MTU 4R 1000 SERIES Operating Instructions Manual Download Page 1

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

Operating Instructions

Summary of Contents for 4R 1000 SERIES

Page 1: ...4R 6R 1000 EU Stage IV US Tier 4 Operating Instructions...

Page 2: ...ention to risks which could lead to damage to your engine sys tem i These symbols indicate useful instruc tions or further information that could be helpful to you X This symbol designates an instruc...

Page 3: ...nd product descrip tion of your engine system may vary depend ing on individual specifications This is descri bed on the data card The engine systems are constantly updated to be state of the art MTU...

Page 4: ...on inhibitor antifreeze agent 55 D Data card 78 DEF AdBlue see AdBlue DEF service products Description of the engine 12 Diagnostics connection 25 Diesel Fuels 56 Low outside temperatures 56 Refuelling...

Page 5: ...st workshop O Oil engine For winter operation 53 Oil change 54 Scope of use 54 Oil pressure 37 Operating data 80 Operating instructions General notes 9 Operating safety 24 Operating safety and registr...

Page 6: ...pecialist workshop 9 Starting see Starting engine Starting engine 34 Stopping and switching off the engine 34 T Technical data Dimensions 79 Filling capacities 81 Operating data 80 Weights 79 Tighteni...

Page 7: ...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 9 F...

Page 8: ...ons All of the components in your engine system are listed in the data card of your engine sys tem Data card Y page 78 Please contact any MTU or MTU authorised Mercedes Benz Service Centre if you have...

Page 9: ...haust gas aftertreat ment unit and has a self diagnostic system If the electronic control system detects a mal function one of the following measures is automatically implemented after an appraisal of...

Page 10: ...Centre In particular work relevant to safety or on safety related systems must be carried out by a qualified specialist workshop If there are legal requirements on emission control please note that R...

Page 11: ...ents Please consult an MTU or MTU authorised Mercedes Benz partner Further applicable documents These operating instructions describe all models and all standard and optional equip ment available for...

Page 12: ...10...

Page 13: ...ation 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 1...

Page 14: ...two camshafts at the top which are driven via a gearwheel drive The engine features a single piece cylinder head In the cylinder head there are two inlet valves and two exhaust valves per cylinder Th...

Page 15: ...aust gas recirculation positioner Rail Fuel filter External engine start engine stop button A High pressure fuel pump B Engine management control module MCM C Dipstick D Air compressor E Power steerin...

Page 16: ...recirculation pipe cold Refrigerant compressor Coolant thermostat A Combined oil filter oil cooler module with coolant pump B Oil pan C Starter motor D Exhaust pipe to exhaust gas aftertreatment unit...

Page 17: ...rant compressor Exhaust gas recirculation positioner Rail Fuel filter A External engine start engine stop button B Engine management control module MCM C Dipstick D Air compressor E Power steering pum...

Page 18: ...sor Combined oil filter oil cooler module with coolant pump A Oil pan B Starter motor C Low pressure exhaust gas turbocharger D Exhaust pipe to exhaust gas aftertreatment unit E High pressure exhaust...

Page 19: ...e treatment reactor Position of identification plate A Exhaust gas aftertreatment box B Exhaust gas outlet C Exhaust gas temperature sensor upstream of the SCR catalytic converter D Pump module E AdBl...

Page 20: ...in an elec tronic network Data is exchanged via CAN Controller Area Network In addition to the engine the exhaust gas aftertreatment and the connection on the vehicle device the electronic engine man...

Page 21: ...e speed for the displays in the instrument cluster Drive control system unit CPC The drive control system unit CPC is instal led in a protected location in the vehicle device by the vehicle device man...

Page 22: ...st gas recirculation Exhaust gas recirculation EGR serves pri marily to reduce the amount of nitrogen oxide prior to exhaust gas aftertreatment This serves to comply with emissions limits Exhaust gas...

Page 23: ...t system or AdBlue DEF supply lit constantly Torque operating restriction flash ing Torque and engine speed operating restriction Charge current optional AdBlue DEF reserve level 5 optional Oil pressu...

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Page 25: ...Operating safety 24 Safety precautions 24 Notes on electronic systems 24 Staff qualifications 25 Organisational measures 25 23 Safety...

Page 26: ...f the rapid battery charger RPlease note that the and terminals on the batteries must be disconnected when carrying out electric welding work RThe control unit connectors may only be connected disconn...

Page 27: ...rements of the next legally prescribed emissions test Staff qualifications G WARNING If you do not have the prescribed service maintenance work or necessary repairs car ried out this could result in m...

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Page 29: ...Transport 28 Installation 28 27 Transport installation...

Page 30: ...sult of a change in the centre of gravity There is a risk of injury Lift the engine only at the lifting points provi ded using suitable lifting gear Make sure that there is nobody in the danger zone w...

Page 31: ...ount If the engine is fitted after repair work for example the information in the Workshop Information System WIS must be observed Y page 9 Observe the sections Qualified specialist workshop Y page 9...

Page 32: ...30...

Page 33: ...ing 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 48...

Page 34: ...the oil level electronically Check the engine oil level on a regular basis e g before each journey or each time you refuel Make sure that you also observe the notes in the vehicle device manufacturer...

Page 35: ...e fuel prefilter on the chassis frame H Environmental note Dispose of the water fuel mixture in an envi ronmentally responsible manner Example fuel prefilter on the chassis frame Function Page 1 Fuel...

Page 36: ...information in the additional operating instructions These will be provided by the vehicle device manufac turer For additional safety the electronic engine management system is equipped with a func ti...

Page 37: ...si tion sensor accelerator remains con stant Rheavy smoke is emitted from the exhaust Rthe coolant or engine oil temperature rises steeply Rabnormal noises suddenly come from the engine or exhaust gas...

Page 38: ...has limited or no effect after the engine has been started Operation of the engine brake see the vehi cle device Operating Instructions Retarder Operation of the retarder see the vehicle device Operat...

Page 39: ...for a maximum of 30 minutes This emergency function by operating the switch can be activated a maximum of three times When the final operating restriction idling speed and 20 of torque has been reach...

Page 40: ...agent is required for reduction of engine emissions The MOT approval operating permit is inva lidated if the vehicle is operated without AdBlue DEF The legal consequence of this is that the vehicle m...

Page 41: ...llowing systems is malfunctioning REngine REngine cooling REngine management RDiesel injection system X If further indicator lamps are displayed take the combination of lamps see below into account wh...

Page 42: ...have the malfunction rectified at a qualified specialist workshop The indicator lamp lights up A malfunction in the coolant circuit has been detected The coolant temperature is too high X If there ar...

Page 43: ...cessary reduce speed by adaptive braking X The speed limit set by the speed limiter was temporarily deac tivated by kickdown and may be exceeded By briefly switching to idle throttle position the set...

Page 44: ...up the AdBlue DEF tank immediately If you do not observe the instructions engine torque and engine speed may be further reduced The and indi cator lamps are lit and and are flashing The AdBlue DEF lev...

Page 45: ...a maximum of 75 across the whole engine speed range The limi tation takes effect by means of a ramp function X Adapt your driving operating style X Drive carefully to the nearest qualified specialist...

Page 46: ...e engine torque is limited to a maximum of 20 across the whole engine speed range The engine speed is limited to idling speed X Stop the vehicle device paying attention to road and traffic conditions...

Page 47: ...ted to a maximum of 75 across the whole engine speed range The limi tation will take effect the next time the engine is started X Adapt your driving operating style X Top up the AdBlue DEF tank immedi...

Page 48: ...mited to a maximum of 20 across the whole engine speed range The engine speed is limited to idling speed X Stop the vehicle device paying attention to road and traffic conditions X Have the malfunctio...

Page 49: ...tervals Always have maintenance work car ried out at a qualified specialist workshop Fuel type The fuel grade also affects fuel consumption Use of lower fuel grades and or non approved fuel additives...

Page 50: ...mixture is lower than that of pure diesel fuel When the engine is running components in the exhaust system may over heat unnoticed There is a risk of fire Never refuel with petrol Never add petrol to...

Page 51: ...EF in accordance with DIN 70070 ISO 22241 Do not use any additives If AdBlue DEF comes into contact with painted or aluminium surfaces when filling the tank rinse the affected area immedi ately with p...

Page 52: ...side temperatures make sure that the engine oil added is of an appropriate SAE classification Using engine oils that are not suitable for very low outside temperatures may result in engine damage Befo...

Page 53: ...General notes 52 Service products 53 Cleaning and care 59 51 Maintenance...

Page 54: ...cumstances require you to do some main tenance work yourself you must observe the environmental protection requirements When disposing of service products e g engine oil you must comply with the legal...

Page 55: ...des Benz Specifications for Service Products For this reason only use approved service products for your engine system Information about approved service products is available from any MTU or MTU auth...

Page 56: ...gine oil ages during driving due to soot and fuel residue This impairs the charac teristics of the engine oil particularly at low outside temperatures If the outside temperature is under 20 Mercedes B...

Page 57: ...nt pro tective effects is filled at the factory The coolant is a mixture of water and corro sion inhibitor antifreeze The corrosion inhibitor antifreeze in the cool ant has the following properties Rh...

Page 58: ...15 ppm The following fuel types are not permitted Rsulphurous fuel with a sulphur content greater than 0 005 by weight 50 ppm Rmarine diesel fuel Raviation turbine fuel Rheating oils Rfatty acid meth...

Page 59: ...harac teristics are flow improvers Do not add flow improvers to winter diesel fuel guaranteed to operate down to 22 The cold flow properties of the fuel may dete riorate as a consequence of the flow i...

Page 60: ...ion of the throat and watering eyes Avoid inhaling ammonia vapours The chemical composition of AdBlue DEF can break down if it heats up to 50 over a long period e g as a result of direct sunlight on t...

Page 61: ...ing never point the water jet at the exhaust pipe The system may oth erwise be damaged When using a high pressure cleaner keep a minimum distance between the high pressure nozzle and the engine parts...

Page 62: ...60...

Page 63: ...General notes 62 Decommissioning for up to 6 months 62 Decommissioning for longer than 6 months 63 61 Decommissioning...

Page 64: ...ank until it is full to prevent AdBlue DEF from crystallising RDrain the water separator for the fuel sys tem Measures during decommissioning Start the engine at least once a month and leave it runnin...

Page 65: ...ring and brakes RCheck whether maintenance is due and if necessary carry it out Decommissioning for longer than 6 months If the vehicle is to be decommissioned for longer than 6 months further measure...

Page 66: ...64...

Page 67: ...Important safety notes 66 Bleeding and draining the fuel sys tem 67 Electrical fuses 68 Jump starting 69 Troubleshooting 71 65 Troubleshooting...

Page 68: ...nce or repair work G WARNING Certain engine components can become very hot There is a risk of injury when carrying out work at the engine Where possible allow the engine to cool down and only touch th...

Page 69: ...EF delivery pump is actuated during this period Bleeding and draining the fuel system Bleeding after refuelling a fuel system which has been run dry is performed the next time the engine is started Au...

Page 70: ...Electrical fuses Important safety notes G WARNING If you manipulate bridge or replace a faulty fuse with a fuse of a higher amperage the electric cables could be overloaded This may result in a fire T...

Page 71: ...e jump starting provided by vehi cles with a 24 V system Ruse jump leads which are protected against polarity reversal and with a wire cross section of approximately 35 50 mm2 and insulated terminal c...

Page 72: ...st connect the negative terminal clamp of the jump lead to the negative terminal of the other vehicle s battery and then to the negative terminal of the starter battery X Assisting vehicle run the eng...

Page 73: ...onsequences and M Solutions The drive pinion does not turn or turns too slowly The battery is not sufficiently charged X Charge the battery The connecting cable to the starter motor is loose X Tighten...

Page 74: ...The power supply to the engine management MCM or the exhaust gas aftertreatment ACM control modules is interrupted or there is a short circuit in the wiring X Check the electrical fuses X Have the po...

Page 75: ...f necessary replace X Consult a qualified specialist workshop An operating restriction is activated due to an emissions relevant malfunction X Observe the notes on warning and indicator lamps Y page 3...

Page 76: ...di cator lamp lights up when the engine is run ning The poly V belt is slipping X Check the belt tensioner function X Check that the poly V belt contact surfaces are not torn dam aged oily or glazed R...

Page 77: ...surfaces are not torn dam aged oily or glazed Replace the poly V belt if necessary Replacing the poly V belt If the poly V belt is torn or shows damage patterns it must be replaced G WARNING The tens...

Page 78: ...ached into the tensioner X Swing back the tensioner X 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...

Page 79: ...Identification plates 78 Data card 78 Engine data 79 77 Technical data...

Page 80: ...the cylinder head cover Position Emission certification label EPA Certification Exhaust gas aftertreatment identifi cation plate The exhaust gas aftertreatment identification plate is located on the e...

Page 81: ...Rthe data card or Rthe complete engine number and the num ber of the exhaust gas aftertreatment unit Engine data Dimensions and weights All data refers to the standard version of the respective engin...

Page 82: ...3 6 2 4 Type of cooling system Forced circulation cooling Engine direction of rotation Anti clockwise when looking at the flywheel Valve clear ance Intake valve 0 30 mm 0 05 mm 0 30 mm 0 05 mm Exhaust...

Page 83: ...l fuels in accord ance with EN 590 as of 2010 or ASTM D975 Sheet No 131 0 Exhaust gas aftertreat ment sys tem AdBlue DEF tank3 AdBlue DEF in accordance with ISO 22241 Sheet No 352 1 AdBlue DEF filter...

Page 84: ...the tightening sequence for the cylinder head cover Light alloy 20 Nm Thermoplastic 25 Nm Valve clearance setting Counternut on the rocker arm adjustment screw 30 Nm Engine brake setting Counternut o...

Page 85: ...idge 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 Ti...

Page 86: ...84...

Page 87: ...y questions or sugges tions regarding this manual you can reach the technical documentation team at the fol lowing address Daimler AG HPC CAC Customer Service 70546 Stuttgart Germany Daimler AG not to...

Page 88: ...Order no 6462 9859 02 Part no 934 584 09 81 Edition 02 15 9345840981 9345840981...

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