DDC SVC MAN 0055 Sensor M2 Freightliner

MBE 900 OPERATOR'S GUIDE
To the Operator personnel to provide prompt

preventive maintenance and skilled
This guide contains instructions on engine repairs.
the safe operation and preventive
The information and specifications
maintenance of your Detroit Diesel
in this publication are based on the
MBE 900 engine. Maintenance
information in effect at the time of
instructions cover routine engine
approval for printing. Contact an
services such as lube oil and filter
authorized Detroit Diesel service
changes in enough detail to permit
outlet for information on the latest
self-servicing if desired.
revision. The right is reserved to
The operator should become familiar make changes at any time without
with the contents of this guide before obligation.
operating the engine or carrying out
maintenance procedures.
NOTICE:
Power-driven equipment is only
Coolant must be inhibited with
as safe as the person operating the
the recommended Supplemental
controls. You are urged, as the
Coolant Additives (SCA) listed in
operator of this diesel engine, to keep
this guide. In addition, the engine
fingers and clothing away from the
can be equipped with a coolant
revolving belts, drive shafts, etc. on
filter/inhibitor system as an installed
engine installation.
option or as an after-sale item.
Throughout this guide CAUTIONS Failure to check and maintain SCA
regarding personal safety and levels at required concentrations will
NOTICES regarding engine result in severe damage corrosion
performance or service life will to the engine cooling system and
appear. To avoid personal injury and related components.
ensure long engine service life, always
heed these instructions.
Trademark Information
Whenever possible, it will benefit you
to rely on an authorized Detroit Diesel Detroit Diesel, DDEC, and
service outlet for all your service Diagnostic Link are registered
needs from maintenance to major trademarks of Detroit Diesel
parts replacement. Authorized service Corporation. Nexiq is a trademark
outlets worldwide stock factory of Nexiq Technologies, Inc. All other
original parts and have the specialized trademarks are the property of their
equipment and experienced, trained respective owners.
All information subject to change without notice. (Rev. 04/08) i

DDC-SVC-MAN-0055 04/08 Copyright 2008 DETROIT DIESEL CORPORATION
ii All information subject to change without notice. (Rev. 04/08)
TABLE OF CONTENTS
CAUTION SUMMARY .......................................................................... 1

ENGINE OPERATION ..................................................................... 1
PREVENTIVE MAINTENANCE ....................................................... 2
ELECTRICAL SYSTEM ................................................................... 4
COOLING SYSTEM ......................................................................... 6
AIR INTAKE SYSTEM ...................................................................... 6
FUEL SYSTEM ................................................................................ 7
COMPRESSED AIR ......................................................................... 9
LUBRICATING OIL AND FILTERS .................................................. 9
IDENTIFICATION ................................................................................. 10
PERSONNEL REQUIREMENTS ..................................................... 13
ENGINE CONVERSIONS AND MODIFICATIONS .......................... 14
GENERAL VIEW OF THE MBE 900 ENGINE ................................. 14
ENGINE IDENTIFICATION NUMBER ............................................. 21
DESCRIPTION OF THE ENGINE .................................................... 22
EXHAUST GAS RECIRCULATION ............................................. 23
EXHAUST BRAKE/CONSTANT-THROTTLE VALVES,
OPTIONAL ....................................................................................... 24
ELECTRONIC ENGINE CONTROL SYSTEM ................................. 25
DDEC-ECU .................................................................................. 26
DDEC-VCU .................................................................................. 27
SENSOR LOCATIONS .................................................................... 28
OPERATION ........................................................................................ 31
BEFORE STARTING THE ENGINE ................................................ 31
CHECKING THE BATTERIES ..................................................... 31
CHECKING THE OIL LEVEL ....................................................... 32
CHECKING THE COOLANT LEVEL (COLD CHECK) ................ 33
ADDING FUEL ............................................................................. 33
PRIMING THE FUEL SYSTEM ................................................... 33
STARTING THE ENGINE ................................................................ 33
CHECKING THE COOLANT LEVEL (HOT CHECK) .................. 34
STARTING AN ENGINE THAT HAS NOT BEEN RUN FOR AN
EXTENDED PERIOD .................................................................. 35
All information subject to change without notice. (Rev. 04/08) iii

TABLE OF CONTENTS
MONITORING ENGINE OPERATION ............................................. 36

BATTERY CHARGE .................................................................... 36
OIL PRESSURE .......................................................................... 36
EXCESSIVE IDLING ................................................................... 37
CHANGING THE IDLE SPEED ....................................................... 37
SHUTTING DOWN THE ENGINE ................................................... 37
SHUTTING DOWN AFTER HARD OPERATION ........................ 37
EMERGENCY RUNNING MODE .................................................... 38
STOP ENGINE OVERRIDE OPTION .............................................. 38
COLD WEATHER OPERATION ...................................................... 39
WINTER FRONTS ....................................................................... 39
CLEANING AND STORAGE ............................................................... 40

CLEANING THE ENGINE ................................................................ 40
HIGH-PRESSURE CLEANING EQUIPMENT ............................. 40
CLEANING THE COOLING SYSTEM ............................................. 40
DEGREASING ............................................................................. 41
STORAGE ........................................................................................ 42
TROUBLESHOOTING ......................................................................... 43
EMERGENCY STARTING ............................................................... 43
TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL
SYSTEM .......................................................................................... 43
GENERAL TROUBLESHOOTING ................................................... 43
SERVICE PRODUCTS ......................................................................... 56

DIESEL FUELS ................................................................................ 56
FLOW IMPROVERS .................................................................... 56
KEROSENE ................................................................................. 56
ENGINE OILS .................................................................................. 57
EGR ENGINES ............................................................................ 57
NON-EGR ENGINES ................................................................... 58
SYNTHETIC OILS ....................................................................... 58
COOLANT ........................................................................................ 58
FULLY-FORMULATED ANTIFREEZE ......................................... 58
WATER ........................................................................................ 59
COOLANT SPECIFICATIONS ..................................................... 59
COOLANT CONCENTRATION ................................................... 59
iv All information subject to change without notice. (Rev. 04/08)

SUPPLEMENTAL COOLANT ADDITIVES FOR FULLY

FORMULATED COOLANT .......................................................... 60
DROPOUT ................................................................................... 61
DISPOSAL ................................................................................... 61
COLD WEATHER PRODUCTS ....................................................... 61
WINTER-GRADE DIESEL FUEL ................................................. 61
LOW-VISCOSITY ENGINE OIL ................................................... 62
WINTER COOLANT ANTIFREEZE PROTECTION .................... 62
BATTERIES ................................................................................. 62
TECHNICAL DATA .............................................................................. 64

ENGINE DATA FOR EGR ENGINE ................................................. 65
ENGINE DATA FOR NON-EGR ENGINE ........................................ 66
TESTING AND ADJUSTING VALUES ............................................. 67
MAINTENANCE ................................................................................... 68
SCHEDULED INTERVALS .............................................................. 68
MAINTENANCE SCHEDULE TYPES ......................................... 68
SEVERE SERVICE ................................................................. 68
SHORT-HAUL ......................................................................... 69
LONG-HAUL ........................................................................... 69
OPERATING HOURS VS. FUEL CONSUMPTION (OIL DRAIN
INTERVAL ONLY) ................................................................... 69
UNIMOG .................................................................................. 69
MAINTENANCE SCHEDULE AND INTERVAL
OPERATIONS ......................................................................... 69
MAINTENANCE INTERVALS ................................................. 69
MAINTENANCE OPERATION SETS ...................................... 70
SCHEDULE USE ............................................................................. 70
MAINTENANCE TABLES AND GRAPHS ........................................ 71
REQUIRED MAINTENANCE OPERATIONS ................................... 79
ENGINE INSPECTING ................................................................ 79
VALVE LASH CHECKING AND ADJUSTING ............................. 79
GAINING ACCESS TO THE VALVES ..................................... 80
METHOD ONE: ADJUST EACH CYLINDER IN FIRING
ORDER ................................................................................... 81
METHOD TWO: ADJUST ALL VALVES USING TWO
CRANKSHAFT POSITIONS ................................................... 82
CHECKING VALVE LASH ....................................................... 83
All information subject to change without notice. (Rev. 04/08) v

TABLE OF CONTENTS
ADJUSTING VALVE LASH ...................................................... 83

RESTORING THE VEHICLE TO OPERATING CONDITION .. 84
FUEL PREFILTER ELEMENT CLEANING ...................................... 84
MAIN FUEL FILTER ELEMENT CHANGING .................................. 86
ENGINE OIL AND FILTER CHANGING .......................................... 87
OIL CENTRIFUGE ....................................................................... 90
COOLANT CONCENTRATION CHECKING .................................... 91
COOLANT FLUSHING AND CHANGING ........................................ 93
COOLING SYSTEM INSPECTING .................................................. 95
CUSTOMER ASSISTANCE ................................................................. 96

WORKING WITH DDC SERVICE OUTLETS .................................. 100
STEP ONE ................................................................................... 100
STEP TWO .................................................................................. 100
STEP THREE .............................................................................. 101
LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900

ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS ......... 102
TERMS OF COVERAGE ................................................................. 102
USES ........................................................................................... 102
DEFECTS .................................................................................... 102
REPAIRS ..................................................................................... 102
WARRANTY PERIOD .................................................................. 102
LIKE REPLACEMENT ENGINE .................................................. 103
SERVICE SUPPLIES .................................................................. 103
ENGINE REMOVAL AND REINSTALLATION ............................. 103
THIS WARRANTY DOES NOT COVER: ......................................... 103
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 103
MAINTENANCE ........................................................................... 104
INCIDENTAL OR CONSEQUENTIAL DAMAGES ...................... 104
OTHER LIMITATIONS ................................................................. 104

ENGINES USED IN SCHOOL BUS APPLICATIONS ......................... 105
USES ........................................................................................... 105
DEFECTS .................................................................................... 105
REPAIRS ..................................................................................... 105
vi All information subject to change without notice. (Rev. 04/08)

WARRANTY PERIOD .................................................................. 105

MAINTENANCE ........................................................................... 107
LIMITED WARRANTY ON NEW DETROIT DIESEL MBE

900 ENGINES USED IN FIRE TRUCK OR CRASH VEHICLE
APPLICATIONS ................................................................................... 108
USES ........................................................................................... 108
DEFECTS .................................................................................... 108
REPAIRS ..................................................................................... 108
WARRANTY PERIOD .................................................................. 108
MAINTENANCE ........................................................................... 110

ENGINES USED IN UNIMOG APPLICATIONS .................................. 111
USES ........................................................................................... 111
DEFECTS .................................................................................... 111
REPAIRS ..................................................................................... 111
WARRANTY PERIOD .................................................................. 111
All information subject to change without notice. (Rev. 04/08) vii

TABLE OF CONTENTS

MAINTENANCE ........................................................................... 113
viii All information subject to change without notice. (Rev. 04/08)

CAUTION SUMMARY
The following cautions must be

observed by the operator of the
vehicle or equipment in which this PERSONAL INJURY
engine is installed and/or by those
Diesel engine exhaust and some
performing basic engine preventive
of its constituents are known to
maintenance. Failure to read and heed
the State of California to cause
these cautions and exercise reasonable
cancer, birth defects, and other
care for personal safety and the
reproductive harm.
safety of others when operating the
vehicle/equipment or performing basic Always start and operate an
engine preventive maintenance may engine in a well ventilated
result in personal injury and engine area.
and/or vehicle/equipment damage.
If operating an engine in
an enclosed area, vent the
Engine Operation exhaust to the outside.
Observe the following cautions when Do not modify or tamper
operating the engine. with the exhaust system or
emission control system.
FIRE
To avoid injury from fire, keep all
potential ignition sources away
from diesel fuel, including open
flames, sparks, and electrical
resistance heating elements. Do
not smoke when refueling.
All information subject to change without notice. (Rev. 04/08) 1

CAUTION SUMMARY
Preventive Maintenance
Observe the following cautions when
performing preventative maintenance. PERSONAL INJURY
To avoid injury when working
near or on an operating engine
equipped with an hydraulic
clutch fan, remove loose items
HOT OIL
of clothing and jewelry. Tie back
To avoid injury from hot oil, do or contain long hair that could
not operate the engine with the be caught in any moving part
rocker cover(s) removed. causing injury. The hydraulic fan
may start without warning.
PERSONAL INJURY
To avoid injury from slipping and HOT COOLANT
falling, immediately clean up any To avoid scalding from the
spilled liquids. expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
at operating temperature. Wear
adequate protective clothing
(face shield, rubber gloves,
apron, and boots). Remove the
USED ENGINE OIL cap slowly to relieve pressure.
To avoid injury to skin from
contact with the contaminants in
used engine oil, wear protective
gloves and apron.
2 All information subject to change without notice. (Rev. 04/08)

PERSONAL INJURY FIRE

To avoid injury from the To avoid injury from combustion
projection of tools or other of heated lubricating-oil vapors,
objects that may fall on or behind stop the engine immediately if an
the vibration damper of an oil leak is detected.
engine, always check and remove
these items before starting the
engine.
FIRE
To avoid injury from fire, do not
smoke or allow open flames when
PERSONAL INJURY
working on an operating engine.
To avoid injury from contact
with rotating parts when an
engine is operating with the air
inlet piping removed, install an
air inlet screen shield over the
turbocharger air inlet. The shield
FIRE
prevents contact with rotating
parts. To avoid injury from fire from a
buildup of volatile vapors, keep
the engine area well ventilated
during operation.
PERSONAL INJURY
To avoid injury when using
caustic cleaning agents, follow
the chemical manufacturers
usage, disposal, and safety
instructions.

CAUTION SUMMARY
Electrical System
jump starting an engine, charging a Battery Explosion and Acid Burn
battery, or working with the vehicle To avoid injury from battery
electrical system. explosion or contact with battery
acid, work in a well ventilated
area, wear protective clothing,
and avoid sparks or flames near
the battery. If you come in contact
PERSONAL INJURY
with battery acid:
To avoid injury from accidental
engine startup while servicing Flush your skin with water.
the engine, disconnect/disable Apply baking soda or lime to
the starting system. help neutralize the acid.
Flush your eyes with water.
Get medical attention

immediately.
Electrical Shock
To avoid injury from electrical
shock, use care when connecting
battery cables. The magnetic ELECTRICAL SHOCK
switch studs are at battery
voltage. To avoid injury from electrical
shock, do not touch battery
terminals, alternator terminals, or
wiring cables while the engine is
operating.

Electrical Shock Hazard

High voltage can remain inside
the Electrostatic Oil Separator
after removal. Wait 30 minutes
after turning off the ignition
before removing the separator.
Never touch parts through
ventilation openings or impeller
opening with finger or conductive
items (e.g. screwdriver or wire).
High voltage can remain inside
the Electrostatic Oil Separator for
up to 12 hours after the ignition
is turned off.

CAUTION SUMMARY
Cooling System Air Intake System

Observe the following cautions when Observe the following cautions when
servicing the cooling system. working on the air intake system.
HOT COOLANT PERSONAL INJURY

To avoid scalding from the To avoid injury from hot surfaces,
expulsion of hot coolant, never wear protective gloves, or allow
remove the cooling system engine to cool before removing
pressure cap while the engine is any component.
cap slowly to relieve pressure.
PERSONAL INJURY
To avoid injury from contact
with rotating parts when an
engine is operating with the air
inlet piping removed, install an
PERSONAL INJURY
air inlet screen shield over the
To avoid injury from slipping and turbocharger air inlet. The shield
falling, immediately clean up any prevents contact with rotating
spilled liquids. parts.

Fuel System
fueling the vehicle or working with FIRE
the fuel system. To avoid injury from fire, keep all
potential ignition sources away
from diesel fuel, including open
resistance heating elements. Do
PERSONAL INJURY
To avoid injury from fuel spills,
do not overfill the fuel tank.
FIRE
To avoid injury from fire, contain
and eliminate leaks of flammable
fluids as they occur. Failure to
eliminate leaks could result in
fire.
PERSONAL INJURY
To prevent the escape of high
pressure fuel that can penetrate
skin, ensure the engine has
been shut down for a minimum
of 10 minutes before servicing
any component within the high
pressure circuit. Residual high
fuel pressure may be present
within the circuit.

CAUTION SUMMARY
FIRE
To avoid injury from fire caused
by heated diesel-fuel vapors:
Keep those people who are not

directly involved in servicing
away from the engine.
Stop the engine immediately if

a fuel leak is detected.
Do not smoke or allow open

flames when working on an
operating engine.
Wear adequate protective

clothing (face shield,
insulated gloves and apron,
etc.).
To prevent a buildup of
potentially volatile vapors,
keep the engine area well
ventilated during operation.

Compressed Air
using compressed air. FIRE
To avoid injury from fire, do not
smoke or allow open flames when
working on an operating engine.
EYE INJURY
To avoid injury from flying debris
when using compressed air, wear
adequate eye protection (face
shield or safety goggles) and do
not exceed 276 kPa (40 psi) air FIRE
pressure.
To avoid injury from fire from a
buildup of volatile vapors, keep
Lubricating Oil and Filters the engine area well ventilated
during operation.
replacing the engine lubricating oil
and filters.
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
FIRE
To avoid injury from combustion
of heated lubricating-oil vapors,
stop the engine immediately if an
oil leak is detected.

IDENTIFICATION
IDENTIFICATION
The MBE 900 engine is built in standards. An emission label is

accordance with sound technological attached to the cylinder head cover, as
principles and based on state-of-the-art required by law. See Figure 1 for the
technology. It complies with all United emission label for the 6-cylinder EGR
States Environmental Protection model and Figure 2 for the 4-cylinder
Agency (USEPA) and California Air EGR model.
Resources Board (CARB) emission
Figure 1 Emission Label, 6Cylinder EGR Engine

Figure 2 Emission Label, 4Cylinder EGR Engine

IDENTIFICATION
See Figure 3 for the emission label for

the 6-cylinder non-EGR model. .
Figure 3 Emission Label, NonEGR 6-Cylinder

See Figure 4 for the 4-cylinder

non-EGR model
Figure 4 Emission Label, NonEGR 4-Cylinder
Despite this, the engine may constitute The safety instructions included in
a risk of damage to property or this manual are disregarded.
injury to persons under the following
conditions: Personnel Requirements
It is not used for its intended Work on the engine should be carried
purpose. out only by skilled technicians who
It is modified or converted in an have been instructed in the specific
incorrect manner. skills necessary for the type of work
being performed.

IDENTIFICATION
Engine Conversions and General View of the MBE

Modifications 900 Engine
The function and safety of the engine The 2004 on-highway MBE 900
could be affected if unauthorized engine is equipped with an Exhaust
modifications are made. Detroit Gas Recirculation (EGR) system to
Diesel will not accept responsibility reduce engine exhaust gas emissions
for any resulting damage. in accordance with EPA regulations.
See Figure 5 for a right front view of
Tampering with the fuel injection
the MBE 900 EGR engine, 6-cylinder
system and engine electronics could
model, and Figure 6 for a left rear
also affect the engine's power output or
view.
exhaust emission levels. Compliance
with the manufacturer's settings The off-highway engine used
and with statutory environmental in construction and industrial
protection regulations cannot then be applications does not have an EGR
guaranteed. system. See Figure 7 for a front view
of the MBE 900 non-EGR engine,
6-cylinder model, and Figure 8 for
a side view of the 6-cylinder model
(right-hand side).
See Figure 9 for a front view of the
MBE 900 non-EGR engine, 4-cylinder
model, and Figure 9 for a rear view of
the 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 6Cylinder 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 6cylinder 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 4Cylinder 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 4Cylinder MBE 900 Non-EGR Engine

Engine Identification
Number
The engine identification numbers are
lasered in large font onto an enlarged
labeling surface on the rear right
crankcase. See Figure 11.
Figure 12 Engine Identification

Number
The last six numbers are the serial

numbers (310187 in Figure 12).
See Figure 13 for an explanation of
the first six numbers found in the
Figure 11 Location of Engine engine identification number.
Identification Number
See Figure 12 for an example of the

numbers as they appear on the engine.
Figure 13 Engine Identification

IDENTIFICATION
NOTE: Charge-air cooling and an exhaust gas

In addition to the fourteen digit number turbocharger are standard equipment
etched on the crankcase, there is a on all MBE 900 engines (charge
ten digit number used for warranty pressure limitation is optional).
and service that is found on the
The engine has a fully electronic
DDEC-ECU label. The ten digit
control system, which regulates the
number is derived from the fourteen
fuel injection quantity and timing
digit number (see Figure 14).
using solenoid valves, allowing
extremely low-emission operation.
Description of the Engine
The control system consists of an
All MBE 900 engines are
engine-resident pump and nozzle
water-cooled, four-stroke,
control unit (the DDEC-ECU) and a
direct-injection diesel engines.
vehicle control unit (the DDEC-VCU).
The cylinders are arranged inline on
The two are connected by a proprietary
both the 6-cylinder and 4-cylinder
datalink.
models. Each has a separate fuel
injection pump (unit pump) with a Engine braking is controlled by a
short injection line to the injection pneumatic and hydraulic (6-cylinder)
nozzle, which is located in the center operated exhaust brake on the
of the combustion chamber. The unit turbocharger and by a constant-throttle
pumps are attached to the crankcase system (optional).
and are driven from the camshaft.
Each cylinder has two intake valves
and one exhaust valve.
Figure 14 Engine Serial Number

The cylinder block has integrated The oil cooler is located near the front
oil and water channels. The upper of the crankcase on the right-hand side
section of the cylinder bore is near the water pump.
induction-hardened. The single-piece
The gear-type fuel pump is bolted to
cylinder head is made of cast
the front of the crankcase. The pump
iron. The cylinder head gasket is a
is driven from the forward end of the
medal-elastomere, adjustment-free
camshaft.
seal with Viton sealing elements.
The air compressor, with a
The pistons are made of aluminum
power-steering pump attached,
alloy with a shallow combustion
is driven by a gear on the camshaft
chamber recess. The pistons are
(optional).
cooled by oil spray nozzles.
The vehicle is cooled by a closed
The crankshaft is precision-forged
system using recirculated coolant;
with seven main bearings (five on
temperature is regulated automatically
the 4-cylinder engine), six of which
by a thermostat.
have custom-forged counterweights
(four on the 4-cylinder engine), and a The alternator and coolant pump (and
vibration damper at the front end. any other accessories) are driven by a
belt with automatic belt tensioner.
The camshaft is made of
case-hardened steel and has seven Electrical equipment includes a starter
main bearings (five on the 4-cylinder and an alternator.
engine). Each cylinder has cams for
intake and exhaust valves and a unit Exhaust Gas Recirculation
pump.
The purpose of the Exhaust Gas
The valves are controlled by Recirculation (EGR) System is to
mushroom tappets, pushrods, and reduce engine exhaust gas emissions
rocker arms. The intake valves are in accordance with EPA regulations.
opened and closed by a valve-guided
bridge. The EGR system consists of an EGR
cooler, EGR valve, reed valves (on the
There is a force-feed lubricating oil MBE904/924/926 only), and an EGR
circuit supplied by a rotary oil pump. mixer.
This pump is positioned at the front
of the crankcase and driven by gears The MBE 900 engines for on-highway
from the crankshaft. EPA 2004 regulation applications use
a cooled EGR system.

IDENTIFICATION
Exhaust gases from the front three The two systems operate
cylinders on six cylinder engines independently of each other and
(all four cylinders on four cylinder in combination.
engines) are routed from the exhaust
Exhaust back pressure is used by the
manifold through the EGR cooler,
exhaust brake to increase braking
past control and reed valves, and
performance. The constant-throttle
mixed with the intake manifold charge
valves use the air that escapes through
air. The addition of cooled exhaust
them on the compression stroke to
gases back into the combustion
provide braking force.
airflow reduces the peak in cylinder
combustion temperature. Less oxides The constant-throttles valves are
of nitrogen (NOx) are produced at small valves which are built into the
lower combustion temperatures. cylinder head and positioned opposite
the exhaust valve. When open, a link
Exhaust is created between the combustion
chamber and the exhaust port.
Brake/Constant-Throttle
Valves, Optional When the engine brake is switched
on, the constant-throttle valves are put
To increase braking performance,
under pressure, which in turn opens
the engine can be equipped with an
the valves.
exhaust brake on the turbocharger
in conjunction with constant-throttle On the 6-cylinder model, the
valves in the cylinder head. See Figure constant-throttle valves are activated
15. by engine oil pressure. On 4-cylinder
engines, the constant-throttle valves
are activated by compressor air
pressure.
The engine brake is activated by the
DDEC-VCU and can be activated
only at engine speeds up to 2700 rpm.
Figure 15 Constant Throttle

Activation

Below 900 rpm, the engine brake Link (DDDL) PC-based software or
is always turned off to prevent the minidiag2.
engine from stalling. Also, the engine
The engine control system monitors
brake is automatically turned off when
both the engine and the datalink.
the accelerator pedal is pressed.
When a malfunction or other problem
is detected, the system selects an
NOTE:
appropriate response; for example,
When in emergency running mode
the emergency running mode may be
(constant rpm), the engine brake can
activated.
be activated only when the engine is
in overrun. When constant rpm has
been attained, the engine brake is
automatically turned off.
Electronic Engine Control

System
The engine is equipped with a fully
electronic control system. Besides the
engine and its related sensors, this
system is composed of the following:
The DDEC-ECU (engine control
unit)
The DDEC-VCU (vehicle control
unit) located under the right-hand
dash panel
The two control units are connected by
a proprietary datalink through which
all necessary data and information can
be exchanged. See Figure 16.
The DDEC-VCU then broadcasts all
information on the J1587 and J1939
datalinks, where it can be read by
the Nexiq Diagnostic Data Reader
(DDR), Detroit Diesel Diagnostic

IDENTIFICATION
Figure 16 Electronic Engine Control System
DDEC-ECU
The DDEC-ECU (see Figure 17) is
located on the left-hand side of the
engine.
The DDEC-ECU processes the data
received from the DDEC-VCU, for
example the position of the accelerator
pedal, engine brake, etc.
Figure 17 DDEC-ECU

These data are evaluated together

with the data from the sensors on
the engine, such as coolant and
fuel temperature and oil and charge
pressure.
The data is then compared to the
characteristic maps or lines stored in
the DDEC-ECU. From these data,
quantity and timing of injection are
calculated and the unit pumps are
actuated accordingly through the Figure 18 DDEC-VCU
solenoid valves.
The DDEC-VCU receives data from
NOTE:
the following sources:
To obtain a replacement DDEC-ECU,
all the data given on the DDEC-ECU The operator (accelerator pedal
label are required. position, engine brake switch)
Other electronic control units
The DDEC-ECU data label has the 10
(for example, the anti-lock brake
digit engine serial number (see Figure
system)
14), the engine horse power and
torque. The DDECECU (oil pressure
and coolant temperature)
DDEC-VCU From these data, instructions are
The DDEC-VCU communicates computed for controlling the engine
with any other electronic control unit and transmitted to the DDEC-ECU via
installed on the vehicle over the J1587 the proprietary datalink.
data link. See Figure 18. The DDEC-VCU controls
Data for specific applications is stored various systems, for example,
in the DDEC-VCU. These include idle communications with the datalink, the
speed, maximum running speed, and engine brake, and the constant-throttle
speed limitation. valves.

IDENTIFICATION
Sensor Locations
See Figure 19 and Figure 20 for
sensor locations on the MBE 900 CHEMICAL BURNS
EGR engine. See Figure 21 for sensor
locations on the MBE 900 non-EGR To avoid injury from chemical
engine. burns, wear a face shield and
neoprene or PVC gloves when
handling sensor hoses.
1. Intake Manifold Pressure/Temper- 3. Engine Oil Pressure Sensor

ature 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 Temperature 5. Camshaft Position Sensor (on
Sensor camshaft)
3. Supply Fuel Temperature Sensor 6. Crankshaft Position Sensor (on
timing case)
Figure 20 Sensor Location on the Left Side of the MBE 900 EGR Engine
NOTE: NOTE:
The 6-cylinder engine is shown; The Barometric Pressure Sensor is
sensor locations are similar on the integrated into the DDEC-ECU.
4-cylinder engine.

IDENTIFICATION
1. Engine Oil Pressure/Temperature 5. Barometric Pressure Sensor

Sensor (integrated into DDEC-ECU)
2. Engine Coolant Temperature 6. Camshaft Position Sensor (on
Sensor camshaft)
3. Intake Manifold Pressure/Temper- 7. Crankshaft Position Sensor (on
ature Sensor timing case)
4. Supply Fuel Temperature Sensor
Figure 21 Sensor Location on the MBE 900 Non-EGR Engine
NOTE: NOTE:
The 6-cylinder engine is shown; The Engine Oil Level Sensor, if used,
sensor locations are similar on the is located at the bottom of the oil pan.
4-cylinder engine.

OPERATION
Important: Before starting the engine, noises, or shows an unusual loss of

do all the recommended pretrip power, turn the engine off as soon
inspections and daily maintenance. as possible and determine the cause.
Check the engine oil and fuel levels, Frequently, engine damage may be
and drain contaminants from the avoided by a quick response to early
fuel/water separator (optional). indications of problems.
If you are starting the engine in cold
Before Starting the Engine weather, refer to "Cold Weather
Products" in the Service Products
NOTE: section of this manual.
If you drain the fuel/water separator
completely, you may have to prime the
Checking the Batteries
fuel system.
Use only batteries that have been
Be sure you are familiar with all of correctly filled and serviced. To
the instruments, gauges and controls provide corrosion protection, apply
which are needed to operate the dielectric grease, part number
engine. 48-02349-000, liberally to the
terminal pads. Approved suppliers are
Note especially the location and
listed in Table 1.
function of the following:
Oil Pressure Gauge Lubricant or
Manufacturer
Coolant Temperature Gauge Part Number
No. 71032; No.
Low Oil Pressure/High Coolant Shell Oil, Co.
71306
Temperature Warning Light
Texaco, Inc. No. 955
Water In Fuel Warning Light
Quaker State No. NYK-77
Tachometer
Table 1 Approved Electrical
Air Restriction Indicator
Lubricants
When starting the engine, and while
driving, watch for any signs of engine
problems. If the engine overheats,
uses excessive fuel or lubricating
oil, vibrates, misfires, makes unusual

OPERATION
Battery Explosion and Acid Burn

To avoid injury from battery
explosion or contact with battery
acid, work in a well ventilated
area, wear protective clothing,
and avoid sparks or flames near
the battery. If you come in contact
with battery acid:
Figure 22 Oil Dipstick
Flush your skin with water.
Apply baking soda or lime to 2. If necessary, top off by filling

help neutralize the acid. engine oil through the oil fill
Flush your eyes with water. collar (see Figure 23) until the
maximum fill level on the oil
Get medical attention dipstick (see Figure 22) has been
immediately. reached. For detailed procedures,
refer to the Maintenance
section. Do not overfill.
Checking the Oil Level
Check the oil level as follows:
1. Check the oil level using the oil
dipstick (see Figure 22).
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
Figure 23 Oil Fill Collar

Checking the Coolant Level NOTICE:

(Cold Check)
Correct torque on the high pressure
Check the coolant level as follows: lines is critical. Incorrect torques
1. Ensure that all coolant plugs in could result in leaks or lack of power
the bottom of the radiator and on due to restricted fuel flow.
the radiator outlet pipe are secure
1. Make sure that all high-pressure
and tight.
and low-pressure lines are
2. Check the coolant level. The securely tightened.
cooling system is correctly filled
2. If equipped with a hand pump on
when the coolant is between the
the fuel/water separator, work the
maximum and minimum marks
hand pump 50 times.
on the surge tank.
3. Crank the engine for 30 seconds
NOTE: at a time, but no longer. Before
For more information, refer to the cranking the engine again, wait
Maintenance section. at least two minutes. The engine
should start within six 30-second
Adding Fuel attempts.
Note the following when adding fuel:
Starting the Engine
Add winter or summer grade fuel
according to the season of the Before operating the engine, follow
year. the steps described in the Before
Starting the Engine section. Start the
Work in the cleanest conditions engine as follows:
possible.
Prevent water from entering the NOTE:
fuel tank. For further information As a safety function, the electronic
refer to Diesel Fuels in Service engine control system may be wired to
Products. start the engine only if the transmission
is in neutral. This is vehicle application
specific.
Priming the Fuel System

Prime the fuel system as follows:

OPERATION
NOTICE: 5. Approximately five minutes after

shutdown, check the engine oil
Never attempt to start the level. If necessary, add oil up to
Mercedes-Benz MBE 900 engine the maximum fill level on the oil
using ether or any other starting dipstick (see Figure 24). Do not
fluid. Serious engine damage could overfill.
result.
1. Turn on the ignition switch.

2. With the accelerator pedal in the
idle position, start the engine.
PERSONAL INJURY
To avoid injury when working
near or on an operating engine, Figure 24 Oil Dipstick
remove loose items of clothing
and jewelry. Tie back or contain
6. Check all the mounting fasteners
long hair that could be caught in
and belts on the engine for
any moving part causing injury.
tightness.
3. Check the engine for leaks. Checking the Coolant Level (Hot
Check)
[a] Check all hoses, hose clamps,
and pipe unions on the engine Check coolant level as follows:
for tightness. Shut down the 1. Allow the engine to run for
engine and tighten them if approximately five minutes at a
necessary. moderate speed.
[b] Check the oil feed and return
lines at the turbocharger for
tightness. Shut down the
engine and tighten them if
necessary.
4. Shut down the engine.

Important: At outside temperatures

below 20C ( 4F), a coolant
HOT COOLANT preheater is recommended.
To avoid scalding from the 1. Chock the tires, place the

expulsion of hot coolant, never transmission in neutral, and set
remove the cooling system the parking brake.
pressure cap while the engine is 2. Turn on the ignition switch and
at operating temperature. Wear start the engine
(face shield, rubber gloves, 3. If the engine doesn't start after
apron, and boots). Remove the 20 seconds, stop. Try again after
cap slowly to relieve pressure. waiting about one minute.
NOTICE:
2. Then, with the coolant
temperature above 50C (122F), Do not rev the engine if the oil
recheck the coolant level. pressure gauge indicates no
oil pressure. To avoid engine
3. Add more coolant if necessary. damage, shut down the engine
Open the heater valves before if no oil pressure appears within
adding coolant. approximately ten seconds. Check
4. Do not close the heater valves to determine the cause of the
until the engine has been run problem.
briefly and the coolant level
again checked and corrected as
necessary. 4. Monitor the oil pressure gauge
immediately after starting the
engine.
Starting an Engine That Has
Not Been Run for an Extended
NOTE:
Period
Do not place the engine under full load
Before starting an engine which has until it reaches operating temperature.
not been run for an extended period,
certain special work must be carried
out. Refer to Storage, under
Cleaning and Storage.

OPERATION
Monitoring Engine
Operation
While the engine is operating, monitor FIRE
the battery charge indicator light, To avoid injury from fire, keep all
the oil pressure and avoid excessive potential ignition sources away
idling. from diesel fuel, including open
Battery Charge resistance heating elements. Do
The battery charge indicator light
(see Figure 25) must go out once the
engine starts. 1. Shut down the engine.
2. Check the poly-V belt for
tightness.
3. Do a load test on the batteries.
Charge or replace the batteries as
needed.
4. If necessary, visit the nearest
authorized dealer to have the
alternator voltage and output
checked.
Figure 25 Battery Charge Indicator
Light
Oil Pressure
When the engine has reached its
If the indicator light comes on
normal operating temperature, the
while the engine is running, do the
engine oil pressure must not drop
following:
below the following values:
36 psi (250 kPa) at rated speed
7 psi (50 kPa) at idling speed
If oil pressure drops below these
values, stop the engine and determine
the cause.

Excessive Idling Engine power and rpm fall, even

though the accelerator pedal
Never allow the engine to idle for
remains steady.
more than 30 minutes. Excessive
idling can cause oil to leak from the The exhaust pipe gives off heavy
turbocharger. smoke.
The coolant and/or oil temperature
Changing the Idle Speed climb abnormally.
The rpm range of the MBE 900 Abnormal sounds suddenly occur
engine is 600 rpm to 850 rpm if the in the engine or turbocharger.
parameters in the DDEC-VCU are set
to the default range.
Shutting Down After Hard
Change the idling speed as follows: Operation
1. Turn the cruise control switch to
the OFF position. NOTICE:
2. To increase the idle speed, push After hard operation, if the engine
the "Resume" switch until the idle has been running at full output or the
is fast enough. coolant temperature has been high,
allow the engine to idle for one to
3. To decrease the idle speed, push
two minutes without load. Shutting
the "Decel" switch until the idle
down the engine without idling may
is slow enough.
cause damage to the turbocharger.
Shutting Down the Engine

Turn off the ignition switch and shut
If the engine has been running at full
down the engine.
output or the coolant temperature has
been high, allow the engine to idle
for one to two minutes without load.
Then turn off the ignition key switch.
If any the following occur, shut down
the engine immediately.
The oil pressure swings back and
forth or falls sharply.

OPERATION
Emergency Running Mode Stop Engine Override

The engine is equipped with the
Option
electronic engine control system, The Stop Engine Override Option is
which monitors the engine as it is used for a momentary override. The
running. DDEC-ECU will record the number
of times the override is activated after
As soon as a fault is detected, it is
a fault occurs.
evaluated and one of the following
measures is initiated. Momentary Override A Stop
Engine Override (SEO) switch
is used to override the shutdown
NOTICE:
sequence (see Figure 26). This
To prevent possible serious engine override resets the 60 second (30
damage, have any faults corrected seconds for oil pressure) shutdown
without delay by an authorized timer, restoring power to the level
dealer. when the Red Stop Lamp (RSL) was
illuminated. The switch must be
recycled after five seconds to obtain a
In conjunction with the subsequent override.
instrumentation control unit
(ICU), the code for the electronic
control unit reporting the fault
can be read immediately on the
display.
Complete fault codes are
transmitted and can be read using
ServiceLink at any authorized
dealer.
If the fault is serious enough to
impair normal operation, the
electronic engine system switches
over to emergency running mode. Figure 26 Typical SEO Switch and
When in emergency running Warning Lamps
mode, the engine operates at a
constant 1300 rpm. This allows NOTE:
you to move the vehicle to a The operator has the responsibility to
service location. take action to avoid engine damage.

Cold Weather Operation

Special precautions must be taken
during cold weather. To protect
your engine, special cold weather
handling is required for fuel, engine
oil, coolant, and batteries. For detailed
information, refer to the service
manual.
Winter Fronts
A winter front may be used to improve
cab heating while idling. At least 25%
of the grill opening should remain
open in sectioned stripes that run
perpendicular to the charge air cooler
tube flow direction. This assures even
cooling across each tube and reduces
header to tube stress and possible
failure. Winter fronts should only be
used when the ambient temperature
remains below 12.2 C (10 F).

CLEANING AND STORAGE
When an engine is to be stored for a After cleaning, and especially

period of time, special precautions when using a high-pressure jet or
should be taken to protect the interior grease-removing agent, lubricate
and exterior of the engine. the engine. Information on suitable
cleaning and protective products is
Cleaning the Engine available from any authorized dealer.
Important: Observe all environmental

Cleaning the Cooling
protection regulations.
System
High-Pressure Cleaning Important: Collect the used coolant,
Equipment cleaning solutions, and washing
liquids. Dispose of them in accordance
Note the equipment manufacturer's with applicable laws regarding the
operating instructions. protection of the environment.
NOTICE: NOTICE:
To prevent damage to engine Clean at moderate pressures only;
components during the cleaning otherwise the fins of the radiator
process, keep the water moving grille could be damaged.
at all times. Never direct water
onto electrical components, plug
connectors, seals or flexible hoses.
Comply with the minimum working

distance between the high-pressure
nozzle 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 dirt
cutters

Clean as follows: water50 grams per liter) of a

mildly alkaline cleaning agent,
such as sodium carbonate.
2. Run the engine at moderate speed
EYE INJURY until the thermostat starts to open,
To avoid injury from flying debris at an operating temperature of
when using compressed air, wear approximately 80C (176F).
adequate eye protection (face Then run it for about five minutes
shield or safety goggles) and do longer. Shut down the engine and
not exceed 276 kPa (40 psi) air allow it to cool to approximately
pressure. 50C (112F).
1. Remove debris (dust, insects,

etc.) from the fins of the radiator
grille by blowing them through HOT COOLANT
with compressed air or spraying To avoid scalding from the
them out with water. Work from expulsion of hot coolant, never
the rear of the radiator (in the remove the cooling system
opposite direction of the normal pressure cap while the engine is
cooling air flow). at operating temperature. Wear
2. Drain the coolant when adequate protective clothing
the engine is cold. For (face shield, rubber gloves,
detailed procedures, see the apron, and boots). Remove the
vehicle/chassis maintenance cap slowly to relieve pressure.
manual. For types of coolant,
refer to Coolant in the Service
Products section. 3. Drain all the cleaning solution.
3. If the HVAC unit is connected 4. Flush the cleaning solution from

to the cooling system, open the the cooling system.
regulating valves all the way. [a] Immediately after draining
the cleaning solution, flush
Degreasing the system with clean water.
Degrease as follows: [b] Once the clean water has
drained, fill the system again
1. Fill the cooling system with a 5%
with clean water.
solution (1.6 ounces per quart of

[c] Run the engine. Allow If the engine is to be out of service

the engine to warm up to for over 12 months, or under
approximately 80C (176F), extraordinary storage or transportation
and then run it about five conditions, then special protective
minutes longer. measures are necessary. Information
is available from any authorized
[d] Drain the hot water.
dealer. It is strongly recommended
5. Fill the cooling system with new that you request this information.
coolant. For detailed procedures,
Important: If the engine is to be out
see the vehicle/chassis
of service for over 18 months, the oil
maintenance manual. For types
must be changed before the engine
of coolant, refer to Coolant in
can be brought back into service.
the Service Products section.
Storage
Required protective measures for
the MBE 900 engine depend on the
following:
The length of time that the engine
will be out of service
The climate and conditions where
the engine is stored
After cleaning, engines should,
whenever possible, be placed in a dry,
well-ventilated area.
In all cases, protect the engine
against direct exposure to moisture
(rain/splash water).
If the engine is to be out of service
for 12 months or less, anticorrosion
measures are not necessary, provided
that the place of storage are dry and
well-ventilated as described above.

TROUBLESHOOTING
In addition to operating the engine General Troubleshooting

carefully and maintaining it properly,
The tables that follow are designed
make sure to correct any malfunction
to identify the causes of common
promptly.
problems, suggest further checks and
appropriate remedies. When dealer
Emergency Starting service is necessary, it is mentioned
For emergency starting procedures in the table.
(jump starting), see the
driver's/operator's manual under NOTE:
the heading "Emergency Starting With Remember to follow all cautions when
Jumper Cables." troubleshooting the engine.
Troubleshooting the
Electronic Engine Control
System
When the electronic engine control
system detects a fault, it broadcasts
a message on the datalink. The dash
display will show the code "ECU
128," indicating there is an engine
fault.
Important: To read the complete
fault code, bring the vehicle to an
authorized dealer. Complete fault
codes can be read using ServiceLink.
For fault codes and their meanings,
see the service/workshop manual.

TROUBLESHOOTING
Problem - The Engine Will Not Crank

Cause Remedy
Test the batteries. Replace them, if
The batteries are damaged or weak.
needed.
The ignition switch is damaged. Replace the ignition switch.
The battery cables are damaged
Replace the battery cables.
and/or corroded.
Have an authorized dealer replace the
The starter is damaged and/or worn.
starter.
The clutch or transmission is Bring the vehicle to an authorized
damaged. dealer for service.
There is internal damage to the Bring the vehicle to an authorized
engine. dealer for service.
ProblemThe Engine Turns Over Slowly

Cause Remedy
needed.
The ignition switch is damaged. Replace the ignition switch.
The battery cables are damaged
Replace the battery cables.
and/or corroded
The starter is damaged and/or worn.
starter.
The engine oil does not meet the Change the engine oil, using the
correct specifications. correct type of oil.
The transmission fluid does not meet Change the transmission fluid, using
the correct specifications. the correct type of fluid.

ProblemThe Engine Cranks, But Won't Start

Cause Remedy
needed.
Bring the vehicle to an authorized
The cranking speed is not set correctly.
dealer for service.
No intake air preheater is installed,
Install an intake air preheater.
and it is too cold to start without one.
The intake air preheater is Check the intake air preheater, and
malfunctioning. replace it, if necessary.
Push both sensors into their holes as
The camshaft TDC sensor and/or the
far as they will go. If this does not
crank angle position sensor are out of
solve the problem, bring the vehicle to
adjustment.
an authorized dealer for service.
The camshaft TDC sensor and/or
the crank angle position sensor are
dealer for service.
damaged.
Check the fuel lines for leaks. Bleed
the fuel system and start the engine
There is air in the fuel system.
according to the instructions in the
service 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 is Have an authorized dealer check the
malfunctioning. operation of the valve.
The valves are not adjusted properly. Check the valve lash.
There are other problems in the fuel Bring the vehicle to an authorized
system. dealer for service.
Check for leaks, add coolant to correct
Coolant level is too low.
level.

TROUBLESHOOTING
ProblemThe Engine Starts Only After Cranking for a Long Time

Cause Remedy
Add fuel and bleed the fuel system, if
The fuel tank is low or empty.
necessary.
Check the fuel lines for leaks and
There are leaks in the fuel lines.
repair them, if necessary.
Clean and bleed the system. Have
The fuel line, the fuel prefilter, or the
the fuel lines and filters checked by an
screen in the fuel tank is blocked.
authorized dealer.
adjustment.
dealer for service.
damaged.

ProblemThe Engine Starts, But Dies

Cause Remedy
Add fuel and bleed the fuel system, if
The fuel tank is low or empty.
necessary.
Clean and bleed the system. Have
The fuel line, the fuel prefilter, or the
the fuel lines and filters checked by an
screen in the fuel tank is blocked.
authorized dealer.
adjustment.
dealer for service.
damaged.
The constant-throttle valves are Bring the vehicle to an authorized
malfunctioning. dealer for service.
ProblemThe Engine Fan Doesn't Work

Cause Remedy
The fan hub is damaged. Replace the fan hub.
The fan wiring is damaged. Repair the fan wiring.
The parameter settings in the
Have an authorized dealer reprogram
DDEC-ECU or DDEC-VCU are
the control unit.
incorrect.

TROUBLESHOOTING
ProblemThe Engine Fan Is Constantly On

Cause Remedy
Check the operation of the fan override
The fan override switch is on.
switch.
The fan hub is damaged. Replace the fan hub
The parameter settings in the
Have an authorized dealer reprogram
DDEC-ECU or DDEC-VCU are
the control unit.
incorrect.
ProblemFuel Consumption Is Too High

Cause Remedy
The tires are not properly inflated. Check all tires for correct pressure.
Check the air restriction indicator.
The air filter and/or intake air system
Clean the intake air system and
is clogged.
replace the air filter if necessary.
The remedies are listed in -48"The
The engine performs poorly, or does
Engine Performs Poorly, Does Not
not develop full power.
Develop Full Power in this section.

ProblemThe Engine Performs Poorly, Does Not

Develop Full Power
Cause Remedy
is clogged.
There are other problems with the fuel Bring the vehicle to an authorized
The valves are not adjusted properly Check the valve lash.
The coolant temperature sensor is Bring the vehicle to an authorized
damaged or reading incorrectly. dealer for service.
The fuel temperature sensor is Bring the vehicle to an authorized
The engine oil temperature sensor is Bring the vehicle to an authorized
The charge-air temperature sensor is Bring the vehicle to an authorized
There are problems with the Bring the vehicle to an authorized
DDEC-ECU or DDEC-VCU. dealer for service.

TROUBLESHOOTING
ProblemThe Engine Is in Emergency Running Mode

(constant speed 1,300 rpm)
Cause Remedy
The DDEC-ECU or DDEC-VCU
or sensor(s), solenoids and other
dealer for service.
electronic parts are damaged.
ProblemThe Coolant Temperature Is Above Normal

Cause Remedy
Check for coolant leaks, and repair as
The coolant level is too low.
needed.
The poly-V belt is loose. Tighten or replace the poly-V belt.
The coolant temperature gauge and/or Bring the vehicle to an authorized
sensor is not reading correctly. dealer for service.
Clean the radiator. Repair or replace
The radiator is damaged or dirty.
the radiator if necessary.
The coolant pump is damaged.
coolant pump.
The thermostat is damaged.
coolant pump.
dealer and have the fan hub checked.
The fan is not operating properly.
dealer and have the parameter
settings reprogrammed in the
DDEC-ECU or DDEC-VCU.

ProblemThe Coolant Temperature Is Below Normal

Cause Remedy
The coolant temperature gauge and/or Bring the vehicle to an authorized
sensor is not reading correctly. dealer for service.
The thermostat is damaged.
thermostat.
dealer and have the fan hub checked.
The fan is not operating properly.
dealer and have the parameter
settings reprogrammed in the
DDEC-ECU or DDEC-VCU.
ProblemThe Cooling System Is Losing Coolant

Cause Remedy
There is an external coolant leak. Repair the leaking component.
The radiator cap is leaking. Replace the radiator cap.
The air compressor head is damaged.
air compressor.
The cylinder head gasket is leaking.
head gasket.
Top tank is leaking.
dealer.
EGR system has an internal leak.
dealer.

TROUBLESHOOTING
ProblemThere Is Coolant in the Engine Oil

Cause Remedy
The cylinder head gasket is damaged.
head gasket.
The oil/water heat exchanger is Have an authorized dealer replace the
leaking. heat exchanger.
There is an internal coolant leak.
dealer for service.
ProblemThere Is Foam in the Engine Oil

Cause Remedy
The oil level is too low or too high. Correct the oil level.
The oil has not been changed within
Change the oil.
the recommended interval.
The oil is not of the recommended
Change the oil.
quality.
ProblemThe Engine Oil Pressure Is Low

Cause Remedy
The oil pressure gauge and/or sensor Bring the vehicle to an authorized
is not reading correctly. dealer for service.
There is fuel in the oil.
dealer 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 is Have an authorized dealer replace the
damaged. oil pump.

ProblemThe Engine Exhaust Is White

Cause Remedy
The fuel is of poor quality. Add fuel of the right quality.
The intake air preheater is Check the intake air preheater, and
malfunctioning. replace it, if necessary.
ProblemThe Engine Exhaust Is Black

Cause Remedy
is clogged.
The intake air preheater is Check that the heater is not staying on
malfunctioning. all of the time.
There is damage to the fuel system:
the fuel pump, one or more fuel Bring the vehicle to an authorized
injectors, or one or more unit pumps dealer for service.
are damaged.
The charge-air temperature sensor is Bring the vehicle to an authorized
damaged. dealer for service.

TROUBLESHOOTING
ProblemThe Engine Exhaust Is Blue

Cause Remedy
The engine oil level is too high Adjust the oil level, and then have the
(engine oil is reaching the combustion oil level checked by an authorized
chamber). dealer.
The turbocharger is leaking oil.
turbocharger
The valve stem seals are loose or Have an authorized dealer replace the
damaged. seals.
The piston rings are worn.
piston rings.
ProblemEngine Brake Performance Is Poor

Cause Remedy
The engine brake control switch is
Replace the switch
damaged.
The exhaust brake is not operating Have an authorized dealer check the
properly. operation of the valve.
The constant-throttle valves are Bring the vehicle to an authorized
malfunctioning. dealer for service.
Components of the DDEC-ECU and/or Bring the vehicle to an authorized
DDEC-VCU are damaged. dealer for service.
ProblemCruise Control Is Not Working

Cause Remedy
One or more of the cruise control
Replace the damaged switch.
switches are damaged.
Components of the DDEC-ECU and/or
DDEC-VCU are damaged or not
dealer for service.
working properly.

ProblemThe Battery Charge Indicator Light Does Not

Come On When the Engine Is Not Running
Cause Remedy
The bulb is damaged. Change the bulb.
The circuit is broken. Repair the break in the circuit.
ProblemThe Battery Charge Indicator Light Comes

On When the Engine is Running
Cause Remedy
Check the belt tension; if necessary,
The poly-V belt is too loose. have an authorized dealer replace the
belt tensioner.
The belt tensioner is damaged.
belt tensioner.
The poly-V belt is worn or damaged. Replace the belt.
The alternator is damaged (has a Have an authorized dealer replace the
damaged rectifier or voltage regulator). alternator.

SERVICE PRODUCTS
SERVICE PRODUCTS
Use only the DDC recommended Fuel added from drums or cans could
lubricants discussed in this section. be contaminated. This could lead
Additional information is available to malfunctions in the fuel system.
from any authorized dealer. Always filter the fuel before adding it
to the tank. Ensure there is no water
Do not use special lubricant additives.
in the fuel.
None are needed, and the use of
additives could affect warranty For information about fuel in cold
coverage. weather operation, refer to the section
Winter-Grade Diesel Fuel" later in
Important: Dispose of service
this chapter.
products in an environmentally
responsible manner. This includes any
parts which have been in contact with Flow Improvers
them (for example, filters). Reclaim The effectiveness of flow improvers is
them or recycle them, if possible, not guaranteed with all fuels. Comply
and be sure to comply with all legal with the product manufacturer's
disposal requirements. recommendations. Any authorized
dealer can provide information on
Diesel Fuels approved flow improvers.
Use only commercially available
vehicle diesel fuel. Grades such as Kerosene
marine diesel fuel, heating oil, and Keep the quantity added as low as
others are not permissible. possible, bearing in mind the outside
Do not use fuel additives. Using fuel temperature.
additives could affect your warranty. The addition of five percent by
Only low sulfur diesel fuel should volume of kerosene will improve
be used for EGR engines (sulfur the fuel's resistance to cold by about
content = 0.05 percent by weight). 1C (1.8F). Never add more than 50
For non-EGR engines if you are percent kerosene to the fuel.
using diesel fuel with a high sulphur
content, exceeding 0.5 percent by
weight, change the engine oil at
shorter intervals. Comply with the
instructions in the service manual.

NOTICE:
For safety reasons, add the
kerosene to the diesel only in the
fuel tank. Add the kerosene first,
then the diesel. Run the engine for
a short time to allow the mixture to
reach all parts of the fuel system.
Engine Oils
The engine is delivered from the Figure 27 API Lubricant Service
factory filled with an approved engine Mark
oil.
When maintenance work is performed,
NOTICE: record engine oil changes including
details of the brand used, the
The use of non-approved engine
quality category, and the Society
oils could affect warranty rights, and
of Automotive Engineers (SAE)
cause engine damage.
viscosity rating of the oil. When
topping off, use only engine oils
To ensure long and trouble-free of the correct API designation
service, it is important to select oil and SAE rating. Detroit Diesel
of the correct viscosity and service POWER GUARD oils meet these
designation. specifications.
For information about oil in cold
EGR Engines weather operation, see the heading
"Low-Viscosity Engine Oil" later in
Only multigrade oils of American this chapter.
Petroleum Institute (API) service
designation CI-4 will achieve proper
performance for the cooled EGR
engines. Detroit Diesel POWER
GUARD oils meet this specification
and are recommended. Look for
the service mark printed on the oil
container. See Figure 27.

SERVICE PRODUCTS
Non-EGR Engines added. For reasons of anticorrosion

protection and to raise the boiling
API CI-4 or CH-4 oils are
point, the coolant with a minimum
recommended for use in all non-EGR
50% of antifreeze must remain in the
engines. These oils are intended for
cooling system all year round.
engines with open breather systems.
Detroit Diesel POWER GUARD Regardless of mileage, replace
oils meet these specifications and are the coolant every two years since
recommended. the degree of corrosion protection
gradually drops with time.
Synthetic Oils
Fully-Formulated Antifreeze
Synthetic oil may be used in MBE
900 engines, provided they are of the Antifreeze approved for use in the
correct API designation and viscosity, MBE 900 engine is a mixture of
as required for non-synthetic oil. glycol compounds (either ethylene
glycol or propylene glycol), and
Synthetic oil offers improved
corrosion inhibitors. Antifreeze
low-temperature flow properties
containing glycol compounds and
and high-temperature resistance to
corrosion inhibitors is known as
oxidation. However, it is generally
fully-formulated antifreeze.
more costly than non-synthetic oil.
Fully-formulated antifreeze has the
Review carefully the product
following properties:
information published by the synthetic
oil manufacturer. Performance It protects the radiator and engine
additive systems often respond from freezing.
differently in synthetic oil. Use of
It provides protection against
synthetic oil does not change the
corrosion and cavitation for all
recommended oil change service
components in the cooling system.
interval.
It raises the boiling point of the
Coolant coolant. This slows the rate of
evaporation, avoiding coolant loss
Coolant is a mixture of water and at high temperatures.
antifreeze. Under normal conditions,
it is a mixture of 50 percent water
and 50 percent antifreeze, but under
extreme cold weather conditions, as
much as 60 percent antifreeze can be

Water Coolant Specifications

Water containing no additives is To avoid damage to the cooling
not suitable as a coolant, even if no system, use only an approved
antifreeze protection is needed. corrosion-inhibiting antifreeze.
Approved antifreeze must be
The water used in the coolant must
fully-formulated and comply with
comply with certain requirements,
the requirements of the Truck
which are not always satisfied by
Maintenance Council (TMC). Coolant
drinking water. If water quality is
specifications are listed in Table
inadequate, the water must undergo
2. Detroit Diesel POWER COOL
suitable treatment.
products meet these specifications
The following types of water are and are recommended.
preferred for use in coolant:
Distilled water Coolant Concentration
Water purified by reverse osmosis When topping off the cooling system
after a drop in the coolant level, the
De-ionized water concentration of corrosion-inhibiting
antifreeze in the coolant must be
NOTICE: 50 percent by volume. This affords
protection down to a temperature of
In some areas, tap water can 37C(34F). The cooling mixing
contain high levels of dissolved ratio is listed in Table 3.
chlorides, sulfates, magnesium, and
calcium, causing scale deposits,
sludge deposits and/or corrosion.
These deposits can damage the
coolant pump and allow the engine
to overheat.
Type of Coolant Requirement

Fully-Formulated Ethylene Glycol TMC RP-329 Type "A"
Fully-Formulated Propylene Glycol TMC RP-330 Type "A"
Temperature Must Not Fall Below
Water plus Corrosion Inhibitors
0C (32F)
Table 2 Coolant Specifications

SERVICE PRODUCTS
Antifreeze Protection Water % Corrosion - Inhibiting

Down to C (F) by Volume Antifreeze % 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 concentration NOTICE:

is too low, there is risk of
Failure to properly maintain coolant
corrosion/cavitation in the cooling
with SCA can result in damage
system.
to the cooling system and its
For information about coolant in related components. Conversely,
cold weather operation, see the over-concentration of SCA inhibitor
heading "Winter Coolant Antifreeze can result in poor heat transfer,
Protection" later in this chapter. leading to engine damage.
Always maintain concentrations at
Supplemental Coolant Additives recommended levels. Do not use
for Fully Formulated Coolant traditional SCAs with NOAT coolant.
The concentrations of some inhibitors

will gradually deplete during normal
engine operation. SCAs replenish
the protection for cooling system The proper application of SCA will
components. The coolant must provide:
be maintained with the proper pH control
concentration of SCA. Detroit Diesel
POWER COOL maintenance SCAs Restored inhibitor levels to prevent
are recommended. corrosion
Water-softening to deter formation
of mineral deposits
Cavitation protection to protect
wet sleeve cylinder liners

Dropout form of "reprocessing" which consists

only of mechanical purification.
Excessive amounts of some corrosion
inhibitors can cause a gel or crystalline
deposit that reduces both heat transfer Cold Weather Products
and coolant flow. This deposit is Special precautions must be taken
called "dropout." during cold weather. To protect your
Dropout takes the color of the coolant engine, take the following special
when wet, but becomes a white or gray measures in cold weather:
powder when dry. It can pick up solid Use special cold weather fuel and
particles in the coolant and become engine oil.
gritty. It will cause premature wear
of the coolant pump seals and other Check the concentration of
components of the cooling system. antifreeze in your coolant.
The wet gel can be removed using an Take special care of your batteries.
alkaline (non-acid) cleaner containing
either sodium nitrite or sodium Winter-Grade Diesel Fuel
tetraborate.
At low outside temperatures, paraffin
If the gel is allowed to dry, it is may separate from the diesel and
necessary to disassemble the engine affect its ability to flow freely.
and clean it with a caustic solution,
Avoid breakdowns caused by this
or physically clean the individual
problem (for example, blocked
components.
filters) by using cold-resistant
winter-grade diesel fuel with improved
Disposal low-temperature flow characteristics.
Coolants are biologically degradable In most cases, winter-grade fuel can
substances. be used without problems at cold
outside temperatures.
When disposing of used coolant,
comply with local legal requirements If using summer-grade fuel or a less
and waste water regulations. cold-resistant winter grade, a flow
improver or kerosene can be added
Consult the local water supply with caution. The amount needed
authorities to determine the best depends on the outside temperature.
method of disposal.
A modern engine coolant has complex
tasks to perform. Do not allow any

SERVICE PRODUCTS
FIRE
To avoid increased risk of a fuel
fire, do not mix gasoline and
diesel fuel.
Flow improver or petroleum spirit

must be mixed with diesel fuel
before its flow characteristics have Figure 28 Engine Oil Temperature
been adversely affected by paraffin Ranges
separation. If changes have already
been caused by paraffin separation, Winter Coolant Antifreeze
they can be corrected only by Protection
heating the entire fuel system. Do
not add anything to cold-resistant Before the temperature dips below
winter-grade diesel fuels. The fuel's freezing, check the concentration of
low-temperature flow characteristics antifreeze in the coolant. If necessary,
could actually deteriorate with increase it.
additives. Do not increase the proportion
(mixing ratio) of corrosion-inhibiting
Low-Viscosity Engine Oil antifreeze beyond 55 percent by
When changing the engine oil, volume (this gives the maximum
estimate the interval before your antifreeze protection). Further
next oil change. Choose an oil increases in the mixing ratio would
from the SAE viscosity class reduce the level of antifreeze
which corresponds to the outside protection and adversely affect the
temperatures anticipated during this coolant's ability to dissipate heat.
period of operation. See Figure 28.
Batteries
Batteries should receive more frequent
maintenance and recharging during
the cold season of the year.

Careful maintenance and low current

consumption will help to maintain the
full battery charge. Starting capacity
drops severely in cold weather. For
example, at 10C (14F) starting
capacity is only about 60 percent
of normal. If the engine is shut
down or out of use for an extended
period of time, store the batteries
out of the vehicle in a heated area
if possible. Ensure good ventilation
when recharging.

TECHNICAL DATA
TECHNICAL DATA
General technical information is

listed in Table 4.
4-Cylinder Engines 6-Cylinder Engines

Description
904 924 906 926
Vertical, inline cylinder block with turbocharger
Engine Type
and charge-air cooler
Cooling System Liquid Circuit
Combustion Principle 4-Stroke direct-injection diesel
Number of Cylinders 4 6
4.02 in 4.17 in 4.02 in 4.17 in
Bore
(102 mm) (106 mm) (102 mm) (106 mm)
5.11 in 5.35 in 5.11 in 5.35 in
Stroke
(130 mm) (136 mm) (130 mm) (136 mm)
259 in 262 in 389 in 439 in
Displacement (total)
(4.25 liters) (4.8 liters) (6.37 liters) (7.2 liters)
Compression Ratio 18.0:1 17.5:1
Starting Speed Approximately 100 rpm
Direction of Engine
Rotation (viewed from Counterclockwise
flywheel)
Starter Electric Motor
The engine starts quickly without additional cold start
Cold-Start device in temperatures down to -15C (+5F).
Temperature Limit An optional grid heater provides easy starting in
(Without starting aids extreme temperatures down to -25C (-13F).
and with battery 75% For temperatures below -25C (-13F) an optional
charged) grid heater with preheating for coolant and lube oil is
available.
Table 4 General Technical Information

Engine Data for EGR

Engine
The engine weights are listed in Table
5. The engine dimensions are
listed in Table 6. Also see Figure 29
and Figure 30. Coolant and lubricating
oil capacities are listed in Table 7
Engine Engine Dry

Weight
Figure 29 Engine Measurements
4-Cylinder 420 kg 926 lb)
(Side View)
6-Cylinder 560 kg (1235 lb)
Table 5 Engine Weights
4-Cylinder 6-Cylinder
A = 1025 mm A = 1219 mm
(40.4 in.) (48 in.)
B = 686 mm B = 810 mm
(27 in.) (31.9 in.)
C = 1000 mm C = 1060 mm
(39.4 in.) (41.7 in.)
Table 6 Engine Dimensions (Front View)
Description 4-Cylinder Engine 6-Cylinder Engine

Coolant Capacity* Max. 8 L (8.5 qt) Max. 12.5 L (13.2 qt.)
Lubricating Oil
Max. 15.8 L (16.7 qt) Max. 29 L (30.6 qt)
Capacity**
*Does not include capacity of cooling system.
**For standard oil pan.
Table 7 Coolant and Lubricating Oil Capacity

TECHNICAL DATA
Engine Data for Non-EGR

Engine
The engine weights are listed in Table
8. The engine dimensions are
listed in Table 9. Also see Figure 31
and Figure 32. Coolant and lubricating
oil capacities are listed in Table 10.
Engine Engine Dry

Weight
(Side View)
Table 8 Engine Weights
4-Cylinder 6-Cylinder
A = 1025 mm A = 1219 mm
(40.4 in.) (48.0 in.)
B = 686 mm B = 810 mm
(27.0 in.) (31.9 in.)
C = 925 mm C = 940 mm
(36.4 in.) (37.0 in.)
Table 9 Engine Dimensions (Front View)
Description 4-Cylinder Engine 6-Cylinder Engine

Coolant Capacity* Max. 8.5 L (9.0 qt.) Max. 12.5 L (13.2 qt.)
Lubricating Oil
Max. 15.8 L (16.7 qt) Max. 29.0 L (30.6 qt)
Capacity
*Does not include capacity of cooling system.
**For standard oil pan
Table 10 Coolant and Lubricating Oil Capacity

Testing and Adjusting Oil Pressure is listed in Table 12.

Values Coolant thermostat conditions are
listed in Table 13. Injector pressures
Valve lash checking and adjustments
are listed in Table 14.
are listed in Table 11. Engine
Valve Type Check For: Adjust To:

mm ( in.) 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 Pressure

At idling rpm 50 kPa (7 psi)
At maximum rpm 250 kPa (36 psi)
Table 12 Engine Oil Pressure
Condition Specification
Starts to open 81 to 85C (177 to 185F)
Fully open 95C (203F)
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, Important: If the engine is stored for

changing the engine oil and filters is more than 18 months, the oil must
the least costly way of obtaining safe be changed before the engine can be
and reliable vehicle operation. Added brought into service.
benefits and savings occur when you
check that the valves, fuel injectors, Maintenance Schedule Types
and oil and cooling circuits are in good
working order during oil changes. There are five types of maintenance
schedule:
The maintenance section of this
manual explains when you should Schedule I (Severe Service)
change your oil and what to look for Schedule II (Short Haul)
when checking for wear or damage.
Schedule III (Long Haul)
For additional information, please
contact your regional office. Operating Hours vs. Fuel
Consumption (Oil Drain Interval
Only)
Scheduled Intervals
UNIMOG Service Schedule
All service intervals and maintenance
operations are based on the parts and To determine which schedule to use,
accessories expressly approved for find the distance traveled by the
your engine. vehicle in a year, regardless of vehicle
type.
The scope and frequency of
maintenance work are determined
by the engine's operating conditions: Severe Service Applies to
severe duty, short haul, long haul or vehicles that annually travel up to
operating hours vs. fuel consumption 100,000 kilometers (60,000 miles) or
(oil drain interval only). that operate under severe conditions.
Examples of Severe Service usage
Evidence of regular maintenance is include: operation on extremely poor
essential if a warranty claim has to be roads or where there is heavy dust
submitted. accumulation; constant exposure
If optional equipment is installed, be to extreme hot, cold, salt-air, or
sure to comply with the maintenance other extreme climates; frequent
requirements for these extra items. short-distance travel; construction-site

operation; city operation (fire truck, different schedules of vehicle usage

garbage truck); or farm operation. (severe, short haul, and long haul) are
listed in Table 15. For each schedule,
Short-Haul Applies to vehicles the appropriate distance interval
that annually travel up to 100,000 (in miles and kilometers) is given
kilometers (60,000 miles) and operate for performing and repeating each
under normal conditions. Examples maintenance operation.
of Short-Haul usage are: operation The descriptions of all maintenance
primarily in cities and densely operations, indicating all maintenance
populated areas; local transport with operation sets at which each operation
infrequent freeway travel; or high must be performed are listed in Table
percentage of stop-and-go travel. 15.
Long-Haul Long Haul Maintenance Intervals The

(over-the-road transport) is for three maintenance interval tables show
vehicles that annually travel more than which maintenance operation must
100,000 kilometers (60,000 miles), be performed at the actual distances
with minimal city or stop-and-go (in miles or kilometers) for each
operation. Examples of Long-Haul maintenance operation (M1M3). The
usage are: regional delivery that schedule of actual distances is based
is mostly freeway miles; interstate on the intervals listed in Table 15. The
transport; or any road operation with UNIMOG maintenance intervals for
high annual mileage. replacement of fluids and filters are
listed by operating hours.
Operating Hours vs. Fuel
The maintenance interval tables are:
Consumption (Oil Drain Interval
Only) Operating hours vs. fuel Maintenance Interval Table,
consumption is for operators who Severe Service (information
want an oil drain interval based on listed in Table 16)
hours of operation instead of miles
Maintenance Interval Table, Short
traveled. See Figure 33.
Haul (information listed in Table
17)
UNIMOG The UNIMOG engine
has long maintenance intervals. Maintenance Interval Table, Long
Haul (information listed in Table
18)
Maintenance Schedule and
Interval Operations The three

MAINTENANCE
The UNIMOG maintenance Complete each Maintenance

intervals for replacement of fluids Operation Set at the required interval.
and filters are listed in Table 21, For example, when you have
Table 22, Table 23, and Table 24. completed Maintenance Operation
Set M3 under the 16th maintenance
Maintenance Operation Sets number listed in the Maintenance
Each Maintenance Operations Interval Table, repeat the pattern. For
Sets Table (M1 through M3) lists the the 17th maintenance, do Maintenance
descriptions of only those maintenance Operation Set M1, under the first
operations that must be performed maintenance number listed in the
at that maintenance operation set. Maintenance Interval Table.
Each maintenance operation set is
listed in Table 19 and Table 20. NOTE:
For Severe Service, the pattern
repeats after 15 maintenance
Schedule Use numbers, not 16 (as for Short Haul
Before placing your new vehicle and Long Haul).
in service, determine the correct
maintenance intervals that apply to
your intended use of the vehicle. Refer
to the Maintenance Schedule Table
to determine the distance interval at
which each maintenance operation
must be performed to comply with
your vehicle's schedule. A detailed
description of maintenance operations
can be found later in this section
When the vehicle reaches the actual
distance given for an interval, refer
to the Maintenance Interval Tables
to find the Maintenance Operation
Set that applies to that interval. Then
perform the maintenance operations
listed in the applicable Maintenance
Interval Operation Table.

Maintenance Tables and

Graphs
Maint. Maintenance Intervals

Maintenance
Interval
Schedule
Operation
Frequency Miles Km
Schedule I Maint. 1 6,000 9,650
every
(Severe Service) (M1) (904/906/926) (904/906/926)
vehicles that
annually travel Maint. 2
up to 6,000 miles every 18,000 29,000
(M2)
(9,650 km)
Schedule II Maint. 1 15,000 24,000
every
(Short Haul) (M1) (904/906/926) (904/906/926)
vehicles that
Maint. 2
annually every 60,000 96,500
(M2)
travel up to
60,000 miles Maint. 3
every 75,000 121,000
(96,500 km) (M3)
Schedule III Maint. 1 20,000 32,000
every
(Long Haul) (M1) (904/906/926) (904/906/926)
vehicles that
Maint. 2
annually travel every 60,000 96,500
(M2)
more than
60,000 miles Maint. 3
every 80,000 129,000
(96,500 km) (M3)
Table 15 Maintenance Schedule Table

MAINTENANCE
Maintenance
Maint. No Miles Km
Interval
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 primary
filter. 4-cylinder engines will not use the oil centrifuge.
Table 16 Maintenance Intervals for Schedule I, Severe Service

Maintenance
Maint. No. Miles Km
Interval
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
Maintenance
Maint. No Miles Km
Interval
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 M2
Engine Inspecting
Fuel Prefilter Element Cleaning
Main Fuel Filter Element Changing
Valve Checking and Adjusting
Engine Oil and Filter Changing, Replace 906 and 926 Oil
Centrifuge Cartridge
Coolant Concentration Checking
Coolant Flushing and Changing
Cooling System Inspecting
Table 19 Required Maintenance Operations Sets, Schedule I
Maintenance Operation Description M1 M2 M3

Engine Inspecting
Valve Lash Checking and Adjusting
Fuel Prefilter Element Cleaning
Main Fuel Filter Element Changing
Engine Oil and Filter Changing, Replace 906 and 926 Oil
Centrifuge Cartridge
Coolant Concentration Checking
Coolant Flushing and Changing
Cooling System Inspecting
Table 20 Required Maintenance Operations Sets, Schedule II and III
NOTE: Oil, Fuel and Filters Requirements

If oil drain intervals are measured by (7SE270) available on the DDC
operating hours, an extension of the extranet.
oil drain interval may be possible.
Refer to DDC publication Lubricating

NOTE:
The engine oil and oil filter MUST be
changed EVERY 200 operating hours.
Operating Hours
Component Maintenance
200 700 1,400
Engine 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
Operating Hours
2,100 2,800 3,500
Change oil filter
Working Hydraulics

MAINTENANCE
Operating Hours
4,200 4,900 5,600
Working Change oil filter

Hydraulics Change oil and oil filter
Operating Hours
6,300 7,000

Change oil filter
Working Hydraulics

Required Maintenance 2. Visually inspect all lines and

Operations hoses. Listen for any sound of
leaking. Make sure all pipes and
The following sections describe the
hoses are undamaged, correctly
required maintenance operations
positioned to avoid chafing, and
listed in Table 19 and 20.
properly secured.
Engine Inspecting
Valve Lash Checking and
Inspect the engine as follows: Adjusting
1. Visually check the engine for Important: Adjust the valve lash
signs of leakage. A slight when the engine is cold. Wait at least
dampness at the sealing points is 30 minutes after shutdown, even if the
no cause for alarm. engine ran only a short time.
The special tool listed in Table 25 is
NOTE:
required for this procedure.
More severe leaks, combined with a
continual loss of oil, must be corrected
without delay.
Tool Description Manufacturer Part Number
Engine Cranking
Kent-Moore J-46392
Tool
Table 25 Special Tool

MAINTENANCE
Gaining Access To The Valves inspection hole on the timing case

Gain access to the valves as follows: (see Figure 35).
NOTE:
Clean the cylinder head cover before
removing it.
1. Remove the cylinder head cover

(see Figure 34).
Figure 35 Inspection Hole in the

Timing Case
4. Select a method for adjusting the

valve lash. See Figure 36 for
the valve layout on both four-
and six-cylinder engines. There
are two acceptable methods for
adjusting valve lash:
In order, according to the
timing sequence used for fuel
injection ("Method One)
By type of valve, depending on
crankshaft position ("Method
Figure 34 Cylinder Head Cover Two)
2. Remove the inspection cover on

the timing case.
3. Fit the cranking device
listed in Table 25 into the

be repositioned after each cylinder is

adjusted as listed in Table 26.
1. For each cylinder, use the
cranking device to rotate the
crankshaft until the piston is
exactly at top dead center (TDC)
in the compression stroke. The
valves must be closed and it must
be possible to turn the push rods
without effort.
NOTE:
When the piston in cylinder #1 is at
ignition TDC, the valves of cylinder
#6 (cylinder #4 on the four-cylinder
engine) will overlap, meaning that both
intake and exhaust valves are partially
Figure 36 Cylinder and Valve open, and show no measurable play
Layout when tested with a feeler gauge.
Method One: Adjust Each 2. Check each valve and adjust it (if
Cylinder In Firing Order necessary), using the procedures
Method One allows you to adjust under the headings "Checking
each cylinder in the order in which Valve Lash" and "Adjusting Valve
fuel is injected. The crankshaft must Lash" in this section.
Crankshaft
Engine Cylinders
Position
Ignition
1 3 4 2 NA NA
4-Cylinder Sequence
Valve Overlap 4 2 1 3 NA NA
Ignition
1 5 3 6 2 4
6-Cylinder Sequence
Valve Overlap 6 2 4 1 5 3
Table 26 Valve Adjustment- Method One

MAINTENANCE
Method Two: Adjust All 3. Using the cranking device, turn

Valves Using Two Crankshaft the crankshaft until cylinder #6
Positions Method two allows (cylinder #4 on the four-cylinder
you to adjust all the valves using just engine) is at the ignition TDC
two crankshaft positions. position (all valves are closed)
and cylinder #1 is at the valve
1. Using the cranking device, turn
overlap position (valves are
the crankshaft until cylinder #1 is
open).
at the ignition TDC position (all
valves are closed) and cylinder #6 4. Using the same procedure, check
(cylinder #4 on the four-cylinder the valves listed in Table 27 in the
engine) is at the valve overlap "Valve Overlap" row and adjust
position (all valves are open). them (if necessary), using the
procedures under the headings
2. Check the valves listed in Table
"Checking Valve Lash" and
27 in the "Ignition TDC" row
"Adjusting Valve Lash."
and adjust them (if necessary),
using the procedures under the
headings "Checking Valve Lash"
and "Adjusting Valve Lash."
Cylinder #1 Cylinders/Valve Types*

Engine Crankshaft
Position 1 2 3 4 5 6
Ignition TDC I/E I E NA NA

4-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 Check

valve lash as follows:
1. For each valve, measure the valve
lash with a feeler gauge between
the rocker arm and valve stem
(exhaust valve) or valve bridge
(intake valve). It should be
possible to pull the feeler gauge
through with no more than light
resistance.
2. If the value measured is within
the range listed in Table 28 in the
"Check For" column, check the
Figure 37 Intake Valves
next valve.
If the value measured is outside the
range listed in Table 28 in the "Check
For" column, adjust the valve lash.
Adjusting Valve Lash Adjust

valve lash as follows:
1. If adjustment is needed, loosen
the locknut. See Figure 37 for
intake valves and Figure 38 for
exhaust valves. Use the exact
settingslisted in Table 28 in the
"Adjust To" column.
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 the

valve lash is correct using the
exact settings listed in Table 28.
Use the range only for checking
adjustment.
3. Tighten the locknut 25 Nm (18
lbft ).
4. Check the valve lash again.
Adjust again if necessary.
Restoring The Vehicle To

Operating Condition Restore to
operating condition as follows:
1. Install the cylinder head cover.
See Figure 39.
2. Remove the cranking device from
the inspection hole in the timing
case. Figure 39 Cylinder Head Cover
3. Replace the end cover on the
inspection hole and tighten the
bolts 25 Nm (18 lbft).
Fuel Prefilter Element

Cleaning
Clean the fuel prefilter element as
follows:
1. Open the fuel filler cap to release
pressure in the fuel system.
Replace and tighten the cap.
Figure 40 Fuel Filters
2. Clean the outside of the prefilter
housing. Keep fuel away from
3. Unscrew the cap on the fuel
hoses or pipes located beneath the
prefilter. Pull the cap and filter
filter. See Figure 40.

element out of the prefilter

housing. See Figure 41.
4. Clean the cap and the filter 7. Bleed the fuel system.
element. If the filter element
is heavily soiled or damaged,
replace it. NOTICE:
5. Check the O-ring on the cap and
lines is critical. Incorrect torques
replace it if necessary.
could result in leaks or lack of power
6. Insert the filter element into the due to restricted fuel flow.
prefilter housing and screw the
cap onto the housing. Tighten the
cap 25 Nm (18 lbft ). [a] Make sure that all
high-pressure lines have
been tightened to 25 Nm (18
lbft) and all banjo bolts to 40
Nm (30 lbft).
[b] If equipped with a hand pump
on the fuel/water separator,
work the hand pump 50 times.
[c] Crank the engine for 30
seconds at a time, but no
longer. Before cranking the
engine again, wait at least two
minutes. The engine should
start within four 30-second
attempts.
Figure 41 Fuel Prefilter

MAINTENANCE
Main Fuel Filter Element

Changing
Change the main fuel filter element as
follows:
1. Open the vehicle fuel tank filler
cap to release pressure in the fuel
system. Replace and tighten the
cap.
2. Clean the outside of the fuel filter
housing. See Figure 40.
3. Using a 36-mm socket wrench
insert, unscrew the cap on the
fuel filter and remove it, along
with the filter element. Pull both
the cap and the filter element a Figure 42 Main Fuel Filter
short distance out of the filter
housing. See Figure 42. Allow 6. Clean the cap and the dirt
the fuel to drain off the filter into collector.
the housing.
7. Replace the O-ring.
4. Remove the cap with the filter
element. To release the filter 8. Install the new filter element
element, twist the lower edge of in the cap. Make sure the filter
the filter element to one side. element is securely in place.
9. Insert the dirt collector into the
NOTICE: filter housing. Make sure the dirt
collector is positioned properly in
To prevent damage to the filter the filter housing.
housing, do not allow dirt to get into
the filter housing. Do not empty the 10. Screw on the cap with the filter
dirt collector into the filter case. element. Tighten the cap 25 Nm
(18 lbft).
5. Pull the dirt collector out of the

filter housing using the tabs on
either side.

NOTICE: Engine Oil and Filter

Changing
lines is critical. Incorrect torques
could result in leaks or lack of power
due to restricted fuel flow.
FIRE
To avoid injury from fire, keep
11. Bleed the fuel system.
open flames, sparks, electrical
[a] Make sure that all resistance heating elements, or
high-pressure lines have other potential ignition sources
been tightened to 25 Nm (18 away when draining lubrication
lbft)) and all banjo bolts to oil. Do not smoke when draining
40 Nm (30 lbft). lubricating oil.
[b] If equipped with a hand pump
on the fuel/water separator,
NOTE:
work the hand pump 50 times.
Select the SAE class (viscosity) on the
[c] Crank the engine for 30 basis of the average air temperature
seconds at a time, but no for the season. See Figure 43. View
longer. Before cranking the the temperature ranges for the various
engine again, wait at least two SAE classes as guidelines which can
minutes. The engine should be exceeded for only a short time.
start within four 30-second
attempts.
12. Start the engine. Check the fuel
filter for leaks.
Figure 43 SAE Oil Viscosity

Classes

MAINTENANCE
To insure the engine is protected

and the oil stays clean until the next
oil change, use only oils of API
classification CI4.
The six-cylinder EGR engines have
an oil centrifuge and an oil filter.
Non-EGR engines have only an oil
filter.
NOTICE:
Figure 44 Oil Filter Cap
Both the primary lube oil filter (front
of engine) and the oil centriguge
cartridge (side of engine) must be 3. Place a suitable receptacle
replaced at each oil drain interval. beneath the oil drain plug on the
underside of the oil pan. Carefully
unscrew the oil drain plug on the
Change the oil filter as follows: oil pan and allow the oil to drain
out. See Figure 45. Discard the
1. Chock the tires, place the O-ring on the oil drain plug.
transmission in neutral, and set
the parking brake.
NOTE:
Change the engine oil only when the
engine is at an operating temperature
of approximately 82C (180F).
2. Using a 36-mm socket, unscrew

the oil filter cap. See Figure 44.
Figure 45 Engine Oil Drain Plug,

Oil Pan
4. Remove both the filter cap and

the filter element. To release the

filter element, twist the lower 9. Add new engine oil through the
edge of the filter element to the oil fill (see Figure 47).
side. See Figure 46.
Figure 47 Oil Fill

Figure 46 Cap with Oil Filter
Element
NOTICE: PERSONAL INJURY

To prevent damage to the filter To avoid injury from slipping and
housing, ensure that no foreign falling, immediately clean up any
objects get inside it. Do not wipe spilled liquids.
clean the filter housing.
NOTE:
5. Replace the O-ring on the cap. Engine oil fill capacity with a standard
See Figure 46. oil pan for the six-cylinder engine
6. Install the new filter into the cap. is 30.6 quarts (29.0 L). For the
Make sure the filter element is four-cylinder engine with a standard oil
securely in place. pan, fill capacity is 16.7 quarts (15.8
L).
7. Screw the cap onto the oil filter
housing. Tighten the cap 25 Nm 10. Fill until the maximum fill level
(18 lbft). on the oil dipstick has been
8. Install the oil drain plug, using a reached. Do not overfill.
new O-ring. Tighten the plug 65
Nm (48 lbft).

MAINTENANCE
NOTICE: 1. Remove the cover of the oil

centrifuge. See Figure 48.
Keep the engine running at idling
speed until an oil pressure reading is
obtained. If no oil pressure is shown
after approximately 10 seconds,
stop the engine and determine the
cause. Failure to do so could result
in engine damage.
11. Start the engine with the

accelerator pedal in the idle
position. Monitor the oil pressure
gauge.
Figure 48 Oil Centrifuge
12. Check the filter and oil drain plug
for signs of leakage.
2. Lift out the dirty cartridge and
13. Stop the engine.
replace it with a clean one
14. Check the oil level again after (see Figure 49).
approximately five minutes.
If necessary, add oil up to the
maximum fill level on the oil
dipstick. Do not overfill.
Oil Centrifuge
The MBE six-cylinder engines
(906/926) have an oil centrifuge.
NOTICE:
Both the primary lube oil filter (front
of engine) and the oil centriguge Figure 49 Centrifuge Cartridge
cartridge (side of engine) must be
replaced at each oil drain interval.
3. Replace the centrifuge cover,
tighten the cap 40 Nm (30 lbft).
Change the oil centrifuge cartridge as
follows:

Coolant Concentration NOTE:

Checking Check and correct the coolant level
only when the coolant temperature is
Check coolant concentration as
below 50C (122F).
follows:
2. Before adding coolant,
use a suitable tester to
check the concentration of
HOT COOLANT corrosion-inhibiting antifreeze. If
To avoid scalding from the the concentration is lower than
expulsion of hot coolant, never 50% by volume, drain coolant/add
remove the cooling system antifreeze until the concentration
pressure cap while the engine is is correct. The coolant mixing
at operating temperature. Wear ratio is listed in Table 29.
(face shield, rubber gloves, NOTE:
apron, and boots). Remove the Concentrations of more than 55% by
cap slowly to relieve pressure. volume should not be used, as this is
the level which affords the maximum
antifreeze protection, down to 45C
1. Open the cap on the surge tank (49F). Higher concentrations
slowly, to allow excess pressure adversely affect heat dissipation.
to escape. Set the cap aside.
Corrosion-Inhibiting
Antifreeze
Water Percentage Antifreeze
Protection Down
by Volume Percentage by
toC (F)
Volume
37 (347) 50 50
45 (49) 45 Maximum 55
Table 29 Coolant Mixing Ratio
NOTICE: NOTE:
When topping off, use only a
If the concentration of antifreeze is pre-prepared coolant mixture
too low, there is a risk of corrosion containing a 50% concentration
or cavitation in the cooling system.

MAINTENANCE
by volume of corrosion-inhibiting
antifreeze.
3. Check the coolant level and add

more coolant if necessary.
4. Close and tighten the cap on the
surge tank.

Coolant Flushing and

Changing
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, never
Figure 50 Coolant Drain Plug
NOTE:
Make sure the coolant can flow
unobstructed into the receptacle.
[b] Open the coolant drain plug

Flush and change the coolant as on the bottom of the radiator.
follows: 4. Flush the radiator.
1. Open the cap on the surge tank
slowly, to allow excess pressure NOTICE:
to escape. Set the cap aside.
When flushing the radiator, do not
2. Open the water regulating valve apply more than 140 kPa (20 psi) air
for the heating system. pressure. Excessive pressure can
3. Drain the coolant from the engine. damage the radiator or heater core.
See Figure 50. Coolant system
capacity is listed in Table 30.
[a] Attach a flushing gun nozzle
[a] Place a receptacle underneath to the radiator outlet.
the coolant drain plug.
[b] Run water in until the radiator
Choose one that is large
is full.
enough to hold the expected
quantity of coolant.

MAINTENANCE
5. Drain the radiator, and flush the

radiator until clean water flows
EYE INJURY from the radiator. Remove the
flushing gun.
To avoid injury from flying debris
when using compressed air, wear 6. When the coolant has drained,
adequate eye protection (face install the coolant drain plug on
shield or safety goggles) and do the radiator.
not exceed 276 kPa (40 psi) air 7. Add coolant in the specified
pressure. concentration until the maximum
mark on the surge tank is reached.
Coolant system capacity is
[c] Apply no more than listed in Table 30.
140 kPa (20 psi) air pressure
intermittently to help dislodge
sediment buildup in the core.
Description 4-Cylinder 6-Cylinder

Engine 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 for 10. Add coolant if necessary.
about one minute at varying
speeds to release air pockets in
the cooling system. Make sure
the heater valve is still open.
Check the coolant level and add
more coolant if necessary.
9. Shut down the engine.

Cooling System Inspecting dirt or debris. Make sure the fins

are not damaged, and straighten
them if necessary.
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, never
NOTE:
Before doing this inspection, make
sure to do either maintenance
operation, "Coolant Concentration
Checking," or maintenance operation,
"Coolant Flushing and Changing."
Inspect the cooling system as follows:

1. Inspect the radiator, the
condenser, the coolant pump,
the engine oil cooler, the freeze
plugs, and the heat exchanger for
damage and leaks.
2. Check all pipes and hoses in the
cooling system for damage and
leaks. Make sure all pipes and
hoses are properly positioned to
avoid chafing, and are securely
fastened.
3. Check the outside of the radiator
and condenser for blockage by

CUSTOMER ASSISTANCE
CUSTOMER ASSISTANCE
The satisfaction and good will of the Corporation and its distributor/dealer
owners of Detroit Diesel engines are organizations.
of primary concern to Detroit Diesel

DDC NORTH AMERICAN NAFTA ON-HIGHWAY OFFICES

EASTERN REGION 1 EASTERN REGION 2
Suwanee, Georgia Detroit, Michigan
3325 Paddocks Parkway 13400 Outer Drive West
Suwanee, GA 30024 Detroit, MI 48239-4001
Telephone: 678-341-6100 Telephone: 313-592-5420
Fax: 678-341-6150 Fax: 313-592-5887
WESTERN REGION 1 WESTERN REGION 2
Irvine, California Irvine, California
7700 Irvine Center, Suite 275 7700 Irvine Center, Suite 275
Irvine, CA 92618 Irvine, CA 92618
Telephone: 949-753-7710 Telephone: 949-753-7710
Fax: 949-753-7711 Fax: 949-753-7711
CANADIAN REGION
London, Ontario
Detroit Diesel of Canada, Ltd.
150 Dufferin Ave., Suite 701
London, ON N5A 5N6
Phone: 519-661-0149
Fax: 519-661-0171

CUSTOMER ASSISTANCE
MTU DETROIT DIESEL OFF-HIGHWAY SALES AND

CUSTOMER ASSURANCE CENTERS
CONSTRUCTION, INDUSTRIAL MARINE SALES (BX6)
AND MINING SALES (BX7) 13400 Outer Drive, West
13400 Outer Drive, West Detroit, MI 48239-4001
Detroit, MI 48239-4001 Phone: 313-592-7806
Phone: 313-592-5608 Fax: 313-592-5137
Fax: 313-592-5625
POWERGEN AND OIL FIELD SALES GOVERNMENT SALES (BX9)
(BX11) 13400 Outer Drive, West
13400 Outer Drive, West Detroit, MI 48239-4001
Detroit, MI 48239-4001 Phone: 313-592-5875
Phone: 313-592-5708 Fax: 313-592-5158
Fax: 313-592-5158
CUSTOMER ASSURANCE (M24)
13400 Outer Drive, West
Detroit, MI 48239-4001
Phone: 313-592-5550
Fax: 313-592-5717

DDC INTERNATIONAL REGIONAL OFFICE LOCATIONS
DETROIT DIESEL DISTRIBUTION LATIN AMERICAN REGION

CENTER B.V. (On/Off-Highway) (Off-Highway)
The Netherlands Miami, Florida
Ridderpoort 9 2277 N.W. 14th Street
2984 Ridderkerk Latin America Building
The Netherlands Miami, FL 33125-0068
Phone: (31) 180-442-900 Phone: 305-637-1555
Fax: (31) 180-462-062 Fax: 305-637-1580
MTU DETROIT DIESEL AUSTRALIA MTU ASIA PTE. LTD. (Off-Highway)

PTY. LTD. (On/Off-Highway) Singapore
Victoria Melbourne No. 1 Benoi Place
488 Blackshaws Road Singapore 629923
Altona North, Victoria. 3025 Phone: (65) 6861-5922
Australia Fax: (65) 6861-3615 Sales Marine,
Phone: (61) 3 9243-9292 Rail, C & I, Electronics
Fax: (61) 3 9243-9271 Fax: (65) 68609959 Sales
PowerGen, Defense
MEXICO (On/Off-Highway)
Detroit Diesel Allison de Mexico, S.A.
Av. Santa Rosa 58
Col. Ampliacion Norte
San Juan Ixtacala, Tlanepantla
C.P. 54160, Edo de Mexico
Phone: 52 55-5333-1803
Fax: 52 55-5333-1875

CUSTOMER ASSISTANCE
Working with DDC Service Step One

Outlets Discuss your problem with a member
As the owner of a Detroit Diesel of management from the authorized
product you have a complete network service outlet. Frequently, complaints
of over 1,000 Detroit Diesel service are the result of a breakdown in
outlets in the U.S. and Canada, plus communication and can quickly be
many outlets worldwide that are resolved by a member of management.
prepared to meet your parts and If you have already discussed the
service needs: problem with the Sales or Service
Manager, contact the General
Service by trained personnel
Manager. If your complaint originates
Sales teams to help determine your with a dealer, explain the matter
specific power requirements to a management member of the
distributorship with whom the dealer
In many areas, emergency service
has his service agreement.
24 hours a day
Complete parts support including Step Two
reliabilt remanufactured parts
When it appears that your problem
Product information and literature cannot readily be resolved at the
We recognize however, that despite distributor level without additional
the best intentions of everyone assistance, contact the Detroit
concerned, misunderstandings may Diesel Regional Product Support or
occur. Normally, any situation Operations Manager responsible for
that arises in connection with the your local distributor. You will be
sale, operation, or service of your assisted by a member of the Manager's
product will be handled by the staff, depending upon the nature of
authorized service outlet in your area your problem.
(in the U.S. and Canada check the Prior to this contact, have the
Yellow Pages or service locator at following information available:
www.detroitdiesel.com for the Detroit
Diesel service outlet nearest you). Engine model and serial number*
To further assure your complete Name and location of authorized

satisfaction, we have developed the service outlet
following procedure to use if you have Type and make of equipment
a problem that has not been handled
satisfactorily.

Engine delivery date and

accumulated miles or hours
of operation
Nature of problem
Chronological summary of
engine's history
Step Three
If you are still not satisfied, present the
entire matter in writing or by phone to:
Sr. Vice President, Parts, Service

and Customer Assurance
Detroit Diesel Corporation
13400 Outer Drive, West
Detroit, Michigan 482394001
Phone: 13135925000
Fax: 13135927244
When contacting the regional or

home office, please keep in mind that
ultimately your problem will likely
be resolved at the distributorship or
dealership, utilizing their facilities,
equipment, and personnel. Therefore,
it is suggested that you first follow
the previously mentioned steps
in sequence when experiencing a
problem.

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

MBE 900 ENGINES USED IN ON-HIGHWAY VEHICLE
APPLICATIONS
Terms of Coverage may, at its discretion, replace rather

than repair components. A reasonable
Uses time must be allowed to perform
the warranty repair after taking the
This warranty applies to the first retail engine to the authorized service outlet.
purchaser and subsequent owners The owner is responsible for the
during the WARRANTY PERIOD of percentage of repair costs shown in
new Detroit Diesel MBE 900 Engines the warranty period chart. Repairs will
(referred to as Engine) manufactured be performed during normal business
by Detroit Diesel Corporation and/or hours.
supplied by Detroit Diesel Corporation
or Detroit Diesel of Canada Limited
Warranty Period
(which are collectively referred to as
DDC) for use in on-highway vehicle The WARRANTY PERIOD begins
applications operated in the United on the date the engine is delivered to
States or Canada. the first retail purchaser or put in use
prior to sale at retail, whichever date
Defects occurs first, and ends at the time or
mileage/kilometer limits shown in the
This warranty covers Engine WARRANTY PERIOD chart.
REPAIRS to correct any malfunction
occurring during the WARRANTY
PERIOD resulting from defects in
material or workmanship.
Repairs
To obtain warranty repairs, you must
request the needed repairs within
the WARRANTY PERIOD from an
authorized DDC service outlet. Only
new genuine parts or remanufactured
parts or components supplied or
approved by DDC will be used. DDC

Warranty Period
Warranty Limitations Repair Charges to be
(Whichever Occurs First) Paid by Owner
Item
Miles/
Months Parts Labor
Kilometers
0-150,000 mi
Engine 0-36 No Charge No Charge
0-240,000 km
0-100,000 mi
Accessories 0-24 No Charge No Charge
0-160,000 km
Table 31 Warranty Period Chart On-highway Vehicle Applications
Like Replacement Engine This Warranty Does Not

Engine(s) supplied by DDC as a
Cover:
replacement for an engine still under
warranty will assume the identity Repairs Due to Accidents,
of the engine being replaced and be Misuse, Storage Damage,
entitled to the remaining warranty Negligence or Certain
coverage. Modifications
Repairs due to an accident, misuse,
Service Supplies misapplication, storage damage,
negligence or modification exceeding
The cost of service supplies such
DDC specifications are not covered by
as coolant, oil and filters which are
this warranty.
not reusable due to needed warranty
repairs is covered by this warranty.
Engine Removal and

Reinstallation
Reasonable labor costs for engine
removal and reinstallation, when
necessary to make a warranty repair,
are covered by this warranty.

IN ON-HIGHWAY VEHICLE APPLICATIONS
Maintenance THIS WARRANTY AND

THE EMISSIONS CONTROL
DDC is not responsible for the
WARRANTY ARE THE ONLY
cost of maintenance or repairs
WARRANTIES APPLICABLE
due to lack of performance of
TO THE ENGINE AS USED
required maintenance services as
IN ON-HIGHWAY VEHICLE
recommended by DDC, or the
APPLICATIONS. DETROIT DIESEL
failure to use fuel, oil, lubricants and
CORPORATION MAKES NO
coolant meeting DDC-recommended
OTHER WARRANTIES EXPRESS
specifications. Performance of the
OR IMPLIED, INCLUDING
required maintenance and use of
ANY IMPLIED WARRANTY
proper fuel, oil, lubricants and coolant
OF MERCHANTABILITY OR
are the responsibility of the owner.
FITNESS FOR A PARTICULAR
PURPOSE. DETROIT DIESEL
Incidental or Consequential CORPORATION SHALL NOT BE
Damages LIABLE FOR ANY INCIDENTAL
Detroit Diesel Corporation is OR CONSEQUENTIAL DAMAGES
not responsible for incidental or AS DESCRIBED ABOVE.
consequential costs or expenses which Some states do not allow the limitation
the owner may incur as a result of of how long this warranty may last
a malfunction or failure covered by or the limitation or exclusion of
this warranty, such as communication incidental or consequential damages,
expenses, meals, lodging, overtime, so the above may not apply to you.
towing, loss of use of the engine or This warranty gives you specific legal
vehicle (downtime), loss of time, rights, and you may also have other
inconvenience, cargo loss or damage, rights which may vary from state to
and other similar costs and expenses. state.
Other Limitations
Performance of REPAIRS is the
exclusive Owner's remedy under this
warranty. Detroit Diesel Corporation
does not authorize any person to
assume or create for it any other
obligation or liability in connection
with the engine or the accessories.


ENGINES USED IN SCHOOL BUS APPLICATIONS
Terms of Coverage than repair components. A reasonable

time must be allowed to perform
Uses the warranty repair after taking the
engine to the authorized service outlet.
This warranty applies to the first retail The owner is responsible for the
purchaser and subsequent owners percentage of repair costs shown in
during the WARRANTY PERIOD of the warranty period chart. Repairs will
new Detroit Diesel MBE 900 Engines be performed during normal business
(referred to as Engine) manufactured hours.
by Detroit Diesel Corporation and/or
Warranty Period
(which are collectively referred The WARRANTY PERIOD begins
to as DDC) for use in school bus on the date the engine is delivered
applications operated in the United to the first retail purchaser or put in
States or Canada. use prior to sale at retail, whichever
date occurs first, and ends at the
Defects time or mileage/kilometer limits
listed in Table 32, the WARRANTY
This warranty covers Engine PERIOD chart.
Repairs
may, at its discretion, replace rather

IN SCHOOL BUS APPLICATIONS
Warranty Period
Item
Miles/
Months Parts Labor
Kilometers
0-150,000 mi
0-240,000 km
0-100,000 mi
0-160,000 km
Table 32 Warranty Period Chart School Bus Applications
Service Supplies This Warranty Does Not

Cover:
not reusable due to needed warranty Repairs Due to Accidents,
repairs is covered by this warranty. Misuse, Storage Damage,
Negligence or Certain
Modifications
Like Replacement Engine
misapplication, storage damage,
warranty will assume the identity
of the engine being replaced and be
this warranty.
entitled to the remaining warranty
coverage.
Engine Removal and

Reinstallation


TO THE ENGINE AS
USED IN SCHOOL BUS
Other Limitations

IN FIRE TRUCK OR CRASH VEHICLE APPLICATIONS
LIMITED WARRANTY ON NEW DETROIT DIESEL

MBE 900 ENGINES USED IN FIRE TRUCK OR CRASH
VEHICLE APPLICATIONS
Terms of Coverage may, at its discretion, replace rather

than repair components. A reasonable
Uses time must be allowed to perform
the warranty repair after taking the
This warranty applies to the first retail engine to the authorized service outlet.
purchaser and subsequent owners The owner is responsible for the
during the WARRANTY PERIOD of percentage of repair costs shown in
new Detroit Diesel MBE 900 Engines the warranty period chart. Repairs will
(referred to as Engine) manufactured be performed during normal business
by Detroit Diesel Corporation and/or hours.
Warranty Period
(which are collectively referred to as
DDC) for use in fire truck or crash The WARRANTY PERIOD begins
vehicle applications operated in the on the date the engine is delivered
United States or Canada. to the first retail purchaser or put in
use prior to sale at retail, whichever
Defects date occurs first, and ends at the
time or mileage/kilometer limits
This warranty covers Engine listed in Table 33, the WARRANTY
REPAIRS to correct any malfunction PERIOD chart.
Repairs

Warranty Period
Item
Miles/
Months Parts Labor
Kilometers
0-150,000 mi
0-240,000 km
0-100,000 mi
0-160,000 km
Table 33 Warranty Period Chart Fire Truck/Crash Vehicle

Applications

Cover:
this warranty.
Engine Removal and

Reinstallation

IN FIRE TRUCK OR CRASH VEHICLE APPLICATIONS

TO THE ENGINE AS USED IN
FIRE TRUCK OR CRASH VEHICLE
Other Limitations


ENGINES USED IN UNIMOG APPLICATIONS
Terms of Coverage than repair components. A reasonable

time must be allowed to perform
Uses the warranty repair after taking the
engine to the authorized service outlet.
This warranty applies to the first The owner is responsible for the
retail purchaser and subsequent percentage of repair costs shown in
owners during the WARRANTY the warranty period chart. Repairs will
PERIOD of new Detroit Diesel be performed during normal business
MBE 900 Engines (referred to as hours.
Engine) manufactured by Detroit
Diesel Corporation and/or supplied by
Warranty Period
Detroit Diesel Corporation or Detroit
Diesel of Canada Limited (which are The WARRANTY PERIOD begins
collectively referred to as DDC) for on the date the engine is delivered
use in UNIMOG applications operated to the first retail purchaser or put in
in the United States or Canada. use prior to sale at retail, whichever
date occurs first, and ends at the
Defects time or mileage/kilometer limits
listed in Table 34, the WARRANTY
This warranty covers Engine PERIOD chart.
Repairs
may, at its discretion, replace rather

IN UNIMOG APPLICATIONS
Warranty Period
Warranty Limitations Repair Charges to
(Whichever Occurs First) be Paid by Owner
Item
Miles/
Months Hours Parts Labor
Kilometers
No
Engine 24 Unlimited Unlimited No Charge
Charge
No
Accessories 24 Unlimited Unlimited No Charge
Charge
Table 34 Warranty Period Chart UNIMOG Applications

Cover:
this warranty.
Engine Removal and

Reinstallation


TO THE ENGINE AS USED
IN UNIMOG APPLICATIONS.
DETROIT DIESEL CORPORATION
MAKES NO OTHER
WARRANTIES EXPRESS
Other Limitations


DDC SVC MAN 0055 Sensor M2 Freightliner

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MBE 900 OPERATOR'S GUIDE

To the Operator personnel to provide prompt

All information subject to change without notice. (Rev. 04/08) i

CAUTION SUMMARY .......................................................................... 1

All information subject to change without notice. (Rev. 04/08) iii

MONITORING ENGINE OPERATION ............................................. 36

CLEANING AND STORAGE ............................................................... 40

SERVICE PRODUCTS ......................................................................... 56

iv All information subject to change without notice. (Rev. 04/08)

SUPPLEMENTAL COOLANT ADDITIVES FOR FULLY

TECHNICAL DATA .............................................................................. 64

All information subject to change without notice. (Rev. 04/08) v

ADJUSTING VALVE LASH ...................................................... 83

CUSTOMER ASSISTANCE ................................................................. 96

LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900

LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900

vi All information subject to change without notice. (Rev. 04/08)

WARRANTY PERIOD .................................................................. 105

LIMITED WARRANTY ON NEW DETROIT DIESEL MBE

LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900

All information subject to change without notice. (Rev. 04/08) vii

THIS WARRANTY DOES NOT COVER: ......................................... 112

viii All information subject to change without notice. (Rev. 04/08)

The following cautions must be

All information subject to change without notice. (Rev. 04/08) 1

2 All information subject to change without notice. (Rev. 04/08)

PERSONAL INJURY FIRE

All information subject to change without notice. (Rev. 04/08) 3

Flush your eyes with water.

Get medical attention

4 All information subject to change without notice. (Rev. 04/08)

Electrical Shock Hazard

All information subject to change without notice. (Rev. 04/08) 5

Cooling System Air Intake System

HOT COOLANT PERSONAL INJURY

6 All information subject to change without notice. (Rev. 04/08)

All information subject to change without notice. (Rev. 04/08) 7

Keep those people who are not

Stop the engine immediately if

Do not smoke or allow open

Wear adequate protective

8 All information subject to change without notice. (Rev. 04/08)

All information subject to change without notice. (Rev. 04/08) 9

The MBE 900 engine is built in standards. An emission label is

Figure 1 Emission Label, 6Cylinder EGR Engine

10 All information subject to change without notice. (Rev. 04/08)

Figure 2 Emission Label, 4Cylinder EGR Engine

All information subject to change without notice. (Rev. 04/08) 11

See Figure 3 for the emission label for

Figure 3 Emission Label, NonEGR 6-Cylinder

12 All information subject to change without notice. (Rev. 04/08)

See Figure 4 for the 4-cylinder

Figure 4 Emission Label, NonEGR 4-Cylinder

All information subject to change without notice. (Rev. 04/08) 13

Engine Conversions and General View of the MBE

14 All information subject to change without notice. (Rev. 04/08)

1. Turbocharger 7. EGR Mixer

Figure 5 Right Front View of the MBE 900 EGR Engine

All information subject to change without notice. (Rev. 04/08) 15

1. Air Compressor 6. Oil Centrifuge

Figure 6 Left Rear View of the MBE 900 EGR Engine

16 All information subject to change without notice. (Rev. 04/08)

1. Fan 10. Cylinder Head Cover

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