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OM 904-926 LA BlueTec , OM 904-926 LA

Operating Instructions

Symbols Warning $ Environmental note % Possible vehicle damage ! Tip i 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 endangering yourself or others. The standard equipment and product description 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: design equipment R technical features You cannot therefore base any claims on the data, illustrations or descriptions in this manual. The manual/instructions are comprised of:
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Operating Instructions Maintenance Booklet Always keep these documents together with the engine/vehicle/device. These documents should be passed on to the new owner if you sell the engine/vehicle/device.
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You 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/betriebsanleitungen The technical documentation team at Daimler AG wishes you safe and pleasant motoring.

9265840681

9265840681

Contents 3

Index ....................................................... 4 At a glance ........................................... 13 General information .............................. 7 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 .....................................

Index
Coolant (engine) Topping up ....................................... 76 Adaptation module .............................. 21 Coolant additive .................................. 48 AdBlue /DEF Cooling system Components .................................... 19 Degreasing ....................................... 76 Consumption ................................... 41 Flushing ........................................... 76 Refuelling ......................................... 42 Correct use ............................................ 9 Replacing the filter ........................... 69 Corrosion inhibitor/antifreeze Service product ............................... 54 agent .................................................... 48 ADM (FR (drive control) unit) .............21 Cranking device ................................... 64 Antifreeze ............................................. 73

Data card ............................................ 100 Bio-diesel fuel Decommissioning ................................ 81 see FAME fatty acid methyl ester fuel Decommissioning the engine ............. 80 Bleeding the fuel system .................... 86 DEF/AdBlue Bleeding the fuel system manually ... 86 see AdBlue /DEF service products BlueTec Description of the engine ................... 21 Exhaust gas aftertreatment ................ 9 Diesel Sensors ............................................ 19 Flow improvers ................................ 52 exhaust gas aftertreatBlueTec Fuels ................................................ 50 ment Low outside temperatures ............... 52 service product .................. AdBlue 54 refuelling .......................................... 41 Braking Sulphur content table ...................... 51 Continuous brake ............................ 40 Dimensions ........................................ 101 Disposal of service products .............. 46 C Draining the coolant ........................... 75 Draining the fuel prefilter ................... 86 Capacities .......................................... 104 Driving tips .......................................... 40 Care products ...................................... 55 Charge current .................................... 37 Checking the fluid ...................... level 34 E Cleaning and care Electronic engine control ................... 38 Engine cleaning ................................ 56 Emergency mode ................................. 87 High-pressure cleaning .................... 55 Emergency running program ................ 8 Notes on care .................................. 55 Engine Cold-start aid ....................................... 27 Capacities ...................................... 104 Consumption Changing the oil and oil filter ........... 62 AdBlue /DEF .................................. 41 Checking for leaks and general Fuel .................................................. 41 condition .......................................... 77 Oil (engine) ...................................... 41 Cleaning ........................................... 55 Continuous brake ................................ 26 Data ............................................... 101 Coolant ................................................. 34 Data card ....................................... 100 Mixing ratio ...................................... 48 Data plate ...................................... 100 Renewing ......................................... 75 Diagnostics (indicator lamp) ............ 94 Service product ............................... 48 Oil consumption ............................... 41 Operating data ............................... 104

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

Personnel ............................................. 30 Poly-V-belt Genuine Mercedes-Benz Checking condition .......................... 66 parts ................................................... 7, 8 Damage patterns ............................. 66 Getting started .................................... 35 Routing ............................................ 97

Index
Preparing for starting operation Sulphur content of....................... fuel 51 see Starting operation Protection of the environment .............7 T Protective treatment .......................... 81 Technical data ................................... 101 Dimensions .................................... 101 Q Filling capacities ............................ 104 Operating data ............................... 104 Qualified specialist workshop ........... 11 Weights .......................................... 101 Tightening torques ............................ 105 R Torque reduction ............................... 106 Re-commissioning ............................... 83 Transport ................................................ 9 Refuelling Troubleshooting .................................. 94 AdBlue/DEF .................................. 42 Fuels ................................................ 41 V Replacing the fuel ...................... filter 69 Replacing the fuel prefilter ................. 68 Valve clearance Checking and adjusting ................... 63 Replacing the poly-V-belt .................... 97 ............... tool 64 Requirements of the personnel ......... 30 Valve clearance special Roadside Assistance ........................... 86 Running the vehicle ........................ in 40 W Warning and indicator lamps Charge indicator .............................. 25 Cold-start aid ................................... 25 Safety and emergency running proElectronics ....................................... 25 gram ....................................................... 8 .............................................. 102 Safety precautions .............................. 30 Weights Winter diesel ........................................ 52 Service products Winter operation ................................. 43 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

General information 7
Environmental note H Environmental note G WARNING

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

injury. Always have maintenance or modification to the engine carried out at a qualified specialist workshop which has the necessary
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General information
specialist knowledge and tools to carry out Mercedes-Benz recommends a Mercedesthe work required. Mercedes-Benz recomBenz or MTU Service Centre. mends that you use a Mercedes-Benz or MTU The Daimler diagnostic tester can be Service Centre for this purpose.

attached to the 14-pin diagnostic socket on the equipment, or to the service plug accordUnauthorised intervention in the injection ing to the EU Directive. Both the malfunction system and the engine electronics can message memory and the saved engine data affect the performance and emissions of the engine. Compliance with factory can set-be read by this device. tings and legal environmental protection conditions can then no longer be guaranteed.

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). Warning lamp electronics (example) When the electronic control system detects a Genuine Mercedes-Benz parts malfunction, one of the following measures is automatically implemented after an appraisal Make sure of the suitability of the replaceof the malfunction: ment parts for your engine. Parts that lead to R The corresponding warning lamp displays a modification of the engine/vehicle/equipthe faults occurring during operationment are considered in many countries to (Y page 25). render the general operating permit invalid. R In conjunction with the electronic engine Such modifications include, for example: control, fault codes can be shown onRa dismodifications that change the approved play. equipment type/vehicle type, as defined by R The system switches to a suitable backup the general operating permit. function for the continued, albeit restricted R modifications that could endanger road operation of the engine (e.g. constant users or persons in the vicinity of the vehiemergency running speed). cle/equipment. G WARNING R modifications that change the exhaust or noise level. If maintenance and repair work on the engine is notcarried out correctly, the operation and The use of unapproved parts can adversely safety may be affected, which can result in safety levels. affect
accidents and personal injury. H Environmental note Always have work on or modifications to the For more economic repairs, Mercedes-Benz engine carried out at a qualified specialist offers Mercedes-Benz reconditioned assemworkshop that has the necessary special bly and parts as part of the recycling process. skills and tools for the work required. The same quality standards and warranty apply as to new parts.

General information 9
You can find more information on recommenThis normally affects the following operating ded conversion parts and accessories, as states: well as permitted technical modifications at a R driving without AdBlue /DEF Mercedes-Benz or MTU Service Centre R the permissible nitrogen oxide (NOx) (Y page 11). thresholds are exceeded Always state the engine number with the R there is a fault or emissions-relevant malmodel designation when ordering genuine function in the monitoring or exhaust gas Mercedes-Benz parts. You can find the numaftertreatment system bers on the identification plate of your engine Y You ( page 100) and on the engine data cardcanfind details in the Engine diagnostics Y page 94). indicator lamp section( (Y page 100). Fault detected in the monitoring system If the monitoring system detects a fault in the exhaust gas aftertreatment BlueTec exhaust gas aftertreatment, operaBlueTec The engines meet the requirements oftion the is limited in accordance with the relevant Y ( relevant emissions level and are correspondregulations page 37). ingly certified. Compliance with emissions laws and regulaCorrect tions is a condition of the operating permit for use the vehicle/equipment. The engine may only be installed as contrac exhaust gas afterEngines with BlueTec tually specified. treatment must be operated with / AdBlue The manufacturer of the end product is DEF in order to meet the emissions laws and responsible for the correct installation and regulations. compatibilitythe of engine in the overall sysThe operating permit is invalidated if the vehitem. cle/equipment is operated without /AdBlue The engine may not be modified. If the engine DEF. The legal consequence of this is that is modified, Mercedes-Benz and MTU do not operation of the vehicle/equipment is no lon- responsibility for any damage arising accept ger permitted. This may be an offenceas ora aresult. breach of road traffic regulations in certain Correct use of the engine requires adherence countries. Special concessions granted to the instructions in this Owner's Manual. either at the time of purchase or to reduce This also requires compliance with the mainoperating costs of the vehicle/equipment, tenance intervals and the professional exee.g. reduced taxes or tolls, may also be ren- of maintenance work in accordance cution dered retroactively invalid. This can be the with this Owner's Manual. case in the country of registration. Or also in another country where you operate the vehicle/equipment. Transport

Legal requirements

G WARNING

The engine can detach and cause injuries if it If the engine/vehicle/equipment is not operoverturns or falls out. ated within the limits of the emissions laws and regulations, it can lead to sanctions.

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General information
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The Operating Instructions contains informaTo lift the engine, only use lifting points tion required for installation in the "Technical attached to the engine. Y page Data" section" ( 101). Only use Mercedes-Benz transport equipPlease consult a Mercedes-Benz or MTU ment intended for this purpose. Service Centre if you have any questions Only lift and transport the engine in the (Ymaxpage 11). installation position. Also, observe the imum permitted angleof while 30 lifting the engine in and out of vehicles.

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: have special equipment and tools as well as specialists who receive continuous training R guarantee that your engine is repaired and maintained thoroughly and expertly R carry out all repairs within the framework Lifting point flywheel-side (example) of the engine warranty and the implied warranty R carry out all maintenance work expertly R confirm in the Maintenance Booklet that the maintenance work has been carried out at the required time R handle warranty claims that are admissible according to the sales contract Please observe the instructions and recommendations as well as the maintenance services in the Maintenance Booklet. Please Lifting point belt-side (example) 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 Installation your entitlements. If the prescribed maintenance work is not The engine may only be installed as contraccarried out, claims can only be decided after tually specified. the manufacturer has inspected the claim. The manufacturer of the end product is responsible for the correct installation and compatibilitythe of engine in the overall system. Observe the sections "Correct use" (Y page 9) and "Modification and changes to Y page the engine" ( 7).
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General information 11
During the engine warranty period in particuAlways have the following work on the vehicle lar, have the prescribed maintenance service carried out at a qualified specialist workshop: carried out as follows: R work relevant to safety regularly R service and maintenance work punctually R repair work R at a qualified specialist workshop which R modifications such as installations or conhas the necessary specialist knowledge versions and tools to carry out the work required. R work on electronic components Mercedes-Benz recommends that you use have warranty and ex gratia work carPlease a Mercedes-Benz or MTU Service Centre ried out at authorised workshops/Service for this purpose. In particular, work releCentres. vant to safety or on safety-related systems R For on-highway applications, contact a must be carried out at a qualified specialist Mercedes-Benz Service Centre. workshop. R Forgas off-highway applications, contact an If there are legal requirements on exhaust MTU or MTU-authorised Mercedes-Benz aftertreatment, please note that: partner. R maintenance on the engines must be carried out according to specific regulations and using special measuring devices. R it 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.
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Qualified specialist workshop


A qualified specialist workshop has the necessary specialist knowledge, tools and qualifications 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 comply with these specifications could lead to the loss of warranty entitlements. Mercedes-Benz recommends that you use a Mercedes-Benz or MTU Service Centre.
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13
Exterior view ....................................... 14 General information ............................ 21

At a glance

14

Exterior view
Exterior view

At a glance
: ;

Engine overview

Engine overview OM 904 LA

= ? A B C D E F G H

Filler neck Stop button Start button Air compressor Power-steering pump Engine control (MR) control unit Oil dipstick Refrigerant compressor Tensioning pulley Coolant pump Fuel prefilter Fuel filter

Exterior view 15

Engine overview OM 904 LA : ; = ? A B C D E F


AdBlue /DEF metering unit Charge air pipe of the charge-air cooler Charge air pipe to the charge-air cooler Crankcase ventilation hose Oil filter Tensioning pulley Alternator Starter Intake air inlet Engine brake

At a glance

16

Exterior view

At a glance
Engine overview OM 906 LA : ; = ? A B C D E F G H I

Filler neck Stop button Start button Air compressor Power-steering pump Engine control (MR) control unit Oil dipstick Refrigerant compressor Tensioning pulley Fuel filter Coolant pump Fuel prefilter Coolant outlet to the radiator

Exterior view 17

Engine overview OM 906 LA : ; = ? A B C D E F G


AdBlue /DEF metering unit Charge air pipe of the charge-air cooler Charge air pipe to the charge-air cooler Crankcase ventilation hose Oil filter Tensioning pulley Alternator Starter Intake air inlet Exhaust gas turbocharger Engine brake

At a glance

18

Exterior view
Sensors overview

At a glance

Sensors, general

Example: OM 926 LA : ; = ? A B C D

Oil temperature Oil pressure Coolant temperature Charge-air temperature/charge-air pressure TDC sensor (on camshaft gear) Crankshaft position sensor (on flywheel) Oil level Fuel temperature

Exterior view 19
AdBlue /DEF components

sensors, overview OM 924 LA BlueTec

: ; = ? A B C D E F G

Valve preheating, AdBlue /DEF system Silencer Temperature and humidity sensor (air filter, clean air side) Metering unit Temperature sensor downstream of catalytic converter NOx sensor Temperature sensor upstream of catalytic converter SCR frame module Supply unit AdBlue /DEF filter AdBlue /DEF tank

At a glance

20

Exterior view

At a glance
sensors, overview OM 926 LA BlueTec

: ; = ? A B C D E F G

Valve preheating, AdBlue /DEF system Silencer Temperature and humidity sensor (air filter, clean air side) Metering unit Temperature sensor downstream of catalytic converter NOx sensor Temperature sensor upstream of catalytic converter SCR frame module Supply unit AdBlue /DEF filter AdBlue /DEF tank

General information 21

sensors and test connection on the metering unit. Example: OM 926 LA BlueTec

: ; = ? A B

AdBlue /DEF pressure sensor AdBlue/DEF temperature sensor Pressure sensor for compressed air Metering unit test connection Metering unit heater Metering valve

pumps sit directly in the crankcase and are driven by the camshaft. Description of the engine The engine is equipped with exhaust gas turbocharger and intercooler as standard. The The engine is a water-cooled four-stroke dieengine can be equipped with optional engine sel engine with direct injection. brakes The cylinders are arranged in a row. Each cyl- (brake valve and constant throttle valves). inder has two inlet valves and one outlet It is a low-emission engine. Start of injection, valve. injection Each cylinder has its own fuel injection pump period and injection quantity are controlled entirely electronically. (unit pump) with a short high-pressure fuel injection line to the multi-hole nozzle at the centre of the combustion chamber. The unit

General information

At a glance

22

General information
These values are analysed together with data from theengine sensors. They are compared The engine has a fully electronic control syswith the charts or characteristic curves tem which, along with the engine and its stored asso- in the engine control unit. ciated sensors, consists of the following comData from the sensors derives from, e.g.: ponents: R charge-air pressure and charge-air temperR the engine control unit (MR) and ature R the drive control unit (FR) and/or other R coolant temperature vehicle-specific control units, e.g. ADM R fuel temperature R SCR frame module (only for engines with BlueTec exhaust gas aftertreatment)R oil pressure Start The control units are interconnected by a of injection, injection period and injection quantity are calculated on this basis and CAN line (Controller Area Network line) which the unit facilitates the exchange of all necessary data. pump is controlled via the solenoid valve accordingly. In addition to the engine and the BlueTec exhaust gas aftertreatment is If BlueTec exhaust gas aftertreatment, the electronic available, the associated sensors are also engine control also monitors itself. Depend analysed and the AdBlue /DEF dosage is ing on the malfunctions/failures that occur, controlled. a safety and emergency Y mode page( 8) may be automatically selected. i To obtain a replacement engine control For vehicle engines, the electronic engine unit, you will require all the data on the control only allows the engine to be started control unit type plate. when the transmission is in neutral.

Electronic drive control

At a glance

Engine control unit (engine resident)


The engine control unit is on the left side of the engine.

Example: OM 926 LA engine control unit

Control unit type plate

: Data record The engine control unit processes values ; Certification no. from the FR (drive control) unit and the ADM. Engine number =the These are, for example, the value from position sensor (accelerator pedal), the ? Equipment code engine brake or engine start/stop, etc.

General information 23
FR (drive control) unit or ADM (on Mercedes-Benz diagnostic testers can be i the equipment) connected to the 14-pin diagnostic socket

on the equipment or with the EU compliant The engine can be adapted to the various service connector. Both fault memory and operation-specific requirements using the FR stored engine data can be read out using (drive control) unit or the adaptation module this equipment. ADM.

SCR frame module (on the frame)

Example: FR (drive control) unit

Various operation specific data such as SCR frame module engine idling speed, maximum working The SCR frame module reads signals and engine speed or speed limiter are stored in transmits them via the CAN line to the engine the FR (drive control) unit or the ADM. control unit. The FR (drive control) unit or the ADM The following signals are read: receives data from: R Temperature sensor upstream of the SCR R user (values from the position sensor, catalytic converter engine start/stop) R Temperature sensor downstream of the R engine brake switch SCR catalytic converter R other systems (e.g. acceleration skid conR NOx sensor downstream of the SCR catatrol) lytic converter R engine control unit (e.g. oil pressure and R Combination sensor for level and tempercoolant temperature) ature in the AdBlue /DEF tank Values for the engine control (MR control R Combination sensor for humidity and air unit) are derived from this and conveyed via charge temperature the CAN line. The FR (drive control) unit or the ADM controls various displays, e.g. the electronics warning lamp, the engine brake and the constant throttle valve. If the electronic engine control detects a fault, the fault code is saved in the control units. It can be read out with the corresponding diagnostic testers (STAR DIAGNOSIS or minidiag2). In addition, the electronics warning ^ lamp is switched on. Example: diagnostic socket

At a glance

24

General information

At a glance
Example: EU compliant service connector

General information 25
Warning and indicator lamps Engine, general
1 Symbol

Reason for display/displayed message Impermissible operating conditions

Fault lamps ; Text in the engine symbol: "CHECK" STOP lamp ; Text in the engine symbol: "STOP" k

2 Serious fault

Electronic Lights up in the event of an electronic engine conengine control trol malfunction. Engine may only be operated in malfunction emergency mode. Charge current Lights up in the event of a charge current (power (power genera-generation) malfunction. If the warning lamp does tion) not go out after starting the engine, or if it goes on while the engine is running, the alternator or poly-V-belt is faulty. Cold-start aid Lights up if the cold-start aid is active.

exhaust gas aftertreatment on-highway 3 BlueTec version

The following indicator lamps could be available on the instrument panel:


1 Symbol

Reason for display/displayed message


AdBlue /DEF level

Fault message/action required (warning before reduction in operating performance) Exhaust system fault

; NO x bulb

Engine indicator lamp

Reduction in operating performActive torque limitation ance

1 2

Symbols may vary depending on the vehicle/equipment version. In addition, a warning tone may sound. 3 On-highway: vehicles with MOT approval.

At a glance

26

General information
exhaust gas aftertreatment off-highway 4 BlueTec version

At a glance

The following indicator lamps could be available on the instrument panel:


1 Symbol

Reason for display/displayed message


AdBlue /DEF level

! lights up (level 1) flashes (level 2)

Fault message/action required (warning before reduction in operating performance)

Check engine/exhaust gas Fault and misuse (failure in the monitoring aftertreatment system) Torque/speed limiter 2 active Slight reduction in operating performance

Significant reduction in operating performance

Continuous brake
If increased braking power is required, the engine can be equipped with a brake valve downstream from the exhaust gas turbocharger in conjunction with constant throttle valves.

OM 926 LA constant throttle valve : ;

Constant throttle valve Hydraulically-actuated line

The brake valve uses exhaust back pressure to increase braking power. The constant throttle valves bring about a reduction of the compression pressure in the power stroke OM 904 LA/OM 924 LA constant throttle valve (third stroke), whilst the compression (sec: Constant throttle valve ond stroke) is not significantly affected. ; Pneumatically-actuated line The constant throttle valve is an additional valve in the cylinder head. When open, the constant throttle valve establishes a connection between the combustion chamber and
4 1

Off-highway: vehicles without MOT approval. Symbols may vary depending on the vehicle/equipment version. 2 In addition, a warning tone may sound.

General information 27
exhaust port. This brings about the desired The cold-start aid is automatically deactivadecompression during the power stroke. ted if: When the engine brake is activated, the conR the engine is not started within 30 seconds stant throttle valves are opened. For of the % indicator lamp going out. OM 904/OM 924 engines, the actuation is R the engine is started while indi% the pneumatic. For OM 906/OM engines, 926 cator lamp is still lit. the actuation is hydraulic. The brake valve on R the coolant temperature reaches around the exhaust gas turbocharger is also closed. 0 while the engine is running. The engine brake is actuated by the FR (drive At a coolant temperature above approxY page control) unit ( 23) or the ADM. imately 4 , the % indicator lamp goes The engine brake is always deactivated below out after approximately 2 seconds (function 900 rpm. This prevents the engine from stallcheck). At a coolant temperature below ing. The engine brake is automatically deacapproximately 4 , % the indicator lamp tivated even if the position sensor (e.g. accelgoes out after approximately 20 seconds. erator pedal) is in use. Have the cold-start aid checked and repaired i In emergency mode (constant engine at a qualified specialist workshop. Mercedesspeed), the engine brake can only be acti-recommends that you use a MercedesBenz vated in overrun mode at increased Benz engine or MTU Service Centre for this purpose speed. Once the constant engine speed is 11). Work relevant to safety or on (Y page reached, the engine brake is automatically safety-related systems must be carried out at deactivated again. a qualified specialist workshop.

Cold-start aid
The cold-start aid makes it easier to start the engine at low outside temperatures (below 15 ); it is activated when the outside temperature falls below 4 .

H Environmental note
At outside temperatures below about 4 the cold-start aid minimises emissions (after starting theengine). In addition, it reduces the load on the starter motor and batteries and enables the engine to be started more rapidly. For this reason you should only start the engine after % the indicator lamp goes out.
X

To activate the cold-start aid: turn the vehicle key to the drive position in the ignition lock. The% indicator lamp lights up in the instrument panel. After the % indicator lamp goes out, start the engine within seconds. 30

At a glance

28

29
Safety precautions .............................. 30 Staff qualifications ............................. 30 Organisational measures 30 ...................

Safety

30

Organisational measures
tions in the vehicle electronics and thus endanger the operating safety of the engine. Damage to the engine can also lead to personal injury. In order to avoid engine damage, the following safety precautions must be Staff qualifications adhered to.

Safety precautions

Safety

Safety precautions
R R R R R

G WARNING
If maintenance and repair work on the engine

is notcarried out correctly, the operation and Only start the engine when the batteries safety may be affected, which can result in are firmly attached. accidents and personal injury. Do not disconnect the batteries when the Always have work on or modifications to the engine is running. engine carried out at a qualified specialist Do not use a rapid charger to start the workshop that has the necessary special engine. skills and tools for the work required. Only perform the jump-starting proceMercedes-Benz recommends a Mercedesdure with separate batteries. Benz or MTU Service Centre. Note, the battery terminals must be disconnected when rapid charging the batThe engine should only be operated, mainteries. tained and repaired by trained personnel who Observe the operating instructionshave of the been briefed and authorised by the operrapid battery charger. ator. The minimum legal age for personnel carrying out maintenance and repair work Please note, when carrying out electric must be observed. welding work, that the batteries must be disconnected and both of the cables ("+" and "-") must be firmly attached to each Organisational measures other. The control unit connectors may only be The responsibilities for operation, mainteconnected/disconnected when the nance elec- and repairs are to be determined by the trical system is switched off. operator. Give the Operating Instructions and Incorrect control unit-power supplythe Maintenance Booklet to the personnel polarity (e.g. by connecting up thethat bat- are charged with operating or carrying teries incorrectly) can cause irreparable out work on the engine. damage to the control units. G WARNING Tighten diesel injection system connecBefore operating the engine, please read tions to the prescribed tightening torque.

If temperatures above 80 are to be read the operating instructions of the vehicle expected (e.g. in a drying oven), the orconthe machine to which the engine is fitted. trol unit on the engine must be removed. You may not recognise dangers and may Only use the appropriate testing probes injure yourself or others. when taking measurements from electriInstruct personnel on how to operate the cal connectors (e.g. a Mercedes-Benz engine using the Operating Instructions. connection set). Telephones and twoWhen doing so, put special emphasis on way radio devices that are not connected safety-relevant information. This is particuto an external aerial, can cause malfunc-

these Operating Instructions. Please also first

Organisational measures 31
larly important for personnel that only work occasionally on the engine. Always keep the Operating Instructions and the Maintenance Booklet 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 prevention and environmental protection must be adhered to.

Safety

32

33
Operation ............................................. 34 Continuous brake ................................ 40 Driving tips 40 .......................................... Refuelling ............................................. 41 Winter operation 43 .................................

Driving m ode/ working m ode

34

Operation
If the engine is at normal operating temperature: wait about one minute. If the Preparation for operation engine is cold: wait about 5 to 10 minutes. X Check the engine oil level with oil dipAt the factory, the engine is filled with 5W30 stick; . The oil level should be between initial operation oil that complies with Sheet 225.6 of the Mercedes-Benz Specifications the upper and lower marks on oil dipfor Service Products. stick; . X If necessary, add oil via filler neck These high-quality engine oils are beneficial : . to the running-in process. They also allow you Do not add too much oil when topping up. to make the first oil change in accordance Topping up with too much oil can result in with the applicable oil change intervals for damage to the engine or the catalytic connormal operation. This eliminates the need verter. Drain or siphon off excess oil. for special initial operation oils and the additional oil change otherwise required. Adding coolant The extended maintenance intervals can only X Information on coolant mixture ratio be observed if engine oils complying with (Y page 76). Sheet 228.5 of the Mercedes-Benz SpecifiY page cations for Service Products are used. X Filling the cooling system ( 48).

Operation

Driving m ode/ working m ode

Refuelling
Use summer or winter fuel depending on the seasonY( page 50).

When refuelling ensure that conditions are clean and do not allow water to enter the tank and thus contaminate the fuel.

Refuelling with AdBlue /DEF


Only use AdBlue /DEF that complies with DIN 70070/ISO 22241. Do not use any addi tives. If AdBlue /DEF comes into contact with painted or aluminium surfaces when filling the tank, rinse the affected surfaces immediately with plenty of water.

Example: OM 926 LA : ;

Filler neck Oil dipstick

Bleeding the fuel system

The bleeding of a fuel system that has been run dry takes place when the engine is next started after refuelling. Automatic continuous Check the engine oil level on a regular basis, bleeding takes place in the filter. e.g. every week or each time you refuel. X Park the vehicle/equipment on a horizontal i The battery must be sufficiently charged when the engine is started in order for the surface. fuel system to be bled. X Engage the parking brake.

Engine oil level

Switch off the engine.

Operation35
i
Use the integrated hand pump Therefore you should: (Y page 68) to bleed the heated-fuel preR keep a safe distance between yourself and filter with water separator mounted on the rotating engine parts, including when the vehicle or equipment.
R

Observe the information contained in the G WARNING equipment/vehicle manufacturer's operating When opening the coolant expansion tank, instructions. there is a risk of scalding due to hot coolant X Connect a power supply. spraying out.The cooling system and coolant X Switch on the ignition. expansion tank are pressurised when the X Start the engine using the key in the ignition engine is at operating temperature. Wear lock or the start button on the engine. Do and eye protection. gloves not depress the accelerator or clutch Only pedal open the coolant expansion tank when while doing so. For equipment, the neutral the coolant temperature is below 50 . position must be engaged.

G WARNING As a safety function, the electronic engine control system facilitates the possibility of Coolant contains glycol and is therefore toxic. only allowing the engine to be started when Do not swallow the coolant. See a doctor the transmission or equipment is in neutral. immediately if you swallow coolant. G WARNING
Make sure that coolant does not come into contact withskin, eyes or clothing. In case of Make sure you do not touch any hot or moving contact with eyes, rinse immediately with engine components (e.g. exhaust manifold, plenty of clean water. Clean affected areas of poly-V-belt, fan) when the engine is running. skin and clothing with soap and water immeYou could injure yourself. diately. Change any affected clothing immeBe aware of the road and traffic situation diately. when working on public roads and secure your position accordingly.

Starting the engine for the first time


X

G WARNING

To check coolant level: leave the engine

There is a danger of limbs being caught, running pulled at a moderate engine speed for around five minutes. inandthereby crushed or severed by rotating X If the coolant temperature is less than engine parts.

50 , check the coolant level again. Add coolant. If a heating system is connected to the cooling system, all heating system valves must be opened while the cooling system is being topped up. Otherwise, there might be too little
Z

Driving m ode/ working m ode

engine is being started. wait until all engine parts have stopped moving before carrying out any work on the Starting the engine for the first time engine. Preparation R wear work clothing which is fastened and close-fitting. Wear a hair net if necessary. Carry out the work listed under "Preparing for Remove jewellery such as watches and operation" before operating the engine for necklaces. Y page the first time ( 34).

36

Operation
coolant in the coolant circuit after it is X filled. To start the engine: turn the key in the Only close the heating system valves onceignition the lock to drive position 2 . engine has been running for a brief period X Vehicles/equipment with a hot-water auxand, where applicable, the coolant has been iliary heater: preheat the engine at outside topped up. temperatures below 20 before starting. X Check the engine for leaks. X Vehicles/equipment with cold-start aid: X Check all hose fittings, hose clamps and wait until the % indicator lamp in the pipe connections on the engine as well as instrument cluster goes out. X Turn the key to start position the oil feed and return lines on the exhaust 3 inthe ignigas turbocharger for leaks and firm seating. tion lock. While doing so, do not depress X Around five minutes after switching off the the accelerator pedal. For equipment, keep engine, check the engine oil level withthe theidling function active. dipstick. X When the engine has started, release the The oil level should be between the upper key. and lower marks on the dipstick. Depending on the vehicle/equipment, the X Check the seating of the bracket secured idling speed is automatically adjusted to to the engine. around 600 rpm. Depending on the nature X Check the tightness of bolts on the exhaust of the work to be performed, higher engine idling speeds are also possible. manifold, engine mountings, coolant pump, starter motor and air compressor. X If the engine does not start, interrupt the starting procedure after no more than seconds. Starting and stopping the engine 30 with X the key Turn the key in the ignition lock back to the stop at key position g . X Repeat the starting procedure after approximately one minute. X After three starting attempts, wait approximately three minutes before trying again. X Observe the oil pressure gauge immediately after having started the engine.

Driving m ode/ working m ode

!
Example: ignition lock

To insert/remove the vehicle key 1 Steering unlocked/radio position 2 Drive position (ignition) 3 Start position
g
X X

After starting the engine, let it run at engine idling speed until the oil pressure is displayed. If no oil pressure is displayed after approximately 10 seconds, switch off the engine. Determine the cause. The operating safety of the engine is jeopardised.

Secure the vehicle/equipment against rollX Switch on the ignition. ing away. X Shift to neutral. Shift the transmission to neutral or engage neutral on the equipment. button will not function if a gear i The start is engaged or the equipment is in an operating position.

Starting and stopping the engine with the start/stop button

Operation37
Engine with one button To start the engine: press start button; . The engine starts and runs at engine idling speed. X To increase the engine speed: while the engine is running, press start ; button again and hold it down until the desired engine speed is reached. After releasing start button ; , the engine continues torun at the currently set speed. The engine speed can be increased up to the limiting speed. To start the engine: press start/stop but- X To stop the engine: while the engine is ton: . running, press stop button : . The engine starts and runs at engine idling The engine switches off. speed. X To turn the engine over without starting To start the engine and increase the it:press and hold start button ; and stop engine speed: press and hold start/stop button at the same time. : button : . The engine turns over without starting. The engine starts and runs at engine idling X ; and stop butspeed. After about three seconds, the Release start button ton . : engine speed increases. The engine remains at a standstill. Hold down start/stop button until the : desired engine speed is reached. After releasing start/stop button : , the Operational monitoring engine continues to run at the currently set speed. The engine speed can be increased Charge current up to the limiting speed. The charge current indicator lamp must go To stop the engine: press start/stop butout after the engine has started. ton: again. The engine switches off.
X

Engine with two buttons

Example: charge current indicator lamp

If the indicator lamp does not go out, or # if it lights up while the engine is running, switch off the engine and check the poly-Vbelt.
Z

Driving m ode/ working m ode

38 !

Operation
Oil pressure Make sure that the poly-V-belt contact surfaces are not damaged (e.g. torn), oily operating temperature has been ! Once the or glazed, as this could cause the poly-Vreached, the engine oil pressure may not belt to slip. Do not run the engine without drop below the following values: a poly-V-belt. Otherwise, the alternator and R 2.5 bar at rated speed coolant pump are not driven, which results in engine damage. R 0.5 bar at idling speed Further information can be found in the If the oil pressure falls below these values, stop the engine and trace the cause. Checking the poly-V-belt for wear (Y page 66) and Replacing the poly-V-belt Y ( page 97). Operating restrictions with on-highway sections applications Electronic engine control
The electronics monitor: The electronics warning lamp must goRout the display, level and quality of the after the engine has started. AdBlue /DEF reducing agent R the efficiency of the catalytic converter in accordance with the permitted thresholds for nitrogen oxide emissions (NOx). Requirements for vehicles The engine output can be automatically reduced thefirst time the vehicle is stationary if:
R R
the AdBlue /DEF reservoir is empty the permitted thresholds for nitrogen oxide (NOx) emissions are exceeded.

Driving m ode/ working m ode

Example: electronics warning lamp If the electronics warning lamp does not go Torque reduction out, or if it lights up while the engine is run If the AdBlue /DEF is used up or if there is a ning, there is a malfunction in the electronic fault, the indicator lamp in the instrument engine control system. panel lights up or flashes. The display also Each malfunction is stored in the system with shows a message. The engine output is only its own fault code. Temporary faults are also after a fault is detected and conreduced stored. firmed after up to four journeys. Fault codes can be read using the MercedesThe degree of torque reduction depends on Benz diagnostic tester STAR DIAGNOSIS or the vehicle category: Y ( minidiag2 page 8). If the electronics warnR vehicles above 7.5 t: torque reduction by ing lamp lights up while the engine is running, approximately 40% read or determine the fault code. R vehicles below 7.5 t: torque reduction by approximately 25%

Fault in the monitoring system If a fault is detected in the electronic monitoring of the exhaust gas aftertreatment sys-

Operation39
tem, the torque is reduced automatically override after function is also used to reset the 36 operating hours of the engine. operating restriction after the fault is corrected. This is the case, for example, after filling up with AdBlue /DEF of the correct quality. Operating restrictions for off-highway

engines

Deleting the fault memory Minor operating restriction A fault stored in the fault memory because of The available torque is reduced withinthe a operating restriction system cannot be deleted with a conventional reading device. period of 10 minutes. The torque is reduced Faults across the entire engine speed range to 80%can only be deleted using the Daimler/ MTU maintenance system. of the maximum torque (see the diagram below). Repeated violations In the event of repeated violations, the periods for the trigger signals and continuous reduction are shortened. When a fault is eliminated (for example the NOx sensor is replaced or reconnected), the operating restrictions are reset. Normal operation can be resumed. If a fault occurs again because of the operating restriction system within 40 hours, the periods of the operating restriction system are shortened. Example: Reduction in output during minor operating restric- if a fault reoccurs within 40 hours of the first elimination, the time until the opertion ating restriction comes into effect is halved. Major operating restriction If the same fault occurs within 40 hours of the The transition between a minor and a second major fault being rectified, the times are operating restriction is achieved by a gradual shortened to a quarter. reduction in engine speed and torque. The reduction takes place over a period of 60 minutes. Stopping and switching off the engine
R

The engine torque is reduced from 80% G of WARNING the rated value by 1% per minute to 20% of When switching off the equipment or parking the rated value. the vehicle, make sure that the exhaust sysSimultaneously, the engine speed is tem does not come into contact with comreduced over the period of 60 minutes from bustible objects, e.g. dry leaves, grass or the initial value to 1000 rpm. other highly flammable materials.

Emergency override X Park the vehicle/equipment. A button is optionally available for overriding X Secure the vehicle/equipment against rollthe operating restriction in an emergency. ing away. The override function makes the full engine X Shift the transmission into neutral/decououtput available for up to 30 minutes and can the drive system. be used a maximum of three times. Theple override can only be activated between the start of the operating restriction system and the end of the major operating restriction. The
Z

Driving m ode/ working m ode

40

Driving tips
Let the engine idle for approximately two Continuous brake minutes before switching off the engine if: airbrake and the constantly open throttle R the coolant temperature is very highThe (over valves are employed as continuous brakes. 90 ). G WARNING R the engine has been operated at full output. X To switch off the engine: turn the vehicleDo not activate the continuous brake (engine key in the ignition lock back to the stop at brake/retarder) on slippery road surfaces. position The wheels may otherwise become locked u . X Press the start/stop button on the engine and the vehicle could skid. or on the engine shutoff device on the You can utilise the engine's braking effect, equipment. particularly onlong downhill gradients, if you: X Safeguard the vehicle/equipment against R activate the continuous brake rolling away. R shift to a lower gear in good time ! Stop the engine immediately if: R the oil pressure falls or fluctuates significantly. Driving tips R the power output or engine speed Running-in decreases and the position of the position sensor (accelerator) remains conEquipment stant. Observe the equipment manufacturer's runR heavy smoke is emitted from the ning-in notes. exhaust. R the coolant or engine oil temperature Vehicles rises steeply. The running-in period of the engine has a sigR abnormal noises suddenly come from nificant effect on the vehicle, especially for the engine or exhaust gas turbocharger. the: i When you switch off the engine, BlueR service life exhaust gas aftertreatment automatTec R operating reliability ically flushes the exhaust system with fresh R economy air. Residues of AdBlue /DEF on the metering unit or the injection nozzle Observe might the following notes during the running-in period up to 2000 km (30 operating otherwise impair the function of BlueTec hours): exhaust gas aftertreatment. Depending on the engine's previous operating load, BlueR avoid subjecting the engine to full load. exhaust gas aftertreatment may flush Tec R run-in the engine with care using differing the exhaust system several times. speeds and engine revs. exhaust gas aftertreatment When BlueTec R avoid high engine revs. flushes the exhaust system, an air valve is R do not drive at more than of the maxiactivated. You may then hear a hissing mum road speed for each gear. sound. This hissing sound does not indicate R change gear in good time. a leak in the compressed-air system. R do not shift down to brake the vehicle. R in the case of vehicles with automatic transmission, do not press the accelerator

Driving m ode/ working m ode

Refuelling41
pedal beyond the point of resistanceOperating (kickconditions down) and only engage the shift4 ranges , Fuel consumption can increase due to poor 3, 2, or1 when driving slowly. operating conditions. After 2000 km (30 operating hours), you can Observe the following notes: gradually bring the vehicle up to full road and R avoid driving in mountainous terrain. increased engine speeds. R do not allow the engine to idle when the vehicle is stationary. Fuel consumption R do not drive with unnecessary weight. R avoid frequent cold starts. General information R avoid frequent short journeys. Fuel consumption depends on: the type of fuel used (diesel fuel, fatty acid consumption methyl ester FAME fuel) AdBlue R the machine version AdBlue /DEF consumption is between 4 and R the operating mode 8% of the fuel consumption, depending on R the operating conditions engine use. R the attached equipment (e.g. hydraulic pumps, mowers, etc.) Engine oil consumption For these reasons, exact details about any single engine's fuel consumption cannot be running in the engine, oil consumption After provided. may reach 0.5% of the vehicle's fuel consumption. Machine version More arduous operating conditions and increased distance covered could result in The following components influence fuel conengines exceeding this oil consumption sumption: value. R tyres (e.g. tyre pressure, tyre condition) R body type R drive train (e.g. transmission ratio) Refuelling R additional equipment (e.g. automatic cliFuels mate control, auxiliary heating)
R

Operating mode

Important safety notes G WARNING

Your operating mode can help to keep the fuel Fuel is highly flammable. Therefore, fire, consumption down: naked flames and smoking are prohibited
R R R

anticipate road and traffic conditions.when handling fuel. avoid frequent acceleration and braking. Deactivate the auxiliary heating when refuelling to prevent fuel vapours from igniting on stay within the economical engine speed the auxiliary heating exhaust system. range.
Fuel is toxic and constitutes a health hazard. Therefore, you should make sure that:

Driving m ode/ working m ode

42

Refuelling
You will find further information on fuel in the fuel does not come into contact with skin, Y page "Service products" section ( 50). eyes or clothing. H Environmental note R you do not inhale fuel vapours. R children are kept away from fuel. If fuels are handled improperly, they pose a If you or anyone else comes into contact danger with to persons and the environment. Do fuel: notallow fuels to run into the sewage system, surface waters, the ground water or into R wash eyes immediately with plenty of the clean the ground. water if fuel comes into contact with the eyes and consult a doctor. Before filling the tank R clean affected areas of skin with soap and water immediately. X Switch off the engine. R change out of clothing which has come into X Secure the vehicle/equipment against rollcontact with fuel immediately. ing away. R if fuel is swallowed, a doctor should be conX Switch off the auxiliary heating system. sulted immediately. X Y
R

Driving m ode/ working m ode

Observe the fuel grade page ( 50).

G WARNING

Do not use petrol to refuel vehicles with a die- or canisters, filter the fuel before drums selengine. Do not mix diesel with petrol. This refuelling. would result in damage to the fuel system and This prevents malfunctions in the fuel sysengine, which could lead to a vehicle fire. tem caused by contaminated fuel.

If you are refuelling the vehicle from

the fuel prefilter with the i Regularly check AdBlue /DEF is not a fuel additive and water separator for condensation must not be added to the diesel tank. heated If (Y page 86). AdBlue /DEF gets into the diesel tank, this could lead to engine damage.

Do not use petrol to refuel vehicles with a /DEF AdBlue diesel engine. Even small amounts of petrol result in damage to the fuel system and Important safety notes engine. If you fill the tank with the wrong fuel by If the AdBlue /DEF tank cap is opened at high accident, do not start the engine. Othertemperatures, ammonia vapours may escape. wise, the fuel lines may be contaminated. vapours have a pungent odour and Notify a qualified specialist workshopAmmonia and have the fuel tank and fuel lines fullyparticularly irritate: drained. R skin
R to mucous membranes Do not add any special fuel additives R eyes the diesel fuel or fatty acid methyl ester FAME fuel. The vapours may cause a burning sensation in the eyes, nose and throat as well as irritaSpecial fuel additives can lead to: R R R

G WARNING

malfunctions Avoid inhaling ammonia vapours. damage to the catalytic converter engine failure

tion of the throat and watering eyes.

Winter operation 43
G WARNING Bleeding the fuel system

AdBlue /DEF must not come into contactIf the fuel system is run dry, the system will with skin, eyes or clothing. be bled the next time the engine is started

R R

ing the starting procedure to ensure that the If AdBlue /DEF is swallowed, immediately fuel system can be bled. rinse your mouth out with a lot of clean Bleed the heated fuel prefilter with water sepwater and drink plenty of water. Change clothing that is soiled with arator mounted on the vehicle or equipment using the integrated hand pump AdBlue /DEF immediately. (Y page 86). If allergic reactions occur, consult a doctor immediately.

Keep AdBlue /DEF out of the reach of chil- Winter operation dren.

Cold-start aids

exhaust gas aftertreatment The BlueTec The following notes should be observed at the will cease to function correctly if you: start of the cold season. R fill the AdBlue /DEF reservoir with cleaning agent or other service products Fuel or fuels G WARNING R mix in additives There is an increased risk of fire when han R dilute AdBlue /DEF dling fuels as they are highly flammable. Avoid Only use AdBlue /DEF in accordance with fire, naked flames and sparks, and refrain DIN 70070/ISO 22241. from smoking when handling fuels. Notify a qualified specialist workshop in the event of incorrect filling. Use cold-resistant dieselYfuel page ( 50).

You will find further information on / AdBlue DEF in the "Service products" section Jump-starting (Y page 54). G WARNING

The use of liquid or gaseous starting aids can Dispose of AdBlue /DEF in an environmen- cause explosions. This may result in severe injuries. tally responsible manner. Do not use liquid or gaseous starting aids such asether or Startpilot to start the engine. Before filling the tank
X X X

H Environmental note

Switch off the engine. Engine oil Secure the vehicle/equipment against rollWhen changing the oil, select an engine oil ing away. that is compatible with the SAE classification Switch off the auxiliary heating system. and the outside temperatures expected durY page ing the period of use ( 46).

Driving m ode/ working m ode

If AdBlue /DEF comes into contact withafter refuelling. Automatic continuous bleeding takes place in the filter. your eyes or skin, rinse affected areas with The battery must be sufficiently charged durclean water immediately.

44

Winter operation
Coolant G WARNING
When opening the coolant expansion tank, there is a risk of scalding due to hot coolant spraying out. The cooling system and coolant expansion tank are pressurised when the engine is at operating temperature. Wear gloves and eye protection. Only open the coolant expansion tank when the coolant temperature is below 50 . gloves, an apron and a face mask. Immediately rinse acid splashes off with clean water. Consult a doctor if necessary. Wear eye protection.

Driving m ode/ working m ode

Keep children away.

G WARNING
Coolant contains glycol and is therefore toxic. Observe this Owner's ManDo not swallow the coolant. See a doctor ual. immediately if you swallow coolant. Make sure that coolant does not come into contact with skin, eyes or clothing. In case of Always aim to achieve the full charge status. contact with eyes, rinse immediately with You of can do this by means of careful mainteplenty of clean water. Clean affected areas nance skin and clothing with soap and water imme- and low electrical consumption. The cold start capacity is reduced when it is very diately. Change any affected clothing immecold. For example, at -10 it is only around diately.

60 % of the normal capacity. Check the antifreeze protection properties of the coolant in good time and increase Notes the forwhen the engine is out of use antifreeze/corrosion inhibitor concentration If the engine/vehicle/equipment is to be out Y page if necessary ( 48). of use for longer than three weeks, disconnect the negative terminal on the battery. This Batteries prevents the batteries from being discharged by no-load current consumers. If the engine/ G WARNING vehicle/equipment is to be out of use for a Comply with safety precautions and take prolonger period, remove the batteries and store tective measures when handling batteries. them in a dry, well-ventilated area. Recharge Risk of explosion the batteries: R before operating the engine/vehicle/ equipment again or Fire, naked flames and R at least every three months for longer perismoking are prohibited ods of disuse. when handling the battery.If the engine/vehicle/equipment is out of use Avoid creating sparks. for a long period, store the batteries in a Battery acid is caustic. heated area if possible. Ensure good ventilaAvoid contact with the skin, tion when recharging. Refer to the "Decomeyes or clothing. missioning the engine" section Wear suitable protective (Y page 80) for further information.
clothing, in particular

45
Service products ................................. 46 Cleaning and care ............................... 55 Maintenance 56 ........................................

Maintenance and care

46

Service products
antifreeze, coolant exhaust gas afterAdBlue /DEF (BlueTec Introduction to service products treatment reduction agent) G WARNING Approved service products fulfil the highest quality standards and are documented in the Service products are hazardous to health. Mercedes-Benz Specifications for Service They contain toxic and caustic substances. Service products are highly flammable.Products. Damage caused by the use of service products that have not been approved Forthisreason, observe the following instrucinvalidates the implied warranty. For this reations to prevent injuries to yourself and othson, only use service products that have been ers: approved for your engine. R Do not inhale the vapours. When indoors, You can recognise service products approved always ensure there is sufficient ventilation by Mercedes-Benz by the following inscripto prevent intoxication. tion on the container:

Service products

R R

Maintenance and care

Mercedes-Benz for your engine is available The use of approved service products is online an at http://bevo.mercedesintegral part of the implied warranty. benz.com/ ! Special additives (except approvedifuel The specification and availability of lubriadditives) are neither required nor cants may vary. Individual lubricants may approved for use with approved service no longer be available, especially for older products. Additives could cause damage to engines. Information is available from any the assemblies. Therefore, do not mix Mercedes-Benz any or MTU Service Centre additives with service products. (Y page 11). You are responsible for the results of using fuel additives.

Do not let service products come into conR MB Approval (e.g. Approval 228.5) tact with skin, eyes or clothing. Should contact occur, however, clean the affected or R MB Approval 228.5 areas of skin with water to prevent caustic burns and other injuries. Other labels and recommendations relating tothorthe quality or indicating that the product In the event of eye contact, wash eyes meets a certain specification are not necesoughly with plenty of clean water. sarily approved by Mercedes-Benz. Further Fire, naked flames and smoking are forbidinformation is available from any Mercedesden when handling service products due to Y page Benz or MTU Service Centre ( 11). their high flammability. Observe the usage and warning notices Information about service products that i on the containers. have been tested and approved by

H Environmental note

Engine oils

Notes on engine oils Dispose of service products in an environmentally-responsible manner. Only use engine oils that comply with the
Service products are, for example:
R R

fuels (e.g. diesel) lubricants, e.g. engine and transmission oils, hydraulic fluids, greases

Mercedes-Benz Specifications for Service Products.

Service products 47
The following engine oils are approved: only use engine oils compliant with Sheet no. 228.5 / 228.51 / 228.3 / 228.31. R Sheet no. 228.5 / 228.3 standard quality exhaust gas For engines without BlueTec multi-grade engine oils aftertreatment, compliant oils with Sheet no. R Sheet no. 228.51 / 228.31 low-ash multi228.1 can also be used. This is also required grade engine oils for a mixture of conventional diesel fuels and R Sheet no. 228.2 standard quality singleFAME fatty acid methyl ester fuels (bio-diesel grade engine oils fuel). R Sheet no. 225.6 multi-grade engine oils, Multi-grade engine oils compliant with Sheet initial operation oils no. 228.5 / 228.51 / 228.3 / 228.31 / 228.1 of a different quality grade arebe used throughout the year. Depending can ! Engine oils not permissible and may damage the on the fuel quality (fuel sulphur content or engine. FAME fatty acid methyl ester fuel), the oil change intervals may be shortened. For Mercedes-Benz particularly recommends engine oils that comply with Sheet no.details, 228.5 see the Maintenance Booklet. Single-grade engine oils compliant with Sheet of the Mercedes-Benz Specifications for no. 228.2 / 228.0 only cover an SAE class Service Products. (viscosity) for a certain temperature range. These engine oils are of a high standard of Change the engine oil to an SAE class suitable quality and have a beneficial effect on: for the time of year and the respective outside R engine wear temperatures. R fuel consumption The use of low-ash engine oils is permissible R exhaust emissions but not essential. When low-ash engine oils compliant with Sheet no. 228.51 and 228.31 The maximum interval for oil change is only are used, achieved with engine oils of a particularly high a low-sulphur diesel fuel (less than 50 ppm, 0.005 % by weight) should be used. quality grade. If this low-sulphur diesel fuel is not available, i You can find information on the quality standard oils compliant with Sheet no. grade, e.g. Sheet no. 228.5, and the vis228.5 / 228.3 / 228.2 should be used. cosity, e.g. SAE class 5W-30, from the designation on the oil container.

Oil change

Oil change intervals are dependent on the following: For engines in vehicles/equipment operating R the operating conditions of the vehicle with diesel fuel, only use multi-grade engine oils compliant with Sheet no. 228.5 / R the grade of the engine oil used 228.51 / 228.3 / 228.31 or single-grade R the fuel grade (sulphur content) engine oils compliant with Sheet no. 228.2. R the fuel type, e.g. FAME fatty acid methyl exhaust gas For engines without BlueTec ester fuel aftertreatment, multi-grade oils compliant For more details, see the Maintenance Bookwith Sheet no. 228.1 and single-gradelet. oils compliant with Sheet no. 228.0 can also be ! If you do not use oil for all-year-round used. operation in your engine, change the For vehicle/equipment operation with FAME engine oil right at the beginning of the cold fatty acid methyl ester fuel (bio-diesel fuel), season. Use only an approved engine oil in the specified SAE classification.

Scope of use

Maintenance and care

48

Service products
If the SAE class (viscosity) of the engine oil oils. Information is available from any engine used is not suitable for continually low Mercedes-Benz outor MTU Service Centre. side temperatures below 20 , this could cause engine damage. Adding/topping up the engine oil The specified temperatures of the SAE Do not add too much oil. If you add too much class always refer to freshly added oil. oil, the engine or the catalytic converter could Engine oil ages during driving due to soot be damaged. Drain or siphon off any excess and fuel residue. This impairs the characoil. teristics of the engine oil, particularly at low When topping up, Mercedes-Benz recomoutside temperatures. mends Mercedes-Benz strongly recommends that, that you only use engine oil of the same at outside temperatures below 20 , you grade and SAE class as the oil filled at use engine oils of SAE class 5W-30. the last oil change. Check the oil level before topping up the Y ( engine oil page 34). You can find more information on topping up the engine oil in the Changing the engine oil Y page and filter section ( 62).

Maintenance and care

Miscibility of engine oils


The benefits of high-quality engine oils are diminished if you mix them. Engine oils are differentiated according to: engine oil brand R quality grade (Sheet no.) R SAE viscosity class If, in exceptional circumstances, the type of engine oil currently used in the engine is not Engine oil SAE classes (viscosity) available, another mineral or synthetic engine : Single-grade engine oils oil may be used. Make sure it is approved for ; Multi-grade engine oils Mercedes-Benz. X Select the SAE class of engine oil in accordObserve the notes in the Service Booklet. ance with outside temperatures. i You can only achieve the maximum oil change intervals by using engine oils Coolants of particularly high quality (e.g. in accordance Coolant additive with antifreeze propwith Sheet no. 228.5 of the Mercedes-Benz erties Specifications for Service Products). The coolant is a mixture of water and corroH Environmental note sion inhibitor/antifreeze.
R

If you operate your vehicle using FAME fatty acid methyl ester fuel (bio-diesel), special precautions must be taken and national specifications complied with when disposing of

Service products 49
The corrosion inhibitor/antifreeze in the antifreeze coolagent, the cooling system must Y page ant has the following properties: first be flushed ( 76). When renewing the coolant, ensure that it R anti-corrosion protection contains 50% by volume of corrosion inhibiR antifreeze protection tor/antifreeze agent. This corresponds to R increases the boiling temperature antifreeze protection down to 37 . Leave the coolant in the engine all year round Do not exceed 55% by volume (antifreeze proin 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 conThe 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/antidrinking water. The water must be treated if freeze agents. its quality does not meet the required standards. Topping up coolant Please note the Mercedes-Benz SpecificaWhen topping up, only use prepared coolant tions for Service Products, Sheet numwith 50% by volume corrosion inhibitor/antiber 310.1. freeze agent. Before topping up, observe the qualityFurther of the information about operating and road for your engine/vehicle/equipment is corrosion inhibitor/antifreeze agent in safety the available from any Mercedes-Benz or MTU cooling system (Sheet no.). Corrosion inhibiY page Service Centre ( 11). tors/antifreeze agents compliant with Sheet 325.3 and 326.3 must not be mixed with Coolant additive without antifreeze propthose of Sheet 325.0/2 or 326.0/2. erties Only top up using a corrosion inhibitor/antiIf your vehicle does not need antifreeze profreeze agent of the same quality grade. tection, e.g. in countries with consistently high outside temperatures, you can, as an Miscibility of corrosion inhibitor/antiexception, use a coolant additive. freeze agents Instead of corrosion inhibitor/antifreeze ! Corrosion inhibitors/antifreeze agents additive, add a coolant additive compliant that comply with Sheet 325.3 and 326.3 with Sheet number 312.0 of the Mercedesmust not be mixed with those of Sheet Benz Specifications for Service Products to 325.0/2 or 326.0/2. This prevents damage to the engine cooling system. the water. Improvers (corrosion-inhibiting oils) are not Renewing coolant permitted. Coolant change with antifreeze protection: Renew the coolant annually. Further information about the required water R every three years if using corrosion inhibiquality and approved coolant additives withtor/antifreeze agent compliant with Sheet out antifreeze protection is available from any 325.0/2 and 326.0/2 Mercedes-Benz or MTU Service Centre R every five years if using corrosion inhibitor/ (Y page 11). antifreeze agent compliant with Sheet 325.3 and 326.3 Coolant change with corrosion inhibitor/antifreeze agent compliant with Sheet 325.3, 326.3: before adding this corrosion inhibitor/
Z

Maintenance and care

50

Service products
Fuel grade in accordance with EN 590 is prescribed as mandatory for engines with Important safety notes exhaust gas aftertreatment. If BlueTec diesel fuel which does not comply with EN G WARNING 590 is used, it can damage the exhaust Fuel is highly flammable. Fire, naked flames system.

Diesel fuels

Maintenance and care

and smoking as well as the use of auxiliary heaters (sparks) are therefore prohibited Fuel grade when handling fuel. The following is an overview of typical sulphur Switch off the engine and the auxiliary heating content in percent by weight of fuel available before refueling.

G WARNING

Avoid contact with fuels. It is hazardous to your health if your skin comes into direct contact with fuels or you i In some countries, diesel fuel of differing sulphur contents is available. Diesel fuel breathe in fuel vapours.

in various countries. You may obtain information about current country-specific fuel sulphur contents from any Mercedes-Benz or Y page MTU Service Centre ( 11).

with a lower sulphur content is sold under If you are using drums or canisters tothe name "Euro diesel" in some countries. refuel the engine/vehicle/equipment, you should filter the fuel before filling. This prevents malfunctions in the fuel system caused by contaminated fuel. Only refuel with commercially available diesel vehicle fuel that complies with the European standard EN 590. EN 590 describes a sulphur-free fuel with a maximum sulphur content of 10 ppm. However, it is also permitted to operate engines exhaust gas aftertreatment with BlueTec with up to 50 ppm. exhaust gas For engines without BlueTec aftertreatment, the maintenance intervals must be reduced when operating with higher sulphur contents. For details on this, see the table below. Even if the maintenance intervals are reduced, operation with higher sulphur contents will lead to increased engine wear, especially on the fuel injectors. When necessary, use only approved fuel additives. There is otherwise a risk of impaired engine performance or engine and catalytic converter damage. The use of appropriate fuel additives is your responsibility.

Service products 51

Fuel sulphur content (proportion by weight, in percent) Continent Country % by weight

5, Armenia, Azerbaijan, Belarus, Belgium, Europe, CIS Albania 0 ... 0.1 Bosnia-Herzegovina, Bulgaria, Denmark, Germany, Estonia, Finland, France, Georgia, Greece, United Kingdom, Ireland, Iceland, Italy, Croatia, Latvia, Lithuania, Luxembourg, Malta, Macedonia, Moldova, Montenegro, Netherlands, Norway, Austria, Poland, Portugal, Romania, Sweden, Switzerland, Serbia, Slovakia, Slovenia, Spain, Czech Republic, Turkey, Turkmenistan, Ukraine, Hungary, Cyprus

Albania, Georgia, Macedonia, Moldova, Russia, 0.1 ... 0.3 Ukraine, Uzbekistan Kazakhstan, Kyrgyzstan, Croatia, Turkmenistan, 0.3Tur... 0.8 key, Ukraine, Uzbekistan Australia, OceAustralia, French Polynesia, New Zealand ania Fiji Islands, New Caledonia Asia 0 ... 0.1 0.3 ... 0.8

Bangladesh, Bhutan, Brunei, China, Hong Kong, 0 ... India, 0.1 Japan, Cambodia, Laos, Nepal, Philippines, Singapore, Sri Lanka, South Korea, Taiwan, Thailand China, Indonesia, Malaysia, Mongolia, Tajikistan 0.1 ... 0.3 Myanmar (Burma), Pakistan, Vietnam 0.3 ... 0.8

Southwest Israel, Qatar, Lebanon, Oman, Palestine, West 0Bank ... 0.1 Asia, Middle Oman, United Arab Emirates 0.1 ... 0.3 East Bahrain, Kuwait, Lebanon, Saudi Arabia, Syria0.3 ... 0.8
5

Diesel fuels with the sales designation "Euro diesel" only.


Z

Maintenance and care

Fuel sulphur content table The following overview specifies the current country-specific sulphur content of fuel in dies fuel in percent by weight (% by weight). You can find a continually updated table of fuel sulphur contents in specific countries in Mercedes-Benz Specification for Service Products, Sheets 136.1 and 136.2 at http:// bevo.mercedes-benz.com. Countries that are mentioned more than once offer different fuel grades with varying fu sulphur contents in parallel. No information is available for countries that are not listed. The maintenance intervals for engine oil and filter replacement must be adapted depen on the fuel grade used. The higher the sulphur content in diesel fuel, the shorter the ma nance intervals for engine oil and filter replacement. Observe the notes in the Maintena Booklet.

52

Service products
Fuel sulphur content (proportion by weight, in percent) Continent Country Iran, Iraq, Jordan, Yemen North America Canada, Mexico, USA % by weight 0.8 ... 0 ... 0.1

Maintenance and care

6, Bolivia, Brazil, Chile Central Amer0 ... 0.1 Argentina ica, South 0.1 ... Suri0.3 America, theArgentina, Brazil, Columbia, Costa Rica, Ecuador, Caribbean name, Trinidad and Tobago, Uruguay Dominican Republic, El Salvador, Guatemala, 0.3 Hondu... 0.8 ras, Cuba, Panama, Peru, Venezuela

Africa

Egypt, Algeria, Morocco, South Africa Angola, Morocco, Mauritius, Tunisia

0 ... 0.1 0.1 ... 0.3

Benin, Ghana, Kenya, Libya, Malawi, Mali, Mozambique, 0.3 ... 0.8 Nigeria, Zambia, Senegal, Tanzania Burkina Faso, Congo, Ethiopia, Ghana, Kenya,0.8 Mada... gascar, Morocco, Sudan, Uganda

Diesel fuels at low temperaturesriorate as a consequence of the flow

improver. At low outside temperatures, paraffin sepaIf the summer diesel fuel or winter diesel fuel with ration may cause the flow properties of less resistance to low temperatures is in use, diesel fuel to be insufficient. add a quantity of flow improver, depending on To prevent operating problems, diesel fuel the outside temperatures. with improved flow properties is available in Add the fuel additive to the diesel fuel in good the winter months. time, before paraffin separation causes the Winter diesel fuels are reliable down to outdiesel fuel's flow properties to be insufficient. side temperatures of22 in Germany and Malfunctions as a result of paraffin separation other Central European countries. You can can only be rectified by heating up the comnormally use winter diesel fuel without probplete fuel system. lems at the outside temperatures expected in The engine can be equipped with a heated the country where it is on sale. fuel prefilter with water separator. This also improves the flow characteristics of the dieFuel additives sel fuel by approximately 8 . General notes Flow improvers Fuel additives used to improve flow characThe effectiveness of flow improvers cannot be teristics are flow improvers. guaranteed with all fuels. Follow the manuDo not add flow improvers to winter diesel facturers recommendations. Information fuel guaranteed to operate down to 22 . approved flow improvers is available about Thecold flow properties of the fuel may dete6

Shell Pura only.

Service products 53
R if the from all Mercedes-Benz or MTU Service Cenvehicle is not used for long periods tres Y ( page 11). of time, FAME fatty acid methyl ester fuel can clog fuel system components. For If you add a flow improver to the FAME fatty this reason, use all the FAME fatty acid acid methyl ester fuel, the fuel's resistance to methyl ester fuel before long periods of low temperatures does not change. time when the vehicle is not used. Fill up the fuel tank with conventional diesel fuel. Allow the engine to run for at least Fatty acid methyl ester (FAME) fuel one hour before switching off the vehi(bio-diesel) cle/equipment. General notes R Mercedes Benz recommends that you do not use FAME fatty acid methyl ester fuel ! To avoid damage to the assemblies and for engines that are not used for long components, observe the following points periods of time, e.g. fire engines. when using FAME fatty acid methyl ester R the auxiliary heating may only be operfuel: ated with conventional diesel fuel. OthR have the fuel filter and the oil filter replaced approximately 1000 km aftererwise, the system may malfunction. switching to FAME fatty acid methyl Conventional diesel fuel already contains a percentage of FAME fatty acid methyl ester fuel. ester fuel. Therefore, do not add more R have the oil filter and the fuel filter than 5% FAME fatty acid methyl ester fuel replaced at every oil change. to conventional diesel fuel. R the oil will have to be changed and the oil An additional fuel tank is required for filter replaced much more frequently. conventional diesel fuel for the auxiliary R FAME fatty acid methyl ester fuel shortheating system, if you operate the vehiens the service life of conventional fuel cle: filters. For this reason, Mercedes-Benzusing FAME fatty acid methyl ester fuel recommends the installation of a special - using a mixture of conventional diesel fuel prefilter. Information about this is fuel and more than 5% FAME fatty acid available at any qualified specialist workmethyl ester fuel. shop, e.g. a Mercedes-Benz or MTU R

H Environmental note Service Centre. only add FAME fatty acid methyl ester If the vehicle runs on FAME fatty acid methyl fuel in compliance with DIN EN 14214. ester fuel, ask your disposal plant whether Fuel additives or fuels that do not comply you have to collect the engine oil separately. with DIN EN 14214 may cause malfuncNot all manufacturers of refined products tions or engine damage. (lubricant manufactured from used engine oil) can process engine oil which has been FAME fatty acid methyl ester fuel corenriched with FAME fatty acid methyl ester rodes painted surfaces. Do not allow fuel. FAME fatty acid methyl ester fuel to come into contact with the paintwork. Observe the special notes and national reguRinse off FAME fatty acid methyl ester lations when disposing of engine oils. Inforfuel with water immediately. mation about this is available at any qualified specialist workshop, e.g. any Mercedes-Benz preferably only add engine oil in accordor MTU Service Centre. ance with Sheet no. 228.5/51 or 228.3/31 of the Mercedes-Benz Specifications for Service Products.
Z

Maintenance and care

54

Service products
Operate your engine using pure FAME High fatty outside temperatures acid methyl ester fuel compliant with G DIN EN 14214. You can also operate your WARNING If the AdBlue /DEFtank cap is opened at high engine using a mixture of conventional diesel temperatures, ammonia vapours may escape. fuel and FAME fatty acid methyl ester fuel. This also applies to engines with BlueTec Ammonia vapours have a pungent odour and exhaust gas aftertreatment. particularly irritate: Observe the specifications in accordance R skin with Sheet no. 135.0 of the Mercedes-Benz R mucous membranes Specifications for Service Products for opereyes ation with FAME fatty acid methyl esterRfuel. The Operating the vehicle with FAME fatty acid vapours may cause a burning sensation in the eyes, nose and throat as well as irritamethyl ester fuel results in:
R R R

Maintenance and care

a slightly higher fuel consumption Avoid inhaling ammonia vapours. a slightly reduced engine power output G WARNING increased white smoke after a cold start

tion of the throat and watering eyes.

Low outside temperatures

AdBlue /DEF must not come into contact with skin, eyes or clothing.

FAME fatty acid methyl ester fuel compliant R If AdBlue /DEF comes into contact with with DIN EN 14214 can be used reliably at your eyes or skin, rinse affected areas with outside temperatures down to 20 . clean water immediately. For lower temperatures, the engine can R be If AdBlue /DEF is swallowed, immediately equipped with a fuel preheating system. This rinse your mouth out with a lot of clean improves the flow characteristics of the FAME water and drink plenty of water. fatty acid methyl ester fuel according to the R Change clothing that is soiled with heat output installed.

R AdBlue /DEF Notes on AdBlue /DEF

AdBlue/DEF immediately. If allergic reactions occur, consult a doctor immediately.

Keep AdBlue /DEF out of the reach of children.

AdBlue /DEF is a non-flammable, non-toxic, The chemical composition of AdBlue /DEF colourless, odourless and water-soluble liqcan break down if it heats up to 50 over a uid. long period (e.g. as a result of direct sunlight The terms "Urea" and "DEF" (Diesel Exhaust on the tank). This creates ammonia vapour. Fluid) are also used for "AdBlue ".

Only use AdBlue /DEF in accordance Low outside temperatures with DIN 70070/ISO 22241 . Do not use AdBlue /DEF freezes at a temperature of any additives. approximately 11 . Winter operation is If AdBlue /DEF comes into contact with alsoensured for temperatures below 11 . painted or aluminium surfaces whenAt filling low temperatures, AdBlue /DEF crystals the tank, rinse the affected area immedimay form on the coiled hose between the ately with plenty of water. engine and the silencer. This crystallisation does not pose a risk to the correct operation

Cleaning and care 55


exhaust gas aftertreatment.Purity of BlueTec The AdBlue/DEF crystals can be removed with /DEF, e.g. due to ! Impurities in AdBlue clean water if necessary. other service products, cleaning products or dust, may lead to:

Additives, tap water !

Ensure that AdBlue /DEF is always pure to exhaust gas avoid malfunctions in BlueTec Only use containers made of the following aftertreatment. materials to store AdBlue /DEF: If AdBlue /DEF is pumped from the tank, e.g. R Cr-Ni steels in accordance with during repairs, do not use this fluid to refill the DIN EN 10 088-1/2/3 tank. Otherwise the purity of the fluid would R Mo-Cr-Ni steels in accordance with no longer be guaranteed. DIN EN 10 088-1/2/3 R Polypropylene Cleaning and care R Polyethylene

Storage

Notes on care Containers made of the following materials are not suitable for the storage of G WARNING AdBlue /DEF:
R

aluminium the reach of children. Always follow the R copper instructions for the use of the care products. R copper alloys Donotuse fuel as a cleaning agent. Fuels are highly flammable and constitute a health hazR unalloyed steel ard. R galvanised steel If AdBlueis stored in these types of conRegular care helps to maintain the value of tainer, constituents of these metals may the engine. exhaust dissolve and damage the BlueTec Mercedes-Benz recommends that you only gas aftertreatment beyond repair. use care products that have been approved

Always keep care products sealed and out of

Disposal H Environmental note

for Mercedes-Benz. You can obtain these care products from any Mercedes-Benz or Y page MTU Service Centre ( 11).

Dispose of AdBlue /DEF in an environmentally responsible manner. High-pressure cleaning

Observe laws and regulations on the disposal ! The exhaust gas aftertreatment system of AdBlue /DEF in the country concerned. may only be cleaned when it is cool. The sensors can otherwise be damaged.

Maintenance and care

Do not mix additives to AdBlue /DEF. Do not dilute AdBlue /DEF with tap water. exhaust This could destroy the BlueTec gas aftertreatment system.

R R R R

increased emission values damage to the catalytic converter engine damage exhaust gas malfunctions in BlueTec aftertreatment.

56 !

Maintenance
When cleaning, never point the water jet Maintenance at the exhaust pipe. The system may othGeneral information erwise be damaged.

Maintenance and care

G WARNING When using a high-pressure cleaner, keep a minimum distance between the highBefore carrying out maintenance or repair pressure nozzle and the engine parts. Oth- you must read the relevant sections of work, erwise, parts of the engine may be damthetechnical documentation relating to mainaged. tenance and repair measures, e.g. the Operating Instructions and workshop information. Observe the following minimum distances:
R R R

about 70 cm with round-spray jets In particular, first familiarise yourself with the legal regulations, e.g. work safety and acciabout 30 cm with 25 flat-spray jets dent prevention regulations. about 30 cm with concentrated-power You could otherwise fail to recognise dangers jets
and injure yourself or others.

Keep the water jet moving constantly Always have maintenance work carried out at while cleaning. In this way, you will avoid a qualified specialist workshop which has the causing damage. necessary specialist knowledge and tools to Do not point the water jet at: carry out the work required.
R R R R

electrical components plug connectors seals hoses

Mercedes-Benz recommends that you use a Mercedes-Benz or MTU Service Centre for this purpose. All work relevant to safety or on safety-related systems must be carried out at a qualified specialist workshop.

Cleaning the engine !

G WARNING
Maintenance work that is carried out incor-

rectly or not at all, e.g. not changing the oil Observe the following notes when cleanfilter or not observing maintenance intervals, ing the engine. This avoids malfunctions can cause engine damage. Engine damage and damage to the engine.
R

R R

When using high-pressure or steamcan lead to an increased risk of accidents. Therefore, observe the notes on engine maincleaners, do not point the spray directly tenance in these Operating Instructions. at electrical components and electric cables. H Make sure that no water enters the air Environmental note If circumstances demand that you have to do intake and ventilation openings. Treat the engine with preservative some maintenance work yourself, environmental protection requirements must be agents after it has been cleaned. When observed. When disposing of service proddoing so, protect the belt drive system ucts, e.g. engine oil, you must comply with the from the preservative agent. legal requirements. This also applies to all Use only wax preservative for engines parts, e.g. filters, that have been in contact according to sheet number 385.4 of the with service products. For vehicles run on Mercedes-Benz Specifications for FAME (fatty acid methyl ester) fuel, the speService Products.

cial instructions on disposing of engine oil must be observed. For more information, visit a qualified specialist workshop, e.g. a

Maintenance 57
Mercedes-Benz or MTU Service Centre. Dispose of empty containers, cleaning cloths and care products in an environmentally responsible manner. Observe the instructions for care products. Do not let the engine run longer than necessary when stationary.

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 instructions for special accessories.

Maintenance and care

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.

58

59
Work schedule overview .................... 60 Work schedules .................................. 62

Notes on m aintenance

60

Work schedule overview


Work schedule overview Maintenance work overview
W ithout BlueTec W ith BlueTec

Notes on m aintenance

Maintenance schedule for maintenance service Engine: oil and filter change
7Operation with diesel fuel: AP18.00-W-0101C carry out an oil and filter change at least every two years . 7Operation with FAME fuels (bio-diesel): AP18.00-W-0101C carry out an oil and filter change at least once a year .

Check and adjust the fluid level


7 Engine cooling system: check corrosion/antifreeze AP20.00-W-2010A protection. Adjustment subject to a separate invoice. In the event of fluid loss, find the cause and remedy it.

Engine
7 Check poly-V-belt for wear and tear and damage. AP13.22-W-1351A

Additional maintenance work every second maintenance service (Z2)


7 Check V2 valve clearance, adjust (first maintenance service, AP05.30-W-0560A third, fifth, seventh, etc.). 7 Replace AdBlue AP14.40-W-1481A /DEF filter.

Additional work every third maintenance service (Z3)


7 Fuel prefilter: cleaning the filter element. AP47.20-W-0730B

7 Fuel prefilter with water separator: replace fuel filter. AP47.20-W-0783A 7 Fuel FAME AP47.20-W-0780A filter: replace fuel filter element. For operation with 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.

Work item number of the Mercedes-Benz workshop information system (WIS).

Work schedule overview 61


W ithout BlueTec W ith BlueTec

Maintenance work by year Once a year (J1)

7 Filling the AdBlue AP14.40-W-1490A /DEF pressure reservoir. 7 Check for leaks and condition of assemblies. AP00.20-W-0050A

7 Lines and hoses, sensor cables check for leaks and condi AP00.20-W-0051A tion.

7 Intake pipe between air filter, charge-air cooler and engine AP09.00-W-0953A check for leaks and condition. 7 All reservoirs, covers, bellows, protective caps. AP20.20-W-T052A

7 Heating system: condition check, radiator, lines and hoses. AP20.00-W-2050A

Every three years (J3) Engine


7 Renew AP20.00-W-2080A coolant, according to Sheet Number of the antifreeze/ anti-corrosion additive in the Specifications for Service Products, every three or five years (observe coolant mixture ratio). If very dirty: clean the cooling system (for a separate order). 7 Replace air filter element according to equipment/vehicle AP09.10-W-0980A manufacturer's specifications. Observe installation date.

Final inspection Visual check/road test/test rig: that the equipment is safe to operate/ check check that the vehicle is roadworthy.

Work item number of the Mercedes-Benz workshop information system (WIS).

Notes on m aintenance

Check for areas of abrasion and incorrect routing. In the event of fluid loss, find cause and remedy.

62

Work schedules
Work schedules Siphoning and draining engine oil
Dispose of engine oil and filters in accordance

H Environmental note Changing the engine oil and filter Temperature for oil and filter change with the applicable regulations for your location. Only change the engine oil when the engine is at normal operating temperature. i Only siphon off/drain engine oil with the engine at normal operating temperature. Oil filter replacement

Notes on m aintenance

X X

Make sure that no foreign objects enter : Filler neck the filter housing. Never wipe the filter ; Oil dipstick housing out because lint or dirt can enter X To siphon off engine pull oil: out oil dipthe oil circuit. stick; . Unscrew oil filter cap : using a socket X Insert the extractor system into the guide spanner insert (SW 36). Allow the oil to tube, using an O-ring to seal it. drain from the filter housing. X Siphon off the engine oil through the guide Remove oil filter : cap with oil filter eletube. ment = and unclip oil filter element = by pressing in a sideways direction. i Observe the extraction pump operating Replace sealing ring ; on cap : . Lightly instructions. grease the sealing ring. G WARNING Insert new oil filter element = intooil filter Hot engine oil escaping under pressure can cap: and press until it clips into place. scald your skin and eyes. Screw on oil filter : cap with the oil filterWear suitable protective gloves, protective element and tighten. Tightening torque: clothing and safety goggles. 25 Nm.

Example: OM 926 LA

Work schedules 63
engine oil in accordance with outside temperatures. 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 anoil pressure reading is displayed. If no oil pressure is displayed after approximately 10 seconds, switch off the engine. Determine the cause.

X X

An oil drain hose is available as optional Layout of cylinders and valves equipment.

Adding engine oil

: # Example: OM 926 LA
X

- B Cylinder number

J C

Add new engine oil to the engine via filler neck: up to the maximum mark on dipstick; . Select the SAE viscosity class of

Intake valve Exhaust valve Flywheel side

Notes on m aintenance

Example: drain plug

X Check the oil filter cap and the drain plug To drain off engine place oil: a suitable for leaks. collecting receptacle under drain X Check the oil level after about 5 minutes : plug on the underside of the oil pan. and add oil up to the upper marking on the Carefully unscrew drain: plug and allow oil dipstick. the oil to drain out. Screw in and tighten drain with a : plug Y page new seal (tightening torque ( 105)). Checking valve clearance, adjusting

64

Work schedules
Special tool G WARNING
If the engine starts automatically, there is a riskof injury by limbs being crushed between the moving parts. Secure the engine against unintentional starting before carrying out maintenance or repair work.

G WARNING

Notes on m aintenance

The engine becomes very hot while it is running and remains so for some time after it has stopped. It will cause burns if touched. Cranking device 904 589 04 63 00 Before starting any work on the engine, allow Valve adjustment tool 422 589 00 11 00 (no all engine parts to cool down, or wear suitable image) gloves and items of clothing to protect yourself from being burned on hot engine compoValve clearance nents.

Inlet valves Exhaust valve Test toler-Inlet ance valves

0.40 mm 0.60 mm +/- 0.05 mm

Removing and fitting the cylinder head covers

Exhaust +/- 0.10 mm valve The tolerance is only applicable for checking, not as a valve clearance setting. Adjust the valve clearance when the engine is cold (at least 30 minutes after stopping the engine, even if it has only been operated for a brief period).

G WARNING
If not properly secured, a vehicle might accidentally be set in motion, knocking somebody Example: cylinder head cover down or trapping them or causing an accident : Engine ventilation hose and injuring you or others. ; Cylinder head cover R Always prevent the vehicle from rolling = Bolt away by applying the parking brake and, if necessary, using chocks. Sealing washer ? R Shift the transmission into neutral. A Seal R Only turn the engine over using the cranking device provided for this purpose.

Work schedules 65
X X

X X X

Clean very dirty cylinder head covers I inlet valve before removal. E exhaust valve Remove engine ventilation from Valve clearance setting OM 906/926 LA : hose cylinder head cover ; . CrankshaftCylinder/valves to be Remove cylinder head cover ; . position adjusted Remove seal the cylinder head A between 1 2 3 4 5 6 cover and the cylinder head. Clean the sealing surfaces of the cylinder 6th cylinderI/ I A I A head cover and the cylinder head. valve over- E lap 1st cylinder valve overlap A I A I I/ E

I inlet valve E exhaust valve Adjust all valve clearances at two crankshaft positions. X Use the cranking device to turn the crankshaft until cylinder no. 6 / cylinder no. 4 is at TDC valve overlap (cylinder no. 1 at ignition TDC). X Turn cylinder no. 1 to TDC valve overlap (cylinder no. 6 at ignition TDC). Example: flywheel inspection hole X Check and adjust the valve clearance of all X Unscrew the cap from the inspection hole valves in accordance with the table above. in the flywheel housing. Checking and adjusting the valve clearX Fit the cranking device 904 589 04 63 00 ance Y ( page 64) to the flywheel housing inspection hole. Tightening torque: 25 Nm. Valve clearance setting Valve clearance setting OM 904/924 LA CrankshaftCylinder/valves to be position adjusted 1 4th cylinderI/ valve over- E lap 1st cylinder valve overlap 2 I 3 A 4 5 6

I/ E
Z

Notes on m aintenance

66
X

Work schedules
Measure the valve clearance between R the Check the poly-V-belt condition regurocker arm and valve bridge using a feeler larly. gauge (arrow). It should be possible to pull R Replace the poly-V-belt concerned through the feeler gauge with only light immediately if there are any signs of resistance. damage. X Loosen counternutto permit adjust; ment of the valve clearance. Adjust the Special tool valve clearance by turning adjustment Cranking device: 904 589 04 63 00 screw : . (Y page 64). X Tighten the counternut again (tightening torqueY( page 105)). Checking the poly-V-belt. X Check the valve clearance again and corX Fit the cranking device to the flywheel rect. housing inspection hole. Tightening torque: 25 Nm. Concluding work X Replace the gaskets on the cylinder X Make a chalk mark on the poly-V-belt. head X covers. Check the poly-V-belt for damage section X Put on the cylinder head covers and tighten by section; to do this, turn the engine or Y poly-V-belt gradually using the cranking them (tightening torque page ( 105)). until the chalk mark is reached X Remove the cranking device from the device flyagain. wheel housing inspection hole. X Remove the cranking device. X Screw on the cap of the inspection hole of X Screw the cap into the inspection hole in the flywheel housing and tighten it (tightthe flywheel housing and tighten. Tightenening torque: 25). Nm ing torque: 25 Nm. X After fitting, run the engine and check the X Replace the poly-V-belt: (Y page 97). cylinder head cover area for leaks.

Notes on m aintenance

Patterns of damage Checking poly-V-belt for wear and ! Replace the poly-V-belts if one of the foldamage. G WARNING
lowing damage patterns occurs on the polyV-belt.
Faulty poly-V-belts can tear, the belt or parts of it could then be thrown off the engine, thereby causing injury to others. R Always observe the specified maintenance intervals for poly-V-belts. R If damage is detected, replace the poly-Vbelt concerned immediately.

If the poly-V-belt is torn, there is no drive tothecoolant pump and the alternator. The engine may overheat as a result.

Work schedules 67

E Cord torn out of the side F ?

Outer cord frayed

Breaks in the ribs

A Transverse cracks in several ribs

G Transverse cracks on the back of the belt H Transverse cracks in several ribs
X

B Rubber nodules at the base of the belt C Deposits of dirt or stones

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.
Z

Notes on m aintenance

New condition (for comparison; trapezoiD Rib detached from the base of the belt dal ribs) ; Single-sided wear: wedge-shaped ribs = Cord visible at the base of the belt
:

68

Work schedules

Notes on m aintenance

Leakage fuel from the engine ; To the fuel pump = From the fuel tank ? Fuel return line to the fuel tank A Fuel pump
:

Vehicle with fuel prefilter at tank level: close shutoff valve ? . X Place a collector under water drain valve E . X Open water drain valve E andbleed screw . Collect the escaping water/fuel mix= ture. X Unscrew filter element Fuel prefilter with water separator: A from filter replacing the fuel filter head : . X Unscrew water separator G WARNING filter eleD from ment and clean or replace as necessary. A There is an increased risk of fire when hanX Replace filter element dling fuels as they are highly flammable. Avoid A . fire, naked flames and sparks, and refrain X Screw water separator new sealing D with from smoking when handling fuels. ringC onto filter element A until it is hand-tight. Lubricate sealing with a C ring 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 inaccordance with relevant local regring onto filter head B : until it is handulations. tight. Lubricate sealing with a thin Bring The fuel prefilter is fitted on the equipment coator of engine oil beforehand. X Close water release valve vehicle. Observe the operating and mainteE . nance instructions in the equipment/vehicle X Vehicle with fuel prefilter at tank level: operating instructions for the fuel prefilter. open shutoff valve ? . X Push fuel hand pump ; repeatedly until thefuel escapes free of bubbles from bleed screw =. X Close bleed screw =.

Work schedules 69
X X Clean the outside of the filter housing. Start the engine and bleed the fuel system. X Open the fuel filler cap to prevent excess Run the engine for approximately 1 minute. The fuel system bleeds automatically. pressure in the fuel tank. If the engine stalls or does not start, X bleed Unscrew fuel filter : cap using a socket Y page the fuel system manually ( 86). spanner insert (SW 36). X Check the fuel prefilter with water separaX Pull fuel filter capwith filter element : tor for leaks while the engine is running. = out of the filter housing slightly. Allow the fuel to drain off. X Remove the cap and filter element. Unclip Replacing the fuel filter element 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 hanR Make sure that no foreign objects enter dling fuels as they are highly flammable. Avoid the filter housing. fire, naked flames and sparks, and refrain R Never wipe inside the filter housing. from smoking when handling fuels.

H Environmental note

R X

Theingress of water must be prevented.

Replace sealing ring ; with a new one Dispose of used filter elements, seals and fuel (grease lightly). residue inaccordance with relevant local X regClip new filter element = into housing ulations. cover : . X Screw on and tighten oil filter cap H Environmental note : with filter element (tightening torque: = If the diesel fuel level (fuel tank) is above 25 Nm). engine height, the feed line must be blocked X Put on the fuel filler cap and tighten it. off during filter replacement. Otherwise, dieX Start the engine and bleed the fuel system sel can drain out. (Y page 86). X Run the engine for approximately 1 minute. The fuel system bleeds automatically. If the engine stalls or does not start, bleed the fuel system manually. X Check the fuel filter for leaks with the engine running.
Replacing the AdBlue /DEF filter

G WARNING
If the AdBlue /DEF tank cap is opened at high temperatures, ammonia vapours may escape.

Example: OM 926 LA

Notes on m aintenance

70

Work schedules
If AdBlue /DEF gets into the coolant cir! and Ammonia vapours have a pungent odour cuit (even minute amounts), thermostats particularly irritate:

skin R Always keep AdBlue /DEF completely R mucous membranes separate from other service products. R eyes R Do 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 irritaother service products. tion of the throat and watering eyes. R Do not continue to use service products Avoid inhaling ammonia vapours.
R

and temperature sensors will be damaged.

that contain traces of AdBlue /DEF.

Notes on m aintenance

G WARNING

Individual components of the BlueTec AdBlue/DEF must not come into contact system react very sensitively to even the slightest trace of impurities in AdBlue / with skin, eyes or clothing. DEF. R If AdBlue /DEF comes into contact with R Only use containers and fluid collecting your eyes or skin, rinse affected areas with pans that are clean and suitable for clean water immediately. AdBlue /DEF. R If AdBlue /DEF is swallowed, immediately R Do not continue to use AdBlue /DEF rinse your mouth out with a lot of clean which contains traces of impurities. water and drink plenty of water.

R R

Change clothing that is soiled with Fire fighting measures AdBlue /DEF immediately. If allergic reactions occur, consult a doctor AdBlue /DEF is not flammable. In the event immediately. of a fire, NH 3 (ammonia) may be released.

This may result in a risk of poisoning. MeasKeep AdBlue /DEF out of the reach of chilures to extinguish a fire must therefore be dren.

G WARNING

adapted to suit the surroundings.

H Environmental note The AdBlue /DEF lines and all connected Disposing of AdBlue /DEF: components are pressurised during operation R Due to its easy degradability, small and could be hot, even after the engine has amounts of spilt AdBlue /DEF can be been switched off. There is a risk of burns. washed into the sewage system without When opening the pressurised system, there any problems. is a risk of scalding due to hot AdBlue /DEF

R Larger amounts of AdBlue /DEF must be spraying out. disposed of correctly, observing the reguR Wait at least 5 minutes after switching off lations on waste treatment/disposal. the engine before starting work on the exhaust gas aftertreatment system. R Packaging that is contaminated with AdBlue /DEF residue must be treated in R Open line connections and caps on system the same way as AdBlue . Packaging components slowly. Cover the area that should be emptied as thoroughly as possiyou are disconnecting with a cloth. ble, cleaned appropriately and then recyR Wear suitable protective gloves, protective cled. clothing and safety goggles.

Work schedules 71
X

Insert new filter element ; into filter bowl? . Use MB silicon grease as a lubricant. Screw filter bowl ? into pump module : and tighten. Tightening torque: 32 Nm. Only MB silicon grease is permissible as a lubricant. Use MB silicon grease very sparingly, otherwise damage to the exhaust gas aftertreatment system could result. The system is self-bleeding and does not need to be bled manually.

AdBlue /DEF pump/filter unit

Filling the AdBlue /DEF pressure reservoir

Pump module ; Filter element = O-ring ? Filter bowl A Dust protection cap
:

Important safety notes G WARNING

If the AdBlue /DEF tank cap is opened at high temperatures, ammonia vapours may escape. Ammonia vapours have a pungent odour and particularly irritate:

skin R mucous membranes R eyes The vapours may cause a burning sensation in the eyes, nose and throat as well as irritation of the throat and watering eyes. Avoid inhaling ammonia vapours.
R

G WARNING
Hose clamp 000 589 54 37 00
X X
AdBlue /DEF must not come into contact with skin, eyes or clothing. Clamp the feed and return lines on the

X X X

pump/filter unit using hose clamps. R If AdBlue /DEF comes into contact with 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. R If AdBlue /DEF is swallowed, immediately Unscrew filter bowl ? from the pump/fil- rinse your mouth out with a lot of clean ter unit. water and drink plenty of water. Remove filter element R Change clothing that is soiled with ; . AdBlue /DEF immediately. Smear O-ring = on new filter element ; R If allergic reactions occur, consult a doctor thinly with MB silicon grease before assemimmediately. bly.
Z

Notes on m aintenance

72

Work schedules
Keep AdBlue /DEF out of the reach of chil- ing hose is disconnected from the valve, a pressure loss of 0.2 bar takes place. dren.

Notes on m aintenance

To reduce the pressure: press button; several times. Dispose of AdBlue /DEF in an environmen- X Only if the pump module or the pressure reservoir was not replaced: check the tally responsible manner. 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. 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.

H Environmental note

Special tool 001 589 00 71 00 pump : Supply unit with pressure reservoir Engine brake - checking condition and setting ; Pressure release = Filling hose ?
X

Filling pressure gauge To check the pressure: unscrew the dust protection cap from the valve of pressure reservoir : . Screw filling hose = onto the valve of the pressure reservoir. Read the pressure on pressure?gauge . The pressure must be adjusted to 3.2 ( 0.2) bar. The operating pressure of 3.2 ( 0.2) bar may not be exceeded. Otherwise malfunctions may occur in the system. Throttle valve lever in rest position Increase or reduce the pressure if necessary. To increase the pressure: press pump lever A . Adjust the pressure to 0.2 above bar the specified operating pressure. When the fill-

A Pump

X X

Work schedules 73
Engine cooling system Checking and correcting the fluid level and the antifreeze/corrosion inhibitor G WARNING
When opening the coolant expansion tank, there is a risk of scalding, due to hot coolant spraying out. The cooling system and coolant expansion tank are pressurised when the engine is at operating temperature. Wear gloves and eye protection. Open the coolant expansion tank only at a coolant temperature below 50 .

G WARNING
Throttle valve lever in operating position
X X X

Coolant contains glycol and is therefore toxic.

X X

not swallow the coolant. See a doctor Remove the wire circlip from the ball Do socket immediately if you swallow coolant. of the engine brake cylinder. Make sure that coolant does not come into Press the ball socket off the ball coupling contact with skin, eyes or clothing. In case of of throttle valve lever : . contact with eyes, rinse immediately with Check the engine brake cylinder, ball couplenty of clean water. Clean affected areas of pling, ball socket and the throttle valve skin and clothing with soap and water immeshaft for wear. diately. Change any affected clothing immeCheck the seating of the throttle valve lever diately. on the throttle valve shaft and retighten the Only check the coolant level when the coolant clamp screw if necessary. temperature is under 50 . Check the antiLubricate the ball socket with heat-resistfreeze/corrosion inhibitor concentration ant lubricant (part number A000 989 76 before correcting the coolant level. Only top 51). up with a prepared coolant having an antiPress the ball socket back onto the ball freeze/corrosion inhibitor concentration of coupling, fit the wire circlip. 50% by volume. corrosion inhibitor/antiWhen the engine brake is applied, throttle freeze agent. valve lever : must rest on bracket ; in Before topping up, check the quality of the the working position (cylinder extended). antifreeze/corrosion inhibitor (Sheet. No.) in The throttle valve lever must also rest on the cooling system. Corrosion/antifreeze bracket when the engine brake cylinder is additives compliant with Sheet 325.3 and in the rest position (cylinder retracted). If must not be mixed with those of Sheet 326.3 this is the case, the return spring preten325.0/2 or 326.0/2. Only top up with corrosion of the engine brake cylinder is adesion inhibitor/antifreeze agent of the same Y page quate. quality grade ( 48). This helps to prevent damage to the engine. Check the position of the throttle valve shaft: when the engine brake is in the rest position, the notch must be horizontal. In the working position, the notch must be vertical.
Z

Notes on m aintenance

74
X

Work schedules
Open the engine cooling system capXslowly, Dry the inside of coolant filler with ; neck relieving the excess pressure. a lint-free cloth. X Check the antifreeze/corrosion inhibitor X Mount pressure tester tool : on the filler concentration using a testing device. The neck of the coolant expansion tank. correct concentration of 50% antifreeze/ X Connect the compressed-air hose with tyre corrosion inhibitor by volume in the coolant inflation connection to pressure tester provides antifreeze protection down to tool: and set it to a test pressure of 37 . If a lower level of antifreeze protec 1.0 bar. tion is indicated, correct the mixture ratio. The testpressure should correspond to the value at which the cooling system pressure ! If the concentration of antifreeze/corrovalve opens. The opening pressure sion inhibitor is too low, there is a risk relief of can be determined from the code on the engine damage as a result of corrosion/ cap or pressure relief valve. cavitation in the cooling system. Example: code 100 = 1.0 bar excess presAvoid concentrations greater than sure. 55% byvolume corrosion inhibitor/antifreeze X After about 5 - 10 minutes, read the drop agent. Otherwise, the maximum antifreeze in pressure on the manometer of protection down 45 to will not be attained. tester 5 - 10 minutes, there must : . After Heat dissipation and antifreeze protection be no drop in pressure detected on the deteriorate at higher concentrations. manometer. Do not exceed the test presX To check the coolant the level: cooling system is filled correctly if the coolant sure is and the test time, as this may damage the cooling and heating system. level with the mark in the filler neck. If the cooling system/heating system is leaking, this will become apparent due to a drop in pressure, indicated by the manomCooling and heating system condieter on tester : . tion check of radiator, lines and hoses X If there is a loss of pressure in the cooling system leading to visible loss of coolant, have theleak in the cooling or heating system 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. Mercedes-Benz recommends that you use a Mercedes-Benz or MTU Service Centre Y page for this purpose ( 11). Work relevant to safety or on safety-related systems must Special tool: pressure tester tool be carried out at a qualified specialist workX Heating systems: open all control valves shop. and shutoff valves for the heating system. X Release the pressure using pressure tester X Remove the coolant expansion tank cap. tool and remove pressure tester X Check the coolant level and top up if nec- : tool: from the coolant expansion tank essary. filler neck. X Check/correct the coolant antifreeze protection content.

Notes on m aintenance

Work schedules 75
X X

Check the coolant level and correct if necessary. Replace coolant expansion tank cap and tighten it.

Renewing the coolant G WARNING


When opening the coolant expansion tank, there is a risk of scalding, due to hot coolant spraying out.The cooling system and coolant expansion tank are pressurised when the engine is at operating temperature. Wear gloves and eye protection. Open the coolant expansion tank only at a X Undo the engine cooling system cap slowly, coolant temperature below 50 .

relieving the excess pressure, and remove it. X Heating systems: open the heating system Coolant contains glycol and is therefore toxic. Do not swallow the coolant. See a doctor temperature control (control valve). X Cover the lines etc. under the drain plugs. immediately if you swallow coolant. X Place a suitably sized receptacle underMake sure that coolant does not come into neath to catch the coolant. contact withskin, eyes or clothing. In case of

G WARNING

contact with eyes, rinse immediately with X Plug the drain hose onto coolant drain plenty of clean water. Clean affected areas of on the crankcase. plug : skin and clothing with soap and water immeX Release drain plug : andcollect the cooldiately. Change any affected clothing immeant. diately.
X Clear blocked drainage openings of deposBefore renewing the coolant, check the coolits. ing and heating system for leaks and condiX Tighten coolant drain plug the engine : on tion. Have the coolant renewal confirmed in with a new seal (tightening torque: the Maintenance Booklet. 60 Nm). X Screw in other drain plugs (without hose Draining the coolant connection) with new seals (tightening torH Environmental note que Y ( page 105)).

Dispose of used coolant in accordance with ! Old coolant and corrosion deposits must current local regulations.

be rinsed out thoroughly. If the cooling system is heavily contaminated, flush it thoroughly before refilling.

Notes on m aintenance

76

Work schedules
Adding coolant
X X

Notes on m aintenance

Add coolant. Start the engine and run it at varyingH Environmental note speeds for approximately 1 minute. Collect used coolant, cleaning solutions and X Add coolant mixed to the prescribed ratio detergents and dispose of them in an enviuntil it reaches the lower edge of the filler ronmentally responsible manner in accordneck. ance with applicable local regulations. X Switch off the engine and seal the cooling X Remove foreign objects (dust, insects, etc.) system again. from the radiator core fin. You can do this Observe any further information in the operby blowing them out with compressed air, ating instructions from the equipment/vehior by spraying water from the rear side of cle manufacturer. the radiator. ! Corrosion inhibitors/antifreeze agents ! Only apply moderate pressure when that comply with Sheet 325.3 and 326.3 cleaning, since the radiator fins could othmust not be mixed with those of Sheet 325.0/2or 326.0/2. This prevents dam-erwise be damaged. age to the engine cooling system. X Drain off coolant when the engine is cold

diately. Change any affected clothing immediately.

Cleaning the cooling system G WARNING

(Y page 75). If a heater is connected to the cooling system, open the regulating valves fully.

Flushing the cooling system The cooling system is pressurised. Hot coolantcanescape under pressure when the X coolFill the cooling system with fresh water and ing system is opened and scald your skin and leave the system running for approximate eyes. five minutes. R Only open the cooling system at coolant X Switch off the engine and drain off the temperatures below 90 . water completely. R Unscrew the cap slowly and release any X Repeat the flushing process at least twice. excess pressure completely before openX Fill the cooling system with new corrosion ing the cap fully. inhibitor/antifreeze agent. Observe the R Wear suitable protective gloves, protective Y page antifreeze protection ( 73). clothing and safety goggles when handling coolant. G WARNING Degreasing the cooling system
X

Coolant contains glycol and is therefore toxic. witha suitable cleaning agent. Information Do not swallow the coolant. See a doctor is available from any Mercedes-Benz or Y page immediately if you swallow coolant. MTU Service Centre ( 11). Make sure that coolant does not come into contact withskin, 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-

If necessary, degrease the cooling system

Work schedules 77
G WARNING Checking for leaks and general condition assemblies There is a danger of limbs being caught, pulled
X

inandthereby crushed or severed by rotating Carry out a visual inspection of the engine engine parts. Therefore you should: for signs of leaks. Slight dampness around R keep a safe distance between yourself and sealed joints can be ignored.

More severe leaks, where there is conengine is being started. stant oil loss, must be rectified immediR wait until all engine parts have stopped ately. moving before carrying out any work on the

rotating engine parts, including when the

X X

Carry out a visual check for leaks from lines and hoses. At the same time, check that all lines and hoses are undamaged, are routed so they do not chafe and are secured correctly. Check the intake pipe between the air filter and the engine for leaks and check the condition. Check the intake pipe and bellows from the air filter as well as the charge-air cooler for the engine for damage and for leaks at connection points. Check the air compressor intake pipe and crankcase ventilation for damage and leaks at connection points. Check all hose clamps for correct seating. Retighten or replace loose hose clamps. Replace porous, leaking or damaged lines and bellows.

G WARNING
The engine becomes very hot while it is running andremains 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 yourself from being burned on hot engine components.

Notes on m aintenance

engine. Lines, hoses and sensor cables wear work clothing which is properly fastened and close-fitting. Wear a hair net if checking for leaks and general condinecessary. Remove jewellery such as tion watches and necklaces.
R

78

79
Decommissioning the engine ............ 80 Protecting the engine ......................... 81

Decom m ission and protection

80

Decommissioning the engine


Fill up the AdBlue /DEF supply reservoir cannot cryscompletely so that AdBlue tallise out. Particular measures are necessary when the engine/vehicle/equipment is to be decomR Fuel prefilter with heated water separator: missioned. drain off the water separator. Decommissioned engines are engines Engine/vehicle/equipment that with exhaust are not operated for a month or more gas afteraftertreatment assembly or after repair work has been carR Decommissioning for more than 12 ried out. months: fill up the AdBlue /DEF supply For engines that have been run in, this applies reservoir completely. after 12 months' standing time. R Decommissioning for more than 24 months: drain off and dispose of AdBlue / DEF. When disposing of AdBlue /DEF, Decommissioning for up to 12 observe the relevant national laws and regmonths ulations. R When decommissioning an engine/vehiR When outside temperatures are low, cle/equipment, keep it in a covered, dry AdBlue /DEF crystals may form on the and well-ventilated area. The room tempercoiled hose between the engine and ature should not fall below -10 in order silencer. Remove the crystals with plenty of prevent the AdBlue /DEF from freezing. water. If this is not possible, these measures must Engine/vehicle/equipment run on FAME be carried out after 6 months rather than (Fatty Acid Methyl Ester) bio-diesel fuel 12. R Empty the fuel tank to the point where the Measures prior to decommissioning remaining fuel still allows the engine to be R Clean the engine/vehicle/equipment thoroperated for 15 to 30 minutes each month oughly. during its decommissioned period. R Remove any patches of corrosion from the the engine at least once a month and R Start engine. leave it running for 15 to 30 minutes at an R Change the engine oil and oil filter if the last speed of around 900 rpm. Doing so engine oil change was carried out more than purges the fuel system or diesel injection 20,000 km (around 300 operating hours) system with fuel. This prevents any caulkago or if the oil is older than 12 months. ing of the fuel injectors. R Disconnect the earth lines from the batterMeasures during decommissioning ies (this prevents self-discharge due to R Before starting the engine, check the closed-circuit accessories). engine oil level and the coolant level. R Charge the batteries. Check the battery R Start the engine and leave it running for fluid levels before and after charging. 15 to 30 minutes at an engine speed of R Check and adjust the concentration of antino more than 900 rpm. corrosion/antifreeze additives in the coolR While the engine is running, observe the ant. indicators for oil pressure, coolant temperR Check and adjust the level of coolant or ature and oil temperature. renew coolant. R While the engine is running, select every gear that can be selected while stationary.

Decommissioning the engine

Decom m ission and protection

Protecting the engine 81


R Check Leave the engine running until the air com- that the electrical system, steering pressor cutoff pressure is reached. system and brakes are functioning correctly. R Fuel prefilter with heated water separator: R Clean the engine/vehicle/equipment thordrain off the water separator. oughly. R Recharge the batteries every three months. Check the battery fluid levels before and after charging. Protecting the engine R Change the engine oil and oil filter every 24 months. Engine protective treatment applies to all fitMeasures prior to decommissioning ted and removed vehicle, industrial and OEM R Empty the fuel tank and fill up with new fuel.as well as new engines, recondiengines When disposing of fuels, observe the rele- engines and short block engines. tioned vant national laws and regulations. Engines that have been removed must be proR Fuel prefilter with heated water separator: tected against moisture (rain or spray water) replace filter element. using special measures. R Replace fuel filter. R Replace air filter cartridge. Protective treatment for up to 12 R Change engine oil and oil filter. months R Check coolant level. On new engines no additional protection R If coolant needs refilling, check and adjust measures are required, as long as initial operthe concentration of anticorrosion/antifreeze in the coolant. Before refillingation cool- oil compliant with Sheet 225.6 and coolant were added at the engine factory. Engines ant, note the quality of the previously filled which have covered a distance of up to Y anticorrosion/antifreeze page ( 48). 300 km or which have been operated for up R Check the charge status of the battery and to 6 hours may be considered new. recharge if necessary. Check the battery R Clean the engine thoroughly and remove fluid levels before and after charging. patches of corrosion. R Connect the earth lines to the batteries. R All machined exterior and unpreserved surR Check that the electrical system is funcfaces must be greased or sprayed with tioning correctly. preservative agent according to Sheet R Check cables, hoses and lines for tears and This is regardless of the duration of 385.4. leaks. the protective treatment. Examples of this R Start the engine and leave it running for are the flywheel and pulley keyway. 15 to 30 minutes at an engine speed R of Where possible, carry out protective measno more than 900 rpm. ures on the fitted engine in the storage R While the engine is running, observe the location. indicators for oil pressure, coolant temperR After protective measures are complete, ature and oil temperature. the engine must not be started again. R Vehicles with auxiliary heating: activate the oil and coolant must be filled to the R Engine auxiliary heating. maximum level. Observe the temperature R Check oil levels in the steering system, ranges when selecting engine oil and coolengine, transmission and drive axles. ant. R

Decom m ission and protection

82
R

Protecting the engine


3 initial operation oil into each Close off all openings on the engine (e.g. 15 20 cm on the charge-air housing, exhaust etc.) cylinder. with an oil-soaked rag. Drain off the coolant completely for Protecting the air compressor engines that have been removed. Unscrew the coolant drain plug on the engineCarry block out the protection of the air compressor at same time as the combustion chamber to do so. When screwing in the coolant the protection. drain plug, observe the tightening torque. X the air intake side of the air compressor, Relieve the tension in the poly-V-belt. On The pour a maximum of 3 5 of cm initial operapoly-V-belt can remain routed. tion oil compliant with Sheet 225.6 into the If the engine has been filled with coolant, compressor. the cooling system must first be filled air with

R R

Decom m ission and protection

Protective treatment for 12 to 36 months Protective treatment for longer than Carry out all measures in "Protective treat36 months ment for up to 12 months". The fuel system,
combustion chambers and air compressor When carrying out protective treatment for also require protective measures. over 36 or 18 months, repeat the protection measures as in "Protective treatment for 12 Carry out protective measures for the to 36 months". fuel system X Drain off engine oil that has been added. X The X Completely fill the fuel tank with diesel oil filter does not have to be replaced. fuel. X Start the engine and allow it to run for 15-30 minutes at approximately 900 rpm.

water. It must then be filled with a mixture After protective measures of water and improver compliant with Sheet 311.0. Coolant without antifreeze X Refit all removed engine parts. Observe the protection compliant with Sheet 312.0 may tightening torques. also be used. ! After protective measures are complete, the engine must not be started again.

Shipping by sea or engine protective treatment in tropical countries Carry out protective measures for the combustion chambers Carry out all measures in "Protective treat-

ment Only carry out protection measures for the for 12 to 36 months". The fuel system, combustion chambers and air compressor combustion chambers when the engine is also require protective measures. cold (coolant temperature under 50 ). Only use initial operation oil compliant with Sheet 225.6 for the protection of the combustion chambers. X Detach the charge-air housing from the cylinder heads. X Briefly press the start button on the engine. At the same time, pour approximately

Protecting the engine 83


The following work is required for engines viously filled anticorrosion/antifreeze that have been run in (distance of over (Y page 48). X New engines: add initial operation oil com300 km or running time of over 6 operating hours): pliant with Sheet 225.6.
X X filter. Drain off engine oil and replace the oil Engines that have been run in (distance of Add initial operation oil compliant withover 300 km or running time of over Sheet 225.6. 6 operating hours): before starting the engine, lubricate the lubrication points on Fill or top up the cooling system with the the engine as necessary, e.g. ball couplings specified coolant. Before refilling coolant, or engine brakes. note the quality of the previously filled antiX Y corrosion/antifreezepage ( 48). Start the engine and leave it running until is at operating temperature (coolant temCarry out protective measures for the it fuel perature approximately 75 to 95 ). While system. doing so, observe the indicators for oil presWarm up the engine at medium engine sure, coolant temperature and oil temperspeeds and allow it to run for approximately ature. 5 to 10 minutes at operating temperature (coolant temperature 75-95 ). Switch off the engine and check the oil level. Add oil up to the upper marking on the oil dipstick. Hermetically seal all engine openings. Drain off the coolant completely for engines that have been removed. Unscrew the coolant drain plug on the engine block to do so.

X X

X X X X

Re-commissioning
X X X

X X

Remove all plugs or rags that have been fitted. Fit removed engines and connect all cables, hoses and lines. Remove protective agents and greases from all protected areas, such as the flywheel, pulley keyway etc. Tension the poly-V-belt as per the regulations. Renew the engine oil and replace the oil filter before re-commissioning. Add oil up to the upper marking on the oil dipstick. Add coolant. Observe the concentration of anticorrosion/antifreeze additives. Before refilling coolant, note the quality of the pre-

Decom m ission and protection

84

85
General notes ...................................... 86 Bleeding the fuel system .................... 86 Activating engine emergency running mode 87 ............................................ Troubleshooting .................................. 89
exhaust gas aftertreatBlueTec ment indicator (on-highway version) ..................................................... 94 exhaust gas aftertreatBlueTec ment indicator (off-highway version) ..................................................... 95 Replacing the poly-V-belt 97 ...................

Breakdown assistance

86

Bleeding the fuel system


Turn the starter motor for up to 30 seconds without interruption until the engine is running smoothly. G WARNING The fuel system is automatically bled when If maintenance and repair work is carried out Y page the tank is empty ( 35).

General notes

Breakdown assistance
!

on the engine incorrectly, this can cause engine failure. Engine failure can lead to an increased risk of accidents. Fuel system with fuel prefilter Maintenance and repair work on the engine may only be carried out by personnel who Fuel prefilter overview have undergone the appropriate training. Always have work on or modifications to the engine carried out at a qualified specialist workshop which has the necessary specialist skills and tools for the work required. Mercedes-Benz recommends that you use a Mercedes-Benz or MTU Service Centre for this purpose.

Apart from careful operation and maintenance of the engine it is also important that malfunctions be rectified in good time. You can rectify certain malfunctions yourself (Y page 89). Have malfunctions that you cannot eliminate yourself rectified at a qualified specialist workshop. Mercedes-Benz recommends that you go to a Mercedes-Benz or MTU Service Centre, as they have the necessary knowledge and tools to carry out the required Ywork page ( 11). In particular, work relevant to safety or on Example: fuel prefilter safety-related systems must be carried at hand pump Fuel : out a qualified specialist workshop. ; Vent valve = Shutoff valve ? Filter housing Bleeding the fuel system A Water separator with inspection window Fuel system without fuel prefilter B Water release valve

Automatic bleeding

If water has collected in inspection window Do not bleed the fuel system by operating A , drain the fuel prefilter before bleeding. the starter motor for an extended period of time. You could otherwise damage the starter motor.

Activating engine emergency running 87 mode


Draining the fuel prefilter H Environmental note Activating engine emergency running mode

Emergency mode for on-highway Dispose of the water-fuel mixture in an enviapplications ronmentally responsible manner.

Emergency mode can be activated for road Drain the fuel prefilter regularly. vehicles with Euro 4/5 certified engines (onX Place a collector under water release valve highway engines). B . X On vehicles with fuel prefilter at tank level: close shutoff valve =. X Unscrew water release valve B . X Briefly press fuel hand pump collect : and the fuel/water mixture. 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 Example: indicator lamp malfunction one minute. The fuel system is bled automatically. The engine is equipped with an electronic X Check the fuel system for leaks. management system that monitors both the engine and itself (self-diagnostic system). The lamp lights up in the event k Bleeding the fuel prefilter with the fuelindicator of a malfunction. Error messages can be dishand pump played as code or text in the display, dependThe fuel prefilter must only be bled when: ing on the vehicle's display format. R the fuel tank is empty or After a malfunction, the engine can be actiR the fuel filter has been replaced. vated again in emergency mode with a limited X Unscrew the fuel tank filler cap. constant engine speed. In engine emergency running X Place the collector underneath the fuel pre- mode, the accelerator pedal is not operational and the engine speed is limited to filter. approximately 1300 rpm. X Open shutoff valve = fully. X To activate engine emergency running X Open vent valve ; . mode : stop the vehicle, paying attention to X Only press fuel hand pump the fuel the road and traffic conditions. : until escaping from vent valve X Engage the parking brake. ; is free of bubbles. Do not continue to pump. X Switch off the engine. X Close vent valve ; . X Restart the engine after approximately X Close the fuel tank filler cap. 10 seconds. X Start the engine. i The STAR DIAGNOSIS or minidiag2 diagThe fuel system is bled automatically. nostic equipment can be connected to the 14-pin diagnostic socket or by using the ! Do not continue to press the fuel hand pump after the engine has started. This EU-compliant service connector. The fault could otherwise damage the hand pump. memory and engine data can be read out
Z

Breakdown assistance

88

Activating engine emergency running mode


using this diagnostic equipment. Information is available from any Mercedes-Benz or Y page MTU Service Centre ( 11).

Breakdown assistance

Emergency mode for off-highway applications


Full engine output can be activated with an emergency switch for devices with Euromot 3B or Tier 4i certified engines (off-highway applications). Emergency mode can only be activated for 30 minutes, and only if the vehicle has the appropriate equipment. For further information, see the device's operating instructions.

Troubleshooting 89
Troubleshooting G WARNING

If maintenance work is carried out incorrectly, the operating safety of your vehicle may be a ted. You could lose control of the vehicle and cause an accident. The safety systems may al no longer be able to protect you or others as they are designed to. Always have service work carried out at a qualified specialist workshop. The qualified specialis workshop must have the specialist skills and tools necessary to carry out the work. Mercede Benz recommends that you use a Mercedes-Benz or MTU Service Centre for this purpose. In particular, work relevant to safety or on safety-related systems must be carried out at a qua specialist workshop.

Apart from careful operation and maintenance of the engine it is also important that ma tions be rectified in good time. You can rectify certain faults yourself. Have malfunctions that you cannot eliminate yourself rectified at a qualified specialist w shop. Mercedes-Benz recommends that you use a Mercedes-Benz or MTU Service Centre Y page this purpose ( 11). Problem Possible causes/consequences and M Solutions

Drive pinion does not Battery is not sufficiently charged. X Charge the battery. turn orturns too slowly. Connecting cable to the starter motor is loose. X Tighten the cable on the terminal. If necessary, solder on a new terminal. Starter motor solenoid switch is faulty or starter motor is faulty. X Have it checked at a qualified specialist workshop. Engine does not start Fuel or tank is empty. stalls again immedi- X Refill the fuel tank Y page ( 41). ately. Fuel filter is blocked. X Replace the filter element Y page ( 69). The fuel prefilter contains water. X Drain the fuel prefilter Y page ( 68). Fuel prefilter is blocked. X Replace the filter element Y page ( 68). Fuel system or filter is leaking. X Replace the seals.

Breakdown assistance

Engine problems

90

Troubleshooting
Problem Possible causes/consequences and M Solutions Fuel is not resistant to cold. X Replace the fuel prefilter Y page ( 68). X Replace the fuel filter Y page ( 69). X Use winter fuel Y page ( 52). Incorrect engine oil viscosity. X Alter the engine oil viscosity to the conditions of use (Y page 47). Engine does not start There is a malfunction in the engine control unit. correctly. X Read out the MR (engine control) unit, have it checked at a qualified specialist workshop. There are leaks or there is insufficient pressure in the low-pressure fuel circuit. X Carry out a check for leaks (visual check). X Have the pressure tested at a qualified specialist workshop. Engine stops inadverMR (engine control) unit is faulty (total failure). tently. X Consult a qualified specialist workshop. Power supply to the MR/ADM control units is interrupted or there is a short circuit in the wiring. X Have the power supply checked at a qualified specialist workshop. There are leaks or 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. Engine is in emergency There is an interruption to the MR/ADM control unit's data flow. running mode. X Read out the control unit's fault memory.
X

Breakdown assistance

Have it checked at a qualified specialist workshop.

Engine surges, vibrates Crankshaft sensor or TDC sensor (on camshaft gear wheel) is or runs irregularly. faulty or the signal is missing. X Consult a qualified specialist workshop. There is a malfunction in the fuel system. X Read out the fault code. X Have it checked at a qualified specialist workshop.

Troubleshooting 91
Problem Possible causes/consequences and M Solutions

The engine's output Air is filter is dirty or blocked. poor (lack of power).X Replace the air filter element.

Charge-air temperature is too high - charge-air cooler or radiator exterior is dirty. X Clean the outsides of the charge-air cooler and radiator. Coolant temperature is too high. X Check the temperature sensor, replace as necessary, check the fan speed. X Thermostat malfunction: consult a qualified specialist workshop. Malfunction in the fuel system (blocked, leaking) X Visual inspection for leaks X Consult a qualified specialist workshop. Charge-air system is leaking, hose clamp on charge-air hose loose or faulty X Check the charge-air system for leaks. X Check the charge-air pressure sensor and replace if necessary. X Consult a qualified specialist workshop. Engine brake flap is faulty or stuck. X Function check and visual inspection Y page(72).
Y flashing The "engine diagnostics" indicator lamp is page 94). ( The AdBlue /DEF tank is empty. X
Top up AdBlue /DEF tankY( page 42).

The "exhaust gas aftertreatment" indicator lamp lights up. There is an emissions-relevant fault or malfunction in the exhaust gas aftertreatment system. Faults or malfunctions could result in damage to the exhaust gas aftertreatment system. X Have the exhaust gas aftertreatment system checked as soon as possible at 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 terminal clamps and the connectors on the MR/ADM control unit for secure seating and corrosion.

Breakdown assistance

92

Troubleshooting
Problem Possible causes/consequences and M Solutions

Breakdown assistance

Engine braking effect There is is an engine brake flap malfunction or a fault in the actuapoor. tion. X Carry out a function check/visual check. X Consult a qualified specialist workshop. Fuel consumption is Connection points (unit pump - line and fuel injectors) are leaking too high. X Have a qualified specialist workshop check for leaks. X Misfiring: have the engine checked at a qualified specialist workshop. Engine cuts off too Electronic engine speed control unit is faulty or parameterised early (maximum engine incorrectly. X Consult a qualified specialist workshop. speed cannot be reached). Engine gets too hot There is not enough coolant in the cooling system. (according to coolant X Top up, bleed Y page ( 76) temperature gauge). Coolant temperature sensor or display is faulty. X Replace sensor or display. Poly-V-belt is damaged. X See Replacing the poly-V-belt Y page ( 97). Fan does not switch on correctly. X Consult a qualified specialist workshop. Radiator is dirty on inside or choked with limescale; radiator is very dirty on outside. X Clean and remove limescale. Thermostat is faulty. X Check and replace as necessary. X Consult a qualified specialist workshop. Charge current indicaLamp is defective or supply line is interrupted. X Replace lamp or repair interruption. tor lamp does not light up while the engine is not running. Charge current indicaPoly-V-belt is too loose. torlamp lights up when X Check belt tensioner for proper functioning. the engine is running.

Troubleshooting 93
Problem Possible causes/consequences and M Solutions Poly-V-belt is torn. X Replace poly-V-belt Y page ( 97). Alternator or sensor is defective. X Check alternator or sensor. X Consult a qualified specialist workshop. Engine emits black Air filter is very dirty. smoke. X Replace the air filter element. Engine brake is faulty. X Consult a qualified specialist workshop. Exhaust gas turbocharger is faulty. X Carry out a visual check. X Consult a qualified specialist workshop. Misfiring, fuel injector is faulty. X Consult a qualified specialist workshop. 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. Exhaust fumes are Coolant is entering the combustion chamber. white. X Have a pressure loss test carried out at a qualified specialist workshop. Engine knocks. The engine is misfiring. X Consult a qualified specialist workshop.

Knocking noise fromThere is bearing damage. the bearings. X Consult a qualified specialist workshop. There are abnormal Leaks in intake pipe and exhaust pipe cause whistling noise. X Repair leaks; replace seals if necessary. sounds.

Breakdown assistance

94

exhaust gas aftertreatment indicator (on-highway vers BlueTec

Problem

Possible causes/consequences and M Solutions Turbine or compressor wheel is scraping the housing; foreign objects in the compressor or turbine; seized bearing in rotating parts. X Have the exhaust gas turbocharger checked at a qualified specialist workshop. Valve clearance is too big. X Check clearance; adjust Y page ( 63).

Breakdown assistance

exhaust gas aftertreatment indicator (on-highway version) BlueTec

G WARNING

If service work is carried out incorrectly, the operating safety of your vehicle/equipment may b affected. You could lose control of the vehicle/equipment and cause an accident. The safety systems may also no longer be able to protect you or others as they are designed to. Always have service work carried out at a qualified specialist workshop. The qualified specialist workshop must have the specialist skills and tools necessary to carry out the work. MercedesBenz recommends that you use a Mercedes-Benz or MTU Service Centre for this purpose. In particular, work relevant to safety or on safety-related systems must be carried out at a qualif specialist workshop.

exhaust gas aftertreatment indicator (off-highway 95 versi BlueTec

Problem

Possible causes/consequences and M Solutions

The; indicator if there are no malfunctions, indicator lamp lights up ; the lamp lights up briefly briefly during the instrument cluster's display check and then goes and goes out again. out again.
The; indicator The AdBlue /DEF tank is empty. lamp flashes. There is a fault. Simultaneously, a dis8. The engine output may be reduced play message with aX Follow the instructions in the display messages. red status indicator appears in the display. 67

exhaust The; indicator The BlueTec gas aftertreatment system has a fault or an lamp lights up permaemissions-relevant malfunction. exhaust nently. A malfunction or fault could damage the BlueTec gas aftertreatment. 8. The engine output may be reduced

exhaust Have the BlueTec gas aftertreatment checked as soon as possible at a qualified specialist workshop.

exhaust gas aftertreatment: Engines with BlueTec When the AdBlue/DEF tank is filled or the fault is rectified, full engine power will be availab again. If the system check does not detect any other indicator the lamp goes out. ; faults, It may take several journeys/working cycles to complete the system check.

exhaust gas aftertreatment indicator (off-highway version) BlueTec AdBlue /DEF level low
If the AdBlue /DEF level is too low, the system registers the following warnings: AdBlue /DEF level

System message The The


AdBlue /DEF indicator lamp lights up.

Trigger 1: Level 20% or less Trigger 2: Level 10% or less

AdBlue /DEF indicator lamp lights up.

The engine output is not reduced in the case of emergency vehicles, e.g. fire engines.
Z

Breakdown assistance

96

exhaust gas aftertreatment indicator (off-highway vers BlueTec

AdBlue /DEF level

System message
R R

Breakdown assistance

30 minutes after trigger 2

The The up.

AdBlue /DEF indicator lamp flashes. torque limitation indicator lamp lights

60 minutes after trigger 2

R R

The AdBlue /DEF indicator lamp flashes. The torque limitation indicator lamp lights up if the torque value prior to tightening is between 80 - 50%. The torque limitation indicator lamp flashes if the torque value prior to tightening is less than 50%.

AdBlue /DEF quality not OK


If the AdBlue /DEF quality is not OK, the system registers the following warnings: AdBlue /DEF quality

System message The


R R
AdBlue /DEF indicator lamp lights up.

Trigger 3: AdBlue /DEF quality is not OK 60 minutes after trigger 3

The The up.

AdBlue /DEF indicator lamp flashes. torque limitation indicator lamp lights

180 minutes after trigger 3

R R

The AdBlue /DEF indicator lamp flashes. The torque limitation indicator lamp lights up if the torque value prior to tightening is between 80 - 50%. The torque limitation indicator lamp flashes if the torque value prior to tightening is less than 50%.

Replacing the poly-V-belt 97


Fault in the monitoring system
Fault Trigger 4:
R R R R R R R
R AdBlue /DEF tank sensor

System message
R

The R The missing up. AdBlue/DEF metering line or metering valve missing AdBlue /DEF metering line or metering valve blocked AdBlue /DEF metering pump missing SCR cable set missing NOx sensor missing AdBlue /DEF temperature sensor missing Exhaust temperature sensor missing
R R R

AdBlue /DEF indicator lamp lights up. torque limitation indicator lamp lights

60 minutes after trigger 4

The The! The up.

AdBlue /DEF indicator lamp flashes. indicator lamp lights up. torque limitation indicator lamp lights

180 minutes after trigger 4

R R R R

The AdBlue /DEF indicator lamp flashes. The! indicator lamp lights up. The torque limitation indicator lamp lights up if the torque value prior to tightening is over 50%. The torque limitation indicator lamp flashes if the torque value prior to tightening is less than 50%.

Always carry out work on the tensioning device with extreme care. If the poly-V-belt is torn or shows damage R Make sure that the tool is handled corY (page 66), it must be replaced. patterns rectly.
R

Replacing the poly-V-belt

G WARNING
The tensioning device is spring-tensioned. When it is loosened or tightened, there is a risk of injury from crushing or entrapment in pretensioned parts.

Breakdown assistance

If faults occur, the system registers the following warnings:

98

Replacing the poly-V-belt

Breakdown assistance

:
X

Releasing the poly-V-belt (example)

Fit the spanner with extension element and 15 mm socket spanner insert into the tensioning device. X Swing the tensioning pulley up and remove Poly-V-belt routing (engine with refrigerant comthe poly-V-belt. pressor) X Swing back the tensioning device. : Alternator X Check that both the tensioning device and ; Tensioning pulley the belt pulley are in perfect condition (e.g. = Coolant pump check for worn bearings on the tensioning ? Refrigerant compressor device, tensioning pulley and guide pulleys as well as for wear on belt pulleys). A Guide pulley X Replace faulty parts. B Crankshaft X Lay the new poly-V-belt on all belt pulleys, except for the tensioning pulley (see the illustration for poly-V-belt routing). X Swing the tensioning pulley up using the lever, lay the poly-V-belt on the tensioning pulley and swing the tensioning pulley back. X Remove the spanner and check for correct seating of the poly-V-belt on the belt pulleys.

Poly-V-belt routing (engine without refrigerant compressor)

Alternator ; Tensioning pulley = Coolant pump ? Crankshaft


:

99
Vehicle identification.............. plate 100 Information on the identification plate 100 ................................................... Engine model designation 100 ................ Engine data card ............................... 100 Engine data 101 ........................................ Operating restriction - off-highway version ............................................... 106

Technical data

100

Engine data card


Vehicle identification plate
The identification plate is located on the lefthand side of the engine underneath the Start/Stop button or Start/Stop buttons. The identification plate data is stamped directly onto the crankcase.

Technical data

Example: identification plate for non-road vehicles (off-highway engines)

Manufacturer's name ; Engine type description = Type approval number ? Engine number
:

Engine model designation


Example: engine model designation OM 9XX L OM Information on the identification plate 9XX The following data is contained on the identiL fication plate in the form of numbers stamped directly onto the crankcase: A Oil engine (diesel) Engine type Intercooler A Exhaust gas turbocharger

Engine data card


The engine data card (A4 sheet) forms an integral part of the documents belonging to the engine and should always be kept with the Maintenance Booklet. It contains details about the design of the engine, including special (onfeatures. Example: identification plate for road vehicles The engine data card must be presented or highway engine) the complete engine number must be speci: Manufacturer's name fied for the procurement of genuine ; Engine type description Mercedes-Benz parts. = Engine number

Engine data 101


Dimensions

Engine data card

The engine data card describes the scope of engine length Example: 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 Example: of the engine width and height respective engine type. Deviations may OM 904 LA OM 906 LA occur, depending on the installation situation OM 924 LA OM 926 LA in the vehicle/equipment. A = engine length B = engine width C = engine height 830 mm 645 mm 925 mm 1078 mm 645 mm 940 mm

Technical data

102

Engine data
Weights
OM 904 LAOM 906 LA OM 924 LAOM 926 LA Dry engine maximum 395 kg 420 kg 530 kg 573 kg

Technical data

Wet engine maximum

Engine data 103


General data

All data refers to the standard version of the respective engine type. Data for other vers is available on request. Engine Engine type Assembly model series Type Combustion principle Number of cylinders Hole Piston displacement Engine capacity Type of cooling system OM 904 LA OM 924 LA 904.9 924.9 OM 906 LA OM 926 LA 906.9 926.9

In-line engine with turbocharging and intercooler 4-stroke diesel direct injection 4 102 mm 106 mm 130 mm 136 mm
3 4250 cm 3 4800 cm

6 102 mm 106 mm 130 mm 136 mm


3 6370 cm 3 7200 cm

Forced circulation cooling

Engine rotation direc- Anticlockwise (when looking at the flywheel) tion Valve clearIntake valve ance Exhaust valve Starter motor Starter Voltage Output Battery Voltage Cold-discharge test current Cold start ability Alternator Voltage Current intensity 0.40 mm 0.60 mm Electric 24 V 4.0 kW 12 V/24 V Maximum 450 A 0.40 mm 0.60 mm Electric 24 V 4.0 kW 12 V/24 V Maximum 450 A

Up to maximum 20 (battery charge level 75%) 28 V 80 A 28 V 80 A

Technical data

104

Engine data
Operating data
Engine type Rated engine speed Effective engine speed range Idling speed OM 904 LA/OM 924 LAOM 906 LA/OM 926 LA 2200 rpm 2500 rpm 2200 rpm 2500 rpm

Approximately 600 rpm Approximately 600 rpm 2700 rpm 1300 rpm 2700 rpm 1300 rpm Minimum 0.5 bar Minimum 2.5 bar

Technical data

Engine brake permissible up to Engine speed limiter (emergency running mode) Oil pres- At idling speed sure At nominal engine speed

Minimum 0.5 bar Minimum 2.5 bar

Coolant Normal operation Approximately 80 95 Approximately 80 95 temperaMaximum permissi100 100 ture ble coolant temperature

Capacities
Capacity Service product 9) approx- (sheet no. imately Engine withOM 904 LA/OM924 LA oil filter OM 906 LA/OM 926 LA 13 l - 16 l For all engines: 24 l - 29 l Engine oil (228.2, 228.3, 228.31, 228.5, 228.51) For engines without BlueTec , also: Engine oil (228.0, 228.1) Diesel fuels (131.0) Fatty acid methyl ester fuel (135.0)
AdBlue /DEF according to DIN 70070/ISO 22241

Fuel tank

Vehicle operation using diesel fuel Vehicle operation with fatty acid methyl ester

Exhaust gas AdBlue /DEF aftertreatment

MB Specifications for Service Products.

Engine data 105


Capacity Service product 9) approx- (sheet no. imately
AdBlue /DEF filter sealing rings

MB silicon grease

Corrosion inhibOM 904/924 LA 4.7 litres itor/antifreeze OM 906/926 LA 6.9 litres agent volume down to -45 C Coolant additive OM 904/924 LA 0.11 litres Coolant additive (coolant without OM 906/926 LA 0.16 litres (310.1, 312.0) antifreeze protection) Engine comProtective wax partment Engine brake Heat-resistant lubricant Wax preservative (385.4)

Heat-resistant lubricant (part number A000 989 76 51)

Tightening torques

All threads on mechanical components and the corresponding contact surfaces must be cle smooth and coated with engine oil. Other lubricants lead to substantially different tighte torques. Engine Cylinder head cover Light alloy (with oil filler cap) 25 Nm Plastic (without oil filler cap) 20 Nm Adjusting the valve clearance Counternut on the rocker 50 Nm arm adjustment screw Inspection hole cap on the timing case Flywheel housing rotation device Charge-air housing on the cylinder head Fuel system
9

25 Nm 25 Nm 30 Nm 25 Nm

Cap on the fuel filter housing

MB Specifications for Service Products.

Technical data

Cooling sysTotal capacity OM tem (withOM out interCorrosion inhibOM cooler) itor/antifreeze OM agent volume down to -37 C

904/924 LA 8.5 litres Coolant (310.1, 906/926 LA 12.5 litres 325.0/2, 326.0/2, 325.3, 326.3) 904/924 LA 4.25 litres 906/926 LA 6.25 litres

106

Operating restriction - off-highway version


Oil circuit Drain plug on the oil panM 20 x 1.5 M 26 x 1.5 Oil filter cap on the oil filter housing Cooling system Coolant drain screw On the crankcase On the radiator 70 Nm 90 Nm 40 Nm 60 Nm 2 Nm 32 Nm

Technical data

Exhaust gas Filter bowl on AdBlue /DEF pump module aftertreatment

Operating restriction - off-highway AdBlue /DEF quality not OK/fault in version the monitoring system AdBlue /DEF level low

Insufficient AdBlue /DEF left; warning and sequence of operating restriction A Acknowledged fault B Minor operating restriction C Speed/torque reduction D Major operating restriction

Poor AdBlue /DEF quality and misuse; warning and sequence of operating restriction A Acknowledged fault B Minor operating restriction C Speed/torque reduction D Major operating restriction

Operating restriction - off-highway version 107


Recurring fault

a Regular operating restriction b Operating restriction after first recurrence

of fault

c Operating restriction after second recur-

rence of fault

Technical data

108

Imprint

Internet
You will find further information about Mercedes-Benz engines, Daimler AG and Togum AG on the Internet at: www.mercedes-benz.com www.daimler.com www.mtu-online.com

Editorial office
You are welcome to forward any queries or suggestions you might have regarding these Operating Instructions to the technical documentation team at the following address: Daimler AG, HPC: R822, D-70546 Stuttgart, Germany Daimler AG Not to be reprinted, translated or otherwise reproduced, in whole or in part, without written permission. Printed in Germany

As at 04.05.2011

9265840681 9265840681
Order no. 6462 9820 Part02 no. 926 584 Edition 06 81 A 06-11