MTU 6R 1000 series Instructions d'exploitation

4R/6R 1000 EU Stage IV/US TIER 4Operating InstructionsOrder no. 6462 9839 02 Part no. 934 584 37 71 Edition 01-14É9345843771)ËÍ9345843771

This is the case if:Rthey result in a change to the vehicle typefrom that for which the vehicle's generaloperating permit was grantedRthey pose a

Mercedes-Benz Service Centres:Rhave special equipment and tools as well asspecialists who receive continuous trainingRguarantee that your engine syste

This data is exclusively technical in natureand can be used to:Rassist in the detection and rectification offaults and defectsRanalyse vehicle functio

General information ... 12Engine overview ... 13Exhaust gas aftertreatment over-view ...

General informationThe engine is a water-cooled four-stroke die-sel engine with direct injection.The engine is equipped with a Common Raildiesel injec

Engine overviewEngine overview: 4R 1000 with single-stage charging:Exhaust gas recirculation positioner;Rail=Fuel filter?External engine start/engine

Engine overview: 4R 1000 with single-stage charging:Crankcase ventilation system;Exhaust gas recirculation pipe (cold)=Refrigerant compressor?Coolant

Engine overview: 6R 1000 with two-stage charging:Refrigerant compressor;Exhaust gas recirculation positioner=Rail?Fuel filterAExternal engine start/en

Engine overview: 6R 1000 with two-stage charging:Crankcase ventilation system;Exhaust gas recirculation pipe (cold)=Refrigerant compressor?Combined oi

Exhaust gas aftertreatment overview:NOx sensor on exhaust gas aftertreatment unit inlet;AdBlue® treatment reactor=Exhaust gas inlet from AdBlue® treat

ImprintInternetFurther information about MTU, Mercedes-Benz and Daimler AG can be found on theInternet at:www.mtu-online.comwww.mercedes-benz.comwww.d

:Mounting brackets;Exhaust gas inlet from engine=Exhaust gas aftertreatment control unit (ACM)?NOx sensor at exhaust gas aftertreatment unit outletAEx

Engine management control module(MCM)The engine management control module(MCM) is located on the side of the engine. Itacts as an interface between th

Functions of the exhaust gas aftertreatmentcontrol unit (ACM):REvaluation of sensor signalsThe sensor signals of the directly connec-ted sensors are e

warning, the warning and indicator lampslight up in different combinations.The following warning and indicator lampsmay be available on the instrument

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Operating safety ... 24Safety precautions ... 24Notes on electronic systems ... 24S

Operating safetyGWARNINGIf you do not have the prescribed service/maintenance work or necessary repairs car-ried out, this could result in malfunction

more and/or jeopardise the operationalsafety of the vehicle. There is an increasedrisk of an accident and injury.Do not attempt to modify the wiring a

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Transport ... 28Installation ... 2827Transport, installation

WelcomeFamiliarise yourself with your engine systemand read the Operating Instructions beforeyou use the engine system. This will help youto avoid end

TransportGWARNINGIf you do not lift the engine as described, thelugs intended for the purpose may be torn outor snap. This may be the case especially

Preparation for operation ... 30Starting and stopping the engine ... 31Switching the continuous brake onand off ...

Preparation for operationEngine with initial operation oil fromthe factoryThe engine is filled at the factory with an initialoperation oil.These high-

XCheck the engine oil level with dipstick ;.The oil level should be between the upperand lower marks on dipstick ;.XIf necessary, use filler neck : to

Example: ignition lockgTo insert/remove the vehicle key1Steering wheel unlocked/radio position2Drive position (ignition)3Start positionXSecure the veh

XPark the vehicle/equipment.XSecure the vehicle/equipment against roll-ing away.XShift the transmission into neutral/decou-ple the drive system.Let th

idling speed may differ in certain operatingconditions depending on the engine or onvehicles with power take-off.The engine idling speed for the 6R100

DisplaysRev counter! If you exceed the maximum permissibleengine speed, the warning tone sounds.You should not drive and change gear bythe sound of th

Warning and indicator lampsWarning and indicator lamps - causes/consequences and solutionsProblemPossible causes/consequences and M SolutionsThe ind

ProblemPossible causes/consequences and M SolutionsIndicator lamps Øand are lit and· flashes.The AdBlue®/DEF level has dropped to approximately 7.5%

ProblemPossible causes/consequences and M SolutionsThe · indicatorlamp lights up.An emissions-relevant malfunction in the exhaust gas aftertreat-ment

ProblemPossible causes/consequences and M SolutionsThe and · indi-cator lamps are flash-ing and lights up.You have not rectified an emissions-rele

ProblemPossible causes/consequences and M SolutionsThe · indicatorlamp lights up.An emissions-relevant malfunction in the exhaust gas aftertreat-ment

ProblemPossible causes/consequences and M SolutionsThe · and indi-cator lamps are flash-ing and lights up.You have not rectified an emissions-rele

Fuel consumptionGeneral notesFuel consumption depends on:Rthe machine version/vehicle versionRthe operating conditionsRthe attached equipment (e.g. hy

RefuellingFuelsImportant safety notesGWARNINGFuels are poisonous and hazardous to health.There is a danger of injury.Do not swallow fuel or let it com

HEnvironmental noteIf fuels are handled improperly, they pose adanger to persons and the environment. Donot allow fuels to run into the sewage system,

AdBlue®/DEF is not refilled as part of themaintenance work. Top up the tank regularlyduring vehicle operation or at the latest whenthe first event mes

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General notes ... 48Service products ... 49Cleaning and care ...

Index ... 4Introduction ... 7At a glance ...

General notesGWARNINGBefore carrying out maintenance or repairwork, you must read the relevant sections ofthe technical documentation relating to main

When working on the vehicle, comply with allsafety regulations, such as operating instruc-tions, regulations concerning hazardousmaterials, environmen

Engine oils according to Sheet No. 228.51and 228.5 have a higher quality standard andhave a favourable effect on:Rlength of oil change intervalsRengin

Engine oils are differentiated according to:Rengine oil brandRquality grade (Sheet No.)RSAE viscosity classIf, in exceptional circumstances, the type

Diesel fuelsImportant safety notesGWARNINGFuel is highly flammable. Improper handing offuel creates a risk of fire and explosion.Avoid fire, naked fla

At low outside temperatures, paraffin sepa-ration may cause the flow properties of thediesel fuel to be insufficient.To prevent operating problems, di

The vapours may cause a burning sensation inthe eyes, nose and throat as well as irritationof the throat and watering eyes.Avoid inhaling ammonia vapo

Observe laws and regulations on the disposalof AdBlue®/DEF in the country concerned.Purity! Impurities in AdBlue®/DEF, e.g. due toother service produc

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General notes ... 58Decommissioning for up to 6months ... 58Decommiss

AAdBlue®/DEFConsumption ... 42Gauge ... 35Important safety notes ...

General notesSpecial measures are required to decommis-sion the engine/vehicle.Information about batteries: if the engine/vehicle is to be out of use

Important safety notes ... 60Bleeding and draining the fuel sys-tem ... 61Elec

Important safety notesGWARNINGIf you do not have the prescribed service/maintenance work or necessary repairs car-ried out, this could result in malfu

start/engine stop button :, the enginecontinues to run at the currently set speed.The engine speed can be increased up tothe limiting speed.XIf the en

Bleeding using the hand pump of the fuel prefilter on the chassis frameXUnscrew the fuel tank filler cap.XPlace the collector underneath fuel prefil-t

Wear suitable protectiveclothing, in particulargloves, an apron and a facemask.Immediately rinse acidsplashes off with cleanwater. Consult a doctor if

XAssisting vehicle: run the engine at a highspeed.XStart the engine and allow it to idle.Disconnecting the jump leadXFirst, disconnect the negative te

TroubleshootingEngine problemsGWARNINGIf you do not have the prescribed service/maintenance work or necessary repairs carried out, thiscould result in

ProblemPossible causes/consequences and M SolutionsLeaks or insufficient pressure in the low-pressure fuel circuitXCheck for leaks (visual check), rep

ProblemPossible causes/consequences and M SolutionsThe charge-air temperature is too high; the charge-air cooler orradiator is dirty on the exterior.X

Mixing ... 50Oil change ... 50Topping up ...

ProblemPossible causes/consequences and M SolutionsThe poly-V-belt is damaged.XReplace the poly-V-belt.The fan does not switch on correctly.XConsult a

ProblemPossible causes/consequences and M SolutionsThe turbine or compressor wheel is scraping the housing; there areforeign objects in the compressor

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Identification plates ... 72Data card ... 72Engine data ...

Identification platesEngine data plate:Position of engine data plate (example)Information on the engine data plateThe following data is contained on t

DimensionsExample: engine lengthExample: engine width and heightR4 1000 R6 1000A = enginelength withfan917 mm 1070 mmB = enginewidth840 mm 1050 mmC =

General dataAll data refers to the standard version of the respective engine type. Data for other versions isavailable on request.Engine Engine type 4

Engine speed of maximum power output Approx. 2200 rpm4R 1000 idling speed Approx. 680 rpm6R 1000 idling speed Approx. 600 rpmOil pressure at idling sp

Capacity approx-imatelyService product(Sheet No.2)Corrosion inhibitor/anti-freeze volumedown to –45 °CMax. 55% by vol-umeEngine com-partmentProtective

Tightening sequence for the cylinderhead coverThe cylinder head cover screws must be tight-ened in the correct tightening sequence in thesame order as

Disposing of AdBlue®/DEF ... 54Engine oil ... 49Fuel additives ... 53

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ImprintInternetFurther information about MTU, Mercedes-Benz and Daimler AG can be found on theInternet at:www.mtu-online.comwww.mercedes-benz.comwww.d

4R/6R 1000 EU Stage IV/US TIER 4Operating InstructionsOrder no. 6462 9839 02 Part no. 934 584 37 71 Edition 01-14É9345843771)ËÍ9345843771

Engine systemThe 4R 1000 and 6R 1000 series of enginesonly function as intended when used in con-junction with the corresponding exhaust gasaftertreat