150 7122Meredes Benz 904 Engine Service Manual

Mercedes Benz

Operating Instructions

Mercedes OM 904 LA

Document No. 150-7122

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Mercedes OM 904 LA Operation Manual

Foreword

Mercedes OM 904 LA Operation Manual Mercedes Engine Publication Date: 1-12-2005

Foreword This component manual forms part of the Service Manual for a Breaker Technology (BTI) product. The information in this document is reprinted by BTI with permission for the sole purpose of supporting BTI products. Although every effort has been made to keep this information current, the information and data in this manual apply at time of publication as stated above. Instructions in this manual may refer to specific tools, lifting devices, and work methods. BTI does not accept responsibility for personal injury, equipment failure or damage if those specified are not used. If any information, work method or instruction in this manual is unclear, contact the component manufacturer or the nearest BTI office.

WARNING! Before attempting any service or maintenance procedure, read the Safety Section of the BTI Service manual for this vehicle.

Canada & International Phone (519) 599-2015 | (866) BTI-PART [284-7278] | Fax: (519) 599-6803 35 Elgin Street | P.O. Box 130 | Thornbury, Ontario, Canada N0H 2P0

www.rockbreaker.com

Western USA & Mexico Phone (951) 369-0878 | Fax: (951) 369-8281 3453 Durahart Street | Riverside, CA 92507 Eastern USA Phone (440) 248-7168 | Fax: (440) 248-8645 30625 Solon Industrial Parkway | Solon, OH 44139

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Foreword

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Foreword

Foreword

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Contents

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Contents Mercedes OM 904 LA............................................................1 Mercedes Engine............................................................2

Foreword........................................................................... 2 Introduction....................................................................... 6

Protection of the environment................................................6 Operating safety.....................................................................7

1. At a glance.................................................................... 9

OM 904 LA overview..............................................................9 OM 906 LA/OM 926 LA overview......................................... 11 Location of sensors..............................................................13 Engine number.....................................................................14

2. Before commissioning............................................... 15 General information..............................................................15 Transport and installation.....................................................22

3. Safety........................................................................... 23

Safety precautions...............................................................23 Staff qualifications................................................................24 Conversion parts and modifications to the engine............... 24 Safety/emergency running programs...................................25 Genuine Mercedes-Benz parts............................................26

4. Operation.................................................................... 27

Starting the engine for the first time.....................................27 Starting the engine...............................................................30 Monitoring engine operation.................................................32 Stopping the engine.............................................................34 Winter operation...................................................................35 Cleaning/protective treatment..............................................36 Service Products..................................................................39 Diesel fuels...................................................................39 Engine oils....................................................................42

5. Maintenance................................................................ 45 Maintenance instructions.....................................................45 Work schedule overview......................................................46 Maintenance service.....................................................46 Additional work with every third maintenance service.. 47 Work schedules....................................................................47

6. Practical advice.......................................................... 63 Malfunctions, causes and solutions.....................................63 Jump-starting.......................................................................67

7. Technical data............................................................. 69

Engine data..........................................................................69 Test values and adjustment values......................................71 Tightening torques................................................................72

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Mercedes OM 904 LA Operation Manual

Introduction

Introduction

Protection of the environment Operating Safety

Protection of the environment

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Introduction

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Operating safety

Correct use

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8 Notes

Mercedes OM 904 LA Operation Manual

1. At a glance

1. At a glance

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OM 904 LA overview OM 906 LA/OM 926 LA overview Location of sensors Engine number

OM 904 LA overview

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Mercedes OM 904 LA Operation Manual

1. At a glance

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1. At a glance

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OM 906 LA/OM 926 LA overview

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Mercedes OM 904 LA Operation Manual

1. At a glance

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1. At a glance

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Location of sensors

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Mercedes OM 904 LA Operation Manual

1. At a glance

Engine number

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2. Before commissioning

2. Before commissioning

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General information Transport and installation

General information Type designation

Engine data card

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2. Before commissioning

Description of the engine

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2. Before commissioning

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Engine brake*/constantly-open throttle valves*

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2. Before commissioning

Flame-start system*

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2. Before commissioning

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Grid heater

Telligent® engine system

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2. Before commissioning

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2. Before commissioning

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Mercedes OM 904 LA Operation Manual

2. Before commissioning

Transport and installation

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3. Safety

3. Safety

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Safety precautions Staff qualifications Conversion parts and modifications to the engine Safety/emergency running programs Genuine Mercedes-Benz parts

Safety precautions

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Mercedes OM 904 LA Operation Manual

3. Safety

Staff qualifications

Conversion parts and modifications to the engine

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3. Safety

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Safety/emergency running programs

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3. Safety

Genuine Mercedes-Benz parts

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4. Operation

4. Operation

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Starting the engine for the first time Monitoring engine operation Stopping the engine Winter operation Cleaning/protective treatment Service products

Starting the engine for the first time Preparation

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4. Operation

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4. Operation

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Mercedes OM 904 LA Operation Manual

4. Operation

Starting the engine

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4. Operation

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Mercedes OM 904 LA Operation Manual

4. Operation

Monitoring engine operation Charge current

Oil pressure

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4. Operation

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Telligente® engine system

Flame-start system*

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4. Operation

Grid heater *

Stopping the engine

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4. Operation

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Winter operation

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Mercedes OM 904 LA Operation Manual

4. Operation

Cleaning/protective treatment Cleaning the engine

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4. Operation

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Cleaning the cooling system

Cleaning/protective treatment

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4. Operation

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4. Operation

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Service Products

Diesel fuels

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4. Operation

FAME fuels

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Mercedes OM 904 LA Operation Manual

4. Operation

Engine oils

Coolant

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4. Operation

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5. Maintenance

5. Maintenance

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Maintenance instructions Work schedule overview Work schedules

Maintenance instructions

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Mercedes OM 904 LA Operation Manual

5. Maintenance

Work schedule overview Maintenance service

Additional work

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5. Maintenance

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Additional work with every third maintenance service

Work schedules Engine: checking for leaks and general condition

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Mercedes OM 904 LA Operation Manual

5. Maintenance

Lines and hoses on the engine: checking for leaks and general condition

Engine: oil change and filter replacement

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5. Maintenance

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5. Maintenance

Adjusting the valve clearance

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5. Maintenance

Fuel prefilter: cleaning the filter element

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Heated fuel prefilter with water separator*: replacing the filter element

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5. Maintenance

Replacing the fuel filter element

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5. Maintenance

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Intake pipe between air cleaner and engine: checking for leaks and general condition

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5. Maintenance

Poly-V-belt: checking condition

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5. Maintenance

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5. Maintenance

Engine brake*: checking conditions and setting

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5. Maintenance

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Engine cooling system: checking and correcting the fluid level and the antifreeze/corrosion inhibitor

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Mercedes OM 904 LA Operation Manual

5. Maintenance

Cooling and heating system: checking for leaks and general condition

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Renewing Coolant

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6. Practical advice

6. Practical advice

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Malfunctions, causes and solutions Jump-starting

Malfunctions, causes and solutions

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6. Practical advice

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6. Practical advice

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6. Practical advice

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6. Practical advice

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Jump-starting

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7. Technical data

7. Technical data

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Engine data Test values and adjustment values Tightening torques

Engine data

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7. Technical data

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Test values and adjustment values

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7. Technical data

Tightening torques

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