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Maintenance

Introduction

G

WARNING

Before carrying out maintenance or repair
work, you must read the relevant sections of
the technical documentation relating to main-
tenance and repair measures, e.g. the Oper-
ating Instructions and workshop information.
In particular, first familiarise yourself with the
legal regulations, e.g. work safety and acci-
dent prevention regulations.
You could otherwise fail to recognise dangers
and injure yourself or others.
Always have maintenance work carried out at
a qualified specialist workshop.

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.

i

All maintenance work and maintenance

intervals refer to genuine Mercedes-Benz
parts and accessories that have been
expressly approved for the engine by
Mercedes Benz.

The scope of maintenance and frequency of
maintenance work depend on the different
operating conditions and are listed in the
Maintenance Booklet.
Have any work that is carried out confirmed
with an entry in the Maintenance Booklet.
This proof of regular maintenance is always
required for any warranty claims.
Please also observe the maintenance instruc-
tions for special accessories.

Maintenance

57

Maintenance and care

Z

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Содержание OM 904 LA

Страница 1: ...OM 904 926 LA BlueTec OM 904 926 LA Operating Instructions...

Страница 2: ...Symbols Warning Environmental note Possible vehicle equipment dam age i Tip X Instructions YY Continuation symbol Y page Page reference...

Страница 3: ...ipment 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 Bookle...

Страница 4: ......

Страница 5: ...x 4 Introduction 7 At a glance 13 Safety 29 Driving mode working mode 33 Maintenance and care 47 Notes on maintenance 59 Decommission and protection 79 Breakdown assistance 85 Technical data 99 Conten...

Страница 6: ...ping up 35 77 Coolant additive 50 Cooling system Degreasing 77 Flushing 77 Correct use 9 Corrosion inhibitor antifreeze agent 50 Cranking device 64 D Data card 100 Decommissioning 81 Decommissioning t...

Страница 7: ...l Additives 53 Consumption 42 Diesel 51 FAME fatty acid methyl ester fuel 53 Refuelling 43 Sulphur content table 52 Fuel filter 68 Fuel grade 52 Fuel prefilter Draining 86 Replacing 69 Fuel system Aut...

Страница 8: ...s 30 SCR frame module see Exhaust gas aftertreatment control unit Service products AdBlue DEF 54 Coolant 50 DEF AdBlue 54 Diesel fuel 51 Disposal 48 Disposing of AdBlue DEF 55 Engine oil 48 FAME fatty...

Страница 9: ...sed by improper use of the engine Therefore please follow the engine operating instructions included in the Owner s Manual G WARNING Faulty or incomplete maintenance work as well as disregarded mainte...

Страница 10: ...lug according to the EU Directive Both the fault memory as well as stored engine data can be read out using this equipment Example electronics warning lamp Genuine Mercedes Benz parts Make sure of the...

Страница 11: ...or exhaust gas aftertreatment system You can find details in the Engine diagnostics indicator lamp section Y page 94 Fault detected in the monitoring system If the monitoring system detects a fault in...

Страница 12: ...MTU Service Centres is available to carry out maintenance work Mercedes Benz and MTU Service Centres Rhave special equipment and tools as well as specialists who receive continuous training Rguarante...

Страница 13: ...nz or MTU Service Centre for further information Qualified specialist workshop A qualified specialist workshop has the nec essary specialist knowledge tools and quali fications to carry out the work r...

Страница 14: ...12...

Страница 15: ...Exterior view 14 General information 21 13 At a glance...

Страница 16: ...A Engine oil filler neck Stop button Start button Air compressor A Power steering pump B Engine control unit MR C Dipstick D Refrigerant compressor E Poly V belt tensioning device F Coolant pump G Fue...

Страница 17: ...it 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 in...

Страница 18: ...tton Start button Air compressor A Power steering pump B Engine control unit MR C Dipstick D Refrigerant compressor E Poly V belt tensioning device F Fuel filter G Coolant pump H Fuel prefilter I Cool...

Страница 19: ...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...

Страница 20: ...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 Fu...

Страница 21: ...t 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 Exh...

Страница 22: ...re 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 af...

Страница 23: ...t valves and one outlet valve Each cylinder has its own fuel injection pump unit pump with a short high pressure fuel injection line to the multi hole nozzle at the centre of the combustion chamber Th...

Страница 24: ...ounted The engine management control unit MR is on the left side of the engine Example OM 926 LA engine management control unit MR The engine control unit MR processes val ues from the drive control u...

Страница 25: ...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 th...

Страница 26: ...work You should therefore top up the AdBlue tank regularly yourself If the AdBlue tank is empty or if there is a malfunction the indicator lamp lights up or flashes in the instrument cluster If a fau...

Страница 27: ...y 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...

Страница 28: ...in conjunction with constant throttle valves OM 904 LA OM 924 LA constant throttle valve Constant throttle valve Pneumatically actuated line OM 926 LA constant throttle valve Constant throttle valve H...

Страница 29: ...ises 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 th...

Страница 30: ...28...

Страница 31: ...Safety precautions 30 Staff qualifications 30 Organisational measures 30 29 Safety...

Страница 32: ...hones and two way radio devices that are not connected to an external aerial can cause malfunc tions in the vehicle electronics and thus endanger the operating safety of the engine Staff qualification...

Страница 33: ...readily accessible in the area of engine operation In addition to the Operating Instructions other general country specific legal and other binding regulations on accident preven tion and environmenta...

Страница 34: ...32...

Страница 35: ...Operation 34 Continuous brake 41 Driving tips 42 Refuelling 43 Winter operation 45 33 Driving mode working mode...

Страница 36: ...detected in the engine control MR control unit and transmitted to the drive control FR control unit via the engine CAN Output is in percentage values and can be displayed on the instrument or on a mat...

Страница 37: ...g the engine for the first time Starting the engine for the first time X Connect a power supply Carry out the work listed under Preparing for operation before operating the engine for the first time Y...

Страница 38: ...isk of scalding from hot coolant spraying out The engine cooling system and the coolant expansion tank are pressurised when the engine is at normal operating tem perature Wear gloves and eye protectio...

Страница 39: ...possible X If the engine does not start immedi ately interrupt the starting procedure after no more than 30 seconds X Turn the key in the ignition lock back to the stop at key position g X Wait appro...

Страница 40: ...me The engine turns over without starting X Release start button and stop but ton The engine remains at a standstill Operational monitoring Charge current The charge current indicator lamp must go out...

Страница 41: ...ted thresholds for nitric oxide emissions NOx Requirements for vehicles The engine output can be automatically reduced the first time the vehicle is stationary if Rthe AdBlue DEF reservoir is empty Rt...

Страница 42: ...ing the fault memory A fault stored in the fault memory because of the operating restriction system cannot be deleted with a conventional reading device Faults can only be deleted using the Daimler MT...

Страница 43: ...ecure the vehicle equipment against roll ing away Stop the engine immediately if Rthe oil pressure falls or fluctuates signif icantly Rthe power output or engine speed decreases and the position of th...

Страница 44: ...kdown only engage the shift ranges 4 3 2 or 1 when driving slowly After 2000 km 30 operating hours you can gradually bring the vehicle up to full road and increased engine speeds Fuel consumption Gene...

Страница 45: ...ntact with fuel immediately Rif fuel is swallowed a doctor should be con sulted immediately G WARNING Do not use petrol to refuel vehicles with a die sel engine Do not mix diesel with petrol This woul...

Страница 46: ...lot of clean water and drink plenty of water RChange clothing that is soiled with AdBlue DEF immediately RIf allergic reactions occur consult a doctor immediately Keep AdBlue DEF out of the reach of...

Страница 47: ...ture Wear gloves and eye protection Only open the coolant expansion tank when the coolant temperature is below 50 G WARNING Coolant contains glycol and is therefore toxic Do not swallow the coolant Se...

Страница 48: ...is prevents the batteries from being discharged by no load current consumers If the engine vehicle equipment is to be out of use for a longer period remove the batteries and store them in a dry and we...

Страница 49: ...Service products 48 Cleaning and care 56 Maintenance 57 47 Maintenance and care...

Страница 50: ...ice products are for example Rfuels e g diesel Rlubricants e g engine and transmission oils hydraulic fluids greases Rantifreeze coolant RAdBlue DEF BlueTec exhaust gas after treatment reduction agent...

Страница 51: ...l ester fuel bio diesel fuel use only engine oils compliant with Sheet Nos 228 5 228 51 228 3 and 228 31 Y page 53 This is also required for a mixture of conven tional diesel fuels and FAME fatty acid...

Страница 52: ...o much oil If you add too much oil the engine or the catalytic converter could be damaged Drain or siphon off any excess oil When topping up Mercedes Benz recom mends that you only use engine oil of t...

Страница 53: ...g system must first be flushed Y page 77 When renewing the coolant ensure that it contains 50 by volume of corrosion inhibi tor antifreeze agent This corresponds to antifreeze protection down to 37 Do...

Страница 54: ...s otherwise a risk of impaired engine performance or engine and catalytic con verter damage The use of appropriate fuel additives is your responsibility Sulphur content in diesel fuel Interval for cha...

Страница 55: ...l ester FAME fuel bio diesel General notes To avoid damage to the assemblies and components observe the following points when using FAME fatty acid methyl ester fuel Rhave the fuel filter and the oil...

Страница 56: ...sing pure FAME fatty acid methyl ester fuel compliant with DIN EN 14214 You can also operate your engine using a mixture of conventional diesel fuel and FAME fatty acid methyl ester fuel This also app...

Страница 57: ...roximately 11 Winter operation is also ensured for temperatures below 11 At low temperatures AdBlue DEF crystals may form on the coiled hose between the engine and the silencer This crystallisation do...

Страница 58: ...nly be cleaned when it is cool The sensors can otherwise be damaged When cleaning never point the water jet at the exhaust pipe The system may oth erwise be damaged When using a high pressure cleaner...

Страница 59: ...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 F...

Страница 60: ...58...

Страница 61: ...Work schedule overview 60 Work schedules 62 59 Notes on maintenance...

Страница 62: ...he engine Rwear work clothing which is fastened and close fitting Wear a hair net if necessary Remove jewellery such as watches and necklaces With BlueTec Without BlueTec Maintenance schedule for main...

Страница 63: ...els 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...

Страница 64: ...rvice Products every 3 or 5 years observe coolant mixture ratio If very dirty clean the cooling system separate order AP09 10 W 0980A Replace air filter element according to equipment vehicle manufact...

Страница 65: ...when the engine is at normal operating temperature Example OM 926 LA Filler neck Dipstick X To siphon off engine oil pull out dip stick X Insert the extractor system into the guide tube using an O rin...

Страница 66: ...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 Ch...

Страница 67: ...by limbs being crushed between the moving parts Secure the engine against unintentional start ing before carrying out maintenance or repair work G WARNING The engine becomes very hot while it is run n...

Страница 68: ...LA Crankshaft position Cylinder valves to be adjusted 1 2 3 4 5 6 Cylinder no 6 valve overlap I E I E I E Cylinder no 1 valve overlap E I E I I E I inlet valve E exhaust valve Adjust all valve cleara...

Страница 69: ...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 If the poly V belt is torn there is n...

Страница 70: ...base of the belt E Cord torn out of the side F Outer cord frayed G Transverse cracks on the back of the belt H Transverse cracks in several ribs X Check the poly V belt for damage regularly Fuel circu...

Страница 71: ...e shutoff valve X Place a collector under water drain valve E X Open water drain valve E and bleed screw Collect the draining water fuel mixture while doing so X Unscrew filter element A from filter h...

Страница 72: ...ure in the fuel tank X Unscrew fuel filter cap using a socket spanner insert SW 36 X Pull fuel filter cap with filter element out of the filter housing slightly Allow the fuel to drain off X Remove th...

Страница 73: ...tive gloves protective clothing and safety goggles If AdBlue DEF gets into the coolant cir cuit even minute amounts thermostats and temperature sensors will be damaged RAlways keep AdBlue DEF complete...

Страница 74: ...ent system could result The system is self bleeding and does not need to be bled manually Filling the AdBlue DEF pressure res ervoir Important safety notes G WARNING If the AdBlue DEF tank cap is open...

Страница 75: ...the pressure if neces sary X To increase the pressure use pump A Adjust the pressure to 0 2 bar above the specified operating pressure When the fill ing hose is disconnected from the valve a pressure...

Страница 76: ...spraying out The engine cooling system and the coolant expansion tank are pressurised when the engine is at normal operating tem perature Wear gloves and eye protection Only open the coolant expansion...

Страница 77: ...ller neck of the coolant expansion tank X Connect the compressed air hose with tyre inflation connection to pressure tester tool and set it to a test pressure of 1 0 bar The test pressure should corre...

Страница 78: ...coolant renewal confirmed in the Maintenance Booklet Draining the coolant H Environmental note Dispose of used coolant in accordance with current local regulations Example coolant drain plug X Undo t...

Страница 79: ...not come into contact with skin eyes or clothing In case of contact with eyes rinse immediately with plenty of clean water Clean affected areas of skin and clothing with soap and water imme diately Ch...

Страница 80: ...damage and leaks at connection points X Check all hose clamps for correct seating Retighten or replace loose hose clamps X Replace porous leaking or damaged lines and bellows G WARNING The engine bec...

Страница 81: ...Decommissioning the engine 80 Protecting the engine 81 79 Decommission and protection...

Страница 82: ...ull to prevent AdBlue DEF from crystallising RFuel prefilter with heated water separator drain off the water separator Engine with exhaust gas aftertreatment RDecommissioning for more than 12 months f...

Страница 83: ...heating RCheck oil levels in the steering system engine transmission and drive axles RCheck that the electrical system steering system and brakes are functioning cor rectly RClean the engine vehicle...

Страница 84: ...measures for the combustion chambers when the engine is cold coolant temperature under 50 Only use initial operation oil compliant with Sheet no 225 6 for the protection of the combustion chambers X...

Страница 85: ...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 T...

Страница 86: ...84...

Страница 87: ...ing engine emergency run 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...

Страница 88: ...ic bleeding Do not bleed the fuel system by operating the starter motor for an extended period of time You could otherwise damage the starter motor X Turn the starter motor for up to 30 seconds withou...

Страница 89: ...y mode can be activated for road vehicles with Euro 4 5 certified engines on highway engines Example indicator lamp malfunction The engine is equipped with an electronic management system that monitor...

Страница 90: ...vices with Euromot 3B or Tier 4i certified engines off highway applications Emergency mode can only be activated for 30 minutes and only if the vehi cle has the appropriate equipment For further infor...

Страница 91: ...pinion does not turn or turns too slowly The battery is not sufficiently charged X Charge the battery The connecting cable to the starter motor is loose X Tighten the cable on the terminal If necessar...

Страница 92: ...r there is insufficient pressure in the low pressure fuel circuit or the fuel pump drive is faulty X Check for leaks visual check X Have the fuel pressure tested at a qualified specialist workshop The...

Страница 93: ...ndicator lamp is flashing Y page 94 The AdBlue DEF tank is empty X Top up AdBlue DEF tank Y page 44 The exhaust gas aftertreatment indicator lamp lights up There is an emissions relevant fault or malf...

Страница 94: ...poly V belt is damaged X See Replacing the poly V belt Y page 95 The fan does not switch on correctly X Consult a qualified specialist workshop The radiator is dirty on the inside the radiator is very...

Страница 95: ...ecialist workshop The exhaust fumes are white Coolant is entering the combustion chamber X Have a pressure loss test carried out at a qualified specialist workshop The engine is knock ing The engine i...

Страница 96: ...ay 67 The AdBlue DEF tank is empty There is a fault The engine output may be reduced6 X Follow the instructions in the display messages The indicator lamp lights up perma nently The BlueTec exhaust ga...

Страница 97: ...e DEF metering pump dis connected RSCR cable set disconnected RNOx sensor disconnected RAdBlue DEF temperature sensor disconnected RExhaust gas temperature sensor disconnected Problem is detected RThe...

Страница 98: ...uting engine without refrigerant compressor Alternator Tensioning pulley Coolant pump Crankshaft Fitting removing poly V belts Example releasing the poly V belt X Insert the 15 mm socket with the hand...

Страница 99: ...ulley 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 swi...

Страница 100: ...98...

Страница 101: ...Engine data plate 100 Information on the engine data plate 100 Engine model designation 100 Engine data card 100 Engine data 101 99 Technical data...

Страница 102: ...road vehicles off highway engine Manufacturer s name Engine model designation Type approval number Engine number Engine model designation Example engine model designation OM 9XX L A OM Oil engine die...

Страница 103: ...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 respective e...

Страница 104: ...Weights OM 904 LA OM 924 LA OM 906 LA OM 926 LA Dry engine maximum 395 kg 530 kg Wet engine maximum 420 kg 573 kg 102 Engine data Technical data...

Страница 105: ...Stroke 130 mm 136 mm 130 mm 136 mm Engine capacity 4250 cm3 4800 cm3 6370 cm3 7200 cm3 Type of cooling system Forced circulation cooling Engine direction of rotation Anti clockwise when looking at the...

Страница 106: ...roximately 80 95 Approximately 80 95 Maximum permissi ble coolant tempera ture 100 100 Capacities Capacity approx imately Service product Sheet No 7 Engine with oil filter with stand ard truck oil pan...

Страница 107: ...ive wax Wax preservative 385 4 Engine brake Heat resistant lubricant Heat resistant lubricant part number A000 989 76 51 Tightening torques All threads on mechanical components and the corresponding c...

Страница 108: ...r bowl on the AdBlue DEF pump module 32 Nm Oil level output values Output Message Warning and checking activities 94 8 100 Oil level too high Yellow CHECK fault lamp 90 MAX 10 90 Permissible range 10...

Страница 109: ...107...

Страница 110: ...108...

Страница 111: ...online com Documentation team Should you have any questions or sugges tions regarding this manual you can reach the technical documentation team at the fol lowing address Daimler AG HPC R822 D 70546...

Страница 112: ...Order no 6462 9827 02 Part no 926 584 21 81 Edition B 06 12 9265842181f 9265842181...

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