Mercedes-Benz OM 904 LA User manual

Bild in der Größe
215x70 mm einfügen
Operating Instructions
OM 904 LA – OM 906 LA – OM 926 LA
EU Level III A (EU 97/68/EC)
EPA TIER 3 (US EPA 40 CFR Part 89)
Order no. 6462 9812 02 Part no. 906 584 26 81 EN Edition A, 01/06
Êzat:qXË
9065842681

Symbols
* Optional equipment
GWarning
HEnvironmental note
!Possible vehicle damage
iTip
Action required
Sequence of actions (several )
  Continuation symbol
  Continuation symbol for a warning
page Page reference
-> Term in the glossary of technical
terms
Display Displays in the multi-function
display
Internet
Further information about
Mercedes-Benz vehicles and
about DaimlerChrysler AG can be
found on the following websites:
www.mercedes-benz.com
www.daimlerchrysler.com
Editorial office
You are welcome to forward any queries
or suggestions you may have regarding
these Operating Instructions to the
technical documentation team at the
following address:
DaimlerChrysler AG, Abt. SVI, HPC: E124,
70546 Stuttgart, Germany
As at: 01.12.2005
Not to be reprinted, translated or
otherwise reproduced, in whole or in
part, without the written permission
of DaimlerChrysler AG.

Symbols
* Optional equipment
GWarning
HEnvironmental note
!Possible vehicle damage
iTip
Action required
Sequence of actions (several )
  Continuation symbol
  Continuation symbol for a warning
page Page reference
-> Term in the glossary of technical
terms
Display Displays in the multi-function
display
Internet
Further information about
Mercedes-Benz vehicles and
about DaimlerChrysler AG can be
found on the following websites:
www.mercedes-benz.com
www.daimlerchrysler.com
Editorial office
You are welcome to forward any queries
or suggestions you may have regarding
these Operating Instructions to the
technical documentation team at the
following address:
DaimlerChrysler AG, Abt. SVI, HPC: E124,
70546 Stuttgart, Germany
As at: 01.12.2005
Not to be reprinted, translated or
otherwise reproduced, in whole or in
part, without the written permission
of DaimlerChrysler AG.

Thank you for choosing this
Mercedes-Benz engine.
Make sure that you read the Operating In-
structions before using the engine for the
first time. This will help you to make opti-
mum use of the engine and avoid endan-
gering yourself and others.
Since the scope of delivery varies depend-
ing on each specific order, the equipment
of your engine may differ from certain
descriptions and illustrations in these
Operating Instructions. These Operating
Instructions also describe items of option-
al equipment where their operation re-
quires explanation.
DaimlerChrysler reserves the right to make
changes to design, equipment and tech-
nology. You cannot, therefore, base any
claims on the data, illustrations or descrip-
tions in these Operating Instructions.
Your nearest Mercedes-Benz Service
Centre will be happy to assist you further
should you have any more queries.
The Operating Instructions and Mainte-
nance Booklet are an integral part of the
engine. You should therefore always keep
them with the engine and pass them on to
the new owner if you sell it.

Contents
i Please also refer to the index (page 113) Introduction
Protection of the environment . . . . . 5
Operating safety . . . . . . . . . . . . . . . . . 6
Correct use . . . . . . . . . . . . . . . . . . . 7
1Ataglance
OM 904 LA overview . . . . . . . . . . . . 10
OM 906 LA/OM 926 LA
overview . . . . . . . . . . . . . . . . . . . . . . 14
Location of sensors . . . . . . . . . . . . . 18
Engine number . . . . . . . . . . . . . . . . . 20
2 Before commissioning
General information . . . . . . . . . . . . . 22
Type designation . . . . . . . . . . . . . . 22
Engine data card . . . . . . . . . . . . . . 22
Description of the engine . . . . . . . 23
Engine brake*/constantly-open
throttle valves* . . . . . . . . . . . . . . . 24
Flame-start system* . . . . . . . . . . . 25
Grid heater* . . . . . . . . . . . . . . . . . . 26
Telligent®engine system . . . . . . . . 27
Transport and installation . . . . . . . . 31
3Safety
Safety precautions . . . . . . . . . . . . . . 34
Staff qualifications . . . . . . . . . . . . . . 35
Conversion parts and
modifications to the engine . . . . . . . 36
Safety/emergency running
programs . . . . . . . . . . . . . . . . . . . . . . 37
Genuine Mercedes-Benz parts . . . . . 38
4Operation
Starting the engine for
the first time . . . . . . . . . . . . . . . . . . . 40
Preparation . . . . . . . . . . . . . . . . . . 40
Starting the engine for
the first time . . . . . . . . . . . . . . . . . 42
Starting the engine . . . . . . . . . . . . 45
Monitoring engine operation . . . . . . 48
Charge current . . . . . . . . . . . . . . . . 48
Oil pressure . . . . . . . . . . . . . . . . . . 48
Telligent®engine system . . . . . . . . 49
Flame-start system* . . . . . . . . . . . 49
Grid heater* . . . . . . . . . . . . . . . . . . 50
Stopping the engine . . . . . . . . . . . . . 51

Contents
Winter operation . . . . . . . . . . . . . . . . 52
Cleaning/protective treatment . . . 54
Cleaning the engine . . . . . . . . . . . . 54
Cleaning the cooling system . . . . . 55
Protective treatment . . . . . . . . . . . 57
Service products . . . . . . . . . . . . . . . . 58
Diesel fuels . . . . . . . . . . . . . . . . . . 59
FAME fuels . . . . . . . . . . . . . . . . . . . 61
Engine oils . . . . . . . . . . . . . . . . . . . 63
Coolant . . . . . . . . . . . . . . . . . . . . . 64
5 Maintenance
Maintenance instructions . . . . . . . . 68
Work schedule overview . . . . . . . . . 69
Maintenance service . . . . . . . . . . . 69
Additional work . . . . . . . . . . . . . . . 69
Additional work with every
third maintenance service . . . . . . . 69
Work schedules . . . . . . . . . . . . . . . . . 70
Engine: checking for leaks and
general condition . . . . . . . . . . . . . . 70
Lines and hoses on the engine:
checking for leaks and general
condition . . . . . . . . . . . . . . . . . . . . 70
Engine: oil change and filter
replacement . . . . . . . . . . . . . . . . . . 71
Adjusting the valve clearance . . . . 74
Fuel prefilter: cleaning the filter
element . . . . . . . . . . . . . . . . . . . . . 78
Heated fuel prefilter with water
separator*: replacing
the filter element . . . . . . . . . . . . . . 79
Replacing the fuel filter
element . . . . . . . . . . . . . . . . . . . . . 80
Intake pipe between air cleaner
and engine: checking for leaks
and general condition . . . . . . . . . . 83
Poly-V-belt: checking condition . . . 83
Engine brake*: checking
condition and setting . . . . . . . . . . . 87
Engine cooling system: checking
and correcting the fluid level
and the antifreeze/
corrosion inhibitor . . . . . . . . . . . . . 88
Cooling and heating system:
checking for leaks and general
condition . . . . . . . . . . . . . . . . . . . . 89
Renewing coolant . . . . . . . . . . . . . 92
6 Practical advice
Malfunctions, causes
and solutions . . . . . . . . . . . . . . . . . . . 96
Jump-starting . . . . . . . . . . . . . . . . . . 104
7 Technical data
Engine data . . . . . . . . . . . . . . . . . . . 106
Test values and adjustment
values . . . . . . . . . . . . . . . . . . . . . . . . 110
Tightening torques . . . . . . . . . . . . . 111
8 Glossary and index
Index . . . . . . . . . . . . . . . . . . . . . . . . . 113

5
Introduction
 Protection of the environment
Environmental note H
DaimlerChrysler’s declared policy is one of
integrated environmental protection. This
policy starts at the root causes and encom-
passes in its management decisions all the
consequences for the environment which
could arise from production processes or
the products themselves.
The objectives are for the natural resources
which form the basis of our existence on this
planet to be used sparingly and in a manner
which takes the requirements of both nature
and humanity into account.
Operate the engine in an environmentally re-
sponsible manner and you will help to pro-
tect the environment.
Fuel consumption and engine wear depend
on the operating conditions.
Therefore:
do not warm up the engine at idle speed
switch off the engine during periods in
stationary traffic
monitor fuel consumption
carry out the specified maintenance
work regularly

6
Introduction
Operating safety
The operating safety of an engine primarily
depends on its proper installation into the
complete system (e.g. vehicle, machine,
etc.). However, as the operator, you also
have a direct influence on the safe opera-
tion of the engine.
Some of the requirements for operating
the engine safely can be met by adhering
to the specified maintenance intervals and
ensuring that the required maintenance
work is carried out correctly.
However, the safe functioning of the en-
gine also depends on correct operation,
which includes, for instance, checking the
engine oil level at regular intervals.
Risk of accident G
Engine damage arising from incorrect oper-
ation could result in an accident.
Therefore, observe the notes on operating
the engine in these Operating Instructions.
Risk of accident G
Maintenance work that is carried out incor-
rectly or not at all, and the failure to observe
the specified maintenance intervals, may re-
duce the service life of the engine and cause
engine damage, which could result in an ac-
cident.
Therefore, observe the notes on engine
maintenance in these Operating Instruc-
tions.

7
Introduction
Operating safety
The engine is only designed for installation
in accordance with the specifications de-
fined in the contract.
The manufacturer of the end product is
personally responsible for the complete
system, and in particular for the correct in-
stallation and compatibility of this engine
with the rest of the system.
The engine must not be modified.
DaimlerChrysler accepts no responsibility
for damage caused as the result of modifi-
cations.
Correct use of the engine includes adher-
ing to these Operating Instructions, adher-
ing to the maintenance intervals and
performing maintenance work correctly in
accordance with these Operating Instruc-
tions.
Risk of accident G
Work incorrectly carried out on electronic
components and their software could impair
the functioning of these components. Since
the electronic systems are networked, this
might also affect systems that have not
been modified.
For this reason, always have work on, or
modifications to, electronic components
carried out at a qualified specialist work-
shop.
DaimlerChrysler recommends that you use
a Mercedes-Benz Service Centre for this
purpose as it has the necessary specialist
knowledge and tools for the work required.
Correct use

8

9
1
At a glance
OM 904 LA overview
OM 906 LA/OM 926 LA overview
Location of sensors
Engine number

10
At a glance
OM 904 LA overview
1

11
At a glance
OM 904 LA overview
1
1Poly-V-belt tensioning pulley
2Coolant pump
3Coolant line heater supply*
4Crankcase breather
5Oil filler opening
6Fuel filter
7Fuel prefilter
8MR (engine control) unit
9Dipstick

12
At a glance
OM 904 LA overview
1

13
At a glance
OM 904 LA overview
1
1Starter motor
2Flywheel housing
3Exhaust gas turbocharger
4Exhaust manifold
5Charge-air housing
6Charge-air pipe connection from the
intercooler
7Charge-air pipe connection to the
intercooler
8Oil filter
9Alternator

14
At a glance
OM 906 LA/OM 926 LA overview
1

15
At a glance
OM 906 LA/OM 926 LA overview
1
1Poly-V-belt tensioning pulley
2Coolant pump
3Coolant line heater supply*
4Crankcase breather
5Oil filler opening
6Fuel filter
7Fuel prefilter
8MR (engine control) unit
9Dipstick

16
At a glance
OM 906 LA/OM 926 LA overview
1

17
At a glance
OM 906 LA/OM 926 LA overview
1
1Starter motor
2Flywheel housing
3Turbocharger with wastegate valve
4Exhaust manifold
5Charge-air housing
6Charge-air pipe connection from the
intercooler
7Charge-air pipe connection to the
intercooler
8Oil filter
9Alternator