Mercedes-Benz OM 904-926 LA BlueTec User manual

OM 904-926 LA BlueTec®, OM 904-926 LA
Operating Instructions

Symbols
$Warning
%Environmental note
!Possible vehicle damage
iTip
XInstructions
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
data, illustrations or descriptions in this man-
ual.
The manual/instructions are comprised of:
ROperating Instructions
RMaintenance Booklet
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.
iYou can find out about your engine's
important functions in German and English
in the online Owner's Manual at: http://
www.mercedes-benz.de/betriebsanleitun-
gen
The technical documentation team at
Daimler AG wishes you safe and pleasant
motoring.
9265840681 É9265840681ÁËÍ

Index ....................................................... 4
General information .............................. 7
At a glance ........................................... 13
Safety ................................................... 29
Driving mode/working mode ............. 33
Maintenance and care ........................ 45
Notes on maintenance ....................... 59
Decommission and protection ........... 79
Breakdown assistance ....................... 85
Technical data ..................................... 99
Contents 3

A
Adaptation module .............................. 21
AdBlue®/DEF
Components .................................... 19
Consumption ................................... 41
Refuelling ......................................... 42
Replacing the filter ........................... 69
Service product ............................... 54
ADM (FR (drive control) unit) ............. 21
Antifreeze ............................................. 73
B
Bio-diesel fuel
see FAME fatty acid methyl ester fuel
Bleeding the fuel system .................... 86
Bleeding the fuel system manually ... 86
BlueTec®
Exhaust gas aftertreatment ................ 9
Sensors ............................................ 19
BlueTec® exhaust gas aftertreat-
ment
AdBlue® service product .................. 54
Braking
Continuous brake ............................ 40
C
Capacities .......................................... 104
Care products ...................................... 55
Charge current .................................... 37
Checking the fluid level ...................... 34
Cleaning and care
Engine cleaning ................................ 56
High-pressure cleaning .................... 55
Notes on care .................................. 55
Cold-start aid ....................................... 27
Consumption
AdBlue®/DEF .................................. 41
Fuel .................................................. 41
Oil (engine) ...................................... 41
Continuous brake ................................ 26
Coolant ................................................. 34
Mixing ratio ...................................... 48
Renewing ......................................... 75
Service product ............................... 48
Coolant (engine)
Topping up ....................................... 76
Coolant additive .................................. 48
Cooling system
Degreasing ....................................... 76
Flushing ........................................... 76
Correct use ............................................ 9
Corrosion inhibitor/antifreeze
agent .................................................... 48
Cranking device ................................... 64
D
Data card ............................................ 100
Decommissioning ................................ 81
Decommissioning the engine ............. 80
DEF/AdBlue®
see AdBlue®/DEF service products
Description of the engine ................... 21
Diesel
Flow improvers ................................ 52
Fuels ................................................ 50
Low outside temperatures ............... 52
refuelling .......................................... 41
Sulphur content table ...................... 51
Dimensions ........................................ 101
Disposal of service products .............. 46
Draining the coolant ........................... 75
Draining the fuel prefilter ................... 86
Driving tips .......................................... 40
E
Electronic engine control ................... 38
Emergency mode ................................. 87
Emergency running program ................ 8
Engine
Capacities ...................................... 104
Changing the oil and oil filter ........... 62
Checking for leaks and general
condition .......................................... 77
Cleaning ........................................... 55
Data ............................................... 101
Data card ....................................... 100
Data plate ...................................... 100
Diagnostics (indicator lamp) ............ 94
Oil consumption ............................... 41
Operating data ............................... 104
4Index

Protective treatment ........................ 81
Re-commissioning ........................... 83
Rectifying faults ............................... 89
Running-in period ............................. 40
Starting ............................................ 36
Stopping .......................................... 39
Engine brake
Condition and setting ....................... 72
Function ........................................... 26
Engine control unit .............................. 22
Engine data ........................................ 101
Engine data card ............................... 100
Engine description .............................. 21
Engine model designation ................ 100
Engine oil
Adding ............................................. 63
For winter operation ........................ 46
Mixing .............................................. 48
Oil change ........................................ 47
Siphoning and draining .................... 62
Topping up ....................................... 48
Engine oil consumption ...................... 41
Engine overview .................................. 14
Engine type plate .............................. 100
Exhaust gas aftertreatment indica-
tor lamp ................................................ 95
F
Filling up the pressure reservoir ....... 71
Flow improvers .................................... 52
FR (drive control) unit
see ADM
Fuel
Additives .......................................... 52
Consumption ................................... 41
Diesel ............................................... 50
FAME fatty acid methyl ester fuel .... 53
refuelling .......................................... 41
Sulphur content table ...................... 51
Fuel filter .............................................. 67
Fuel grade ............................................ 50
G
Genuine Mercedes-Benz
parts ................................................... 7, 8
Getting started .................................... 35
H
High-pressure cleaning ....................... 55
I
Identification plate ............................ 100
Indicator and warning lamps
BlueTec® exhaust gas aftertreat-
ment ................................................ 25
Installation ........................................... 10
L
Lines and hoses
Checking for leaks ........................... 77
M
Maintenance ........................................ 56
Mercedes-Benz Service Centre
see Qualified specialist workshop
Modifications and changes .................. 7
O
Oil (engine)
For winter operation ........................ 46
Oil change ........................................ 47
Scope of use .................................... 47
Oil change ............................................ 62
Oil filter replacement .......................... 62
Oil pressure ......................................... 38
Operating data ................................... 104
Operating restriction override ........... 39
Operating safety .................................... 7
Operational monitoring ...................... 37
Organisational measures ................... 30
Original parts ......................................... 7
Overview, sensors ............................... 18
Overview of maintenance work ......... 60
Overview of work plans ...................... 60
P
Personnel ............................................. 30
Poly-V-belt
Checking condition .......................... 66
Damage patterns ............................. 66
Routing ............................................ 97
Index 5

Preparing for starting operation
see Starting operation
Protection of the environment ............. 7
Protective treatment .......................... 81
Q
Qualified specialist workshop ........... 11
R
Re-commissioning ............................... 83
Refuelling
AdBlue®/DEF .................................. 42
Fuels ................................................ 41
Replacing the fuel filter ...................... 69
Replacing the fuel prefilter ................. 68
Replacing the poly-V-belt .................... 97
Requirements of the personnel ......... 30
Roadside Assistance ........................... 86
Running the vehicle in ........................ 40
S
Safety and emergency running pro-
gram ....................................................... 8
Safety precautions .............................. 30
Service products
AdBlue®/DEF .................................. 54
Coolant ............................................ 48
DEF/AdBlue® .................................. 54
Diesel fuel ........................................ 50
Disposal ........................................... 46
Disposing of AdBlue®/DEF .............. 55
Engine oil ......................................... 46
FAME fatty acid methyl ester fuel .... 53
Flow improvers ................................ 52
Fuel additives ................................... 52
Purity of AdBlue®/DEF .................... 55
Storing AdBlue®/DEF ...................... 55
Specialist workshop ............................ 11
Starting
see Starting (engine)
Starting (engine) .................................. 36
Starting the engine for the first
time ...................................................... 35
Stopping and switching off the
engine ................................................... 39
Sulphur content of fuel ....................... 51
T
Technical data ................................... 101
Dimensions .................................... 101
Filling capacities ............................ 104
Operating data ............................... 104
Weights .......................................... 101
Tightening torques ............................ 105
Torque reduction ............................... 106
Transport ................................................ 9
Troubleshooting .................................. 94
V
Valve clearance
Checking and adjusting ................... 63
Valve clearance special tool ............... 64
W
Warning and indicator lamps
Charge indicator .............................. 25
Cold-start aid ................................... 25
Electronics ....................................... 25
Weights .............................................. 102
Winter diesel ........................................ 52
Winter operation ................................. 43
6Index

Environmental note
HEnvironmental note
Daimler AG has a declared policy of compre-
hensive environmental protection.
The objectives are to use the natural resour-
ces which form the basis of our existence on
this planet sparingly and in a manner which
takes the requirements of both nature and
humanity into account.
You also can help to protect the environment
by operating your engine in an environmen-
tally responsible manner.
The fuel consumption and wear and tear of an
engine depend upon the conditions under
which it is operated. For this reason, you
should:
Rnot warm up the engine in neutral
Rswitch off the engine during operation-rela-
ted delays
Rmonitor the fuel consumption
Rcarry out the specified maintenance work.
Always have maintenance work carried out at
a qualified specialist workshop, e.g. a
Mercedes-Benz or MTU Service Centre.
Operating safety and vehicle approval
Operating safety
The operating safety of an engine depends on
its professional installation in the overall sys-
tem (e.g. the vehicle or working machinery).
As the operator of the engine, you also affect
its safe operation.
Through compliance with the prescribed
maintenance intervals, you fulfil part of the
requirements for safe operation of the
engine.
However, safe operation of the engine also
depends upon its proper use, which includes,
for example, regular checks of the oil level.
GWARNING
Accidents can occur as a result of engine
damage caused by improper use of the
engine.
Therefore, please follow the engine operating
instructions included in the Owner's Manual.
GWARNING
Faulty or incomplete maintenance work, as
well as disregarded maintenance intervals,
can decrease the engine's operating life,
cause engine damage and lead to accidents.
Therefore, please follow the engine operating
instructions included in the Owner's Manual.
Notes on electronic systems
GWARNING
If work on electronic equipment and its soft-
ware is carried out incorrectly, this equipment
could stop working. The electronic systems
are networked via interfaces. Tampering with
these electronic systems could cause mal-
functions in systems which have not been
modified. Malfunctions such as these can
seriously jeopardise the vehicle's operating
safety and therefore your own safety.
Other work or modifications incorrectly car-
ried out on the vehicle could also jeopardise
operating safety.
Some safety systems only function when the
engine is running. You should therefore never
switch off the engine when driving.
Conversion parts and modifications
to the engine
GWARNING
Unauthorised changes to the engine can
reduce its functionality and safety, lead to
accidents and consequently to personal
injury. Always have maintenance or modifica-
tion to the engine carried out at a qualified
specialist workshop which has the necessary
General information 7
Z

specialist knowledge and tools to carry out
the work required. Mercedes-Benz recom-
mends that you use a Mercedes-Benz or MTU
Service Centre for this purpose.
! Unauthorised intervention in the injection
system and the engine electronics can
affect the performance and emissions of
the engine. Compliance with factory set-
tings and legal environmental protection
conditions can then no longer be guaran-
teed.
The implied warranty does not cover damage
resulting from unauthorised modifications to
the engine.
Safety/emergency running program
The engine is equipped with an electronic
control system, which monitors both the
engine and itself (self-diagnosis).
When the electronic control system detects a
malfunction, one of the following measures is
automatically implemented after an appraisal
of the malfunction:
RThe corresponding warning lamp displays
the faults occurring during operation
(Y page 25).
RIn conjunction with the electronic engine
control, fault codes can be shown on a dis-
play.
RThe system switches to a suitable backup
function for the continued, albeit restricted
operation of the engine (e.g. constant
emergency running speed).
GWARNING
If maintenance and repair work on the engine
is not carried out correctly, the operation and
safety may be affected, which can result in
accidents and personal injury.
Always have work on or modifications to the
engine carried out at a qualified specialist
workshop that has the necessary special
skills and tools for the work required.
Mercedes-Benz recommends a Mercedes-
Benz or MTU Service Centre.
The Daimler diagnostic tester can be
attached to the 14-pin diagnostic socket on
the equipment, or to the service plug accord-
ing to the EU Directive. Both the malfunction
message memory and the saved engine data
can be read by this device.
Warning lamp electronics (example)
Genuine Mercedes-Benz parts
Make sure of the suitability of the replace-
ment parts for your engine. Parts that lead to
a modification of the engine/vehicle/equip-
ment are considered in many countries to
render the general operating permit invalid.
Such modifications include, for example:
Rmodifications that change the approved
equipment type/vehicle type, as defined by
the general operating permit.
Rmodifications that could endanger road
users or persons in the vicinity of the vehi-
cle/equipment.
Rmodifications that change the exhaust or
noise level.
The use of unapproved parts can adversely
affect safety levels.
HEnvironmental note
For more economic repairs, Mercedes-Benz
offers Mercedes-Benz reconditioned assem-
bly and parts as part of the recycling process.
The same quality standards and warranty
apply as to new parts.
8General information

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
(Y page 100) and on the engine data card
(Y page 100).
BlueTec® exhaust gas aftertreatment
The engines meet the requirements of the
relevant emissions level and are correspond-
ingly certified.
Compliance with emissions laws and regula-
tions is a condition of the operating permit for
the vehicle/equipment.
Engines with BlueTec® exhaust gas after-
treatment must be operated with AdBlue®/
DEF in order to meet the emissions laws and
regulations.
The operating permit is invalidated if the vehi-
cle/equipment is operated without AdBlue®/
DEF. The legal consequence of this is that
operation of the vehicle/equipment is no lon-
ger permitted. This may be an offence or a
breach of road traffic regulations in certain
countries. Special concessions granted
either at the time of purchase or to reduce
operating costs of the vehicle/equipment,
e.g. reduced taxes or tolls, may also be ren-
dered retroactively invalid. This can be the
case in the country of registration. Or also in
another country where you operate the vehi-
cle/equipment.
Legal requirements
If the engine/vehicle/equipment is not oper-
ated within the limits of the emissions laws
and regulations, it can lead to sanctions.
This normally affects the following operating
states:
Rdriving without AdBlue®/DEF
Rthe permissible nitrogen oxide (NOx)
thresholds are exceeded
Rthere is a fault or emissions-relevant mal-
function in the monitoring 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 the
BlueTec® exhaust gas aftertreatment, opera-
tion is limited in accordance with the relevant
regulations (Y page 37).
Correct use
The engine may only be installed as contrac-
tually specified.
The manufacturer of the end product is
responsible for the correct installation and
compatibility of the engine in the overall sys-
tem.
The engine may not be modified. If the engine
is modified, Mercedes-Benz and MTU do not
accept responsibility for any damage arising
as a result.
Correct use of the engine requires adherence
to the instructions in this Owner's Manual.
This also requires compliance with the main-
tenance intervals and the professional exe-
cution of maintenance work in accordance
with this Owner's Manual.
Transport
GWARNING
The engine can detach and cause injuries if it
overturns or falls out.
General information 9
Z

RTo lift the engine, only use lifting points
attached to the engine.
ROnly use Mercedes-Benz transport equip-
ment intended for this purpose.
ROnly lift and transport the engine in the
installation position. Also, observe the max-
imum permitted angle of 30° while lifting
the engine in and out of vehicles.
Lifting point flywheel-side (example)
Lifting point belt-side (example)
Installation
The engine may only be installed as contrac-
tually specified.
The manufacturer of the end product is
responsible for the correct installation and
compatibility of the engine in the overall sys-
tem.
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
Service Centre if you have any questions
(Y page 11).
Information on the implied warranty
A well-developed network of Mercedes-Benz
and 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
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
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 as well as the maintenance serv-
ices in the Maintenance Booklet. Please
observe these instructions even if you let a
third party use and care for your engine. This
is the only way to ensure that you do not lose
your entitlements.
If the prescribed maintenance work is not
carried out, claims can only be decided after
the manufacturer has inspected the claim.
10 General information

During the engine warranty period in particu-
lar, have the prescribed maintenance service
carried out as follows:
Rregularly
Rpunctually
Rat a qualified specialist workshop which
has the necessary specialist knowledge
and tools to carry out the work required.
Mercedes-Benz recommends that you use
a Mercedes-Benz or MTU Service Centre
for this purpose. In particular, work rele-
vant to safety or on safety-related systems
must be carried out at a qualified specialist
workshop.
If there are legal requirements on exhaust gas
aftertreatment, please note that:
Rmaintenance on the engines must be car-
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 aware of 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.
Qualified specialist workshop
A qualified specialist workshop has the nec-
essary specialist knowledge, tools and quali-
fications to carry out the work required on the
engine to a professional standard. This is
especially important for work relevant to
safety.
A qualified specialist workshop must carry
out the required service, maintenance and
repair work and document it according to the
specifications of Daimler AG. Failure to com-
ply with these specifications could lead to the
loss of warranty entitlements.
Mercedes-Benz recommends that you use a
Mercedes-Benz or MTU Service Centre.
Always have the following work on the vehicle
carried out at a qualified specialist workshop:
Rwork relevant to safety
Rservice and maintenance work
Rrepair work
Rmodifications such as installations or con-
versions
Rwork on electronic components
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.
General information 11
Z

12

Exterior view ....................................... 14
General information ............................ 21
13
At a glance

Exterior view
Engine overview
Engine overview OM 904 LA
:Filler neck
;Stop button
=Start button
?Air compressor
APower-steering pump
BEngine control (MR) control unit
COil dipstick
DRefrigerant compressor
ETensioning pulley
FCoolant pump
GFuel prefilter
HFuel filter
14 Exterior view
At a glance

Engine overview OM 904 LA
:AdBlue®/DEF metering unit
;Charge air pipe of the charge-air cooler
=Charge air pipe to the charge-air cooler
?Crankcase ventilation hose
AOil filter
BTensioning pulley
CAlternator
DStarter
EIntake air inlet
FEngine brake
Exterior view 15
At a glance

Engine overview OM 906 LA
:Filler neck
;Stop button
=Start button
?Air compressor
APower-steering pump
BEngine control (MR) control unit
COil dipstick
DRefrigerant compressor
ETensioning pulley
FFuel filter
GCoolant pump
HFuel prefilter
ICoolant outlet to the radiator
16 Exterior view
At a glance

Engine overview OM 906 LA
:AdBlue®/DEF metering unit
;Charge air pipe of the charge-air cooler
=Charge air pipe to the charge-air cooler
?Crankcase ventilation hose
AOil filter
BTensioning pulley
CAlternator
DStarter
EIntake air inlet
FExhaust gas turbocharger
GEngine brake
Exterior view 17
At a glance

Sensors overview
Sensors, general
Example: OM 926 LA
:Oil temperature
;Oil pressure
=Coolant temperature
?Charge-air temperature/charge-air pressure
ATDC sensor (on camshaft gear)
BCrankshaft position sensor (on flywheel)
COil level
DFuel temperature
18 Exterior view
At a glance