
  • Page 47 Warning and indicator lamps Problem Possible causes/consequences and M Solutions The · indicator An emissions-relevant malfunction in the exhaust gas aftertreat- lamp lights up. ® ment system or in the AdBlue /DEF supply has been detected. ® Top up the AdBlue /DEF tank immediately.

  • Page 48: Operating Instructions

    Operating instructions Problem Possible causes/consequences and M Solutions You have not rectified an emissions-relevant malfunction that has The · and indi- been detected in the exhaust gas aftertreatment system or in the cator lamps are flash- ® AdBlue /DEF supply. ing and lights up.

  • Page 49: Consumption

    Operating instructions Fuel type do not shift down to brake the vehicle. for vehicles with automatic transmission, The fuel grade also affects fuel consumption. do not depress the accelerator pedal Use of lower fuel grades and/or non- beyond the point of resistance (kickdown). approved fuel additives will increase fuel con- After 2,000 km (30 operating hours), you can sumption.

  • Page 50: Refuelling

    Refuelling page 80) is exceeded. The operating components in the exhaust system may over- safety of the engine is jeopardised. heat unnoticed. There is a risk of fire. an emissions-relevant fault is detected or Never refuel with petrol. Never add petrol to there is an operating restriction due to an diesel fuel.

  • Page 51: Important Safety Notes

    Refuelling ® ® AdBlue /DEF gets into the diesel tank, this If AdBlue /DEF comes into contact with could lead to engine damage. painted or aluminium surfaces when filling the tank, rinse the affected area immedi- ! A higher fuel sulphur content accelerates ately with plenty of water.

  • Page 52: Winter Operation

    Winter operation Jump-starting immediately. Seek medical attention immediately. WARNING ® if you have swallowed AdBlue /DEF, The use of liquid or gaseous starting aids can immediately rinse your mouth with water cause explosions. This may result in severe and drink plenty of water. Seek medical injuries.
  • Page 53 General notes ........52 Service products ......... 53 Cleaning and care ....... 59...

  • Page 54: Notes

    General notes General notes Environmental note If circumstances require you to do some main- WARNING tenance work yourself, you must observe the environmental protection requirements. Before carrying out maintenance or repair When disposing of service products, e.g. work, you must read the relevant sections of engine oil, you must comply with the legal the technical documentation relating to main- requirements.

  • Page 55: Engine Oil

    Service products When working on the vehicle, comply with all Information about approved service products safety regulations, such as operating instruc- is available from any MTU or MTU-authorised tions, regulations concerning hazardous Mercedes-Benz Service Centre ( page 9). materials, environmental protection meas-...

  • Page 56: Oil Change

    Service products Engine oils according to Sheet No. 228.51 Use only all-season oils. and 228.5 have a higher quality standard and have a favourable effect on: length of oil change intervals engine wear fuel consumption exhaust emissions Before delivery, the engine is filled with oil in SAE class 5W-30 ( page 32).

  • Page 57: Service Product

    Service products Engine oils are differentiated according to: The coolant is a mixture of water and corro- sion inhibitor/antifreeze. engine oil brand The corrosion inhibitor/antifreeze in the cool- quality grade (Sheet No.) ant has the following properties: SAE viscosity class heat transfer If, in exceptional circumstances, the type of anti-corrosion protection...

  • Page 58: Diesel Fuels

    Information about current country-specific If you get fuel in your eyes, rinse them thor- sulphur contents can be obtained from any oughly with clean water immediately. Seek MTU or MTU-authorised Mercedes-Benz Ser- immediate medical attention. vice Centre ( page 9).

  • Page 59: Service Product

    Service products ® engine is running. There is a risk of fire and AdBlue /DEF explosion. Important safety notes Never heat fuel system components. Contact a qualified specialist workshop to rectify the WARNING malfunction. ® AdBlue /DEF must not come into contact with skin, eyes or clothing.

  • Page 60: Disposal

    Service products Low outside temperatures The vapours may cause a burning sensation in the eyes, nose and throat as well as irritation ® AdBlue /DEF freezes at a temperature of of the throat and watering eyes. approximately −11 † . Avoid inhaling ammonia vapours.

  • Page 61: Care Products

    Mercedes-Benz. You can obtain these Make sure that no water enters the air care products from any MTU or MTU-author- intake and ventilation openings. ised Mercedes-Benz Service Centre page 9). Treat the engine with preservative agents after it has been cleaned.
  • Page 63 General notes ........62 Decommissioning for up to 6 months ..........62 Decommissioning for longer than 6 months ..........63...
  • Page 64 Decommissioning for up to 6 months ® General notes Top up the AdBlue /DEF tank until it is full, ® to prevent AdBlue /DEF from crystallising. Special measures are required to decommis- Drain the water separator for the fuel sys- sion the engine/vehicle.
  • Page 65 Decommissioning for longer than 6 months If the vehicle is to be decommissioned for longer than 6 months, further measures are required. For more details, consult your MTU or MTU-authorised Mercedes-Benz Service Centre ( page 9).
  • Page 67 Important safety notes ....... 66 Bleeding and draining the fuel sys- tem ............67 Electrical fuses ........68 Jump-starting ........69 Troubleshooting ........71...

  • Page 68: Important Safety Notes

    Important safety notes When working on the vehicle, comply with all Important safety notes safety regulations, such as operating instruc- tions, regulations concerning hazardous WARNING materials, environmental protection meas- If you do not have the prescribed service/ ures, work safety and accident prevention maintenance work or necessary repairs car- regulations.

  • Page 69: Bleeding And Draining The Fuel System

    Bleeding and draining the fuel system Starting the engine and increasing the When the engine is started, the battery must engine speed have sufficient charge to bleed the fuel sys- tem. Hold down external engine start/engine Bleed the heated fuel prefilter with water sep- stop button : until the desired engine arator on the vehicle before the fuel circuit on speed is achieved.

  • Page 70: Electrical Fuses

    A is free fuse rating are the same colour. of bubbles. Further information is available from any MTU Tighten bleed screw A. or MTU-authorised Mercedes-Benz Service If there was no fuel in the fuel tank, press Centre ( page 9).

  • Page 71: Jump-Starting

    Jump-starting only have jump-starting provided by vehi- Jump-starting cles with a 24 V system. Important safety notes use jump leads which are protected against polarity reversal and with a wire WARNING cross section of approximately 35– Comply with safety precautions and take pro- 50 mm and insulated terminal clamps.
  • Page 72 Jump-starting Vehicles without a jump-starting con- nection point Connecting the jump lead Remove the battery compartment cover. First, connect the positive terminal clamp of the jump lead to the positive terminal of the other vehicle's battery and then to the q positive terminal of the starter battery.

  • Page 73: Troubleshooting

    Troubleshooting Troubleshooting Engine problems WARNING If you do not have the prescribed service/maintenance work or necessary repairs carried out, this could result in malfunctions or system failures. There is a risk of an accident. Always have the prescribed service/maintenance work as well as necessary repairs carried out at a qualified specialist workshop.
  • Page 74 Troubleshooting Problem Possible causes/consequences and M Solutions Leaks or insufficient pressure in the low-pressure fuel circuit Check for leaks (visual check), replace the seals if necessary. Have the fuel pressure tested at a qualified specialist workshop. Replace the seals. Engine fails to start The fuel is not resistant to cold.
  • Page 75 Troubleshooting Problem Possible causes/consequences and M Solutions The charge-air temperature is too high; the charge-air cooler or coolant radiator is dirty on the exterior. Clean the exterior of the charge-air cooler and coolant radiator. The coolant temperature is too high. Check the temperature sensor;...
  • Page 76 Troubleshooting Problem Possible causes/consequences and M Solutions The poly-V-belt is damaged. Replace the poly-V-belt. The fan does not switch on correctly. Consult a qualified specialist workshop. The coolant radiator is dirty on the inside; the coolant radiator is very dirty on the outside. Clean the coolant radiator.

  • Page 77: Routing

    Troubleshooting Problem Possible causes/consequences and M Solutions The turbine or compressor wheel is scraping the housing; there are foreign objects in the compressor or turbine housing; bearings have seized on the rotating parts. Have the exhaust gas turbocharger checked at a qualified spe- cialist workshop.
  • Page 78 Troubleshooting Fitting/removing poly-V-belts Insert the 15 mm socket, with the handle and extension attached, into the tensioner. Swing back the tensioner. Check that both the tensioner and the belt pulley are in fault-free condition. Check for such defects as worn bearings in the ten- sioner, tensioning pulley and guide pulleys and for wear of the tooth profile on the belt pulleys.
  • Page 79 Identification plates ......78 Data card ..........78 Engine data .......... 79...

  • Page 80: Data Card

    Data card Identification plates Engine data plate Position Emission certification label (EPA Certification) Position of engine data plate (example) Information on the engine data plate The following data is contained on the engine data plate in the form of numbers stamped directly onto the crankcase: Exhaust gas aftertreatment identifi- cation plate...

  • Page 81: Dimensions

    Engine data of the engine and the exhaust gas aftertreat- ment system, including special features. Conversion parts on the engine system which change the scope of the engine delivered by Mercedes-Benz should be reported to Mercedes-Benz. Once the documentation (VeDoc) has been updated, an updated data card is supplied.

  • Page 82: Operating Data

    Engine data General data All data refers to the standard version of the respective engine type. Data for other versions is available on request. Engine Engine type 4R 1000 6R 1000 Assembly model series 933.91 935.91 Type In-line engine with exhaust gas recirculation and charge-air pressure control Combustion principle 4-stroke direct injection diesel...

  • Page 83: Capacities

    Engine data Engine speed of maximum power output Approx. 2200 rpm Idling speed Approx. 600 rpm Oil pressure at idling speed Minimum 0.5 bar Coolant temper- Normal operation Approx. 85 - 100 † ature Maximum permissible tempera- 105 † ture of coolant (automatic tor- que limitation up to 50 % from 103 †) Capacities and service products...

  • Page 84: Tightening Torques

    Engine data Capacity approx- Service product imately (Sheet No. Corrosion inhibitor/anti- Max. 55% by vol- freeze volume down to –45 °C Engine com- Protective wax Wax preservative in partment accordance with Sheet No. 385.4 Tightening torques All threads on mechanical components and the corresponding contact surfaces must be clean, smooth and coated with engine oil.
  • Page 85 Engine data Exhaust gas Filter housing on the pump module 80 Nm aftertreatment Air dryer Granulate cartridge on the air dryer 15 Nm Tightening sequence for the cylinder head cover The cylinder head cover screws must be tight- ened in the correct tightening sequence in the same order as described below.
  • Page 87 Publication details Internet Further information about MTU, Mercedes- Benz and Daimler AG can be found online at: www.mtu-online.com www.mercedes-benz.com www.daimler.com Documentation team Should you have any questions or sugges- tions regarding this manual, you can reach the technical documentation team at the fol-...
  • Page 88 É9345840981-ËÍ 9345840981 Order no. 6462 9859 02 Part no. 934 584 09 81 Edition 02-15...

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6r 1000 series

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