Mercedes-Benz OM 501, OM 502 Service manual
Order no. 6462 9807 02 Part no . 5 41 58 4 09 81 EN Edition A, 0 8/03
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215x70 m m ein fügen
OM 501 LA – OM 502 LA engin es
Operating Ins tructions
Than k you fo r ch oosing this
Mercedes- Benz engine.
Please get to know your new MercedesBenz en gine first. Make sure y ou read the
Operati ng Ins truc tions in parti cular befor e
using the engine for the first time. In this
way you can ensure succes sful and safe
use. At the same time you will avoid endanger ing your self a nd others when o perat ing
the engine.
Items of special equipment are mar ked
with an asterisk *. The equipment in your
Mercedes-Benz d rive train may vary, depending on the version. Mercedes-Benz is
constantly updating its engines to the
state of the art. You cannot, therefore,
base a ny claims on the data, illust rations
or descriptions in these Operating Instructions.
For further information contact a
Mercedes-Benz Service Centre.
The Operating Ins tructions and Maintenance Booklet bel ong with the engine. You
should therefore always keep them with
the engine and pass them on to the new
owner if y ou sell it.
The technical documentation team at
DaimlerChrys ler AG wishes you every
suc cess .
Contents
Introduction
The aim of these Operating
Instructions . . . . . . . . . . . . . . . . . . . . . 5
Sym bo ls . . . . . . . . . . . . . . . . . . . . . . . . 6
Protection of the environment . . . . . . 7
Op erat ing s af ety . . . . . . . . . . . . . . . . . 8
Correct use. . . . . . . . . . . . . . . . . . . . 9
1At a glance
OM 501 LA overview . . . . . . . . . . . . . 12
OM 502 LA overview . . . . . . . . . . . . . 16
Location of senso rs . . . . . . . . . . . . . . 20
Engi ne pl ate . . . . . . . . . . . . . . . . . . . . 22
2 Before commissioning
General remarks . . . . . . . . . . . . . . . . 26
Type designation . . . . . . . . . . . . . . 26
Engine data card. . . . . . . . . . . . . . . 26
Description of the engine . . . . . . . . 27
Flame-start system*. . . . . . . . . . . . 28
Engine exhaust brake/ cons tantly-
open throttle valves* . . . . . . . . . . . 29
Telligent® engine system . . . . . . . . 31
Transport/installation . . . . . . . . . . . 35
3Safety
Safety precautions. . . . . . . . . . . . . . . 38
Personnel requirements . . . . . . . . . . 39
Commissioning parts and
modifications . . . . . . . . . . . . . . . . . . . 40
Safety/emergency running
programs . . . . . . . . . . . . . . . . . . . . . . 41
Replacement parts. . . . . . . . . . . . . . . 42
4Operation
Co mmi ssioning . . . . . . . . . . . . . . . . . . 44
P re paration . . . . . . . . . . . . . . . . . . . 44
Initial comm issioning . . . . . . . . . . . 46
Sta rting the eng ine . . . . . . . . . . . . . 49
Mo nito ring en gine oper ati on . . . . . . 51
Charge curr en t . . . . . . . . . . . . . . . . 51
Telligent® engine system . . . . . . . . 52
Oil pre ss ure . . . . . . . . . . . . . . . . . . 52
Flame-s tart syste m* . . . . . . . . . . . . 53
Stopping the engine. . . . . . . . . . . . . . 54
Wint er operation . . . . . . . . . . . . . . . . 55
Cleaning /protective treatment . . . . 57
Cl eaning the eng ine . . . . . . . . . . . . 57
Cleaning the cooling system. . . . . . 58
P ro te c tive trea tment . . . . . . . . . . . . 60
Service products . . . . . . . . . . . . . . . . 61
D ie se l fuel s . . . . . . . . . . . . . . . . . . . 62
Engine oils . . . . . . . . . . . . . . . . . . . 64
Coolant. . . . . . . . . . . . . . . . . . . . . . 65
5 M aint en anc e
Main te nan ce i nst r uctio ns . . . . . . . . . 68
Overview of w ork plans . . . . . . . . . . . 69
Main ten anc e s ervice. . . . . . . . . . . . 69
Ad ditional work. . . . . . . . . . . . . . . . 69
Additional work during every
3rd maintenanc e service . . . . . . . . 69
Wo rk plan s . . . . . . . . . . . . . . . . . . . . . 70
Engine: Checking for leaks and
gener al condition . . . . . . . . . . . . . . 70
Lines and hoses on the engine:
Checking for leaks and general
condition. . . . . . . . . . . . . . . . . . . . . 70
Engine: Oil change and filter
replacement . . . . . . . . . . . . . . . . . . 71
Adjusting the valve clearance. . . . . 74
Fuel connections. . . . . . . . . . . . . . . 78
Fuel pr efil te r with he at ed wat er
separator*: Replacing the filter
element. . . . . . . . . . . . . . . . . . . . . . 79
Replacing the fuel filter element. . . 81
Intake pi pe between air cleaner
and engine: Checki ng for leaks and
gener al condition . . . . . . . . . . . . . . 83
Contents
Poly-V-belt : Checking the condition 83
Engine brake*: Checking t he
condition and adjustment. . . . . . . . 88
Engine cooling s ystem: Checking
and cor recting the fluid level and
the antifreeze/ corrosion inhibitor . 90
Cooling and heating system:
Checking for leaks and general
condition. . . . . . . . . . . . . . . . . . . . . 91
Renewing coolant . . . . . . . . . . . . . . 93
6 Practical advice
Malfunctions, causes and solutions 96
Jump-starti ng . . . . . . . . . . . . . . . . . . 104
7Technical data
Engi ne da ta . . . . . . . . . . . . . . . . . . . . 1 06
Test values and adjustment values 109
Tightening torques. . . . . . . . . . . . . . 110
8 Glossary and index
Technical terms . . . . . . . . . . . . . . . . 113
Index . . . . . . . . . . . . . . . . . . . . . . . . . 115
The aim of these Operating Instructions
These Operating Instructions are intended
to a ssi st you i n all situatio ns wi th your new
engine. Each section has a print register to
help you find the information you require
quickly:
1At a glance
This section gives you an overview of the
layout of important components i n the engine.
2 Getting started
This contains the basic i nformation you
require for i nitial operation. I f this is y our
first Mercedes-Benz engine, you shoul d
read this section fir st.
3Safety
4 Controls in detail
Here you will fi nd all the informati on you
will need w hen you are operating the engine.
5Operation
This is where you will find m ore detailed in formation about maintenance work.
6 Practical advice
Here you will fi nd practical hel p for possible problems.
7Technical data
All the important techni cal data for the engine is listed here.
Introduction
The aim of these Operating Instru ctions
The engine documentation comprises the
fol lo win g:
these Operating Instructions
the Maintenance Booklet
Specifications for Service Produc ts
You may receive additional supp lements
depending on the equipment.
This section contains important aspects
with r egard to safety in the use of the
Mercedes-Benz OM 501 LA and
OM 502 LA engines.
8 Glossary and index
The glossary of technical terms explains
the mos t important tec hnical terms.
The index is intended to help you find infor mation quickly.
5
Introduction
Symbols
You will find the following symbols used in
these Operating Instructions:
* This aster isk i ndicates special
equipment. Since not all models
hav e the same standard equipment, the layout of your engine may
differ from certain descriptions and
illust rations.
Wa rnin g G
A warning draws your attention to possible
risks of accident and injury to yourself and
others.
You sho uld th eref ore always read an d observe all warning notices.
Environm ental n ote H
An environmen tal no te gi ves yo u tips o n the
protection of the environment.
!
This note draws your attention to possible hazards to your engine.
i
This tip contains advice or further information you may find useful.
This symbol means that you have to do
so mething.
A number of these symbols one after
the other indicates a sequence of action s.
page This symbol indicates the page
on which you will find further information on t he subject.
This continuation symbol indi-
cates an interrupted sequence
of actions that w ill be continued
on the next page.
-> This symbol in the gl ossary of
technical terms means that the
term following the arrow is also
explained.
6
Protection of the environment
Introduction
Protecti on of the e nvir on men t
Environmental note H
DaimlerChrysler's declared policy is one of
integrated envir onmen tal pro tection. This
policy start s at the ro ot cause s and encompasses in its management decisions all the
conseq ue nce s f or t h e e nvironmen t which
could arise from production processes or
the products themselves.
The objectives are for the natural resources
which f orm t he b asis of our e xistence on this
planet to be used sparingly and in a manner
which takes the requirements of b oth nature
and huma nity in to ac count.
Ope ra te the en gine in an env ironme ntally responsible manner, and you will help to protect the environment.
F uel con sump tion and e ng ine wear de pen d
on the op erating conditions.
Th ere fore y ou sh ould:
n ot warm up the engine in idling mode
switch off the engine during operation-
associated waiting times
check fuel consumption
c arry out the specified maintenance
work regularly
7
Introduction
Operating safet y
The operating safety of an engine firstly depends on its proper installation into the
comp le te sy stem (e. g. vehicl e, m achi ne,
etc.). Secondly, as operator or service personnel, you also have a direct in fluence on
the safe operation of the engine.
Some of the requiremen ts for operating
the engine safely can be achieved b y adhering to t he specified maintenance inter vals and ensuring that the required
maintenance work is carried out correctly.
However, s afe engine operation also depends on correct servicing, such as checking the engine oil level at regular i ntervals.
Risk of accident G
Impro per op erat ion of the en gine, e .g. exceeding the permitted maximum engine
spee d in o verrun mode or operating the en gine wi th to o l ittle oil , can cause eng ine
dama ge. En gin e damag e can le ad to an increase in the risk of accide nt.
The refo re, obs erv e th e notes on oper ating
the engine in these Operating Instructions.
Risk of accide nt G
Faulty maintenance work or failure to carry
ou t main te na nce wor k , e. g. not cha ng ing
the oil filter or not observing the correct
main te na nce int e rva l, ca n c ause en gin e
da mage . E ng ine da ma ge can lea d to an increase in the risk o f accident.
Therefore, observe the notes on engine
maintenance in these Operating Instructions.
8
Introduction
Operating safety
Risk of accident G
Work incorrectly carried out on electronic
components and its software could impair
the functioning of these components. Since
the electronic systems are networked, this
might also affect systems that h ave not
be en mod ifie d.
Always have work on or modifications to
elec tro nic comp onents carried out at a qualified specialist workshop which has the necessary specialist knowledge and to ols to
carry out the work required.
Mercedes-Benz recommends that you use a
Mercedes-Benz Service Centre for this purpo se.
Correct use
The engine i s only designed for installation
in accordance w ith the specifications determined in the contract.
The manufacturer of the end product is
pers onally respo nsible for t he compl ete
system of the end product, and in particular for the correct installation and compatibi lity of t his engine with the compl ete
system.
The engine must not be modified.
DaimlerChr ysler accepts no respon sibil ity
for damage caused as the result of modifications.
Correct use of the engine includes adhering to thes e Op er at ing Instructions, adhering to the maintenance i ntervals and
performing maintenance wo rk correctly in
accordance with these Operating Instructions.
9
10
At a glance
OM 501 LA overview
OM 502 LA overview
Location of sensors
Engine plate
1
11
At a glance
OM 501 LA overview
1
12
1 Fan
2 Coolant pump
3 Charge-air pres sure pipe (with flame-
start sy stem*) from charg e-ai r cooler
4 Charge-air pres sure pipe to charge-air
cooler
5 Oi l fil le r nec k
6 Exhaust gas turbocharger
7 Crankcase ventilation system oil trap
8 Exhaust pipe (with engine b rake throt-
tle valve*)
9 Oi l fil te r
a Fuel filter
b St arter motor
c Dipstick
At a glance
OM 501 LA o verview
1
13
At a glance
OM 501 LA overview
1
14
1 Oi l sump
2 Engine control unit
3 Flywheel housing
4 Exhaust manifold
5 Fuel pump (with flange-mounted
power-steering pump*)
6 A ir compressor*
7 Resonator* (onl y in conjunction
with air compressor)
8 Start-Stop buttons
9 Alternator
At a glance
OM 501 LA o verview
1
15
At a glance
OM 502 LA overview
1
16
1 Fan
2 Coolant pump
3 Charge-air pres sure pipe (with flame-
start sy stem*) from charg e-ai r cooler
4 Charge-air pres sure pipe to charge-air
cooler
5 Oi l fil le r nec k
6 Exhaust gas turbocharger
7 Crankcase ventilation system oil trap
8 Exhaust pipe (with engine b rake throt-
tle valve*)
9 Oi l fil te r
a Fuel filter
b St arter motor
c Dipstick
At a glance
OM 502 LA o verview
1
17
At a glance
OM 502 LA overview
1
18
1 Oi l sump
2 Engine control unit
3 Flywheel housing
4 Exhaust manifold
5 Fuel pump (with flange-mounted
power-steering pump*)
6 A ir compressor*
7 Resonator* (onl y in conjunction
with air compressor)
8 Start-Stop buttons
9 Alternator
At a glance
OM 502 LA o verview
1
19
At a glance
Location of sensors
1
20
1 Oi l l evel sen sor
2 Crankshaft position sensor (on the
flywheel)
3 Cylinder 1 TDC sensor (on the cam-
shaft sproc ket)
4 Fuel temperature sensor
5 Combined charge-air pressure and
temperature sensor
6 Coolant temperature sensor
7 Oi l pr essur e sensor
8 Oil temperature sensor
At a glance
Location of s ensor s
1
21
At a glance
Engine plate
Location
The engine plate is located on the left-hand
side of the engine, on the engine block af-
1
ter the l as t cylinder.
Engine plate, left-hand side of engine, flywhee l end
A second engine plate is mounted on the
front of the oil filter casing.
Engine plate, left-hand side of engi ne, fan
end
22
Information on the engine plate
On motor vehicles, t he engine plate shows
the engine model designation 1 and the
full engine number 2 along with the manufacturer' s name.
In addition to this, engines for mobil e machines and equipment carry the engine series designation and approval number.
At a glance
Engine plate
1
Engine plate
1 Engine mo del designation
2 Engine number
23
24
Before commissioning
General remarks
Transport / installa tion
2
25
Before commissioning
Genera l rem arks
Type designation
OM 501 L A
OM Oil engine (diesel
2
en gi ne)
501 Engine model
L Charge-air co oling
AExhaust gas turbo-
cha rger
1
Engine mode l 501 : 6-cyli nde r,
eng ine model 502: 8-cylinder
Engi ne da ta card
The en gine d ata c ard (DIN A4 sheet) forms
an i ntegral part of the documents belonging to the engine and should always be
kept w ith the Maintenance Booklet. It contains details about the engine's construction, including special equipment features.
The engine data card must be produced for
the procurement of genuine parts.
i
The engine data card describes the
scope of delivery from the supplying
factory; later changes to the scope of
delivery are not included on the data
card.
1
Engine data card
Always keep the engine data card with
the Maintenance Booklet.
26
Before commissioning
General remarks
Descr iption of th e engine
The OM 501 LA and OM 502 LA engines
are water-cooled 4-stroke direct injection
diesel engines.
The 6 or 8 cylinders are arranged in a
90° V and have separate fuel-injection
pumps (unit pumps) with a short highpressure fuel injection line to the multihole
injection nozzle located centr ally in relation to th e combustion chamber. The unit
pu mp s are moun t ed dir ectly on th e cra nkcase and is dr iven by the camshaft. Each
cylinder has two inlet valves and two exhaust valves.
The OM 501 LA and OM 502 LA engines
are equipped with an exhaust gas turb ocharger and a charge-air cooler as standard. The engine can be optionally equipped
with an engine brake* (throttle valve and
constantly-open throttle valves) and a
flame- sta rt sy stem .
Thanks to their fully electronic control system for controll ing the injection quantity
and injection timing v ia solenoid valves,
thes e are part icularly low-emiss ion engines.
The control system comprises an engineresident control unit, an engine control
(MR) wit h inte gra ted heat excha nger fo r
cooling by means of the forward fuel flow
and an application-related contr ol unit , a
vehicle control (FR) or an adaptation module (ADM), all interconnected via the Controller Area Network (CAN).
2
27
Before commissioning
Genera l rem arks
Flame-start system*
T h e flam e- s tar t s yst em i s a cold - start a i d
for starting at low outside temperatures. It
reduces the white smoke emission after
the engine is st arted. In addition, it reduces the strain on the starter motor and bat-
2
teries by shortening the startup ti me.
Flame-start system
Fuel can be ignited by a flame heater plug
mounted in the charge-air duct intake. The
fuel is supplied to the fl ame heater plug via
a solenoid valv e with a dosing jet.
Flame- sta rt sys te m i ndicato r lamp (exa mpl e)
The flame-start system is primed after a
preglow time (m aximum 20 seconds)
which is dependent on the outside temperature. After this time the flame-start system indicator lamp goes out.
Once the engine has started, the flamestart sys tem is suppli ed w ith fuel by t he engine's fuel delivery pump.
28
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