Professional Documents
Culture Documents
Operating Instructions
Symbols
$ Warning
% Environmental note
! Possible vehicle/equipment dam-
age
i Tip
X Instructions
YY Continuation symbol
(Y page) Page reference
Welcome to the world of Mercedes-Benz
Familiarise yourself with your engine and read
the Operating Instructions before you use the
engine. This will help you to avoid endanger-
ing yourself or others.
The standard equipment and product descrip-
tion of your engine may vary, depending on
individual specifications. This is described on
the engine data card.
Mercedes-Benz constantly updates its
engines to the state of the art.
Mercedes-Benz reserves the right to make
changes to the following:
Rdesign
Requipment
Rtechnical features
You cannot therefore base any claims on the
illustrations or descriptions in this manual.
The manual/instructions are comprised of:
ROperating Instructions
RMaintenance Booklet
ROnly for US-certified engines: "Emission
Related Warranty" supplement
Always keep these documents together with
the engine/vehicle/device. These docu-
ments should be passed on to the new owner
if you sell the engine/vehicle/device.
Please have warranty and ex gratia work car-
ried out at authorised workshops/Service
Centres.
RFor on-highway applications, contact a
Mercedes-Benz Service Centre.
RFor off-highway applications, contact an
MTU or MTU-authorised Mercedes-Benz
partner.
9265842181 É9265842181fËÍ
Contents 3
A Cooling system
Degreasing ....................................... 77
Adaptation module .............................. 21 Flushing ........................................... 77
AdBlue®/DEF Correct use ............................................ 9
Components .................................... 19 Corrosion inhibitor/antifreeze
Consumption ................................... 43 agent .................................................... 50
Refuelling ......................................... 44 Cranking device ................................... 64
Replacing the filter ........................... 70
Service product ............................... 54 D
ADM (FR (drive control) unit) ............. 21
Antifreeze ............................................. 74 Data card ............................................ 100
Decommissioning ................................ 81
B Decommissioning the engine ............. 80
DEF/AdBlue®
Bio-diesel fuel
see AdBlue®/DEF service products
see FAME fatty acid methyl ester fuel
Description of the engine ................... 21
BlueTec® Diesel
Exhaust gas aftertreatment ................ 9 Fuels ................................................ 51
Sensors ............................................ 19 Low outside temperatures ............... 53
BlueTec® exhaust gas aftertreat- Refuelling ......................................... 43
ment Sulphur content table ...................... 52
AdBlue® service product .................. 54 Dimensions ........................................ 101
Braking Disposal of service products .............. 48
Continuous brake ............................ 41 Driving tips .......................................... 42
C E
Capacities .......................................... 104 Electronic engine control
Care products ...................................... 56 see Engine management
Charge current .................................... 38 Electronic engine control unit ............ 38
Checking the fluid level ...................... 34 Emergency mode ................................. 87
Cleaning and care Emergency running program ................ 8
Engine cleaning ................................ 56 Engine
High-pressure cleaning .................... 56 Capacities ...................................... 104
Notes on care .................................. 56 Changing the oil and oil filter ........... 62
Cold-start aid ....................................... 27 Checking for leaks and general
Consumption condition .......................................... 78
AdBlue®/DEF .................................. 43 Cleaning ........................................... 56
Fuel .................................................. 42 Data ............................................... 101
Oil (engine) ...................................... 43 Data card ....................................... 100
Continuous brake ................................ 26 Data plate ...................................... 100
Coolant Diagnostics (indicator lamp) ............ 94
Draining ........................................... 76 Oil consumption ............................... 43
Mixing ratio ...................................... 50 Operating data ............................... 104
Renewing ......................................... 76 Protective treatment ........................ 81
Service product ............................... 50 Re-commissioning ........................... 83
Topping up ................................. 35, 77 Rectifying faults ............................... 89
Coolant additive .................................. 50 Running-in period ............................. 42
Index 5
Z
8 Introduction
Incorrectly executed maintenance and repair users or persons in the vicinity of the vehi-
work on the engine can reduce its functional- cle/equipment
ity and safety and consequently lead to acci- Rmodifications that change the exhaust or
dents causing personal injury. noise level
Always have any work on or modifications to The use of non-approved parts can adversely
the engine carried out at a qualified specialist affect safety.
workshop.
H Environmental note
The Daimler diagnostic tester can be For more economic repairs, Mercedes-Benz
attached to the 14-pin diagnostics connec- offers Mercedes-Benz reconditioned assem-
tion or to the service plug according to the EU bly and parts as part of the recycling process.
Directive. Both the fault memory as well as The same quality standards and warranty
stored engine data can be read out using this apply as to new parts.
equipment.
You can find more information on recommen-
ded conversion parts and accessories, as well
as permitted technical modifications at a
Mercedes-Benz or MTU Service Centre
(Y page 11).
Always state the engine number with the
model designation when ordering genuine
Mercedes-Benz parts. You can find the num-
bers on the identification plate of your engine
Introduction 9
(Y page 100) and on the engine data card Fault detected in the monitoring system
(Y page 100). If the monitoring system detects a fault in the
BlueTec® exhaust gas aftertreatment, opera-
tion is limited in accordance with the relevant
BlueTec® exhaust gas aftertreatment regulations (Y page 38).
The engines meet the requirements of the
relevant emissions level and are correspond-
ingly certified. Correct use
Compliance with emissions laws and regula- The engine may only be installed as contrac-
tions is a condition of the operating permit for tually specified.
the vehicle/equipment. The manufacturer of the end product is
Engines with BlueTec® exhaust gas after- responsible for the correct installation of the
treatment must be operated with AdBlue®/ engine in the entire system.
DEF in order to meet the emissions laws and The engine may not be modified. If the engine
regulations. is modified, Mercedes-Benz and MTU do not
The operating permit is invalidated if the vehi- accept responsibility for any damage arising
cle/equipment is operated without AdBlue®/ as a result.
DEF. Failure to use AdBlue®/DEF during Correct use of the engine requires adherence
operation may be a criminal offence or a reg- to the instructions in these Operating Instruc-
ulatory offence in certain countries. Special tions. This also requires compliance with the
concessions granted either at the time of pur- maintenance intervals and the professional
chase or to reduce operating costs of the execution of maintenance work in accord-
vehicle/equipment, e.g. reduced taxes or ance with these Operating Instructions.
tolls, may also be rendered retroactively inva-
lid. This can be the case in the country of reg-
istration. Or also in another country where Transport
you operate the vehicle/equipment.
G WARNING
Legal requirements If you do not lift the engine as described, the
lugs intended for the purpose may be torn out
If emissions laws and regulations are not or snap. This may be the case especially if the
adhered to when operating the engine/vehi- maximum permissible lug load is exceeded.
cle/equipment, you may be penalised. The engine could then drop uncontrolled,
This normally affects the following operating causing serious or even fatal injury.
states: Always make sure that:
Rdriving without AdBlue®/DEF Rthe engine is only lifted at the intended lift-
Rthe permissible nitrogen oxide (NOx) ing points/lifting lugs.
thresholds are exceeded Rthe engine is only lifted and transported in
Rthere is a fault or emissions-relevant mal- the fitting position.
function in the monitoring or exhaust gas Rropes/chains are always routed vertically.
aftertreatment system Ronly parts which are typically in the original
You can find details in the "Engine diagnostics scope of delivery are attached to the
indicator lamp" section (Y page 94). engine.
Z
10 Introduction
Installation
The engine may only be installed as contrac-
tually specified.
Observe the sections "Correct use"
(Y page 9) and "Modification and changes to
the engine" (Y page 7).
The Operating Instructions contains informa-
tion required for installation in the "Technical
Data" section" (Y page 101).
Please consult a Mercedes-Benz or MTU
Example display for OM 457 hLA
Service Centre (Y page 11) if you have any
The engine may only be lifted using a beam/ questions.
crossmember, so that the chain angle/rope
angle is 90° relative to the horizontal engine.
! The engines are by default delivered filled Information on the implied warranty
with oil. If the engine is transported at an A well-developed network of Mercedes-Benz
angle or on its side, oil could leak out. Only and MTU Service Centres is available to carry
transport the engine in the installation posi- out maintenance work.
tion. Mercedes-Benz and MTU Service Centres:
Rhave special equipment and tools as well
as specialists who receive continuous
training
Rguarantee that your engine is repaired and
maintained thoroughly and expertly
Rcarry out all repairs within the framework
of the engine warranty and the implied war-
ranty
Rcarry out all maintenance work expertly
Rconfirm in the Maintenance Booklet that
: Flywheel-side lifting point the maintenance work has been carried out
at the required time
Rhandle warranty claims that are admissible
according to the sales contract
Please observe the instructions and recom-
mendations in the Operating Instructions.
Always observe the maintenance intervals
specified in the Maintenance Booklet. Please
observe these instructions even if you let a
third party use and care for your engine. This
is the only way to ensure that you do not lose
your entitlements.
; Belt-side lifting point
If the prescribed maintenance work is not
carried out, claims can only be decided after
the manufacturer has inspected the claim.
Introduction 11
During the engine warranty period in particu- You should always have the following work on
lar, have the prescribed maintenance service your vehicle carried out at a qualified special-
carried out as follows: ist workshop:
Rregularly Rwork relevant to safety
Rpunctually Rservice and maintenance work
Rat a qualified specialist workshop which Rrepair work
has the necessary specialist knowledge Rmodifications as well as installations and
and tools to carry out the work required conversions
Mercedes-Benz recommends that you use Rwork on electronic components
a Mercedes-Benz or MTU Service Centre Please have warranty and ex gratia work car-
for this purpose. In particular, work rele- ried out at authorised workshops/Service
vant to safety or on safety-related systems Centres.
must be carried out at a qualified specialist
RFor on-highway applications, contact a
workshop.
Mercedes-Benz Service Centre.
If there are legal requirements on exhaust gas
RFor off-highway applications, contact an
aftertreatment, please note that:
MTU or MTU-authorised Mercedes-Benz
Rmaintenance on the engines must be car- partner.
ried out according to specific regulations
and using special measuring devices
Rit is prohibited to modify or tamper with
components relevant to emissions
All Mercedes-Benz and MTU Service Centres
are familiar with the relevant regulations.
Maintenance work does not include repair
work. Repair work requires a separate order.
You may also consult a Mercedes-Benz or
MTU Service Centre for further information.
Z
12
13
At a glance
14 Exterior view
Exterior view
Engine overview
At a glance
At a glance
Engine overview: OM 904 LA
: AdBlue®/DEF metering unit
; Charge-air pipe from the charge-air cooler
= Charge-air pipe to the charge-air cooler
? Engine ventilation hose
A Oil filter
B Poly V-belt tensioning device
C Alternator
D Starter motor
E Intake air inlet
F Engine brake
16
At a glance Exterior view
At a glance
Engine overview: OM 906 LA
: AdBlue®/DEF metering unit
; Charge-air pipe from the charge-air cooler
= Charge-air pipe to the charge-air cooler
? Engine ventilation hose
A Oil filter
B Poly V-belt tensioning device
C Alternator
D Starter motor
E Intake air inlet
F Exhaust gas turbocharger
G Engine brake
18 Exterior view
Sensors overview
Sensors, general
At a glance
Example: OM 926 LA
: Oil temperature
; Oil pressure
= Coolant temperature
? Charge-air temperature/charge-air pressure
A Camshaft position sensor (on camshaft gear)
B Crankshaft position sensor (on flywheel)
C Oil level
D Fuel temperature
Exterior view 19
AdBlue®/DEF components
At a glance
BlueTec® sensors, overview: OM 924 LA
: Valve preheating, AdBlue®/DEF system
; Exhaust aftertreatment unit
= Temperature and humidity sensor (air filter, clean air side)
? Metering unit
A Temperature sensor downstream of catalytic converter
B NOx sensor
C Temperature sensor upstream of catalytic converter
D Exhaust gas aftertreatment control unit
E Supply unit
F AdBlue®/DEF filter
G AdBlue®/DEF tank
20
At a glance Exterior view
At a glance
Example: BlueTec® sensors and test connection on the metering unit
: AdBlue®/DEF pressure sensor
; AdBlue®/DEF temperature sensor
= Pressure sensor for compressed air
? Metering unit test connection
A Metering unit heater
B Metering valve
Electronic engine control unit adaptation module (ADM). These are, for
example, the signal from the position sensor
The engine has a fully electronic management (accelerator pedal), the engine brake or
At a glance
system which, along with the engine and its engine start/stop, etc.
associated sensors, consists of the following
These values are analysed together with data
components:
from the engine sensors. They are compared
Rengine control unit (MR) with the charts or characteristic curves
Rdrive control unit (FR) and/or other vehicle- stored in the engine management (MR) con-
specific control units, e.g. adaptation mod- trol unit.
ule (ADM) Data from the sensors derives from informa-
Rexhaust gas aftertreatment control unit tion such as:
(only for engines with BlueTec® exhaust Rcharge-air pressure and charge-air temper-
gas aftertreatment) ature
The control units are interconnected by a Rcoolant temperature
CAN line (Controller Area Network line), Rfuel temperature
which facilitates the exchange of all neces-
Roil pressure
sary data.
In addition to the engine and the BlueTec® Start of injection, injection duration and injec-
exhaust gas aftertreatment, the electronic tion quantity are calculated on this basis and
engine control unit also monitors itself. the unit pumps are controlled via the solenoid
Depending on the malfunctions/failures that valve accordingly.
occur, a safety and emergency mode If BlueTec® exhaust gas aftertreatment is
(Y page 8) may be automatically selected. available, the associated sensors are also
For vehicle engines, the electronic engine analysed and the AdBlue®/DEF dosage is
control unit only allows the engine to be star- controlled.
ted when the transmission is in neutral. i To obtain a replacement engine manage-
ment (MR) control unit, you will require all
Engine management control unit (MR) the data on the control unit type plate.
(engine-mounted)
The engine management control unit (MR) is
on the left side of the engine.
At a glance
engine Start/Stop)
Rengine brake switch
Rother systems (e.g. acceleration skid con-
trol)
Rengine management (MR) control unit (e.g.
oil pressure and coolant temperature)
Values for the engine management (MR) con-
trol unit are derived from this and transferred
via the CAN line.
The drive control unit (FR) unit or the adapta-
tion module (ADM) controls devices such as
the electronics warning lamp, the engine
Control unit type plate brake and the constant throttle valve.
: Data record
; Certification no. Exhaust gas aftertreatment control unit
= Engine number (on the frame)
? Equipment code
Rcombination sensor for level and tempera- only operate the engine/vehicle/equipment
ture in the AdBlue®/DEF tank with the reducing agent AdBlue®. AdBlue® is
Rcombination sensor for humidity and intake not refilled as part of the maintenance work.
At a glance
At a glance
Symbol1 Reason for display/displayed message
; Malfunction Impermissible operating conditions
Text in the engine lamp
symbol: "CHECK"
; Stop lamp Severe fault2
Text in the engine
symbol: "STOP"
k Malfunction in Lights up in the event of an electronic engine con-
the electronic trol unit malfunction. Engine may only be operated
engine control in emergency mode.
unit
# Charge current Lights up in the event of a charge current (power
(power genera- generation) malfunction.
tion) The alternator or poly-V-belt is faulty if:
Rthe indicator lamp does not go out when the
engine is started.
Rthe indicator lamp lights up while the engine is
running.
% Cold-start aid Lights up if the cold-start aid is active.
Continuous brake
If increased braking power is required, the
engine can be equipped with a brake valve
downstream from the exhaust gas turbo-
charger in conjunction with constant throttle
valves.
exhaust port. This brings about the desired X To activate the cold-start aid: turn the
decompression during the power stroke. vehicle key to the drive position in the igni-
When the engine brake is activated, the con- tion lock.
At a glance
stant throttle valves are opened. For The % indicator lamp lights up in the
OM 904/OM 924 engines, the actuation is instrument panel.
pneumatic. For OM 906/OM 926 engines, X After the % indicator lamp goes out,
the actuation is hydraulic. The brake valve on start the engine within 30 seconds.
the exhaust gas turbocharger is also closed.
The cold-start aid is automatically deactiva-
The engine brake is activated by the drive ted if:
control system (FR) control unit or adaptation
Rthe engine is not started within
module (ADM) control unit (Y page 23).
30 seconds of the % indicator lamp
The engine brake is always deactivated below
going out.
900 rpm. This prevents the engine from stall-
Rthe engine is started when the % indi-
ing. The engine brake is automatically deac-
tivated even if the position sensor (e.g. accel- cator lamp is lit.
erator pedal) is in use. Rthe coolant temperature reaches around
0 † while the engine is running.
i In emergency mode (constant engine
speed), the engine brake can only be acti- At a coolant temperature above approx-
vated in overrun mode at increased engine imately -4 †, the % indicator lamp goes
speed. Once the constant engine speed is out after approximately 2 seconds (function
reached, the engine brake is automatically check). At a coolant temperature below
deactivated again. approximately -4 †, the % indicator lamp
goes out after approximately 20 seconds.
Have the cold-start aid checked and repaired
Cold-start aid only at a qualified specialist workshop.
Mercedes-Benz recommends that you use a
The cold-start aid makes it easier to start the Mercedes-Benz or MTU Service Centre for
engine at low outside temperatures (below this purpose (Y page 11). Work relevant to
-15 †); it is activated when the outside tem- safety or on safety-related systems must be
perature falls below -4 †. carried out at a qualified specialist workshop.
H Environmental note
At outside temperatures below approximately
Ò4 †, the cold-start aid minimises pollutant
emissions (after the engine is started). In addi-
tion, it reduces the load on the starter motor
and batteries and enables the engine to be
started more rapidly. For this reason, only
start the engine once the % indicator lamp
in the status area of the on-board computer
has gone out.
Z
28
29
Safety
30 Organisational measures
adhered to.
G WARNING
Safety precautions Incorrectly executed maintenance and repair
ROnly start the engine when the batteries work on the engine can reduce its functional-
are firmly attached. ity and safety and consequently lead to acci-
RDo not disconnect the batteries when the
dents causing personal injury.
engine is running. Always have any work on or modifications to
RDo not use a rapid charger to start the
the engine carried out at a qualified specialist
workshop.
engine.
ROnly perform the jump-starting proce- The engine should only be operated, main-
dure with separate batteries. tained and repaired by trained personnel who
RNote, the battery terminals must be dis- have been briefed and authorised by the oper-
connected when rapid charging the bat- ator. The prescribed minimum legal age for
teries. personnel carrying out maintenance and
RObserve the operating instructions of the repair work must be observed.
rapid battery charger.
RPlease note, when carrying out electric Organisational measures
welding work, that the batteries must be
disconnected and both of the cables ("+" The responsibilities for operation, mainte-
and "-") must be firmly attached to each nance and repairs are to be determined by the
other. operator. Give the Operating Instructions and
RThe control unit connectors may only be the Maintenance Booklet to the personnel
connected/disconnected when the elec- that are charged with operating or carrying
trical system is switched off. out work on the engine.
RIncorrect control unit-power supply
polarity (e.g. by connecting up the bat- G WARNING
teries incorrectly) can cause irreparable Before operating the engine, please read
damage to the control units. these Operating Instructions. Please also first
RTighten diesel injection system connec-
read the operating instructions of the vehicle
or the machine to which the engine is fitted.
tions to the prescribed tightening torque.
You may not recognise dangers and may
RIftemperatures above 80 † are to be injure yourself or others.
expected (e.g. in a drying oven), the con-
trol unit on the engine must be removed. Instruct personnel on how to operate the
ROnly use the appropriate testing probes engine using the Operating Instructions.
when taking measurements from electri- When doing so, put special emphasis on
cal connectors (e.g. a Mercedes-Benz safety-relevant information. This is particu-
connection set). Telephones and two- larly important for personnel that only work
way radio devices that are not connected occasionally on the engine.
to an external aerial, can cause malfunc-
Organisational measures 31
Safety
other binding regulations on accident preven-
tion and environmental protection must be
adhered to.
Z
32
33
Operation ............................................. 34
Continuous brake ................................ 41
Driving tips .......................................... 42
Refuelling ............................................. 43
Winter operation ................................. 45
X Check the engine for leaks. the coolant expansion tank are pressurised
X Check all hose fittings, hose clamps and when the engine is at normal operating tem-
pipe connections on the engine, as well as perature. Wear gloves and eye protection.
the oil feed and return on the exhaust gas Only open the coolant expansion tank when
turbocharger, for leaks and correct seating. the coolant temperature is below 50 †.
X Approximately five to ten minutes after
switching off the engine, check the engine G WARNING
oil level (Y page 34). Coolant contains glycol and is therefore toxic.
Driving mode/working mode
X Check the seating of the bracket secured Do not swallow the coolant. See a doctor
to the engine. immediately if you swallow coolant.
X Check the tightness of bolts on the exhaust Make sure that coolant does not come into
manifold, engine mountings, coolant pump, contact with skin, eyes or clothing. In case of
starter motor and air compressor. contact with eyes, rinse immediately with
plenty of clean water. Clean affected areas of
Starting the engine skin and clothing with soap and water imme-
diately. Change any affected clothing imme-
G WARNING diately.
Make sure you do not touch any hot or moving
engine components (e.g. exhaust manifold, Observe the information contained in the
poly-V-belt, fan) when the engine is running. equipment/vehicle operating instructions.
You could injure yourself. X Switch on the ignition.
Be aware of the road and traffic situation X Start the engine using the key in the ignition
when working on public roads and secure lock or the start button on the engine. Do
your position accordingly. not depress the accelerator or clutch pedal
while doing so. For equipment, the neutral
G WARNING position must be engaged.
There is a danger of limbs being caught, pulled The safety functions of the electronic engine
in and thereby crushed or severed by rotating control unit only allow the engine to be star-
engine parts. ted when the transmission is in neutral or
Therefore you should: equipment is not being driven (disengaged).
Rkeep a safe distance between yourself and Starting and stopping the engine with the
rotating engine parts, including when the key
engine is being started. ! After starting the engine, let it run at
Rwait until all engine parts have stopped
engine idling speed until the oil pressure is
moving before carrying out any work on the displayed. If no oil pressure is displayed
engine. after approximately 10 seconds, switch off
Rwear work clothing which is fastened and the engine. Determine the cause. The oper-
close-fitting. Wear a hair net if necessary. ating safety of the engine is jeopardised.
Remove jewellery such as watches and
necklaces.
G WARNING
When opening the coolant expansion tank,
there is a risk of scalding from hot coolant
spraying out. The engine cooling system and
Operation 37
1 Steering wheel unlocked/radio position i The start button will not function if a gear
2 Drive position (ignition) is engaged or the equipment is in an oper-
3 Start position ating position.
X Secure the vehicle/equipment against roll- Engine with one button
ing away.
X Shift the transmission to neutral or engage
neutral on the equipment.
X To start the engine: turn the key in the
ignition lock to drive position 2.
X Vehicles/equipment with a hot-water aux-
iliary heater: preheat the engine at outside
temperatures below −20 † before starting.
X Vehicles/equipment with cold-start aid:
wait until the % indicator lamp in the
instrument cluster goes out. X To start the engine: press Start/Stop but-
X Turn the key to start position 3 in the igni- ton :.
tion lock. Do not depress the accelerator The engine starts and runs at engine idling
pedal whilst doing so. For equipment, keep speed.
the idling function active. X To start the engine and increase the
X When the engine has started, release the engine speed: press and hold Start/Stop
key. button :.
Depending on the vehicle/equipment, the The engine starts and runs at engine idling
idling speed is automatically adjusted to speed. After about three seconds, the
around 600 rpm. Depending on the nature engine speed increases.
of the work to be performed, higher engine
X Hold down Start/Stop button : until the
idling speeds are also possible.
desired engine speed is reached.
X If the engine does not start immedi-
After releasing Start/Stop button :, the
ately: interrupt the starting procedure
engine continues to run at the currently set
after no more than 30 seconds.
X Turn the key in the ignition lock back to the
stop at key position g.
Z
38 Operation
Continuous brake
Z
42 Driving tips
Observe the following notes during the run- mate control, auxiliary heating)
ning-in period up to 2000 km (30 operating
hours): Operating mode
Ravoid subjecting the engine to full load. The operating mode you choose can help to
Rrun in the engine with care, using differing keep fuel consumption down:
speeds and engine revs. Ranticipate road and traffic conditions.
Ravoid high engine revs. Ravoid frequent acceleration and braking.
Rdo not drive at more than ¾ of the maxi- Rstay within the economical engine speed
mum road speed for each gear. range.
Rchange gear in good time. Rif possible, avoid driving in mountainous
Rdo not shift down to brake the vehicle. terrain.
Rfor vehicles with automatic transmission, Rdo not allow the engine to idle when the
do not depress the accelerator pedal vehicle is stationary.
beyond the point of resistance (kickdown). Rdo not drive with unnecessary weight.
only engage the shift ranges 4, 3, 2, or 1 Ravoid frequent cold starts.
when driving slowly. Rif possible, avoid frequent short journeys.
Refuelling 43
Z
44 Refuelling
This will prevent malfunctions in the fuel cleaning agent or other service products
system due to contaminated fuel. or fuels
Rmix in additives
i Regularly check the fuel prefilter with the
Rdilute AdBlue®/DEF
heated water separator for condensation
(Y page 69). Only use AdBlue®/DEF in accordance with
DIN 70070/ISO 22241.
Notify a qualified specialist workshop in the
AdBlue®/DEF event of incorrect filling.
Important safety notes You will find further information on AdBlue®/
DEF in the "Service products" section
G WARNING (Y page 54).
If the AdBlue®/DEF tank cap is opened at high
temperatures, ammonia vapours may escape. H Environmental note
Ammonia vapours have a pungent odour and Dispose of AdBlue®/DEF in an environmen-
particularly irritate: tally responsible manner.
Rskin
Before filling the tank
Rmucous membranes
Reyes X Switch off the engine.
X Secure the vehicle/equipment against roll-
The vapours may cause a burning sensation
in the eyes, nose and throat as well as irrita- ing away.
tion of the throat and watering eyes. X Switch off the auxiliary heating system.
Z
46 Winter operation
The following engine oils are approved: use only engine oils compliant with Sheet
RSheet No. 228.5 / 228.3 / 228.1 standard Nos. 228.5, 228.51, 228.3 and 228.31
quality multi-grade engine oils (Y page 53).
RSheet No. 228.51 / 228.31 low-ash multi- This is also required for a mixture of conven-
grade engine oils tional diesel fuels and FAME fatty acid methyl
RSheet No. 228.0 / 228.2 standard quality
ester fuels (bio-diesel fuel).
single-grade engine oils Multi-grade engine oils compliant with Sheet
RSheet No. 225.6 multi-grade engine oils,
Nos. 228.5, 228.51, 228.3, 228.31 and
228.1 can be used all year round. Depending
initial operation oils
on the fuel quality (fuel sulphur content or
Z
50 Service products
Leave the coolant in the engine all year round Do not exceed 55% by volume (antifreeze pro-
in order to prevent corrosion and to increase tection down to approximately −45 †). Heat
the boiling point. Also do this in countries with dissipation properties are otherwise
hot outside temperatures. impaired.
Check the corrosion inhibitor/antifreeze con- The water in the coolant must meet certain
centration in the coolant every six months. requirements, which are often fulfilled by
Only use approved corrosion inhibitor/anti- drinking water. The water must be treated if
freeze agents. its quality does not meet the required stand-
ards.
Topping up coolant Please note the Mercedes-Benz Specifica-
Only top up with a prepared coolant having an
Switch off the engine and the auxiliary heating Sulphur content in Interval for chang-
before refueling. diesel fuel ing engine oil and
filter
G WARNING
Avoid contact with fuels. Up to 0.3% by weight 100%
(3000 ppm)
It is hazardous to your health if your skin
comes into direct contact with fuels or you From 0.3% by weight 50%
breathe in fuel vapours. (3000 ppm) to 0.8%
by weight
! If you are using drums or canisters to (8000 ppm)
Maintenance and care
Diesel fuels at low temperatures Fatty acid methyl ester (FAME) fuel
At low outside temperatures, paraffin sepa- (bio-diesel)
ration may cause the flow properties of the General notes
diesel fuel to be insufficient.
To prevent operating problems, diesel fuel ! To avoid damage to the assemblies and
with improved flow properties is available in components, observe the following points
the winter months. when using FAME fatty acid methyl ester
fuel:
Winter diesel fuels are reliable down to out-
side temperatures of −22 † in Germany and Rhave the fuel filter and the oil filter
other Central European countries. You can replaced approximately 1000 km after
fuel. Allow the engine to run for at least Observe the specifications in accordance
one hour before switching off the vehi- with Sheet no. 135.0 of the Mercedes-Benz
cle/equipment. Specifications for Service Products for oper-
RMercedes Benz recommends that you do ation with FAME fatty acid methyl ester fuel.
not use FAME fatty acid methyl ester fuel Operating the vehicle with FAME fatty acid
for engines that are not used for long methyl ester fuel results in:
periods of time, e.g. fire engines. Ra slightly higher fuel consumption
Rthe auxiliary heating may only be oper-
Ra slightly reduced engine power output
ated with conventional diesel fuel. Mal- Rincreased white smoke after a cold start
functions may otherwise occur. Conven-
Maintenance and care
Z
56 Cleaning and care
Ensure that AdBlue®/DEF is always pure to Rabout 30 cm with 25° flat-spray jets
avoid malfunctions in BlueTec® exhaust gas Rabout 30 cm with concentrated-power
aftertreatment. jets
If AdBlue®/DEF is pumped from the tank, e.g.
during repairs, do not use this fluid to refill the
! Keep the water jet moving constantly
tank. Otherwise the purity of the fluid would while cleaning. In this way, you will avoid
no longer be guaranteed. causing damage.
Do not point the water jet at:
Relectrical
components
Cleaning and care Rplug connectors
Notes on care Rseals
Rhoses
G WARNING
Always keep care products sealed and out of
the reach of children. Always follow the Cleaning the engine
instructions for the use of the care products.
! Observe the following notes when clean-
Do not use fuel as a cleaning agent. Fuels are
highly flammable and constitute a health haz-
ing the engine. This avoids malfunctions
ard.
and damage to the engine.
RWhen using high-pressure or steam
Regular care helps to maintain the value of cleaners, do not point the spray directly
the engine. at electrical components and electric
Mercedes-Benz recommends that you only cables.
use care products that have been approved RMake sure that no water enters the air
for Mercedes-Benz. You can obtain these intake and ventilation openings.
care products from any Mercedes-Benz or RTreat the engine with preservative
MTU Service Centre (Y page 11). agents after it has been cleaned. When
doing so, protect the belt drive system
from the preservative agent.
High-pressure cleaning ROnly use wax preservative complying
! The exhaust gas aftertreatment system with Sheet No. 385.4 of the Mercedes-
may only be cleaned when it is cool. The Benz specifications for Service Products.
sensors can otherwise be damaged.
Maintenance 57
G WARNING
Maintenance work that is carried out incor-
rectly or not at all, e.g. not changing the oil
filter or not observing maintenance intervals,
can cause engine damage. Engine damage
can lead to an increased risk of accidents.
Therefore, observe the notes on engine main-
tenance in these Operating Instructions.
H Environmental note
If circumstances demand that you have to do
some maintenance work yourself, environ-
mental protection requirements must be
observed. When disposing of service prod-
ucts, e.g. engine oil, you must comply with the
legal requirements. This also applies to all
parts, e.g. filters, that have been in contact
with service products. For vehicles operated
on fatty acid methyl ester FAME, observe the
special instructions on disposing of engine oil.
For more information, visit a qualified special-
ist workshop. Dispose of empty containers,
cleaning cloths and care products in an envi-
ronmentally responsible manner. Observe the
instructions for care products. Do not let the
engine run longer than necessary when sta-
tionary.
Z
58
59
Notes on maintenance
60 Work schedule overview
G WARNING
There is a danger of limbs being caught, pulled in and thereby crushed or severed by rotating
engine parts.
Notes on maintenance
Without BlueTec®
With BlueTec®
Maintenance schedule for maintenance service
Engine: oil and filter change
AP18.00-G-0101DD5Operation with diesel fuel: carry out an oil and filter change • •
at least every two years. If operating using acid methyl ester (bio-diesel):
change the oil and filter at least once a year.
Check and adjust the fluid level
AP20.00-W-2010A Engine cooling system: check corrosion/antifreeze protection. • •
Adjustment subject to a separate invoice. In the event of fluid loss, find the cause
and remedy it. For further information, see the vehicle manufacturer's instructions.
Engine
AP13.22-G-1351DD Check poly-V-belt for wear and damage. • •
Without BlueTec®
With BlueTec®
Additional maintenance work every second maintenance service (Z2)
AP05.30-G-0560DD Check V2 valve clearance, adjust (first maintenance service, • •
3rd, 5th, 7th etc.).
AP14.40-G-1481DD Replace AdBlue®/DEF filter. •
Notes on maintenance
Additional work every third maintenance service (Z3)
AP47.20-G-0730DD Fuel prefilter: clean the filter element. • •
AP47.20-G-0783DD Fuel prefilter with water separator: replace fuel filter. • •
AP47.20-G-0780DD Fuel filter: replace fuel filter element. For operation with FAME • •
fuels (bio-diesel): replace fuel filter at the same time as renewing the engine oil
and replacing the filter.
Engine brake: check condition and setting. • •
Final inspection
Visual check/road test/test rig: check that the equipment is safe to operate/ • •
check that the vehicle is roadworthy.
Without BlueTec®
With BlueTec®
Z
62 Work schedules
Without BlueTec®
With BlueTec®
AP09.00-W-0953A Intake pipe between air filter, charge-air cooler and engine: • •
check for leaks and condition.
AP20.20-W-T052A All reservoirs, covers, bellows, protective caps. • •
AP20.00-W-2050A Heating system: condition check, radiator, lines and hoses. • •
Notes on maintenance
X Unscrew oil filter cap : using a socket X To siphon off engine oil: pull out dip-
spanner insert (SW 36). Allow the oil to stick ;.
drain from the filter housing. X Insert the extractor system into the guide
X Remove oil filter cap : with oil filter ele- tube, using an O-ring to seal it.
ment = and unclip oil filter element = by X Siphon off the engine oil through the guide
pressing in a sideways direction. tube.
X Replace sealing ring ; on cap :.
i Observe the extraction pump operating
X Lightly grease sealing ring ;. instructions.
X Insert new oil filter element = into oil filter
G WARNING
cap : and press until it clips into place.
Hot engine oil escaping under pressure can
X Screw on oil filter cap : with the oil filter
scald your skin and eyes.
element and tighten. Tightening torque:
Notes on maintenance
Wear suitable protective gloves, protective
(Y page 105). clothing and safety goggles.
Example: OM 926 LA
: Filler neck
; Dipstick
Z
64 Work schedules
Example: OM 926 LA
: Filler neck
; Dipstick
: - B Cylinder number
X Add the new engine oil at filler neck :. # Intake valve
Select the SAE viscosity class of engine oil J Exhaust valve
in accordance with outside temperatures.
Engine oil capacity (Y page 104).
C Flywheel side
X Check the oil level (Y page 34)
Special tool
X Start the engine without depressing the
accelerator pedal. When running at idling
speed, observe the oil pressure display.
! Keep the engine running at idling speed
until an oil pressure reading is displayed. If
no oil pressure is displayed after approx-
imately 10 seconds, switch off the engine.
Determine the cause.
X Check the oil filter cap and the drain plug
for leaks.
X Check the engine oil level again after 5
Cranking device 904 589 04 63 00
minutes (Y page 34) and top up the oil if
necessary. Valve adjustment tool 422 589 00 11 00 (no
image)
Valve clearance
Test toler- Inlet +/- 0.05 mm Removing and fitting the cylinder head
ance valves covers
Notes on maintenance
If not properly secured, a vehicle might acci-
dentally be set in motion, knocking somebody
down or trapping them or causing an accident
and injuring you or others.
RAlways prevent the vehicle from rolling Example: cylinder head cover
away by applying the parking brake and, if : Engine ventilation hose
necessary, using chocks. ; Cylinder head cover
RShift the transmission into neutral.
= Bolt
ROnly turn the engine over using the crank-
? Sealing washer
ing device provided for this purpose.
A Seal
The engine becomes very hot while it is run- cover ; and the cylinder head.
ning and remains so for some time after it has
stopped. It will cause burns if touched.
Before starting any work on the engine, allow
all engine parts to cool down, or wear suitable
gloves and items of clothing to protect your-
self from being burned on hot engine compo-
nents.
Z
66 Work schedules
Crankshaft Cylinder/valves to be
position adjusted
1 2 3 4 5 6
Cylinder no. I/ I E I E -
6, valve E
overlap
Cylinder no. - E I E I I/
1, valve E
overlap
Notes on maintenance
I – inlet valve
E – exhaust valve
Example: flywheel inspection hole Adjust all valve clearances at two crankshaft
X Unscrew the cap from the inspection hole positions.
in the flywheel housing. X Use the cranking device to turn the crank-
X Fit cranking device 904 589 04 63 00 shaft until cylinder no. 6 / cylinder no. 4 is
(Y page 64) to the flywheel housing inspec- at TDC valve overlap (cylinder no. 1 at igni-
tion hole. Tightening torque: 25 Nm. tion TDC).
X Check and adjust the valve clearance in
Valve clearance setting accordance with the above table.
Valve clearance setting OM 904/924 LA X Turn cylinder no. 1 to TDC valve overlap
(cylinder no. 6 at ignition TDC).
Crankshaft Cylinder/valves to be
X Check and adjust the valve clearance in
position adjusted
accordance with the above table.
1 2 3 4 5 6
Checking and adjusting the valve clear-
Cylinder no. I/ I E - ance
4, valve E
overlap
Cylinder no. - E I I/
1, valve E
overlap
I – inlet valve
E – exhaust valve
Work schedules 67
X Measure the valve clearance between the RCheck the poly-V-belt condition regu-
rocker arm and the valve bridge using a larly.
feeler gauge (arrow). It should be possible RReplace the poly-V-belt concerned
to pull the feeler gauge through with only immediately if there are any signs of
light resistance. damage.
X Loosen locknut ; to adjust the valve clear-
ance. Adjust the valve clearance by turning Special tool
adjustment screw :.
Cranking device: 904 589 04 63 00
X Retighten locknut ;. Tightening torque (Y page 64).
(Y page 105).
X Check the valve clearance again and cor- Checking the poly-V-belt.
rect.
X Fit the cranking device to the flywheel
Notes on maintenance
Final tasks housing inspection hole. Tightening torque:
X Replace the gaskets on the cylinder head
25 Nm.
covers. X Make a chalk mark on the poly-V-belt.
X Attach the cylinder head covers and tighten X Check the poly-V-belt section by section for
them. Make sure that the apertures in the damage. To do this, turn the engine or poly-
valve cover are aligned centrally over the V-belt gradually using the cranking device
spark plug shafts. Tightening torque until the chalk mark is reached again.
(Y page 105). X Remove the cranking device.
X Remove the cranking device from the fly- X Screw the cap into the inspection hole in
wheel housing inspection hole. the flywheel housing and tighten it. Tight-
X Screw on the cap of the inspection hole of ening torque: 25 Nm.
the flywheel housing and tighten it (tight- X Replace the poly-V-belt:(Y page 95).
ening torque: 25 Nm).
X After fitting, run the engine and check the Patterns of damage
cylinder head cover area for leaks.
! Replace the poly-V-belts if one of the fol-
lowing damage patterns occurs on the poly-
V-belt.
Check the poly-V-belt for wear and
damage
G WARNING
Faulty poly-V-belts can tear, the belt or parts
of it could then be thrown off the engine,
thereby causing injury to others.
RAlways observe the specified maintenance
intervals for poly-V-belts.
RIf damage is detected, replace the poly-V-
belt concerned immediately.
: New condition (for comparison; trapezoi-
! If the poly-V-belt is torn, there is no drive
dal ribs)
to the coolant pump and the alternator. The
; Single-sided wear: wedge-shaped ribs
engine may overheat as a result.
= Cord visible at the base of the belt
Z
68 Work schedules
B Rubber nodules at the base of the belt G Transverse cracks on the back of the belt
C Deposits of dirt and stones H Transverse cracks in several ribs
X Check the poly-V-belt for damage regularly.
Fuel circuit
The following picture shows the arrangement
of the fuel connectors with the fuel filter
mounted on the engine.
Notes on maintenance
: Leakage fuel from the engine X Vehicle with fuel prefilter at tank level:
; To the fuel pump close shutoff valve ?.
= From the fuel tank X Place a collector under water drain valve
? Fuel return line to the fuel tank E.
A Fuel pump X Open water drain valve E and bleed screw
=. Collect the draining water-fuel mixture
while doing so.
Fuel prefilter with water separator: X Unscrew filter element A from filter
replacing the fuel filter head :.
G WARNING X Unscrew water separator D from filter ele-
There is an increased risk of fire when han- ment A and clean or replace as necessary.
dling fuels as they are highly flammable. Avoid X Replace filter element A.
fire, naked flames and sparks, and refrain X Screw water separator D with new sealing
from smoking when handling fuels.
ring C onto filter element A until it is
hand-tight. Lubricate sealing ring C with a
H Environmental note
thin coat of engine oil beforehand.
Dispose of used filter elements, seals and fuel
X Screw filter element A with new sealing
residue in accordance with relevant local reg-
ulations. ring B onto filter head : until it is hand-
tight. Lubricate sealing ring B with a thin
The fuel prefilter is fitted on the equipment or coat of engine oil beforehand.
vehicle. Observe the operating and mainte- X Close water drain valve E.
nance instructions in the equipment/vehicle
X Vehicle with fuel prefilter at tank level:
operating instructions.
open shutoff valve ?.
X Push manual fuel pump ; repeatedly until
the fuel escapes free of bubbles from bleed
screw =.
X Close bleed screw =.
Z
70 Work schedules
X Start the engine and bleed the fuel system. X Clean the outside of the filter housing.
Run the engine for approximately 1 minute. X Open the fuel filler cap to prevent excess
The fuel system is self-bleeding. pressure in the fuel tank.
If the engine stalls or does not start, bleed X Unscrew fuel filter cap : using a socket
the fuel system manually (Y page 86).
spanner insert (SW 36).
X Check the fuel prefilter with water separa-
X Pull fuel filter cap : with filter element
tor for leaks while the engine is running.
= out of the filter housing slightly. Allow
the fuel to drain off.
Replacing the fuel filter element X Remove the cap and filter element. Unclip
the filter element by pressing the sides of
G WARNING the lower edge of the filter element.
There is an increased risk of fire when han-
Notes on maintenance
If the diesel fuel level (fuel tank) is above filter element = (tightening torque:
engine height, the feed line must be blocked 25 Nm).
off during filter replacement. Otherwise, die- X Put on the fuel filler cap and tighten it.
sel can drain out. X Start the engine and bleed the fuel system
(Y page 86).
X Run the engine for approximately 1 minute.
The fuel system is self-bleeding.
If the engine stalls or does not start, bleed
the fuel system manually.
X Check the fuel filter for leaks with the
engine running.
Example: OM 926 LA
Work schedules 71
Ammonia vapours have a pungent odour and ! If AdBlue®/DEF gets into the coolant cir-
particularly irritate: cuit (even minute amounts), thermostats
Rskin
and temperature sensors will be damaged.
RAlways keep AdBlue®/DEF completely
Rmucous membranes
separate from other service products.
Reyes
RDo not use the same containers and fluid
The vapours may cause a burning sensation
collecting pans for AdBlue®/DEF and
in the eyes, nose and throat as well as irrita-
other service products.
tion of the throat and watering eyes.
RDo not continue to use service products
Avoid inhaling ammonia vapours.
that contain traces of AdBlue®/DEF.
G WARNING ! Individual components of the BlueTec®
AdBlue®/DEF must not come into contact system react very sensitively to even the
Notes on maintenance
with skin, eyes or clothing. slightest trace of impurities in AdBlue®/
DEF.
RIf AdBlue®/DEF comes into contact with
ROnly use containers and fluid collecting
your eyes or skin, rinse affected areas with
clean water immediately. pans that are clean and suitable for
AdBlue®/DEF.
RIf AdBlue®/DEF is swallowed, immediately
RDo not continue to use AdBlue®/DEF
rinse your mouth out with a lot of clean
water and drink plenty of water. which contains traces of impurities.
RChange clothing that is soiled with
AdBlue®/DEF immediately. Fire fighting measures
RIf allergic reactions occur, consult a doctor AdBlue®/DEF is not flammable. In the event
immediately. of a fire, NH3 (ammonia) may be released.
Keep AdBlue®/DEF out of the reach of chil- This may result in a risk of poisoning. Meas-
dren. ures to extinguish a fire must therefore be
adapted to suit the surroundings.
G WARNING H Environmental note
The AdBlue®/DEF lines and all connected
Disposing of AdBlue®/DEF:
components are pressurised during operation
RDue to its easy degradability, small
and could be hot, even after the engine has
been switched off. There is a risk of burns. amounts of spilt AdBlue®/DEF can be
When opening the pressurised system, there washed into the sewage system without
is a risk of scalding due to hot AdBlue®/DEF any problems.
spraying out. RLarger amounts of AdBlue®/DEF must be
RWait at least 5 minutes after switching off disposed of correctly, observing the regu-
the engine before starting work on the lations on waste treatment/disposal.
exhaust gas aftertreatment system. RPackaging that is contaminated with
ROpen line connections and caps on system AdBlue®/DEF residue must be treated in
components slowly. Cover the area that the same way as AdBlue®. Packaging
you are disconnecting with a cloth. should be emptied as thoroughly as possi-
RWear suitable protective gloves, protective ble, cleaned appropriately and then recy-
clothing and safety goggles. cled.
Z
72 Work schedules
G WARNING
Hose clamp 000 589 54 37 00 AdBlue®/DEF must not come into contact
X Clamp the feed and return lines on the with skin, eyes or clothing.
pump/filter unit using hose clamps. RIf AdBlue®/DEF comes into contact with
X Place a suitable receptacle under the your eyes or skin, rinse affected areas with
pump/filter unit to collect any AdBlue®/ clean water immediately.
DEF fluid that escapes. RIf AdBlue®/DEF is swallowed, immediately
X Unscrew filter bowl ? from the pump/fil- rinse your mouth out with a lot of clean
ter unit. water and drink plenty of water.
X Remove filter element ;. RChange clothing that is soiled with
X Smear O-ring = on new filter element ; AdBlue®/DEF immediately.
thinly with MB silicon grease before assem- RIf allergic reactions occur, consult a doctor
bly. immediately.
Work schedules 73
Keep AdBlue®/DEF out of the reach of chil- ing hose is disconnected from the valve, a
dren. pressure loss of 0.2 bar takes place.
X To reduce the pressure: press but-
H Environmental note ton ; several times.
Dispose of AdBlue®/DEF in an environmen- X Only if the pump module or the pressure
tally responsible manner. reservoir was not replaced: check the
pressure: if the pressure was increased, it
You will find further information on AdBlue®/ must be tested again after at least
DEF in the "Service products" section 5 minutes.
(Y page 54). To do this, check the pressure as described
above.
If the drop in pressure is only approximately
0.2 bar, the pressure reservoir is OK.
Notes on maintenance
If a greater pressure loss is apparent, the
pressure reservoir must be replaced.
X If the pressure reservoir is OK:
Equalise the pressure loss.
X Screw the dust protection cap onto the
valve of the pressure reservoir.
Z
74 Work schedules
G WARNING
Throttle valve lever in operating position Coolant contains glycol and is therefore toxic.
X Remove the wire circlip from the ball socket Do not swallow the coolant. See a doctor
of the engine brake cylinder. immediately if you swallow coolant.
X Press the ball socket off the ball coupling Make sure that coolant does not come into
of throttle valve lever :. contact with skin, eyes or clothing. In case of
X Check the engine brake cylinder, ball cou-
contact with eyes, rinse immediately with
plenty of clean water. Clean affected areas of
pling, ball socket and the throttle valve
skin and clothing with soap and water imme-
shaft for wear.
diately. Change any affected clothing imme-
X Check the seating of the throttle valve lever
diately.
on the throttle valve shaft and retighten the
clamp screw if necessary. Only check the coolant level when the coolant
X Lubricate the ball socket with heat-resist-
temperature is under 50 †. Check the anti-
ant lubricant (part number A000 989 76 freeze/corrosion inhibitor concentration
51). before correcting the coolant level. Only top
up with a prepared coolant having an anti-
X Press the ball socket back onto the ball
freeze/corrosion inhibitor concentration of
coupling, fit the wire circlip. 50% by volume.
X When the engine brake is applied, throttle
Before topping up, check the quality of the
valve lever : must rest on bracket ; in antifreeze/corrosion inhibitor (Sheet. No.) in
the working position (cylinder extended). the cooling system. Corrosion/antifreeze
The throttle valve lever must also rest on additives compliant with Sheet 325.3 and
the bracket when the engine brake cylinder 326.3 must not be mixed with those of Sheet
is in the rest position (cylinder retracted). 325.0/2 or 326.0/2. Only top up with corro-
If this is the case, the return spring preten- sion inhibitor/antifreeze agent of the same
sion of the engine brake cylinder is suffi- quality grade (Y page 50). This helps to pre-
cient. vent damage to the engine.
X Check the position of the throttle valve X Open the engine cooling system cap slowly,
shaft: when the engine brake is in the rest relieving the excess pressure.
position, the notch must be horizontal. In X Check the antifreeze/corrosion inhibitor
the working position, the notch must be concentration using a testing device. The
vertical.
Work schedules 75
correct concentration of 50% antifreeze/ X Mount pressure tester tool : on the filler
corrosion inhibitor by volume in the coolant neck of the coolant expansion tank.
provides antifreeze protection down to X Connect the compressed-air hose with tyre
Ò37 †. If a lower level of antifreeze protec- inflation connection to pressure tester
tion is indicated, correct the mixture ratio. tool : and set it to a test pressure of
! If the concentration of antifreeze/corro- 1.0 bar.
sion inhibitor is too low, there is a risk of The test pressure should correspond to the
engine damage as a result of corrosion/ value at which the cooling system pressure
cavitation in the cooling system. relief valve opens. The release pressure can
be determined from the value on the cap or
Avoid concentrations greater than pressure relief valve.
55% by volume corrosion inhibitor/antifreeze
agent. Otherwise, the maximum antifreeze Example: code 100 = 1.0 bar excess pres-
sure.
Notes on maintenance
protection down to Ò45 † will not be attained.
X After about 5 - 10 minutes, read the man-
Heat dissipation and antifreeze protection
deteriorate at higher concentrations. ometer on tester : to check for pressure
loss. After 5 - 10 minutes, there must be no
X To check the coolant level: the cooling
drop in pressure detected on the manom-
system is filled correctly if the coolant is
eter. Do not exceed the test pressure and
level with the mark in the filler neck.
the test time, as this may damage the cool-
ing and heating system.
If the cooling system/heating system is
Cooling and heating system – condi- leaking, this will become apparent due to a
tion check of radiator, lines and hoses drop in pressure, indicated by the manom-
eter on tester :.
X If there is a loss of pressure in the cooling
system leading to visible loss of coolant,
have the leak in the cooling or heating sys-
tem repaired.
X If there is a pressure drop with no visible
loss of coolant: have the cause identified
and immediately rectified by a qualified
specialist workshop.
X Release the pressure using pressure tester
Special tool: pressure tester tool tool : and remove pressure tester
X
tool : from the coolant expansion tank
Heating systems: open all control valves
and shutoff valves for the heating system. filler neck.
X Check the coolant level and correct if nec-
X Remove the coolant expansion tank cap.
essary.
X Check the coolant level and top up if nec-
X Replace coolant expansion tank cap and
essary.
tighten it.
X Check/correct the coolant antifreeze pro-
tection content.
X Rub dry the inside of coolant filler
neck ; with a lint-free cloth.
Z
76 Work schedules
G WARNING
Notes on maintenance
If the cooling system is heavily contamina- plenty of clean water. Clean affected areas of
ted, flush it thoroughly before refilling. skin and clothing with soap and water imme-
diately. Change any affected clothing imme-
Topping up the coolant diately.
X Add coolant.
H Environmental note
X Start the engine and run it at varying
Collect used coolant, cleaning solutions and
speeds for approximately 1 minute.
detergents and dispose of them in an envi-
X Add coolant mixed to the prescribed ratio
ronmentally responsible manner in accord-
until it reaches the lower edge of the filler ance with applicable local regulations.
neck.
X Switch off the engine and seal the cooling X Remove foreign objects (dust, insects, etc.)
system again. from the radiator core fins. You can do this
Notes on maintenance
Observe any further information in the Oper- by blowing them out with compressed air
ating Instructions from the equipment/vehi- or by spraying water from the rear side of
cle manufacturer. the radiator, for example.
Z
78 Work schedules
G WARNING
The engine becomes very hot while it is run-
ning and remains so for some time after it has
stopped. It will cause burns if touched.
Before starting any work on the engine, allow
all engine parts to cool down, or wear suitable
gloves and items of clothing to protect your-
self from being burned on hot engine compo-
nents.
79
RFuel prefilter with heated water separator: RCheck that the electrical system, steering
drain off the water separator. system and brakes are functioning cor-
RRecharge the batteries every three months. rectly.
Check the battery fluid levels before and RClean the engine/vehicle/equipment thor-
after charging. oughly.
RChange the engine oil and oil filter every
24 months.
Measures prior to decommissioning: Protecting the engine
REmpty the fuel tank and fill up with new fuel.
Engine protective treatment applies to all fit-
When disposing of fuels, observe the rele- ted and removed vehicle, industrial and fixed
vant national laws and regulations. installation engines as well as new engines,
RFuel prefilter with heated water separator: reconditioned engines and short engines.
replace filter element. Engines that have been removed must be pro-
RReplace fuel filter. tected against moisture (rain or spray water)
using special measures.
RClose off all openings on the engine (e.g. X Detach the charge-air distributor from the
on the charge-air distributor, exhaust etc.) cylinder heads.
with an oil-soaked rag. X Briefly press the start button on the engine.
RDrain off the coolant completely for At the same time, pour approximately
engines that have been removed. Unscrew 15 to 20 cm3 of initial operation oil into
the coolant drain plug on the crankcase to each cylinder.
do so. When screwing in the coolant drain
plug, observe the tightening torque. Carrying out protective measures for
RRelieve the tension in the poly-V-belt. The the air compressor
poly-V-belt can remain in place.
RIf the engine has been filled with coolant,
Carry out the protection of the air compressor
at the same time as the combustion chamber
the engine cooling system must first be fil-
protection.
led with water. It must then be filled with a
mixture of water and improver compliant X On the air intake side of the compressor,
with Sheet No. 311.0. Coolant without anti- pour a maximum of 5 cm3 of initial opera-
tion oil compliant with Sheet No. 225.6 into
Decommission and protection
Carrying out protective measures for Protective treatment for longer than
the fuel system 36 months
X Start the engine and allow it to run for For protective treatment for periods exceed-
15 - 30 minutes at approximately ing 36 months, repeat the protection meas-
900 rpm. ures as in "Protective treatment for 12 to
X Completely fill the fuel tank with diesel fuel.
36 months".
X Drain off engine oil that has been added.
Carrying out protective measures for The oil filter does not have to be replaced.
the combustion chambers
Only carry out protective measures for the Shipping by sea or engine protective
combustion chambers when the engine is treatment in tropical countries
cold (coolant temperature under 50 †).
Only use initial operation oil compliant with Carry out all measures in "Protective treat-
Sheet no. 225.6 for the protection of the ment for 12 to 36 months".
combustion chambers.
Protecting the engine 83
The following work is required for engines X New engines: add initial operation oil com-
that have already been in operation (distance pliant with Sheet No. 225.6.
of over 300 km or running time of over 6 X For engines that have already been in oper-
operating hours): ation (distance over 300 km or running time
X Drain off engine oil and replace the oil filter. of over 6 operating hours): before starting
Add initial operation oil compliant with the engine, lubricate the lubrication points
Sheet No. 225.6. on the engine as necessary, e.g. the ball
X Fill or top up the engine cooling system with couplings of the engine brake.
the specified coolant. Before refilling cool- X Start the engine and leave it running until
ant, note the quality of the previously filled it is at operating temperature (coolant tem-
anticorrosion/antifreeze (Y page 50). perature approximately 75 to 95 †). While
X Carry out protective measures for the fuel doing so, observe the indicators for oil pres-
system. sure, coolant temperature and oil temper-
ature.
X Warm up the engine at medium engine
speeds and allow it to run for approximately
Re-commissioning
X Remove all plugs or rags that have been fit-
ted.
X Fit removed engines and connect all
cables, hoses and lines.
X Remove protective agents and greases
from all protected areas, such as the fly-
wheel, pulley keyway etc.
X Tension the poly-V-belt as per the regula-
tions.
X Renew the engine oil and replace the oil fil-
ter before re-commissioning.
X Add coolant. Observe the concentration of
anticorrosion/antifreeze additives. Before
refilling coolant, note the quality of the pre-
viously filled anticorrosion/antifreeze
(Y page 50).
84
85
Breakdown assistance
ning mode ............................................ 87
Troubleshooting .................................. 89
BlueTec® exhaust gas aftertreat-
ment indicator (on-highway ver-
sion) ..................................................... 94
BlueTec® exhaust gas aftertreat-
ment indicator lamp (off-highway
version) ................................................ 95
Replacing the poly-V-belt ................... 95
86 Bleeding the fuel system
Breakdown assistance
X Close water release valve B.
X On vehicles with fuel prefilter at tank level:
open shutoff valve =.
X Start the engine and allow it to run for about
one minute.
The fuel system is bled automatically.
X Check the fuel system for leaks.
Example: indicator lamp malfunction
The engine is equipped with an electronic
Bleeding the fuel prefilter using the
management system that monitors both the
manual fuel pump
engine and itself (self-diagnostic system).
The fuel prefilter must only be bled when: The k indicator lamp lights up in the event
Rthe fuel tank is empty or of a malfunction. Error messages can be dis-
Rthe fuel filter has been replaced. played as code or text in the display, depend-
X Unscrew the fuel tank filler cap.
ing on the vehicle's display format.
X Place the collector underneath the fuel pre-
After a malfunction, the engine can be acti-
filter. vated again in emergency mode with a limited
constant engine speed. In engine emergency
X Open shutoff valve = fully.
running mode, the accelerator pedal is not
X Open bleed nipple ;. operational and the engine speed is limited to
X Only press manual fuel pump : until the approximately 1300 rpm.
fuel escaping from bleed nipple ; is free X To activate engine emergency running
of bubbles. Do not continue to pump. mode: stop the vehicle, paying attention to
X Close bleed nipple ;. the road and traffic conditions.
X Close the fuel tank filler cap. X Engage the parking brake.
The fuel system is bled automatically. X Restart the engine after approximately
10 seconds.
! Do not continue to press the fuel hand
pump after the engine has started. This i STAR DIAGNOSIS or minidiag2 diagnostic
could otherwise damage the hand pump. equipment can be connected to the 14-pin
diagnostic socket or by using the EU-com-
pliant service connector. The fault memory
Activating engine emergency running and engine data can be read out using this
mode diagnostic equipment. Information is avail-
able from any Mercedes-Benz or MTU
Emergency mode for on-highway Service Centre (Y page 11).
applications
Emergency mode can be activated for road
vehicles with Euro 4/5 certified engines (on-
highway engines).
Z
88 Activating engine emergency running mode
Troubleshooting
Engine problems
G WARNING
Breakdown assistance
The operating safety of your vehicle could be affected if maintenance work is carried out incor-
rectly. You could lose control of the vehicle and cause an accident. The safety systems may also
no longer be able to protect you or others as they are designed to do.
Always have maintenance work carried out at a qualified specialist workshop.
Apart from careful operation and maintenance of the engine it is also important that malfunc-
tions be rectified in good time. You can rectify certain faults yourself.
Have malfunctions that you cannot eliminate yourself rectified at a qualified specialist work-
shop.
Problem Possible causes/consequences and M Solutions
The drive pinion does The battery is not sufficiently charged.
not turn or turns too X Charge the battery.
slowly.
The connecting cable to the starter motor is loose.
X Tighten the cable on the terminal. If necessary, solder on a new
terminal.
Z
90 Troubleshooting
(Y page 49).
The engine does not There is a malfunction in the engine control unit.
start correctly. X Read out the MR (engine control) unit; have it checked at a
qualified specialist workshop.
The engine stops inad- The MR (engine control) unit is faulty (total failure).
vertently. X Consult a qualified specialist workshop.
The engine is in emer- There is an interruption to the MR/ADM control unit's data flow.
gency running mode. X Read out the control unit's fault memory.
X Have it checked at a qualified specialist workshop.
The engine surges, The crankshaft position sensor or camshaft position sensor (on
vibrates or runs irregu- the camshaft gear) is faulty or is not emitting a signal.
larly. X Consult a qualified specialist workshop.
Breakdown assistance
fan speed.
X The thermostat is malfunctioning: consult a qualified specialist
workshop.
There is an interruption There is an increased voltage drop to the MR/ADM control unit
in the tractive power. (loose contact).
X Check the battery terminals and the connectors on the MR/
ADM control unit for secure seating and corrosion.
The engine braking There is an engine brake flap malfunction or a fault in the actua-
effect is poor. tion.
X Carry out a function check/visual check.
X Consult a qualified specialist workshop.
Z
92 Troubleshooting
The engine cuts off too The engine management (MR) control unit is faulty or parametr-
early (maximum engine ised incorrectly.
speed cannot be X Consult a qualified specialist workshop.
reached).
The engine gets too hot There is not enough coolant in the cooling system.
(according to the cool- X Top up, bleed (Y page 77).
ant temperature
gauge). The coolant temperature sensor or display is faulty.
X Replace the sensor or display.
The radiator is dirty on the inside; the radiator is very dirty on the
outside.
X Clean the radiator.
The charge current indi- The lamp is faulty or the supply line is interrupted.
cator lamp does not X Replace the lamp or repair the break in the cable.
light up while the
engine is not running.
Breakdown assistance
The engine brake is faulty.
X Consult a qualified specialist workshop.
The exhaust fumes are The oil level in the engine is too high; the crankcase ventilation
blue. system is faulty; engine oil has entered the combustion chamber.
X Adjust the oil level correctly.
X Have the crankcase ventilation system checked at a qualified
specialist workshop.
There are abnormal The intake pipe and exhaust pipe are leaking, causing a whistling
sounds. noise.
X Rectify the cause of the leak and, if necessary, replace gaskets.
Z
94 BlueTec® exhaust gas aftertreatment indicator (on-highway version)
G WARNING
Breakdown assistance
The operating safety of your vehicle could be affected if maintenance work is carried out incor-
rectly. You could lose control of the vehicle and cause an accident. The safety systems may also
no longer be able to protect you or others as they are designed to do.
Always have maintenance work carried out at a qualified specialist workshop.
6 The engine output is not reduced in the case of emergency vehicles, e.g. fire engines.
Replacing the poly-V-belt 95
Breakdown assistance
Problem System message
AdBlue®/DEF level low The å AdBlue®/DEF indicator lamp lights up.
®
AdBlue /DEF quality not OK
AdBlue®/DEF level too low, no sup- RThe å AdBlue®/DEF indicator lamp flashes.
ply RThe È torque limitation indicator lamp lights
AdBlue®/DEF quality not OK for a up.
long time RBeginning of operating restriction.
AdBlue®/DEF level too low, supply RThe å AdBlue®/DEF indicator lamp flashes.
not sustainable RThe È torque limitation indicator lamp lights up
AdBlue®/DEF quality not sustainable at the beginning of operating restriction.
RThe È torque limitation indicator lamp flashes
in the event of permanent operating restriction
and a low torque value prior to tightening.
Detection of: Problem is detected:
RAdBlue®/DEF level sensor discon- RThe å AdBlue®/DEF indicator lamp lights up.
nected RThe ! indicator lamp lights up.
RAdBlue®/DEF metering line or
Problem continues for a long time:
metering valve disconnected
RThe å AdBlue®/DEF indicator lamp flashes.
RAdBlue®/DEF metering line or
RThe ! indicator lamp lights up.
metering valve blocked
RThe È torque limitation indicator lamp lights up
RAdBlue®/DEF metering pump dis-
connected at the beginning of operating restriction.
RThe È torque limitation indicator lamp lights up
RSCR cable set disconnected
RNOx sensor disconnected
during active operating restriction.
RAdBlue®/DEF temperature sensor
Problem is continuous:
RThe å AdBlue®/DEF indicator lamp flashes.
disconnected
RExhaust gas temperature sensor R The ! indicator lamp lights up.
disconnected RThe È torque limitation indicator lamp lights up
at the beginning of torque limitation.
RThe È torque limitation indicator lamp flashes
in the event of permanent operating restriction
and a low torque value prior to tightening.
Belt profiles
Fitting/removing poly-V-belts
Poly-V-belt routing (engine with refrigerant com-
pressor)
: Alternator
; Tensioning pulley
= Coolant pump
? Refrigerant compressor
A Guide pulley
B Crankshaft
Breakdown assistance
leys except the tensioning pulley (observe
the poly-V-belt routing shown in the illus-
tration).
X Swing the tensioning pulley up using the
lever, lay the poly-V-belt over the tension-
ing pulley and allow the tensioning pulley
to swing back.
X Remove the spanner and check for correct
seating of the poly-V-belt on the belt pul-
leys.
Z
98
99
Technical data
100 Engine data card
OM 9XX L A
Information on the engine data plate OM Oil engine (die-
sel)
The following data is contained on the engine
data plate in the form of numbers stamped 9XX Engine type
directly onto the crankcase:
L Intercooler
A Exhaust gas tur-
bocharger
Dimensions
Technical data
Engine data card
The engine data card describes the scope of Example: engine length
delivery from the Mercedes-Benz factory.
Later changes to the scope of delivery are not
recorded on the data card.
Conversion parts on the engine which change
the scope of the engine delivered by
Mercedes-Benz must be recorded on the data
card.
In order to prevent incorrect ordering of
replacement parts, the Mercedes-Benz
replacement parts service must also be
informed.
Engine data
Dimensions and weights
All data refers to the standard version of the Example: engine width and height
respective engine type. Deviations may
occur, depending on the installation situation OM 904 LA OM 906 LA
in the vehicle/equipment. OM 924 LA OM 926 LA
A = engine 830 mm 1078 mm
length
B = engine 645 mm 645 mm
width
C = engine 925 mm 940 mm
height
102 Engine data
Weights
OM 904 LA OM 906 LA
OM 924 LA OM 926 LA
Dry engine 395 kg 530 kg
maximum
Wet engine 420 kg 573 kg
maximum
Technical data
Engine data 103
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 OM 904 LA OM 906 LA
OM 924 LA OM 926 LA
Assembly model series 904.9 906.9
924.9 926.9
Type Turbocharged in-line engine with intercooler
Technical data
Combustion principle 4-stroke direct injection diesel
Number of cylinders 4 6
Bore 102 mm 102 mm
106 mm 106 mm
Stroke 130 mm 130 mm
136 mm 136 mm
Engine capacity 4250 cm3 6370 cm3
4800 cm3 7200 cm3
Type of cooling system Forced circulation cooling
Engine, direction of Anti-clockwise (when looking at the flywheel)
rotation
Valve clear- Intake valve 0.40 mm 0.40 mm
ance
Exhaust valve 0.60 mm 0.60 mm
Starter Starter Electric Electric
motor
Voltage 24 V 24 V
Output 4.0 kW 4.0 kW
Battery Voltage 12 V/24 V 12 V/24 V
Cold-discharge test Maximum 450 A Maximum 450 A
current
Cold start ability Down to maximum Ò20 † (battery charge level
75%)
Alternator Voltage 28 V 28 V
Amperage 80 A 80 A
104 Engine data
Operating data
running mode)
Oil pres- At idling speed Minimum 0.5 bar Minimum 0.5 bar
sure
At nominal engine Minimum 2.5 bar Minimum 2.5 bar
speed
Coolant Normal operation Approximately 80-95 † Approximately 80-95 †
tempera-
ture Maximum permissi- 100 † 100 †
ble coolant tempera-
ture
Capacities
Technical data
agent volume
down to –37 °C
Corrosion inhib- OM 904/924 LA 4.7 l
itor/antifreeze OM 906/926 LA 6.9 l
volume
down to –45 °C
Coolant additive OM 904/924 LA 0.11 l Coolant additive
(coolant without OM 906/926 LA 0.16 l (310.1, 312.0)
antifreeze pro-
tection)
Engine com- Protective wax - Wax preservative
partment (385.4)
Engine Heat-resistant lubricant - Heat-resistant lubricant
brake (part number A000 989
76 51)
Tightening torques
All threads on mechanical components and the corresponding contact surfaces must be clean,
smooth and coated with engine oil. Other lubricants lead to substantially different tightening
torques.
Engine Cylinder head cover Light alloy (with oil filler cap) 25 Nm
Plastic (without oil filler cap) 20 Nm
Valve clearance setting Counternut to the rocker arm 50 Nm
adjustment screw
Inspection hole cap on the timing case 25 Nm
Flywheel housing rotation device 25 Nm
Charge-air distributor at cylinder head 30 Nm
Fuel system Cap on the fuel filter housing 25 Nm
7 MB Specifications for Service Products.
106 Engine data
Documentation team
As at 19.04.2012
É9265842181fËÍ
9265842181
Order no. 6462 9827 02 Part no. 926 584 21 81 Edition B 06-12