150453255 150 7122Meredes Benz 904 Engine Service Manual

Operating Instructions

Document No. 150-7122

Mercedes Benz

Mercedes OM 904 LA

Mercedes OM 904 LA Operation Manual2

BREAKER TECHNOLOGY 12/2005

Foreword

Eastern USAPhone (440) 248-7168 | Fax: (440) 248-864530625 Solon Industrial Parkway | Solon, OH 44139

Western USA & MexicoPhone (951) 369-0878 | Fax: (951) 369-82813453 Durahart Street | Riverside, CA 92507

Canada & InternationalPhone (519) 599-2015 | (866) BTI-PART [284-7278] | Fax: (519) 599-680335 Elgin Street | P.O. Box 130 | Thornbury, Ontario, Canada N0H 2P0

www.rockbreaker.com

Mercedes OM 904 LA Operation ManualMercedes EnginePublication Date: 1-12-2005

ForewordThis 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.

Mercedes OM 904 LA Operation Manual 3

12/2005 BREAKER TECHNOLOGY

Foreword



Foreword

Foreword



Contents

ContentsMercedes OM 904 LA............................................................1

Mercedes Engine ...........................................................2Foreword .......................................................................... 2Introduction ...................................................................... 6

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

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

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

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

4. Operation.................................................................... 27Starting the engine for the first time ....................................27Starting the engine ..............................................................30Monitoring engine operation ................................................32Stopping the engine ............................................................34Winter operation ..................................................................35Cleaning/protective treatment .............................................36Service Products .................................................................39

Diesel fuels...................................................................39Engine oils....................................................................42

5. Maintenance ............................................................... 45Maintenance instructions.....................................................45Work schedule overview .....................................................46

Maintenance service ....................................................46Additional work with every third maintenance service..47

Work schedules ...................................................................476. Practical advice ......................................................... 63

Malfunctions, causes and solutions.....................................63Jump-starting.......................................................................67

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



IntroductionMercedes OM 904 LA Operation Manual


Introduction

Protection of the environment

Protection of the environment

Operating Safety



Introduction

Operating safety

Correct use

NOTES

8



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



1. At a glance

OM 906 LA/OM 926 LA overview



1. At a glance



1. At a glance

Location of sensors



1. At a glance

Engine number



2. Before commissioning

2. Before commissioning General information

Transport and installation

General information

Type designation

Engine data card




Description of the engine




Engine brake*/constantly-open throttle valves*




Flame-start system*




Grid heater

Telligent® engine system










Transport and installation



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



3. Safety

Safety/emergency running programs



3. Safety

Genuine Mercedes-Benz parts



4. Operation

4. Operation

Starting the engine for the first time

Starting the engine for the first time

Monitoring engine operation

Stopping the engine

Winter operation

Cleaning/protective treatment

Service products

Preparation



4. Operation



4. Operation



4. Operation

Starting the engine



4. Operation



4. Operation

Monitoring engine operation

Charge current

Oil pressure



4. Operation

Telligente® engine system

Flame-start system*



4. Operation

Grid heater *

Stopping the engine



4. Operation

Winter operation



4. Operation

Cleaning/protective treatmentCleaning the engine



4. Operation

Cleaning the cooling system

Cleaning/protective treatment



4. Operation



4. Operation

Service Products

Diesel fuels



4. Operation

FAME fuels



4. Operation



4. Operation

Engine oils

Coolant



4. Operation

NOTES

44



5. Maintenance

5. Maintenance Maintenance instructions

Work schedule overview

Work schedules

Maintenance instructions



5. Maintenance

Work schedule overview

Maintenance service

Additional work



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



5. Maintenance



5. Maintenance

Adjusting the valve clearance



5. Maintenance



5. Maintenance

Fuel prefilter: cleaning the filter element



5. Maintenance

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



5. Maintenance

Replacing the fuel filter element



5. Maintenance

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



5. Maintenance

Poly-V-belt: checking condition



5. Maintenance



5. Maintenance

Engine brake*: checking conditions and setting



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



5. Maintenance

Renewing Coolant

NOTES

62



6. Practical advice

6. Practical advice Malfunctions, causes and solutions

Jump-starting

Malfunctions, causes and solutions



6. Practical advice



6. Practical advice



6. Practical advice



6. Practical advice

Jump-starting

NOTES

68



7. Technical data

7. Technical data Engine data

Test values and adjustment values

Tightening torques

Engine data



7. Technical data



7. Technical data

Test values and adjustment values



7. Technical data

Tightening torques

150453255 150 7122Meredes Benz 904 Engine Service Manual

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