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Table of Contents
Related Manuals for MTU 4R 1000 SERIES
Summary of Contents for MTU 4R 1000 SERIES
- Page 1 4R/6R 1000 EU Stage IV/US TIER 4 Operating Instructions...
- Page 2 Symbols WARNING Warning notes make you aware 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.
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Page 5: Contents
Contents Index ............4 At a glance ........... 11 Introduction ........... 7 Safety ........... 23 Transport, installation ......27 Operation ..........29 Maintenance ........47 Decommissioning ....... 57 Troubleshooting ........59 Technical data ........71... -
Page 6: Index
Index ® Data card ..........72 AdBlue /DEF ® Consumption ........42 DEF/AdBlue Gauge ..........35 ® see AdBlue /DEF service products Important safety notes ....44 Description of the engine ....12 Refuelling ......... 44 Diagnostics connection ...... 25 Service product ....... -
Page 7: Table Of Contents
Index Mixing ..........50 Oil change ........50 Oil (engine) Topping up ........50 For winter operation ......49 Engine overview ........13 Oil change ........50 Engine speed ........35 Scope of use ........50 Exhaust gas aftertreatment ....20 Oil pressure ......... - Page 8 Index ® Disposing of AdBlue /DEF ....54 Engine oil ......... 49 Fuel additives ........53 General notes ........49 ® Purity of AdBlue /DEF ....55 ® Storing AdBlue /DEF ...... 54 Specialist workshop ......10 Starting see Starting (engine) Starting (engine) ........
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Page 9: Genuine Mercedes-Benz Parts
Introduction Please contact an MTU or MTU-authorised Engine system Mercedes-Benz Service Centre if you have any questions about the equipment or oper- The 4R 1000 and 6R 1000 series of engines ation. only function as intended when used in con- junction with the corresponding exhaust gas aftertreatment unit. -
Page 10: Operating Safety And Registration Changes In Engine Performance
The engine and the exhaust gas aftertreat- ! Increased power could: ment system may not be modified. If the change emission levels engine is modified, Mercedes-Benz and MTU cause malfunctions do not accept responsibility for any damage lead to consequential damage arising as a result. -
Page 11: Mercedes-Benz Service Centre
Introduction Mercedes-Benz Service Centres: If there are legal requirements on emission control, please note that: have special equipment and tools as well as specialists who receive continuous training maintenance on the engines must be car- ried out according to specific regulations guarantee that your engine system is and using special measuring devices repaired and maintained thoroughly and... -
Page 12: Operating Instructions
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 Exhaust gas aftertreatment ....20 Exhaust gas recirculation ....20 Warning and indicator lamps ..... 20...
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Page 14: General Information
General information General information The engine is a water-cooled four-stroke 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...
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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 vehicle/equipment- side connection, 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 equipment by the vehicle/equipment manu- acts as an interface between the electric and facturer.
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Page 22: Exhaust Gas Aftertreatment
Operating Instructions for the vehicle/ ® AdBlue or with another, non-Mercedes-Benz equipment. The symbols listed below are or non-MTU approved medium, invalidates examples and may differ from those symbols the engine's operation certification/ displayed in the vehicle/equipment. approval. In the event of a fault or warning, a warning lamp or indicator lamp lights up automati- cally. - 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 ®...
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Page 25: Safety
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, when carrying out electric Operating safety welding work, that the batteries must be disconnected and both of the cables ("+" WARNING and "-") must be firmly attached to each If you do not have the prescribed service/ other. -
Page 27: Organisational Measures
Organisational measures Staff qualifications more and/or jeopardise the operational 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 If you do not have the prescribed service/ electronic components or their software. - Page 29 Transport ..........28 Installation ........... 28...
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Page 30: Installation
( page 10) and "Further applica- member with the chain/rope at 90° relative ble documents" ( page 10). to the horizontal engine. Please consult an MTU or MTU-authorised Mercedes-Benz Service Centre ( page 10) if you have any questions. . -
Page 31: Operation
Preparation for operation ....30 Starting and stopping the engine ..31 Switching the continuous brake on and off ..........33 Idling speed ......... 33 Operational monitoring ...... 34 Displays ..........35 Warning and indicator lamps ..... 36 Operating instructions ....... 41 Refuelling .......... -
Page 32: Preparation For Operation
Preparation for operation possible with the engine switched off and the Preparation for operation ignition switched on. Engine with initial operation oil from Park the vehicle/device on a level surface. the factory Engage the parking brake. The engine is filled at the factory with an initial Switch off the engine. -
Page 33: Starting And Stopping The Engine
Starting and stopping the engine Check the engine oil level with dipstick ;. ! If the oil pressure in the engine is too low, The oil level should be between the upper a warning light lights up on the instrument and lower marks on dipstick ;. -
Page 34: Stopping
Starting and stopping the engine Starting the engine with the external engine start/engine stop button To start the engine with the external engine start/engine stop button: page 60). Stopping the engine WARNING When switching off the equipment or parking Example: ignition lock the vehicle, make sure that the exhaust sys- To insert/remove the vehicle key tem does not come into contact with com-... -
Page 35: Idling Speed Engine
Idling speed Park the vehicle/equipment. The engine brake and retarder are used as a continuous brake. Secure the vehicle/equipment against roll- ing away. You can utilise the engine's braking effect, particularly on long downhill gradients if you: Shift the transmission into neutral/decou- ple the drive system. -
Page 36: Oil Pressure
Operational monitoring idling speed may differ in certain operating Oil pressure conditions depending on the engine or on If the 1 indicator lamp does not go out or vehicles with power take-off. if it lights up when the engine is running, The engine idling speed for the 6R1000 switch off the engine. -
Page 37: Engine Speed
Displays Displays ® AdBlue /DEF level Rev counter ® The AdBlue /DEF gauge is the responsibility of the vehicle manufacturer. It is not neces- ! If you exceed the maximum permissible sarily supplied by Mercedes-Benz. Daimler engine speed, the warning tone sounds. AG recommends that the vehicle manufac- You should not drive and change gear by ®... -
Page 38: Warning And Indicator Lamps
Warning and indicator lamps Warning and indicator lamps Warning and indicator lamps - causes/consequences and solutions Problem Possible causes/consequences and M Solutions A serious fault in the engine system has been detected. indicator lamp flashes red. Immediately stop the vehicle/equipment while paying attention to the traffic conditions and contact a qualified specialist work- shop. - Page 39 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 40 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. Have the exhaust gas aftertreatment system checked at a quali- fied specialist workshop.
- Page 41 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 42 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.
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Page 43: Running The Vehicle In
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 44: Consumption
Operating instructions Fuel consumption ® AdBlue /DEF consumption General notes ® AdBlue consumption is between 2 and 4% of the fuel consumption, depending on engine Fuel consumption depends on: use. the machine version/vehicle version the operating conditions Engine oil consumption the attached equipment (e.g. -
Page 45: Refuelling
Refuelling ! Only refuel using commercially available, Refuelling sulphur-free diesel fuel that complies with Fuels the following standards: Important safety notes EN 590 as of 2010, et seq. (max. 0.001% sulphur by weight) (10 ppm) or WARNING ASTM D975 (max. 0.0015% sulphur by Fuels are poisonous and hazardous to health. -
Page 46: Refuelling Adblue ® /Def
Refuelling ® ! Always close the AdBlue /DEF tank Environmental note properly. Otherwise impurities may get into If fuels are handled improperly, they pose a the exhaust gas aftertreatment system and danger to persons and the environment. Do damage it. not allow fuels to run into the sewage system, the surface waters, the ground water or into ! Make sure that you do not overfill the... -
Page 47: Winter Operation
Winter operation ® AdBlue /DEF is not refilled as part of the Batteries maintenance work. Top up the tank regularly Always aim to achieve the full charge status. during vehicle operation or at the latest when You can do this by means of careful mainte- the first event message is displayed on the nance and low electrical consumption. - Page 49 General notes ........48 Service products ......... 49 Cleaning and care ....... 55...
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Page 50: Maintenance 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 51: Oil (Engine) For Winter Operation
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 10). materials, environmental protection meas-... -
Page 52: Mixing
Service products Engine oils according to Sheet No. 228.51 If the outside temperature is under -20 †, and 228.5 have a higher quality standard and Mercedes-Benz strongly recommends have a favourable effect on: using engine oils of SAE class 5W-30 or 0W-30. -
Page 53: Coolant
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 54: Diesel
Information about current country-specific dren. fuel sulphur contents can be obtained from If you or others come into contact with fuel, any MTU or MTU-authorised Mercedes-Benz observe the following: Service Centre ( page 10). Wash the fuel off any affected areas of skin Water content with water and soap immediately. -
Page 55: Fuel Additives
Service products At low outside temperatures, paraffin sepa- ® AdBlue /DEF ration may cause the flow properties of the Important safety notes diesel fuel to be insufficient. To prevent operating problems, diesel fuel WARNING with improved flow properties is available in ®... - Page 56 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.
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Page 57: High-Pressure Cleaning
Mercedes-Benz. You can obtain these Make sure that no water enters the air care products from any Mercedes-Benz or intake and ventilation openings. MTU Service Centre ( page 10). Treat the engine with preservative agents after it has been cleaned. When... -
Page 59: Decommissioning
General notes ........58 Decommissioning for up to 6 months ..........58 Decommissioning for longer than 6 months ..........58... - Page 60 If the vehicle is to be decommissioned for longer than 6 months, further measures are Also change the engine oil and filter if the required. For more details, consult your MTU oil is more than 12 months old. or MTU-authorised Mercedes-Benz Service...
- Page 61 Important safety notes ....... 60 Bleeding and draining the fuel sys- tem ............61 Electrical fuses ........62 Jump-starting ........62 Troubleshooting ........65...
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Page 62: Roadside Assistance
Important safety notes Apart from careful operation and mainte- Important safety notes nance of the engine it is also important that malfunctions be rectified in good time. WARNING You can rectify certain malfunctions yourself If you do not have the prescribed service/ page 36), ( page 65). -
Page 63: Fuel System Automatic Bleeding
Bleeding and draining the fuel system start/engine stop button :, the engine Bleeding the fuel system without a continues to run at the currently set speed. fuel prefilter on the chassis frame The engine speed can be increased up to Turn the key to the start position in the the limiting speed. -
Page 64: Checking And Replacing A Safety Fuse
Bleeding using the hand pump of the fuel fuse rating are the same colour. Further infor- prefilter on the chassis frame mation is available from any MTU or MTU- authorised Mercedes-Benz Service Centre Unscrew the fuel tank filler cap. page 10). - Page 65 Jump-starting ! When you remove the jump leads, let the Wear suitable protective engine of the vehicle being jump-started clothing, in particular idle. This avoids damage being caused to gloves, an apron and a face the vehicle electronics. mask. Immediately rinse acid splashes off with clean General notes water.
- Page 66 Jump-starting Assisting vehicle: run the engine at a high speed. Start the engine and allow it to idle. Disconnecting the jump lead First, disconnect the negative terminal clamps of the jump lead from the negative terminals. Remove the positive terminal clamps of the jump lead from the positive terminals.
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Page 67: 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 68 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 69 Troubleshooting Problem Possible causes/consequences and M Solutions The charge-air temperature is too high; the charge-air cooler or radiator is dirty on the exterior. Clean the exterior of the charge-air cooler and radiator. The coolant temperature is too high. Check the temperature sensor; replace if necessary. Check the fan speed.
- Page 70 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 radiator is dirty on the inside; the radiator is very dirty on the outside.
- Page 71 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 73 Identification plates ......72 Data card ..........72 Engine data .......... 72...
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Page 74: Identification Plate
Engine data Information on the exhaust gas after- Identification plates treatment identification plate Engine data plate The identification plate for the exhaust gas aftertreatment unit contains the 14-digit identification number (AGN ID number) of the exhaust gas aftertreatment unit. Data card The data card forms an integral part of the documents belonging to the engine and should always be kept with the Maintenance... -
Page 75: Dimensions
Engine data Dimensions Weights Engine weight DIN 70020 - GZ 4R 1000 6R 1000 Single stage charging Two stage charging Example: engine length Example: engine width and height R4 1000 R6 1000 A = engine 917 mm 1070 mm length with B = engine 840 mm 1050 mm... -
Page 76: 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 77: Capacities
Engine data Engine speed of maximum power output Approx. 2200 rpm 4R 1000 idling speed Approx. 680 rpm 6R 1000 idling speed Approx. 600 rpm Oil pressure at idling speed Minimum 0.5 bar Coolant temper- Normal operation Approx. 85 - 100 † ature Maximum permissible tempera- 105 †... -
Page 78: 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 385.4 Tightening torques All threads on mechanical components and the corresponding contact surfaces must be clean, smooth and coated with engine oil. - Page 79 Engine data 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. Tightening sequence for 4R 1000 Tightening sequence for 6R 1000...
- Page 83 Imprint Internet Further information about MTU, Mercedes- Benz and Daimler AG can be found on the Internet 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 84 É9345843771)ËÍ 9345843771 Order no. 6462 9839 02 Part no. 934 584 37 71 Edition 01-14...