MTU 4R 1000 SERIES Operating Instructions Manual

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

Operating Instructions

Symbols

G

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.

H

Environmental note

Environmental notes provide you with infor-

mation on environmentally aware actions or

disposal.

!

The

purpose of material damage warnings

is to draw your attention 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-

tion you must follow.

X

Several consecutive symbols indi-

cate an instruction with several

steps.

(Y page)

This symbol tells you where you

can find further information on a

topic.

Y Y

This symbol indicates a warning or

an

instruction that is continued on

the next page.

Display

This text indicates an indicator in

the display.

Welcome

Familiarise yourself with your engine system

and read the operating instructions before

you

use the engine system. This will help you

to avoid endangering yourself or others.

The standard equipment and product descrip-

tion of your engine system may vary, depend-

ing on individual specifications. This is descri-

bed on the data card.

The engine systems are constantly updated

to be state of the art.

MTU/Mercedes-Benz reserves the right to

make changes to the following:

R

design

R

equipment

R

technical features

Descriptions may therefore differ in individual

cases from your engine system.

9345840981

É93458

40981-ËÍ

A

AdBlue

®

/DEF

Consumption ...................................

47

Gauge .............................................. 38

Important safety notes .................... 49

Refuelling ......................................... 49

Service product ............................... 57

ADM (FR (drive control) unit) ............. 12

B

Battery (vehicle)

Jump starting ...................................

69

Bleeding the fuel system

Bleeding the prefilter with a hand

pump ............................................... 67

Braking

Continuous brake ............................ 35

Engine brake .................................... 36

Retarder ........................................... 36

Buzzer ................................................... 47

C

Capacities ............................................

81

Care products ...................................... 59

Charge current .................................... 36

Checking the fluid level ...................... 32

Cleaning and care

Engine cleaning ................................ 59

High-pressure cleaning .................... 59

Notes on care .................................. 59

Consumption

AdBlue

®

/DEF .................................. 47

Fuel .................................................. 47

Oil (engine) ...................................... 47

Continuous brake

Important safety notes .................... 35

Coolant

Mixing ratio ...................................... 55

Service product ............................... 55

Topping up ....................................... 33

Coolant additive .................................. 55

Correct use ............................................ 7

Corrosion 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 ......................................... 48

Dimensions .......................................... 79

Disposal of service products .............. 53

Driving mode

Idling speed ..................................... 36

Driving tips .......................................... 46

E

Electronic engine control

see Engine management

Electronic engine control unit ............

36

Emergency gearshift

Using the emergency switch ............ 37

Emergency running program ................ 7

Engine

Capacities ........................................ 81

Cleaning ........................................... 59

Data ................................................. 79

Data card ......................................... 78

Data plate ........................................ 78

Modifying the power output ............... 7

Oil consumption ............................... 47

Operating data ................................. 80

Rectifying faults ............................... 71

Running-in period ............................. 46

Starting ............................................ 34

Stopping .......................................... 35

Engine brake ........................................ 36

Engine data .......................................... 79

Engine data card .................................. 78

Engine description .............................. 12

Engine idling speed ............................. 36

Engine management ........................... 18

Engine oil

Consumption ................................... 47

For winter operation ........................ 53

Mixing .............................................. 54

2

Index

Oil change ........................................ 54

Topping up

....................................... 54

Engine overview .................................. 13

Engine speed ....................................... 37

Exhaust gas aftertreatment ............... 20

F

Fuel

Additives ..........................................

57

Consumption ................................... 47

Diesel ............................................... 56

Refuelling ......................................... 48

Fuel grade ............................................ 56

Fuel system

Automatic bleeding .......................... 67

Manual bleeding .............................. 67

Fuses

Checking and replacing a safety

fuse .................................................. 68

Important safety notes .................... 68

G

Gauge

AdBlue

®

/DEF

.................................. 38

Genuine Mercedes-Benz parts ............. 6

H

High-pressure cleaning ....................... 59

I

Identification plate ..............................

78

Idling speed

Engine .............................................. 36

Installation ........................................... 28

J

Jump-starting .......................................

69

M

Maintenance

Notes

............................................... 52

Mercedes-Benz Service Centre

see Qualified specialist 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 registration

Changes in engine performance ........ 7

Implied warranty ................................ 7

Operational monitoring ...................... 36

Organisational measures ................... 25

P

Personnel .............................................

25

Poly-V-belt

Replacing ......................................... 75

Routing ............................................ 75

Preparing for starting operation

see Starting operation

Protection of the environment ............. 6

Q

Qualified specialist workshop ..............

9

R

Refuelling

AdBlue

®

/DEF .................................. 49

Fuels ................................................ 48

Requirements of the personnel ......... 25

Rev counter .......................................... 37

Roadside Assistance ........................... 66

Running the vehicle in ........................ 46

S

Safety

and emergency running pro-

gram ....................................................... 7

Safety precautions .............................. 24

Service products

AdBlue

®

/DEF .................................. 57

Coolant ............................................ 55

Index

3

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 ...................... 58

Specialist 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

Tightening torques .............................. 82

Transport .............................................. 28

W

Warning and indicator lamps

Electronics

....................................... 39

Engine, general ................................ 20

Warning buzzer .................................... 47

Weights ................................................ 79

Winter diesel ........................................ 56

Winter operation ................................. 50

4

Index

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 .............. 9

Further applicable documents ............. 9

5

Introduction

Engine system

The 4R 1000 and 6R 1000 series of engines

only function as intended when used in con-

junction with the corresponding exhaust gas

aftertreatment

unit. Therefore, in these Oper-

ating Instructions, the term "engine system"

refers to the engine and the exhaust gas after-

treatment unit.

Protection of the environment

H

Environmental note

Daimler AG has a declared policy of compre-

hensive environmental protection.

The objectives are to use the natural resour-

ces which form the basis of our existence on

this planet sparingly and in a manner which

takes the requirements of both nature and

humanity into account.

You too can help to protect the environment

by operating your vehicle in an environmen-

tally responsible manner.

Information and notes on driving in an envi-

ronmentally

responsible and fuel-saving man-

ner can be found in the "Operating notes"

section (Y page 47).

Assembly equipment

These Operating Instructions describe all

models and all standard and optional equip-

ment available for your engine system at the

time of publication of the Operating Instruc-

tions. Country-specific deviations are possi-

ble.

Note that your engine system may not be

fitted with all features described. This also

applies to safety-relevant systems and func-

tions. Therefore, the equipment on your

engine system may differ from certain

descriptions and illustrations.

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

any questions about equipment and opera-

tion

(see addresses in the publication details

on the inside of the back cover).

Genuine Mercedes-Benz parts

H

Environmental note

Daimler AG also supplies reconditioned

assemblies and parts which are of the same

quality

as new parts. For these, the same war-

ranty applies as for new parts.

If you use parts which have not been

approved by Mercedes-Benz, the operational

safety of the engine system may be jeopar-

dised. This could lead to malfunctions in

safety-relevant systems. Use only genuine

Mercedes-Benz parts or parts of equal qual-

ity. Only use parts that have been approved

for your engine type.

Mercedes-Benz checks genuine Mercedes-

Benz parts for:

R

reliability

R

safety

R

suitability

Despite ongoing market research, Mercedes-

Benz is unable to assess other parts.

Mercedes-Benz therefore accepts no respon-

sibility for the use of such parts in Mercedes-

Benz vehicles, even if they have been officially

approved or independently approved by a

testing centre.

In Germany, certain parts are only officially

approved for installation or modification if

they comply with legal requirements. This

also applies to some other countries. All gen-

uine Mercedes-Benz parts meet the approval

requirements. The use of non-approved parts

may invalidate the vehicle general operating

permit.

6

Genuine Mercedes-Benz parts

Introduction

This is the case if:

R

they result in a change to the vehicle type

from that for which the vehicle general

operating permit was granted

R

they pose a possible risk for road users

R

they

adversely affect the emission or noise

levels

You can find more information on recommen-

ded conversion parts and accessories, as well

as permitted technical modifications at any

MTU or MTU-authorised Mercedes-Benz Ser-

vice Centre (Y page 9).

Always specify the assembly system ID num-

ber (AGS ID), the engine number and the

number of the exhaust gas aftertreatment

unit when ordering genuine Mercedes-Benz

parts. You can find the engine number on the

identification plate of your engine. You can

find the number of the exhaust gas aftertreat-

ment unit on the identification plate of the

exhaust gas aftertreatment control module

(ACM) (Y page 78). You can also find the

two numbers on the data card (Y page 78).

Modifying the engine output

!

Increased power could:

R

change emission levels

R

cause malfunctions

R

lead to consequential damage

The operating safety of the engine cannot

be guaranteed in all situations.

Any tampering with the engine management

system

in order to increase the engine power

output will lead to a loss of warranty entitle-

ments.

Safety/emergency running program

The engine is equipped with an electronic

engine management system that monitors

the engine and the exhaust 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 the malfunction:

R

faults during operation are indicated by the

corresponding warning lamp (Y page 39).

R

in conjunction with the electronic engine

management system, fault codes with addi-

tional information can be shown on a dis-

play.

R

the system switches to a suitable backup

function for the continued, albeit restric-

ted, operation of the engine. This includes

torque and engine speed limitation, for

example, as well as road speed limitation or

constant emergency running speed.

Correct use

The engine system may only be installed as

contractually specified.

The manufacturer of the end product is

responsible

for the correct installation of the

engine and the exhaust gas aftertreatment

system in the overall system.

The engine and the exhaust gas aftertreat-

ment system may not be modified. If the

engine is modified, Mercedes-Benz and MTU

do not accept responsibility for any damage

arising as a result.

Correct use of the engine system also

requires adherence to the instructions in

these Operating Instructions. This also

requires compliance with the maintenance

intervals and the professional execution of

maintenance work. Please observe the Work-

shop Information System (WIS) (Y page 9).

Implied warranty

A well-developed network of MTU or MTU-

authorised

Mercedes-Benz Service Centres is

available to carry out maintenance work.

Implied warranty

7

Introduction

Z

These MTU or MTU-authorised Mercedes-

Benz Service Centres:

R

have

special equipment and tools as well as

specialists who receive continuous training

R

guarantee that your engine system is

repaired and maintained thoroughly and

expertly

R

carry out all repairs related to implied war-

ranty

R

carry out all maintenance work expertly

R

confirm in the Maintenance Booklet that

the maintenance work has been carried out

at the required time

R

handle implied warranty claims that are

admissible according to the sales contract

Please observe the instructions and recom-

mendations as well as the maintenance serv-

ices in the Maintenance Booklet. Please

observe these instructions even if you let a

third party use and care for your vehicle/

device. This is the only way to ensure that you

do not lose your entitlements.

If the prescribed maintenance work is not

carried out, claims can only be decided after

the manufacturer has inspected the claim.

During the implied warranty period, have the

prescribed maintenance service for your

engine system carried out as follows:

R

regularly

R

punctually

R

at a qualified specialist workshop which

has the necessary specialist knowledge

and tools to carry out the work required

Mercedes-Benz recommends that you use

an MTU or MTU-authorised Mercedes-Benz

Service 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

maintenance on the engines must be car-

ried out according to specific regulations

and using special measuring devices

R

it is prohibited to modify or tamper with

components relevant to emissions

All MTU or MTU-authorised Mercedes-Benz

Service Centres are familiar with the relevant

regulations.

Maintenance work does not include repair

work. Issue a separate order for repair work.

You can obtain further information on the

maintenance of your engine system from any

MTU or MTU-authorised Mercedes-Benz Ser-

vice Centre.

Stored data

Several

of the electronic components in your

engine system contain data memories.

These data memories temporarily or perma-

nently store technical information about:

R

the engine system state

R

events

R

malfunctions

In general, this technical information docu-

ments the state of a component, a module, a

system or the surroundings.

This includes, for example:

R

operating conditions of system compo-

nents, e.g. fluid levels

R

the vehicle/device status messages and

those of its individual components, e.g.

speed, deceleration in movement, acceler-

ator position

R

malfunctions and defects in important sys-

tem components

R

the vehicle/device reactions and operating

statuses in special driving situations

R

ambient conditions, e.g. outside tempera-

ture

8

Stored data

Introduction

This data is exclusively technical in nature

and can be used to:

R

assist in the detection and rectification of

faults and defects

R

analyse

vehicle functions, e.g. after an acci-

dent

The data cannot be used to trace the vehicle's

movements.

When you use one of the available services,

technical information may be read from the

event data memory and fault data memory.

Services include, for example:

R

repair services

R

service processes

R

implied warranty and guarantee cases

R

quality assurance

The information is read out by employees of

the service network (including manufactur-

ers) using special diagnostic testers. Further

information is available there if required.

After a fault has been rectified, the informa-

tion is deleted from the fault memory or is

continually overwritten.

Qualified specialist workshop

A qualified specialist workshop has the nec-

essary specialist knowledge, tools and quali-

fications

to carry out the work required on the

engine to a professional standard. This is par-

ticularly applicable to work relevant to safety.

Observe the notes in the Maintenance Book-

let.

Always have the following maintenance work

carried out at a qualified specialist workshop:

R

work relevant to safety

R

service and maintenance work

R

repair work

R

modifications as well as installations and

conversions

R

work on electronic components

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 your engine system within

the scope of delivery of Daimler AG. The

installation of the engine system into the vehi-

cle/device may require additional operating

instructions adapted to the vehicle/device

and the appropriate use thereof. These addi-

tional operating instructions will be provided

by the vehicle/device manufacturer (manu-

facturer of the end product). The additional

operating instructions will describe, in partic-

ular, the functions specific to the installation

and operation, the use of such functions as

well as warning and control mechanisms.

To use the engine correctly, you also require

the Maintenance Booklet.

For US-certified off-highway engines you also

require the "Emission Warranty" supplement.

Always keep these documents together with

the engine, vehicle or device. These docu-

ments should be passed on to the new owner

if you sell the engine, vehicle or device.

When carrying out maintenance work, you

require access to the Workshop Information

System (WIS) via the Internet. This access is

subject to a fee.

Current information on the system and prices

can be found at this web address: http://

service-parts.mercedes-benz.com. Click on

"EPC, WIS/ASRA" in the "Service and parts

information" tab and then on "WIS".

You can log in by clicking on "Register" on the

right-hand side.

Further applicable documents

9

Introduction

Z

10

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

11

At a glance

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

exhaust gas turbochargers of differing dimen-

sions.

The valve gear has 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.

The valves are arranged symmetrically. The

symmetrical valve arrangement is optimal for

combustion.

The exhaust gas aftertreatment unit is char-

acterised by the following technologies:

R

selective catalytic reduction (SCR) with

ammonia slip catalytic converter

R

the diesel oxidation catalytic converter

(DOC)

The engine brake is a decompression brake. It

has a controlled exhaust valve which gives it

high braking power. The engine brake is con-

trollable in steps or modulated.

12

General information

At a glance

Engine overview

Engine overview: 4R 1000 with single-stage charging

:

Exhaust 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-steering pump

F

Oil pan

G

Charge-air pipe (cold)

Engine overview

13

At a glance

Engine overview: 4R 1000 with single-stage charging

:

Crankcase ventilation system

;

Exhaust gas 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

E

Exhaust gas turbocharger

F

Exhaust gas recirculation cooler

14

Engine overview

At a glance

Engine overview: 6R 1000 with two-stage charging

:

Refrigerant 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 pump

F

Alternator

G

Oil pan

Engine overview

15

At a glance

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

A

Oil pan

B

Starter motor

C

Low pressure exhaust gas turbocharger

D

Exhaust pipe to exhaust gas aftertreatment unit

E

High pressure exhaust gas turbocharger

F

Power take-off (PTO)

G

Boost pressure positioner

H

Exhaust gas recirculation cooler

16

Engine overview

At a glance

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

A

Exhaust gas aftertreatment box

B

Exhaust gas outlet

C

Exhaust gas temperature sensor upstream of the SCR catalytic converter

D

Pump module

E

AdBlue

®

/DEF metering unit

F

Exhaust gas temperature sensor upstream of the AdBlue

®

metering unit

Exhaust gas aftertreatment overview

17

At a glance

:

Mounting brackets

;

Exhaust gas inlet from engine

=

Exhaust gas aftertreatment control unit (ACM)

?

NOx sensor at exhaust gas aftertreatment unit outlet

A

Exhaust gas temperature sensor downstream of the SCR catalytic converter

Electronic engine management

The engine system is equipped with an elec-

tronic engine management system which

comprises the following control units:

R

Engine management control module

(MCM)

R

Drive control system unit (CPC)

R

Exhaust gas aftertreatment control unit

(ACM)

The control units are connected 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-

agement system also monitors itself.

Depending on the malfunctions/failures

which occur, warning and information dis-

plays are activated

(Y page 20). The mal-

function is stored in the fault memory and if

necessary a safety and emergency mode is

automatically selected (Y page 36). If the

electronic engine management control

detects a fault, the fault code is stored in the

control units. It can then be read by a qualified

specialist workshop (Y page 9) using a diag-

nostic tester.

18

Electronic engine management

At a glance

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