motor mercedes benz - om501 om502 em inglês

8/18/2019 Motor Mercedes Benz - Om501 Om502 Em inglês

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Bild in der Größe215x70 mm einfügen

Operating InstructionsOM501LA– OM502 LA

EU Level III A (EU 97/68 /EC)EPA TIER 3 (US EPA 40 CFR Part 89)

Order no. 6462981102 Part no. 541 58416 81 EN Edition A, 01/06

5415841681


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Symbols

* Opt ional equip ment

G WarningH Environmental note! Possible vehicle damage

i Tip

Action required

Sequence of actions (several )

Continuation symbol

Continuation symbol for a warning

page Page reference

-> Term in the glossary of technicalterms

Display Displays in the multi-functiondisplay

Internet

Further information aboutMercedes-Benzvehicles andabout DaimlerChrysler AG can befound on the following websites:

www.mercedes-benz.comwww.daimlerchrysler.com

Editorial office

You are welcome to forward any queriesor suggestions you may have regardingthese Operating Instructions to thetechnical documentation team at thefollowing address:

DaimlerChrysler AG, Abt. SVI, HPC: E124,D-70546 Stuttgart, Germany

As at: 01.12.2005

Not to be reprinted, translated orotherwise reproduced, in whole or in part,without the written permission ofDaimlerChrysler AG.


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Thank you for choosing thisMercedes-Benz engine.

Make sure that you read the OperatingInstructions before using the engine forthe first time. This will help you to makeoptimum use of the engine and avoid en-

dangering yourself and others.

Since the scope of delivery varies depend-ing on each specific order, the equipmentof your engine may differ from certaindescriptions and illustrations in these Op-erating Instructions. These OperatingInstructions also describe items of option-

al equipment where their operation re-quires explanation.

DaimlerChrysler reserves the right to makechanges to design, equipment and tech-nology. You cannot, therefore, base anyclaims on the data, illustrations or descrip-tions in these Operating Instructions.

Your nearest Mercedes-Benz Service Cen-

tre will be happy to assist you furthershould you have any more queries.

The Operating Instructions and Mainte-nance Booklet are an integral part of theengine. You should therefore always keepthem with the engine and pass them onto the new owner if you sell it.


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Contents

i P lease also refer to the index ( page 117) Introduction

Protection of the environment . . . . . 5Operating safety . . . . . . . . . . . . . . . . . 6

Correct use . . . . . . . . . . . . . . . . . . . 7

1 At a glance

OM 501 LA overview . . . . . . . . . . . . 10OM 502 LA overview(2 turbochargers) . . . . . . . . . . . . . . . 14OM 502 LA overview(1 turbocharger) . . . . . . . . . . . . . . . . 18Location of sensors . . . . . . . . . . . . . 22Engine number . . . . . . . . . . . . . . . . . 24

2 Before commissioning

General information . . . . . . . . . . . . . 26Type designation . . . . . . . . . . . . . . 26Engine data card . . . . . . . . . . . . . . 26Description of the engine . . . . . . . 27Flame-start system* . . . . . . . . . . . 27Engine brake*/constantly-openthrottle valves* . . . . . . . . . . . . . . . 29Telligent ® engine system . . . . . . . . 30

Transport and installation . . . . . . . . 34

3 Safety

Safety precautions . . . . . . . . . . . . . . 38Staff qualifications . . . . . . . . . . . . . . 39Conversion parts andmodifications to the engine . . . . . . . 40Safety/emergency runningprograms . . . . . . . . . . . . . . . . . . . . . . 41Genuine Mercedes-Benz parts . . . . . 42

4 Operation

Starting the engine for thefirst time . . . . . . . . . . . . . . . . . . . . . . 44

Preparation . . . . . . . . . . . . . . . . . . 44Starting the enginefor the first time . . . . . . . . . . . . . . . 46Starting the engine . . . . . . . . . . . . 49

Monitoring engine operation . . . . . . 51Charge current . . . . . . . . . . . . . . . . 51Telligent ® engine system . . . . . . . . 51

Oil pressure . . . . . . . . . . . . . . . . . . 52Flame-start system* . . . . . . . . . . . 52

Stopping the engine . . . . . . . . . . . . . 53Winter operation . . . . . . . . . . . . . . . . 54


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Contents

Cleaning/protective treatment . . . 56Cleaning the engine . . . . . . . . . . . . 56Cleaning the cooling system . . . . . 57Protective treatment . . . . . . . . . . . 59

Service products . . . . . . . . . . . . . . . . 60Diesel fuels . . . . . . . . . . . . . . . . . . 61FAME fuels . . . . . . . . . . . . . . . . . . . 63Engine oils . . . . . . . . . . . . . . . . . . . 65Coolant . . . . . . . . . . . . . . . . . . . . . 66

5 Maintenance

Maintenance instructions . . . . . . . . 70Work schedule overview . . . . . . . . . 71

Maintenance service . . . . . . . . . . . 71Additional work . . . . . . . . . . . . . . . 71Additional work with everythird maintenance service . . . . . . . 71

Work schedules . . . . . . . . . . . . . . . . . 72Engine: checking for leaks andgeneral condition . . . . . . . . . . . . . . 72

Lines and hoses on the engine:checking for leaks and generalcondition . . . . . . . . . . . . . . . . . . . . 72

Engine: oil change and filterreplacement . . . . . . . . . . . . . . . . . . 73Adjusting the valve clearance . . . . 76Fuel connections . . . . . . . . . . . . . . 80Heated fuel prefilter with waterseparator*: replacing the filterelement . . . . . . . . . . . . . . . . . . . . . 81Replacing the fuel filterelement . . . . . . . . . . . . . . . . . . . . . 82Intake pipe between air cleanerand engine: checking for leaksand general condition . . . . . . . . . . 85Poly-V-belt: checking condition . . . 85Engine brake*: checking

condition and adjustment . . . . . . . 89Engine cooling system: checkingand correcting the fluid level and theantifreeze /corrosion inhibitor . . . . 90Cooling and heating system:checking for leaks and

general condition . . . . . . . . . . . . . . 91Renewing coolant . . . . . . . . . . . . . 94

6 Practical advice

Malfunctions, causes andsolutions . . . . . . . . . . . . . . . . . . . . . . . 98

Jump-starting . . . . . . . . . . . . . . . . . . 106

7 Technical data

Engine data . . . . . . . . . . . . . . . . . . . 108Test values and adjustmentvalues . . . . . . . . . . . . . . . . . . . . . . . . 113Tightening torques . . . . . . . . . . . . . 114

8 Glossary

Index . . . . . . . . . . . . . . . . . . . . . . . . . 117


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5

Introduction

Protection of the environment

Environmental note HDaimlerChrysler’s declared policy is one ofintegrated environmental protection. Thispolicy starts at the root causes and encom-passes in its management decisions all theconsequences for the environment which

could arise from production processes orthe products themselves.

The objectives are for the natural resourceswhich form the basis of our existence on thisplanet to be used sparingly and in a mannerwhich takes the requirements of both natureand humanity into account.

Operate the engine in an environmentally-responsible manner and you will help to pro-tect the environment.

Fuel consumption and engine wear depend

on the operating conditions.Therefore:

do not warm up the engine at idle speed

switch off the engine during periods instationary traffic

monitor fuel consumptioncarry out the specified maintenancework regularly


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6

Introduction

Operating safety

The operating safety of an engine primarilydepends on its proper installation in thesystem as a whole (e.g. vehicle, machine,etc.). However, as the operator, you alsohave a direct influence on the safe opera-tion of the engine.

Some of the requirements for operatingthe engine safely can be met by adheringto the specified maintenance intervals andensuring that the required maintenancework is carried out correctly.

However, the safe functioning of the en-gine also depends on correct operation,which includes, for instance, checking theengine oil level at regular intervals.

Risk of accident GEngine damage arising from incorrect oper-ation could result in an accident.

Therefore, observe the notes on operating

the engine in these Operating Instructions.

Risk of accident GMaintenance work that is carried out incor-

rectly or not at all, and the failure to observethe specified maintenance intervals, mayreduce the service life of the engine andcause engine damage, which could result inan accident.

Therefore, observe the notes on engine

maintenance in these Operating Instruc-tions.


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7

Introduction

Operating safety

The engine is only designed for installationin accordance with the specifications de-fined in the contract.

The manufacturer of the end product ispersonally responsible for the completesystem, and in particular for the correct in-stallation and compatibility of this enginewith the rest of the system.

The engine must not be modified.DaimlerChrysler accepts no responsibilityfor damage caused as the result of modifi-cations.

Correct use of the engine includes adher-ing to these Operating Instructions, ad-hering to the maintenance intervals andperforming maintenance work correctly in

accordance with these Operating Instruc-tions.

Risk of accident GWork incorrectly carried out on electroniccomponents and their software could impairthe functioning of these components. Sincethe electronic systems are networked, this

might also affect systems that have notbeen modified.

For this reason, always have work on, ormodifications to, electronic componentscarried out at a qualified specialist work-shop.

DaimlerChrysler recommends that you usea Mercedes-Benz Service Centre for thispurpose as it has the necessary specialistknowledge and tools for the work required.

Correct use


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8


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9

1

At a glance

OM 501 LA overview

OM 502 LA overview (2 turbochargers)

OM 502 LA overview (1 turbocharger)

Location of sensors

Engine number


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10

At a glance

OM 501 LA overview

1


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11

At a glance

OM 501 LA overview

11 Coolant pump2 Charge pressure pipe from intercooler(with flame-start system*)

3 Charge pressure pipe to the intercooler4 Oil filler opening5 Exhaust gas turbocharger

6 Oil trap crankcase ventilation system7 Flue pipe (with engine brake throttlevalve*)

8 Oil filter9 Fuel filtera Starter motorb Dipstick


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12

At a glance

OM 501 LA overview

1


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13

At a glance

OM 501 LA overview

11 Oil pan2 MR (engine control) unit3 Flywheel housing4 Exhaust manifold5 Fuel pump (with flanged power steering

pump*)

6 Air compressor*7 Resonator* (only in conjunction withair compressor)

8 START/ STOP buttons9 Alternator


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14

At a glance


1

OM 502 LA with two turbochargers

A l


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15

At a glance



3 Charge pressure pipe to the intercooler4 Oil filler opening5 Turbocharger

6Oil trap crankcase ventilation system

7 Flue pipe (with engine brake throttlevalve*)

8 Oil filter9 Fuel filtera Starter motorb Dipstick

At l


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16

At a glance


1

At a glance


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17

At a glance


11 Oil pan2 MR (engine control) unit3 Flywheel housing4 Exhaust manifold5 Fuel pump (with flanged power

steering pump*)6 Air compressor*7 Resonator* (only in conjunction

with air compressor)8 START/ STOP buttons9 Alternator

At a glance


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18

At a glance


1

OM 502 LA with one turbocharger

At a glance


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19

At a glance



3 Charge pressure pipe to the intercooler4 Intake opening (from air cleaner)5 Exhaust gas turbocharger6 Oil trap crankcase ventilation system7 Oil filler opening8 Oil filter9 Fuel filtera Starter motorb Dipstick

At a glance


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20

At a glance


1

At a glance


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21

At a glance


11 Oil pan2 MR (engine control) unit3 Flywheel housing4 Exhaust manifold5 Fuel pump (with flanged power

steering pump*)6 Air compressor*7 START/ STOP buttons8 Alternator

At a glance


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22

g

Location of sensors

1

Example OM 501 LA

At a glance


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23

g

Location of sensors

11Oil level sensor

2 Crankshaft position sensor(on the flywheel)

3 TDC sensor (on the camshaft sprocket)4 Fuel temperature sensor5 Combined charge-air pressure/

temperature sensor6 Coolant temperature sensor7 Oil pressure sensor8 Oil temperature sensor

At a glance


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24

Engine number

1

Location

The engine number is located on the left-hand side of the engine, behind the lastcylinder on the engine block.

Location of the engine number on the rearleft-hand side

The engine number is also located on the

front of the oil filter housing.

Location of the engine number on the left-hand side of the fan

Information on the engine

As well as the manufacturer’s specifica-tions, the following data is listed:

Information on the engine

1 Engine model designation2 Engine number3 Type approval number4 Engine group


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Before commissioning


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28

General information

2

Flame-start system indicator lamp(example)

Following the preglow time, which is de-pendent on the outside temperature (max-

imum 20 seconds), the flame-start systemis activated and the flame-start indicatorlamp goes out.

Once the engine has been started, theflame-start system is supplied with fuel bythe fuel pump.

The flame-start system is only enabled if

the engine is started within 30 seconds ofthe flame-start system indicator lamp go-ing out.

iIf the flame-start system indicator lamp

does not go out after more than 20 sec-onds, there is a malfunction in theflame-start system.

iFor operation at low outside temper-atures, see also the “ Diesel fuels ”( page 61) and “ Coolant ”( page 66) sections.



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29

General information

2To increase the braking power, the enginescan be equipped with an exhaust brakevalve on the exhaust gas turbocharger inconjunction with constantly-open throttlevalves on the cylinders.

Whereas exhaust gas backpressure, actingthrough the exhaust brake valves, can beused to increase the braking power,the constantly-open throttle valves causea reduction of compression in the power

stroke (3rd stroke), leaving compression(2nd stroke) practically unaffected.

The constantly-open throttle valves arevalves in the cylinder head. When open,they connect the combustion chamberto the exhaust duct, which generates the

required decompression in the powerstroke.

Activation of the constantly open throttlevalves

When the engine brake is activated, theconstantly-open throttle valves are opened

by compressed air. At the same time, theexhaust brake valve on the exhaust gasturbocharger is closed.

The engine brake is controlled by the drivecontrol unit ( page 32) or the ADM.

The engine brake always remains deacti-

vated at engine speeds of below 900 rpmto prevent the engine from stalling. Theengine brake is also automatically deacti-vated if the position sensor is triggered(e.g. if the accelerator pedal is depressed).

Engine brake*/constantly-openthrottle valves*

iIn the emergency running program(constant engine speed), the enginebrake can only be activated in overrunmode at an increased engine speed.The engine brake is automatically deac-

tivated again once a constant enginespeed has been reached.



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General information

2

The engine has a fully electronic controlsystem, which, in addition to the engineand associated sensors, also comprises:

an MR (engine control) unit and

an FR (drive control) unit and /or othervehicle-specific control units, e.g. ADM

Both are interconnected via a CAN (Con-troller Area Network) line, on which all thenecessary data/information is exchanged.

The engine control monitors itself as well

as the engine. A safety and emergency run-ning program is selected automatically,depending on the malfunctions/systemfailures that occur ( page 41).

MR (engine control) unit (mounted on

the engine)The MR (engine control) unit is mounted onthe right-hand side of the engine.

MR (engine control) unit

The MR (engine control) unit processes

data from the drive control unit or theADM, indicating for example the positionof the position sensor (accelerator pedal),the engine brake* or engine start/stop,etc.

Telligent ® engine system



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General information

2

This data is evaluated along with data from

the sensors on the engine, such as thosefor:

charge-air pressure and temperature

coolant temperature

fuel temperature

oil pressure

The data is compared with the maps andcharacteristic curves stored in the enginecontrol unit.

Injection timing, period and volume arecalculated based on these comparisonsand the solenoid valves are actuated toadjust the unit pumps accordingly.

Control unit type plate

1 Data record2 Certification no.3 Engine number

4 Equipment code

iAll the information on the control unittype plate is required to obtain a re-placement engine control unit.



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32

General information

2

FR (drive control) unit or ADM (mounted

on the equipment)The engine can be adapted to meet variousapplication-specific requirements bymeans of the drive control unit or adapta-tion module (ADM).

FR (drive control) unit

The FR (drive control) unit or the ADM

stores a range of application-specific data,such as idling speed, maximum workingspeed or speed limitation.

The FR (drive control) unit or the ADM re-

ceive data from the:operator (position of the position sen-sor, engine start/stop)

engine brake switch*

other systems (e.g. acceleration skid

control system)MR (engine control) unit (e.g. oil pres-sure and coolant temperature)

This data is used to determine the instruc-tions for engine control (MR control unit),

which are then sent to the engine controlon the CAN line.

The FR (drive control) unit or the ADM con-trols various displays, e.g. the electronicswarning lamp, the engine brake* and theconstantly-open throttle valves*.

If the Telligent ® engine system detects a

fault, this is stored in the control units as afault code, which can then be read usingappropriate diagnostic equipment (STARDIAGNOSIS or minidiag2).

In addition, the electronics warning lamplights up.

iThe DaimlerChrysler diagnostic equip-ment can be connected to the equip-ment-mounted 14-pin diagnostic sock-et or using the EU-compliant service

connector. This equipment can be usedto read both the malfunction memoryand the stored engine data.



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33

General information

2

Diagnostic socket

EU-compliant service connector

Organisational measures

The Operating Instructions and Mainte-nance Booklet must be given to the per-sonnel responsible for operating or car-rying out work on the engine, and shouldbe kept in an easily accessible locationwhere the engine is used.

These Operating Instructions must be usedto instruct personnel how to handle the en-gine. In particular, the notes concerningsafety must be explained. This is especiallyimportant for personnel who only work onthe engine occasionally.

All universally applicable, country-specific,legal and other mandatory regulations foraccident prevention and protection of theenvironment must be observed in additionto these Operating Instructions.

Risk of injury GBefore operating the engine, please readthese Operating Instructions and other rele-vant documentation, such as the operatinginstructions for the vehicle or the machinethe engine is installed in.

You could otherwise fail to recognise dan-gers and could injure yourself or others.


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T t d i t ll ti


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35

Transport and installation

2

Installation

The engine is only designed for installationin accordance with the specifications de-fined in the contract.

The manufacturer of the end product ispersonally responsible for the complete

system, and in particular for the correct in-stallation and compatibility of this enginewith the rest of the system.

Observe the “Correct use” ( page 7) and“Conversion parts and modifications to theengine” ( page 40) sections.

The “Technical data” section of theseOperating Instructions contains informa-tion required for the installation of theengine.

Please consult a Mercedes-Benz ServiceCentre if you have any questions.

iThe engine is filled with engine oil atthe factory.


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36

Safety

Safety precautions


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37

3

Safety precautions

Staff qualifications

Conversion parts and modifications to the engineSafety/emergency running programs

Genuine Mercedes-Benz parts

Safety

Safety precautions


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38

Safety precautions

3

The safety precautions in this section must

be observed to prevent injury to anybodyand damage to the engine, componentsand cable harness.

!Do not start the engine unless thebatteries are securely connected.

Do not disconnect the batterieswith the engine running.

Do not use a rapid charger to startthe engine.

Only perform jump-starting withseparate batteries.

Note that the battery terminalsmust be removed for rapid batterycharging. Observe the rapid chargeroperating instructions.

!Note that for electric welding work,the batteries must be disconnectedand both cables (“+” and “–”)securely connected to each other.

The connectors for control unitsmust not be disconnected or con-nected unless the electrical systemis switched off.

Incorrect polarity in the control unitpower supply (e.g. caused by in-correct battery polarity) can cause

irreparable damage to the controlunits.

Tighten the connections on the fuel-injection system to the specifiedtightening torque.

!The control units must be removedif temperatures of over 80 °C(e.g. in the drying oven) are ex-pected.

Only use suitable test leads(e.g. DaimlerChrysler connectionset) for taking measurements atconnections.

Telephones and two-way radiosthat are not connected to an exteri-or aerial can cause malfunctions in

the vehicle electronics system andthereby jeopardise the operatingsafety of the engine.

Safety



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3

Staff qualificationsEngines may only be operated, maintainedand repaired by trained personnel instruct-ed and authorised by the operator.

The responsibilities for operation, mainte-nance and repairs must be assigned by theoperator.

The legal minimum age for carrying out thework listed above must be observed.

Risk of accident GMaintenance and repair work to the enginecarried out incorrectly can impair both itscorrect operation and safety, leading to ac-cidents and injury.

Always have work on or modifications to theengine carried out at a qualified specialistworkshop which has the necessary special-ist knowledge and tools for the work re-quired.

Mercedes-Benz recommends that you use aMercedes-Benz Service Centre for this pur-pose.

Safety

Conversion parts and modifications to the engine


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40

Conversion parts and modifications to the engine

3

The warranty does not cover damage aris-ing from tampering with the engine.Risk of accident G

Tampering with the engine to modify it canimpair both its correct operation and itssafety, leading to accidents and injury.

Always have work on or modifications to theengine carried out at a qualified specialistworkshop which has the necessary special-ist knowledge and tools for the work re-quired.

Mercedes-Benz recommends that you use aMercedes-Benz Service Centre for this pur-pose.

!Tampering with the fuel-injection sys-tem and engine electronics may affect

the performance and emission levels ofthe engine. It would no longer be possi-ble to guarantee compliance with fac-tory settings or legal environmentalprotection conditions.


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Safety

Genuine Mercedes-Benz parts


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42

p

3

Make sure that the replacement parts are

suitable for your engine. Parts that lead toan engine/vehicle modification that:

changes the type of machine/vehicleapproved in the General OperatingPermit

poses a potential risk to road users, or

causes a deterioration in exhaust gasemission levels or noise levels

will result in the invalidation of the GeneralOperating Permit (in many countries). Theuse of non-approved parts can jeopardise

safety.

Additional information about recommend-

ed conversion parts and accessories andpermissible technical modifications isavailable from any Mercedes-Benz ServiceCentre.

Always quote the engine number and mod-el designation when ordering genuine

parts. You will find the numbers on the en-gine plate ( page 24) and on the enginedata card ( page 26).

Environmental note HTo combine cost-effective repairs with recy-cling, Mercedes-Benz also offers recondi-tioned engines and parts. These are of thesame quality and have the same warranty asnew parts.

Operation

Starting the engine for the first time


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43

4

Monitoring engine operation

Stopping the engineWinter operation

Cleaning/protective treatment

Service products

Operation



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44

4

When it leaves the factory, the engine isfilled with an engine oil complying withSheet 228.5 of the Mercedes-Benz Specifi-cations for Service Products.

These high-quality engine oils assist therunning-in process, enabling the first oilchange to take place in accordance withthe specified oil change intervals for nor-mal operation. This eliminates the need forspecial initial operation oils and the oilchange otherwise required.

The extended maintenance intervals canonly be observed if engine oils complyingwith Sheet 228.5 of the Mercedes-BenzSpecifications for Service Products areused.

1 Oil filler opening

Check the oil level and, if necessary,add engine oil via filler opening 1 upto the maximum mark on the dipstick( see page 74) .

Adding coolant

Coolant composition ( see page 66) .Filling the cooling system( see page 94) .

Preparation

Operation



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4

Refuelling

Use summer or winter fuel depending onthe season. See also “Diesel fuels”( page 61).

Bleeding the fuel system

If the fuel system is run dry, the system willbe bled the next time the engine is startedafter refuelling. Automatic continuousbleeding takes place in the filter.

Checking the batteries

Only use batteries that have been correctlyfilled and maintained. Grease the batteryterminals with acid-proof grease (batteryterminal grease).

!When refuelling do not allow water to

enter the tank, contaminating the fuel.

iThe battery must be sufficientlycharged during the starting procedureto ensure that the fuel system can be

bled.

iBleed the heated fuel prefilter with wa-ter separator* mounted on the vehicleor machine with the integrated handpump.

Risk of injury GThe acid contained in batteries burns skinand eyes on contact.

Do not allow acid to come into contactwith your skin, eyes or clothing.

Wear suitable protective clothing, asbattery acid can burn through normalclothing. In addition, protective glovesand safety goggles should be worn.

Rinse acid splashes off immediately withclean water and consult a doctor if nec-essary.

Risk of explosion GGases leaking from batteries may explodeand therefore cause injury.

Fire, naked flames, smoking and sparks aretherefore not permitted in the vicinity of the

batteries.

iThe cable cross-sections are depend-ent on the distance between the bat-tery and the starter motor.

Operation



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46

4

Carry out the work listed under “Prepara-tion” ( page 44) before operating the en-gine for the first time.

Switch on the operating current.

Start the engine with the position sen-

sor (e.g. accelerator pedal) in the idlingposition, e.g. by pressing START button1 on the engine ( see page 49) .

Start/stop buttons

1 START button2 STOP button

Starting the engine for the first time iFor additional safety, the Telligent ® en-gine system is equipped with a functionthat only allows the engine to be start-ed with the transmission in neutral.

Risk of injury GThe engine becomes very hot while it is run-ning and remains so for some time after ithas stopped. It will cause burns if touched.

Before starting any work on the engine, al-low all engine parts to cool down or elsewear suitable gloves and items of clothing toprotect yourself against hot engine compo-nents.

Operation



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47

4

To check the coolant level:

Run the engine at moderate speeds forabout 5 minutes.

If the coolant temperature is below50 °C, check the coolant level againand add coolant if necessary.

Risk of injury GThere is a danger of limbs being caught, en-trapped, crushed or torn off by rotating en-gine parts. Therefore you should:

Keep a safe distance between yourselfand rotating engine parts, includingwhen the engine is being started.

Wait until all engine parts have stoppedmoving before carrying out any work onthe engine.

Wear work clothing which is fastenedand close-fitting. Wear a hair net ifnecessary. Remove jewellery such aswatches and necklaces.

Risk of injury GThe cooling system is pressurised. Hot cool-ant can escape under pressure when thecooling system is opened and scald yourskin and eyes.

Only open the cooling system at coolanttemperatures below 90 °C.

Unscrew the cap slowly and release anyexcess pressure completely beforeopening the cap fully.

Wear suitable protective gloves, protec-tive clothing and safety goggles whenhandling coolant.

Risk of poisoning GThere is a risk of poisoning if coolant is swal-lowed.

Never swallow coolant.

Never store coolant in containers nor-mally used for drinks.

Store coolant out of the reach of chil-dren.

Operation



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48

4Only close the heating system valves oncethe engine has been running for a brief pe-riod and, where applicable, the coolant hasbeen topped up.

Check the engine for leaks.

Check the hose fittings, hose clampsand pipe connections on the engine aswell as the oil feed and return lines onthe exhaust gas turbocharger for leaks

and firm seating, and retighten if nec-essary.

Check the engine oil level approximate-

ly 5 minutes after stopping the engineand add oil up to the maximum mark onthe dipstick if necessary.

Check brackets secured to the enginefor firm seating.

Check the securing bolts on the ex-haust manifold, engine mountings,coolant pump, starter motor and aircompressor for tightness.

iIf a heating system is connected to thecooling system, all heating systemvalves must be opened while the cool-ing system is being topped up.

Otherwise, there might be too littlecoolant in the cooling system after it isfilled.


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Operation



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50

4

To start the engine using the START button

on the machine or on the engine:

Start/stop buttons

1 START button

2 STOP buttonOn the engine: press START button 1 on the engine.

Monitor the oil pressure gauge immedi-ately after starting the engine.

If the vehicle is equipped with a flame-start

system*:Wait until the flame-start system* indi-cator lamp goes out.

Start the engine within 30 seconds us-ing the START button on the machineor engine.

!Keep the engine running at idling speeduntil an oil pressure reading is dis-played (do not rev the engine). If no oilpressure is displayed after approxi-

mately 10 seconds, switch off the en-gine. Determine the cause( page 52) .If necessary, interrupt the starting pro-cedure after a maximum of 20 seconds,and then repeat after approximately

1 minute.The charge current indicator lamp andelectronic system warning lamp mustgo out after the engine has started. Ifthey remain lit, this indicates that thereis a malfunction; ( see page 51) and

( page 51) .

iDepending on the outside temperature,the flame-start system* indicator lamplights up:

from approximately 2 seconds(function check, flame-start systemnot in operation)

to approximately 20 seconds(maximum preglow time)

If the flame-start system* indicatorlamp does not go out after 20 seconds,there is a malfunction.

Do not place the cold engine under fullload immediately.

Operation


M it i i ti


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

Charge current indicator lamp

If the indicator lamp does not go out or if itlights up when the engine is running, stopthe engine and check the poly-V-belt.

The electronic system warning lamp mustgo out after the engine has started.

If the warning lamp does not go out or if itlights up while the engine is running, thereis a malfunction in the Telligent ® enginesystem.

Each malfunction is stored in the systemwith its own fault code. Temporary faultsare also stored.

Electronic system warning lamp

Fault codes can be read usingDaimlerChrysler diagnostic equipment(STAR DIAGNOSIS or minidiag2 tester)( see page 32) . If the electronic systemwarning lamp lights up while the engine isrunning, read or determine the fault code.

Charge current !Make sure that the poly-V-belt contactsurfaces are not damaged (e.g. torn),oily or glazed as this could cause thepoly-V-belt to slip.

Do not run the engine without a poly-V-

belt. The alternator and coolant pumpwould not be driven, which would resultin engine damage.

Telligent ® engine system

Operation



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There is a malfunction in the flame-startsystem if:

the flame-start system indicator lamplights up while the engine is running

the indicator lamp does not go outwithin 20 seconds of the engine beingstarted

Flame-start system indicator lamp(example)

Oil pressure

!After the engine has reached normaloperating temperature, the engine oilpressure must not fall below:

2.5 bar at rated speed

0.5 bar at idling speed

If the oil pressure falls below these val-ues, stop the engine and trace thecause.

Flame-start system*

iThe flame-start system is automaticallydeactivated if:

the engine is not started within30 seconds of the flame-start sys-tem indicator lamp going out

the engine is started when theflame-start indicator lamp is lit

the charge current indicator lampdoes not go out while the engine isrunning

the engine reaches a temperatureat which the flame-start system isno longer required

Operation

Stopping the engine

Stopping the engine


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Stopping the engineRun the engine at idling speed for one

or two minutes without load after oper-ation at full power or a high coolanttemperature.

Start/stop buttons1 START button2 STOP button

Press STOP button 2 on the engine or

on the machine-mounted engine shut-down facility.

!Stop the engine immediately if any ofthe following occur:

significant drops or fluctuations inoil pressure

falling power output and enginespeed with the position sensor(accelerator pedal) in the sameposition

large amounts of exhaust smokeemitted from the exhaust

significant increases in coolant andoil temperature

sudden, unusual noises from theengine or exhaust gas turbocharger

Operation

Winter operation


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The following points should be observed at

the start of the cold season:

Fuel

Use cold-resistant diesel fuel( see page 61) .

Jump-starting

Engine oil

When changing the engine oil, select anengine oil that is compatible with the SAEclassification and the ambient tempera-tures expected during the period of use( see page 65) .

Coolant

Risk of fire GFuel is highly flammable. For this reason,avoid fire and naked flames and refrain fromsmoking when handling fuel.

Risk of explosion GThe use of liquid or gaseous jump-startingequipment can cause explosions. This mayresult in severe injuries.

Do not use liquid or gaseous jump-starting equipment, such as ether orStartpilot to start the engine.

Risk of injury GThe cooling system is pressurised. Hot cool-ant can escape under pressure when thecooling system is opened and scald your

skin and eyes.




Operation

Winter operation


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Check the antifreeze protection propertiesof the coolant in good time and increasethe antifreeze/corrosion inhibitor concen-tration if necessary ( see page 66) .

Batteries

Have the batteries serviced and rechargedmore frequently during the cold months ofthe year.

Careful maintenance and low power con-sumption will help to maintain the full bat-tery charge. Starting capacity is greatlyreduced in cold weather; at –10 °C, for ex-ample, it is only around 60% of normal ca-pacity. If the engine is not used for a longperiod of time, store the batteries in aheated place if possible. Ensure good ven-tilation when recharging.





Risk of injury GThe acid contained in batteries burns skinand eyes on contact.

Do not allow acid to come into contactwith your skin, eyes or clothing.

Wear suitable protective clothing, as

battery acid can burn through normalclothing. In addition, protective glovesand safety goggles should be worn.

Rinse acid splashes off immediately withclean water and consult a doctor if nec-essary.

Risk of explosion GGases leaking from batteries may explodeand therefore cause injury.

Fire, naked flames, smoking and sparks aretherefore not permitted in the vicinity of the

batteries.

Operation



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Cleaning the engine

Risk of poisoning GCare and cleaning agents can be toxic andlead to severe poisoning if swallowed.

Always keep care and cleaning agentcontainers closed and out of the reachof children.

Never store care or cleaning products incontainers for comestibles such as bot-tles so as to avoid confusion.

Observe the instructions for using careand cleaning products.

Risk of fire and injury G

Fuels are highly flammable and can consti-tute a health hazard. If they are used ascleaning agents, they can cause burns orskin irritation and poisoning.

Never use fuels for cleaning.

Environmental note HObserve the regulations for environmentalprotection.

Only clean the engine in a washing area de-signed for this purpose. Dispose of emptypackaging and used cleaning materials in anenvironmentally-responsible manner.

!

Make sure that water does not enterthe intake, ventilation or bleed ducts.

Protect the engine after cleaning. Becareful to protect the belt drive fromexposure to preservative agents.

iInformation about suitable cleaningand preservative agents is availablefrom any Mercedes-Benz Service Cen-tre.

Operation



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High-pressure cleaners

Observe the manufacturer’s operating in-structions.

Blow out any foreign objects (dust, in-sects, etc.) from the radiator fins usingcompressed air or remove them byspraying water from the rear side of the

radiator (against the direction of thecooling air flow).

!Maintain the minimum distance be-tween the high-pressure cleaner nozzle

and the object to be cleaned:approximately 70 cm for round-spray jets

approximately 30 cm for 25° flat-spray jets and concentrated power

jets

Keep the water jet moving constantlywhile cleaning. To avoid damage, donot aim the water jet directly at:

electrical components

connectors

seals or

hoses

Cleaning the cooling system

Environmental note HCollect used coolant, cleaning solutions anddetergents and dispose of them in an envi-ronmentally responsible manner in accord-

ance with relevant local regulations.

!Only apply moderate pressure whencleaning since the radiator fins could

otherwise be damaged.




Wear suitable protective gloves, protec-

tive clothing and safety goggles whenhandling coolant.

Operation



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Drain off coolant when the engine iscold ( page 94).

If a heater is connected to the coolingsystem, open the regulating valvesfully.

Degreasing

Fill the cooling system with a 5% solu-tion of water and a mild alkaline clean-er, e.g. “P3 Croni” (50 g cleaning agentper litre of water).

Warm the engine up to approximately80 °C (coolant thermostat starts toopen) at a moderate engine speed andallow it to run for approximately 5 min-utes longer.

Switch off the engine and allow it tocool to approximately 50 °C.

Drain off the cleaning solution com-pletely.

Immediately afterwards, fill the coolingsystem with clean water, warm up theengine, and drain off the water after5 more minutes. Then repeat the pro-cedure a second time.

Fill the cooling system with new cool-ant ( page 95) and observe the notesin the “Coolant” section ( page 66) .



Never store coolant in containers nor-

mally used for drinks.Store coolant out of the reach of chil-dren.


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Operation

Service products


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Greases and lubricants must be com-patible with engine components. Forthis reason, only brands that have beentested and approved by DaimlerChryslermust be used. These are listed in theMercedes-Benz Specifications for Service

Products.

Special lubricant additives are not neces-

sary. The use of special lubricant additivesmay limit your warranty entitlement.

Risk of poisoningand injury GService products can cause injury or poison-ing if they come into contact with skin or areswallowed.

Observe the relevant regulations when han-dling, storing and disposing of service prod-ucts. Service products could otherwiseendanger people and the environment.

Always wear appropriate protectiveclothing and a breathing mask when

handling service products. Avoid inhal-ing vapours where possible.

Do not allow service products to comeinto contact with your skin, eyes orclothing. Clean affected areas of skinwith soap and water.

If service products do come into contactwith your eyes, rinse them thoroughlywith clean water and consult a doctor ifnecessary.

Consult a doctor immediately if a serv-ice product is swallowed.

Keep service products out of the reachof children.

Risk of fire GThere is an increased risk of fire when han-

dling fuels and lubricants as they are highlyflammable.

Avoid fire, naked flames and sparks, and re-frain from smoking when handling serviceproducts.

iInformation about service products isavailable from any Mercedes-Benz

Service Centre.

Environmental note HDispose of service products and parts thatcome into contact with service products,e.g. filters, in an environmentally-responsi-ble manner.

Observe legal requirements.

Operation

Service products

Di l f l i l ld h If di l f l l ld i


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Only use commercially available dieselfuels (EN 590). The use of other fuelsis subject to official approval fromDaimlerChrysler.

Fuel additives are not necessary. The useof fuel additives may limit your warrantyentitlement.

If diesel fuels with a sulphur content ofmore than 0.3% by weight are used, the en-gine oil must be changed at shorter inter-vals. Observe the information in the

Maintenance Booklet.Filling the vehicle’s fuel tank from drums orcanisters may introduce impurities into thefuel system. This can lead to fuel systemmalfunctions. The fuel must therefore befiltered when filling the tank.

The fuel must not be mixed with water un-der any circumstances.

Diesel fuels in extremely cold weather

At low outside temperatures, paraffin sep-aration may affect the flow characteristicsof diesel fuel.

To prevent operating problems (e.g. as aresult of blocked filters), diesel fuels withimproved cold flow properties are availableon the market in the winter months. Devia-tions are possible in individual countriesand in the transition between the cold andwarm seasons. In Germany, special cold-resistant winter-grade diesel fuels areavailable that ensure reliable operation

down to approximately –20 °C. Winter-grade diesel fuel can normally be usedwithout risk of malfunctions at the outsidetemperatures to be expected in the coun-try of sale.

If summer diesel fuel or less cold-resistantwinter diesel fuel is used, only add a specif-ic quantity of flow improver or kerosenesuitable for the outside temperatures.

Diesel fuels

Risk of explosion G

Adding petrol reduces the flash point for thediesel fuel and increases the risk of fire andexplosion.

For this reason, do not mix petrol withthe diesel fuel under any circumstances.

For this reason, you must avoid fire, na-

ked flames and sparks, and refrain fromsmoking when handling these serviceproducts.

Observe the relevant safety regulations.

Operation

Service products

K


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4Mix the additive with the diesel fuel in goodtime, before the flow properties of the die-sel are affected by paraffin separation.Malfunctions caused by paraffin separa-tion can only be remedied by warming upthe entire fuel system.

Do not mix additives with special cold-resistant winter diesel fuels as the cold-flow properties of the fuel could deterio-rate.

Flow improvers

The effectiveness of flow improvers cannotbe guaranteed with all fuels. Observe themanufacturer’s recommendations. Infor-mation about approved flow improvers isavailable from any Mercedes-Benz ServiceCentre.

Kerosene

Add only as much as is required for theprevailing outside temperatures. The addi-tion of 5% by volume of kerosene improvesthe cold-resistance of diesel fuel by ap-proximately 1 °C. Do not exceed the max-imum mixing ratio of 50% kerosene.

Run the engine for a while to ensure thatthe additive reaches all parts of the fuelsystem.

!

There is a risk of serious engine dam-age if petrol is mixed with diesel.

For this reason, do not mix petrolwith the diesel fuel under any circum-stances.

!There is a risk of engine damage if ker-osene is permanently mixed with die-sel.

It is therefore not permissible to mix

kerosene with diesel on a permanentbasis.

Risk of explosion G

Adding kerosene reduces the flash point ofthe fuel, increasing the risk of fire and explo-sion.

For this reason, avoid fire and nakedflames and refrain from smoking whenhandling these service products.

Only mix kerosene with diesel in the fueltank.

First add the kerosene and then the die-sel fuel.

Observe the relevant safety regulations.

Operation

Service products

! !


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The OM 501 LA and OM 502 LA enginesare suitable for operation with FAME fuel(bio-diesel fuel) complying with EN 14214.

The following effects arise from operationwith FAME fuel:

slight increase in fuel consumptionslightly reduced engine power output

increased white smoke developmentafter a cold engine start

Before operation with any FAME fuel, a

Mercedes-Benz Service Centre must be consulted to clarify the precise proce-dures for use (e.g. maintenance intervals).

Observe the following points for operationwith FAME fuel:

FAME fuels !

The fuel filter and engine oil filtermust be replaced approximately200 operating hours following con-version to FAME fuel.The oil and fuel filter must be re-placed with every engine oil

change.FAME fuels reduce the service lifeof a conventional fuel filter.The engine oil change and filter re-placement intervals are significant-ly reduced. The engine oil changeand filter replacement must be car-ried out at least once a year.

Only use FAME fuels complyingwith EN 14214. Special additivesare not permitted. The use of fuelsthat do not comply with theEN 14214 standard or the additionof special additives may lead to

malfunctions or damage to the en-gine.FAME fuels attack painted surfaces.Immediately rinse off the FAMEfuel with water before it has timeto react with the paintwork. Use

only engine oils complying withMercedes-Benz Specifications forService Products sheet number228.5 or 228.3.

!

Operation

Service products

! !


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!

FAME fuels may cause componentsin the fuel system to stick if the en-gine is left switched off for long pe-riods. For this reason, always useup the amount of FAME fuel remain-ing in the fuel tank and refuel with

conventional diesel fuel before theengine is switched off for long peri-ods. Run the engine for at least onehour before the vehicle is parkedup.The quality of hoses adjacent to the

engine, and connected either to thevehicle or machine, must satisfy therequirements of FAME fuels.

Based on negative experiences,DaimlerChrysler does not acceptthe use of pure vegetable oils as analternative to diesel or FAME fuels.The use of pure vegetable oils canlead to engine damage arising from

coking and oil sludge forming aswell as deposits in combustionchambers.

!Environmental note

HIf you operate your vehicle using bio-dieselfuel, please consult your disposal firm as towhether the engine oil must be collectedseparately. Not all manufacturers of rere-fined products (lubricants manufacturedfrom used engine oils) are able to processengine oil contaminated with bio-diesel fuel.

Observe the special notes and national reg-ulations on the disposal of engine oils. Infor-mation is available from any qualified spe-cialist workshop or Mercedes-Benz ServiceCentre.

Operation

Service products

Mercedes-Benz does not accept warranty FAME fuels (bio-diesel fuels) at low Engine oils are specially tested for their


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Mercedes Benz does not accept warrantyclaims for damage if:

the cause of the damage is in anyway connected to the use of a FAMEfuel that does not comply with theEN 14214 standard

the regulations of sheet number 135 of

the Mercedes-Benz Specifications forService Products concerning operationwith FAME fuels have not been ob-served

malfunctions or consequential damage(e.g. paint damage) arise from the han-dling of or operation with FAME fuels

FAME fuels (bio diesel fuels) at lowtemperatures

FAME fuels are reliable down to outsidetemperatures of approximately –20 °C inaccordance with EN 14214.

Flow improvers

The addition of flow improvers or kerosenehas no effect on the cold stability of FAMEfuels.

SAE engine oil classes

Engine oils are specially tested for theirsuitability for use in our engines. For thisreason, only use engine oil brands ap-proved by Mercedes-Benz. These are listedin the Mercedes-Benz Specifications forService Products. Observe the informationin the Maintenance Booklet.

Engine oils

iThe use of non-approved engine oilbrands may limit your warranty entitle-ment.


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Operation

Service products

Antifreeze/corrosion inhibitor Coolant mixing ratio: Disposal


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Observe the following to prevent damageto the cooling system:

Only use an approved corrosioninhibitor/antifreeze. Information isavailable from any Mercedes-BenzService Centre.

When topping up (after a loss of cool-ant), a corrosion inhibitor /antifreezeconcentration of 50% by volume mustbe ensured (antifreeze protection downto –37 °C).

Do not use an antifreeze/corrosion in-

hibitor concentration of more than 55%by volume (maximum antifreeze pro-tection). Above this concentration, an-tifreeze protection deteriorates andheat dissipation is less effective.

g

In exceptional cases, when no antifreeze/corrosion inhibitor is available and /or noantifreeze protection is required (in tropi-

cal zones), use an approved coolant addi-tive without antifreeze properties (seeMercedes-Benz Specifications for ServiceProducts).

p

!If the concentration is too low, thereis a risk of engine damage as a conse-quence of corrosion/cavitation.

Antifreeze pro-tection downto ° C

–37 approx.–45

Water % by vol. 50 45

Corrosion

inhibitor/anti-freeze % by vol.

50 max. 55

!In this case, the coolant must be re-newed every year.

Information is available from anyMercedes-Benz Service Centre.

Environmental note HThe coolants described are biodegradablesubstances. Observe the legal requirementsand waste water regulations in the country

concerned when disposing of used coolants.We recommend that you consult the rele-vant local water authority for advice on thedisposal of coolant.

Due to the complex tasks that a moderncoolant must perform, improper “recycling”

consisting simply of mechanical pre-clean-ing must be categorically rejected.


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68

Maintenance

Maintenance instructions

Work schedule overview


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Work schedules

Maintenance

Maintenance instructions

This section describes all maintenance The scope of maintenance and frequency


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This section describes all maintenance

work to be carried out on the engine.

The scope of maintenance and frequency

of maintenance work depend on the differ-ent operating conditions and are listed inthe Maintenance Booklet.

Have work that is carried out confirmedwith an entry in the Maintenance Booklet.This proof of regular maintenance is al-

ways required for any warranty claims.Please also observe the maintenance in-structions for special accessories.

Risk of injury GBefore having maintenance or repair workcarried out, please make sure that you read

the relevant sections of the technical docu-mentation relating to maintenance and re-pair measures, e.g.:

Operating Instructions and workshop in-formation.

You should also familiarise yourself first withthe legal requirements, such as:

health and safety as well as accidentprevention regulations.

You could otherwise fail to recognise dan-gers and could injure yourself or others.

Risk of accident GMaintenance work that is carried out incor-rectly or not at all, e.g. not changing the oilfilter or not observing maintenance inter-vals, can cause engine damage. Engine dam-age can lead to an increased risk of an acci-dent.

Therefore, observe the notes on enginemaintenance in these Operating Instruc-tions.

iAll maintenance intervals and main-tenance work refer to genuineMercedes-Benz parts and accessoriesthat have been expressly approvedfor the engine by DaimlerChrysler.

!Change the engine oil filled at the fac-

tory, which complies with Sheet 228.5of the Mercedes-Benz Specificationsfor Service Products, if more than24 months have elapsed before the en-gine is operated for the first time.

Maintenance

Work schedule overview

Work schedule overviewChecking and correcting fluid levelMaintenance service Additional work with every


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Engine:Oil change and filter replacement

Poly-V-belt:Check condition

Checking for leaks and general condition

Check for points of abrasion and incorrectpositioning.

Engine:Lines and hoses on the engineIntake pipe between the air cleaner andengineCooling and heating system

g g

If more fluid is lost than can be accounted forby normal consumption, trace the cause andrectify it

Engine cooling system:Check and correct fluid level andantifreeze/corrosion inhibitor concen-

tration

Valve clearance:Check and adjust

Fuel filter:Replace filter

Fuel prefilter with water separator:Replace filter element

Engine brake*:Check condition and setting

Coolant:Renew

Maintenance service

iFor operation with diesel fuel:

Change the engine oil and replace the

oil filter at least every two years .If operated with FAME fuel (bio-dieselfuel):

Change the engine oil and replace theoil filter at least once every year .

Additional work

iThe valve clearance must be adjustedduring the first maintenance service andthen during the 3rd, 5th, 7th mainte-nance services and so on.

Additional work with every

third maintenance service

iIf operated with FAME fuel:Replace the fuel filter together withengine oil change and filter replace-ment.

iRenewal interval depends on the coolantadditive used (see Mercedes-Benz Speci-fications for Service Products).

Maintenance

Work schedules

Engine: checking for leaks and Lines and hoses on the engine:k f G


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Visual inspection of the engine forsigns of leakage.

Sealing points which are slightly damp canbe ignored.

Visual and aural check for leaks fromlines and hoses. Also check that alllines and hoses are undamaged, routedin such a way that there will be no chaf-

ing and secured correctly.

general condition

!More significant leaks involving con-stant oil loss must be rectified immedi-ately.

checking for leaks and generalcondition

Risk of injury GThe engine becomes very hot while it is run-ning and remains so for some time after it

has stopped. It will cause burns upon con-tact.

Before starting any work on the engine,allow all engine parts to cool down orwear suitable gloves and items of cloth-ing to protect yourself against hot en-

gine components.

Risk of injury GThere is a danger of limbs being caught, en-trapped, crushed or torn off by rotating en-gine parts. Therefore you should:

Keep a safe distance between yourselfand rotating engine parts, includingwhen the engine is being started.

Wait until all engine parts have stoppedmoving before carrying out any work onthe engine.

Wear work clothing which is fastenedand close-fitting. Wear a hair net if nec-essary. Remove jewellery such aswatches and necklaces.


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Maintenance

Work schedules

Replace sealing ring 2 on oil filtercap 1 with a new one The sealing ring


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cap 1 with a new one. The sealing ringmust be lightly greased.

Insert new oil filter element 3 into oilfilter cap 1 and press until it clips intoplace.

Screw on cap 1 with the oil filter ele-ment and tighten.Tightening torque: 40 Nm.

Siphoning and draining engine oil

To siphon:

Siphon off the engine oil through the

dipstick guide pipe.To do this, pull out oil dipstick 1 andinsert an extractor unit sealed with anO-ring into dipstick guide pipe 2 .

1 Dipstick2 Dipstick guide pipe

To drain:

Place a suitable collecting receptacleunder drain plug 1 on the underside ofthe oil sump.

Unscrew drain plug 1 carefully and al-low the oil to drain out.

1 Oil drain plug!Observe the operating instructions forthe engine oil extractor unit.

Maintenance

Work schedules

Environmental note H !


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Screw the oil drain plug back in with anew sealing ring and tighten.Tightening torque: 60 Nm.

Adding engine oil

Add new engine oil to the engine via theoil filler opening 1 up to the maximummark on the oil dipstick. 1 Oil filler opening

Start the engine and run it at idlingspeed (with the position sensor in theidling position) and monitor the oilpressure gauge.

Check the oil filter and drain plug forleaks.

Stop the engine. Check the oil level af-ter approximately 5 minutes. Top upthe oil to the maximum mark on thedipstick if necessary.

Environmental note HDispose of engine oil and filters in accord-ance with the regulations in force where theengine is operated.

Keep the engine running at idling speeduntil an oil pressure reading is dis-played. If no oil pressure is displayedafter approximately 10 seconds, switchoff the engine. Determine the cause.


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Maintenance

Work schedules

Removing and fitting the cylinder headcovers

Concluding work


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5

covers

Undo hexagon bolts 2 on cylinderhead cover 1 .

Remove cylinder head cover 1 .

To refit, follow the instructions for remov-ing in the reverse order.

Cylinder head cover mounting

Flywheel inspection hole

Unscrew the cap from the inspectionhole in the flywheel housing.

Fit turning tool 904 589 04 63 00 tothe flywheel housing inspection hole.

After adjusting the valves:Refit the cylinder head cover( see page 77) .

Remove the turning tool from the fly-wheel housing inspection hole.

Seal the inspection hole with the cap.Tightening torque: 25 Nm.

iValve clearance adjustmentOM 501 LA: page 78.

Valve clearance adjustmentOM 502 LA: page 79.

Maintenance

Work schedules

Valve clearance adjustment OM 501 LA


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I – intake valveE – exhaust valve

Adjust all valve clearances in 2 crankshaftpositions.

Use the turning tool to turn the crank-

shaft until the 5th cylinder is at overlapTDC (1st cylinder in ignition TDC). Thenmove the 1st cylinder to overlap TDC(5th cylinder in ignition TDC).

Check and adjust the valves in accord-ance with the table above.

Checking and adjusting the valve clear-ance

1 Adjustment screw

2Counternut

Measure the valve clearance betweenthe rocker arm and valve bridge using afeeler gauge (arrow). It must be possi-ble to pull the feeler gauge throughwith only light resistance.

Loosen counternut 2 to permit adjustment of the valve clearance. Adjustthe valve clearance by turning adjust-ment screw 1 .

Retighten the counternut; tighteningtorque 50 Nm.

Check the valve clearance again andreadjust if necessary.

Engine Crankshaft position Cylinder/valves to be adjusted1 2 3 4 5 6

OM 501 LA 5th cylinder valve overlap I /E E I E — I

6-cylinder 1st cylinder valve overlap — I E I I/E E

Maintenance

Work schedules

Valve clearance adjustment OM 502 LA


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I – intake valveE – exhaust valve

Adjust all valve clearances in 2 crankshaftpositions.

Use the turning tool to turn the crank-

shaft until the 6th cylinder is at overlapTDC (1st cylinder in ignition TDC). Thenmove the 1st cylinder to overlap TDC(6th cylinder in ignition TDC).

Check and adjust the valves in accord-ance with the table above.

Checking and adjusting the valve clear-ance

1 Adjustment screw

2Counternut

Measure the valve clearance betweenthe rocker arm and valve bridge using afeeler gauge (arrow). It must be possi-ble to pull the feeler gauge throughwith only light resistance.

Loosen counternut 2 to permit adjustment of the valve clearance. Adjustthe valve clearance by turning adjust-ment screw 1 .

Retighten the counternut; tighteningtorque 50 Nm.

Check the valve clearance again andreadjust if necessary.

Engine Crankshaft position Cylinder/valves to be adjusted1 2 3 4 5 6 7 8

OM 502 LA 6th cylinder valve overlap I/E E I I E — E I

8-cylinder 1st cylinder valve overlap — I E E I I/E I E

Maintenance

Work schedules

Fuel connections


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Maintenance

Work schedules

Low-pressure fuel circuit Heated fuel prefilter with waterseparator*: replacing the filter


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5

1 From the fuel tank2 To the fuel pump3 To the fuel filter4 To the unit pumps5 Return line to the fuel tank6 Return line to the unit pumps

Heated fuel prefilter with water separator*

1 Fuel hand pump2 Filter housing3 Water separator4 Water drain valve

separator : replacing the filterelement

Risk of fire GThere is an increased risk of fire when han-dling fuels as they are highly flammable.

Avoid fire, naked flames and sparks, and re-frain from smoking when handling fuels.

Environmental note HDispose of used filter elements, seals andfuel residue in accordance with relevant lo-cal regulations.

Maintenance

Work schedules

Open water drain valve 4 and thebleed screw. Collect the fuel/water

i Replacing the fuel filter element


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5

bleed screw. Collect the fuel/watermixture from the filter element in acontainer.

Unscrew filter housing 2 .

Unscrew water separator 3 from filterhousing 2 and clean or replace asnecessary.

Refit in the reverse order. Use newseals.

Close the drain valve and fill the prefil-ter using fuel hand pump 1 . Thenclose the bleed screw.

Start the engine and bleed the fuel sys-tem.

Start the engine, check the prefilter forleaks.

!Screw filter housing 2 onto the filterhead tightly by hand.

Run the engine for approximately1 minute. The fuel system bleeds auto-matically. If the engine stalls or doesnot start, bleed the fuel system manu-ally.

Risk of fire GThere is an increased risk of fire when han-dling fuels as they are highly flammable.

Avoid fire, naked flames and sparks, and re-frain from smoking when handling fuels.

Environmental note HDispose of used filter elements, seals andfuel residue in accordance with relevant lo-cal regulations.

Maintenance

Work schedules

Open the tank cap to prevent excesspressure in the fuel tank.

i


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Replacing the fuel filter element

1 Cap

p

Unscrew fuel filter cap 1 using thesocket spanner insert (WAF 36).

Pull cap 1 with the filter element outof filter housing 3 slightly. Allow thefuel to flow out.

Remove the cap and filter element. Un-clip the filter element by pressing thesides of the lower edge of the filter ele-ment.

Fuel filter element

1 Cap2 Sealing ring3 Filter element

Replace sealing ring 2 with a new one(grease lightly).

Clip new filter element 3 into cap 1 .

The fuel prefilter is fitted on the ma-chine or vehicle.

Observe the operating and mainte-nance instructions in the machine/vehicle operating instructions for thefuel prefilter.

!Make sure that no foreign objectsenter the filter housing.

Never wipe the filter housing out.

The ingress of water must be pre-vented.

Maintenance

Work schedules

Screw on cap 1 with filter element 3 and tighten.

i


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gTightening torque: 25 Nm.

Bleed the fuel system ( page 45)

Start the engine and bleed the fuel sys-tem.

Check the fuel filter for leaks with theengine running.

Start the engine, check the fuel filterfor leaks.

!Run the engine for approximately1 minute. The fuel system bleeds auto-matically.

If the engine stalls or does not start,bleed the fuel system manually.

To bleed the system manually, the ma-chine or vehicle must be equipped witha hand pump, e.g. on a fuel prefilter.

Environmental note HIf the diesel fuel level (fuel tank) is aboveengine height, the feed line must be closedwhen the filter is replaced. Diesel fuel could

otherwise flow out.


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Maintenance

Work schedules


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Damage patterns

MaintenanceWork schedules

1 Condition as new (as reference: trape-zoidal ribs)

2 O id d d h d ib

Removing and fitting the poly-V-beltRisk of injury G


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2 One-sided wear: wedge-shaped ribs3 Cord visible at the base of the ribs4 Ribs split5 Transverse cracks in several ribs6 Rubber nodules at the base of the belt7 Deposits of dirt or stones

8 Rib detached from the base of the belt9 Cord torn out at the sidea Outer cord frayedb Transverse cracks on the back of the

beltc Transverse cracks in several ribs

Clamping handle with extension in the ten-sioning device

Fit the clamping handle with 1/2" ex-tension into the tensioning device.

Swing the tensioning pulley down andremove the poly-V-belt.

Swing back the tensioning device.

The tensioning device is spring-tensioned.When it is loosened or tightened, there is arisk of injury from crushing or entrapment inpretensioned parts.

For this reason, always carry out workon the tensioning device with extremecare .

Make sure that the tool is handled cor-rectly.


Check that both the tensioning deviceand the belt pulley are in perfect condi-

( h k f b


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tion (e.g. check for worn bearings onthe tensioning device, tensioning pul-ley and guide pulleys as well as forwear on belt pulleys); replace parts ifnecessary.

Lay the poly-V-belt (new) on all belt pul-leys, except for the tensioning pulley(see illustrations for poly-V-belt rout-ing).

Swing the tensioning pulley down usingthe lever, lay the poly-V-belt on the ten-

sioning pulley and swing the tensioningpulley back.

Remove the clamping handle andcheck for correct seating of the poly-V-belt on the belt pulleys.

Poly-V-belt routing without refrigerant com-pressor OM 501 LA/OM 502 LA

1 Coolant pump pulley2 Crankshaft pulley3 Tensioning pulley (tensioning device)4 Alternator

Poly-V-belt routing with refrigerant com-pressor OM 501 LA/OM 502 LA

1 Coolant pump pulley2 Crankshaft pulley3 Tensioning pulley (tensioning device)4 Refrigerant compressor pulley5 Alternator


Remove the wire circlip from the en-gine brake cylinder ball socket.

P i ff th b ll k t f th ttl

Engine brake*: checking conditionand adjustment


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Checking condition

Throttle valve lever in inactive position

1 Retainer2 Throttle valve lever

Prise off the ball socket from throttlevalve lever 2 ball neck.

Check the engine brake cylinder, ballneck and ball socket as well as thethrottle valve shaft for wear.

Check the throttle valve lever on thethrottle valve shaft for firm seating andretighten the clamping screws if neces-sary.

Lubricate the ball socket with the spec-ified grease.

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

Throttle valve lever in active position

1 Retainer2 Throttle valve lever


Checking adjustment

i

Engine cooling system: checkingand correcting the fluid level and theantifreeze/corrosion inhibitor

Risk of poisoning G


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iWhen the engine brake is applied,throttle valve lever 2 must make con-tact with retainer 1 when the throttlevalve lever is in its active position (cyl-inder extended).

The throttle valve lever must also makecontact with the retainer when the en-gine brake cylinder is in its inactive po-sition (cylinder retracted); if this is thecase the return spring pretension of theengine brake cylinder is adequate.

Check the position of the throttle valveshaft: when the engine brake is inac-tive, the slot ( page 89, illustration onleft) must be vertical. When the enginebrake is in the active position, the slot( page 89 , illustration on right) mustbe horizontal.

antifreeze/corrosion inhibitor



Unscrew the sealing cap slowly and re-

lease any excess pressure completelybefore opening the cap fully.


There is a risk of poisoning if coolant is swal-lowed.




!Only use service products approved byDaimlerChrysler (see specification forservice products).


iOnly check and correct the coolant lev-

!

If the concentration is too low there is

Cooling and heating system:

checking for leaks and general


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5Open the engine cooling system capslowly, relieving the excess pressure.

Check the antifreeze/corrosion in-

hibitor concentration using a testingdevice. The specified antifreeze/ corro-sion inhibitor concentration of 50% byvolume is present if antifreeze protec-tion is ensured down to –37 °C. If lessantifreeze protection is displayed, cor-

rect the mixing ratio.

Check the coolant level.The cooling system is correctly filled ifthe coolant reaches the mark in the fill-er neck.

Carry out a visual inspection of the ra-diator for leaks and damage.

Check the radiator for external dirt.The fins must not be dirty.

Only check and correct the coolant level when the coolant temperature isbelow 50 °C. Check the antifreeze /corrosion inhibitor concentration be-fore correcting the coolant level. Onlyuse a prepared coolant with an anti-

freeze/corrosion inhibitor concentra-tion of 50% by volume for topping up.

If the concentration is too low, there isa risk of engine damage as a result ofcorrosion/cavitation in the coolingsystem.

iAvoid antifreeze/corrosion inhibitorconcentrations of more than 55% byvolume, otherwise maximum antifreezeprotection down to –45 °C will not beachieved. Heat dissipation and anti-freeze protection deteriorate at higherconcentrations.

checking for leaks and generalcondition

iThe “Engine cooling system: checkingand correcting the fluid level andantifreeze/corrosion inhibitor” opera-tion must have already been carriedout.

!If damage/faults are detected, repairthe radiator or replace it.


Check the radiators, coolant pump, en-gine oil radiator and engine cap forleaks

Risk of injury G Risk of poisoning G


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leaks.

Check that all cooling and heating sys-tem lines and hoses are undamaged,that they are routed in such a way thatchafing is avoided and that they are se-

cured in accordance with regulations.

The cooling system is pressurised. Hot cool-ant can escape under pressure when thecooling system is opened and scald yourskin and eyes.



Wear suitable protective gloves, protec-

tive clothing and safety goggles whenhandling coolant.



Never store coolant in containers nor-

mally used for drinks.Store coolant out of the reach of chil-dren.


Remove the coolant expansion tankcap.

Fit the pressure tester.


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Pressure tester special tool

On heating systems: open the regulat-ing valves and shut-off valves.

Fit the pressure tester.

Connect the compressed-air hose withtyre inflator connection to the valveand build up a test pressure equal tothe cooling system opening pressure.

iSpecial tool:

Pressure tester 001 589 83 21 00

iThe cooling system opening pressurecan be determined from the code onthe cap or pressure relief valve.

Example: code 70 = 0.7 bar overpres-

sure.The cooling system pressure tester hasa built-in pressure relief valve so thata pressure of 1.2 bar cannot be ex-ceeded.


Draining coolantRenewing coolant

Risk of injury GRisk of poisoning G


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Coolant drain plug

Open the engine cooling system capslowly, relieving the excess pressure,and remove it.

On heating systems: open the heatingtemperature selectors (regulatingvalves).









!Only use antifreeze/corrosion inhibitor

approved by Mercedes-Benz, (seespecifications for service products).

iBefore renewing the coolant, check thecooling and heating system for leaksand condition. Have the coolant renew-al confirmed in the Maintenance Book-let.


Connect the drain hose to the coolantdrainage connection on the radiator

and drain the coolant.

Clear blocked drainage openings of de-posits.

Fit a new seal to the coolant drain plug

iObserve any further information in theoperating instructions from the ma-


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Unscrew coolant drain plug 1 fromthe engine block and collect the cool-ant in a suitable receptacle.

p gon the engine and retighten.

Fit additional drain plugs (without hoseconnections) with new seals and screwthem in tight.

Adding coolant

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

Add coolant of the specified composi-tion until it reaches the lower edge ofthe filler nec

motor mercedes benz - om501 om502 em inglês

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