MBE 900 OPERATOR'S GUIDE - ddcsn.comddcsn.com/cps/rde/xbcr/ddcsn/DDC-SVC-MAN-0055.pdf · MBE 900...

MBE 900 OPERATOR'S GUIDE

To the Operator

This guide contains instructions onthe safe operation and preventivemaintenance of your Detroit DieselMBE 900 engine. Maintenanceinstructions cover routine engineservices such as lube oil and filterchanges in enough detail to permitself-servicing if desired.

The operator should become familiarwith the contents of this guide beforeoperating the engine or carrying outmaintenance procedures.

Power-driven equipment is onlyas safe as the person operating thecontrols. You are urged, as theoperator of this diesel engine, to keepfingers and clothing away from therevolving belts, drive shafts, etc. onengine installation.

Throughout this guide CAUTIONSregarding personal safety andNOTICES regarding engineperformance or service life willappear. To avoid personal injury andensure long engine service life, alwaysheed these instructions.

Whenever possible, it will benefit youto rely on an authorized Detroit Dieselservice outlet for all your serviceneeds from maintenance to majorparts replacement. Authorized serviceoutlets worldwide stock factoryoriginal parts and have the specializedequipment and experienced, trained

personnel to provide promptpreventive maintenance and skilledengine repairs.

The information and specificationsin this publication are based on theinformation in effect at the time ofapproval for printing. Contact anauthorized Detroit Diesel serviceoutlet for information on the latestrevision. The right is reserved tomake changes at any time withoutobligation.

NOTICE:

Coolant must be inhibited withthe recommended SupplementalCoolant Additives (SCA) listed inthis guide. In addition, the enginecan be equipped with a coolantfilter/inhibitor system as an installedoption or as an after-sale item.Failure to check and maintain SCAlevels at required concentrations willresult in severe damage corrosionto the engine cooling system andrelated components.

Trademark Information

Detroit Diesel®, DDEC®, andDiagnostic Link® are registeredtrademarks of Detroit DieselCorporation. Nexiq™ is a trademarkof Nexiq Technologies, Inc. All othertrademarks are the property of theirrespective owners.

All information subject to change without notice. (Rev. 04/08) iDDC-SVC-MAN-0055 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION


TABLE OF CONTENTS

CAUTION SUMMARY .......................................................................... 1ENGINE OPERATION ..................................................................... 1PREVENTIVE MAINTENANCE ....................................................... 2ELECTRICAL SYSTEM ................................................................... 4COOLING SYSTEM ......................................................................... 6AIR INTAKE SYSTEM ...................................................................... 6FUEL SYSTEM ................................................................................ 7COMPRESSED AIR ......................................................................... 9LUBRICATING OIL AND FILTERS .................................................. 9

IDENTIFICATION ................................................................................. 10PERSONNEL REQUIREMENTS ..................................................... 13ENGINE CONVERSIONS AND MODIFICATIONS .......................... 14GENERAL VIEW OF THE MBE 900 ENGINE ................................. 14ENGINE IDENTIFICATION NUMBER ............................................. 21DESCRIPTION OF THE ENGINE .................................................... 22

EXHAUST GAS RECIRCULATION ............................................. 23EXHAUST BRAKE/CONSTANT-THROTTLE VALVES,OPTIONAL ....................................................................................... 24ELECTRONIC ENGINE CONTROL SYSTEM ................................. 25

DDEC-ECU .................................................................................. 26DDEC-VCU .................................................................................. 27

SENSOR LOCATIONS .................................................................... 28

OPERATION ........................................................................................ 31BEFORE STARTING THE ENGINE ................................................ 31

CHECKING THE BATTERIES ..................................................... 31CHECKING THE OIL LEVEL ....................................................... 32CHECKING THE COOLANT LEVEL (COLD CHECK) ................ 33ADDING FUEL ............................................................................. 33PRIMING THE FUEL SYSTEM ................................................... 33

STARTING THE ENGINE ................................................................ 33CHECKING THE COOLANT LEVEL (HOT CHECK) .................. 34STARTING AN ENGINE THAT HAS NOT BEEN RUN FOR ANEXTENDED PERIOD .................................................................. 35

All information subject to change without notice. (Rev. 04/08) iiiDDC-SVC-MAN-0055 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

TABLE OF CONTENTS

MONITORING ENGINE OPERATION ............................................. 36BATTERY CHARGE .................................................................... 36OIL PRESSURE .......................................................................... 36EXCESSIVE IDLING ................................................................... 37

CHANGING THE IDLE SPEED ....................................................... 37SHUTTING DOWN THE ENGINE ................................................... 37

SHUTTING DOWN AFTER HARD OPERATION ........................ 37EMERGENCY RUNNING MODE .................................................... 38STOP ENGINE OVERRIDE OPTION .............................................. 38COLD WEATHER OPERATION ...................................................... 39

WINTER FRONTS ....................................................................... 39

CLEANING AND STORAGE ............................................................... 40CLEANING THE ENGINE ................................................................ 40

HIGH-PRESSURE CLEANING EQUIPMENT ............................. 40CLEANING THE COOLING SYSTEM ............................................. 40

DEGREASING ............................................................................. 41STORAGE ........................................................................................ 42

TROUBLESHOOTING ......................................................................... 43EMERGENCY STARTING ............................................................... 43TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROLSYSTEM .......................................................................................... 43GENERAL TROUBLESHOOTING ................................................... 43

SERVICE PRODUCTS ......................................................................... 56DIESEL FUELS ................................................................................ 56

FLOW IMPROVERS .................................................................... 56KEROSENE ................................................................................. 56

ENGINE OILS .................................................................................. 57EGR ENGINES ............................................................................ 57NON-EGR ENGINES ................................................................... 58SYNTHETIC OILS ....................................................................... 58

COOLANT ........................................................................................ 58FULLY-FORMULATED ANTIFREEZE ......................................... 58WATER ........................................................................................ 59COOLANT SPECIFICATIONS ..................................................... 59COOLANT CONCENTRATION ................................................... 59

iv All information subject to change without notice. (Rev. 04/08)DDC-SVC-MAN-0055 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION


SUPPLEMENTAL COOLANT ADDITIVES FOR FULLYFORMULATED COOLANT .......................................................... 60DROPOUT ................................................................................... 61DISPOSAL ................................................................................... 61

COLD WEATHER PRODUCTS ....................................................... 61WINTER-GRADE DIESEL FUEL ................................................. 61LOW-VISCOSITY ENGINE OIL ................................................... 62WINTER COOLANT ANTIFREEZE PROTECTION .................... 62BATTERIES ................................................................................. 62

TECHNICAL DATA .............................................................................. 64ENGINE DATA FOR EGR ENGINE ................................................. 65ENGINE DATA FOR NON-EGR ENGINE ........................................ 66TESTING AND ADJUSTING VALUES ............................................. 67

MAINTENANCE ................................................................................... 68SCHEDULED INTERVALS .............................................................. 68

MAINTENANCE SCHEDULE TYPES ......................................... 68SEVERE SERVICE ................................................................. 68SHORT-HAUL ......................................................................... 69LONG-HAUL ........................................................................... 69OPERATING HOURS VS. FUEL CONSUMPTION (OIL DRAININTERVAL ONLY) ................................................................... 69UNIMOG .................................................................................. 69MAINTENANCE SCHEDULE AND INTERVALOPERATIONS ......................................................................... 69MAINTENANCE INTERVALS ................................................. 69MAINTENANCE OPERATION SETS ...................................... 70

SCHEDULE USE ............................................................................. 70MAINTENANCE TABLES AND GRAPHS ........................................ 71REQUIRED MAINTENANCE OPERATIONS ................................... 79

ENGINE INSPECTING ................................................................ 79VALVE LASH CHECKING AND ADJUSTING ............................. 79

GAINING ACCESS TO THE VALVES ..................................... 80METHOD ONE: ADJUST EACH CYLINDER IN FIRINGORDER ................................................................................... 81METHOD TWO: ADJUST ALL VALVES USING TWOCRANKSHAFT POSITIONS ................................................... 82CHECKING VALVE LASH ....................................................... 83

All information subject to change without notice. (Rev. 04/08) vDDC-SVC-MAN-0055 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

TABLE OF CONTENTS

ADJUSTING VALVE LASH ...................................................... 83RESTORING THE VEHICLE TO OPERATING CONDITION .. 84

FUEL PREFILTER ELEMENT CLEANING ...................................... 84MAIN FUEL FILTER ELEMENT CHANGING .................................. 86ENGINE OIL AND FILTER CHANGING .......................................... 87

OIL CENTRIFUGE ....................................................................... 90COOLANT CONCENTRATION CHECKING .................................... 91COOLANT FLUSHING AND CHANGING ........................................ 93COOLING SYSTEM INSPECTING .................................................. 95

CUSTOMER ASSISTANCE ................................................................. 96WORKING WITH DDC SERVICE OUTLETS .................................. 100

STEP ONE ................................................................................... 100STEP TWO .................................................................................. 100STEP THREE .............................................................................. 101

LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS ......... 102

TERMS OF COVERAGE ................................................................. 102USES ........................................................................................... 102DEFECTS .................................................................................... 102REPAIRS ..................................................................................... 102WARRANTY PERIOD .................................................................. 102LIKE REPLACEMENT ENGINE .................................................. 103SERVICE SUPPLIES .................................................................. 103ENGINE REMOVAL AND REINSTALLATION ............................. 103

THIS WARRANTY DOES NOT COVER: ......................................... 103REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 103MAINTENANCE ........................................................................... 104INCIDENTAL OR CONSEQUENTIAL DAMAGES ...................... 104OTHER LIMITATIONS ................................................................. 104

LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900ENGINES USED IN SCHOOL BUS APPLICATIONS ......................... 105

TERMS OF COVERAGE ................................................................. 105USES ........................................................................................... 105DEFECTS .................................................................................... 105REPAIRS ..................................................................................... 105

vi All information subject to change without notice. (Rev. 04/08)DDC-SVC-MAN-0055 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION


WARRANTY PERIOD .................................................................. 105SERVICE SUPPLIES .................................................................. 106LIKE REPLACEMENT ENGINE .................................................. 106ENGINE REMOVAL AND REINSTALLATION ............................. 106


LIMITED WARRANTY ON NEW DETROIT DIESEL MBE900 ENGINES USED IN FIRE TRUCK OR CRASH VEHICLEAPPLICATIONS ................................................................................... 108



LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900ENGINES USED IN UNIMOG APPLICATIONS .................................. 111


All information subject to change without notice. (Rev. 04/08) viiDDC-SVC-MAN-0055 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

TABLE OF CONTENTS


viii All information subject to change without notice. (Rev. 04/08)DDC-SVC-MAN-0055 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION


CAUTION SUMMARY

The following cautions must beobserved by the operator of thevehicle or equipment in which thisengine is installed and/or by thoseperforming basic engine preventivemaintenance. Failure to read and heedthese cautions and exercise reasonablecare for personal safety and thesafety of others when operating thevehicle/equipment or performing basicengine preventive maintenance mayresult in personal injury and engineand/or vehicle/equipment damage.

Engine OperationObserve the following cautions whenoperating the engine.

FIRE

To avoid injury from fire, keep allpotential ignition sources awayfrom diesel fuel, including openflames, sparks, and electricalresistance heating elements. Donot smoke when refueling.

PERSONAL INJURY

Diesel engine exhaust and someof its constituents are known tothe State of California to causecancer, birth defects, and otherreproductive harm.

□ Always start and operate anengine in a well ventilatedarea.

□ If operating an engine inan enclosed area, vent theexhaust to the outside.

□ Do not modify or tamperwith the exhaust system oremission control system.

All information subject to change without notice. (Rev. 04/08) 1DDC-SVC-MAN-0055 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

CAUTION SUMMARY

Preventive MaintenanceObserve the following cautions whenperforming preventative maintenance.

HOT OIL

To avoid injury from hot oil, donot operate the engine with therocker cover(s) removed.

PERSONAL INJURY

To avoid injury from slipping andfalling, immediately clean up anyspilled liquids.

USED ENGINE OIL

To avoid injury to skin fromcontact with the contaminants inused engine oil, wear protectivegloves and apron.

PERSONAL INJURY

To avoid injury when workingnear or on an operating engineequipped with an hydraulicclutch fan, remove loose itemsof clothing and jewelry. Tie backor contain long hair that couldbe caught in any moving partcausing injury. The hydraulic fanmay start without warning.

HOT COOLANT

To avoid scalding from theexpulsion of hot coolant, neverremove the cooling systempressure cap while the engine isat operating temperature. Wearadequate protective clothing(face shield, rubber gloves,apron, and boots). Remove thecap slowly to relieve pressure.

2 All information subject to change without notice. (Rev. 04/08)DDC-SVC-MAN-0055 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION


PERSONAL INJURY

To avoid injury from theprojection of tools or otherobjects that may fall on or behindthe vibration damper of anengine, always check and removethese items before starting theengine.

PERSONAL INJURY

To avoid injury from contactwith rotating parts when anengine is operating with the airinlet piping removed, install anair inlet screen shield over theturbocharger air inlet. The shieldprevents contact with rotatingparts.

PERSONAL INJURY

To avoid injury when usingcaustic cleaning agents, followthe chemical manufacturersusage, disposal, and safetyinstructions.

FIRE

To avoid injury from combustionof heated lubricating-oil vapors,stop the engine immediately if anoil leak is detected.

FIRE

To avoid injury from fire, do notsmoke or allow open flames whenworking on an operating engine.

FIRE

To avoid injury from fire from abuildup of volatile vapors, keepthe engine area well ventilatedduring operation.


CAUTION SUMMARY

Electrical SystemObserve the following cautions whenjump starting an engine, charging abattery, or working with the vehicleelectrical system.

PERSONAL INJURY

To avoid injury from accidentalengine startup while servicingthe engine, disconnect/disablethe starting system.

Electrical Shock

To avoid injury from electricalshock, use care when connectingbattery cables. The magneticswitch studs are at batteryvoltage.

Battery Explosion and Acid Burn

To avoid injury from batteryexplosion or contact with batteryacid, work in a well ventilatedarea, wear protective clothing,and avoid sparks or flames nearthe battery. If you come in contactwith battery acid:

□ Flush your skin with water.

□ Apply baking soda or lime tohelp neutralize the acid.

□ Flush your eyes with water.

□ Get medical attentionimmediately.

ELECTRICAL SHOCK

To avoid injury from electricalshock, do not touch batteryterminals, alternator terminals, orwiring cables while the engine isoperating.



Electrical Shock Hazard

High voltage can remain insidethe Electrostatic Oil Separatorafter removal. Wait 30 minutesafter turning off the ignitionbefore removing the separator.Never touch parts throughventilation openings or impelleropening with finger or conductiveitems (e.g. screwdriver or wire).High voltage can remain insidethe Electrostatic Oil Separator forup to 12 hours after the ignitionis turned off.


CAUTION SUMMARY

Cooling SystemObserve the following cautions whenservicing the cooling system.

HOT COOLANT


PERSONAL INJURY


Air Intake SystemObserve the following cautions whenworking on the air intake system.

PERSONAL INJURY

To avoid injury from hot surfaces,wear protective gloves, or allowengine to cool before removingany component.

PERSONAL INJURY

To avoid injury from contactwith rotating parts when anengine is operating with the airinlet piping removed, install anair inlet screen shield over theturbocharger air inlet. The shieldprevents contact with rotatingparts.



Fuel SystemObserve the following cautions whenfueling the vehicle or working withthe fuel system.

PERSONAL INJURY

To avoid injury from fuel spills,do not overfill the fuel tank.

FIRE

To avoid injury from fire, containand eliminate leaks of flammablefluids as they occur. Failure toeliminate leaks could result infire.

PERSONAL INJURY

To prevent the escape of highpressure fuel that can penetrateskin, ensure the engine hasbeen shut down for a minimumof 10 minutes before servicingany component within the highpressure circuit. Residual highfuel pressure may be presentwithin the circuit.

FIRE



CAUTION SUMMARY

FIRE

To avoid injury from fire causedby heated diesel-fuel vapors:

□ Keep those people who are notdirectly involved in servicingaway from the engine.

□ Stop the engine immediately ifa fuel leak is detected.

□ Do not smoke or allow openflames when working on anoperating engine.

□ Wear adequate protectiveclothing (face shield,insulated gloves and apron,etc.).

□ To prevent a buildup ofpotentially volatile vapors,keep the engine area wellventilated during operation.



Compressed AirObserve the following cautions whenusing compressed air.

EYE INJURY

To avoid injury from flying debriswhen using compressed air, wearadequate eye protection (faceshield or safety goggles) and donot exceed 276 kPa (40 psi) airpressure.

Lubricating Oil and FiltersObserve the following cautions whenreplacing the engine lubricating oiland filters.

PERSONAL INJURY


FIRE

To avoid injury from combustionof heated lubricating-oil vapors,stop the engine immediately if anoil leak is detected.

FIRE

To avoid injury from fire, do notsmoke or allow open flames whenworking on an operating engine.

FIRE

To avoid injury from fire from abuildup of volatile vapors, keepthe engine area well ventilatedduring operation.


IDENTIFICATION

IDENTIFICATION

The MBE 900 engine is built inaccordance with sound technologicalprinciples and based on state-of-the-arttechnology. It complies with all UnitedStates Environmental ProtectionAgency (USEPA) and California AirResources Board (CARB) emission

standards. An emission label isattached to the cylinder head cover, asrequired by law. See Figure 1 for theemission label for the 6-cylinder EGRmodel and Figure 2 for the 4-cylinderEGR model.

Figure 1 Emission Label, 6–Cylinder EGR Engine



Figure 2 Emission Label, 4–Cylinder EGR Engine


IDENTIFICATION

See Figure 3 for the emission label forthe 6-cylinder non-EGR model. .

Figure 3 Emission Label, Non–EGR 6-Cylinder



See Figure 4 for the 4-cylindernon-EGR model

Figure 4 Emission Label, Non–EGR 4-Cylinder

Despite this, the engine may constitutea risk of damage to property orinjury to persons under the followingconditions:

□ It is not used for its intendedpurpose.

□ It is modified or converted in anincorrect manner.

□ The safety instructions included inthis manual are disregarded.

Personnel RequirementsWork on the engine should be carriedout only by skilled technicians whohave been instructed in the specificskills necessary for the type of workbeing performed.


IDENTIFICATION

Engine Conversions andModificationsThe function and safety of the enginecould be affected if unauthorizedmodifications are made. DetroitDiesel will not accept responsibilityfor any resulting damage.

Tampering with the fuel injectionsystem and engine electronics couldalso affect the engine's power output orexhaust emission levels. Compliancewith the manufacturer's settingsand with statutory environmentalprotection regulations cannot then beguaranteed.

General View of the MBE900 EngineThe 2004 on-highway MBE 900engine is equipped with an ExhaustGas Recirculation (EGR) system toreduce engine exhaust gas emissionsin accordance with EPA regulations.See Figure 5 for a right front view ofthe MBE 900 EGR engine, 6-cylindermodel, and Figure 6 for a left rearview.

The off-highway engine usedin construction and industrialapplications does not have an EGRsystem. See Figure 7 for a front viewof the MBE 900 non-EGR engine,6-cylinder model, and Figure 8 fora side view of the 6-cylinder model(right-hand side).

See Figure 9 for a front view of theMBE 900 non-EGR engine, 4-cylindermodel, and Figure 9 for a rear view ofthe 4-cylinder model.



1. Turbocharger 7. EGR Mixer

2. Starter Motor 8. Oil Fill Cap

3. Flywheel Housing 9. Oil Filter

4. Exhaust Manifold 10. Turbocharger Compressor Out

5. EGR Cooler 11. Belt Tensioner Assembly

6. Cylinder Head Cover 12. Oil Pan

Figure 5 Right Front View of the MBE 900 EGR Engine


IDENTIFICATION

1. Air Compressor 6. Oil Centrifuge

2. DDEC-ECU 7. EGR Mixer

3. Fuel Filter 8. Cylinder Head Cover

4. Thermostat Housing 9. Flywheel Housing

5. Oil Fill Cap 10. Oil Pan

Figure 6 Left Rear View of the MBE 900 EGR Engine



1. Fan 10. Cylinder Head Cover

2. Belt Tensioner 11. Fuel Filter

3. Alternator Pulley 12. Fuel Prefilter

4. Oil Filter 13. DDEC-ECU

5. Turbo Compressor Out 14. Air Compressor (optional)

6. Intake Manifold Inlet 15. Power-Steering Pump

7. Crankcase Breather 16. Oil Dipstick

8. Oil Fill Cap 17. Coolant Pump Pulley

9. Intake Manifold

Figure 7 Front View of 6–Cylinder MBE 900 Non-EGR Engine


IDENTIFICATION

1. Cylinder Head Cover 7. Alternator

2. Intake Manifold 8. Turbocharger

3. Exhaust Manifold 9. Starter Motor

4. Intake Manifold Inlet 10. Flywheel Housing

5. Oil Fill Cap 11. Exhaust Brake (optional)

6. Turbo Compressor Out

Figure 8 Side View of a 6–cylinder MBE 900 Non-EGR Engine



1. Cylinder Head Cover 9. Belt Tensioner

2. DDEC-ECU Control Unit 10. Alternator Pulley

3. Fuel Prefilter 11. Intake Manifold Inlet

4. Air Compressor (optional) 12. Turbo Compressor Out

5. Power-Steering Pump 13. Crankcase Breather

6. Oil Dipstick 14. Oil Fill Cap

7. Fuel Filter 15. Intake Manifold

8. Fan

Figure 9 Front View of 4–Cylinder MBE 900 Non-EGR Engine


IDENTIFICATION

1. Oil Fill Cap 7. Starter Motor

2. Turbo Compressor Outlet 8. Exhaust Brake (optional)

3. Intake Manifold Inlet 9. Flywheel Housing

4. Oil Filter 10. Exhaust Manifold

5. Alternator 11. Intake Manifold

6. Turbocharger

Figure 10 Rear View of 4–Cylinder MBE 900 Non-EGR Engine



Engine IdentificationNumberThe engine identification numbers arelasered in large font onto an enlargedlabeling surface on the rear rightcrankcase. See Figure 11.

Figure 11 Location of EngineIdentification Number

See Figure 12 for an example of thenumbers as they appear on the engine.

Figure 12 Engine IdentificationNumber

The last six numbers are the serialnumbers (310187 in Figure 12).

See Figure 13 for an explanation ofthe first six numbers found in theengine identification number.

Figure 13 Engine Identification


IDENTIFICATION

NOTE:In addition to the fourteen digit numberetched on the crankcase, there is aten digit number used for warrantyand service that is found on theDDEC-ECU label. The ten digitnumber is derived from the fourteendigit number (see Figure 14).

Description of the EngineAll MBE 900 engines arewater-cooled, four-stroke,direct-injection diesel engines.The cylinders are arranged inline onboth the 6-cylinder and 4-cylindermodels. Each has a separate fuelinjection pump (unit pump) with ashort injection line to the injectionnozzle, which is located in the centerof the combustion chamber. The unitpumps are attached to the crankcaseand are driven from the camshaft.Each cylinder has two intake valvesand one exhaust valve.

Charge-air cooling and an exhaust gasturbocharger are standard equipmenton all MBE 900 engines (chargepressure limitation is optional).

The engine has a fully electroniccontrol system, which regulates thefuel injection quantity and timingusing solenoid valves, allowingextremely low-emission operation.

The control system consists of anengine-resident pump and nozzlecontrol unit (the DDEC-ECU) and avehicle control unit (the DDEC-VCU).The two are connected by a proprietarydatalink.

Engine braking is controlled by apneumatic and hydraulic (6-cylinder)operated exhaust brake on theturbocharger and by a constant-throttlesystem (optional).

Figure 14 Engine Serial Number



The cylinder block has integratedoil and water channels. The uppersection of the cylinder bore isinduction-hardened. The single-piececylinder head is made of castiron. The cylinder head gasket is amedal-elastomere, adjustment-freeseal with Viton® sealing elements.

The pistons are made of aluminumalloy with a shallow combustionchamber recess. The pistons arecooled by oil spray nozzles.

The crankshaft is precision-forgedwith seven main bearings (five onthe 4-cylinder engine), six of whichhave custom-forged counterweights(four on the 4-cylinder engine), and avibration damper at the front end.

The camshaft is made ofcase-hardened steel and has sevenmain bearings (five on the 4-cylinderengine). Each cylinder has cams forintake and exhaust valves and a unitpump.

The valves are controlled bymushroom tappets, pushrods, androcker arms. The intake valves areopened and closed by a valve-guidedbridge.

There is a force-feed lubricating oilcircuit supplied by a rotary oil pump.This pump is positioned at the frontof the crankcase and driven by gearsfrom the crankshaft.

The oil cooler is located near the frontof the crankcase on the right-hand sidenear the water pump.

The gear-type fuel pump is bolted tothe front of the crankcase. The pumpis driven from the forward end of thecamshaft.

The air compressor, with apower-steering pump attached,is driven by a gear on the camshaft(optional).

The vehicle is cooled by a closedsystem using recirculated coolant;temperature is regulated automaticallyby a thermostat.

The alternator and coolant pump (andany other accessories) are driven by abelt with automatic belt tensioner.

Electrical equipment includes a starterand an alternator.

Exhaust Gas Recirculation

The purpose of the Exhaust GasRecirculation (EGR) System is toreduce engine exhaust gas emissionsin accordance with EPA regulations.

The EGR system consists of an EGRcooler, EGR valve, reed valves (on theMBE904/924/926 only), and an EGRmixer.

The MBE 900 engines for on-highwayEPA 2004 regulation applications usea cooled EGR system.


IDENTIFICATION

Exhaust gases from the front threecylinders on six cylinder engines(all four cylinders on four cylinderengines) are routed from the exhaustmanifold through the EGR cooler,past control and reed valves, andmixed with the intake manifold chargeair. The addition of cooled exhaustgases back into the combustionairflow reduces the peak in cylindercombustion temperature. Less oxidesof nitrogen (NOx) are produced atlower combustion temperatures.

ExhaustBrake/Constant-ThrottleValves, OptionalTo increase braking performance,the engine can be equipped with anexhaust brake on the turbochargerin conjunction with constant-throttlevalves in the cylinder head. See Figure15.

Figure 15 Constant — ThrottleActivation

The two systems operateindependently of each other andin combination.

Exhaust back pressure is used by theexhaust brake to increase brakingperformance. The constant-throttlevalves use the air that escapes throughthem on the compression stroke toprovide braking force.

The constant-throttles valves aresmall valves which are built into thecylinder head and positioned oppositethe exhaust valve. When open, a linkis created between the combustionchamber and the exhaust port.

When the engine brake is switchedon, the constant-throttle valves are putunder pressure, which in turn opensthe valves.

On the 6-cylinder model, theconstant-throttle valves are activatedby engine oil pressure. On 4-cylinderengines, the constant-throttle valvesare activated by compressor airpressure.

The engine brake is activated by theDDEC-VCU and can be activatedonly at engine speeds up to 2700 rpm.



Below 900 rpm, the engine brakeis always turned off to prevent theengine from stalling. Also, the enginebrake is automatically turned off whenthe accelerator pedal is pressed.

NOTE:When in emergency running mode(constant rpm), the engine brake canbe activated only when the engine isin overrun. When constant rpm hasbeen attained, the engine brake isautomatically turned off.

Electronic Engine ControlSystemThe engine is equipped with a fullyelectronic control system. Besides theengine and its related sensors, thissystem is composed of the following:

□ The DDEC-ECU (engine controlunit)

□ The DDEC-VCU (vehicle controlunit) located under the right-handdash panel

The two control units are connected bya proprietary datalink through whichall necessary data and information canbe exchanged. See Figure 16.

The DDEC-VCU then broadcasts allinformation on the J1587 and J1939datalinks, where it can be read bythe Nexiq™ Diagnostic Data Reader(DDR), Detroit Diesel Diagnostic

Link® (DDDL) PC-based software orminidiag2.

The engine control system monitorsboth the engine and the datalink.When a malfunction or other problemis detected, the system selects anappropriate response; for example,the emergency running mode may beactivated.


IDENTIFICATION

Figure 16 Electronic Engine Control System

DDEC-ECU

The DDEC-ECU (see Figure 17) islocated on the left-hand side of theengine.

The DDEC-ECU processes the datareceived from the DDEC-VCU, forexample the position of the acceleratorpedal, engine brake, etc.

Figure 17 DDEC-ECU



These data are evaluated togetherwith the data from the sensors onthe engine, such as coolant andfuel temperature and oil and chargepressure.

The data is then compared to thecharacteristic maps or lines stored inthe DDEC-ECU. From these data,quantity and timing of injection arecalculated and the unit pumps areactuated accordingly through thesolenoid valves.

NOTE:To obtain a replacement DDEC-ECU,all the data given on the DDEC-ECUlabel are required.

The DDEC-ECU data label has the 10digit engine serial number (see Figure14), the engine horse power andtorque.

DDEC-VCU

The DDEC-VCU communicateswith any other electronic control unitinstalled on the vehicle over the J1587data link. See Figure 18.

Data for specific applications is storedin the DDEC-VCU. These include idlespeed, maximum running speed, andspeed limitation.

Figure 18 DDEC-VCU

The DDEC-VCU receives data fromthe following sources:

□ The operator (accelerator pedalposition, engine brake switch)

□ Other electronic control units(for example, the anti-lock brakesystem)

□ The DDEC—ECU (oil pressureand coolant temperature)

From these data, instructions arecomputed for controlling the engineand transmitted to the DDEC-ECU viathe proprietary datalink.

The DDEC-VCU controlsvarious systems, for example,communications with the datalink, theengine brake, and the constant-throttlevalves.


IDENTIFICATION

Sensor LocationsSee Figure 19 and Figure 20 forsensor locations on the MBE 900EGR engine. See Figure 21 for sensorlocations on the MBE 900 non-EGRengine.

CHEMICAL BURNS

To avoid injury from chemicalburns, wear a face shield andneoprene or PVC gloves whenhandling sensor hoses.

1. Intake Manifold Pressure/Temper-ature Sensor

3. Engine Oil Pressure Sensor

2. Engine Oil Temperature Sensor

Figure 19 Sensor Location on the Right Side of the MBE 900 EGR Engine



1. EGR Temperature Sensor 4. Barometric Pressure Sensor(integrated into DDEC-ECU)

2. Engine Coolant TemperatureSensor

5. Camshaft Position Sensor (oncamshaft)

3. Supply Fuel Temperature Sensor 6. Crankshaft Position Sensor (ontiming case)

Figure 20 Sensor Location on the Left Side of the MBE 900 EGR Engine

NOTE:The 6-cylinder engine is shown;sensor locations are similar on the4-cylinder engine.

NOTE:The Barometric Pressure Sensor isintegrated into the DDEC-ECU.


IDENTIFICATION

1. Engine Oil Pressure/TemperatureSensor

5. Barometric Pressure Sensor(integrated into DDEC-ECU)

2. Engine Coolant TemperatureSensor

6. Camshaft Position Sensor (oncamshaft)

3. Intake Manifold Pressure/Temper-ature Sensor

7. Crankshaft Position Sensor (ontiming case)

4. Supply Fuel Temperature Sensor

Figure 21 Sensor Location on the MBE 900 Non-EGR Engine

NOTE:The 6-cylinder engine is shown;sensor locations are similar on the4-cylinder engine.

NOTE:The Engine Oil Level Sensor, if used,is located at the bottom of the oil pan.



OPERATION

Important: Before starting the engine,do all the recommended pretripinspections and daily maintenance.Check the engine oil and fuel levels,and drain contaminants from thefuel/water separator (optional).

Before Starting the Engine

NOTE:If you drain the fuel/water separatorcompletely, you may have to prime thefuel system.

Be sure you are familiar with all ofthe instruments, gauges and controlswhich are needed to operate theengine.

Note especially the location andfunction of the following:

□ Oil Pressure Gauge

□ Coolant Temperature Gauge

□ Low Oil Pressure/High CoolantTemperature Warning Light

□ Water In Fuel Warning Light

□ Tachometer

□ Air Restriction Indicator

When starting the engine, and whiledriving, watch for any signs of engineproblems. If the engine overheats,uses excessive fuel or lubricatingoil, vibrates, misfires, makes unusual

noises, or shows an unusual loss ofpower, turn the engine off as soonas possible and determine the cause.Frequently, engine damage may beavoided by a quick response to earlyindications of problems.

If you are starting the engine in coldweather, refer to "Cold WeatherProducts" in the “Service Products”section of this manual.

Checking the Batteries

Use only batteries that have beencorrectly filled and serviced. Toprovide corrosion protection, applydielectric grease, part number48-02349-000, liberally to theterminal pads. Approved suppliers arelisted in Table 1.

Manufacturer Lubricant orPart Number

Shell Oil, Co. No. 71032; No.71306

Texaco, Inc. No. 955

Quaker State No. NYK-77

Table 1 Approved ElectricalLubricants


OPERATION

Battery Explosion and Acid Burn

To avoid injury from batteryexplosion or contact with batteryacid, work in a well ventilatedarea, wear protective clothing,and avoid sparks or flames nearthe battery. If you come in contactwith battery acid:

□ Flush your skin with water.

□ Apply baking soda or lime tohelp neutralize the acid.

□ Flush your eyes with water.

□ Get medical attentionimmediately.

Checking the Oil Level

Check the oil level as follows:

1. Check the oil level using the oildipstick (see Figure 22).

PERSONAL INJURY


Figure 22 Oil Dipstick

2. If necessary, top off by fillingengine oil through the oil fillcollar (see Figure 23) until themaximum fill level on the oildipstick (see Figure 22) has beenreached. For detailed procedures,refer to the ”Maintenance”section. Do not overfill.

Figure 23 Oil Fill Collar



Checking the Coolant Level(Cold Check)

Check the coolant level as follows:

1. Ensure that all coolant plugs inthe bottom of the radiator and onthe radiator outlet pipe are secureand tight.

2. Check the coolant level. Thecooling system is correctly filledwhen the coolant is between themaximum and minimum markson the surge tank.

NOTE:For more information, refer to the”Maintenance” section.

Adding Fuel

Note the following when adding fuel:

□ Add winter or summer grade fuelaccording to the season of theyear.

□ Work in the cleanest conditionspossible.

□ Prevent water from entering thefuel tank. For further informationrefer to “Diesel Fuels” in “ServiceProducts.”

Priming the Fuel System

Prime the fuel system as follows:

NOTICE:Correct torque on the high pressurelines is critical. Incorrect torquescould result in leaks or lack of powerdue to restricted fuel flow.

1. Make sure that all high-pressureand low-pressure lines aresecurely tightened.

2. If equipped with a hand pump onthe fuel/water separator, work thehand pump 50 times.

3. Crank the engine for 30 secondsat a time, but no longer. Beforecranking the engine again, waitat least two minutes. The engineshould start within six 30-secondattempts.

Starting the EngineBefore operating the engine, followthe steps described in the “BeforeStarting the Engine” section. Start theengine as follows:

NOTE:As a safety function, the electronicengine control system may be wired tostart the engine only if the transmissionis in neutral. This is vehicle applicationspecific.


OPERATION

NOTICE:Never attempt to start theMercedes-Benz MBE 900 engineusing ether or any other startingfluid. Serious engine damage couldresult.

1. Turn on the ignition switch.

2. With the accelerator pedal in theidle position, start the engine.

PERSONAL INJURY

To avoid injury when workingnear or on an operating engine,remove loose items of clothingand jewelry. Tie back or containlong hair that could be caught inany moving part causing injury.

3. Check the engine for leaks.

[a] Check all hoses, hose clamps,and pipe unions on the enginefor tightness. Shut down theengine and tighten them ifnecessary.

[b] Check the oil feed and returnlines at the turbocharger fortightness. Shut down theengine and tighten them ifnecessary.

4. Shut down the engine.

5. Approximately five minutes aftershutdown, check the engine oillevel. If necessary, add oil up tothe maximum fill level on the oildipstick (see Figure 24). Do notoverfill.

Figure 24 Oil Dipstick

6. Check all the mounting fastenersand belts on the engine fortightness.

Checking the Coolant Level (HotCheck)

Check coolant level as follows:

1. Allow the engine to run forapproximately five minutes at amoderate speed.



HOT COOLANT


2. Then, with the coolanttemperature above 50°C (122°F),recheck the coolant level.

3. Add more coolant if necessary.Open the heater valves beforeadding coolant.

4. Do not close the heater valvesuntil the engine has been runbriefly and the coolant levelagain checked and corrected asnecessary.

Starting an Engine That HasNot Been Run for an ExtendedPeriod

Before starting an engine which hasnot been run for an extended period,certain special work must be carriedout. Refer to “Storage,” under“Cleaning and Storage.”

Important: At outside temperaturesbelow –20°C (– 4°F), a coolantpreheater is recommended.

1. Chock the tires, place thetransmission in neutral, and setthe parking brake.

2. Turn on the ignition switch andstart the engine

3. If the engine doesn't start after20 seconds, stop. Try again afterwaiting about one minute.

NOTICE:Do not rev the engine if the oilpressure gauge indicates nooil pressure. To avoid enginedamage, shut down the engineif no oil pressure appears withinapproximately ten seconds. Checkto determine the cause of theproblem.

4. Monitor the oil pressure gaugeimmediately after starting theengine.

NOTE:Do not place the engine under full loaduntil it reaches operating temperature.


OPERATION

Monitoring EngineOperationWhile the engine is operating, monitorthe battery charge indicator light,the oil pressure and avoid excessiveidling.

Battery Charge

The battery charge indicator light(see Figure 25) must go out once theengine starts.

Figure 25 Battery Charge IndicatorLight

If the indicator light comes onwhile the engine is running, do thefollowing:

FIRE



2. Check the poly-V belt fortightness.

3. Do a load test on the batteries.Charge or replace the batteries asneeded.

4. If necessary, visit the nearestauthorized dealer to have thealternator voltage and outputchecked.

Oil Pressure

When the engine has reached itsnormal operating temperature, theengine oil pressure must not dropbelow the following values:

□ 36 psi (250 kPa) at rated speed

□ 7 psi (50 kPa) at idling speed

If oil pressure drops below thesevalues, stop the engine and determinethe cause.



Excessive Idling

Never allow the engine to idle formore than 30 minutes. Excessiveidling can cause oil to leak from theturbocharger.

Changing the Idle SpeedThe rpm range of the MBE 900engine is 600 rpm to 850 rpm if theparameters in the DDEC-VCU are setto the default range.

Change the idling speed as follows:

1. Turn the cruise control switch tothe OFF position.

2. To increase the idle speed, pushthe "Resume" switch until the idleis fast enough.

3. To decrease the idle speed, pushthe "Decel" switch until the idleis slow enough.

Shutting Down the EngineIf the engine has been running at fulloutput or the coolant temperature hasbeen high, allow the engine to idlefor one to two minutes without load.Then turn off the ignition key switch.

If any the following occur, shut downthe engine immediately.

□ The oil pressure swings back andforth or falls sharply.

□ Engine power and rpm fall, eventhough the accelerator pedalremains steady.

□ The exhaust pipe gives off heavysmoke.

□ The coolant and/or oil temperatureclimb abnormally.

□ Abnormal sounds suddenly occurin the engine or turbocharger.

Shutting Down After HardOperation

NOTICE:After hard operation, if the enginehas been running at full output or thecoolant temperature has been high,allow the engine to idle for one totwo minutes without load. Shuttingdown the engine without idling maycause damage to the turbocharger.

Turn off the ignition switch and shutdown the engine.


OPERATION

Emergency Running ModeThe engine is equipped with theelectronic engine control system,which monitors the engine as it isrunning.

As soon as a fault is detected, it isevaluated and one of the followingmeasures is initiated.

NOTICE:To prevent possible serious enginedamage, have any faults correctedwithout delay by an authorizeddealer.

□ In conjunction with theinstrumentation control unit(ICU), the code for the electroniccontrol unit reporting the faultcan be read immediately on thedisplay.

□ Complete fault codes aretransmitted and can be read usingServiceLink at any authorizeddealer.

□ If the fault is serious enough toimpair normal operation, theelectronic engine system switchesover to emergency running mode.When in emergency runningmode, the engine operates at aconstant 1300 rpm. This allowsyou to move the vehicle to aservice location.

Stop Engine OverrideOptionThe Stop Engine Override Option isused for a momentary override. TheDDEC-ECU will record the numberof times the override is activated aftera fault occurs.

Momentary Override – A StopEngine Override (SEO) switchis used to override the shutdownsequence (see Figure 26). Thisoverride resets the 60 second (30seconds for oil pressure) shutdowntimer, restoring power to the levelwhen the Red Stop Lamp (RSL) wasilluminated. The switch must berecycled after five seconds to obtain asubsequent override.

Figure 26 Typical SEO Switch andWarning Lamps

NOTE:The operator has the responsibility totake action to avoid engine damage.



Cold Weather OperationSpecial precautions must be takenduring cold weather. To protectyour engine, special cold weatherhandling is required for fuel, engineoil, coolant, and batteries. For detailedinformation, refer to the servicemanual.

Winter Fronts

A winter front may be used to improvecab heating while idling. At least 25%of the grill opening should remainopen in sectioned stripes that runperpendicular to the charge air coolertube flow direction. This assures evencooling across each tube and reducesheader to tube stress and possiblefailure. Winter fronts should only beused when the ambient temperatureremains below –12.2° C (10° F).


CLEANING AND STORAGE


When an engine is to be stored for aperiod of time, special precautionsshould be taken to protect the interiorand exterior of the engine.

Cleaning the EngineImportant: Observe all environmentalprotection regulations.

High-Pressure CleaningEquipment

Note the equipment manufacturer'soperating instructions.

NOTICE:To prevent damage to enginecomponents during the cleaningprocess, keep the water movingat all times. Never direct wateronto electrical components, plugconnectors, seals or flexible hoses.

Comply with the minimum workingdistance between the high-pressurenozzle and the surface being cleaned:

□ Approximately 700 mm (28 in.)for circular pattern jets

□ Approximately 300 mm (12 in.)for 25-degree flat jets and dirtcutters

After cleaning, and especiallywhen using a high-pressure jet orgrease-removing agent, lubricatethe engine. Information on suitablecleaning and protective products isavailable from any authorized dealer.

Cleaning the CoolingSystemImportant: Collect the used coolant,cleaning solutions, and washingliquids. Dispose of them in accordancewith applicable laws regarding theprotection of the environment.

NOTICE:Clean at moderate pressures only;otherwise the fins of the radiatorgrille could be damaged.



Clean as follows:

EYE INJURY


1. Remove debris (dust, insects,etc.) from the fins of the radiatorgrille by blowing them throughwith compressed air or sprayingthem out with water. Work fromthe rear of the radiator (in theopposite direction of the normalcooling air flow).

2. Drain the coolant whenthe engine is cold. Fordetailed procedures, see thevehicle/chassis maintenancemanual. For types of coolant,refer to “Coolant” in the “ServiceProducts” section.

3. If the HVAC unit is connectedto the cooling system, open theregulating valves all the way.

Degreasing

Degrease as follows:

1. Fill the cooling system with a 5%solution (1.6 ounces per quart of

water—50 grams per liter) of amildly alkaline cleaning agent,such as sodium carbonate.

2. Run the engine at moderate speeduntil the thermostat starts to open,at an operating temperature ofapproximately 80°C (176°F).Then run it for about five minuteslonger. Shut down the engine andallow it to cool to approximately50°C (112°F).

HOT COOLANT


3. Drain all the cleaning solution.

4. Flush the cleaning solution fromthe cooling system.

[a] Immediately after drainingthe cleaning solution, flushthe system with clean water.

[b] Once the clean water hasdrained, fill the system againwith clean water.



[c] Run the engine. Allowthe engine to warm up toapproximately 80°C (176°F),and then run it about fiveminutes longer.

[d] Drain the hot water.

5. Fill the cooling system with newcoolant. For detailed procedures,see the vehicle/chassismaintenance manual. For typesof coolant, refer to “Coolant” inthe “Service Products” section.

StorageRequired protective measures forthe MBE 900 engine depend on thefollowing:

□ The length of time that the enginewill be out of service

□ The climate and conditions wherethe engine is stored

After cleaning, engines should,whenever possible, be placed in a dry,well-ventilated area.

In all cases, protect the engineagainst direct exposure to moisture(rain/splash water).

If the engine is to be out of servicefor 12 months or less, anticorrosionmeasures are not necessary, providedthat the place of storage are dry andwell-ventilated as described above.

If the engine is to be out of servicefor over 12 months, or underextraordinary storage or transportationconditions, then special protectivemeasures are necessary. Informationis available from any authorizeddealer. It is strongly recommendedthat you request this information.

Important: If the engine is to be outof service for over 18 months, the oilmust be changed before the enginecan be brought back into service.



TROUBLESHOOTING

In addition to operating the enginecarefully and maintaining it properly,make sure to correct any malfunctionpromptly.

Emergency StartingFor emergency starting procedures(jump starting), see thedriver's/operator's manual underthe heading "Emergency Starting WithJumper Cables."

Troubleshooting theElectronic Engine ControlSystemWhen the electronic engine controlsystem detects a fault, it broadcastsa message on the datalink. The dashdisplay will show the code "ECU128," indicating there is an enginefault.

Important: To read the completefault code, bring the vehicle to anauthorized dealer. Complete faultcodes can be read using ServiceLink.

For fault codes and their meanings,see the service/workshop manual.

General TroubleshootingThe tables that follow are designedto identify the causes of commonproblems, suggest further checks andappropriate remedies. When dealerservice is necessary, it is mentionedin the table.

NOTE:Remember to follow all cautions whentroubleshooting the engine.


TROUBLESHOOTING

Problem - The Engine Will Not Crank

Cause Remedy

The batteries are damaged or weak. Test the batteries. Replace them, ifneeded.

The ignition switch is damaged. Replace the ignition switch.

The battery cables are damagedand/or corroded. Replace the battery cables.

The starter is damaged and/or worn. Have an authorized dealer replace thestarter.

The clutch or transmission isdamaged.

Bring the vehicle to an authorizeddealer for service.

There is internal damage to theengine.


Problem—The Engine Turns Over Slowly

Cause Remedy


The ignition switch is damaged. Replace the ignition switch.

The battery cables are damagedand/or corroded Replace the battery cables.

The starter is damaged and/or worn. Have an authorized dealer replace thestarter.

The engine oil does not meet thecorrect specifications.

Change the engine oil, using thecorrect type of oil.

The transmission fluid does not meetthe correct specifications.

Change the transmission fluid, usingthe correct type of fluid.



Problem—The Engine Cranks, But Won't Start

Cause Remedy


The cranking speed is not set correctly. Bring the vehicle to an authorizeddealer for service.

No intake air preheater is installed,and it is too cold to start without one. Install an intake air preheater.

The intake air preheater ismalfunctioning.

Check the intake air preheater, andreplace it, if necessary.

The camshaft TDC sensor and/or thecrank angle position sensor are out ofadjustment.

Push both sensors into their holes asfar as they will go. If this does notsolve the problem, bring the vehicle toan authorized dealer for service.

The camshaft TDC sensor and/orthe crank angle position sensor aredamaged.


There is air in the fuel system.

Check the fuel lines for leaks. Bleedthe fuel system and start the engineaccording to the instructions in theservice manual.

The air filter is clogged. Clean or replace the air filter.

The fuel filter is clogged. Replace the filter element.

The exhaust brake valve ismalfunctioning.

Have an authorized dealer check theoperation of the valve.

The valves are not adjusted properly. Check the valve lash.

There are other problems in the fuelsystem.


Coolant level is too low. Check for leaks, add coolant to correctlevel.


TROUBLESHOOTING

Problem—The Engine Starts Only After Cranking for a Long Time

Cause Remedy

The fuel tank is low or empty. Add fuel and bleed the fuel system, ifnecessary.

There are leaks in the fuel lines. Check the fuel lines for leaks andrepair them, if necessary.


The fuel line, the fuel prefilter, or thescreen in the fuel tank is blocked.

Clean and bleed the system. Havethe fuel lines and filters checked by anauthorized dealer.









Problem—The Engine Starts, But Dies

Cause Remedy

The fuel tank is low or empty. Add fuel and bleed the fuel system, ifnecessary.


The fuel line, the fuel prefilter, or thescreen in the fuel tank is blocked.

Clean and bleed the system. Havethe fuel lines and filters checked by anauthorized dealer.





The constant-throttle valves aremalfunctioning.




Problem—The Engine Fan Doesn't Work

Cause RemedyThe fan hub is damaged. Replace the fan hub.

The fan wiring is damaged. Repair the fan wiring.

The parameter settings in theDDEC-ECU or DDEC-VCU areincorrect.

Have an authorized dealer reprogramthe control unit.


TROUBLESHOOTING

Problem—The Engine Fan Is Constantly On

Cause Remedy

The fan override switch is on. Check the operation of the fan overrideswitch.

The fan hub is damaged. Replace the fan hub

The parameter settings in theDDEC-ECU or DDEC-VCU areincorrect.

Have an authorized dealer reprogramthe control unit.

Problem—Fuel Consumption Is Too High

Cause RemedyThe tires are not properly inflated. Check all tires for correct pressure.

The air filter and/or intake air systemis clogged.

Check the air restriction indicator.Clean the intake air system andreplace the air filter if necessary.




The engine performs poorly, or doesnot develop full power.

The remedies are listed in -48"TheEngine Performs Poorly, Does NotDevelop Full Power” in this section.



Problem—The Engine Performs Poorly, Does NotDevelop Full Power

Cause Remedy






There are other problems with the fuelsystem.


The valves are not adjusted properly Check the valve lash.

The coolant temperature sensor isdamaged or reading incorrectly.


The fuel temperature sensor isdamaged or reading incorrectly.


The engine oil temperature sensor isdamaged or reading incorrectly.


The charge-air temperature sensor isdamaged or reading incorrectly.


There are problems with theDDEC-ECU or DDEC-VCU.





TROUBLESHOOTING

Problem—The Engine Is in Emergency Running Mode(constant speed 1,300 rpm)

Cause RemedyThe DDEC-ECU or DDEC-VCUor sensor(s), solenoids and otherelectronic parts are damaged.


Problem—The Coolant Temperature Is Above Normal

Cause Remedy

The coolant level is too low. Check for coolant leaks, and repair asneeded.

The poly-V belt is loose. Tighten or replace the poly-V belt.

The coolant temperature gauge and/orsensor is not reading correctly.


The radiator is damaged or dirty. Clean the radiator. Repair or replacethe radiator if necessary.

The coolant pump is damaged. Have an authorized dealer replace thecoolant pump.

The thermostat is damaged. Have an authorized dealer replace thecoolant pump.

The fan is not operating properly.

Bring the vehicle to an authorizeddealer and have the fan hub checked.Bring the vehicle to an authorizeddealer and have the parametersettings reprogrammed in theDDEC-ECU or DDEC-VCU.



Problem—The Coolant Temperature Is Below Normal

Cause RemedyThe coolant temperature gauge and/orsensor is not reading correctly.


The thermostat is damaged. Have an authorized dealer replace thethermostat.

The fan is not operating properly.

Bring the vehicle to an authorizeddealer and have the fan hub checked.Bring the vehicle to an authorizeddealer and have the parametersettings reprogrammed in theDDEC-ECU or DDEC-VCU.

Problem—The Cooling System Is Losing Coolant

Cause RemedyThere is an external coolant leak. Repair the leaking component.

The radiator cap is leaking. Replace the radiator cap.

The air compressor head is damaged. Have an authorized dealer replace theair compressor.

The cylinder head gasket is leaking. Have an authorized dealer replace thehead gasket.

Top tank is leaking. Bring the vehicle to an authorizeddealer.

EGR system has an internal leak. Bring the vehicle to an authorizeddealer.


TROUBLESHOOTING

Problem—There Is Coolant in the Engine Oil

Cause Remedy

The cylinder head gasket is damaged. Have an authorized dealer replace thehead gasket.

The oil/water heat exchanger isleaking.

Have an authorized dealer replace theheat exchanger.

There is an internal coolant leak. Bring the vehicle to an authorizeddealer for service.

Problem—There Is Foam in the Engine Oil

Cause RemedyThe oil level is too low or too high. Correct the oil level.

The oil has not been changed withinthe recommended interval. Change the oil.

The oil is not of the recommendedquality. Change the oil.

Problem—The Engine Oil Pressure Is Low

Cause RemedyThe oil pressure gauge and/or sensoris not reading correctly.


There is fuel in the oil. Bring the vehicle to an authorizeddealer for service.

The oil filter is clogged. Replace the filter element.

The oil filter bypass valve is damaged. Replace the bypass valve.

The oil pump and/or relief valve isdamaged.

Have an authorized dealer replace theoil pump.



Problem—The Engine Exhaust Is White

Cause RemedyThe fuel is of poor quality. Add fuel of the right quality.


Check the intake air preheater, andreplace it, if necessary.


Problem—The Engine Exhaust Is Black

Cause Remedy






Check that the heater is not staying onall of the time.


There is damage to the fuel system:the fuel pump, one or more fuelinjectors, or one or more unit pumpsare damaged.


The charge-air temperature sensor isdamaged.





TROUBLESHOOTING

Problem—The Engine Exhaust Is Blue

Cause RemedyThe engine oil level is too high(engine oil is reaching the combustionchamber).

Adjust the oil level, and then have theoil level checked by an authorizeddealer.

The turbocharger is leaking oil. Have an authorized dealer replace theturbocharger

The valve stem seals are loose ordamaged.

Have an authorized dealer replace theseals.

The piston rings are worn. Have an authorized dealer replace thepiston rings.

Problem—Engine Brake Performance Is Poor

Cause RemedyThe engine brake control switch isdamaged. Replace the switch

The exhaust brake is not operatingproperly.


The constant-throttle valves aremalfunctioning.


Components of the DDEC-ECU and/orDDEC-VCU are damaged.


Problem—Cruise Control Is Not Working

Cause RemedyOne or more of the cruise controlswitches are damaged. Replace the damaged switch.

Components of the DDEC-ECU and/orDDEC-VCU are damaged or notworking properly.




Problem—The Battery Charge Indicator Light Does NotCome On When the Engine Is Not Running

Cause RemedyThe bulb is damaged. Change the bulb.

The circuit is broken. Repair the break in the circuit.

Problem—The Battery Charge Indicator Light ComesOn When the Engine is Running

Cause Remedy

The poly-V belt is too loose.Check the belt tension; if necessary,have an authorized dealer replace thebelt tensioner.

The belt tensioner is damaged. Have an authorized dealer replace thebelt tensioner.

The poly-V belt is worn or damaged. Replace the belt.

The alternator is damaged (has adamaged rectifier or voltage regulator).

Have an authorized dealer replace thealternator.


SERVICE PRODUCTS

SERVICE PRODUCTS

Use only the DDC recommendedlubricants discussed in this section.Additional information is availablefrom any authorized dealer.

Do not use special lubricant additives.None are needed, and the use ofadditives could affect warrantycoverage.

Important: Dispose of serviceproducts in an environmentallyresponsible manner. This includes anyparts which have been in contact withthem (for example, filters). Reclaimthem or recycle them, if possible,and be sure to comply with all legaldisposal requirements.

Diesel FuelsUse only commercially availablevehicle diesel fuel. Grades such asmarine diesel fuel, heating oil, andothers are not permissible.

Do not use fuel additives. Using fueladditives could affect your warranty.

Only low sulfur diesel fuel shouldbe used for EGR engines (sulfurcontent = 0.05 percent by weight).For non-EGR engines if you areusing diesel fuel with a high sulphurcontent, exceeding 0.5 percent byweight, change the engine oil atshorter intervals. Comply with theinstructions in the service manual.

Fuel added from drums or cans couldbe contaminated. This could leadto malfunctions in the fuel system.Always filter the fuel before adding itto the tank. Ensure there is no waterin the fuel.

For information about fuel in coldweather operation, refer to the section“Winter-Grade Diesel Fuel" later inthis chapter.

Flow Improvers

The effectiveness of flow improvers isnot guaranteed with all fuels. Complywith the product manufacturer'srecommendations. Any authorizeddealer can provide information onapproved flow improvers.

Kerosene

Keep the quantity added as low aspossible, bearing in mind the outsidetemperature.

The addition of five percent byvolume of kerosene will improvethe fuel's resistance to cold by about1°C (1.8°F). Never add more than 50percent kerosene to the fuel.



NOTICE:For safety reasons, add thekerosene to the diesel only in thefuel tank. Add the kerosene first,then the diesel. Run the engine fora short time to allow the mixture toreach all parts of the fuel system.

Engine OilsThe engine is delivered from thefactory filled with an approved engineoil.

NOTICE:The use of non-approved engineoils could affect warranty rights, andcause engine damage.

To ensure long and trouble-freeservice, it is important to select oilof the correct viscosity and servicedesignation.

EGR Engines

Only multigrade oils of AmericanPetroleum Institute (API) servicedesignation CI-4 will achieve properperformance for the cooled EGRengines. Detroit Diesel POWERGUARD oils meet this specificationand are recommended. Look forthe service mark printed on the oilcontainer. See Figure 27.

Figure 27 API Lubricant ServiceMark

When maintenance work is performed,record engine oil changes includingdetails of the brand used, thequality category, and the Societyof Automotive Engineers (SAE)viscosity rating of the oil. Whentopping off, use only engine oilsof the correct API designationand SAE rating. Detroit DieselPOWER GUARD oils meet thesespecifications.

For information about oil in coldweather operation, see the heading"Low-Viscosity Engine Oil" later inthis chapter.


SERVICE PRODUCTS

Non-EGR Engines

API CI-4 or CH-4 oils arerecommended for use in all non-EGRengines. These oils are intended forengines with open breather systems.Detroit Diesel POWER GUARDoils meet these specifications and arerecommended.

Synthetic Oils

Synthetic oil may be used in MBE900 engines, provided they are of thecorrect API designation and viscosity,as required for non-synthetic oil.

Synthetic oil offers improvedlow-temperature flow propertiesand high-temperature resistance tooxidation. However, it is generallymore costly than non-synthetic oil.

Review carefully the productinformation published by the syntheticoil manufacturer. Performanceadditive systems often responddifferently in synthetic oil. Use ofsynthetic oil does not change therecommended oil change serviceinterval.

CoolantCoolant is a mixture of water andantifreeze. Under normal conditions,it is a mixture of 50 percent waterand 50 percent antifreeze, but underextreme cold weather conditions, asmuch as 60 percent antifreeze can be

added. For reasons of anticorrosionprotection and to raise the boilingpoint, the coolant with a minimum50% of antifreeze must remain in thecooling system all year round.

Regardless of mileage, replacethe coolant every two years sincethe degree of corrosion protectiongradually drops with time.

Fully-Formulated Antifreeze

Antifreeze approved for use in theMBE 900 engine is a mixture ofglycol compounds (either ethyleneglycol or propylene glycol), andcorrosion inhibitors. Antifreezecontaining glycol compounds andcorrosion inhibitors is known asfully-formulated antifreeze.

Fully-formulated antifreeze has thefollowing properties:

□ It protects the radiator and enginefrom freezing.

□ It provides protection againstcorrosion and cavitation for allcomponents in the cooling system.

□ It raises the boiling point of thecoolant. This slows the rate ofevaporation, avoiding coolant lossat high temperatures.



Water

Water containing no additives isnot suitable as a coolant, even if noantifreeze protection is needed.

The water used in the coolant mustcomply with certain requirements,which are not always satisfied bydrinking water. If water quality isinadequate, the water must undergosuitable treatment.

The following types of water arepreferred for use in coolant:

□ Distilled water

□ Water purified by reverse osmosis

□ De-ionized water

NOTICE:In some areas, tap water cancontain high levels of dissolvedchlorides, sulfates, magnesium, andcalcium, causing scale deposits,sludge deposits and/or corrosion.These deposits can damage thecoolant pump and allow the engineto overheat.

Coolant Specifications

To avoid damage to the coolingsystem, use only an approvedcorrosion-inhibiting antifreeze.Approved antifreeze must befully-formulated and comply withthe requirements of the TruckMaintenance Council (TMC). Coolantspecifications are listed in Table2. Detroit Diesel POWER COOLproducts meet these specificationsand are recommended.

Coolant Concentration

When topping off the cooling systemafter a drop in the coolant level, theconcentration of corrosion-inhibitingantifreeze in the coolant must be50 percent by volume. This affordsprotection down to a temperature of–37°C(–34°F). The cooling mixingratio is listed in Table 3.

Type of Coolant RequirementFully-Formulated Ethylene Glycol TMC RP-329 Type "A"

Fully-Formulated Propylene Glycol TMC RP-330 Type "A"

Water plus Corrosion Inhibitors Temperature Must Not Fall Below0°C (32°F)

Table 2 Coolant Specifications


SERVICE PRODUCTS

Antifreeze ProtectionDown to °C (°F)

Water %by Volume

Corrosion - InhibitingAntifreeze % by Volume

–37 (–34) 50 50 minimum

–52 (–62) 40 The cooling mix ratio is Max. 60

Table 3 Coolant Mixing Ratio

Important: If the concentrationis too low, there is risk ofcorrosion/cavitation in the coolingsystem.

For information about coolant incold weather operation, see theheading "Winter Coolant AntifreezeProtection" later in this chapter.

Supplemental Coolant Additivesfor Fully Formulated Coolant

The concentrations of some inhibitorswill gradually deplete during normalengine operation. SCAs replenishthe protection for cooling systemcomponents. The coolant mustbe maintained with the properconcentration of SCA. Detroit DieselPOWER COOL maintenance SCAsare recommended.

NOTICE:Failure to properly maintain coolantwith SCA can result in damageto the cooling system and itsrelated components. Conversely,over-concentration of SCA inhibitorcan result in poor heat transfer,leading to engine damage.Always maintain concentrations atrecommended levels. Do not usetraditional SCAs with NOAT coolant.

The proper application of SCA willprovide:

□ pH control

□ Restored inhibitor levels to preventcorrosion

□ Water-softening to deter formationof mineral deposits

□ Cavitation protection to protectwet sleeve cylinder liners



Dropout

Excessive amounts of some corrosioninhibitors can cause a gel or crystallinedeposit that reduces both heat transferand coolant flow. This deposit iscalled "dropout."

Dropout takes the color of the coolantwhen wet, but becomes a white or graypowder when dry. It can pick up solidparticles in the coolant and becomegritty. It will cause premature wearof the coolant pump seals and othercomponents of the cooling system.

The wet gel can be removed using analkaline (non-acid) cleaner containingeither sodium nitrite or sodiumtetraborate.

If the gel is allowed to dry, it isnecessary to disassemble the engineand clean it with a caustic solution,or physically clean the individualcomponents.

Disposal

Coolants are biologically degradablesubstances.

When disposing of used coolant,comply with local legal requirementsand waste water regulations.

Consult the local water supplyauthorities to determine the bestmethod of disposal.

A modern engine coolant has complextasks to perform. Do not allow any

form of "reprocessing" which consistsonly of mechanical purification.

Cold Weather ProductsSpecial precautions must be takenduring cold weather. To protect yourengine, take the following specialmeasures in cold weather:

□ Use special cold weather fuel andengine oil.

□ Check the concentration ofantifreeze in your coolant.

□ Take special care of your batteries.

Winter-Grade Diesel Fuel

At low outside temperatures, paraffinmay separate from the diesel andaffect its ability to flow freely.

Avoid breakdowns caused by thisproblem (for example, blockedfilters) by using cold-resistantwinter-grade diesel fuel with improvedlow-temperature flow characteristics.In most cases, winter-grade fuel canbe used without problems at coldoutside temperatures.

If using summer-grade fuel or a lesscold-resistant winter grade, a flowimprover or kerosene can be addedwith caution. The amount neededdepends on the outside temperature.


SERVICE PRODUCTS

FIRE

To avoid increased risk of a fuelfire, do not mix gasoline anddiesel fuel.

Flow improver or petroleum spiritmust be mixed with diesel fuelbefore its flow characteristics havebeen adversely affected by paraffinseparation. If changes have alreadybeen caused by paraffin separation,they can be corrected only byheating the entire fuel system. Donot add anything to cold-resistantwinter-grade diesel fuels. The fuel'slow-temperature flow characteristicscould actually deteriorate withadditives.

Low-Viscosity Engine Oil

When changing the engine oil,estimate the interval before yournext oil change. Choose an oilfrom the SAE viscosity classwhich corresponds to the outsidetemperatures anticipated during thisperiod of operation. See Figure 28.

Figure 28 Engine Oil TemperatureRanges

Winter Coolant AntifreezeProtection

Before the temperature dips belowfreezing, check the concentration ofantifreeze in the coolant. If necessary,increase it.

Do not increase the proportion(mixing ratio) of corrosion-inhibitingantifreeze beyond 55 percent byvolume (this gives the maximumantifreeze protection). Furtherincreases in the mixing ratio wouldreduce the level of antifreezeprotection and adversely affect thecoolant's ability to dissipate heat.

Batteries

Batteries should receive more frequentmaintenance and recharging duringthe cold season of the year.



Careful maintenance and low currentconsumption will help to maintain thefull battery charge. Starting capacitydrops severely in cold weather. Forexample, at –10°C (14°F) startingcapacity is only about 60 percentof normal. If the engine is shutdown or out of use for an extendedperiod of time, store the batteriesout of the vehicle in a heated areaif possible. Ensure good ventilationwhen recharging.


TECHNICAL DATA

TECHNICAL DATA

General technical information islisted in Table 4.

4-Cylinder Engines 6-Cylinder EnginesDescription

904 924 906 926

Engine Type Vertical, inline cylinder block with turbochargerand charge-air cooler

Cooling System Liquid Circuit

Combustion Principle 4-Stroke direct-injection diesel

Number of Cylinders 4 6

Bore 4.02 in(102 mm)

4.17 in(106 mm)

4.02 in(102 mm)

4.17 in(106 mm)

Stroke 5.11 in(130 mm)

5.35 in(136 mm)

5.11 in(130 mm)

5.35 in(136 mm)

Displacement (total) 259 in³(4.25 liters)

262 in³(4.8 liters)



Compression Ratio 18.0:1 17.5:1

Starting Speed Approximately 100 rpm

Direction of EngineRotation (viewed fromflywheel)

Counterclockwise

Starter Electric Motor

Cold-StartTemperature Limit(Without starting aidsand with battery 75%charged)

The engine starts quickly without additional cold startdevice in temperatures down to -15°C (+5°F).An optional grid heater provides easy starting inextreme temperatures down to -25°C (-13°F).For temperatures below -25°C (-13°F) an optionalgrid heater with preheating for coolant and lube oil isavailable.

Table 4 General Technical Information



Engine Data for EGREngineThe engine weights are listed in Table5. The engine dimensions arelisted in Table 6. Also see Figure 29and Figure 30. Coolant and lubricatingoil capacities are listed in Table 7

Engine Engine DryWeight

4-Cylinder 420 kg 926 lb)

6-Cylinder 560 kg (1235 lb)

Table 5 Engine Weights

4-Cylinder 6-CylinderA = 1025 mm

(40.4 in.)A = 1219 mm

(48 in.)

B = 686 mm(27 in.)

B = 810 mm(31.9 in.)

C = 1000 mm(39.4 in.)

C = 1060 mm(41.7 in.)

Table 6 Engine Dimensions

Figure 29 Engine Measurements(Side View)

Figure 30 Engine Measurements(Front View)

Description 4-Cylinder Engine 6-Cylinder EngineCoolant Capacity* Max. 8 L (8.5 qt) Max. 12.5 L (13.2 qt.)

Lubricating OilCapacity** Max. 15.8 L (16.7 qt) Max. 29 L (30.6 qt)

*Does not include capacity of cooling system.**For standard oil pan.

Table 7 Coolant and Lubricating Oil Capacity


TECHNICAL DATA

Engine Data for Non-EGREngineThe engine weights are listed in Table8. The engine dimensions arelisted in Table 9. Also see Figure 31and Figure 32. Coolant and lubricatingoil capacities are listed in Table 10.

Engine Engine DryWeight



Table 8 Engine Weights

4-Cylinder 6-CylinderA = 1025 mm

(40.4 in.)A = 1219 mm

(48.0 in.)

B = 686 mm(27.0 in.)

B = 810 mm(31.9 in.)

C = 925 mm(36.4 in.)

C = 940 mm(37.0 in.)

Table 9 Engine Dimensions

Figure 31 Engine Measurements(Side View)

Figure 32 Engine Measurements(Front View)

Description 4-Cylinder Engine 6-Cylinder EngineCoolant Capacity* Max. 8.5 L (9.0 qt.) Max. 12.5 L (13.2 qt.)

Lubricating OilCapacity Max. 15.8 L (16.7 qt) Max. 29.0 L (30.6 qt)

*Does not include capacity of cooling system.**For standard oil pan

Table 10 Coolant and Lubricating Oil Capacity



Testing and AdjustingValuesValve lash checking and adjustmentsare listed in Table 11. Engine

Oil Pressure is listed in Table 12.Coolant thermostat conditions arelisted in Table 13. Injector pressuresare listed in Table 14.

Valve Type Check For:mm ( in.)

Adjust To:mm ( in.)

Intake 0.30 to 0.60 (0.012 to 0.024) 0.016 (0.40)

Exhaust 0.50 to 0.80 (0.020 to 0.032) 0.60 (0.024)

Table 11 Valve Lash Checking and Adjustment

Engine Speed Minimum PressureAt idling rpm 50 kPa (7 psi)

At maximum rpm 250 kPa (36 psi)

Table 12 Engine Oil Pressure

Condition SpecificationStarts to open 81 to 85°C (177 to 185°F)

Fully open 95°C (203°F)

Minimum lift 8 mm ( 0.3 in.)

Table 13 Coolant Thermostat

Opening Pressure Value in kPa (psi)Minimum opening pressure 24,497 (3,553)

Maximum opening pressure 25,697 (3,727)

Table 14 Injector Pressure


MAINTENANCE

MAINTENANCE

When performed on a regular basis,changing the engine oil and filters isthe least costly way of obtaining safeand reliable vehicle operation. Addedbenefits and savings occur when youcheck that the valves, fuel injectors,and oil and cooling circuits are in goodworking order during oil changes.

The maintenance section of thismanual explains when you shouldchange your oil and what to look forwhen checking for wear or damage.

For additional information, pleasecontact your regional office.

Scheduled IntervalsAll service intervals and maintenanceoperations are based on the parts andaccessories expressly approved foryour engine.

The scope and frequency ofmaintenance work are determinedby the engine's operating conditions:severe duty, short haul, long haul oroperating hours vs. fuel consumption(oil drain interval only).

Evidence of regular maintenance isessential if a warranty claim has to besubmitted.

If optional equipment is installed, besure to comply with the maintenancerequirements for these extra items.

Important: If the engine is stored formore than 18 months, the oil mustbe changed before the engine can bebrought into service.

Maintenance Schedule Types

There are five types of maintenanceschedule:

□ Schedule I (Severe Service)

□ Schedule II (Short Haul)

□ Schedule III (Long Haul)

□ Operating Hours vs. FuelConsumption (Oil Drain IntervalOnly)

□ UNIMOG Service Schedule

To determine which schedule to use,find the distance traveled by thevehicle in a year, regardless of vehicletype.

Severe Service — Applies tovehicles that annually travel up to100,000 kilometers (60,000 miles) orthat operate under severe conditions.Examples of Severe Service usageinclude: operation on extremely poorroads or where there is heavy dustaccumulation; constant exposureto extreme hot, cold, salt-air, orother extreme climates; frequentshort-distance travel; construction-site



operation; city operation (fire truck,garbage truck); or farm operation.

Short-Haul — Applies to vehiclesthat annually travel up to 100,000kilometers (60,000 miles) and operateunder normal conditions. Examplesof Short-Haul usage are: operationprimarily in cities and denselypopulated areas; local transport withinfrequent freeway travel; or highpercentage of stop-and-go travel.

Long-Haul — Long Haul(over-the-road transport) is forvehicles that annually travel more than100,000 kilometers (60,000 miles),with minimal city or stop-and-gooperation. Examples of Long-Haulusage are: regional delivery thatis mostly freeway miles; interstatetransport; or any road operation withhigh annual mileage.

Operating Hours vs. FuelConsumption (Oil Drain IntervalOnly) — Operating hours vs. fuelconsumption is for operators whowant an oil drain interval based onhours of operation instead of milestraveled. See Figure 33.

UNIMOG — The UNIMOG enginehas long maintenance intervals.

Maintenance Schedule andInterval Operations — The three

different schedules of vehicle usage(severe, short haul, and long haul) arelisted in Table 15. For each schedule,the appropriate distance interval(in miles and kilometers) is givenfor performing and repeating eachmaintenance operation.

The descriptions of all maintenanceoperations, indicating all maintenanceoperation sets at which each operationmust be performed are listed in Table15.

Maintenance Intervals — Thethree maintenance interval tables showwhich maintenance operation mustbe performed at the actual distances(in miles or kilometers) for eachmaintenance operation (M1–M3). Theschedule of actual distances is basedon the intervals listed in Table 15. TheUNIMOG maintenance intervals forreplacement of fluids and filters arelisted by operating hours.

The maintenance interval tables are:

□ Maintenance Interval Table,Severe Service (informationlisted in Table 16)

□ Maintenance Interval Table, ShortHaul (information listed in Table17)

□ Maintenance Interval Table, LongHaul (information listed in Table18)


MAINTENANCE

□ The UNIMOG maintenanceintervals for replacement of fluidsand filters are listed in Table 21,Table 22, Table 23, and Table 24.

Maintenance Operation Sets —Each Maintenance OperationsSets Table (M1 through M3) lists thedescriptions of only those maintenanceoperations that must be performedat that maintenance operation set.Each maintenance operation set islisted in Table 19 and Table 20.

Schedule UseBefore placing your new vehiclein service, determine the correctmaintenance intervals that apply toyour intended use of the vehicle. Referto the Maintenance Schedule Tableto determine the distance interval atwhich each maintenance operationmust be performed to comply withyour vehicle's schedule. A detaileddescription of maintenance operationscan be found later in this section

When the vehicle reaches the actualdistance given for an interval, referto the Maintenance Interval Tablesto find the Maintenance OperationSet that applies to that interval. Thenperform the maintenance operationslisted in the applicable MaintenanceInterval Operation Table.

Complete each MaintenanceOperation Set at the required interval.For example, when you havecompleted Maintenance OperationSet M3 under the 16th maintenancenumber listed in the MaintenanceInterval Table, repeat the pattern. Forthe 17th maintenance, do MaintenanceOperation Set M1, under the firstmaintenance number listed in theMaintenance Interval Table.

NOTE:For Severe Service, the patternrepeats after 15 maintenancenumbers, not 16 (as for Short Hauland Long Haul).



Maintenance Tables andGraphs

Maintenance IntervalsMaintenanceSchedule

Maint.IntervalOperation

Frequency Miles KmMaint. 1

(M1) every 6,000(904/906/926)

9,650(904/906/926)

Schedule I(Severe Service)

vehicles thatannually travel

up to 6,000 miles(9,650 km)

Maint. 2(M2) every 18,000 29,000

Maint. 1(M1) every 15,000

(904/906/926)24,000

(904/906/926)

Maint. 2(M2) every 60,000 96,500

Schedule II(Short Haul)vehicles that

annuallytravel up to60,000 miles(96,500 km)

Maint. 3(M3) every 75,000 121,000

Maint. 1(M1) every 20,000

(904/906/926)32,000

(904/906/926)

Maint. 2(M2) every 60,000 96,500

Schedule III(Long Haul)vehicles that

annually travelmore than

60,000 miles(96,500 km)

Maint. 3(M3) every 80,000 129,000

Table 15 Maintenance Schedule Table


MAINTENANCE

Maint. No MaintenanceInterval Miles Km

1 M1* 6,000 9,650

2 M1 12,000 18,000

3 M1 and M2 18,000 30,000

4 M1 24,000 40,000

5 M1 30,000 50,000

6 M1 and M2 36,000 60,000

7 M1 42,000 70,000

8 M1 48,000 80,000

9 M1 and M2 54,000 90,000

10 M1 60,000 96,500

11 M1 66,000 110,000

12 M1 and M2 72,000 120,000

13 M1 78,000 130,000

14 M1 84,000 140,000

15 M1 and M2 90,000 150,000

* 6-cylinder engines use a oil centrifuge filter to meet the above intervals,the cartridge in the centrifuge has the same interval as the primaryfilter. 4-cylinder engines will not use the oil centrifuge.

Table 16 Maintenance Intervals for Schedule I, Severe Service



Maint. No. MaintenanceInterval Miles Km

1 M1* 15,000 24,000

2 M1 30,000 48,000

3 M1 45,000 72,000

4 M1 and M2 60,000 96,500

5 M1 and M3 75,000 120,000

6 M1 90,000 144,000

7 M1 105,000 168,000

8 M1 and M2 120,000 192,000

9 M1 135,000 216,000

10 M1 and M3 150,000 241,000

11 M1 165,000 265,000

12 M1 and M2 180,000 289,000

13 M1 195,000 314,000

14 M1 210,000 338,000

15 M1 and M3 225,000 362,000

16 M1, M2 and M3 240,000 386,000


Table 17 Maintenance Intervals for Schedule II, Short Haul


MAINTENANCE

Maint. No MaintenanceInterval Miles Km

1 M1* 20,000 32,000

2 M1 40,000 64,000

3 M1 and M2 60,000 96,500

4 M1 and M3 80,000 128,000

5 M1 100,000 160,000

6 M1 and M2 120,000 193,000

7 M1 140,000 225,000

8 M1 and M3 160,000 257,000

9 M1 and M2 180,000 290,000

10 M1 200,000 322,000

11 M1 220,000 354,000

12 M1, M2 and M3 240,000 386,000

13 M1 260,000 418,000

14 M1 280,000 450,000

15 M1 and M2 300,000 482,000

16 M1 and M3 320,000 515,000


Table 18 Maintenance Intervals for Schedule III, Long Haul



Figure 33 Oil Drain Interval — Operating Hours vs. Fuel Consumption


MAINTENANCE

Operation Description M1 M2Engine Inspecting

Fuel Prefilter Element Cleaning —

Main Fuel Filter Element Changing —

Valve Checking and Adjusting —

Engine Oil and Filter Changing, Replace 906 and 926 OilCentrifuge Cartridge

Coolant Concentration Checking

Coolant Flushing and Changing —

Cooling System Inspecting

Table 19 Required Maintenance Operations Sets, Schedule I

Maintenance Operation Description M1 M2 M3Engine Inspecting —

Valve Lash Checking and Adjusting — —

Fuel Prefilter Element Cleaning —

Main Fuel Filter Element Changing —

Engine Oil and Filter Changing, Replace 906 and 926 OilCentrifuge Cartridge

Coolant Concentration Checking —

Coolant Flushing and Changing — —

Cooling System Inspecting —

Table 20 Required Maintenance Operations Sets, Schedule II and III

NOTE:If oil drain intervals are measured byoperating hours, an extension of theoil drain interval may be possible.Refer to DDC publication Lubricating

Oil, Fuel and Filters Requirements(7SE270) available on the DDCextranet.



NOTE:The engine oil and oil filter MUST bechanged EVERY 200 operating hours.

Operating HoursComponent Maintenance

200 700 1,400Engine Change oil and oil filter Every 200 hours

Fuel System Change filter and vent system — —

Transmission Change oil — — —

PTO Transmission Change oil and oil filter — — —

Axle Gear Change oil — —

Change oil filter — —Working Hydraulics

Change oil and oil filter — — —

Table 21 UNIMOG Service Intervals, 200 - 1400 Operating Hours


2,100 2,800 3,500Engine Change oil and oil filter Every 200 hours

Fuel System Change filter and vent system

Transmission Change oil — —

PTO Transmission Change oil and oil filter — —

Axle Gear Change oil —


Change oil and oil filter — — —



MAINTENANCE


4,200 4,900 5,600Engine Change oil and oil filter Every 200 hours

Fuel System Change filter and vent system —

Transmission Change oil — —

PTO Transmission Change oil and oil filter — —

Axle Gear Change oil — —

Change oil filter — — —WorkingHydraulics Change oil and oil filter — —



6,300 7,000Engine Change oil and oil filter Every 200 hours

Fuel System Change filter and vent system

Transmission Change oil —

PTO Transmission Change oil and oil filter —

Axle Gear Change oil —


Change oil and oil filter —




Required MaintenanceOperationsThe following sections describe therequired maintenance operationslisted in Table 19 and 20.

Engine Inspecting

Inspect the engine as follows:

1. Visually check the engine forsigns of leakage. A slightdampness at the sealing points isno cause for alarm.

NOTE:More severe leaks, combined with acontinual loss of oil, must be correctedwithout delay.

2. Visually inspect all lines andhoses. Listen for any sound ofleaking. Make sure all pipes andhoses are undamaged, correctlypositioned to avoid chafing, andproperly secured.

Valve Lash Checking andAdjusting

Important: Adjust the valve lashwhen the engine is cold. Wait at least30 minutes after shutdown, even if theengine ran only a short time.

The special tool listed in Table 25 isrequired for this procedure.

Tool Description Manufacturer Part Number

Engine CrankingTool Kent-Moore J-46392

Table 25 Special Tool


MAINTENANCE

Gaining Access To The Valves—Gain access to the valves as follows:

NOTE:Clean the cylinder head cover beforeremoving it.

1. Remove the cylinder head cover(see Figure 34).

Figure 34 Cylinder Head Cover

2. Remove the inspection cover onthe timing case.

3. Fit the cranking devicelisted in Table 25 into the

inspection hole on the timing case(see Figure 35).

Figure 35 Inspection Hole in theTiming Case

4. Select a method for adjusting thevalve lash. See Figure 36 forthe valve layout on both four-and six-cylinder engines. Thereare two acceptable methods foradjusting valve lash:

• In order, according to thetiming sequence used for fuelinjection ("Method One”)

• By type of valve, depending oncrankshaft position ("MethodTwo”)



Figure 36 Cylinder and ValveLayout

Method One: Adjust EachCylinder In Firing Order —Method One allows you to adjusteach cylinder in the order in whichfuel is injected. The crankshaft must

be repositioned after each cylinder isadjusted as listed in Table 26.

1. For each cylinder, use thecranking device to rotate thecrankshaft until the piston isexactly at top dead center (TDC)in the compression stroke. Thevalves must be closed and it mustbe possible to turn the push rodswithout effort.

NOTE:When the piston in cylinder #1 is atignition TDC, the valves of cylinder#6 (cylinder #4 on the four-cylinderengine) will overlap, meaning that bothintake and exhaust valves are partiallyopen, and show no measurable playwhen tested with a feeler gauge.

2. Check each valve and adjust it (ifnecessary), using the proceduresunder the headings "CheckingValve Lash" and "Adjusting ValveLash" in this section.

Engine CrankshaftPosition Cylinders

IgnitionSequence 1 3 4 2 NA NA

4-CylinderValve Overlap 4 2 1 3 NA NA

IgnitionSequence 1 5 3 6 2 4

6-CylinderValve Overlap 6 2 4 1 5 3

Table 26 Valve Adjustment- Method One


MAINTENANCE

Method Two: Adjust AllValves Using Two CrankshaftPositions — Method two allowsyou to adjust all the valves using justtwo crankshaft positions.

1. Using the cranking device, turnthe crankshaft until cylinder #1 isat the ignition TDC position (allvalves are closed) and cylinder #6(cylinder #4 on the four-cylinderengine) is at the valve overlapposition (all valves are open).

2. Check the valves listed in Table27 in the "Ignition TDC" rowand adjust them (if necessary),using the procedures under theheadings "Checking Valve Lash"and "Adjusting Valve Lash."

3. Using the cranking device, turnthe crankshaft until cylinder #6(cylinder #4 on the four-cylinderengine) is at the ignition TDCposition (all valves are closed)and cylinder #1 is at the valveoverlap position (valves areopen).

4. Using the same procedure, checkthe valves listed in Table 27 in the"Valve Overlap" row and adjustthem (if necessary), using theprocedures under the headings"Checking Valve Lash" and"Adjusting Valve Lash."

Cylinders/Valve Types*Engine

Cylinder #1CrankshaftPosition 1 2 3 4 5 6

Ignition TDC I/E I E — NA NA4-Cylinder

Valve Overlap — E I I/E NA NA

Ignition TDC I/E I E I E —6-Cylinder

Valve Overlap — E I E I I/E

* I = Intake Valve and E = Exhaust Valve

Table 27 Valve Adjustment - Method Two



Checking Valve Lash — Checkvalve lash as follows:

1. For each valve, measure the valvelash with a feeler gauge betweenthe rocker arm and valve stem(exhaust valve) or valve bridge(intake valve). It should bepossible to pull the feeler gaugethrough with no more than lightresistance.

2. If the value measured is withinthe range listed in Table 28 in the"Check For" column, check thenext valve.

If the value measured is outside therange listed in Table 28 in the "CheckFor" column, adjust the valve lash.

Adjusting Valve Lash — Adjustvalve lash as follows:

1. If adjustment is needed, loosenthe locknut. See Figure 37 forintake valves and Figure 38 forexhaust valves. Use the exactsettingslisted in Table 28 in the"Adjust To" column.

Figure 37 Intake Valves

Figure 38 Exhaust Valves

Valve Type Check For: Adjust to:Intake 0.30 to 0.60 mm (0.012 to 0.024 in.) 0.40 mm (0.016 in.)

Exhaust 0.50 to 0.80 mm (0.020 to 0.032 in.) 0.60 mm(0.024 in.)

Table 28 Valve Lash Checking and Adjustment


MAINTENANCE

2. Turn the adjusting screw until thevalve lash is correct using theexact settings listed in Table 28.Use the range only for checkingadjustment.

3. Tighten the locknut 25 N·m (18lb·ft ).

4. Check the valve lash again.Adjust again if necessary.

Restoring The Vehicle ToOperating Condition — Restore tooperating condition as follows:

1. Install the cylinder head cover.See Figure 39.

2. Remove the cranking device fromthe inspection hole in the timingcase.

3. Replace the end cover on theinspection hole and tighten thebolts 25 N·m (18 lb·ft).

Fuel Prefilter ElementCleaningClean the fuel prefilter element asfollows:

1. Open the fuel filler cap to releasepressure in the fuel system.Replace and tighten the cap.

2. Clean the outside of the prefilterhousing. Keep fuel away fromhoses or pipes located beneath thefilter. See Figure 40.

Figure 39 Cylinder Head Cover

Figure 40 Fuel Filters

3. Unscrew the cap on the fuelprefilter. Pull the cap and filter



element out of the prefilterhousing. See Figure 41.

4. Clean the cap and the filterelement. If the filter elementis heavily soiled or damaged,replace it.

5. Check the O-ring on the cap andreplace it if necessary.

6. Insert the filter element into theprefilter housing and screw thecap onto the housing. Tighten thecap 25 N·m (18 lb·ft ).

Figure 41 Fuel Prefilter

7. Bleed the fuel system.


[a] Make sure that allhigh-pressure lines havebeen tightened to 25 N·m (18lb·ft) and all banjo bolts to 40N·m (30 lb·ft).

[b] If equipped with a hand pumpon the fuel/water separator,work the hand pump 50 times.

[c] Crank the engine for 30seconds at a time, but nolonger. Before cranking theengine again, wait at least twominutes. The engine shouldstart within four 30-secondattempts.


MAINTENANCE

Main Fuel Filter ElementChangingChange the main fuel filter element asfollows:

1. Open the vehicle fuel tank fillercap to release pressure in the fuelsystem. Replace and tighten thecap.

2. Clean the outside of the fuel filterhousing. See Figure 40.

3. Using a 36-mm socket wrenchinsert, unscrew the cap on thefuel filter and remove it, alongwith the filter element. Pull boththe cap and the filter element ashort distance out of the filterhousing. See Figure 42. Allowthe fuel to drain off the filter intothe housing.

4. Remove the cap with the filterelement. To release the filterelement, twist the lower edge ofthe filter element to one side.

NOTICE:To prevent damage to the filterhousing, do not allow dirt to get intothe filter housing. Do not empty thedirt collector into the filter case.

5. Pull the dirt collector out of thefilter housing using the tabs oneither side.

Figure 42 Main Fuel Filter

6. Clean the cap and the dirtcollector.

7. Replace the O-ring.

8. Install the new filter elementin the cap. Make sure the filterelement is securely in place.

9. Insert the dirt collector into thefilter housing. Make sure the dirtcollector is positioned properly inthe filter housing.

10. Screw on the cap with the filterelement. Tighten the cap 25 N·m(18 lb·ft).




11. Bleed the fuel system.

[a] Make sure that allhigh-pressure lines havebeen tightened to 25 N·m (18lb·ft)) and all banjo bolts to40 N·m (30 lb·ft).

[b] If equipped with a hand pumpon the fuel/water separator,work the hand pump 50 times.

[c] Crank the engine for 30seconds at a time, but nolonger. Before cranking theengine again, wait at least twominutes. The engine shouldstart within four 30-secondattempts.

12. Start the engine. Check the fuelfilter for leaks.

Engine Oil and FilterChanging

FIRE

To avoid injury from fire, keepopen flames, sparks, electricalresistance heating elements, orother potential ignition sourcesaway when draining lubricationoil. Do not smoke when draininglubricating oil.

NOTE:Select the SAE class (viscosity) on thebasis of the average air temperaturefor the season. See Figure 43. Viewthe temperature ranges for the variousSAE classes as guidelines which canbe exceeded for only a short time.

Figure 43 SAE Oil ViscosityClasses


MAINTENANCE

To insure the engine is protectedand the oil stays clean until the nextoil change, use only oils of APIclassification CI4.

The six-cylinder EGR engines havean oil centrifuge and an oil filter.Non-EGR engines have only an oilfilter.

NOTICE:Both the primary lube oil filter (frontof engine) and the oil centrigugecartridge (side of engine) must bereplaced at each oil drain interval.

Change the oil filter as follows:

1. Chock the tires, place thetransmission in neutral, and setthe parking brake.

NOTE:Change the engine oil only when theengine is at an operating temperatureof approximately 82°C (180°F).

2. Using a 36-mm socket, unscrewthe oil filter cap. See Figure 44.

Figure 44 Oil Filter Cap

3. Place a suitable receptaclebeneath the oil drain plug on theunderside of the oil pan. Carefullyunscrew the oil drain plug on theoil pan and allow the oil to drainout. See Figure 45. Discard theO-ring on the oil drain plug.

Figure 45 Engine Oil Drain Plug,Oil Pan

4. Remove both the filter cap andthe filter element. To release the



filter element, twist the loweredge of the filter element to theside. See Figure 46.

Figure 46 Cap with Oil FilterElement

NOTICE:To prevent damage to the filterhousing, ensure that no foreignobjects get inside it. Do not wipeclean the filter housing.

5. Replace the O-ring on the cap.See Figure 46.

6. Install the new filter into the cap.Make sure the filter element issecurely in place.

7. Screw the cap onto the oil filterhousing. Tighten the cap 25 N·m(18 lb·ft).

8. Install the oil drain plug, using anew O-ring. Tighten the plug 65N·m (48 lb·ft).

9. Add new engine oil through theoil fill (see Figure 47).

Figure 47 Oil Fill

PERSONAL INJURY


NOTE:Engine oil fill capacity with a standardoil pan for the six-cylinder engineis 30.6 quarts (29.0 L). For thefour-cylinder engine with a standard oilpan, fill capacity is 16.7 quarts (15.8L).

10. Fill until the maximum fill levelon the oil dipstick has beenreached. Do not overfill.


MAINTENANCE

NOTICE:Keep the engine running at idlingspeed until an oil pressure reading isobtained. If no oil pressure is shownafter approximately 10 seconds,stop the engine and determine thecause. Failure to do so could resultin engine damage.

11. Start the engine with theaccelerator pedal in the idleposition. Monitor the oil pressuregauge.

12. Check the filter and oil drain plugfor signs of leakage.

13. Stop the engine.

14. Check the oil level again afterapproximately five minutes.If necessary, add oil up to themaximum fill level on the oildipstick. Do not overfill.

Oil Centrifuge

The MBE six-cylinder engines(906/926) have an oil centrifuge.

NOTICE:Both the primary lube oil filter (frontof engine) and the oil centrigugecartridge (side of engine) must bereplaced at each oil drain interval.

Change the oil centrifuge cartridge asfollows:

1. Remove the cover of the oilcentrifuge. See Figure 48.

Figure 48 Oil Centrifuge

2. Lift out the dirty cartridge andreplace it with a clean one(see Figure 49).

Figure 49 Centrifuge Cartridge

3. Replace the centrifuge cover,tighten the cap 40 Nm (30 lb·ft).



Coolant ConcentrationCheckingCheck coolant concentration asfollows:

HOT COOLANT


1. Open the cap on the surge tankslowly, to allow excess pressureto escape. Set the cap aside.

NOTE:Check and correct the coolant levelonly when the coolant temperature isbelow 50°C (122°F).

2. Before adding coolant,use a suitable tester tocheck the concentration ofcorrosion-inhibiting antifreeze. Ifthe concentration is lower than50% by volume, drain coolant/addantifreeze until the concentrationis correct. The coolant mixingratio is listed in Table 29.

NOTE:Concentrations of more than 55% byvolume should not be used, as this isthe level which affords the maximumantifreeze protection, down to –45°C(–49°F). Higher concentrationsadversely affect heat dissipation.

AntifreezeProtection Down

to°C (°F)

Water Percentageby Volume

Corrosion-InhibitingAntifreeze

Percentage byVolume

–37 (–347) 50 50

–45 (–49) 45 Maximum 55

Table 29 Coolant Mixing Ratio

NOTICE:If the concentration of antifreeze istoo low, there is a risk of corrosionor cavitation in the cooling system.

NOTE:When topping off, use only apre-prepared coolant mixturecontaining a 50% concentration


MAINTENANCE

by volume of corrosion-inhibitingantifreeze.

3. Check the coolant level and addmore coolant if necessary.

4. Close and tighten the cap on thesurge tank.



Coolant Flushing andChanging

HOT COOLANT


Flush and change the coolant asfollows:

1. Open the cap on the surge tankslowly, to allow excess pressureto escape. Set the cap aside.

2. Open the water regulating valvefor the heating system.

3. Drain the coolant from the engine.See Figure 50. Coolant systemcapacity is listed in Table 30.

[a] Place a receptacle underneaththe coolant drain plug.Choose one that is largeenough to hold the expectedquantity of coolant.

Figure 50 Coolant Drain Plug

NOTE:Make sure the coolant can flowunobstructed into the receptacle.

[b] Open the coolant drain plugon the bottom of the radiator.

4. Flush the radiator.

NOTICE:When flushing the radiator, do notapply more than 140 kPa (20 psi) airpressure. Excessive pressure candamage the radiator or heater core.

[a] Attach a flushing gun nozzleto the radiator outlet.

[b] Run water in until the radiatoris full.


MAINTENANCE

EYE INJURY


[c] Apply no more than140 kPa (20 psi) air pressureintermittently to help dislodgesediment buildup in the core.

5. Drain the radiator, and flush theradiator until clean water flowsfrom the radiator. Remove theflushing gun.

6. When the coolant has drained,install the coolant drain plug onthe radiator.

7. Add coolant in the specifiedconcentration until the maximummark on the surge tank is reached.Coolant system capacity islisted in Table 30.

Description 4-Cylinder 6-CylinderEngine Coolant Capacity (all vehicles) L (Qt)

Engine capacity 8 (8.5) 12 (12.7)

Business Class Coolant System Capacity L (Qt)

Total capacity 19.8 (21) 23.6 (25)

Antifreeze quantity at 50% 9.9 (10.5) 11.8 (12.5)

Antifreeze quantity at 55% 10.8 (11.5) 13.1 (13.8)

Table 30 Coolant System Capacity

8. Start the engine and run it forabout one minute at varyingspeeds to release air pockets inthe cooling system. Make surethe heater valve is still open.Check the coolant level and addmore coolant if necessary.


10. Add coolant if necessary.



Cooling System Inspecting

HOT COOLANT


NOTE:Before doing this inspection, makesure to do either maintenanceoperation, "Coolant ConcentrationChecking," or maintenance operation,"Coolant Flushing and Changing."

Inspect the cooling system as follows:

1. Inspect the radiator, thecondenser, the coolant pump,the engine oil cooler, the freezeplugs, and the heat exchanger fordamage and leaks.

2. Check all pipes and hoses in thecooling system for damage andleaks. Make sure all pipes andhoses are properly positioned toavoid chafing, and are securelyfastened.

3. Check the outside of the radiatorand condenser for blockage by

dirt or debris. Make sure the finsare not damaged, and straightenthem if necessary.


CUSTOMER ASSISTANCE

CUSTOMER ASSISTANCE

The satisfaction and good will of theowners of Detroit Diesel engines areof primary concern to Detroit Diesel

Corporation and its distributor/dealerorganizations.



DDC NORTH AMERICAN NAFTA ON-HIGHWAY OFFICESEASTERN REGION 1Suwanee, Georgia3325 Paddocks ParkwaySuwanee, GA 30024Telephone: 678-341-6100Fax: 678-341-6150

EASTERN REGION 2Detroit, Michigan13400 Outer Drive WestDetroit, MI 48239-4001Telephone: 313-592-5420Fax: 313-592-5887

WESTERN REGION 1Irvine, California7700 Irvine Center, Suite 275Irvine, CA 92618Telephone: 949-753-7710Fax: 949-753-7711

WESTERN REGION 2Irvine, California7700 Irvine Center, Suite 275Irvine, CA 92618Telephone: 949-753-7710Fax: 949-753-7711

CANADIAN REGIONLondon, OntarioDetroit Diesel of Canada, Ltd.150 Dufferin Ave., Suite 701London, ON N5A 5N6Phone: 519-661-0149Fax: 519-661-0171


CUSTOMER ASSISTANCE

MTU DETROIT DIESEL OFF-HIGHWAY SALES ANDCUSTOMER ASSURANCE CENTERS

CONSTRUCTION, INDUSTRIALAND MINING SALES (BX7)13400 Outer Drive, WestDetroit, MI 48239-4001Phone: 313-592-5608Fax: 313-592-5625

MARINE SALES (BX6)13400 Outer Drive, WestDetroit, MI 48239-4001Phone: 313-592-7806Fax: 313-592-5137

POWERGEN AND OIL FIELD SALES(BX11)13400 Outer Drive, WestDetroit, MI 48239-4001Phone: 313-592-5708Fax: 313-592-5158

GOVERNMENT SALES (BX9)13400 Outer Drive, WestDetroit, MI 48239-4001Phone: 313-592-5875Fax: 313-592-5158

CUSTOMER ASSURANCE (M24)13400 Outer Drive, WestDetroit, MI 48239-4001Phone: 313-592-5550Fax: 313-592-5717



DDC INTERNATIONAL REGIONAL OFFICE LOCATIONS

DETROIT DIESEL DISTRIBUTIONCENTER B.V. (On/Off-Highway)The NetherlandsRidderpoort 92984 RidderkerkThe NetherlandsPhone: (31) 180-442-900Fax: (31) 180-462-062

LATIN AMERICAN REGION(Off-Highway)Miami, Florida2277 N.W. 14th StreetLatin America BuildingMiami, FL 33125-0068Phone: 305-637-1555Fax: 305-637-1580

MTU DETROIT DIESEL AUSTRALIAPTY. LTD. (On/Off-Highway)Victoria – Melbourne488 Blackshaws RoadAltona North, Victoria. 3025AustraliaPhone: (61) 3 9243-9292Fax: (61) 3 9243-9271

MTU ASIA PTE. LTD. (Off-Highway)SingaporeNo. 1 Benoi PlaceSingapore 629923Phone: (65) 6861-5922Fax: (65) 6861-3615 Sales Marine,Rail, C & I, ElectronicsFax: (65) 6860–9959 SalesPowerGen, Defense

MEXICO (On/Off-Highway)Detroit Diesel Allison de Mexico, S.A.Av. Santa Rosa 58Col. Ampliacion NorteSan Juan Ixtacala, TlanepantlaC.P. 54160, Edo de MexicoPhone: 52 55-5333-1803Fax: 52 55-5333-1875


CUSTOMER ASSISTANCE

Working with DDC ServiceOutletsAs the owner of a Detroit Dieselproduct you have a complete networkof over 1,000 Detroit Diesel serviceoutlets in the U.S. and Canada, plusmany outlets worldwide that areprepared to meet your parts andservice needs:

□ Service by trained personnel

□ Sales teams to help determine yourspecific power requirements

□ In many areas, emergency service24 hours a day

□ Complete parts support includingreliabilt® remanufactured parts

□ Product information and literature

We recognize however, that despitethe best intentions of everyoneconcerned, misunderstandings mayoccur. Normally, any situationthat arises in connection with thesale, operation, or service of yourproduct will be handled by theauthorized service outlet in your area(in the U.S. and Canada check theYellow Pages or service locator atwww.detroitdiesel.com for the DetroitDiesel service outlet nearest you).

To further assure your completesatisfaction, we have developed thefollowing procedure to use if you havea problem that has not been handledsatisfactorily.

Step One

Discuss your problem with a memberof management from the authorizedservice outlet. Frequently, complaintsare the result of a breakdown incommunication and can quickly beresolved by a member of management.If you have already discussed theproblem with the Sales or ServiceManager, contact the GeneralManager. If your complaint originateswith a dealer, explain the matterto a management member of thedistributorship with whom the dealerhas his service agreement.

Step Two

When it appears that your problemcannot readily be resolved at thedistributor level without additionalassistance, contact the DetroitDiesel Regional Product Support orOperations Manager responsible foryour local distributor. You will beassisted by a member of the Manager'sstaff, depending upon the nature ofyour problem.

Prior to this contact, have thefollowing information available:

□ Engine model and serial number*

□ Name and location of authorizedservice outlet

□ Type and make of equipment



□ Engine delivery date andaccumulated miles or hoursof operation

□ Nature of problem

□ Chronological summary ofengine's history

Step Three

If you are still not satisfied, present theentire matter in writing or by phone to:

Sr. Vice President, Parts, Serviceand Customer AssuranceDetroit Diesel Corporation13400 Outer Drive, WestDetroit, Michigan 48239–4001Phone: 1–313–592–5000Fax: 1–313–592–7244

When contacting the regional orhome office, please keep in mind thatultimately your problem will likelybe resolved at the distributorship ordealership, utilizing their facilities,equipment, and personnel. Therefore,it is suggested that you first followthe previously mentioned stepsin sequence when experiencing aproblem.


LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900 ENGINES USEDIN ON-HIGHWAY VEHICLE APPLICATIONS

LIMITED WARRANTY ON NEW DETROIT DIESELMBE 900 ENGINES USED IN ON-HIGHWAY VEHICLEAPPLICATIONS

Terms of Coverage

Uses

This warranty applies to the first retailpurchaser and subsequent ownersduring the WARRANTY PERIOD ofnew Detroit Diesel MBE 900 Engines(referred to as Engine) manufacturedby Detroit Diesel Corporation and/orsupplied by Detroit Diesel Corporationor Detroit Diesel of Canada Limited(which are collectively referred to asDDC) for use in on-highway vehicleapplications operated in the UnitedStates or Canada.

Defects

This warranty covers EngineREPAIRS to correct any malfunctionoccurring during the WARRANTYPERIOD resulting from defects inmaterial or workmanship.

Repairs

To obtain warranty repairs, you mustrequest the needed repairs withinthe WARRANTY PERIOD from anauthorized DDC service outlet. Onlynew genuine parts or remanufacturedparts or components supplied orapproved by DDC will be used. DDC

may, at its discretion, replace ratherthan repair components. A reasonabletime must be allowed to performthe warranty repair after taking theengine to the authorized service outlet.The owner is responsible for thepercentage of repair costs shown inthe warranty period chart. Repairs willbe performed during normal businesshours.

Warranty Period

The WARRANTY PERIOD beginson the date the engine is delivered tothe first retail purchaser or put in useprior to sale at retail, whichever dateoccurs first, and ends at the time ormileage/kilometer limits shown in theWARRANTY PERIOD chart.



Warranty Period

Warranty Limitations(Whichever Occurs First)

Repair Charges to bePaid by Owner

ItemMonths Miles/

Kilometers Parts Labor

Engine 0-36 0-150,000 mi0-240,000 km No Charge No Charge

Accessories 0-24 0-100,000 mi0-160,000 km No Charge No Charge

Table 31 Warranty Period Chart — On-highway Vehicle Applications

Like Replacement Engine

Engine(s) supplied by DDC as areplacement for an engine still underwarranty will assume the identityof the engine being replaced and beentitled to the remaining warrantycoverage.

Service Supplies

The cost of service supplies suchas coolant, oil and filters which arenot reusable due to needed warrantyrepairs is covered by this warranty.

Engine Removal andReinstallation

Reasonable labor costs for engineremoval and reinstallation, whennecessary to make a warranty repair,are covered by this warranty.

This Warranty Does NotCover:

Repairs Due to Accidents,Misuse, Storage Damage,Negligence or CertainModifications

Repairs due to an accident, misuse,misapplication, storage damage,negligence or modification exceedingDDC specifications are not covered bythis warranty.


LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900 ENGINES USEDIN ON-HIGHWAY VEHICLE APPLICATIONS

Maintenance

DDC is not responsible for thecost of maintenance or repairsdue to lack of performance ofrequired maintenance services asrecommended by DDC, or thefailure to use fuel, oil, lubricants andcoolant meeting DDC-recommendedspecifications. Performance of therequired maintenance and use ofproper fuel, oil, lubricants and coolantare the responsibility of the owner.

Incidental or ConsequentialDamages

Detroit Diesel Corporation isnot responsible for incidental orconsequential costs or expenses whichthe owner may incur as a result ofa malfunction or failure covered bythis warranty, such as communicationexpenses, meals, lodging, overtime,towing, loss of use of the engine orvehicle (“downtime”), loss of time,inconvenience, cargo loss or damage,and other similar costs and expenses.

Other Limitations

Performance of REPAIRS is theexclusive Owner's remedy under thiswarranty. Detroit Diesel Corporationdoes not authorize any person toassume or create for it any otherobligation or liability in connectionwith the engine or the accessories.

THIS WARRANTY ANDTHE EMISSIONS CONTROLWARRANTY ARE THE ONLYWARRANTIES APPLICABLETO THE ENGINE AS USEDIN ON-HIGHWAY VEHICLEAPPLICATIONS. DETROIT DIESELCORPORATION MAKES NOOTHER WARRANTIES EXPRESSOR IMPLIED, INCLUDINGANY IMPLIED WARRANTYOF MERCHANTABILITY ORFITNESS FOR A PARTICULARPURPOSE. DETROIT DIESELCORPORATION SHALL NOT BELIABLE FOR ANY INCIDENTALOR CONSEQUENTIAL DAMAGESAS DESCRIBED ABOVE.

Some states do not allow the limitationof how long this warranty may lastor the limitation or exclusion ofincidental or consequential damages,so the above may not apply to you.This warranty gives you specific legalrights, and you may also have otherrights which may vary from state tostate.



LIMITEDWARRANTY ON NEW DETROIT DIESEL MBE 900ENGINES USED IN SCHOOL BUS APPLICATIONS

Terms of Coverage

Uses

This warranty applies to the first retailpurchaser and subsequent ownersduring the WARRANTY PERIOD ofnew Detroit Diesel MBE 900 Engines(referred to as Engine) manufacturedby Detroit Diesel Corporation and/orsupplied by Detroit Diesel Corporationor Detroit Diesel of Canada Limited(which are collectively referredto as DDC) for use in school busapplications operated in the UnitedStates or Canada.

Defects


Repairs

To obtain warranty repairs, you mustrequest the needed repairs withinthe WARRANTY PERIOD from anauthorized DDC service outlet. Onlynew genuine parts or remanufacturedparts or components supplied orapproved by DDC will be used. DDCmay, at its discretion, replace rather

than repair components. A reasonabletime must be allowed to performthe warranty repair after taking theengine to the authorized service outlet.The owner is responsible for thepercentage of repair costs shown inthe warranty period chart. Repairs willbe performed during normal businesshours.

Warranty Period

The WARRANTY PERIOD beginson the date the engine is deliveredto the first retail purchaser or put inuse prior to sale at retail, whicheverdate occurs first, and ends at thetime or mileage/kilometer limitslisted in Table 32, the WARRANTYPERIOD chart.


LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900 ENGINES USEDIN SCHOOL BUS APPLICATIONS

Warranty Period



ItemMonths Miles/




Table 32 Warranty Period Chart — School Bus Applications

Service Supplies











Maintenance




Other Limitations


THIS WARRANTY ANDTHE EMISSIONS CONTROLWARRANTY ARE THE ONLYWARRANTIES APPLICABLETO THE ENGINE ASUSED IN SCHOOL BUSAPPLICATIONS. DETROIT DIESELCORPORATION MAKES NOOTHER WARRANTIES EXPRESSOR IMPLIED, INCLUDINGANY IMPLIED WARRANTYOF MERCHANTABILITY ORFITNESS FOR A PARTICULARPURPOSE. DETROIT DIESELCORPORATION SHALL NOT BELIABLE FOR ANY INCIDENTALOR CONSEQUENTIAL DAMAGESAS DESCRIBED ABOVE.



LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900 ENGINES USEDIN FIRE TRUCK OR CRASH VEHICLE APPLICATIONS

LIMITED WARRANTY ON NEW DETROIT DIESELMBE 900 ENGINES USED IN FIRE TRUCK OR CRASHVEHICLE APPLICATIONS

Terms of Coverage

Uses

This warranty applies to the first retailpurchaser and subsequent ownersduring the WARRANTY PERIOD ofnew Detroit Diesel MBE 900 Engines(referred to as Engine) manufacturedby Detroit Diesel Corporation and/orsupplied by Detroit Diesel Corporationor Detroit Diesel of Canada Limited(which are collectively referred to asDDC) for use in fire truck or crashvehicle applications operated in theUnited States or Canada.

Defects


Repairs

To obtain warranty repairs, you mustrequest the needed repairs withinthe WARRANTY PERIOD from anauthorized DDC service outlet. Onlynew genuine parts or remanufacturedparts or components supplied orapproved by DDC will be used. DDC

may, at its discretion, replace ratherthan repair components. A reasonabletime must be allowed to performthe warranty repair after taking theengine to the authorized service outlet.The owner is responsible for thepercentage of repair costs shown inthe warranty period chart. Repairs willbe performed during normal businesshours.

Warranty Period




Warranty Period



ItemMonths Miles/




Table 33 Warranty Period Chart — Fire Truck/Crash VehicleApplications



Service Supplies








LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900 ENGINES USEDIN FIRE TRUCK OR CRASH VEHICLE APPLICATIONS

Maintenance




Other Limitations


THIS WARRANTY ANDTHE EMISSIONS CONTROLWARRANTY ARE THE ONLYWARRANTIES APPLICABLETO THE ENGINE AS USED INFIRE TRUCKOR CRASH VEHICLEAPPLICATIONS. DETROIT DIESELCORPORATION MAKES NOOTHER WARRANTIES EXPRESSOR IMPLIED, INCLUDINGANY IMPLIED WARRANTYOF MERCHANTABILITY ORFITNESS FOR A PARTICULARPURPOSE. DETROIT DIESELCORPORATION SHALL NOT BELIABLE FOR ANY INCIDENTALOR CONSEQUENTIAL DAMAGESAS DESCRIBED ABOVE.




LIMITEDWARRANTY ON NEW DETROIT DIESEL MBE 900ENGINES USED IN UNIMOG APPLICATIONS

Terms of Coverage

Uses

This warranty applies to the firstretail purchaser and subsequentowners during the WARRANTYPERIOD of new Detroit DieselMBE 900 Engines (referred to asEngine) manufactured by DetroitDiesel Corporation and/or supplied byDetroit Diesel Corporation or DetroitDiesel of Canada Limited (which arecollectively referred to as DDC) foruse in UNIMOG applications operatedin the United States or Canada.

Defects


Repairs

To obtain warranty repairs, you mustrequest the needed repairs withinthe WARRANTY PERIOD from anauthorized DDC service outlet. Onlynew genuine parts or remanufacturedparts or components supplied orapproved by DDC will be used. DDCmay, at its discretion, replace rather

than repair components. A reasonabletime must be allowed to performthe warranty repair after taking theengine to the authorized service outlet.The owner is responsible for thepercentage of repair costs shown inthe warranty period chart. Repairs willbe performed during normal businesshours.

Warranty Period



LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900 ENGINES USEDIN UNIMOG APPLICATIONS

Warranty Period


Repair Charges tobe Paid by Owner

ItemMonths Hours Miles/


Engine 24 Unlimited Unlimited No Charge NoCharge

Accessories 24 Unlimited Unlimited No Charge NoCharge

Table 34 Warranty Period Chart — UNIMOG Applications



Service Supplies









Maintenance




Other Limitations


THIS WARRANTY ANDTHE EMISSIONS CONTROLWARRANTY ARE THE ONLYWARRANTIES APPLICABLETO THE ENGINE AS USEDIN UNIMOG APPLICATIONS.DETROIT DIESEL CORPORATIONMAKES NO OTHERWARRANTIES EXPRESSOR IMPLIED, INCLUDINGANY IMPLIED WARRANTYOF MERCHANTABILITY ORFITNESS FOR A PARTICULARPURPOSE. DETROIT DIESELCORPORATION SHALL NOT BELIABLE FOR ANY INCIDENTALOR CONSEQUENTIAL DAMAGESAS DESCRIBED ABOVE.



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