Professional Documents
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Om 457 La Bluetec /om 457 La Om 460 La Bluetec /om 460 La: Operator'S Manual
Om 457 La Bluetec /om 457 La Om 460 La Bluetec /om 460 La: Operator'S Manual
Om 457 La Bluetec /om 457 La Om 460 La Bluetec /om 460 La: Operator'S Manual
ohne Éohne-ËÍ
Contents 3
A Cooling system
Degreasing ....................................... 73
Adaptation module .............................. 18 Flushing ........................................... 73
ADM (FR (drive control) unit) ............. 18 Correct use ............................................ 9
Antifreeze ............................................. 70 Cranking device ................................... 60
Antifreeze/corrosion inhibitor ........... 46
Authorized Mercedes-Benz Center D
see Qualified specialist workshop
Data card .............................................. 94
B Decommissioning ................................ 77
Decommissioning the engine ............. 76
Bio-diesel fuel DEF
see FAME fatty acid methyl ester fuel Components .................................... 17
BlueTec® Consumption ................................... 39
Exhaust gas aftertreatment ................ 9 Refueling .......................................... 40
Sensors ............................................ 17 Replacing the filter ........................... 66
BlueTec® exhaust gas Service products .............................. 50
aftertreatment see DEF service products
DEF service product ......................... 50 Description of the engine ................... 18
Brakes Diesel
Continuous brake ............................ 37 Fuels ................................................ 48
Breaking in the vehicle ....................... 38 Low outside temperatures ............... 49
Refueling .......................................... 39
C Sulfur content table ......................... 48
Capacities ............................................ 98 Dimensions .......................................... 95
Care products ...................................... 52 Disposal of service products .............. 44
Charge current .................................... 34 Driving tips .......................................... 38
Checking the engine oil level ............. 30
Cleaning and care E
Engine cleaning ................................ 52 Electronic drive control
High-pressure cleaning .................... 52 see Engine management
Notes on care .................................. 52 Electronic engine control unit ............ 34
Cold-start aid ....................................... 24 Emergency mode ................................. 83
Consumption Emergency running program ................ 8
DEF .................................................. 39 Engine
Fuel .................................................. 38 Break-in period ................................ 38
Oil (engine) ...................................... 39 Capacities ........................................ 98
Continuous brake ................................ 23 Changing the oil and oil filter ........... 58
Coolant Checking for leaks and general
Adding ............................................. 31 condition .......................................... 73
Draining ........................................... 71 Cleaning ........................................... 52
Mixing ratio ...................................... 46 Data ................................................. 95
Renewing ......................................... 71 Data card ......................................... 94
Service product ............................... 46 Data plate ........................................ 94
Topping up ....................................... 72 Diagnostics (indicator lamp) ............ 90
Coolant additive .................................. 46 Oil consumption ............................... 39
Operating data ................................. 97
Index 5
Z
8 General information
Z
10 General information
Installation
The engine may only be installed as
contractually specified.
Observe the sections "Correct use"
(Y page 9) and "Modification and changes to
the engine" (Y page 7).
The Operating Instructions contains
information required for installation in the
"Technical data" section" (Y page 95).
Please consult an authorized Mercedes-Benz
Example display for OM 457 hLA
Center or MTU Service Center (Y page 11)
The engine may only be lifted using a beam/ if you have any questions.
crossmember, so that the chain angle/rope
angle is 90° relative to the horizontal engine.
! The engines are delivered filled with oil as Information on the Limited Warranty
standard. If the engine is transported at an A well-developed network of Mercedes-Benz
angle or on its side, oil could leak out. Only and MTU Service Centers is available to carry
transport the engine in the installation out maintenance work.
position. Mercedes-Benz and MTU Service Centers:
Rhave special equipment and tools as well
as specialists who receive continuous
training
Rguarantee that your engine is repaired and
maintained thoroughly and expertly
Rcarry out all repairs within the framework
of the engine warranty and the Limited
Warranty
Rcarry out all maintenance work expertly
Rconfirm in the Maintenance Booklet that
Example: flywheel-side lifting point the maintenance work has been carried out
at the required time
Rhandle warranty claims that are admissible
according to the sales contract
Please observe the instructions and
recommendations in the Operating
Instructions. Always observe the
maintenance intervals specified in the
Maintenance Booklet. Please observe these
instructions even if you let a third party use
and care for your engine. This is the only way
Example: belt-side lifting point
to ensure that you do not lose your
entitlements.
General information 11
If the prescribed maintenance work is not with these specifications could lead to the
carried out, claims can only be decided after loss of warranty entitlements.
the manufacturer has inspected the claim. Mercedes-Benz recommends that you use a
During the engine warranty period in Mercedes-Benz or MTU Service Center.
particular, have the prescribed maintenance You should always have the following work on
service carried out as follows: your vehicle carried out at a qualified
Rregularly specialist workshop:
Rpunctually Rwork relevant to safety
Rat a qualified specialist workshop which Rservice and maintenance work
has the necessary specialist knowledge Rrepair work
and tools to carry out the work required Rmodifications as well as installations and
Mercedes-Benz recommends that you use conversions
a Mercedes-Benz or MTU Service Center Rwork on electronic components
for this purpose. In particular, work
Please have warranty and ex gratia work
relevant to safety or on safety-related
carried out at authorized workshops/Service
systems must be carried out at a qualified
Centers.
specialist workshop.
RFor on-highway applications, contact an
If there are legal requirements on exhaust gas
aftertreatment, please note that: authorized Mercedes-Benz Center.
RFor off-highway applications, contact an
Rmaintenance on the engines must be
MTU or MTU-authorized Mercedes-Benz
carried out according to specific
partner.
regulations and using special measuring
devices
Rit is prohibited to modify or tamper with
components relevant to emissions
All Mercedes-Benz and MTU Service Centers
are aware of the relevant regulations.
Maintenance work does not include repair
work. Repair work requires a separate order.
You may also consult a Mercedes-Benz or
MTU Service Center for further information.
Z
12
13
At a glance
14 Exterior view
Exterior view
Engine overview
At a glance
: Poly-V-belt
; Fuel pump
= Thermostat housing
? Fuel filter
A Oil filter
B Cylinder head cover
C Start/Stop button
D Charge-air distributor
E Charge pressure pipe from charge-air cooler
F Crankcase ventilation system
G Engine control unit (MR)
H Air compressor
I Power-steering pump
J Dipstick
K Engine oil filler neck
Exterior view 15
At a glance
: Alternator
; Starter motor
= Exhaust gas turbocharger
? Exhaust manifold
A Coolant pump
B Poly-V-belt tensioning device
16 Exterior view
Sensors overview
Sensors, general
At a glance
DEF components
At a glance
BlueTec® sensors, overview
: NOX sensor
; Metering unit
= Exhaust aftertreatment unit
? Temperature and humidity sensor (air filter, clean air side)
A Valve preheating, DEF system
B Exhaust gas temperature sensor (inlet)
C Exhaust gas temperature sensor (outlet)
D Exhaust gas aftertreatment control unit
E Supply unit
F DEF filter
G DEF tank
18
At a glance General information
At a glance
system which, along with the engine and its
associated sensors, consists of the following
components:
Rengine control unit (MR)
Rdrive control unit (FR) and/or other vehicle-
specific control units, e.g. adaptation
module (ADM)
Rexhaust gas aftertreatment control unit
(only for engines with BlueTec® exhaust
gas aftertreatment)
The control units are interconnected by a
CAN line (Controller Area Network line),
which facilitates the exchange of all Example: engine management control unit (MR)
necessary data.
The engine control unit (MR) processes
In addition to the engine and the BlueTec® values from the drive control unit (FR) and the
exhaust gas aftertreatment, the electronic adaptation module (ADM). These are, for
engine control unit also monitors itself. example, the signal from the position sensor
Depending on the malfunctions/failures that (accelerator pedal), the engine brake or
occur, the safety and emergency mode engine start/stop, etc.
(Y page 8) may be automatically selected.
These values are analyzed together with data
For vehicle engines, the electronic engine from the engine sensors. They are compared
control unit only allows the engine to be with the charts or characteristic curves
started when the transmission is in neutral. stored in the engine management (MR)
control unit.
Engine management control unit (MR) Data from the sensors derives from, e.g.:
(engine-mounted)
Rcharge-air pressure and charge-air
The engine management control unit (MR) is temperature
on the left side of the engine. Rcoolant temperature
Rfuel temperature
Roil pressure
engine Start/Stop)
Rengine brake switch
Rother systems (e.g. acceleration skid
control)
Rengine management (MR) control unit (e.g.
oil pressure and coolant temperature)
Values for the engine management (MR)
control unit are derived from this and
transferred via the CAN line.
The drive control unit (FR) unit or the
adaptation module (ADM) controls devices
such as the electronics warning lamp, the
Control unit type plate engine brake and the constant throttle valve.
: Data record
; Certification no. Exhaust gas aftertreatment control unit
= Engine number (on the frame)
? Equipment code
At a glance
air temperature should therefore fill up the DEF tank regularly
If the electronic engine management control yourself.
detects a malfunction, the malfunction code If the DEF tank is empty or if there is a
is stored in the control units. It can be read malfunction, the ; indicator lamp lights
out with the corresponding diagnostic testers up or flashes in the instrument cluster. If a
(STAR DIAGNOSIS or minidiag2). malfunction is detected by the electronic
In addition, the ^ electronics warning management system, a malfunction code is
lamp is switched on. stored in the engine control unit and can be
read out using the corresponding diagnostic
i Mercedes-Benz diagnostic testers can be tester (STAR DIAGNOSIS or minidiag2). The
connected to the 14-pin diagnostics engine output may be reduced automatically
connection on the equipment or with the the first time that it is switched off or the
EU-compliant service connector. Both vehicle comes to a standstill. Adapt your
malfunction memory and stored engine driving style accordingly. Drive with even
data can be read out using this equipment. greater care. Fill the DEF tank as soon as
possible. If there is a malfunction with the
BlueTec® exhaust gas aftertreatment system,
have it checked and repaired at a qualified
specialist workshop.
Mercedes-Benz recommends that you use an
authorized Mercedes-Benz Center or MTU
Service Center for this purpose.
BlueTec® technology is one part of the engine
homologation that requires certification.
Operating the engine/vehicle/equipment
without DEF or with another non-Daimler
Example: diagnostics connection
approved medium invalidates the engine's
operation certification/approval.
At a glance
Symbol1 Reason for display/displayed message
þ DEF level Malfunction message/action required
(warning before reduction in operating
performance)
! Check engine/exhaust gas Malfunction and misuse (failure in the
aftertreatment monitoring system)
È Torque/speed limiter Minor operating restriction
lights up active2
(level 1)
È Major operating restriction
flashes
(level 2)
deactivated even if the position sensor (e.g. goes out after approximately 2 seconds
accelerator pedal) is in use. (function check). At a coolant temperature
below approximately -4 †, the % indicator
i In emergency mode (constant engine
At a glance
Safety
26 Organizational measures
Staff qualifications
Safety precautions
ROnly start the engine when the batteries G WARNING
are firmly attached. Incorrectly executed maintenance and repair
RDo not disconnect the batteries when the
work on the engine can reduce its
functionality and safety and consequently
engine is running.
lead to accidents causing personal injury.
RDo not use a rapid charger to start the
Always have any work on or modifications to
engine.
the engine carried out at a qualified specialist
ROnly perform the jump-starting
workshop.
procedure with separate batteries.
RNote, the battery terminals must be The engine should only be operated,
disconnected when rapid charging the maintained and repaired by trained personnel
batteries. who have been briefed and authorized by the
RObserve the operating instructions of the operator. The prescribed minimum legal age
rapid battery charger. for personnel carrying out maintenance and
repair work must be observed.
RPlease note, when carrying out electric
welding work, that the batteries must be
disconnected and both of the cables ("+" Organizational measures
and "-") must be firmly attached to each
other. The responsibilities for operation,
RThe control unit connectors may only be maintenance and repairs are to be
connected/disconnected when the determined by the operator. Give the
electrical system is switched off. Operating Instructions and the Maintenance
RIncorrect control unit-power supply Booklet to the personnel that are charged
polarity (e.g. by connecting up the with operating or carrying out work on the
batteries incorrectly) can cause engine.
irreparable damage to the control units.
G WARNING
RTighten diesel injection system
Before operating the engine, please read
connections to the prescribed tightening
these Operating Instructions. Please also first
torque.
read the operating instructions of the vehicle
RIftemperatures above 80 † are to be or the machine to which the engine is
expected (e.g. in a drying oven), the installed. You may not recognize dangers and
control unit on the engine must be may injure yourself or others.
removed.
ROnly use the appropriate testing probes Instruct personnel on how to operate the
when taking measurements from engine using the Operating Instructions.
electrical connectors (e.g. a Mercedes- When doing so, put special emphasis on
Benz connection set). Telephones and safety-relevant information. This is
Organizational measures 27
Safety
In addition to the Operating Instructions,
other general, country-specific, legal and
other binding regulations on accident
prevention and environmental protection
must be adhered to.
Z
28
29
Operation ............................................. 30
Continuous brake ................................ 37
Driving tips .......................................... 38
Refueling .............................................. 39
Winter operation ................................. 40
Number 225.6 of the Mercedes-Benz display of the engine oil level is therefore only
Specifications for Service Products. possible with the engine switched off and the
These high-quality engine oils are beneficial ignition switched on.
to the breaking-in process. They also allow X Park the vehicle/equipment on a horizontal
you to make the first oil change in accordance surface.
with the applicable oil change intervals. This X Engage the parking brake.
eliminates the need for special initial X Switch off the engine.
operation oils and the additional oil change
X Wait approximately five to ten minutes. If
otherwise required.
you call up the oil level in the engine too
The extended maintenance intervals can only
early or while the engine is running, it is not
be used if engine oils complying with Sheet
available.
Number 228.5 or 228.51 of the
X If necessary, use filler neck ; to add oil.
Mercedes-Benz Specifications for Service
Products are used. Only use engine oil which has been approved
for the engine and which meets the specified
Engine oil level SAE classification.
The engine is equipped with an electronic oil ! Do not add too much oil. If you add too
level detection system. The electronic oil much oil, the engine or the catalytic
level measurement system is significantly converter could be damaged. Drain or
more accurate than oil level measurement siphon off any excess oil.
using the dipstick.
Checking the oil level with the dipstick
If the engine is also equipped with a dipstick,
this is subsidiary to the electronic oil level Check the engine oil level on a regular basis,
measurement system and is merely used for e.g. every week or each time you refuel.
a general check to determine if there is oil in X Park the vehicle/equipment on a horizontal
the engine. surface.
X Engage the parking brake.
Electronic oil level measurement –
X Switch off the engine.
system description
X Wait approximately five to ten minutes.
The engine oil level sensor is installed in the
oil pan for oil level measurement. The
electrical signals are detected in the engine
control (MR) control unit and transmitted to
the drive control (FR) control unit via the
engine CAN.
Output is in percentage values and can be
displayed on the instrument or on a matrix
display.
Operation 31
Adding DEF
Only use DEF that complies with DIN 70070/
ISO 22241. Do not use any additives. If DEF
comes into contact with painted or aluminum
surfaces, rinse the affected surfaces
immediately with plenty of water.
X Check the engine for leaks. spraying out. The engine cooling system and
X Check all hose connections, hose clamps the coolant expansion tank are pressurised
and pipe connections on the engine, as well when the engine is at normal operating
as the oil feed and return on the exhaust temperature. Wear gloves and eye protection.
gas turbocharger, for leaks and correct Only open the coolant expansion tank when
seating. the coolant temperature is below 50 †.
X Approximately five to ten minutes after
switching off the engine, check the engine G WARNING
Driving mode/working mode
oil level (Y page 30). Coolant contains glycol and is therefore toxic.
X Check the seating of the bracket secured Do not swallow the coolant. See a doctor
to the engine. immediately if you swallow coolant.
X Check the tightness of bolts on the exhaust Make sure that coolant does not come into
manifold, engine mountings, coolant pump, contact with skin, eyes or clothing. In case of
starter motor and air compressor. contact with eyes, rinse immediately with
plenty of clean water. Clean affected areas of
Starting the engine skin and clothing with soap and water
immediately. Change any affected clothing
G WARNING immediately.
Make sure you do not touch any hot or moving
engine components (e.g. exhaust manifold, Observe the information contained in the
poly-V-belt, fan) when the engine is running. equipment/vehicle operating instructions.
You could injure yourself. X Switch on the ignition.
Be aware of the road and traffic situation X Start the engine using the key in the ignition
when working on public roads and secure lock or the start button on the engine. Do
your position accordingly. not depress the accelerator or clutch pedal
while doing so. For equipment, the neutral
G WARNING position must be engaged.
There is a danger of limbs being caught, pulled The safety functions of the electronic engine
in and thereby crushed or severed by rotating control unit only allow the engine to be
engine parts. started when the transmission is in neutral or
Therefore you should: equipment is not being driven (disengaged).
Rkeep a safe distance between yourself and Starting and stopping the engine with the
rotating engine parts, including when the key
engine is being started. ! After starting the engine, let it run at idling
Rwait until all engine parts have stopped
speed until the oil pressure is displayed. If
moving before carrying out any work on the no oil pressure is displayed after
engine. approximately 10 seconds, switch off the
Rwear work clothing which is fastened and engine. Determine the cause. The
close-fitting. Wear a hair net if necessary. operating safety of the engine is
Remove jewelry such as watches and jeopardized.
necklaces.
G WARNING
When opening the coolant expansion tank,
there is a risk of scalding due to hot coolant
Operation 33
Z
34 Operation
Z
36 Operation
Repeated violations
In the event of repeated violations, the
periods for the operating restriction system
are shortened. When a malfunction is
eliminated (for example the NOx sensor is
replaced or reconnected), the operating
restrictions are reset. Normal operation can
be resumed.
Driving mode/working mode
Torque/time diagrams
Reduction in output during minor operating DEF level low
restriction
Z
38 Driving tips
Observe the following notes during the break- climate control, auxiliary heating)
in period up to 1250 miles/2000 km (30
operating hours): Operating mode
Ravoid subjecting the engine to full load. Your operating mode can help to keep the fuel
Rbreak in the engine with care by varying the consumption down:
road speed and engine revs. Ranticipate road and traffic conditions.
Ravoid high engine revs. Ravoid frequent acceleration and braking.
Rdo not drive at more than ¾ of the Rstay within the economical engine speed
maximum road speed for each gear. range.
Rchange gear in good time. Rif possible, avoid driving in mountainous
Rdo not shift down to brake the vehicle. terrain.
Rfor vehicles with automatic transmission, Rdo not allow the engine to idle when the
do not depress the accelerator pedal vehicle is stationary.
beyond the point of resistance (kickdown). Rdo not drive with unnecessary weight.
Only engage the shift ranges 4, 3, 2, or 1 Ravoid frequent cold starts.
when driving slowly. Rif possible, avoid frequent short journeys.
Refueling 39
After breaking in the engine, oil consumption ! DEF is not a fuel additive and must not be
Z
40 Winter operation
X Switch off the auxiliary heating system. ! The BlueTec® exhaust gas aftertreatment
X Observe the fuel grade (Y page 48). will cease to function correctly if you:
Rfill the DEF reservoir with cleaning agents
! Filter the fuel before transferring it to the or other service products or fuels
vehicle if you are refueling the vehicle from
Rmix in additives
barrels or containers.
Rdilute DEF
This will prevent malfunctions in the fuel
system due to contaminated fuel. Only use DEF in accordance with DIN
Driving mode/working mode
70070/ISO 22241.
i Regularly check the fuel prefilter with
Notify a qualified specialist workshop in the
heated water separator for condensation
event of incorrect filling.
(Y page 64).
You will find further information on DEF in the
"Service products" section (Y page 50).
DEF H Environmental note
Important safety notes Dispose of DEF in an environmentally
responsible manner.
G WARNING
If the DEF tank cap is opened at high Before filling the tank
temperatures, ammonia vapors may escape.
X Switch off the engine.
Ammonia vapors have a pungent odor and
particularly irritate: X Secure the vehicle/equipment against
rolling away.
Rskin
X Switch off the auxiliary heating system.
Rmucous membranes
Reyes
The vapors may cause a burning sensation in Bleeding the fuel system
the eyes, nose and throat as well as irritation
of the throat and watering eyes. If the fuel system is run dry, the system will
be bled the next time the engine is started
Avoid inhaling ammonia vapors.
after refueling. Automatic continuous
bleeding takes place in the filter.
G WARNING
The battery must be sufficiently charged
DEF must not come into contact with skin,
during the starting procedure to ensure that
eyes or clothing.
the fuel system can be bled.
RIf DEF comes into contact with your eyes or
Use the integrated hand pump
skin, rinse affected areas with clean water (Y page 82) to bleed the heated-fuel
immediately. prefilter with water separator mounted on the
RIf DEF is swallowed, immediately rinse your vehicle or equipment.
mouth out with a lot of clean water and
drink plenty of water.
RImmediately change out of clothing Winter operation
contaminated with DEF.
Cold-start aids
RIf allergic reactions occur, consult a
physician immediately. The following notes should be observed at the
Keep DEF out of the reach of children. start of the cold season.
Winter operation 41
G WARNING
Coolant contains glycol and is therefore toxic.
Do not swallow the coolant. See a doctor Observe this Operator's
immediately if you swallow coolant. Manual.
Make sure that coolant does not come into
contact with skin, eyes or clothing. In case of
contact with eyes, rinse immediately with Always aim to achieve the full condition of
plenty of clean water. Clean affected areas of charge. You can do this by means of careful
skin and clothing with soap and water maintenance and low electrical consumption.
The cold start capacity is reduced when it is
Z
42 Winter operation
Rdo not inhale fumes. Make sure that Products. Damage caused by the use of
enclosed spaces are adequately ventilated service products that have not been approved
to prevent poisoning. invalidates the Limited Warranty. For this
Rservice products must not come into reason, only use service products that have
contact with the skin, eyes or clothing. If been approved for your engine.
contact is made with a service product, You can recognize service products approved
clean the affected areas of skin with water by Mercedes-Benz by the following
and soap to prevent acid burns and other inscription on the container:
injuries. RMB Approval (e.g. Approval 228.5)
If coolant comes into contact with eyes, or
wash them with plenty of clean water.
RMB Approval 228.5
Rfire, open flames and smoking are
Other labels and recommendations relating
prohibited when handling service products,
to the quality or indicating that the product
due to their highly flammable nature.
meets a certain specification are not
Robserve the usage and warning notes on
necessarily approved by Mercedes-Benz.
the containers.
Further information is available from any
The use of approved service products is an authorized Mercedes-Benz Center or MTU
integral part of the Limited Warranty. Service Center (Y page 11).
! Special additives (except approved fuel i Information about service products that
additives) are neither required nor have been tested and approved by
approved for use with approved service Mercedes-Benz for your engine is available
products. Additives may cause damage to online at http://bevo.mercedes-
major assemblies. Therefore, do not mix benz.com/
any additives with service products. You i The specification and availability of
are responsible for the results of using fuel lubricants may vary. Individual lubricants
additives. may no longer be available, especially for
H Environmental note older engines. Information is available from
any authorized Mercedes-Benz Center or
Dispose of service products in an
MTU Service Center (Y page 11).
environmentally responsible manner.
Service products 45
For engines in vehicles/equipment and for Rthe fuel type, e.g. FAME fatty acid methyl
operation with diesel fuel, only use multi- ester fuel
grade engine oils compliant with Sheet For more details, see the Maintenance
Nos. 228.5, 228.51, 228.3 and 228.31 or in Booklet.
exceptional cases single-grade engine oils
compliant with Sheet No. 228.2. ! If you do not use oil for all-year-round
operation in your engine, change the
engine oil right at the beginning of the cold
Z
46 Service products
season. Use only an approved engine oil in specifications complied with when disposing
the specified SAE classification. of engine oils. Information is available from
If the SAE class (viscosity) of the engine oil any Mercedes-Benz or MTU Service center.
used is not suitable for continually low
outside temperatures below −20 †, this Adding engine oil
could cause engine damage.
The specified temperatures of the SAE Do not add too much oil. If you add too much
class always refer to freshly added oil. oil, the engine or the catalytic converter could
Engine oil ages during driving due to soot be damaged. Drain or siphon off any excess
and fuel residue. This impairs the oil.
When topping up, Mercedes-Benz
Maintenance and care
The corrosion inhibitor/antifreeze in the 326.3: before adding this corrosion inhibitor/
coolant has the following properties: antifreeze agent, the cooling system must
Ranti-corrosion protection first be flushed (Y page 73).
Rantifreeze protection When renewing the coolant, ensure that it
Rincreases the boiling temperature
contains a corrosion inhibitor/antifreeze
agent at a concentration of 50% by volume.
Leave the coolant in the engine all year round This corresponds to antifreeze protection
in order to prevent corrosion and to increase down to −37 †.
the boiling point. Also do this in countries with
Do not exceed a concentration of
hot outside temperatures.
55% by volume (antifreeze protection down to
Check the corrosion inhibitor/antifreeze
Z
48 Service products
depending on the fuel grade used. The higher Fatty acid methyl ester (FAME) fuel
the sulfur content in diesel fuel, the shorter (bio-diesel)
the maintenance intervals for engine oil and
filter replacement. Observe the notes in the General notes
Maintenance Booklet. ! To avoid damage to the assemblies and
components, observe the following points
Diesel fuels at low temperatures when using FAME fatty acid methyl ester
At low outside temperatures, paraffin fuel:
separation may cause the flow properties of Rhave the fuel filter and the oil filter
the diesel fuel to be insufficient. replaced approximately 1000 km after
fuel. Allow the engine to run for at least Observe the specifications in accordance
one hour before switching off the with Sheet no. 135.0 of the Mercedes-Benz
vehicle/equipment. Specifications for Service Products for
RMercedes Benz recommends that you do operation with FAME fatty acid methyl ester
not use FAME fatty acid methyl ester fuel fuel.
for engines that are not used for long Operating the vehicle with FAME fatty acid
periods of time, e.g. fire engines. methyl ester fuel results in:
Rthe auxiliary heating may only be Ra slightly higher fuel consumption
operated with conventional diesel fuel. Ra slightly reduced engine power output
Malfunctions may otherwise occur. Rincreased white smoke after a cold start
Maintenance and care
Z
52 Cleaning and care
Ensure that DEF is always pure to avoid Rabout 30 cm with 25° flat-spray jets
malfunctions in BlueTec® exhaust gas Rabout 30 cm with concentrated-power
aftertreatment.
jets
If DEF is pumped from the tank, e.g. during
repairs, do not use this fluid to refill the tank. ! Keep the water jet moving constantly
Otherwise, the purity of the fluid would no while cleaning. In this way, you will avoid
longer be guaranteed. causing damage.
Do not point the water jet at:
Relectrical
components
Cleaning and care Rplug connectors
Notes on care Rseals
Rhoses
G WARNING
Always keep care products sealed and out of
the reach of children. Always follow the
Cleaning the engine
instructions for the use of the care products.
Do not use fuel as a cleaning agent. Fuels are ! Observe the following notes when
highly flammable and hazardous to health. cleaning the engine. This avoids
malfunctions and damage to the engine.
Regular care helps to maintain the value of RWhen using high-pressure or steam
the engine. cleaners, do not point the spray directly
Mercedes-Benz recommends that you only at electrical components and electric
use care products that have been approved cables.
for Mercedes-Benz. You can obtain these RMake sure that no water enters the air
care products from any authorized Mercedes- intake and ventilation openings.
Benz Center or MTU Service Center RTreat the engine with preservative
(Y page 11).
agents after it has been cleaned. When
doing so, protect the belt drive system
from the preservative agent.
High-pressure cleaning
ROnly use wax-based protective agents
! The exhaust gas aftertreatment system for engines that comply with
may only be cleaned when it is cool. The Sheet no. 385.4 of the Mercedes-Benz
sensors can otherwise be damaged. Specifications for Service Products.
Maintenance 53
G WARNING
Maintenance work that is carried out
incorrectly or not at all, e.g. not changing the
oil filter or not observing maintenance
intervals, can cause engine damage. Engine
failure can lead to an increased risk of
accidents.
Therefore, observe the notes on engine
maintenance in these Operating Instructions.
H Environmental note
If circumstances demand that you have to do
some maintenance work yourself,
environmental protection requirements must
be observed. When disposing of service
products, e.g. engine oil, you must comply
with the legal requirements. This also applies
to all parts, e.g. filters, that have been in
contact with service products. For vehicles
operated on fatty acid methyl ester FAME,
observe the special instructions on disposing
of engine oil. For more information, visit a
qualified specialist workshop. Dispose of
empty containers, cleaning cloths and care
products in an environmentally responsible
manner. Observe the instructions for care
products. Do not let the engine run longer
than necessary when stationary.
Z
54
55
Notes on maintenance
56 Work schedule overview
G WARNING
There is a danger of limbs being caught, pulled in and thereby crushed or severed by rotating
engine parts.
Notes on maintenance
Without BlueTec®
With BlueTec®
Maintenance schedule for maintenance service
Engine: oil and filter change
AP18.00-G-0101CH5 Operation with diesel fuel: carry out an oil and filter change • •
at least every two years. If operating using acid methyl ester (bio-diesel):
change the oil and filter at least once a year.
Check and adjust the fluid level
AP20.00-W-2010MT Engine cooling system: check corrosion/antifreeze • •
protection. Adjustment subject to a separate invoice. In the event of fluid loss, find
the cause and remedy it. For further information, see the vehicle manufacturer's
instructions.
Engine
AP13.22-G-1351CH Check poly-V-belt for wear and damage. • •
Without BlueTec®
With BlueTec®
Additional maintenance work every second maintenance service (Z2)
AP05.30-G-0560CH Check V2 valve clearance, adjust (first maintenance service, • •
3rd, 5th, 7th etc.).
AP14.40-G-1481DD Replace DEF filter. •
Notes on maintenance
Additional work every third maintenance service (Z3)
AP47.20-G-0730CI Fuel prefilter: clean the filter element. • •
AP47.20-G-0783DD Fuel prefilter with water separator: replace fuel filter. • •
AP47.20-G-0780CI Fuel filter: replace fuel filter element. For operation with FAME • •
fuels (bio-diesel): replace fuel filter at the same time as renewing the engine oil
and replacing the filter.
Engine brake: check condition and setting. • •
Final inspection
Visual check/road test/test rig: check that the equipment is safe to operate/ • •
check that the vehicle is roadworthy.
Without BlueTec®
With BlueTec®
Z
58 Work schedules
Without BlueTec®
With BlueTec®
AP09.00-W-0953A Intake pipe between air filter, charge-air cooler and engine - • •
check for leaks and condition.
AP20.20-W-T052A All reservoirs, covers, bellows, protective caps. • •
AP20.00-W-2050A Heating system: condition check, radiator, lines and hoses. • •
Notes on maintenance
X Unscrew oil filter cap : using a socket X To siphon off engine oil: pull out
wrench insert (SW 36). Allow the oil to drain dipstick :.
from the filter housing. X Insert the extractor system into the guide
X Remove oil filter cap : with oil filter tube, using an O-ring to seal it.
element = and unclip oil filter X Siphon off the engine oil through the guide
element = by pressing in a sideways tube.
direction.
i Observe the extraction pump operating
X Replace sealing ring ; on cap :.
instructions.
X Lightly grease sealing ring ;.
G WARNING
X Insert new oil filter element = into oil filter
Hot engine oil escaping under pressure can
cap : and press until it clips into place.
scald your skin and eyes.
X Screw on oil filter cap : with the oil filter
Notes on maintenance
Wear suitable protective gloves, protective
element and tighten. Tightening torque: clothing and safety goggles.
(Y page 99).
: Dipstick
; Filler neck
Z
60 Work schedules
: Dipstick
; Filler neck
X Add the new engine oil at filler neck ;. : - B Cylinder number
Select the SAE viscosity class of engine oil # Intake valve
in accordance with outside temperatures.
J Exhaust valve
Engine oil capacity (Y page 98).
C Flywheel side
X Check the oil level (Y page 30)
X Start the engine without depressing the
Special tool
accelerator pedal. When running at idling
speed, observe the oil pressure display.
! Keep the engine running at idling speed
until an oil pressure reading is displayed. If
no oil pressure is displayed after
approximately 10 seconds, switch off the
engine. Determine the cause.
X Check the oil filter cap and the drain plug
for leaks.
X Check the engine oil level again after 5
minutes (Y page 30) and add oil if
Cranking device 904 589 04 63 00
necessary.
Valve adjustment tool 422 589 00 11 00 (no
image)
Work schedules 61
Notes on maintenance
Example: mounting of the cylinder head covers
G WARNING X Clean very dirty cylinder head covers
If not properly secured, a vehicle might before removal.
accidentally be set in motion, knocking X Remove screws ; on cylinder head
somebody down or trapping them or causing
cover :.
an accident and injuring you or others.
X Remove cylinder head cover :.
RAlways prevent the vehicle from rolling
away by applying the parking brake and, if X Remove gasket = between the cylinder
G WARNING
If the engine starts automatically, there is a
risk of injury by limbs being crushed between
the moving parts.
Secure the engine against unintentional
starting before carrying out maintenance or
repair work.
G WARNING
The engine becomes very hot while it is
running and remains so for some time after it
has stopped. It will cause burns if touched.
Before starting any work on the engine, allow
all engine parts to cool down, or wear suitable
Example: flywheel inspection hole
gloves and items of clothing to protect
X Unscrew the cap from the inspection hole
yourself from being burned on hot engine
components. in the flywheel housing.
X install the cranking device 904 589 04 63
00 (Y page 60) to the flywheel housing
inspection hole. Tightening torque: 25 Nm.
Z
62 Work schedules
Special tool
Cranking device: 904 589 04 63 00
(Y page 60).
Notes on maintenance
housing inspection hole. Tightening torque:
25 Nm.
X Make a chalk mark on the poly-V-belt.
X Check the poly-V-belt section by section for
damage. To do this, turn the engine or poly-
V-belt gradually using the cranking device
until the chalk mark is reached again.
X Remove the cranking device.
X Screw the cap into the inspection hole in
the flywheel housing and tighten it.
Tightening torque: 25 Nm. B Rubber nodules at the base of the belt
X Replace the poly-V-belt:(Y page 91). C Deposits of dirt and stones
Patterns of damage
! Replace the poly-V-belts if one of the
following damage patterns occurs on the
poly-V-belt.
Z
64 Work schedules
Notes on maintenance
There is an increased risk of fire when
handling fuels as they are highly flammable.
Avoid fire, open flames and sparks, and
X Vehicle with fuel prefilter at tank level: refrain from smoking when handling fuels.
close shutoff valve ?.
X Place a collector under water drain valve H Environmental note
E. Dispose of used filter elements, seals and fuel
X Open water drain valve E and bleed screw residue in accordance with relevant local
=. Collect the draining water-fuel mixture regulations.
while doing so.
H Environmental note
X Unscrew filter element A from filter
If the diesel fuel level (fuel tank) is above
head :. engine height, the feed line must be blocked
X Unscrew water separator D from filter off during filter replacement. Otherwise,
element A and clean or replace as diesel can drain out.
necessary.
X Replace filter element A.
X Screw water separator D with new sealing
ring C onto filter element A until it is
hand-tight. Lubricate sealing ring C with a
thin coat of engine oil beforehand.
X Screw filter element A with new sealing
ring B onto filter head : until it is hand-
tight. Lubricate sealing ring B with a thin
coat of engine oil beforehand.
X Close water drain valve E.
X Vehicle with fuel prefilter at tank level:
open shutoff valve ?.
X Push manual fuel pump ; repeatedly until
the fuel escapes free of bubbles from bleed
screw =.
X Close bleed screw =.
Z
66 Work schedules
X Clean the outside of the filter housing. Ammonia vapors have a pungent odor and
X Open the fuel filler cap to prevent excess particularly irritate:
pressure in the fuel tank. Rskin
X Unscrew fuel filter cap : using a socket Rmucous membranes
wrench insert (SW 36). Reyes
X Pull fuel filter cap : with filter element The vapors may cause a burning sensation in
= out of the filter housing slightly. Allow the eyes, nose and throat as well as irritation
the fuel to drain off. of the throat and watering eyes.
X Remove the cap and filter element. Unclip Avoid inhaling ammonia vapors.
the filter element by pressing the sides of
the lower edge of the filter element. G WARNING
DEF must not come into contact with skin,
Notes on maintenance
Notes on maintenance
RDo not continue to use DEF which
contains traces of impurities.
DEF pump/filter unit
Fire fighting measures
: Pump module
DEF is not flammable. In the event of a fire, ; Filter element
NH3 (ammonia) may be released. This may
= O-ring
result in a risk of poisoning. Measures to
? Filter bowl
extinguish a fire must therefore be adapted
to suit the surroundings. A Dust protection cap
H Environmental note
Disposing of DEF:
RDue to its easy degradability, small
amounts of spilled DEF can be washed into
the sewage system without any problems.
RLarger amounts of DEF must be disposed
of correctly, observing the regulations on
waste treatment/disposal.
RPackaging that is contaminated with DEF
residue must be treated in the same way as
DEF. Packaging should be emptied as Hose clamp 000 589 54 37 00
thoroughly as possible, cleaned X Clamp the feed and return lines on the
appropriately and then recycled. pump/filter unit using hose clamps.
X Place a suitable receptacle under the pump
filter unit to collect any DEF fluid that
escapes.
X Unscrew filter bowl ? from the pump/
filter unit.
X Remove filter element ;.
X Smear O-ring = on new filter element ;
thinly with MB silicon grease before
assembly.
Z
68 Work schedules
Notes on maintenance
Equalize the pressure loss.
X Screw the dust protection cap onto the
valve of the pressure reservoir.
Throttle valve lever in operating position
: Bracket
Engine brake - checking condition and ; Notch of throttle valve shaft
setting = Throttle valve lever
? Wire circlip
A Clamp screws
The throttle valve lever must rest on
bracket : when the engine brake cylinder is
in the rest position (cylinder retracted). If this
is the case, the return spring pretension of the
engine brake cylinder is adequate.
X Remove wire circlip ? from the ball socket
of the engine brake cylinder.
X Check the engine brake cylinder, ball
coupling, ball socket and the throttle valve
shaft for wear.
X Check the seating of throttle valve lever
= on the throttle valve shaft and retighten
clamp screw A if necessary.
Throttle valve lever in rest position
: Bracket X Turn throttle valve lever = to the operating
; Notch of throttle valve shaft position. When the inner stop is reached,
there must still be a gap between the
= Throttle valve lever
outside of throttle valve lever = and
? Wire circlip bracket :.
X Lubricate the ball socket with heat-
resistant lubricant (part number A000 989
76 51).
Z
70 Work schedules
X Press the ball socket back onto the ball grade (Y page 46). This helps to prevent
coupling, install wire circlip ?. damage to the engine.
X When the engine brake is applied, check X Open the engine cooling system cap slowly,
the clearance between throttle valve lever relieving the excess pressure.
= and bracket : again. X Check the antifreeze/corrosion inhibitor
concentration using a testing device. The
correct antifreeze/corrosion inhibitor
Engine cooling system concentration in the coolant of
50% by volume is provided for antifreeze
Checking and correcting the fluid level protection down to Ò37 †. If a lower level
and the antifreeze/corrosion inhibitor of antifreeze protection is indicated,
G WARNING correct the mixture ratio.
Notes on maintenance
X Check the coolant level and top up if X Check the coolant level and correct if
necessary. necessary.
X Check/correct the coolant antifreeze X Replace coolant expansion tank cap and
protection content. tighten it.
X Rub dry the inside of coolant filler
neck ; with a lint-free cloth.
X Mount pressure tester tool : on the filler Renewing the coolant
neck of the coolant expansion tank. G WARNING
X Connect the compressed-air hose with tire
When opening the coolant expansion tank,
inflation connection to pressure tester there is a risk of scalding due to hot coolant
tool : and set it to a test pressure of spraying out. The engine cooling system and
1.0 bar. the coolant expansion tank are pressurised
Notes on maintenance
The test pressure should correspond to the when the engine is at normal operating
value at which the cooling system pressure temperature. Wear gloves and eye protection.
relief valve opens. The release pressure can Only open the coolant expansion tank when
be determined from the value on the cap or the coolant temperature is below 50 †.
pressure relief valve.
Example: code 100 = 1.0 bar excess G WARNING
pressure. Coolant contains glycol and is therefore toxic.
X After about 5 - 10 minutes, read the Do not swallow the coolant. See a doctor
manometer on tester : to check for immediately if you swallow coolant.
pressure loss. After 5 - 10 minutes, there Make sure that coolant does not come into
must be no drop in pressure detected on contact with skin, eyes or clothing. In case of
the manometer. Do not exceed the test contact with eyes, rinse immediately with
pressure and the test time, as this may plenty of clean water. Clean affected areas of
damage the cooling and heating system. skin and clothing with soap and water
If the cooling system/heating system is immediately. Change any affected clothing
leaking, this will become apparent due to a immediately.
drop in pressure, indicated by the
manometer on tester :. Before renewing the coolant, check the
X If there is a loss of pressure in the cooling cooling and heating system for leaks and
system leading to visible loss of coolant, condition. Have the coolant renewal
have the leak in the cooling or heating confirmed in the Maintenance Booklet.
system repaired.
X If there is a pressure drop with no visible
Draining the coolant
loss of coolant: have the cause identified H Environmental note
and immediately rectified by a qualified Dispose of used coolant in accordance with
specialist workshop. current local regulations.
X Release the pressure using pressure tester
tool : and remove pressure tester
tool : from the coolant expansion tank
filler neck.
Z
72 Work schedules
Adding coolant
X Add coolant.
X Start the engine and run it at varying
speeds for approximately 1 minute.
X Add coolant mixed to the prescribed ratio
until it reaches the lower edge of the filler
Notes on maintenance
neck.
X Switch off the engine and seal the cooling
system again.
: Example: coolant drain plug on the
crankcase Observe any further information in the
operating instructions from the equipment/
X Undo the engine cooling system cap slowly,
vehicle manufacturer.
relieving the excess pressure, and remove
it. ! Corrosion/antifreeze additives compliant
X Heating systems: open the heating system with Sheet 325.3 and 326.3 must not be
temperature control (control valve). mixed with those of Sheet 325.0/2 or
X Cover the lines etc. under the coolant drain 326.0/2. This helps to prevent damage to
plugs. the engine cooling system.
X Place a suitably sized receptacle
underneath to catch the coolant. Cleaning the cooling system
X Connect the drain hose to the radiator
coolant drain pipe. G WARNING
X Unscrew coolant drain plugs : from the
The cooling system is pressurized. Hot
coolant can escape under pressure when the
crankcase and radiator and collect the
cooling system is opened and scald your skin
coolant.
and eyes.
X If there are additional coolant drain plugs ROnly open the cooling system at coolant
in the system, open these as well and temperatures below 90 †.
completely drain the system. RUnscrew the cap slowly and release any
X Clear blocked drainage openings of excess pressure completely before
deposits. opening the cap fully.
X Tighten coolant drain plug : on the engine RWear suitable protective gloves, protective
with a new seal (tightening torque: clothing and safety goggles when handling
60 Nm). coolant.
X Attach the other drain plugs (without hose
connections) with new seals and screw G WARNING
them in tight. Tightening torque Coolant contains glycol and is therefore toxic.
(Y page 99). Do not swallow the coolant. See a doctor
immediately if you swallow coolant.
Work schedules 73
Make sure that coolant does not come into Checking for leaks and general
contact with skin, eyes or clothing. In case of condition – assemblies
contact with eyes, rinse immediately with X Carry out a visual inspection of the engine
plenty of clean water. Clean affected areas of
for signs of leaks. Slight dampness around
skin and clothing with soap and water
sealed joints can be ignored.
immediately. Change any affected clothing
immediately. ! More severe leaks, where there is
constant oil loss, must be rectified
H Environmental note immediately.
Collect used coolant, cleaning solutions and
detergents and dispose of them in an
environmentally responsible manner in Lines, hoses and sensor cables –
accordance with applicable local regulations. checking for leaks and general
Notes on maintenance
condition
X Remove foreign objects (dust, insects, etc.)
X Carry out a visual check for leaks from lines
from the radiator core fins. You can do this
by blowing them out with compressed air and hoses. At the same time, check that all
or by spraying water from the rear side of lines and hoses are undamaged, are routed
the radiator, for example. so they do not chafe and are secured
correctly.
! Only apply moderate pressure when X Check the intake pipe between the air filter
cleaning, since the radiator fins could and the engine for leaks and check the
otherwise be damaged. condition.
X Drain off coolant when the engine is cold X Check the intake pipe and bellows from the
(Y page 71). air filter as well as the charge-air cooler for
X If a heater is connected to the cooling the engine for damage and for leaks at
system, open the regulating valves fully. connection points.
X Check the air compressor intake pipe and
Flushing the cooling system crankcase ventilation for damage and leaks
at the connection points.
X Fill the cooling system with fresh water. X Check all hose clamps for correct seating.
X Start the engine and allow it to run for about Retighten or replace loose hose clamps.
5 minutes. X Replace porous, leaking or damaged lines
X Switch off the engine and drain off the and bellows.
water completely.
X Repeat the flushing process at least twice. G WARNING
X Fill the cooling system with new corrosion The engine becomes very hot while it is
inhibitor/antifreeze agent. Observe the running and remains so for some time after it
antifreeze protection (Y page 70). has stopped. It will cause burns if touched.
Before starting any work on the engine, allow
all engine parts to cool down, or wear suitable
Degreasing the cooling system
gloves and items of clothing to protect
X If necessary, degrease the cooling system yourself from being burned on hot engine
with a suitable cleaning agent. Information components.
is available from any authorized Mercedes-
Benz Center or MTU Service Center
(Y page 11).
Z
74 Work schedules
G WARNING
There is a danger of limbs being caught, pulled
in and thereby crushed or severed by rotating
engine parts. Therefore you should:
Rkeep a safe distance between yourself and
rotating engine parts, including when the
engine is being started.
Rwait until all engine parts have stopped
moving before carrying out any work on the
engine.
Rwear work clothing which is properly
fastened and close-fitting. Wear a hair net
Notes on maintenance
do so. When screwing in the coolant drain Carrying out protective measures for
plug, observe the tightening torque. the air compressor
RRelieve the tension in the poly-V-belt. The
Carry out the protection of the air compressor
poly-V-belt can remain routed. at the same time as the combustion chamber
RIf the engine has been filled with coolant, protection.
the engine cooling system must first be X On the air intake side of the compressor,
filled with water. It must then be filled with
pour a maximum of 5 cm3 of initial
a mixture of water and improver compliant
operation oil compliant with
with Sheet No. 311.0. Coolant without
Sheet No. 225.6 into the compressor.
antifreeze protection compliant with
Sheet No. 312.0 may also be used.
After protective measures
X re-install all removed engine parts. Observe
Protective treatment for 12 to 36 the tightening torques.
months
! After protective measures are complete,
Decommission and protection
X Carry out protective measures for the fuel oil pressure, coolant temperature and oil
system. temperature.
X Warm up the engine at medium engine
speeds and allow it to run for approximately
5 to 10 minutes at operating temperature
(coolant temperature 75 to 95 †).
X Switch off the engine and check the oil level
(Y page 30).
X Hermetically seal all engine openings.
X Drain off the coolant completely for
engines that have been removed. Unscrew
the coolant drain plug in the crankcase to
do so.
Breakdown assistance
ning mode ............................................ 83
Troubleshooting .................................. 85
BlueTec® exhaust gas aftertreat-
ment indicator (on-highway ver-
sion) ..................................................... 90
BlueTec® exhaust gas aftertreat-
ment indicator (off-highway ver-
sion) ..................................................... 91
Replacing the poly-V-belt ................... 91
82 Bleeding the fuel system
Breakdown assistance
X Close water release valve B.
X On vehicles with fuel prefilter at tank level:
open shutoff valve =.
X Start the engine and allow it to run for about
one minute.
The fuel system is bled automatically.
X Check the fuel system for leaks.
Z
84 Activating engine emergency running mode
Troubleshooting
Engine problems
G WARNING
Breakdown assistance
If maintenance work is carried out incorrectly, the operating safety of your vehicle may be
affected. This could cause you to lose control of your vehicle and cause an accident. Moreover,
the safety systems may no longer be able to protect you or others as they are designed to do.
Always have service work carried out at a qualified specialist workshop.
Apart from careful operation and maintenance of the engine it is also important that
malfunctions be rectified in good time. You can rectify certain malfunctions yourself.
Have malfunctions that you cannot eliminate yourself rectified at a qualified specialist
workshop.
Problem Possible causes/consequences and M Solutions
Drive pinion does not The battery is not sufficiently charged.
turn or turns too slowly. X Charge the battery.
Z
86 Troubleshooting
(Y page 45).
The engine does not There is a malfunction in the engine control unit.
start correctly. X Read out the MR (engine control) unit, have it checked at a
qualified specialist workshop.
The engine stops The MR (engine control) unit is faulty (total failure).
inadvertently. X Consult a qualified specialist workshop.
The engine is in There is an interruption to the MR/ADM control unit's data flow.
emergency running X Read out the control unit's malfunction memory.
mode. X Have it checked at a qualified specialist workshop.
The engine surges, The crankshaft position sensor or camshaft position sensor (on
vibrates or runs the camshaft gear) is faulty or is not emitting a signal.
irregularly. X Consult a qualified specialist workshop.
Breakdown assistance
fan speed.
X Thermostat malfunction: consult a qualified specialist
workshop.
There is an interruption There is an increased voltage drop to the MR/ADM control unit
in the tractive power. (loose contact).
X Check the battery terminals and the connectors on the MR/
ADM control unit for secure seating and corrosion.
The engine braking There is an engine brake flap malfunction or a malfunction in the
effect is poor. actuation.
X Carry out a function check/visual check.
X Consult a qualified specialist workshop.
Z
88 Troubleshooting
The engine cuts off too The engine management (MR) control unit is malfunctioning or
early (maximum engine parametrized incorrectly.
speed cannot be X Consult a qualified specialist workshop.
reached).
Engine gets too hot There is not enough coolant in the cooling system.
(according to coolant X Top up, bleed (Y page 72)
temperature gauge).
The coolant temperature sensor or display is faulty.
X Replace sensor or display.
The radiator is dirty on the inside; the radiator is very dirty on the
outside.
X Clean the radiator.
Breakdown assistance
The engine brake is faulty.
X Consult a qualified specialist workshop.
Exhaust fumes are The oil level in the engine is too high; the crankcase ventilation
blue. system is faulty; engine oil has entered the combustion chamber.
X Adjust the oil level correctly.
X Have the crankcase ventilation system checked at a qualified
specialist workshop.
There are abnormal Leaks in intake pipe and exhaust pipe cause whistling noise.
sounds. X Repair leaks; replace seals if necessary.
Z
90 BlueTec® exhaust gas aftertreatment indicator (on-highway version)
G WARNING
Breakdown assistance
If maintenance work is carried out incorrectly, the operating safety of your vehicle may be
affected. This could cause you to lose control of your vehicle and cause an accident. Moreover,
the safety systems may no longer be able to protect you or others as they are designed to do.
Always have service work carried out at a qualified specialist workshop.
6 The engine output is not reduced in the case of emergency vehicles, e.g. fire engines.
Replacing the poly-V-belt 91
Breakdown assistance
Problem System message
DEF level low The å DEF indicator lamp lights up.
DEF quality not OK
DEF level too low, no supply RThe å DEF indicator lamp flashes.
DEF quality not OK for a long time RThe È torque limitation indicator lamp lights
up.
RBeginning of operating restriction.
DEF level too low, supply not RThe å DEF indicator lamp flashes.
sustainable RThe È torque limitation indicator lamp lights up
DEF quality not sustainable at the beginning of operating restriction.
RThe È torque limitation indicator lamp flashes
in the event of permanent operating restriction
and a low torque value prior to tightening.
Detection of: Problem is detected:
RDEF level sensor disconnected RThe å DEF indicator lamp lights up.
RDEF metering line or metering RThe ! indicator lamp lights up.
valve disconnected Problem continues for a long time:
RDEF metering line or metering
RThe å DEF indicator lamp flashes.
valve blocked
RThe ! indicator lamp lights up.
RDEF metering pump disconnected
RThe È torque limitation indicator lamp lights up
RSCR cable set disconnected
at the beginning of operating restriction.
RNOx sensor disconnected
RThe È torque limitation indicator lamp lights up
RDEF temperature sensor
during active operating restriction.
disconnected
RExhaust gas temperature sensor
Problem is continuous:
disconnected RThe å DEF indicator lamp flashes.
RThe ! indicator lamp lights up.
RThe È torque limitation indicator lamp lights up
at the beginning of torque limitation.
RThe È torque limitation indicator lamp flashes
in the event of permanent operating restriction
and a low torque value prior to tightening.
Z
92 Replacing the poly-V-belt
Technical data
94 Engine data card
OM 460 L A
OM Oil engine
Information on the engine data plate (diesel)
The following data is contained on the engine 460 Engine type
data plate in the form of numbers stamped
directly onto the crankcase: L Intercooler
A Exhaust gas
turbocharger
Dimensions
Technical data
Engine data card
The engine data card describes the scope of
delivery from the Mercedes-Benz factory.
Later changes to the scope of delivery are not
recorded on the data card.
Conversion parts on the engine which change
the scope of the engine delivered by
Mercedes-Benz must be recorded on the data
card.
In order to prevent incorrect ordering of
replacement parts, the Mercedes-Benz
replacement parts service must also be
informed.
Engine data
Dimensions and weights
OM 457 LA OM 460 LA
All data refers to the standard version of the
respective engine type. Deviations may A = engine 1320 mm 1320 mm
occur, depending on the installation situation length
in the vehicle/equipment.
B = engine 750 mm 750 mm
width
C = engine 1115 mm 1115 mm
height
96 Engine data
Weights
OM 457 LA OM 460 LA
Dry engine 930 kg 930 kg
maximum
Wet engine 980 kg 980 kg
maximum
Technical data
Engine data 97
General data
All data refers to the standard version of the respective engine type. Data for other versions
is available on request.
Engine Engine type OM 457 LA OM 460 LA
Assembly model series 457.9 458.9
Type Turbocharged in-line engine with intercooler
Combustion principle 4-stroke diesel direct injection
Technical data
Number of cylinders 6 6
Bore 128 mm 128 mm
Piston displacement 155 mm 166 mm
Engine capacity 11970 cm3 12820 cm3
Type of cooling system Forced circulation cooling
Engine rotation Counter-clockwise (when looking at the flywheel)
direction
Valve Intake valve 0.40 mm 0.40 mm
clearance
Exhaust valve 0.60 mm 0.60 mm
Starter Starter Electric Electric
motor
Voltage 24 V 24 V
Output 7.0 kW 7.0 kW
Battery Voltage 12/24 V 12/24 V
Cold-discharge test Maximum 700 A Maximum 700 A
current
Cold start ability Down to maximum Ò20 † (battery charge level
75%)
Alternator Voltage 28 V 28 V
Current intensity 35/80 A 35/80 A
Operating data
Capacities
Technical data
Engine Protective wax - Wax preservative (385.4)
compartment
Engine brake Heat-resistant lubricant - Heat-resistant lubricant (part
number A000 989 76 51)
Tightening torques
All threads on mechanical components and the corresponding contact surfaces must be clean,
smooth and coated with engine oil. Other lubricants lead to substantially different tightening
torques.
Engine Cylinder head cover Light alloy (with oil filler cap) 25 Nm
Plastic (without oil filler cap) 20 Nm
Valve clearance setting Counternut to the rocker arm 50 Nm
adjustment screw
Inspection hole cap on the timing case 25 Nm
Flywheel housing rotation device 25 Nm
Charge-air distributor at cylinder head 30 Nm
Fuel system Cap on the fuel filter housing 25 Nm
Oil circuit Drain plug on the oil pan M 18 x 1.5 50 Nm
M 20 x 1.5 70 Nm
M 22 x 1.5 80 Nm
M 26 x 1.5 90 Nm
Oil filter cap on the oil filter housing 40 Nm
Cooling system Coolant drain screw On the crankcase 60 Nm
On the radiator 2 Nm
Exhaust gas Filter bowl on the DEF pump module 32 Nm
aftertreatment
94.8% - 100% Oil level too high Yellow “CHECK” fault lamp
90% MAX
10% - 90% Permissible range
10% MIN
0% Oil level too low Yellow “CHECK” fault lamp
and fault entry
0% (+ continuously below the Oil level too low Red “STOP” stop lamp,
lower threshold) Critical engine operation warning buzzer and fault
entry
Imprint
Internet
Documentation team
As at 25.06.2012
Éohne-ËÍ
ohne