Engine model series OM 457 LA..............................................................................................................................................................................................................2
Engine OM 457 LA...................................................................................................................................................................................................................................4
Series 457<>Cylinder head....................................................................................................................................................................................................................11
Series 457<>Cylinder head - cross section (transverse and longitudinal)............................................................................................................................................12
Series 457 LA<>Port assignments in the cylinder head gasket............................................................................................................................................................13
Series 457<>Cylinder head bolts - tightening instructions....................................................................................................................................................................14
Series 457<>Setting valve play.............................................................................................................................................................................................................16
Series 457<>Removing/installing the nozzle holder combination........................................................................................................................................................19
Series 457<>Valve cover and valve cover gasket.................................................................................................................................................................................25
Series 457<>Oil pan..............................................................................................................................................................................................................................26
Series 457<>Pump-line-nozzle injection system...................................................................................................................................................................................27
Series 457<>Removing/installing the MR/PLD unit pump...................................................................................................................................................................28
Series 457<>Pistons..............................................................................................................................................................................................................................35
Series 457<>Lubrication schematic diagram........................................................................................................................................................................................36
Series 457<>Oil spray nozzle.................................................................................................................................................................................................................38
Series 457<>Crankcase and cylinder liner............................................................................................................................................................................................39
Series 457<>Camshaft..........................................................................................................................................................................................................................40
05/03Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training
Content
I2
Series 457<>Fuel system......................................................................................................................................................................................................................42
Series 457<>Fuel pump.........................................................................................................................................................................................................................45
Series 457<>Fuel prefilter with heated water separator.......................................................................................................................................................................46
Series 457<>Planetary drive starter......................................................................................................................................................................................................48
Series 457<>Fan drive and fan systems................................................................................................................................................................................................50
Series 457<>Air compressor.................................................................................................................................................................................................................52
Series 457<>Turbocharger BR S400.....................................................................................................................................................................................................53
Series 457<>Engine oil and filter change..............................................................................................................................................................................................54
Series 457<>Replacing the fuel filter....................................................................................................................................................................................................56
Series 457<>Fuel filter with water separator - replacing the filter element..........................................................................................................................................58
Series 457<>Air cleaner, engine coolant service..................................................................................................................................................................................60
Series 500<>Engine models..................................................................................................................................................................................................................62
Series 500<>Technical features............................................................................................................................................................................................................64
Series 500<>Cylinder head - port assignment......................................................................................................................................................................................70
Series 500<>Cylinder head....................................................................................................................................................................................................................71
Series 500<>Cylinder head mounting...................................................................................................................................................................................................73
Series 500<>Cylinder head gasket........................................................................................................................................................................................................74
Series 500<>EURO 2 and EURO 3 cylinder heads compared...............................................................................................................................................................75
Series 500<>Valve assembly.................................................................................................................................................................................................................77
Series 500<>Pump-line-nozzle injection system (PLD).........................................................................................................................................................................83
Series 500<>Removing/installing the MR/PLD unit pump...................................................................................................................................................................91
Series 500<>EURO 2 and EURO 3 pistons.........................................................................................................................................................................................101
05/03Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training
Content
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Series 500<>Connecting rod..............................................................................................................................................................................................................102
Series 500<>Crankcase......................................................................................................................................................................................................................103
Series 500<>Cylinder liners................................................................................................................................................................................................................104
Series 500<>EURO 2 and EURO 3 cylinder liners compared.............................................................................................................................................................107
Series 500<>Crankcase ventilation system.......................................................................................................................................................................................108
Series 500<>Fuel system...................................................................................................................................................................................................................112
Series 500<>Oil cooler and oil filter housing – component locations................................................................................................................................................124
Series 500<>Oil circuit.......................................................................................................................................................................................................................128
Series 500<>Engine oil system...........................................................................................................................................................................................................129
Series 500<>Oil spray nozzle..............................................................................................................................................................................................................130
Series 500<>Water guide...................................................................................................................................................................................................................134
Series 500<>Thermostat location.......................................................................................................................................................................................................136
Series 500<>Supercharging system and charge air ducting..............................................................................................................................................................137
Series 500<>Engine oil and filter change...........................................................................................................................................................................................140
Series 500<>Cleaning the fuel prefilter / filter insert........................................................................................................................................................................144
Series 500<>-Fuel prefilter with water separator - replacing the filter element................................................................................................................................146
Series 500<>Replacing the oil separator insert.................................................................................................................................................................................148
Series 500<>Replacing the fuel filter - air cleaner - coolant..............................................................................................................................................................150
Engines OM 904 and 906...................................................................................................................................................................................................................152
Engine series 900...............................................................................................................................................................................................................................153
Series 900<>Technical features.........................................................................................................................................................................................................156
Series 900<>Port assignments in the cylinder head gasket..............................................................................................................................................................159
05/03Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training
Content
I4
Series 900<>Tightening instructions for cylinder head bolts.............................................................................................................................................................160
Series 900<>Valve control..................................................................................................................................................................................................................162
Series 900<>Setting valve play..........................................................................................................................................................................................................164
Series 900<>Pump-line-nozzle injection system (PLD)......................................................................................................................................................................167
Series 900<>Crankcase......................................................................................................................................................................................................................185
Series 900<>Ölspritzdüsen - Unterschiede........................................................................................................................................................................................188
Series 900<>Pistons and piston rings................................................................................................................................................................................................189
Series 900<>Connecting rod..............................................................................................................................................................................................................190
Series 900<>Pistons and connecting rod - modifications..................................................................................................................................................................191
Series 900<>Engine oil circuit............................................................................................................................................................................................................192
Series 900<>Removing/installing the oil pan....................................................................................................................................................................................196
Series 900<>Fuel system...................................................................................................................................................................................................................200
Series 900<>Supercharging system and charge air ducting..............................................................................................................................................................212
Series 900<>Removing/installing the coolant thermostatic control.................................................................................................................................................216
Series 900<>Engine oil and filter change...........................................................................................................................................................................................218
Series 900<>Cleaning the fuel prefilter - filter insert.........................................................................................................................................................................221
Series 900<>Fuel prefilter with water separator - replacing the filter element.................................................................................................................................223
Series 900<>Replacing the fuel filter - air cleaner - coolant..............................................................................................................................................................226
05/03Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training
Welcome
1
Welcome07.05.2003
OM 457 LAOM 502 LAOM 906 LA
N01.10-2073-50N01.10-0341-50N01.00-2301-50
05/03Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training
Series 500<>Engine models
62
Series 500<>Engine models07.05.2003
The 500 engine model series is future-ready, and
comes in V6 and V8 cylinder variants with 2 litre
swept volume per cylinder.
The sales designation is formed in the same way
as the 400 model series:
6-cylinder engine: OM 501 LA
8-cylinder engine: OM 502 LA
At the same time, the OM 457 LA engine was
developed with the same basic design as the V-
engines.
The Series 2000 V12 and V16 MTU engines are
derived from the BR 500, and are intended for
industrial applications.
Model series 500
V
6
OM 501 L
A
V
8
OM 502 L
A
V
H
= 12lV
H
= 16l
OM 501 LA
OM 501 LA
Turbocharger
Char
g
e air cooler
1=6-cylinder V-engine
2=8-cylinder V-engine
Model series 500
Diesel engine
05/03Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training
Series 500<>Engine models
63
N01.10-2026-11N01.10-2028-11
The development of the 500 series encapsulates all the knowledge and experience gained from the 1 million V-engines manufactured since 1969, when
production of the OM 403 V10 engine began.
05/03Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training
Series 500<>Technical features
64
Series 500<>Technical features07.05.2003
ÞOutstanding power output and torque characteristics over the whole
rpm range
ÞDynamic start-off characteristics and pulling power
ÞAttractive power/weight ratio
ÞLow fuel consumption
ÞEnormous potential: the V6 engines meet the requirements of the highly
popular 400 HP Class
ÞHigh-pressure direct injection, pump-line-nozzle system with peak
pressures up to 1,800 bar.
ÞElectronic engine control (MR) with electronic system fixed to the
engine, and extensive engine protection functions
ÞDirect injection with centrally positioned 6-hole injection nozzle.
Þ4-valve technology
ÞUseful engine brake rpm well over rated rpm, up to 2400 rpm
ÞMeets the emission legislation of EURO 3 and EUROMOT/EPA Level 2
ÞTurbocharger with charge air cooling
ÞV8 with 2 turbochargers
ÞViscous fan clutch, electromagnetic fan clutch and high-speed fan
drive on the most powerful engines
ÞRated engine speed 1,800 rpm or 2000 rpm
ÞLow maintenance requirement
ÞLong maintenance intervals
ÞEngine oil and fuel filter located at the front, for easy maintenance
ÞMaintenance-free belt drive
ÞCan run on FAME / RME (rape methyl ester) or biodiesel, and engine oil
changes are halved
ÞHigh reliability and long runtime
ÞLow number of component variants, as many parts are the same on both
6 and 8 cylinder engines
ÞRear engine power take-off ex works
05/03Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training
Series 500<>Technical features
65
05/03Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training
Series 500<>Technical features
66
Overview of BR 500 engines with EURO 3 certification
05/03Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training
Series 500<>Valve assembly
82
05/03Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training
Series 500<>Pump-line-nozzle injection system (PLD)
83
Series 500<>Pump-line-nozzle injection system (PLD)07.05.2003
Engines of the OM 500 model series use the direct
fuel injection process.
The injection process is performed by the newly
developed pump-line-nozzle (PLD) system,
controlled by an electronic engine management
system that has also been newly developed.
In the PLD system, fuel is delivered to the injection
nozzle by individual unit pumps over short, rigid
high-pressure injection lines, and through the
pressure pipe connection screwed into the cylinder
head.
The connection to the nozzle and nozzle holder is
located centrally at the cylinder, and is integrated
with, and removable from, the cylinder head.
A unit pump fitted for each cylinder is located
directly on the crankcase.
N07.02-2018-50
05/03Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training
Series 500<>Pump-line-nozzle injection system (PLD)
84
The electronic engine management system controls the injection timing point and quantity injected individually per cylinder, by means of solenoid valves.
Separation of the high pressure pump and injection nozzle made it necessary to develop a high pressure injection line of special tube material with a surface
hardened by internal high pressure forming, able to support continuous injection pressures over 2000 bar.
With high pressure injection (peak pressures up to 1800 bar) together with the central, vertically positioned nozzle with 8 or 6 injection orifices and flat
combustion chamber cavity in the piston, outstanding particulate values are achieved.
Advantages over the Pump-Nozzle system
¦No overhead camshaft
- therefore lower space requirement and reduced engine height
- lower noise emission
¦On the V-engine, only one camshaft needed, which controls both cylinder banks.
- Weight saving
¦Locating the camshaft in the center of the crankcase means there is optimal power absorption. With an overhead camshaft, measures would be
necessary for strengthening the cylinder head.
¦Easy to repair
- Individual cylinder heads, which are all identical
- Compact unit pumps, which are simple to replace
- Inexpensive replacement due to separate pump and nozzle
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