Mercedes Engine Operator Manual

Mercedes Benz
Operating Instructions
Mercedes OM 904 LA
Document No. 150-7122

2 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
Western USA & Mexico

www.rockbreaker.com 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
BREAKER TECHNOLOGY 12/2005

3
Foreword
12/2005 BREAKER TECHNOLOGY

Foreword
Foreword

5
Contents
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

Introduction
Protection of the environment

Introduction
Operating Safety
Protection of the environment

12/2005
7
Introduction
Operating safety
Correct use

8
Notes
9
1. At a glance
1. At a glance OM 904 LA overview

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

1. At a glance

11
1. At a glance
OM 906 LA/OM 926 LA overview

1. At a glance

13
1. At a glance
Location of sensors

1. At a glance
Engine number

15
2. Before commissioning
2. Before commissioning General information

Transport and installation
General information
Type designation
Engine data card

Description of the engine

17
Engine brake*/constantly-open throttle valves*

Flame-start system*

19
Grid heater
Telligent® engine system


21

Transport and installation

23
3. Safety
3. Safety Safety precautions

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

3. Safety
Staff qualifications
Conversion parts and modifications to the engine

25
3. Safety
Safety/emergency running programs

3. Safety
Genuine Mercedes-Benz parts

27
4. Operation
4. Operation 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

4. Operation

29
4. Operation

4. Operation
Starting the engine

31
4. Operation

4. Operation
Monitoring engine operation
Charge current
Oil pressure

33
4. Operation
Telligente® engine system
Flame-start system*

4. Operation
Grid heater *
Stopping the engine

35
4. Operation
Winter operation

4. Operation
Cleaning the engine

37
4. Operation
Cleaning the cooling system

4. Operation

39
4. Operation
Service Products
Diesel fuels

4. Operation
FAME fuels

41
4. Operation

4. Operation
Engine oils
Coolant

43
4. Operation

44
Notes
45
5. Maintenance
5. Maintenance Maintenance instructions

Work schedule overview
Work schedules
Maintenance instructions

5. Maintenance
Work schedule overview
Maintenance service
Additional work

47
5. Maintenance
Additional work with every third maintenance service
Work schedules
Engine: checking for leaks and general condition

5. Maintenance
Lines and hoses on the engine: checking for leaks and general condition
Engine: oil change and filter replacement

49
5. Maintenance

5. Maintenance
Adjusting the valve clearance

51
5. Maintenance

5. Maintenance
Fuel prefilter: cleaning the filter element

53
5. Maintenance
Heated fuel prefilter with water separator*: replacing the filter element

5. Maintenance
Replacing the fuel filter element

55
5. Maintenance
Intake pipe between air cleaner and engine: checking for leaks and general condition

5. Maintenance
Poly-V-belt: checking condition

57
5. Maintenance

5. Maintenance
Engine brake*: checking conditions and setting

59
5. Maintenance
Engine cooling system: checking and correcting the fluid level and the antifreeze/corrosion inhibitor

5. Maintenance
Cooling and heating system: checking for leaks and general condition

61
5. Maintenance
Renewing Coolant

62
Notes
63
6. Practical advice
6. Practical advice Malfunctions, causes and solutions

Jump-starting
Malfunctions, causes and solutions

6. Practical advice

65
6. Practical advice

6. Practical advice

67
6. Practical advice
Jump-starting

68
Notes
69
7. Technical data
7. Technical data Engine data

Test values and adjustment values
Tightening torques
Engine data

7. Technical data

71
7. Technical data
Test values and adjustment values

7. Technical data
Tightening torques

Mercedes Engine Operator Manual

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Mercedes Benz

Document No. 150-7122

Mercedes OM 904 LA Operation Manual

Canada & International

Western USA & Mexico

BREAKER TECHNOLOGY 12/2005

12/2005 BREAKER TECHNOLOGY

BREAKER TECHNOLOGY 12/2005

12/2005 BREAKER TECHNOLOGY

Protection of the environment

Protection of the environment

BREAKER TECHNOLOGY 04/2006

12/2005 BREAKER TECHNOLOGY

1. At a glance OM 904 LA overview

12/2005 BREAKER TECHNOLOGY

BREAKER TECHNOLOGY 12/2005

OM 906 LA/OM 926 LA overview

12/2005 BREAKER TECHNOLOGY

BREAKER TECHNOLOGY 12/2005

12/2005 BREAKER TECHNOLOGY

BREAKER TECHNOLOGY 12/2005

2. Before commissioning General information

Engine data card

12/2005 BREAKER TECHNOLOGY

Description of the engine

BREAKER TECHNOLOGY 12/2005

Engine brake*/constantly-open throttle valves*

12/2005 BREAKER TECHNOLOGY

BREAKER TECHNOLOGY 12/2005

Telligent® engine system

12/2005 BREAKER TECHNOLOGY

BREAKER TECHNOLOGY 12/2005

12/2005 BREAKER TECHNOLOGY

Transport and installation

BREAKER TECHNOLOGY 12/2005

3. Safety Safety precautions

12/2005 BREAKER TECHNOLOGY

Conversion parts and modifications to the engine

BREAKER TECHNOLOGY 12/2005

Safety/emergency running programs

12/2005 BREAKER TECHNOLOGY

Genuine Mercedes-Benz parts

BREAKER TECHNOLOGY 12/2005

4. Operation Starting the engine for the first time

Starting the engine for the first time

12/2005 BREAKER TECHNOLOGY

BREAKER TECHNOLOGY 12/2005

12/2005 BREAKER TECHNOLOGY

Starting the engine

BREAKER TECHNOLOGY 12/2005

12/2005 BREAKER TECHNOLOGY

Monitoring engine operation

BREAKER TECHNOLOGY 12/2005

Telligente® engine system

12/2005 BREAKER TECHNOLOGY

Stopping the engine

BREAKER TECHNOLOGY 12/2005

12/2005 BREAKER TECHNOLOGY

BREAKER TECHNOLOGY 12/2005

Cleaning the cooling system

12/2005 BREAKER TECHNOLOGY

BREAKER TECHNOLOGY 12/2005

12/2005 BREAKER TECHNOLOGY

Engine brake/constantly-open throttle valves