Mercedes-Benz OM 904-926 LA BlueTec, OM 904-926 LA Operating Instructions Manual

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OM 904-926 LA BlueTec

Operating Instructions

, OM 904-926 LA

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$ %

X YY

(Y page)

Warning

Environmental note

Possible vehicle damage

Tip

Instructions

Continuation symbol

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

technical features

You cannot therefore base any claims on the data, illustrations or descriptions in this manual.

The manual/instructions are comprised of:

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.

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

É9265840681ÁËÍ

Contents

Index ....................................................... 4

General information .............................. 7

At a glance ........................................... 13

Safety ................................................... 29

Driving mode/working mode ............. 33

Maintenance and care ........................ 45

Notes on maintenance ....................... 59

Decommission and protection ........... 79

Breakdown assistance ....................... 85

Technical data ..................................... 99

Index

Adaptation module .............................. 21

AdBlue®/DEF

Components .................................... 19

Consumption ................................... 41

Refuelling

Replacing the filter ...........................

......................................... 42

Service product ............................... 54

ADM (FR (drive control) unit) ............. 21

Antifreeze ............................................. 73

Bio-diesel fuel

see FAME fatty acid methyl ester fuel

Bleeding the fuel system .................... 86

Bleeding the fuel system manually ... 86 BlueTec

Exhaust gas aftertreatment ................ 9

Sensors ............................................ 19

BlueTec® exhaust gas aftertreatment

AdBlue® service product .................. 54

Braking

Continuous brake ............................ 40

Capacities .......................................... 104

Care products ...................................... 55

Charge current .................................... 37

Checking the fluid level ...................... 34

Cleaning and care

Engine cleaning ................................

High-pressure cleaning .................... 55

Notes on care .................................. 55

Cold-start aid

....................................... 27

Consumption

AdBlue®/DEF .................................. 41

Fuel .................................................. 41

Oil (engine) ...................................... 41

Continuous brake ................................ 26

Coolant ................................................. 34

Mixing ratio ...................................... 48

Renewing ......................................... 75

Service product ............................... 48

Coolant (engine)

Topping up

....................................... 76

Coolant additive .................................. 48

Cooling system

Degreasing ....................................... 76

Flushing ........................................... 76

Correct use ............................................ 9

Corrosion inhibitor/antifreeze

agent .................................................... 48

Cranking device ................................... 64

Data card ............................................

Decommissioning

................................ 81

100

Decommissioning the engine ............. 80

DEF/AdBlue

see AdBlue®/DEF service products

Description of the engine ................... 21

Diesel

Flow improvers ................................ 52

Fuels ................................................ 50

Low outside temperatures ............... 52

refuelling .......................................... 41

Sulphur content table ...................... 51

Dimensions ........................................ 101

Disposal of service products .............. 46

Draining the coolant ........................... 75

Draining the fuel prefilter ................... 86

Driving tips .......................................... 40

Electronic engine control ................... 38

Emergency mode .................................

Emergency running program

................ 8

Engine

Capacities ...................................... 104

Changing the oil and oil filter ........... 62

Checking for leaks and general

condition .......................................... 77

Cleaning ........................................... 55

Data ............................................... 101

Data card ....................................... 100

Data plate ...................................... 100

Diagnostics (indicator lamp) ............ 94

Oil consumption ............................... 41

Operating data ............................... 104

Index

Protective treatment ........................ 81

Re-commissioning ........................... 83

Rectifying faults ............................... 89

Running-in period ............................. 40

Starting

Stopping .......................................... 39

Engine brake

Condition and setting ....................... 72

Function ........................................... 26

Engine control unit .............................. 22

Engine data ........................................ 101

Engine data card ............................... 100

Engine description .............................. 21

Engine model designation ................ 100

Engine oil

Adding ............................................. 63

For winter operation ........................ 46

Mixing .............................................. 48

Oil change ........................................ 47

Siphoning and draining .................... 62

Topping up ....................................... 48

Engine oil consumption ...................... 41

Engine overview .................................. 14

Engine type plate .............................. 100

Exhaust gas aftertreatment indica-

tor lamp ................................................ 95

............................................ 36

Filling up the pressure reservoir ....... 71

Flow improvers .................................... 52

FR (drive control) unit

see ADM

Fuel

Additives

Consumption ................................... 41

Diesel ............................................... 50

FAME fatty acid methyl ester fuel .... 53

refuelling .......................................... 41

Sulphur content table ...................... 51

Fuel filter .............................................. 67

Fuel grade ............................................ 50

.......................................... 52

Genuine Mercedes-Benz

parts ................................................... 7, 8

Getting started .................................... 35

High-pressure cleaning ....................... 55

Identification plate ............................ 100

Indicator and warning lamps

BlueTec® exhaust gas aftertreat-

ment ................................................ 25

Installation ........................................... 10

Lines and hoses

Checking for leaks ........................... 77

Maintenance ........................................ 56

Mercedes-Benz Service Centre

see Qualified specialist workshop

Modifications and changes .................. 7

Oil (engine)

For winter operation ........................ 46

Oil change ........................................

Scope of use

Oil change ............................................ 62

Oil filter replacement .......................... 62

Oil pressure ......................................... 38

Operating data ................................... 104

Operating restriction override ........... 39

Operating safety .................................... 7

Operational monitoring ...................... 37

Organisational measures ................... 30

Original parts ......................................... 7

Overview, sensors ............................... 18

Overview of maintenance work ......... 60

Overview of work plans ...................... 60

.................................... 47

Personnel ............................................. 30

Poly-V-belt

Checking condition .......................... 66

Damage patterns ............................. 66

Routing ............................................ 97

Index

Preparing for starting operation

see Starting operation

Protection of the environment ............. 7

Protective treatment .......................... 81

Qualified specialist workshop ........... 11

Re-commissioning ............................... 83

Refuelling

AdBlue®/DEF .................................. 42

Fuels ................................................ 41

Replacing the fuel filter

Replacing the fuel prefilter ................. 68

Replacing the poly-V-belt .................... 97

Requirements of the personnel ......... 30

Roadside Assistance ........................... 86

Running the vehicle in ........................ 40

...................... 69

Safety and

gram ....................................................... 8

Safety precautions .............................. 30

Service products

AdBlue®/DEF .................................. 54

Coolant ............................................ 48

DEF/AdBlue® .................................. 54

Diesel fuel ........................................ 50

Disposal ........................................... 46

Disposing of AdBlue®/DEF .............. 55

Engine oil ......................................... 46

FAME fatty acid methyl ester fuel .... 53

Flow improvers ................................ 52

Fuel additives ................................... 52

Purity of AdBlue®/DEF .................... 55

Storing AdBlue®/DEF ...................... 55

Specialist workshop ............................ 11

Starting

see Starting (engine)

Starting (engine) .................................. 36

Starting the engine for the first

time ...................................................... 35

Stopping and switching off the

engine ................................................... 39

emergency running pro-

Sulphur content of fuel ....................... 51

Technical data ................................... 101

Dimensions .................................... 101

Filling capacities

Operating data ............................... 104

Weights .......................................... 101

Tightening torques ............................ 105

Torque reduction ............................... 106

Transport ................................................ 9

Troubleshooting .................................. 94

............................ 104

Valve clearance

Checking and adjusting ................... 63

Valve clearance special tool ...............

Warning and indicator lamps

Charge indicator .............................. 25

Cold-start aid ................................... 25

Electronics

Weights .............................................. 102

Winter diesel ........................................ 52

Winter operation ................................. 43

....................................... 25

General information

Environmental note

Daimler AG has a declared policy of comprehensive environmental protection.

The objectives are to use the natural resources which form the basis of our existence on this planet sparingly and in a manner which takes the requirements of both nature and humanity into account.

You by operating your engine in an environmentally responsible manner.

The fuel consumption and wear and tear of an engine depend upon the conditions under which it is operated. For this reason, you should:

Always have maintenance work carried out at a qualified specialist workshop, e.g. a Mercedes-Benz or MTU Service Centre.

can help to protect the environment

also

not warm up the engine in neutral

switch off the engine during operation-related delays

monitor the fuel consumption

carry out the specified maintenance work.

Operating safety and vehicle approval

Operating safety

The operating

safety of an engine depends on its professional installation in the overall system (e.g. the vehicle or working machinery). As the operator of the engine, you also affect its safe operation.

Through compliance with the prescribed maintenance intervals, you fulfil part of the requirements for safe operation of the engine.

However, safe operation of the engine also depends upon its proper use, which includes, for example, regular checks of the oil level.

WARNING

Accidents can occur as a result of engine damage caused by improper use of the engine.

Therefore, instructions included in the Owner's Manual.

WARNING

Faulty or incomplete maintenance work, as well as disregarded maintenance intervals, can decrease the engine's operating life, cause engine damage and lead to accidents.

Therefore, instructions included in the Owner's Manual.

follow the engine operating

please

follow the engine operating

please

Notes on electronic systems

WARNING

If work on electronic equipment and its software

carried out incorrectly, this equipment

is could stop working. The electronic systems are networked via interfaces. Tampering with these electronic systems could cause malfunctions in systems which have not been modified. Malfunctions such as these can seriously jeopardise the vehicle's operating safety and therefore your own safety.

Other work or modifications incorrectly carried out on the vehicle could also jeopardise operating safety.

Some safety systems only function when the engine is running. You should therefore never switch off the engine when driving.

Conversion parts and modifications to the engine

WARNING

Unauthorised changes to the engine can reduce its functionality and safety, lead to accidents and consequently to personal injury. tion to the engine carried out at a qualified specialist workshop which has the necessary

have maintenance or modifica-

Always

General information

specialist knowledge and tools to carry out the work required. Mercedes-Benz recommends that Service Centre for this purpose.

Unauthorised intervention in the injection

you use a Mercedes-Benz or MTU

system and the engine electronics can affect the performance and emissions of the engine. Compliance with factory settings 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).

When the

electronic control system detects a malfunction, one of the following measures is automatically implemented after an appraisal of the malfunction:

The corresponding warning lamp displays the faults occurring during operation (Y page 25).

In conjunction with the electronic engine control, fault codes can be shown on a display.

The system switches to a suitable backup function for the continued, albeit restricted operation of the engine (e.g. constant emergency running speed).

WARNING

If maintenance and repair work on the engine is

carried out correctly, the operation and

not safety may be affected, which can result in accidents and personal injury.

Always have work on or modifications to the engine carried out at a qualified specialist workshop that has the necessary special skills and tools for the work required.

Mercedes-Benz recommends a MercedesBenz or MTU Service Centre.

The Daimler diagnostic tester can be attached to the 14-pin diagnostic socket on the equipment,

or to the service plug according to the EU Directive. Both the malfunction message memory and the saved engine data can be read by this device.

Warning lamp electronics (example)

Genuine Mercedes-Benz parts

Make sure of the suitability of the replacement parts

for your engine. Parts that lead to a modification of the engine/vehicle/equipment are considered in many countries to render the general operating permit invalid.

Such modifications include, for example:

modifications that change the approved equipment type/vehicle type, as defined by the general operating permit.

modifications that could endanger road users or persons in the vicinity of the vehicle/equipment.

modifications that change the exhaust or noise level.

The use of unapproved parts can adversely affect safety levels.

Environmental note

For more economic repairs, Mercedes-Benz offers Mercedes-Benz reconditioned assembly and

parts as part of the recycling process. The same quality standards and warranty apply as to new parts.

General information

You can find more information on recommended conversion

parts and accessories, as well as permitted technical modifications at a Mercedes-Benz or MTU Service Centre (Y page 11).

Always state the engine number with the model designation when ordering genuine Mercedes-Benz parts. You can find the numbers on the identification plate of your engine (Y page 100) and on the engine data card (Y page 100).

BlueTec® exhaust gas aftertreatment

The engines meet the requirements of the relevant emissions

level and are correspond-

ingly certified.

Compliance with emissions laws and regulations is a condition of the operating permit for the vehicle/equipment.

Engines with BlueTec® exhaust gas aftertreatment must be operated with AdBlue®/ DEF in order to meet the emissions laws and regulations.

The operating permit is invalidated if the vehicle/equipment is operated without AdBlue®/ DEF. The legal consequence of this is that operation of the vehicle/equipment is no longer permitted. This may be an offence or a breach of road traffic regulations in certain countries. Special concessions granted either at the time of purchase or to reduce operating costs of the vehicle/equipment, e.g. reduced taxes or tolls, may also be rendered retroactively invalid. This can be the case in the country of registration. Or also in another country where you operate the vehicle/equipment.

This normally affects the following operating states:

driving without AdBlue®/DEF

the permissible nitrogen oxide (NOx) thresholds are exceeded

there is a fault or emissions-relevant malfunction in the monitoring or exhaust gas aftertreatment system

can

You

find details in the “Engine diagnostics

indicator lamp” section(Y page 94).

Fault detected in the monitoring system

If the monitoring system detects a fault in the BlueTec® exhaust gas aftertreatment, operation is limited in accordance with the relevant regulations (Y page 37).

Correct use

The engine may only be installed as contractually specified.

The manufacturer of the end product is responsible for the correct installation and compatibility of

the engine in the overall sys-

tem.

The engine may not be modified. If the engine is modified, Mercedes-Benz and MTU do not accept responsibility for any damage arising as a result.

Correct use of the engine requires adherence to the instructions in this Owner's Manual. This also requires compliance with the maintenance intervals and the professional execution of maintenance work in accordance with this Owner's Manual.

Transport

Legal requirements

If the engine/vehicle/equipment is not operated within the limits of the emissions laws and regulations, it can lead to sanctions.

WARNING

The engine can detach and cause injuries if it overturns or falls out.

General information

To lift the engine, only use lifting points attached to the engine.

Only use Mercedes-Benz transport equipment intended for this purpose.

Only lift and transport the engine in the installation position. Also, observe the maximum permitted angle of 30° while lifting the engine in and out of vehicles.

Lifting point flywheel-side (example)

Lifting point belt-side (example)

Installation

The engine may only be installed as contractually specified.

The manufacturer of the end product is responsible for the correct installation and compatibility of

the engine in the overall sys-

tem.

Observe the sections "Correct use" (Y page 9) and "Modification and changes to the engine" (Y page 7).

The Operating Instructions contains information required

for installation in the "Technical

Data" section" (Y page 101).

Please consult a Mercedes-Benz or MTU Service Centre if you have any questions (Y page 11).

Information on the implied warranty

A well-developed network of Mercedes-Benz and MTU

Service Centres is available to carry

out maintenance work.

Mercedes-Benz and MTU Service Centres:

have special equipment and tools as well as specialists who receive continuous training

guarantee that your engine is repaired and maintained thoroughly and expertly

carry out all repairs within the framework of the engine warranty and the implied warranty

carry out all maintenance work expertly

confirm in the Maintenance Booklet that the maintenance work has been carried out at the required time

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 observe these instructions even if you let a third party use and care for your engine. This is the only way to ensure that you do not lose your entitlements.

If the prescribed maintenance work is not carried out, claims can only be decided after the manufacturer has inspected the claim.

General information

During the engine warranty period in particular, have

the prescribed maintenance service

carried out as follows:

regularly

punctually

at a qualified specialist workshop which has the necessary specialist knowledge and tools to carry out the work required.

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

If there are legal requirements on exhaust gas aftertreatment, please note that:

maintenance on the engines must be carried out according to specific regulations and using special measuring devices.

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.

Always have the following work on the vehicle carried out

work relevant to safety

service and maintenance work

repair work

modifications such as installations or con-

at a qualified specialist workshop:

versions

work on electronic components

Please have warranty and ex gratia work carried out at authorised workshops/Service Centres.

For on-highway applications, contact a Mercedes-Benz Service Centre.

For off-highway applications, contact an MTU or MTU-authorised Mercedes-Benz partner.

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.

Exterior view ....................................... 14

General information ............................ 21

At a glance

Exterior view

Engine overview

At a glance

Engine overview OM 904 LA

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

At a glance

Engine overview OM 904 LA

AdBlue®/DEF metering unit

;

Charge air pipe of the charge-air cooler

Charge air pipe to the charge-air cooler

Crankcase ventilation hose

Oil filter

Tensioning pulley

Alternator

Starter

Intake air inlet

Engine brake

Exterior view

At a glance

Engine overview OM 906 LA

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

At a glance

Engine overview OM 906 LA

AdBlue®/DEF metering unit

;

Charge air pipe of the charge-air cooler

Charge air pipe to the charge-air cooler

Crankcase ventilation hose

Oil filter

Tensioning pulley

Alternator

Starter

Intake air inlet

Exhaust gas turbocharger

Engine brake

Exterior view

Sensors overview

Sensors, general

At a glance

Example: OM 926 LA

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

AdBlue®/DEF components

Exterior view

At a glance

BlueTec® sensors, overview OM 924 LA

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

Exterior view

At a glance

BlueTec® sensors, overview OM 926 LA

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

At a glance

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

AdBlue®/DEF pressure sensor

;

AdBlue®/DEF temperature sensor

Pressure sensor for compressed air

Metering unit test connection

Metering unit heater

Metering valve

General information

Description of the engine

The engine is a water-cooled four-stroke diesel engine with direct injection.

The cylinders inder has two inlet valves and one outlet valve.

Each cylinder has its own fuel injection pump (unit pump) with a short high-pressure fuel injection line to the multi-hole nozzle at the centre of the combustion chamber. The unit

are arranged in a row. Each cyl-

pumps sit directly in the crankcase and are driven by the camshaft.

The engine is equipped with exhaust gas turbocharger and intercooler as standard. The engine can brakes (brake valve and constant throttle valves).

It is a low-emission engine. Start of injection, injection period and injection quantity are controlled entirely electronically.

be equipped with optional engine

General information

Electronic drive control

The engine has a fully electronic control system which,

along with the engine and its associated sensors, consists of the following components:

the engine control unit (MR) and

the drive control unit (FR) and/or other

At a glance

vehicle-specific control units, e.g. ADM

SCR frame module (only for engines with BlueTec® exhaust gas aftertreatment)

The control units are interconnected by a CAN line (Controller Area Network line) which facilitates the exchange of all necessary data.

In addition to the engine and the BlueTec exhaust gas aftertreatment, the electronic engine control also monitors itself. Depending on the malfunctions/failures that occur, a safety and emergency mode (Y page 8) may be automatically selected.

For vehicle engines, the electronic engine control only allows the engine to be started when the transmission is in neutral.

Engine control unit (engine resident)

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

These values are analysed together with data

the

from

engine sensors. They are compared with the charts or characteristic curves stored in the engine control unit.

Data from the sensors derives from, e.g.:

charge-air pressure and charge-air temperature

coolant temperature

fuel temperature

oil pressure

Start of injection, injection period and injection quantity are calculated on this basis and the unit pump is controlled via the solenoid valve accordingly.

If BlueTec® exhaust gas aftertreatment is available, the associated sensors are also analysed and the AdBlue®/DEF dosage is controlled.

To obtain a replacement engine control unit, you will require all the data on the control unit type plate.

Example: OM 926 LA engine control unit

The engine control unit processes values from the

FR (drive control) unit and the ADM. These are, for example, the value from the position sensor (accelerator pedal), the engine brake or engine start/stop, etc.

Control unit type plate

Data record

;

Certification no.

Engine number

Equipment code

General information

FR (drive control) unit or ADM (on the equipment)

The engine can be adapted to the various operation-specific requirements

using the FR (drive control) unit or the adaptation module ADM.

Example: FR (drive control) unit

Various operation specific data such as engine idling speed, maximum working engine speed or speed limiter are stored in the FR (drive control) unit or the ADM.

The FR (drive control) unit or the ADM receives data from:

user (values from the position sensor, engine start/stop)

engine brake switch

other systems (e.g. acceleration skid control)

engine control unit (e.g. oil pressure and coolant temperature)

Values for the engine control (MR control unit) are derived from this and conveyed via 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.

Mercedes-Benz diagnostic

testers can be connected to the 14-pin diagnostic socket on the equipment or with the EU compliant service connector. Both fault memory and stored engine data can be read out using this equipment.

SCR frame module (on the frame)

SCR frame module

The SCR frame module reads signals and transmits them

via the CAN line to the engine

control unit.

The following signals are read:

Temperature sensor upstream of the SCR catalytic converter

Temperature sensor downstream of the SCR catalytic converter

NOx sensor downstream of the SCR catalytic converter

Combination sensor for level and temperature in the AdBlue®/DEF tank

Combination sensor for humidity and air charge temperature

Example: diagnostic socket

At a glance

General information

At a glance

Example: EU compliant service connector

Warning and indicator lamps

Engine, general

General information

Symbol

;

Reason for display/displayed message

Fault lamps Impermissible operating conditions

Text in the engine symbol: "CHECK"

;

STOP lamp

Serious fault

Text in the engine symbol: "STOP"

Electronic engine control malfunction

Charge current (power generation)

Lights up in the event of an electronic engine control malfunction. Engine may only be operated in emergency mode.

Lights up in the event of a charge current (power generation) malfunction.

If the warning lamp does 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.

BlueTec® exhaust gas aftertreatment on-highway version

Cold-start aid Lights up if the cold-start aid is active.

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

Symbol

Reason for display/displayed message

AdBlue®/DEF level

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

;

NOx bulb

Engine indicator lamp Exhaust system fault

Reduction in operating perform-

Active torque limitation

ance

At a glance

Symbols may vary depending on the vehicle/equipment version.

In addition, a warning tone may sound.

On-highway: vehicles with MOT approval.

General information

BlueTec® exhaust gas aftertreatment off-highway version

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

Symbol

Reason for display/displayed message

AdBlue®/DEF level

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

At a glance

lights up

Check engine/exhaust gas aftertreatment

Torque/speed limiter

active

Fault and misuse (failure in the monitoring system)

Slight reduction in operating performance

(level 1)

flashes

Significant reduction in operating performance

(level 2)

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

;

The brake valve uses exhaust back pressure to increase braking power. The constant throttle

OM 904 LA/OM 924 LA constant throttle valve

Constant throttle valve

;

Pneumatically-actuated line

compression pressure in the power stroke (third stroke), whilst the compression (second stroke) is not significantly affected.

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

Off-highway: vehicles without MOT approval.

Symbols may vary depending on the vehicle/equipment version.

In addition, a warning tone may sound.

Constant throttle valve

Hydraulically-actuated line

valves

bring about a reduction of the

General information

exhaust port. This brings about the desired decompression during the power stroke.

When the engine brake is activated, the constant throttle valves are opened. For OM 904/OM 924 engines, the actuation is pneumatic. For OM 906/OM 926

engines, the actuation is hydraulic. The brake valve on the exhaust gas turbocharger is also closed.

The engine brake is actuated by the FR (drive control) unit (Y page 23) or the ADM.

The engine brake is always deactivated below 900 rpm. This prevents the engine from stalling. The engine brake is automatically deactivated even if the position sensor (e.g. accelerator pedal) is in use.

In emergency mode (constant engine speed), the engine brake can only be activated in overrun mode at increased engine speed. Once the constant engine speed is reached, the engine brake is automatically deactivated again.

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 †.

Environmental note

At outside temperatures below about –4 † the cold-start aid minimises emissions (after starting 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.

engine). In addition, it reduces the

the

The cold-start aid is automatically deactivated if:

the engine

is not started within 30 seconds

of the % indicator lamp going out.

the engine is started while the % indicator lamp is still lit.

the coolant temperature reaches around 0 † while the engine is running.

At a coolant temperature above approximately –4 †, the % indicator lamp goes out after approximately 2 seconds (function check). At a coolant temperature below approximately –4 †, the % indicator lamp goes out after approximately 20 seconds.

Have the cold-start aid checked and repaired at a qualified specialist workshop. MercedesBenz recommends that you use a MercedesBenz or MTU Service Centre for this purpose (Y page 11). Work relevant to safety or on safety-related systems must be carried out at a qualified specialist workshop.

At a glance

To activate the cold-start aid: turn the vehicle key

to the drive position in the igni-

tion lock. The % indicator lamp lights up in the instrument panel.

After the % indicator lamp goes out, start the engine within 30

seconds.

Safety precautions .............................. 30

Staff qualifications ............................. 30

Organisational measures ................... 30

Safety

Organisational measures

Safety precautions

Damage to the engine can also lead to personal injury.

In order to avoid engine damage, the following safety precautions must be adhered to.

Safety

Safety precautions

Only start

the engine when the batteries

are firmly attached.

Do not disconnect the batteries when the engine is running.

Do not use a rapid charger to start the engine.

Only perform the jump-starting procedure with separate batteries.

Note, the battery terminals must be disconnected when rapid charging the batteries.

Observe the operating instructions of the rapid battery charger.

Please note, when carrying out electric welding work, that the batteries must be disconnected and both of the cables ("+" and "-") must be firmly attached to each other.

The control unit connectors may only be connected/disconnected when the electrical system is switched off.

Incorrect control unit-power supply polarity (e.g. by connecting up the batteries incorrectly) can cause irreparable damage to the control units.

Tighten diesel injection system connections to the prescribed tightening torque.

If temperatures above 80 † are to be expected (e.g. in a drying oven), the control unit on the engine must be removed.

Only use the appropriate testing probes when taking measurements from electrical connectors (e.g. a Mercedes-Benz connection set). Telephones and twoway radio devices that are not connected to an external aerial, can cause malfunc-

tions in the vehicle electronics and thus endanger the operating safety of the engine.

Staff qualifications

WARNING

If maintenance and repair work on the engine is

carried out correctly, the operation and

not safety may be affected, which can result in accidents and personal injury.

Always have work on or modifications to the engine carried out at a qualified specialist workshop that has the necessary special skills and tools for the work required.

Mercedes-Benz recommends a MercedesBenz or MTU Service Centre.

The engine should only be operated, maintained and repaired by trained personnel who have been briefed and authorised by the operator. The minimum legal age for personnel carrying out maintenance and repair work must be observed.

Organisational measures

The responsibilities for operation, maintenance and

repairs are to be determined by the operator. Give the Operating Instructions and the Maintenance Booklet to the personnel that are charged with operating or carrying out work on the engine.

WARNING

Before operating the engine, please read these

Operating read the operating instructions of the vehicle or the machine to which the engine is fitted. You may not recognise dangers and may injure yourself or others.

Instructions. Please also first

Instruct personnel on how to operate the engine using the Operating Instructions. When doing so, put special emphasis on safety-relevant information. This is particu-

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 tion and environmental protection must be adhered to.

regulations on accident preven-

Organisational measures

Safety

Operation ............................................. 34

Continuous brake ................................ 40

Driving tips .......................................... 40

Refuelling ............................................. 41

Winter operation ................................. 43

Driving mode/working mode

Operation

Preparation for operation

At the factory, the engine is filled with 5W30 initial operation oil that complies with Sheet

225.6 of the Mercedes-Benz Specifications for Service Products.

These high-quality engine oils are beneficial

running-in process. They also allow you

to the to make the first oil change in accordance with the applicable oil change intervals for normal operation. This eliminates the need for special initial operation oils and the additional oil change otherwise required.

The extended maintenance intervals can only be observed if engine oils complying with Sheet 228.5 of the Mercedes-Benz Specifications for Service Products are used.

Driving mode/working mode

If the engine is at normal operating temperature: wait about one minute. If the engine is

Check the engine oil level with oil dip-

cold: wait about 5 to 10 minutes.

stick ;. The oil level should be between the upper and lower marks on oil dipstick ;.

If necessary, add oil via filler neck :.

Do not add too much oil when topping up. Topping up with too much oil can result in damage to the engine or the catalytic converter. Drain or siphon off excess oil.

Adding coolant

Information on coolant mixture ratio (Y page 76).

Filling the cooling system (Y page 48).

Refuelling

Use summer or winter fuel depending on the season (Y page 50).

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

Example: OM 926 LA

Filler neck

;

Oil dipstick

Engine oil level

Check the engine oil level on a regular basis, e.g. every week or each time you refuel.

Park the vehicle/equipment on a horizontal surface.

Engage the parking brake.

Switch off the engine.

Refuelling with AdBlue®/DEF

Only use AdBlue®/DEF that complies with DIN 70070/ISO

22241. Do not use any additives. If AdBlue®/DEF comes into contact with painted or aluminium surfaces when filling the tank, rinse the affected surfaces immediately with plenty of water.

Bleeding the fuel system

The bleeding of a fuel system that has been run dry takes place when the engine is next started

refuelling. Automatic continuous

after

bleeding takes place in the filter.

The battery must be sufficiently charged when the engine is started in order for the fuel system to be bled.

Use the integrated hand pump (Y page 68) to bleed the heated-fuel prefilter with

water separator mounted on the

vehicle or equipment.

Starting the engine for the first time

Preparation

Carry out the work listed under "Preparing for operation" before operating the engine for the first time (Y page 34).

Observe the information contained in the equipment/vehicle manufacturer's

operating

instructions.

Connect a power supply.

Switch on the ignition.

Start the engine using the key in the ignition lock or the start button on the engine. Do not depress the accelerator or clutch pedal while doing so. For equipment, the neutral position must be engaged.

As a safety function, the electronic engine control system facilitates the possibility of only allowing the engine to be started when the transmission or equipment is in neutral.

WARNING

Make sure you do not touch any hot or moving engine components (e.g. exhaust manifold, poly-V-belt, fan) when the engine is running. You could injure yourself.

Be aware of the road and traffic situation when working on public roads and secure your position accordingly.

WARNING

There is a danger of limbs being caught, pulled in

thereby crushed or severed by rotating

and

engine parts.

Operation

Therefore you should:

When opening the coolant expansion tank, there is a risk of scalding due to hot coolant spraying 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 †.

Coolant contains glycol and is therefore toxic. Do not swallow the coolant. See a doctor immediately if you swallow coolant.

Make sure that coolant does not come into contact contact with eyes, rinse immediately with plenty of clean water. Clean affected areas of skin and clothing with soap and water immediately. Change any affected clothing immediately.

Starting the engine for the first time

To check coolant level: leave the engine running at a moderate engine speed for around five minutes.

If the coolant temperature is less than 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

safe distance between yourself and

keep a rotating engine parts, including when the engine is being started.

wait until all engine parts have stopped moving before carrying out any work on the engine.

wear work clothing which is fastened and close-fitting. Wear a hair net if necessary. Remove jewellery such as watches and necklaces.

WARNING

The cooling system and coolant

out.

WARNING

skin, eyes or clothing. In case of

with

Driving mode/working mode

Operation

coolant in the coolant circuit after it is filled. Only close

the heating system valves once the engine has been running for a brief period and, where applicable, the coolant has been topped up.

Check the engine for leaks.

Check all hose fittings, hose clamps and pipe connections on the engine as well as the oil feed and return lines on the exhaust gas turbocharger for leaks and firm seating.

Around five minutes after switching off the engine, check the engine oil level with the dipstick. The oil level should be between the upper and lower marks on the dipstick.

Check the seating of the bracket secured to the engine.

Check the tightness of bolts on the exhaust manifold, engine mountings, coolant pump, starter motor and air compressor.

Driving mode/working mode

Starting and stopping the engine with the key

To start the engine: turn the key in the ignition lock to drive position 2.

Vehicles/equipment with a hot-water auxiliary heater: preheat the engine at outside temperatures below −20 † before starting.

Vehicles/equipment with cold-start aid: wait until the % indicator lamp in the instrument cluster goes out.

Turn the key to start position 3 in

the ignition lock. While doing so, do not depress the accelerator pedal. For equipment, keep the idling function active.

When the engine has started, release the key. Depending on the vehicle/equipment, the idling speed is automatically adjusted to around 600 rpm. Depending on the nature

work to be performed, higher engine

of the idling speeds are also possible.

If the engine does not start, interrupt the starting procedure after no more than 30 seconds.

Turn the key in the ignition lock back to the stop at key position g.

Repeat the starting procedure after approximately

After three starting attempts, wait approx-

one minute.

imately three minutes before trying again.

Observe the oil pressure gauge immediately after having started the engine.

Example: ignition lock

To insert/remove the vehicle key

Steering unlocked/radio position

Drive position (ignition)

Start position

Secure the vehicle/equipment against rolling away.

Shift the transmission to neutral or engage neutral on the equipment.

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.

Starting and stopping the engine with the start/stop button

Switch on the ignition.

Shift to neutral.

The start

button will not function if a gear is engaged or the equipment is in an operating position.

Operation

Engine with one button

To start the engine: press

start/stop but-

ton :. The engine starts and runs at engine idling speed.

To start the engine and increase the engine speed: press and hold start/stop

button :. The engine

starts and runs at engine idling speed. After about three seconds, the engine speed increases.

Hold down start/stop button : until the desired engine speed is reached. After releasing start/stop button :, the engine

continues

to run at the currently set speed. The engine speed can be increased up to the limiting speed.

To stop the engine: press start/stop button : again. The engine switches off.

To start the engine: press start button ;. The engine

starts and runs at engine idling

speed.

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

run at the currently set speed.

continues

to The engine speed can be increased up to the limiting speed.

To stop the engine: while the engine is running, press stop button :. The engine switches off.

To turn the engine over without starting it: press and hold start button ; and stop

button : at the same time. The engine turns over without starting.

Release start button ; and stop button :. The engine remains at a standstill.

Operational monitoring

Charge current

The charge current indicator lamp must go out after the engine has started.

Driving mode/working mode

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.

Operation

Make sure that the poly-V-belt contact surfaces are not damaged (e.g. torn), oily or glazed, as this could cause the poly-Vbelt to slip. Do not run the engine without a poly-V-belt.

Otherwise, the alternator and coolant pump are not driven, which results in engine damage.

Further information can be found in the “Checking the poly-V-belt for wear” (Y page 66) and “Replacing the poly-V-belt” sections (Y page 97).

Electronic engine control

The electronics warning lamp must go out after the engine has started.

Driving mode/working mode

Example: electronics warning lamp

If the electronics warning lamp does not go out, or if it lights up while the engine is running, there is a malfunction in the electronic engine control system.

Each malfunction its own fault code. Temporary faults are also stored.

Fault codes can be read using the MercedesBenz diagnostic tester STAR DIAGNOSIS or minidiag2 (Y page 8). If the electronics warning lamp lights up while the engine is running, read or determine the fault code.

is stored in the system with

Oil pressure

Once the

operating temperature has been reached, the engine oil pressure may not drop below the following values:

2.5 bar at rated speed

0.5 bar at idling speed

If the oil pressure falls below these values, stop the engine and trace the cause.

Operating restrictions with on-highway applications

The electronics monitor:

the display, level and quality of the AdBlue®/DEF reducing agent

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

the

reduced

first time the vehicle is stationary

if:

the AdBlue®/DEF reservoir is empty

the permitted thresholds for nitrogen oxide (NOx) emissions are exceeded.

Torque reduction

If the AdBlue®/DEF is used up or if there is a fault, the indicator lamp in the instrument panel lights up or flashes. The display also shows a message. The engine output is only reduced after a fault is detected and confirmed after up to four journeys.

The degree of torque reduction depends on the vehicle category:

vehicles above 7.5 t: torque reduction by approximately 40%

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-

Operation

tem, the torque is reduced automatically after 36 operating hours of the engine.

Operating restrictions for off-highway engines

Minor operating restriction

The available torque is reduced within a period of 10 minutes. The torque is reduced across the entire engine speed range to 80% of the maximum torque (see the diagram below).

Reduction in output during minor operating restriction

Major operating restriction

The transition between a minor and a major operating restriction

is achieved by a gradual reduction in engine speed and torque. The reduction takes place over a period of 60 minutes.

The engine torque is reduced from 80% of the rated value by 1% per minute to 20% of the rated value.

Simultaneously, the engine speed is reduced over the period of 60 minutes from the initial value to 1000 rpm.

Emergency override

A button is optionally available for overriding the operating restriction in an emergency. The override function makes the full engine output available for up to 30 minutes and can be used a maximum of three times. The override can only be activated between the start of the operating restriction system and the end of the major operating restriction. The

override function is also used to reset the operating restriction after the fault is corrected. This

is the case, for example, after filling

up with AdBlue®/DEF of the correct quality.

Deleting the fault memory

A fault stored in the fault memory because of the operating restriction system cannot be deleted with a conventional reading device. Faults can only be deleted using the Daimler/ MTU maintenance system.

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: if a fault reoccurs within 40 hours of the first elimination, the time until the operating restriction comes into effect is halved. If the same fault occurs within 40 hours of the second fault being rectified, the times are shortened to a quarter.

Stopping and switching off the engine

WARNING

When switching off the equipment or parking the vehicle, make sure that the exhaust system does not come into contact with combustible objects, e.g. dry leaves, grass or other highly flammable materials.

Park the vehicle/equipment.

Secure the vehicle/equipment against rolling away.

Shift the transmission into neutral/decouple the drive system.

Driving mode/working mode

Driving tips

Let the engine idle for approximately two minutes before switching off the engine if:

the coolant temperature is very high (over 90 †).

the engine

To switch off the engine: turn the vehicle

has been operated at full output.

key in the ignition lock back to the stop at position u.

Press the start/stop button on the engine or on the engine shutoff device on the equipment.

Safeguard the vehicle/equipment against rolling away.

Stop the engine immediately if:

the oil pressure falls or fluctuates significantly.

the power output or engine speed decreases and the position of the position sensor (accelerator) remains constant.

Driving mode/working mode

heavy smoke is emitted from the exhaust.

the coolant or engine oil temperature rises steeply.

abnormal noises suddenly come from the engine or exhaust gas turbocharger.

When you switch off the engine, BlueTec® exhaust gas aftertreatment automatically

the exhaust system with fresh

flushes air. Residues of AdBlue®/DEF on the metering unit or the injection nozzle might otherwise impair the function of BlueTec exhaust gas aftertreatment. Depending on the engine's previous operating load, BlueTec® exhaust gas aftertreatment may flush the exhaust system several times.

When BlueTec® exhaust gas aftertreatment flushes the exhaust system, an air valve is activated. You may then hear a hissing sound. This hissing sound does not indicate a leak in the compressed-air system.

Continuous brake

The airbrake

and the constantly open throttle

valves are employed as continuous brakes.

WARNING

Do not activate the continuous brake (engine brake/retarder) on slippery road surfaces. The wheels may otherwise become locked and the vehicle could skid.

You can utilise the engine's braking effect, particularly

activate the continuous brake

shift to a lower gear in good time

long downhill gradients, if you:

Driving tips

Running-in

Equipment

Observe the equipment manufacturer's running-in notes.

Vehicles

The running-in period of the engine has a significant effect on the vehicle, especially for the:

service life

operating reliability

economy

Observe the following notes during the run-

ning-in period up to 2000 km (30 operating hours):

avoid subjecting the engine to full load.

run-in the engine with care using differing speeds and engine revs.

avoid high engine revs.

do not drive at more than ¾ of the maximum road speed for each gear.

change gear in good time.

do not shift down to brake the vehicle.

in the case of vehicles with automatic transmission, do not press the accelerator

Refuelling

pedal beyond the point of resistance (kickdown) and only engage the shift ranges 4, 3, 2, or 1 when driving slowly.

After 2000

km (30 operating hours), you can gradually bring the vehicle up to full road and increased engine speeds.

Fuel consumption

General information

Fuel consumption depends on:

the type

of fuel used (diesel fuel, fatty acid

methyl ester FAME fuel)

the machine version

the operating mode

the operating conditions

the attached equipment (e.g. hydraulic pumps, mowers, etc.)

For these reasons, exact details about any single engine's fuel consumption cannot be provided.

Machine version

The following components influence fuel consumption:

tyres (e.g. tyre pressure, tyre condition)

body type

drive train (e.g. transmission ratio)

additional equipment (e.g. automatic climate control, auxiliary heating)

Operating mode

Your operating mode can help to keep the fuel consumption down:

anticipate road and traffic conditions.

avoid frequent acceleration and braking.

stay within the economical engine speed range.

Operating conditions

Fuel consumption can increase due to poor operating conditions.

Observe the following notes:

avoid driving in mountainous terrain.

do not allow the engine to idle when the vehicle is stationary.

do not drive with unnecessary weight.

avoid frequent cold starts.

avoid frequent short journeys.

AdBlue® consumption

AdBlue®/DEF consumption

is between 4 and 8% of the fuel consumption, depending on engine use.

Engine oil consumption

After running in the engine, oil consumption may reach 0.5% of the vehicle's fuel consumption.

More arduous operating conditions and increased distance covered could result in engines exceeding this oil consumption value.

Refuelling

Fuels

Important safety notes

WARNING

Fuel is highly flammable. Therefore, fire, naked flames and smoking are prohibited when handling fuel.

Deactivate the auxiliary heating when refuelling to prevent fuel vapours from igniting on the auxiliary heating exhaust system.

Fuel is toxic and constitutes a health hazard. Therefore, you should make sure that:

Driving mode/working mode

Refuelling

fuel does not come into contact with skin, eyes or clothing.

you do not inhale fuel vapours.

children are kept away from fuel.

If you or anyone else comes into contact with fuel:

wash eyes immediately with plenty of clean water if fuel comes into contact with the eyes and consult a doctor.

clean affected areas of skin with soap and water immediately.

change out of clothing which has come into contact with fuel immediately.

if fuel is swallowed, a doctor should be consulted immediately.

WARNING

Do not use petrol to refuel vehicles with a diesel would result in damage to the fuel system and engine, which could lead to a vehicle fire.

Driving mode/working mode

AdBlue®/DEF is not a fuel additive and

Do not mix diesel with petrol. This

engine.

must not be added to the diesel tank. If AdBlue®/DEF gets into the diesel tank, this could lead to engine damage.

Do not use petrol to refuel vehicles with a diesel engine. Even small amounts of petrol result in damage to the fuel system and engine.

If you fill the tank with the wrong fuel by accident, do not start the engine. Otherwise, the fuel lines may be contaminated. Notify a qualified specialist workshop and have the fuel tank and fuel lines fully drained.

Do not add any special fuel additives to the diesel fuel or fatty acid methyl ester FAME fuel.

Special fuel additives can lead to:

malfunctions

damage to the catalytic converter

engine failure

You will find further information on fuel in the "Service products" section (Y page 50).

Environmental note

If fuels are handled improperly, they pose a danger to persons and the environment. Do not the surface waters, the ground water or into the ground.

fuels to run into the sewage system,

allow

Before filling the tank

Switch off the engine.

Secure the vehicle/equipment against rolling away.

Switch off the auxiliary heating system.

Observe the fuel grade (Y page 50).

If you are refuelling the vehicle from drums or canisters, filter the fuel before refuelling.

This prevents malfunctions in the fuel system caused by contaminated fuel.

Regularly check

the fuel prefilter with the heated water separator for condensation (Y page 86).

AdBlue®/DEF

Important safety notes

WARNING

If the AdBlue®/DEF tank temperatures, ammonia vapours may escape.

Ammonia vapours have a pungent odour and particularly irritate:

skin

mucous membranes

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.

cap is opened at high

Winter operation

WARNING

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

If AdBlue®/DEF comes into contact with your eyes clean water immediately.

If AdBlue®/DEF is swallowed, immediately rinse your mouth out with a lot of clean water and drink plenty of water.

Change clothing that is soiled with AdBlue®/DEF immediately.

If allergic reactions occur, consult a doctor immediately.

Keep AdBlue®/DEF out of the reach of children.

The BlueTec® exhaust gas aftertreatment

or skin, rinse affected areas with

will cease to function correctly if you:

fill the AdBlue®/DEF reservoir with cleaning agent or other service products or fuels

mix in additives

dilute AdBlue®/DEF

Only use AdBlue®/DEF in accordance with DIN 70070/ISO 22241.

Notify a qualified specialist workshop in the event of incorrect filling.

You will find further information on AdBlue®/ DEF in the "Service products" section (Y page 54).

Environmental note

Dispose of AdBlue®/DEF in an environmentally responsible manner.

Before filling the tank

Switch off the engine.

Secure the vehicle/equipment against rolling away.

Switch off the auxiliary heating system.

Bleeding the fuel system

If the fuel system is run dry, the system will be bled the next time the engine is started after refuelling. Automatic continuous bleeding takes place in the filter.

The battery

must be sufficiently charged during the starting procedure to ensure that the fuel system can be bled.

Bleed the heated fuel prefilter with water separator mounted on the vehicle or equipment using the integrated hand pump (Y page 86).

Winter operation

Cold-start aids

The following

notes should be observed at the

start of the cold season.

Fuel

WARNING

There is an increased risk of fire when handling fire, naked flames and sparks, and refrain from smoking when handling fuels.

as they are highly flammable. Avoid

fuels

Use cold-resistant diesel fuel (Y page 50).

Jump-starting

WARNING

The use of liquid or gaseous starting aids can cause explosions. This may result in severe injuries.

Do not use liquid or gaseous starting aids such

ether or Startpilot to start the engine.

Engine oil

When changing the oil, select an engine oil that is

compatible with the SAE classification and the outside temperatures expected during the period of use (Y page 46).

Driving mode/working mode

Winter operation

Coolant

WARNING

When opening the coolant expansion tank, there is a risk of scalding due to hot coolant spraying out. 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 †.

WARNING

Coolant contains glycol and is therefore toxic. Do not swallow the coolant. See a doctor immediately if you swallow coolant.

Make sure that coolant does not come into contact with contact with eyes, rinse immediately with plenty of clean water. Clean affected areas of skin and clothing with soap and water immediately. Change any affected clothing imme-

Driving mode/working mode

diately.

The cooling system and coolant

skin, eyes or clothing. In case of

Check the antifreeze protection properties of the coolant in good time and increase the antifreeze/corrosion inhibitor concentration if necessary (Y page 48).

Batteries

WARNING

Comply with safety precautions and take protective measures when handling batteries.

Risk of explosion

Fire, naked flames and smoking are prohibited when handling the battery. Avoid creating sparks.

Battery acid is caustic. Avoid contact eyes or clothing.

Wear suitable protective clothing, in particular

with the skin,

gloves, an apron and a face mask.

Immediately rinse acid splashes off with clean water. Consult a doctor if necessary.

Wear eye protection.

Keep children away.

Observe this Owner's Manual.

Always aim to achieve the full charge status. You can do this by means of careful maintenance and low electrical consumption. The cold start capacity is reduced when it is very cold. For example, at -10 † it is only around 60 % of the normal capacity.

Notes

when the engine is out of use

for

If the engine/vehicle/equipment is to be out of use for longer than three weeks, disconnect the

negative terminal on the battery. This prevents the batteries from being discharged by no-load current consumers. If the engine/ vehicle/equipment is to be out of use for a longer period, remove the batteries and store them in a dry, well-ventilated area. Recharge the batteries:

before operating the engine/vehicle/ equipment again or

at least every three months for longer periods of disuse.

If the engine/vehicle/equipment is out of use for a long period, store the batteries in a heated area if possible. Ensure good ventilation when recharging. Refer to the "Decommissioning the engine" section (Y page 80) for further information.

Service products ................................. 46

Cleaning and care ............................... 55

Maintenance ........................................ 56

Maintenance and care

Service products

Introduction to service products

WARNING

Service products are hazardous to health. They contain toxic and caustic substances.

Service products are highly flammable.

For

reason, observe the following instruc-

this tions to prevent injuries to yourself and others:

Do not inhale the vapours. When indoors, always ensure there is sufficient ventilation to prevent intoxication.

Do not let service products come into contact with skin, eyes or clothing. Should contact occur, however, clean the affected areas of skin with water to prevent caustic burns and other injuries.

In the event of eye contact, wash eyes thoroughly with plenty of clean water.

Maintenance and care

Fire, naked flames and smoking are forbidden when handling service products due to their high flammability.

Observe the usage and warning notices on the containers.

The use of approved service products is an integral part of the implied warranty.

Special additives (except approved fuel additives) are neither required nor approved for use with approved service products. Additives could cause damage to the assemblies. Therefore, do not mix any additives with service products.

You are responsible for the results of using fuel additives.

Environmental note

Dispose of service products in an environmentally-responsible manner.

Service products are, for example:

fuels (e.g. diesel)

lubricants, e.g. engine and transmission oils, hydraulic fluids, greases

antifreeze, coolant

AdBlue®/DEF

(BlueTec®

exhaust gas after-

treatment reduction agent)

Approved service products fulfil the highest quality standards and are documented in the Mercedes-Benz Specifications for Service Products. Damage caused by the use of service products that have not been approved invalidates the implied warranty. For this reason, only use service products that have been approved for your engine.

You can recognise service products approved by Mercedes-Benz by the following inscription on the container:

MB Approval (e.g. Approval 228.5)

MB Approval 228.5

Other labels and recommendations relating to the quality or indicating that the product meets a certain specification are not necessarily approved by Mercedes-Benz. Further information is available from any MercedesBenz or MTU Service Centre (Y page 11).

Information about service products that have been tested and approved by Mercedes-Benz for your engine is available online at http://bevo.mercedes-

benz.com/

The specification and availability of lubricants may vary. Individual lubricants may no longer be available, especially for older engines. Information is available from any Mercedes-Benz or MTU Service Centre (Y page 11).

Engine oils

Notes on engine oils

Only use engine oils that comply with the Mercedes-Benz Specifications for Service Products.

Service products

The following engine oils are approved:

Sheet no. 228.5 / 228.3 standard quality multi-grade engine oils

Sheet no. 228.51 / 228.31 low-ash multigrade engine oils

Sheet no. 228.2 standard quality singlegrade engine oils

Sheet no. 225.6 multi-grade engine oils, initial operation oils

Engine oils

of a different quality grade are not permissible and may damage the engine.

Mercedes-Benz particularly recommends engine oils that comply with Sheet no. 228.5 of the Mercedes-Benz Specifications for Service Products.

These engine oils are of a high standard of quality and have a beneficial effect on:

engine wear

fuel consumption

exhaust emissions

The maximum interval for oil change is only achieved with engine oils of a particularly high quality grade.

You can find information on the quality grade, e.g. Sheet no. 228.5, and the viscosity, e.g. SAE class 5W-30, from the designation on the oil container.

Scope of use

For engines in vehicles/equipment operating with diesel fuel, only use multi-grade engine oils compliant with Sheet no. 228.5 /

228.51 / 228.3 / 228.31 or single-grade engine oils compliant with Sheet no. 228.2.

For engines without BlueTec® exhaust gas aftertreatment, multi-grade oils compliant with Sheet no. 228.1 and single-grade oils compliant with Sheet no. 228.0 can also be used.

For vehicle/equipment operation with FAME fatty acid methyl ester fuel (bio-diesel fuel),

only use engine oils compliant with Sheet no.

228.5 / 228.51 / 228.3 / 228.31.

For engines without BlueTec® exhaust gas aftertreatment, oils

compliant with Sheet no.

228.1 can also be used. This is also required for a mixture of conventional diesel fuels and FAME fatty acid methyl ester fuels (bio-diesel fuel).

Multi-grade engine oils compliant with Sheet no. 228.5 / 228.51 / 228.3 / 228.31 / 228.1 can be used throughout the year. Depending on the fuel quality (fuel sulphur content or FAME fatty acid methyl ester fuel), the oil change intervals may be shortened. For details, see the Maintenance Booklet.

Single-grade engine oils compliant with Sheet no. 228.2 / 228.0 only cover an SAE class (viscosity) for a certain temperature range. Change the engine oil to an SAE class suitable for the time of year and the respective outside temperatures.

The use of low-ash engine oils is permissible but not essential. When low-ash engine oils compliant with Sheet no. 228.51 and 228.31 are used, a low-sulphur diesel fuel (less than 50 ppm, 0.005 % by weight) should be used. If this low-sulphur diesel fuel is not available, standard oils compliant with Sheet no.

228.5 / 228.3 / 228.2 should be used.

Oil change

Oil change intervals are dependent on the following:

the operating conditions of the vehicle

the grade of the engine oil used

the fuel grade (sulphur content)

the fuel type, e.g. FAME fatty acid methyl ester fuel

For more

details, see the Maintenance Book-

let.

If you do not use oil for all-year-round operation in your engine, change the engine oil right at the beginning of the cold season. Use only an approved engine oil in the specified SAE classification.

Maintenance and care

Service products

If the SAE class (viscosity) of the engine oil used is

not suitable for continually low outside temperatures below −20 †, this could cause engine damage.

The specified temperatures of the SAE class always refer to freshly added oil. Engine oil ages during driving due to soot and fuel residue. This impairs the characteristics of the engine oil, particularly at low outside temperatures.

Mercedes-Benz strongly recommends that, at outside temperatures below −20 †, you use engine oils of SAE class 5W-30.

Maintenance and care

Engine oil SAE classes (viscosity)

Single-grade engine oils

;

Multi-grade engine oils

Select the SAE class of engine oil in accordance with outside temperatures.

You can only achieve the maximum oil

change intervals by using engine oils of

high

particularly with Sheet no. 228.5 of the Mercedes-Benz Specifications for Service Products).

Environmental note

If you operate your vehicle using FAME fatty acid

methyl cautions must be taken and national specifications complied with when disposing of

quality (e.g. in accordance

ester fuel (bio-diesel), special pre-

engine oils. Information is available from any Mercedes-Benz or MTU Service Centre.

Adding/topping up the engine oil

Do not add too much oil. If you add too much

engine or the catalytic converter could

oil, the be damaged. Drain or siphon off any excess oil.

When topping up, Mercedes-Benz recommends that you only use engine oil of the same grade and SAE class as the oil filled at the last oil change.

Check the oil level before topping up the engine oil (Y page 34).

You can find more information on topping up the engine oil in the “Changing the engine oil and filter” section (Y page 62).

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

quality grade (Sheet no.)

SAE viscosity class

If, in exceptional circumstances, the type of engine oil currently used in the engine is not available,

another

mineral or synthetic engine oil may be used. Make sure it is approved for Mercedes-Benz.

Observe the notes in the Service Booklet.

Coolants

Coolant additive with antifreeze properties

The coolant is a mixture of water and corrosion inhibitor/antifreeze.

Service products

The corrosion inhibitor/antifreeze in the coolant has the following properties:

anti-corrosion protection

antifreeze protection

increases the boiling temperature

Leave the

coolant in the engine all year round in order to prevent corrosion and to increase the boiling point. Also do this in countries with hot outside temperatures.

Check the corrosion inhibitor/antifreeze concentration in the coolant every six months.

Only use approved corrosion inhibitor/antifreeze agents.

Topping up coolant

When topping up, only use prepared coolant with 50% by volume corrosion inhibitor/antifreeze agent.

Before topping up, observe the quality of the corrosion inhibitor/antifreeze agent in the cooling system (Sheet no.). Corrosion inhibitors/antifreeze agents compliant with Sheet

325.3 and 326.3 must not be mixed with those of Sheet 325.0/2 or 326.0/2.

Only top up using a corrosion inhibitor/antifreeze agent of the same quality grade.

Miscibility of corrosion inhibitor/antifreeze agents

Corrosion inhibitors/antifreeze agents that comply with Sheet 325.3 and 326.3 must not be mixed with those of Sheet

325.0/2 or 326.0/2. This prevents damage to the engine cooling system.

Renewing coolant

Coolant change with antifreeze protection:

every three years if using corrosion inhibitor/antifreeze agent compliant with Sheet

325.0/2 and 326.0/2

every five years if using corrosion inhibitor/ 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/

antifreeze agent, the cooling system must first be flushed (Y page 76).

When renewing the coolant, ensure that it contains 50% by volume of corrosion inhibitor/antifreeze agent. This corresponds to antifreeze protection down to −37 †.

Do not exceed 55% by volume (antifreeze protection down to approximately −45 †). Heat dissipation properties are otherwise impaired.

The water in the coolant must meet certain requirements, which are often fulfilled by drinking water. The water must be treated if its quality does not meet the required standards.

Please note the Mercedes-Benz Specifications for Service Products, Sheet number 310.1.

Further information about operating and road safety for your engine/vehicle/equipment is available from any Mercedes-Benz or MTU Service Centre (Y page 11).

Coolant additive without antifreeze properties

If your vehicle does not need antifreeze protection, e.g. in countries with consistently high outside temperatures, you can, as an exception, use a coolant additive.

Instead of corrosion inhibitor/antifreeze additive, add a coolant additive compliant with Sheet number 312.0 of the MercedesBenz Specifications for Service Products to the water.

Improvers (corrosion-inhibiting oils) are not permitted.

Renew the coolant annually.

Further information about the required water quality and approved coolant additives without antifreeze protection is available from any Mercedes-Benz or MTU Service Centre (Y page 11).

Maintenance and care

Service products

Diesel fuels

Important safety notes

WARNING

Fuel is highly flammable. Fire, naked flames and smoking as well as the use of auxiliary heaters (sparks) are therefore prohibited when handling fuel.

Switch off before refueling.

Avoid contact with fuels.

It is hazardous to your health if your skin comes into direct contact with fuels or you breathe in fuel vapours.

refuel the engine/vehicle/equipment, you should filter the fuel before filling.

Maintenance and care

This prevents malfunctions in the fuel system caused by contaminated fuel.

diesel vehicle fuel that complies with the European standard EN 590.

EN 590 maximum sulphur content of 10 ppm. However, it is also permitted to operate engines with BlueTec® exhaust gas aftertreatment with up to 50 ppm.

For engines without BlueTec® exhaust gas 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.

the engine and the auxiliary heating

WARNING

If you are using drums or canisters to

Only refuel with commercially available

describes a sulphur-free fuel with a

Fuel grade in accordance with EN 590 is prescribed as mandatory for engines with BlueTec® exhaust gas aftertreatment. If diesel fuel which does not comply with EN 590 is used, it can damage the exhaust system.

Fuel grade

The following is an overview of typical sulphur content in in various countries. You may obtain information about current country-specific fuel sulphur contents from any Mercedes-Benz or MTU Service Centre (Y page 11).

sulphur contents is available. Diesel fuel with a lower sulphur content is sold under the name "Euro diesel" in some countries.

percent by weight of fuel available

In some countries, diesel fuel of differing

Service products

Fuel sulphur content table

The following fuel in percent by weight (% by weight).

You can find a continually updated table of fuel sulphur contents in specific countries in the 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 fuel 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 depending on the fuel grade used. The higher the sulphur content in diesel fuel, the shorter the maintenance intervals for engine oil and filter replacement. Observe the notes in the Maintenance Booklet.

Continent Country % by weight

overview specifies the current country-specific sulphur content of fuel in diesel

Fuel sulphur content (proportion by weight, in percent)

Europe, CIS

Australia, Oceania

Asia

Southwest Asia, Middle East

Albania5, Armenia, Azerbaijan, Belarus, Belgium, Bosnia-Herzegovina, Bulgaria,

Denmark, Germany, Estonia,

0 ... 0.1

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, Tur-

0.3 ... 0.8

key, Ukraine, Uzbekistan

Australia, French Polynesia, New Zealand 0 ... 0.1

Fiji Islands, New Caledonia 0.3 ... 0.8

Bangladesh, Bhutan, Brunei, China, Hong Kong, India,

0 ... 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

Israel, Qatar, Lebanon, Oman, Palestine, West Bank 0 ... 0.1

Oman, United Arab Emirates 0.1 ... 0.3

Bahrain, Kuwait, Lebanon, Saudi Arabia, Syria 0.3 ... 0.8

Maintenance and care

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

Service products

Continent Country % by weight

Fuel sulphur content (proportion by weight, in percent)

Iran, Iraq, Jordan, Yemen 0.8 ...

North America

Central America, South America, the Caribbean

Africa

Maintenance and care

Canada, Mexico, USA 0 ... 0.1

Argentina6, Bolivia, Brazil, Chile

Argentina, Brazil, Columbia, Costa Rica, Ecuador, Suriname, Trinidad and Tobago, Uruguay

Dominican Republic, El Salvador, Guatemala, Honduras, Cuba, Panama, Peru, Venezuela

Egypt, Algeria, Morocco, South Africa 0 ... 0.1

Angola, Morocco, Mauritius, Tunisia 0.1 ... 0.3

Benin, Ghana, Kenya, Libya, Malawi, Mali, Mozambique, Nigeria, Zambia, Senegal, Tanzania

Burkina Faso, Congo, Ethiopia, Ghana, Kenya, Madagascar, Morocco, Sudan, Uganda

Diesel fuels at low temperatures

At low outside temperatures, paraffin separation may cause the flow properties of the diesel fuel to be insufficient.

To prevent operating problems, diesel fuel with improved flow properties is available in the winter months.

Winter diesel fuels are reliable down to outside temperatures of −22 other Central European countries. You can normally use winter diesel fuel without problems at the outside temperatures expected in the country where it is on sale.

† in Germany and

Fuel additives

General notes

Fuel additives used to improve flow characteristics are flow improvers.

Do not add flow improvers to winter diesel fuel guaranteed to operate down to −22 †.

cold flow properties of the fuel may dete-

The

0 ... 0.1

0.1 ... 0.3

0.3 ... 0.8

0.8 ...

riorate as a consequence of the flow improver.

If summer less resistance to low temperatures is in use, add a quantity of flow improver, depending on the outside temperatures.

Add the fuel additive to the diesel fuel in good time, before paraffin separation causes the diesel fuel's flow properties to be insufficient. Malfunctions as a result of paraffin separation can only be rectified by heating up the complete fuel system.

The engine can be equipped with a heated fuel prefilter with water separator. This also improves the flow characteristics of the diesel fuel by approximately 8 †.

Flow improvers

The effectiveness of flow improvers cannot be guaranteed with all fuels. Follow the manufacturer’s recommendations. Information about approved flow improvers is available

diesel fuel or winter diesel fuel with

Shell Pura only.

from all Mercedes-Benz or MTU Service Centres (Y page 11).

If you add a flow improver to the FAME fatty acid methyl

ester fuel, the fuel's resistance to

low temperatures does not change.

Fatty acid methyl ester (FAME) fuel (bio-diesel)

General notes

To avoid damage to the assemblies and components, observe the following points when using FAME fatty acid methyl ester fuel:

have the fuel filter and the oil filter replaced approximately 1000 km after switching to FAME fatty acid methyl ester fuel.

have the oil filter and the fuel filter replaced at every oil change.

will have to be changed and the oil

the oil filter replaced much more frequently.

FAME fatty acid methyl ester fuel shortens the service life of conventional fuel filters. For this reason, Mercedes-Benz recommends the installation of a special fuel prefilter. Information about this is available at any qualified specialist workshop, e.g. a Mercedes-Benz or MTU Service Centre.

only add FAME fatty acid methyl ester fuel in compliance with DIN EN 14214. Fuel additives or fuels that do not comply with DIN EN 14214 may cause malfunctions or engine damage.

FAME fatty acid methyl ester fuel corrodes painted surfaces. Do not allow FAME fatty acid methyl ester fuel to come into contact with the paintwork. Rinse off FAME fatty acid methyl ester fuel with water immediately.

preferably only add engine oil in accordance with Sheet no. 228.5/51 or

228.3/31 of the Mercedes-Benz Specifications for Service Products.

Service products

if the

vehicle is not used for long periods of time, FAME fatty acid methyl ester fuel can clog fuel system components. For this reason, use all the FAME fatty acid methyl ester fuel before long periods of time when the vehicle is not used. Fill up the fuel tank with conventional diesel fuel. Allow the engine to run for at least one hour before switching off the vehicle/equipment.

Mercedes Benz recommends that you do not use FAME fatty acid methyl ester fuel for engines that are not used for long periods of time, e.g. fire engines.

the auxiliary heating may only be operated with conventional diesel fuel. Otherwise, the system may malfunction. Conventional diesel fuel already contains a percentage of FAME fatty acid methyl ester fuel. Therefore, do not add more than 5% FAME fatty acid methyl ester fuel to conventional diesel fuel.

An additional fuel tank is required for conventional diesel fuel for the auxiliary heating system, if you operate the vehicle:

using FAME fatty acid methyl ester fuel

using a mixture of conventional diesel fuel and more than 5% FAME fatty acid methyl ester fuel.

Environmental note

If the vehicle runs on FAME fatty acid methyl ester fuel, ask your disposal plant whether you have to collect the engine oil separately. Not all manufacturers of refined products (lubricant can process engine oil which has been enriched with FAME fatty acid methyl ester fuel.

Observe the special notes and national regulations when disposing of engine oils. Information about this is available at any qualified specialist workshop, e.g. any Mercedes-Benz or MTU Service Centre.

manufactured

from used engine oil)

Maintenance and care

Service products

Operate your engine using pure FAME fatty acid methyl ester fuel compliant with DIN EN 14214. You can also operate your engine

using a mixture of conventional diesel fuel and FAME fatty acid methyl ester fuel. This also applies to engines with BlueTec exhaust gas aftertreatment.

Observe the specifications in accordance with Sheet no. 135.0 of the Mercedes-Benz Specifications for Service Products for operation with FAME fatty acid methyl ester fuel.

Operating the vehicle with FAME fatty acid methyl ester fuel results in:

a slightly higher fuel consumption

a slightly reduced engine power output

increased white smoke after a cold start

Low outside temperatures

FAME fatty acid methyl ester fuel compliant with DIN EN 14214 can be used reliably at

Maintenance and care

outside temperatures down to −20 †.

For lower temperatures, the engine can be equipped

with a fuel preheating system. This improves the flow characteristics of the FAME fatty acid methyl ester fuel according to the heat output installed.

AdBlue®/DEF

Notes on AdBlue®/DEF

AdBlue®/DEF is a non-flammable, non-toxic, colourless, odourless and water-soluble liquid.

The terms "Urea" and "DEF" (Diesel Exhaust Fluid) are also used for "AdBlue®".

Only use AdBlue®/DEF in accordance

with DIN 70070/ISO 22241

. Do not use

any additives.

If AdBlue®/DEF comes into contact with painted or aluminium surfaces when filling the tank, rinse the affected area immediately with plenty of water.

High outside temperatures

WARNING

tank

If the AdBlue®/DEF temperatures, ammonia vapours may escape.

Ammonia vapours have a pungent odour and particularly irritate:

skin

mucous membranes

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.

WARNING

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

If AdBlue®/DEF comes into contact with your eyes clean water immediately.

If AdBlue®/DEF is swallowed, immediately rinse your mouth out with a lot of clean water and drink plenty of water.

Change clothing that is soiled with AdBlue®/DEF immediately.

If allergic reactions occur, consult a doctor immediately.

Keep AdBlue®/DEF out of the reach of children.

or skin, rinse affected areas with

cap is opened at high

The chemical composition of AdBlue®/DEF can break down if it heats up to 50 † over a long period (e.g. as a result of direct sunlight on the tank). This creates ammonia vapour.

Low outside temperatures

AdBlue®/DEF freezes at a temperature of approximately −11 †. Winter operation is

ensured for temperatures below −11 †.

also

At low temperatures, AdBlue®/DEF crystals may form on the coiled hose between the engine and the silencer. This crystallisation does not pose a risk to the correct operation

Cleaning and care

of BlueTec® exhaust gas aftertreatment. The AdBlue®/DEF crystals can be removed with clean water if necessary.

Additives, tap water

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

Storage

Only use containers made of the following materials to store AdBlue®/DEF:

Cr-Ni steels in accordance with DIN EN 10 088-1/2/3

Mo-Cr-Ni steels in accordance with DIN EN 10 088-1/2/3

Polypropylene

Polyethylene

Containers made of the following materials are not suitable for the storage of AdBlue®/DEF:

aluminium

copper

copper alloys

unalloyed steel

galvanised steel

If AdBlue® is stored in these types of container, constituents of these metals may dissolve

damage the BlueTec® exhaust

and

gas aftertreatment beyond repair.

Disposal

Environmental note

Dispose of AdBlue®/DEF in an environmentally responsible manner.

Observe laws

and regulations on the disposal

of AdBlue®/DEF in the country concerned.

Purity

Impurities in AdBlue®/DEF, e.g. due to other service products, cleaning products or dust, may lead to:

increased emission values

damage to the catalytic converter

engine damage

malfunctions in BlueTec® exhaust gas aftertreatment.

Ensure that AdBlue®/DEF is always pure to avoid malfunctions in BlueTec® exhaust gas aftertreatment.

AdBlue®/DEF

is pumped from the tank, e.g. during repairs, do not use this fluid to refill the tank. Otherwise the purity of the fluid would no longer be guaranteed.

Cleaning and care

Notes on care

WARNING

Always keep care products sealed and out of the reach of children. Always follow the instructions for the use of the care products.

use fuel as a cleaning agent. Fuels are

not highly flammable and constitute a health hazard.

Regular care helps to maintain the value of the engine.

Mercedes-Benz recommends that you only use care products that have been approved for Mercedes-Benz. You can obtain these care products from any Mercedes-Benz or MTU Service Centre (Y page 11).

High-pressure cleaning

The exhaust gas aftertreatment system may only be cleaned when it is cool. The sensors can otherwise be damaged.

Maintenance and care

Maintenance

When cleaning, never point the water jet at the exhaust pipe. The system may otherwise be damaged.

When using

a high-pressure cleaner, keep a minimum distance between the highpressure nozzle and the engine parts. Otherwise, parts of the engine may be damaged.

Observe the following minimum distances:

about 70 cm with round-spray jets

about 30 cm with 25° flat-spray jets

about 30 cm with concentrated-power jets

Keep the water jet moving constantly while cleaning. In this way, you will avoid causing damage.

Do not point the water jet at:

electrical components

plug connectors

Maintenance and care

seals

hoses

Maintenance

General information

WARNING

Before carrying out maintenance or repair work, you must read the relevant sections of the

technical tenance and repair measures, e.g. the Operating Instructions and workshop information.

In particular, first familiarise yourself with the legal regulations, e.g. work safety and accident prevention regulations.

You could otherwise fail to recognise dangers and injure yourself or others.

Always have maintenance work carried out at a qualified specialist workshop which has the necessary specialist knowledge and tools to carry out the work required.

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

documentation relating to main-

Cleaning the engine

Observe the following notes when cleaning the engine. This avoids malfunctions and damage to the engine.

When using high-pressure or steam cleaners, do not point the spray directly at electrical components and electric cables.

Make sure that no water enters the air intake and ventilation openings.

Treat the engine with preservative agents after it has been cleaned. When doing so, protect the belt drive system from the preservative agent.

Use only wax preservative for engines according to sheet number 385.4 of the Mercedes-Benz Specifications for Service Products.

WARNING

Maintenance work that is carried out incorrectly or not at all, e.g. not changing the oil filter or not observing maintenance intervals, can cause engine damage. Engine damage can lead to an increased risk of accidents.

Therefore, tenance in these Operating Instructions.

If circumstances demand that you have to do some maintenance work yourself, environmental protection requirements must be observed. When disposing of service products, legal requirements. This also applies to all parts, e.g. filters, that have been in contact with service products. For vehicles run on FAME (fatty acid methyl ester) fuel, the special instructions on disposing of engine oil must be observed. For more information, visit a qualified specialist workshop, e.g. a

observe

Environmental note

engine oil, you must comply with the

e.g.

the notes on engine main-

Mercedes-Benz or MTU Service Centre. Dis-

empty containers, cleaning cloths and

pose of care products in an environmentally responsible manner. Observe the instructions for care products. Do not let the engine run longer than necessary when stationary.

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.

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

Maintenance and care

Work schedule overview .................... 60

Work schedules .................................. 62

Notes on maintenance

Work schedule overview

Maintenance work overview

Maintenance schedule for maintenance service

Engine: oil and filter change

With BlueTec

Without BlueTec

AP18.00-W-0101C7Operation with

diesel fuel: carry out an oil and filter change

at least every two years.

with

AP18.00-W-0101C7Operation

FAME fuels (bio-diesel): carry out an oil and

filter change at least once a year.

Check and adjust the fluid level

AP20.00-W-2010A7 Engine cooling system: check corrosion/antifreeze protection. Adjustment subject to a separate invoice. In the event of fluid loss, find the cause and remedy it.

Notes on maintenance

Engine

AP13.22-W-1351A7 Check poly-V-belt for wear and tear and damage.

Additional maintenance work every second maintenance service (Z2)

AP05.30-W-0560A7 Check V2 valve clearance, adjust (first maintenance service, third, fifth, seventh, etc.).

AP14.40-W-1481A7 Replace AdBlue®/DEF filter.

Additional work every third maintenance service (Z3)

AP47.20-W-0730B7 Fuel prefilter: cleaning the filter element.

AP47.20-W-0783A7 Fuel prefilter with water separator: replace fuel filter.

AP47.20-W-0780A7 Fuel

filter: replace fuel filter element. For operation with FAME 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

Maintenance work by year

Once a year (J1)

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

With BlueTec

Without BlueTec

AP14.40-W-1490A7 Filling the AdBlue®/DEF pressure reservoir.

AP00.20-W-0050A7 Check for leaks and condition of assemblies.

AP00.20-W-0051A7 Lines and hoses, sensor cables – check for leaks and condition.

AP09.00-W-0953A7 Intake pipe between air filter, charge-air cooler and engine check for leaks and condition.

AP20.20-W-T052A7 All reservoirs, covers, bellows, protective caps.

AP20.00-W-2050A7 Heating system: condition check, radiator, lines and hoses.

Every three years (J3)

Engine

AP20.00-W-2080A7 Renew

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).

AP09.10-W-0980A7 Replace air filter element according to equipment/vehicle manufacturer's specifications. Observe installation date.

Final inspection

Visual check/road test/test rig: check that the equipment is safe to operate/

check that the vehicle is roadworthy.

•

• •

Notes on maintenance

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

Work schedules

Changing the engine oil and filter

Temperature for oil and filter change

Only change the engine oil when the engine is at normal operating temperature.

Oil filter replacement

Notes on maintenance

Make sure that no foreign objects enter the filter housing. Never wipe the filter housing out because lint or dirt can enter the oil circuit.

Unscrew oil filter cap : using a socket spanner insert (SW 36). Allow the oil to drain from the filter housing.

Remove oil filter cap : with oil filter element = and unclip oil filter element = by pressing in a sideways direction.

Replace sealing ring ; on cap :. Lightly grease the sealing ring.

Insert new oil filter element = cap : and press until it clips into place.

Screw on oil filter cap : with the oil filter element and tighten. Tightening torque: 25 Nm.

into

oil filter

Siphoning and draining engine oil

Environmental note

Dispose of engine oil and filters in accordance with the applicable regulations for your location.

Only siphon off/drain engine oil with the

engine at normal operating temperature.

Example: OM 926 LA

Filler neck

;

Oil dipstick

To siphon off engine oil: pull out oil dipstick ;.

Insert the extractor system into the guide tube, using an O-ring to seal it.

Siphon off the engine oil through the guide tube.

Observe the extraction pump operating

instructions.

WARNING

Hot engine oil escaping under pressure can scald your skin and eyes.

Wear suitable protective gloves, protective clothing and safety goggles.

Example: drain plug

To drain off engine oil: place a suitable collecting receptacle under drain plug : on the underside of the oil pan.

Carefully unscrew drain plug : and allow the oil to drain out.

Screw in and tighten drain plug : with a new seal (tightening torque (Y page 105)).

An oil drain hose is available as optional equipment.

Work schedules

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 no oil pressure is displayed after approximately 10 seconds, switch off the engine. Determine the cause.

Check the oil filter cap and the drain plug for leaks.

Check the oil level after about 5 minutes and add oil dipstick.

Checking valve clearance, adjusting

Layout of cylinders and valves

oil pressure reading is displayed. If

oil up to the upper marking on the

Adding engine oil

Example: OM 926 LA

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

: - B

Notes on maintenance

Cylinder number

Intake valve

Exhaust valve

Flywheel side

Work schedules

Special tool

Cranking device 904 589 04 63 00

Valve adjustment

tool 422 589 00 11 00 (no

image)

Valve clearance

Inlet valves 0.40 mm

Exhaust valve 0.60 mm

Test tolerance

Notes on maintenance

Inlet valves

Exhaust

+/- 0.05 mm

+/- 0.10 mm

valve

WARNING

If the engine starts automatically, there is a risk

injury by limbs being crushed between

the moving parts.

Secure the engine against unintentional starting before carrying out maintenance or repair work.

WARNING

The engine becomes very hot while it is running 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.

remains so for some time after it has

and

Removing and fitting the cylinder head covers

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).

WARNING

If not properly secured, a vehicle might accidentally down or trapping them or causing an accident and injuring you or others.

be set in motion, knocking somebody

Always prevent the vehicle from rolling away by applying the parking brake and, if necessary, using chocks.

Shift the transmission into neutral.

Only turn the engine over using the cranking device provided for this purpose.

Example: cylinder head cover

Engine ventilation hose

;

Cylinder head cover

Bolt

Sealing washer

Seal

Clean very dirty cylinder head covers before removal.

Remove engine ventilation hose : from cylinder head cover ;.

Remove cylinder head cover ;.

Remove seal A between

the cylinder head

cover and the cylinder head.

Clean the sealing surfaces of the cylinder head cover and the cylinder head.

Work schedules

I – inlet valve

E – exhaust valve

Valve clearance setting OM 906/926 LA

Crankshaft position

6th cylinder valve overlap

Cylinder/valves to be adjusted

1 2 3 4 5 6

I/EI A I A -

Example: flywheel inspection hole

Unscrew the cap from the inspection hole in the flywheel housing.

Fit the cranking device 904 589 04 63 00 (Y page

64) to the flywheel housing inspec-

tion hole. Tightening torque: 25 Nm.

Valve clearance setting

Valve clearance setting OM 904/924 LA

Crankshaft position

Cylinder/valves to be adjusted

1st cylinder valve over-

- A I A I I/ E

lap

I – inlet valve

E – exhaust valve

Adjust all valve clearances at two crankshaft positions.

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).

Turn cylinder no. 1 to TDC valve overlap (cylinder no. 6 at ignition TDC).

Check and adjust the valve clearance of all valves in accordance with the table above.

Checking and adjusting the valve clearance

Notes on maintenance

4th cylinder valve overlap

1st cylinder valve overlap

1 2 3 4 5 6

I/EI A -

- A I I/ E

Work schedules

Measure the valve clearance between the rocker arm and valve bridge using a feeler gauge (arrow).

It should be possible to pull through the feeler gauge with only light resistance.

Loosen counternut ; to permit adjustment of the valve clearance. Adjust the valve clearance by turning adjustment screw :.

Tighten the counternut again (tightening torque (Y page 105)).

Check the valve clearance again and correct.

Concluding work

Replace the gaskets on the cylinder head covers.

Put on the cylinder head covers and tighten them (tightening torque (Y page 105)).

Remove the cranking device from the flywheel housing inspection hole.

Screw on the cap of the inspection hole of the flywheel housing and tighten it (tight-

Notes on maintenance

ening torque: 25 Nm

After fitting, run the engine and check the

cylinder head cover area for leaks.

Check the poly-V-belt condition regularly.

Replace the poly-V-belt concerned immediately if there are any signs of damage.

Special tool

Cranking device: 904 589 04 63 00 (Y page 64).

Checking the poly-V-belt.

Fit the cranking device to the flywheel housing inspection hole. Tightening torque: 25 Nm.

Make a chalk mark on the poly-V-belt.

Check the poly-V-belt for damage section by section; to do this, turn the engine or poly-V-belt gradually using the cranking device until the chalk mark is reached again.

Remove the cranking device.

Screw the cap into the inspection hole in the flywheel housing and tighten. Tightening torque: 25 Nm.

Replace the poly-V-belt: (Y page 97).

Checking poly-V-belt for wear and damage.

WARNING

Faulty poly-V-belts can tear, the belt or parts of it could then be thrown off the engine, thereby causing injury to others.

Always observe the specified maintenance intervals for poly-V-belts.

If damage is detected, replace the poly-Vbelt concerned immediately.

If the poly-V-belt is torn, there is no drive

the

coolant pump and the alternator. The

engine may overheat as a result.

Patterns of damage

Replace the poly-V-belts if one of the fol-

lowing damage

patterns occurs on the poly-

V-belt.

Work schedules

New condition (for comparison; trapezoidal ribs)

;

Single-sided wear: wedge-shaped ribs

Cord visible at the base of the belt

Breaks in the ribs

Transverse cracks in several ribs

Rubber nodules at the base of the belt

Deposits of dirt or stones

Rib detached from the base of the belt

Cord torn out of the side

Outer cord frayed

Transverse cracks on the back of the belt

Transverse cracks in several ribs

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.

Notes on maintenance

Work schedules

Leakage fuel from the engine

;

To the fuel pump

From the fuel tank

Fuel return line to the fuel tank

Fuel pump

Notes on maintenance

Fuel prefilter with water separator: replacing the fuel filter

WARNING

There is an increased risk of fire when handling fire, naked flames and sparks, and refrain from smoking when handling fuels.

Dispose of used filter elements, seals and fuel residue ulations.

as they are highly flammable. Avoid

fuels

Environmental note

accordance with relevant local reg-

The fuel prefilter is fitted on the equipment or vehicle. Observe the operating and maintenance instructions in the equipment/vehicle operating instructions for the fuel prefilter.

Vehicle with fuel prefilter at tank level: close shutoff valve ?.

Place a collector under water drain valve E.

Open water drain valve E

and

bleed screw

=. Collect the escaping water/fuel mixture.

Unscrew filter element A from filter head :.

Unscrew water separator D

from

filter ele-

ment A and clean or replace as necessary.

Replace filter element A.

Screw water separator D with

new sealing

ring C onto filter element A until it is hand-tight. Lubricate sealing ring C with a thin coat of engine oil beforehand.

Screw filter element A with new sealing ring B onto filter head : until it is handtight. Lubricate sealing ring B with a thin coat of engine oil beforehand.

Close water release valve E.

Vehicle with fuel prefilter at tank level: open shutoff valve ?.

Push fuel hand pump ; repeatedly until

fuel

the

escapes free of bubbles from bleed

screw =.

Close bleed screw =.

Work schedules

Start the engine and bleed the fuel system. 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 (Y page 86).

Check the fuel prefilter with water separator for leaks while the engine is running.

Replacing the fuel filter element

WARNING

There is an increased risk of fire when handling fire, naked flames and sparks, and refrain from smoking when handling fuels.

Dispose of used filter elements, seals and fuel residue ulations.

If the diesel fuel level (fuel tank) is above engine height, the feed line must be blocked off during filter replacement. Otherwise, diesel can drain out.

as they are highly flammable. Avoid

fuels

Environmental note

accordance with relevant local reg-

Environmental note

Clean the outside of the filter housing.

Open the fuel filler cap to prevent excess pressure in the fuel tank.

Unscrew fuel filter cap : using a socket spanner insert (SW 36).

Pull fuel filter cap : with filter element = out of the filter housing slightly. Allow

the fuel to drain off.

Remove the cap and filter element. Unclip the filter element by pressing the sides of the lower edge of the filter element.

Make sure that no foreign objects enter the filter housing.

Never wipe inside the filter housing.

ingress of water must be prevented.

The

Replace sealing ring ; with a new one (grease lightly).

Clip new filter element = into housing cover :.

Screw on and tighten oil filter cap : with filter element = (tightening torque: 25 Nm).

Put on the fuel filler cap and tighten it.

Start the engine and bleed the fuel system (Y page 86).

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.

Check the fuel filter for leaks with the engine running.

Notes on maintenance

Example: OM 926 LA

Replacing the AdBlue®/DEF filter

WARNING

If the AdBlue®/DEF tank temperatures, ammonia vapours may escape.

cap is opened at high

Work schedules

Ammonia vapours have a pungent odour and particularly irritate:

skin

mucous membranes

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.

WARNING

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

If AdBlue®/DEF comes into contact with your eyes

or skin, rinse affected areas with

clean water immediately.

If AdBlue®/DEF is swallowed, immediately rinse your mouth out with a lot of clean water and drink plenty of water.

Change clothing that is soiled with AdBlue®/DEF immediately.

If allergic reactions occur, consult a doctor

Notes on maintenance

immediately.

Keep AdBlue®/DEF out of the reach of children.

WARNING

The AdBlue®/DEF lines and all connected components are

pressurised during operation and could be hot, even after the engine has been switched off. There is a risk of burns. When opening the pressurised system, there is a risk of scalding due to hot AdBlue®/DEF spraying out.

Wait at least 5 minutes after switching off the engine before starting work on the exhaust gas aftertreatment system.

Open line connections and caps on system components slowly. Cover the area that you are disconnecting with a cloth.

Wear suitable protective gloves, protective clothing and safety goggles.

If AdBlue®/DEF gets into the coolant circuit (even minute amounts), thermostats and temperature

Always keep AdBlue®/DEF completely

sensors will be damaged.

separate from other service products.

Do not use the same containers and fluid collecting pans for AdBlue®/DEF and other service products.

Do not continue to use service products that contain traces of AdBlue®/DEF.

Individual components of the BlueTec

system react very sensitively to even the slightest trace of impurities in AdBlue®/ DEF.

Only use containers and fluid collecting pans that are clean and suitable for AdBlue®/DEF.

Do not continue to use AdBlue®/DEF which contains traces of impurities.

Fire fighting measures

AdBlue®/DEF is not flammable. In the event of a fire, NH3 (ammonia) may be released.

This may result in a risk of poisoning. Measures to extinguish a fire must therefore be adapted to suit the surroundings.

Environmental note

Disposing of AdBlue®/DEF:

Due to its easy degradability, small amounts of spilt AdBlue®/DEF can be washed into the sewage system without any problems.

Larger amounts of AdBlue®/DEF must be disposed of correctly, observing the regulations on waste treatment/disposal.

Packaging that is contaminated with AdBlue®/DEF residue must be treated in the same way as AdBlue®. Packaging should be emptied as thoroughly as possible, cleaned appropriately and then recycled.

Work schedules

Insert new filter element ; into filter bowl ?. Use MB silicon grease as a lubricant.

Screw filter bowl ? into pump module : and tighten. Tightening torque:

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.

32 Nm.

AdBlue®/DEF pump/filter unit

Pump module

;

Filter element

O-ring

Filter bowl

Dust protection cap

Hose clamp 000 589 54 37 00

Clamp the feed and return lines on the pump/filter unit using hose clamps.

Place a suitable receptacle under the pump/filter unit to collect any AdBlue®/ DEF fluid that escapes.

Unscrew filter bowl ? from the pump/filter unit.

Remove filter element ;.

Smear O-ring = on new filter element ; thinly with

MB silicon grease before assem-

bly.

Filling the AdBlue®/DEF pressure

res-

ervoir

Important safety notes

WARNING

tank

If the AdBlue®/DEF temperatures, ammonia vapours may escape.

Ammonia vapours have a pungent odour and particularly irritate:

skin

mucous membranes

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.

WARNING

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

If AdBlue®/DEF comes into contact with

eyes

your

or skin, rinse affected areas with

clean water immediately.

If AdBlue®/DEF is swallowed, immediately rinse your mouth out with a lot of clean water and drink plenty of water.

Change clothing that is soiled with AdBlue®/DEF immediately.

If allergic reactions occur, consult a doctor immediately.

cap is opened at high

Notes on maintenance

Work schedules

Keep AdBlue®/DEF out of the reach of children.

Environmental note

Dispose of AdBlue®/DEF in an environmentally responsible manner.

You will

find further information on AdBlue®/ DEF in the "Service products" section (Y page 54).

Special tool 001 589 00 71 00 pump

Supply unit with pressure reservoir

Notes on maintenance

;

Pressure release

Filling hose

Filling pressure gauge

Pump

To check the pressure:

unscrew

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.

Increase or reduce the pressure if necessary.

To increase the pressure: press pump lever A.

Adjust the pressure to 0.2 bar specified

operating pressure. When the fill-

above the

the dust

ing hose is disconnected from the valve, a pressure loss of 0.2 bar takes place.

To reduce the pressure: press but-

several times.

ton ;

Only if the pump module or the pressure reservoir was not replaced: check the pressure:

the pressure was increased, it

if must be tested again after at least 5 minutes.

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.

If the pressure reservoir is OK:

Equalise the pressure loss.

Screw the dust protection cap onto the valve of the pressure reservoir.

Engine brake - checking condition and setting

Throttle valve lever in rest position

Throttle valve lever in operating position

Remove the wire circlip from the ball socket of the engine brake cylinder.

Press the ball socket off the ball coupling of throttle valve lever :.

Check the engine brake cylinder, ball coupling, ball socket and the throttle valve shaft for wear.

Check the seating of the throttle valve lever

throttle valve shaft and retighten the

on the clamp screw if necessary.

Lubricate the ball socket with heat-resistant lubricant (part number A000 989 76

51).

Press the ball socket back onto the ball coupling, fit the wire circlip.

When the engine brake is applied, throttle valve lever : must rest on bracket ; in the working position (cylinder extended).

The throttle valve lever must also rest on bracket when the engine brake cylinder is in the rest position (cylinder retracted). If this is the case, the return spring pretension of the engine brake cylinder is adequate.

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.

Work schedules

Engine cooling system

Checking and correcting the fluid level and the antifreeze/corrosion inhibitor

WARNING

When opening the coolant expansion tank, there is a risk of scalding, due to hot coolant spraying out. 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 † .

WARNING

Coolant contains glycol and is therefore toxic. Do not swallow the coolant. See a doctor immediately if you swallow coolant.

Only check the coolant level when the coolant temperature is under 50 †. Check the antifreeze/corrosion inhibitor concentration before correcting the coolant level. Only top up with a prepared coolant having an antifreeze/corrosion inhibitor concentration of 50% by volume. corrosion inhibitor/antifreeze agent.

Before topping up, check the quality of the antifreeze/corrosion inhibitor (Sheet. No.) in the cooling system. Corrosion/antifreeze additives compliant with Sheet 325.3 and

326.3 must not be mixed with those of Sheet

325.0/2 or 326.0/2. Only top up with corrosion inhibitor/antifreeze agent of the same quality grade (Y page 48). This helps to prevent damage to the engine.

The cooling system and coolant

skin, eyes or clothing. In case of

Notes on maintenance

Work schedules

Open the engine cooling system cap slowly, relieving the excess pressure.

Check the antifreeze/corrosion inhibitor concentration using a testing device. The correct concentration of 50% antifreeze/ corrosion

inhibitor by volume in the coolant

provides antifreeze protection down to Ò37 †. If a lower level of antifreeze protection is indicated, correct the mixture ratio.

If the concentration of antifreeze/corrosion inhibitor is too low, there is a risk of engine damage as a result of corrosion/ cavitation in the cooling system.

Avoid concentrations greater than

volume corrosion inhibitor/antifreeze

55% agent. Otherwise, the maximum antifreeze protection down to Ò45 † will not be attained. Heat dissipation and antifreeze protection deteriorate at higher concentrations.

To check the coolant level: the cooling system is filled correctly if the coolant is level with the mark in the filler neck.

Notes on maintenance

Cooling and heating system – condition check

Special tool: pressure tester tool

Heating systems: open all control valves and shutoff valves for the heating system.

Remove the coolant expansion tank cap.

Check the coolant level and top up if necessary.

Check/correct the coolant antifreeze protection content.

of radiator, lines and hoses

Dry the inside of coolant filler neck ; a lint-free cloth.

Mount pressure tester tool

: on the filler

neck of the coolant expansion tank.

Connect the compressed-air hose with tyre inflation connection to pressure tester tool : and set it to a test pressure of

1.0 bar.

test

The

pressure should correspond to the value at which the cooling system pressure relief valve opens. The opening pressure can be determined from the code on the cap or pressure relief valve.

Example: code 100 = 1.0 bar excess pressure.

After about 5 - 10 minutes, read the drop in pressure on the manometer of tester :. After

5 - 10 minutes, there must be no drop in pressure detected on the manometer. Do not exceed the test pressure and the test time, as this may damage the cooling and heating system. If the cooling system/heating system is leaking, this will become apparent due to a drop in pressure, indicated by the manometer on tester :.

If there is a loss of pressure in the cooling system leading to visible loss of coolant,

the

have

leak in the cooling or heating sys-

tem repaired.

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 for this purpose (Y page 11). Work relevant to safety or on safety-related systems must be carried out at a qualified specialist workshop.

Release the pressure using pressure tester tool : and remove pressure tester tool : from the coolant expansion tank filler neck.

with

Check the coolant level and correct if necessary.

Replace coolant expansion tank cap and tighten it.

Renewing the coolant

WARNING

When opening the coolant expansion tank, there is a risk of scalding, due to hot coolant spraying 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 † .

WARNING

Coolant contains glycol and is therefore toxic. Do not swallow the coolant. See a doctor immediately if you swallow coolant.

The cooling system and coolant

out.

skin, eyes or clothing. In case of

with

Before renewing the coolant, check the cooling and heating system for leaks and condition. Have the coolant renewal confirmed in the Maintenance Booklet.

Draining the coolant

Environmental note

Dispose of used coolant in accordance with current local regulations.

Work schedules

Undo the engine cooling system cap slowly, relieving the excess pressure, and remove it.

Heating systems: open the heating system temperature control (control valve).

Cover the lines etc. under the drain plugs.

Place a suitably sized receptacle underneath to catch the coolant.

Plug the drain hose onto coolant drain plug : on the crankcase.

Release drain plug : ant.

Clear blocked drainage openings of deposits.

Tighten coolant drain plug : on with a new seal (tightening torque: 60 Nm).

Screw in other drain plugs (without hose connection) with

new seals (tightening tor-

que (Y page 105)).

Old coolant and corrosion deposits must

be rinsed out thoroughly.

cooling system is heavily contamina-

If the ted, flush it thoroughly before refilling.

collect the cool-

and

the engine

Notes on maintenance

Work schedules

Adding coolant

Add coolant.

Start the engine and run it at varying speeds for approximately 1 minute.

Add coolant mixed to the prescribed ratio until it reaches the lower edge of the filler neck.

Switch off the engine and seal the cooling system again.

Observe any further information in the operating instructions from the equipment/vehicle manufacturer.

Corrosion inhibitors/antifreeze agents that comply with Sheet 325.3 and 326.3 must not be mixed with those of Sheet

325.0/2

or 326.0/2. This prevents dam-

age to the engine cooling system.

Cleaning the cooling system

WARNING

Notes on maintenance

The cooling system is pressurised. Hot coolant

escape under pressure when the cool-

can ing system is opened and scald your skin and eyes.

Only open the cooling system at coolant temperatures below 90 †.

Unscrew the cap slowly and release any excess pressure completely before opening the cap fully.

Wear suitable protective gloves, protective clothing and safety goggles when handling coolant.

WARNING

Coolant contains glycol and is therefore toxic. Do not swallow the coolant. See a doctor immediately if you swallow coolant.

Make sure that coolant does not come into contact contact with eyes, rinse immediately with plenty of clean water. Clean affected areas of skin and clothing with soap and water imme-

skin, eyes or clothing. In case of

with

diately. Change any affected clothing immediately.

Environmental note

Collect used coolant, cleaning solutions and detergents and dispose of them in an environmentally responsible manner in accordance with applicable local regulations.

Remove foreign objects (dust, insects, etc.) from the radiator core fin. You can do this by blowing them out with compressed air, or by spraying water from the rear side of the radiator.

Only apply moderate pressure when cleaning, since the radiator fins could otherwise be damaged.

Drain off coolant when the engine is cold (Y page 75).

If a heater is connected to the cooling system, open the regulating valves fully.

Flushing the cooling system

Fill the cooling system with fresh water and leave the system running for approximate five minutes.

Switch off the engine and drain off the water completely.

Repeat the flushing process at least twice.

Fill the cooling system with new corrosion inhibitor/antifreeze agent. Observe the antifreeze protection (

Y page 73).

Degreasing the cooling system

If necessary, degrease the cooling system with

suitable cleaning agent. Information

a is available from any Mercedes-Benz or MTU Service Centre (Y page 11).

Work schedules

Checking for leaks and general condition – assemblies

Carry out a visual inspection of the engine for signs

of leaks. Slight dampness around

sealed joints can be ignored.

More severe leaks, where there is constant oil loss, must be rectified immediately.

Lines, hoses and sensor cables – checking for

leaks and general condi-

tion

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.

WARNING

There is a danger of limbs being caught, pulled in

thereby crushed or severed by rotating

and

engine parts. Therefore you should:

keep a safe distance between yourself and rotating engine parts, including when the engine is being started.

wait until all engine parts have stopped moving before carrying out any work on the engine.

wear work clothing which is properly fastened and close-fitting. Wear a hair net if necessary. Remove jewellery such as watches and necklaces.

Notes on maintenance

WARNING

The engine becomes very hot while it is running 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.

remains so for some time after it has

and

Decommissioning the engine ............ 80

Protecting the engine ......................... 81

Decommission and protection

Decommissioning the engine

Particular measures are necessary when the engine/vehicle/equipment is to be decommissioned.

Decommissioned engines are engines that are not operated for a month or more after assembly or after repair work has been carried out.

For engines

that have been run in, this applies

after 12 months' standing time.

Decommissioning for up to 12 months

When decommissioning an engine/vehicle/equipment, keep it in a covered, dry and well-ventilated

area. The room temperature should not fall below -10 † in order prevent the AdBlue®/DEF from freezing.

If this is not possible, these measures must be carried out after 6 months rather than

12.

Measures prior to decommissioning

Clean the engine/vehicle/equipment thoroughly.

Remove any patches of corrosion from the engine.

Decommission and protection

Change the engine oil and oil filter if the last oil change was carried out more than 20,000 km (around 300 operating hours) ago or if the oil is older than 12 months.

Disconnect the earth lines from the batteries (this prevents self-discharge due to closed-circuit accessories).

Charge the batteries. Check the battery fluid levels before and after charging.

Check and adjust the concentration of anticorrosion/antifreeze additives in the coolant.

Check and adjust the level of coolant or renew coolant.

Fill up the AdBlue®/DEF supply reservoir completely so that AdBlue® cannot crystallise out.

Fuel prefilter with heated water separator: drain off the water separator.

Engine/vehicle/equipment

with

exhaust

gas aftertreatment

Decommissioning for more than 12 months: fill up the AdBlue®/DEF supply

reservoir completely.

Decommissioning for more than 24 months: drain off and dispose of AdBlue®/

DEF. When disposing of AdBlue®/DEF, observe the relevant national laws and regulations.

When outside temperatures are low, AdBlue®/DEF crystals may form on the coiled hose between the engine and silencer. Remove the crystals with plenty of water.

Engine/vehicle/equipment run on FAME (Fatty Acid Methyl Ester) bio-diesel fuel

Empty the fuel tank to the point where the remaining fuel still allows the engine to be operated for 15 to 30 minutes each month during its decommissioned period.

Start the engine at least once a month and leave it running for 15 to 30 minutes at an engine speed of around 900 rpm. Doing so purges the fuel system or diesel injection system with fuel. This prevents any caulking of the fuel injectors.

Measures during decommissioning

Before starting the engine, check the engine oil level and the coolant level.

Start the engine and leave it running for 15 to 30 minutes at an engine speed of no more than 900 rpm.

While the engine is running, observe the indicators for oil pressure, coolant temperature and oil temperature.

While the engine is running, select every gear that can be selected while stationary.

Protecting the engine

Leave the engine running until the air compressor cutoff pressure is reached.

Fuel prefilter with heated water separator: drain off the water separator.

Recharge the batteries every three months. Check the battery fluid levels before and after charging.

Change the engine oil and oil filter every 24 months.

Measures prior to decommissioning

Empty the fuel tank and fill up with new fuel. When disposing of fuels, observe the relevant national laws and regulations.

Fuel prefilter with heated water separator: replace filter element.

Replace fuel filter.

Replace air filter cartridge.

Change engine oil and oil filter.

Check coolant level.

If coolant needs refilling, check and adjust the concentration of anticorrosion/antifreeze in the coolant. Before refilling coolant, note the quality of the previously filled anticorrosion/antifreeze (Y page 48).

Check the charge status of the battery and recharge if necessary. Check the battery fluid levels before and after charging.

Connect the earth lines to the batteries.

Check that the electrical system is functioning correctly.

Check cables, hoses and lines for tears and leaks.

Start the engine and leave it running for 15 to 30 minutes at an engine speed of no more than 900 rpm.

While the engine is running, observe the indicators for oil pressure, coolant temperature and oil temperature.

Vehicles with auxiliary heating: activate the auxiliary heating.

Check oil levels in the steering system, engine, transmission and drive axles.

Check that the electrical system, steering system and brakes are functioning correctly.

Clean the engine/vehicle/equipment thoroughly.

Protecting the engine

Engine protective treatment applies to all fitted and

removed vehicle, industrial and OEM engines as well as new engines, reconditioned engines and short block engines.

Engines that have been removed must be protected against moisture (rain or spray water) using special measures.

Protective treatment for up to 12 months

On new engines no additional protection measures are

required, as long as initial operation oil compliant with Sheet 225.6 and coolant were added at the engine factory. Engines which have covered a distance of up to 300 km or which have been operated for up to 6 hours may be considered new.

Clean the engine thoroughly and remove patches of corrosion.

All machined exterior and unpreserved surfaces must be greased or sprayed with preservative agent according to Sheet

385.4. This is regardless of the duration of the protective treatment. Examples of this are the flywheel and pulley keyway.

Where possible, carry out protective measures on the fitted engine in the storage location.

After protective measures are complete, the engine must not be started again.

Engine oil and coolant must be filled to the maximum level. Observe the temperature ranges when selecting engine oil and coolant.

Decommission and protection

Protecting the engine

Close off all openings on the engine (e.g. on the charge-air housing, exhaust etc.) with an oil-soaked rag.

Drain off the coolant completely for engines that have been removed. Unscrew the coolant drain plug on the engine block to do so. When screwing in the coolant drain plug, observe the tightening torque.

Relieve the tension in the poly-V-belt. The poly-V-belt can remain routed.

If the engine has been filled with coolant, the cooling system must first be filled with water. It must then be filled with a mixture of water and improver compliant with Sheet 311.0. Coolant without antifreeze protection compliant with Sheet 312.0 may also be used.

Protective treatment for 12 to 36 months

Carry out all measures in "Protective treatment for up to 12 months". The fuel system, combustion chambers and air compressor also require protective measures.

Carry out protective measures for the fuel system

Completely fill the fuel tank with diesel fuel.

Decommission and protection

Start the engine and allow it to run for 15-30 minutes at approximately

Carry out protective measures for the combustion chambers

Only carry out protection measures for the combustion chambers when the engine is cold (coolant temperature under 50 † ).

Only use initial operation oil compliant with Sheet 225.6 for the protection of the combustion chambers.

Detach the charge-air housing from the cylinder heads.

Briefly press the start button on the engine. At the same time, pour approximately

900 rpm.

15 – 20 cm3 initial operation oil into each cylinder.

Protecting the air compressor

Carry out the protection of the air compressor at the

same time as the combustion chamber

protection.

On the air intake side of the air compressor, pour a maximum of 5 cm3 of initial operation oil compliant with Sheet 225.6 into the air compressor.

After protective measures

Refit all removed engine parts. Observe the tightening torques.

After protective measures are complete,

the engine must not be started again.

Protective treatment for longer than 36 months

When carrying out protective treatment for over 36 or 18 months, repeat the protection measures as in "Protective treatment for 12 to 36 months".

Drain off engine oil that has been added.

The oil filter does not have to be replaced.

Shipping by sea or engine protective treatment in tropical countries

Carry out all measures in "Protective treatment for 12 to 36 months". The fuel system, combustion chambers and air compressor also require protective measures.

Protecting the engine

The following work is required for engines that have been run in (distance of over 300 km or running time of over 6 operating hours):

Drain

off engine oil and replace the oil filter. Add initial operation oil compliant with Sheet 225.6.

Fill or top up the cooling system with the specified coolant. Before refilling coolant, note the quality of the previously filled anticorrosion/antifreeze (Y page 48).

Carry out protective measures for the fuel system.

Warm up the engine at medium engine speeds and allow it to run for approximately 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.

viously filled anticorrosion/antifreeze (Y page 48).

New engines: add initial operation oil compliant with Sheet 225.6.

Engines that have been run in (distance of over 300 km or running time of over 6 operating hours): before starting the engine, lubricate the lubrication points on the engine as necessary, e.g. ball couplings or engine brakes.

Start the engine and leave it running until it is at operating temperature (coolant temperature approximately 75 to 95 †). While doing so, observe the indicators for oil pressure, coolant temperature and oil temperature.

Re-commissioning

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-

Decommission and protection

General notes ...................................... 86

Bleeding the fuel system .................... 86

Activating engine emergency run-

ning mode ............................................ 87

Troubleshooting .................................. 89

BlueTec® exhaust gas aftertreatment indicator (on-highway ver-

sion) ..................................................... 94

BlueTec® exhaust gas aftertreatment indicator (off-highway ver-

sion) ..................................................... 95

Replacing the poly-V-belt ................... 97

Breakdown assistance

Bleeding the fuel system

General notes

WARNING

If maintenance and repair work is carried out on the engine incorrectly, this can cause engine failure. Engine failure can lead to an increased risk of accidents.

Maintenance and repair work on the engine may only be carried out by personnel who have undergone the appropriate training.

Always have work on or modifications to the engine carried out at a qualified specialist workshop skills and tools for the work required.

Breakdown assistance

Mercedes-Benz recommends that you use a Mercedes-Benz or MTU Service Centre for this purpose.

has the necessary specialist

which

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 work (Y page 11). In particular, work relevant to safety or on safety-related systems must be carried out at a qualified specialist workshop.

Bleeding the fuel system

Fuel system without fuel prefilter

Automatic bleeding

bleed the fuel system by operating

Do not the starter motor for an extended period of time. You could otherwise damage the starter motor.

Turn the starter motor for up to 30 seconds without

interruption

until the engine is running smoothly. The fuel system is automatically bled when the tank is empty (Y page 35).

Fuel system with fuel prefilter

Fuel prefilter overview

Example: fuel prefilter

Fuel hand pump

;

Vent valve

Shutoff valve

Filter housing

Water separator with inspection window

Water release valve

If water has collected in inspection window A, drain the fuel prefilter before bleeding.

Activating engine emergency running mode

Draining the fuel prefilter

Environmental note

Dispose of the water-fuel mixture in an environmentally responsible manner.

Drain the fuel prefilter regularly.

Place a collector under water release valve B.

On vehicles with fuel prefilter at tank level: close shutoff valve =.

Unscrew water release valve B.

Briefly press fuel hand pump : and

collect

the fuel/water mixture.

Close water release valve B.

On vehicles with fuel prefilter at tank level: open shutoff valve =.

Start the engine and allow it to run for about one minute. The fuel system is bled automatically.

Check the fuel system for leaks.

Bleeding the fuel prefilter with the fuel hand pump

The fuel prefilter must only be bled when:

the fuel tank is empty or

the fuel filter has been replaced.

Unscrew the fuel tank filler cap.

Place the collector underneath the fuel prefilter.

Open shutoff valve = fully.

Open vent valve ;.

Only press fuel hand pump :

until

the fuel

escaping from vent valve ; is free of bub- bles. Do not continue to pump.

Close vent valve ;.

Close the fuel tank filler cap.

Start the engine. The fuel system is bled automatically.

Do not continue to press the fuel hand pump after the engine has started. This could otherwise damage the hand pump.

Activating engine emergency running mode

Emergency mode for on-highway applications

Emergency mode can be activated for road vehicles with Euro 4/5 certified engines (onhighway engines).

Example: indicator lamp malfunction

The engine is equipped with an electronic management system that monitors both the engine and itself (self-diagnostic system).

The k indicator

lamp lights up in the event of a malfunction. Error messages can be displayed as code or text in the display, depending on the vehicle's display format.

After a malfunction, the engine can be activated again in emergency mode with a limited constant engine speed. In engine emergency running mode, the accelerator pedal is not operational and the engine speed is limited to approximately 1300 rpm.

To activate engine emergency running mode: stop

the vehicle, paying attention to

the road and traffic conditions.

Engage the parking brake.

Switch off the engine.

Restart the engine after approximately 10 seconds.

The STAR DIAGNOSIS or minidiag2 diagnostic equipment can be connected to the 14-pin diagnostic socket or by using the EU-compliant service connector. The fault memory and engine data can be read out

Breakdown assistance

Activating engine emergency running mode

using this diagnostic equipment. Information is

available from any Mercedes-Benz or

MTU Service Centre (Y page 11).

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 cle has the appropriate equipment.

For further information, see the device's

Breakdown assistance

operating instructions.

30 minutes, and only if the vehi-

Troubleshooting

Engine problems

WARNING

If maintenance work is carried out incorrectly, the operating safety of your vehicle may be affected. You could lose control of the vehicle and cause an accident. The safety systems may also no longer be able to protect you or others as they are designed to.

Always 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 qualified specialist workshop.

service work carried out at a qualified specialist workshop. The qualified specialist

have

Apart from careful operation and maintenance of the engine it is also important that malfunctions be rectified in good time. You can rectify certain faults yourself.

Have malfunctions that you cannot eliminate yourself rectified at a qualified specialist workshop. Mercedes-Benz recommends that you use a Mercedes-Benz or MTU Service Centre for this purpose (Y page 11).

Problem Possible causes/consequences and M Solutions

Drive pinion does not turn

turns too slowly.

Battery is not sufficiently charged.

Charge the battery.

Connecting cable to the starter motor is loose.

Tighten the cable on the terminal. If necessary, solder on a new terminal.

Starter motor solenoid switch is faulty or starter motor is faulty.

Have it checked at a qualified specialist workshop.

Engine does not start or stalls again immedi-

Fuel tank is empty.

Refill the fuel tank (Y page 41).

ately.

Fuel filter is blocked.

Replace the filter element (Y page 69).

The fuel prefilter contains water.

Drain the fuel prefilter (Y page 68).

Breakdown assistance

Fuel prefilter is blocked.

Replace the filter element (Y page 68).

Fuel system or filter is leaking.

Replace the seals.

Troubleshooting

Problem Possible causes/consequences and M Solutions

Fuel is not resistant to cold.

Replace the fuel prefilter (Y page 68).

Replace the fuel filter (Y page 69).

Use winter fuel (Y page 52).

Incorrect engine oil viscosity.

Alter the engine oil viscosity to the conditions of use (Y page 47).

Engine does not start correctly.

Breakdown assistance

There is a malfunction in the engine control unit.

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.

Carry out a check for leaks (visual check).

Have the pressure tested at a qualified specialist workshop.

Engine stops inadvertently.

MR (engine control) unit is faulty (total failure).

Consult a qualified specialist workshop.

Power supply to the MR/ADM control units is interrupted or there is a short circuit in the wiring.

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.

Check for leaks (visual check).

Have the fuel pressure tested at a qualified specialist workshop.

Engine is in emergency running mode.

There is an interruption to the MR/ADM control unit's data flow.

Read out the control unit's fault memory.

Have it checked at a qualified specialist workshop.

Engine surges, vibrates or runs irregularly.

Crankshaft sensor or TDC sensor (on camshaft gear wheel) is faulty or the signal is missing.

Consult a qualified specialist workshop.

There is a malfunction in the fuel system.

Read out the fault code.

Have it checked at a qualified specialist workshop.

Troubleshooting

Problem Possible causes/consequences and M Solutions

The engine's output is poor (lack of power).

Air filter is dirty or blocked.

Replace the air filter element.

Charge-air temperature is too high - charge-air cooler or radiator exterior is dirty.

Clean the outsides of the charge-air cooler and radiator.

Coolant temperature is too high.

Check the temperature sensor, replace as necessary, check the fan speed.

Thermostat malfunction: consult a qualified specialist workshop.

Malfunction in the fuel system (blocked, leaking)

Visual inspection for leaks

Consult a qualified specialist workshop.

Charge-air system is leaking, hose clamp on charge-air hose loose or faulty

Check the charge-air system for leaks.

Check the charge-air pressure sensor and replace if necessary.

Consult a qualified specialist workshop.

Engine brake flap is faulty or stuck.

Function check and visual inspection (Y page 72).

Breakdown assistance

There is an interruption in the tractive power.

The "engine diagnostics" indicator lamp is flashing (Y page 94). The AdBlue®/DEF tank is empty.

Top up AdBlue®/DEF tank (

Y 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.

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

There is an increased voltage drop to the MR/ADM control unit (loose contact).

Check the battery terminal clamps and the connectors on the MR/ADM control unit for secure seating and corrosion.

Troubleshooting

Problem Possible causes/consequences and M Solutions

Engine braking effect is poor.

Fuel consumption is too high.

There is an engine brake flap malfunction or a fault in the actuation.

Carry out a function check/visual check.

Consult a qualified specialist workshop.

Connection points (unit pump - line and fuel injectors) are leaking

Have a qualified specialist workshop check for leaks.

Misfiring: have the engine checked at a qualified specialist workshop.

Engine cuts off too early

Breakdown assistance

(maximum

speed cannot be

engine

Electronic engine speed control unit is faulty or parameterised incorrectly.

Consult a qualified specialist workshop.

reached).

Engine gets too hot (according to coolant

There is not enough coolant in the cooling system.

Top up, bleed (Y page 76)

temperature gauge).

Coolant temperature sensor or display is faulty.

Replace sensor or display.

Poly-V-belt is damaged.

See “Replacing the poly-V-belt” (Y page 97).

Fan does not switch on correctly.

Consult a qualified specialist workshop.

Charge current indicator lamp does not light up while the engine is not running.

Charge current indicator

lights up when

lamp

the engine is running.

Radiator is dirty on inside or choked with limescale; radiator is very dirty on outside.

Clean and remove limescale.

Thermostat is faulty.

Check and replace as necessary.

Consult a qualified specialist workshop.

Lamp is defective or supply line is interrupted.

Replace lamp or repair interruption.

Poly-V-belt is too loose.

Check belt tensioner for proper functioning.

Troubleshooting

Problem Possible causes/consequences and M Solutions

Poly-V-belt is torn.

Replace poly-V-belt (Y page 97).

Alternator or sensor is defective.

Check alternator or sensor.

Consult a qualified specialist workshop.

Engine emits black smoke.

Air filter is very dirty.

Replace the air filter element.

Engine brake is faulty.

Consult a qualified specialist workshop.

Exhaust gas turbocharger is faulty.

Carry out a visual check.

Consult a qualified specialist workshop.

Misfiring, fuel injector is faulty.

Consult a qualified specialist workshop.

Exhaust fumes are blue.

The oil level in the engine is too high; the crankcase ventilation system

faulty; engine oil has entered the combustion chamber.

Adjust the oil level correctly.

Have the crankcase ventilation system checked at a qualified specialist workshop.

Exhaust fumes are white.

Coolant is entering the combustion chamber.

Have a pressure loss test carried out at a qualified specialist workshop.

Engine “knocks”. The engine is misfiring.

Consult a qualified specialist workshop.

Breakdown assistance

Knocking noise from the bearings.

There are abnormal sounds.

There is bearing damage.

Consult a qualified specialist workshop.

Leaks in intake pipe and exhaust pipe cause whistling noise.

Repair leaks; replace seals if necessary.

BlueTec® exhaust gas aftertreatment indicator (on-highway version)

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.

Have the exhaust gas turbocharger checked at a qualified specialist workshop.

Valve clearance is too big.

Check clearance; adjust (Y page 63).

BlueTec® exhaust gas aftertreatment indicator (on-highway version)

Breakdown assistance

WARNING

If service work is carried out incorrectly, the operating safety of your vehicle/equipment may be 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.

service work carried out at a qualified specialist workshop. The qualified specialist

have

BlueTec® exhaust gas aftertreatment indicator (off-highway version)

Problem Possible causes/consequences and M Solutions

The ; indicator lamp lights up briefly and goes out again.

if there are no malfunctions, the ; indicator lamp lights up briefly

the instrument cluster's display check and then goes

during

out again.

The ; indicator lamp flashes.

Simultaneously, a display message with a red status indicator

The AdBlue®/DEF tank is empty.

There is a fault.

The engine output may be reduced8.

Follow the instructions in the display messages.

appears in the display.

The ; indicator lamp lights up permanently.

The BlueTec® exhaust emissions-relevant malfunction.

A malfunction or fault could damage the BlueTec® exhaust gas

gas aftertreatment system has a fault or an

aftertreatment.

The engine output may be reduced8.

Have the BlueTec® exhaust

gas aftertreatment checked as soon

as possible at a qualified specialist workshop.

Engines with BlueTec® exhaust gas aftertreatment:

When the

AdBlue®/DEF tank is filled or the fault is rectified, full engine power will be available

again. If the system check does not detect any other faults, the ; indicator lamp goes out. It may take several journeys/working cycles to complete the system check.

Breakdown assistance

BlueTec® exhaust gas aftertreatment indicator (off-highway version)

AdBlue®/DEF level low

If the AdBlue®/DEF level is too low, the system registers the following warnings:

AdBlue®/DEF level

Trigger 1:

System message

The å AdBlue®/DEF indicator lamp lights up.

Level 20% or less

Trigger 2:

The å AdBlue®/DEF indicator lamp lights up.

Level 10% or less

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

BlueTec® exhaust gas aftertreatment indicator (off-highway version)

AdBlue®/DEF level

30 minutes after trigger 2

System message

The å AdBlue®/DEF indicator lamp flashes.

The È torque limitation indicator lamp lights up.

60 minutes after trigger 2

The å AdBlue®/DEF indicator lamp flashes.

The È

torque limitation indicator lamp lights up if the torque value prior to tightening is between 80 - 50%.

The È torque limitation indicator lamp flashes if the torque value prior to tightening is less than 50%.

Breakdown assistance

AdBlue®/DEF quality not OK

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

AdBlue®/DEF quality

Trigger 3:

AdBlue®/DEF quality is not OK

60 minutes after trigger 3

180 minutes after trigger 3

System message

The å AdBlue®/DEF indicator lamp lights up.

The å AdBlue®/DEF indicator lamp flashes.

The È torque limitation indicator lamp lights up.

The å AdBlue®/DEF indicator lamp flashes.

The È

limitation indicator lamp lights up

torque if the torque value prior to tightening is between 80 - 50%.

The È torque limitation indicator lamp flashes if the torque value prior to tightening is less than 50%.

Replacing the poly-V-belt

Fault in the monitoring system

If faults occur, the system registers the following warnings:

Fault System message

Trigger 4:

AdBlue®/DEF

AdBlue®/DEF metering line or

tank

sensor missing

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

60 minutes after trigger 4

180 minutes after trigger 4

The å AdBlue®/DEF indicator lamp lights up.

The È torque limitation indicator lamp lights up.

The å AdBlue®/DEF indicator lamp flashes.

The ! indicator lamp lights up.

The È torque limitation indicator lamp lights up.

The å AdBlue®/DEF indicator lamp flashes.

The ! indicator lamp lights up.

The È

torque

if the torque value prior to tightening is over 50%.

The È torque limitation indicator lamp flashes if the torque value prior to tightening is less than 50%.

Breakdown assistance

limitation indicator lamp lights up

Replacing the poly-V-belt

If the poly-V-belt is torn or shows damage patterns (Y page 66), it must be replaced.

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.

Always carry out work on the tensioning device with extreme care.

Make sure that the tool is handled correctly.

Replacing the poly-V-belt

Breakdown assistance

Poly-V-belt routing (engine with refrigerant compressor)

Alternator

;

Tensioning pulley

Coolant pump

Refrigerant compressor

Guide pulley

Crankshaft

Releasing the poly-V-belt (example)

Fit the spanner with extension element and 15 mm socket spanner insert into the tensioning device.

Swing the tensioning pulley up and remove the poly-V-belt.

Swing back the tensioning device.

Check that both the tensioning device and the belt

pulley are in perfect condition (e.g. check for worn bearings on the tensioning device, tensioning pulley and guide pulleys as well as for wear on belt pulleys).

Replace faulty parts.

Lay the new poly-V-belt on all belt pulleys, except for the tensioning pulley (see the illustration for poly-V-belt routing).

Swing the tensioning pulley up using the lever, lay the poly-V-belt on the tensioning pulley and swing the tensioning pulley back.

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

Mercedes-Benz OM 904-926 LA BlueTec, OM 904-926 LA Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

General information

Environmental note

Operating safety and vehicle approval

Operating safety

Notes on electronic systems

Conversion parts and modifications to the engine

BlueTec® exhaust gas aftertreatment

Correct use

Transport

Installation

Information on the implied warranty

Qualified specialist workshop

Exterior view

Engine overview

At a glance

Sensors overview

General information

Description of the engine

Electronic drive control

Warning and indicator lamps

Continuous brake

Cold-start aid

Organisational measures

Safety precautions

Safety

Safety precautions

Staff qualifications

Operation

Preparation for operation

Driving mode/working mode

Starting the engine for the first time

Operational monitoring

Stopping and switching off the engine

Driving tips

Continuous brake

Running-in

Refuelling

Fuel consumption

AdBlue® consumption

Engine oil consumption

Fuels

AdBlue®/DEF

Winter operation

Bleeding the fuel system

Cold-start aids

Service products

Introduction to service products

Maintenance and care

Engine oils

Coolants

Diesel fuels

Fatty acid methyl ester (FAME) fuel (bio-diesel)

AdBlue®/DEF

Cleaning and care

Notes on care

High-pressure cleaning

Maintenance

General information

Cleaning the engine

Work schedule overview

Maintenance work overview

Notes on maintenance

Work schedules

Changing the engine oil and filter

Checking valve clearance, adjusting

Checking poly-V-belt for wear and damage.

Fuel circuit

Fuel prefilter with water separator: replacing the fuel filter

Replacing the fuel filter element

Replacing the AdBlue®/DEF filter

Engine brake - checking condition and setting

Engine cooling system

Renewing the coolant

Cleaning the cooling system

Decommissioning the engine

Decommissioning for up to 12 months