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Detroit Diesel EPA04 MBE 900, Operator'S Manual

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MBE 900 OPERATOR'S MANUAL

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

Terms of Coverage

Uses

This warranty applies to the

fi

rst retail

purchaser and subsequent owners
during the WARRANTY PERIOD of
new Detroit Diesel MBE900 Engines
(referred to as Engine) manufactured
by Detroit Diesel Corporation and/or
supplied by Detroit Diesel Corporation
or Detroit Diesel of Canada Limited
(which are collectively referred
to as DDC) for use in school bus
applications operated in the United
States or Canada.

Defects

This warranty covers Engine
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
may, at its discretion, replace rather

than repair components. A reasonable
time must be allowed to perform
the warranty repair after taking the
engine to the authorized service outlet.
The owner is responsible for the
percentage of repair costs shown in
the warranty period chart. Repairs will
be performed during normal business
hours.

Warranty Period

The WARRANTY PERIOD begins
on the date the engine is delivered
to the

fi

rst retail purchaser or put in

use prior to sale at retail, whichever
date occurs

fi

rst, and ends at the

time or mileage/kilometer limits
listed in Table 32, the WARRANTY
PERIOD chart.

All information subject to change without notice.

(Rev. )

103

DDC-SVC-MAN-0055

Copyright © 2009 DETROIT DIESEL CORPORATION

Summary of Contents for EPA04 MBE 900

Page 1: ...poration is registered to ISO 9001 2001 Copyright Detroit Diesel Corporation All rights reserved Detroit Diesel Corporation is a Daimler company Printed in U S A 13400 Outer Drive West Detroit Michigan 48239 4001 Telephone 313 592 5000 www detroitdiesel com EPA04 MBE 900 Operator s Manual ...

Page 2: ......

Page 3: ...eplacement Authorized service outlets worldwide stock factory original parts and have the specialized equipment and experienced trained personnel to provide prompt preventive maintenance and skilled engine repairs The information and specifications in this publication are based on the information in effect at the time of approval for printing Contact an authorized Detroit Diesel service outlet for...

Page 4: ...ii All information subject to change without notice Rev DDC SVC MAN 0055 Copyright 2009 DETROIT DIESEL CORPORATION ...

Page 5: ...E ENGINE 21 EXHAUST GAS RECIRCULATION 22 EXHAUST BRAKE CONSTANT THROTTLE VALVES OPTIONAL 23 ELECTRONIC ENGINE CONTROL SYSTEM 24 DDEC ECU 25 DDEC VCU 26 SENSOR LOCATIONS 27 OPERATION 30 BEFORE STARTING THE ENGINE 30 CHECKING THE BATTERIES 30 CHECKING THE OIL LEVEL 31 CHECKING THE COOLANT LEVEL COLD CHECK 32 ADDING FUEL 32 PRIMING THE FUEL SYSTEM 32 STARTING THE ENGINE 32 CHECKING THE COOLANT LEVEL ...

Page 6: ...URE CLEANING EQUIPMENT 39 CLEANING THE COOLING SYSTEM 39 DEGREASING 40 STORAGE 41 TROUBLESHOOTING 42 EMERGENCY STARTING 42 TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL SYSTEM 42 GENERAL TROUBLESHOOTING 42 SERVICE PRODUCTS 55 DIESEL FUELS 55 FLOW IMPROVERS 55 KEROSENE 55 ENGINE OILS 56 EGR ENGINES 56 NON EGR ENGINES 57 SYNTHETIC OILS 57 COOLANT 57 FULLY FORMULATED ANTIFREEZE 57 WATER 58 COOLANT SP...

Page 7: ...ERVICE 67 SHORT HAUL 68 LONG HAUL 68 OPERATING HOURS VS FUEL CONSUMPTION OIL DRAIN INTERVAL ONLY 68 UNIMOG 68 MAINTENANCE SCHEDULE AND INTERVAL OPERATIONS 68 MAINTENANCE INTERVALS 68 MAINTENANCE OPERATION SETS 69 SCHEDULE USE 69 MAINTENANCE TABLES AND GRAPHS 70 REQUIRED MAINTENANCE OPERATIONS 78 ENGINE INSPECTING 78 VALVE LASH CHECKING AND ADJUSTING 78 GAINING ACCESS TO THE VALVES 79 METHOD ONE AD...

Page 8: ...USED IN ON HIGHWAY VEHICLE APPLICATIONS 100 TERMS OF COVERAGE 100 USES 100 DEFECTS 100 REPAIRS 100 WARRANTY PERIOD 100 LIKE REPLACEMENT ENGINE 101 SERVICE SUPPLIES 101 ENGINE REMOVAL AND REINSTALLATION 101 THIS WARRANTY DOES NOT COVER 101 REPAIRS DUE TO ACCIDENTS MISUSE STORAGE DAMAGE NEGLIGENCE OR CERTAIN MODIFICATIONS 101 MAINTENANCE 102 INCIDENTAL OR CONSEQUENTIAL DAMAGES 102 OTHER LIMITATIONS ...

Page 9: ... REPAIRS 106 WARRANTY PERIOD 106 LIKE REPLACEMENT ENGINE 107 SERVICE SUPPLIES 107 ENGINE REMOVAL AND REINSTALLATION 107 THIS WARRANTY DOES NOT COVER 107 REPAIRS DUE TO ACCIDENTS MISUSE STORAGE DAMAGE NEGLIGENCE OR CERTAIN MODIFICATIONS 107 MAINTENANCE 108 INCIDENTAL OR CONSEQUENTIAL DAMAGES 108 OTHER LIMITATIONS 108 LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900 ENGINES USED IN UNIMOG APPLICATIONS...

Page 10: ... ACCIDENTS MISUSE STORAGE DAMAGE NEGLIGENCE OR CERTAIN MODIFICATIONS 110 MAINTENANCE 111 INCIDENTAL OR CONSEQUENTIAL DAMAGES 111 OTHER LIMITATIONS 111 viii All information subject to change without notice Rev DDC SVC MAN 0055 Copyright 2009 DETROIT DIESEL CORPORATION ...

Page 11: ...the following cautions when operating the engine 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 PERSONAL INJURY Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm ...

Page 12: ...avoid injury when working near or on an operating engine equipped with an hydraulic clutch fan remove loose items of clothing and jewelry Tie back or contain long hair that could be caught in any moving part causing injury The hydraulic fan may start without warning HOT COOLANT To avoid scalding from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at o...

Page 13: ...prevents contact with rotating parts PERSONAL INJURY To avoid injury when using caustic cleaning agents follow the chemical manufacturers usage disposal and safety instructions FIRE To avoid injury from combustion of heated lubricating oil vapors stop the engine immediately if an oil leak is detected FIRE To avoid injury from fire do not smoke or allow open flames when working on an operating engi...

Page 14: ...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 Flush your skin with water Apply baking soda or lime to help neutralize the acid Flush your eyes with water Get medical attention immediately ELECTRICAL SHOCK To avoid...

Page 15: ...ield rubber gloves apron and boots Remove the cap slowly to relieve pressure PERSONAL INJURY To avoid injury from slipping and falling immediately clean up any spilled liquids Air Intake System Observe the following cautions when working on the air intake system PERSONAL INJURY To avoid injury from hot surfaces wear protective gloves or allow engine to cool before removing any component All inform...

Page 16: ... an engine is operating with the air inlet piping removed install an air inlet screen shield over the turbocharger air inlet The shield prevents contact with rotating parts 6 All information subject to change without notice Rev DDC SVC MAN 0055 Copyright 2009 DETROIT DIESEL CORPORATION ...

Page 17: ...ames sparks and electrical resistance heating elements Do not smoke when refueling 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 shie...

Page 18: ...nd 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 FIRE To avoid injury from fire do not smoke or allow open flames when working on an operating engine FIRE To avoid injury from fire from a buildup of volatile vapors...

Page 19: ...on Agency USEPA and California Air Resources Board CARB emission standards An emission label is attached to the cylinder head cover as required by law See Figure 1 for the emission label for the 6 cylinder EGR model and Figure 2 for the 4 cylinder EGR model Figure 1 Emission Label 6 Cylinder EGR Engine All information subject to change without notice Rev 9 DDC SVC MAN 0055 Copyright 2009 DETROIT D...

Page 20: ...IDENTIFICATION Figure 2 Emission Label 4 Cylinder EGR Engine 10 All information subject to change without notice Rev DDC SVC MAN 0055 Copyright 2009 DETROIT DIESEL CORPORATION ...

Page 21: ... See Figure 3 for the emission label for the 6 cylinder non EGR model Figure 3 Emission Label Non EGR 6 Cylinder All information subject to change without notice Rev 11 DDC SVC MAN 0055 Copyright 2009 DETROIT DIESEL CORPORATION ...

Page 22: ...for its intended purpose It is modified or converted in an incorrect manner The safety instructions included in this manual are disregarded Personnel Requirements Work on the engine should be carried out only by skilled technicians who have been instructed in the specific skills necessary for the type of work being performed 12 All information subject to change without notice Rev DDC SVC MAN 0055 ...

Page 23: ...MBE900 engine is equipped with an Exhaust Gas Recirculation EGR system to reduce engine exhaust gas emissions in accordance with EPA regulations See Figure 5 for a right front view of the MBE900 EGR engine 6 cylinder model and Figure 6 for a left rear view The off highway engine used in construction and industrial applications does not have an EGR system See Figure 7 for a front view of the MBE900...

Page 24: ...l 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 MBE900 EGR Engine 14 All information subject to change without notice Rev DDC SVC MAN 0055 Copyright 2009 DETROIT DIESEL CORPORATION ...

Page 25: ...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 MBE900 EGR Engine All information subject to change without notice Rev 15 DDC SVC MAN 0055 Copyright 2009 DETROIT DIESEL CORPORATION ...

Page 26: ...mpressor Out 14 Air Compressor optional 6 Intake Manifold Inlet 15 Power Steering Pump 7 Crankcase Breather 16 Oil Dipstick 8 Oil Fill Cap 17 Coolant Pump Pulley 9 Intake Manifold Figure 7 Front View of 6 Cylinder MBE900 Non EGR Engine 16 All information subject to change without notice Rev DDC SVC MAN 0055 Copyright 2009 DETROIT DIESEL CORPORATION ...

Page 27: ... Manifold 9 Starter Motor 4 Intake Manifold Inlet 10 Flywheel Housing 5 Oil Fill Cap 11 Exhaust Brake optional 6 Turbo Compressor Out Figure 8 Side View of a 6 cylinder MBE900 Non EGR Engine All information subject to change without notice Rev 17 DDC SVC MAN 0055 Copyright 2009 DETROIT DIESEL CORPORATION ...

Page 28: ...let 4 Air Compressor optional 12 Turbo Compressor Out 5 Power Steering Pump 13 Crankcase Breather 6 Oil Dipstick 14 Oil Fill Cap 7 Fuel Filter 15 Intake Manifold 8 Fan Figure 9 Front View of 4 Cylinder MBE900 Non EGR Engine 18 All information subject to change without notice Rev DDC SVC MAN 0055 Copyright 2009 DETROIT DIESEL CORPORATION ...

Page 29: ...ptional 3 Intake Manifold Inlet 9 Flywheel Housing 4 Oil Filter 10 Exhaust Manifold 5 Alternator 11 Intake Manifold 6 Turbocharger Figure 10 Rear View of 4 Cylinder MBE900 Non EGR Engine All information subject to change without notice Rev 19 DDC SVC MAN 0055 Copyright 2009 DETROIT DIESEL CORPORATION ...

Page 30: ...mber See Figure 12 for an example of the numbers as they appear on the engine 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 engine identification number Figure 13 Engine Identification 20 All information subject to change without notice Rev DDC SVC MAN 0055 Copyright 2009...

Page 31: ...driven from the camshaft Each cylinder has two intake valves and one exhaust valve Charge air cooling and an exhaust gas turbocharger are standard equipment on all MBE900 engines charge pressure limitation is optional The engine has a fully electronic control system which regulates the fuel injection quantity and timing using solenoid valves allowing extremely low emission operation The control sy...

Page 32: ... oil pump This pump is positioned at the front of the crankcase and driven by gears from the crankshaft The oil cooler is located near the front of the crankcase on the right hand side near the water pump The gear type fuel pump is bolted to the front of the crankcase The pump is driven from the forward end of the camshaft The air compressor with a power steering pump attached is driven by a gear ...

Page 33: ...ndently of each other and in combination Exhaust back pressure is used by the exhaust brake to increase braking performance The constant throttle valves use the air that escapes through them on the compression stroke to provide braking force The constant throttles valves are small valves which are built into the cylinder head and positioned opposite the exhaust valve When open a link is created be...

Page 34: ...C 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 Diag...

Page 35: ...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 All information subject to change without notice Rev 25 DDC SVC MAN 0055 Copyright 2009 DETROIT DIESEL CORPORATION ...

Page 36: ...ronic control unit installed on the vehicle over the J1587 data link See Figure 18 Data for specific applications is stored in the DDEC VCU These include idle speed maximum running speed and speed limitation Figure 18 DDEC VCU The DDEC VCU receives data from the following sources The operator accelerator pedal position engine brake switch Other electronic control units for example the anti lock br...

Page 37: ...o avoid injury from chemical burns wear a face shield and neoprene or PVC gloves when handling sensor hoses 1 Intake Manifold Pressure Temper ature Sensor 3 Engine Oil Pressure Sensor 2 Engine Oil Temperature Sensor Figure 19 Sensor Location on the Right Side of the MBE900 EGR Engine All information subject to change without notice Rev 27 DDC SVC MAN 0055 Copyright 2009 DETROIT DIESEL CORPORATION ...

Page 38: ...re Sensor 6 Crankshaft Position Sensor on timing case Figure 20 Sensor Location on the Left Side of the MBE900 EGR Engine NOTE The 6 cylinder engine is shown sensor locations are similar on the 4 cylinder engine NOTE The Barometric Pressure Sensor is integrated into the DDEC ECU 28 All information subject to change without notice Rev DDC SVC MAN 0055 Copyright 2009 DETROIT DIESEL CORPORATION ...

Page 39: ... ature Sensor 7 Crankshaft Position Sensor on timing case 4 Supply Fuel Temperature Sensor Figure 21 Sensor Location on the MBE900 Non EGR Engine NOTE The 6 cylinder engine is shown sensor locations are similar on the 4 cylinder engine NOTE The Engine Oil Level Sensor if used is located at the bottom of the oil pan All information subject to change without notice Rev 29 DDC SVC MAN 0055 Copyright ...

Page 40: ... of engine problems If the engine overheats uses excessive fuel or lubricating oil vibrates misfires makes unusual noises or shows an unusual loss of power turn the engine off as soon as possible and determine the cause Frequently engine damage may be avoided by a quick response to early indications of problems If you are starting the engine in cold weather refer to Cold Weather Products in the Se...

Page 41: ...ecking 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 22 Oil Dipstick 2 If necessary top off by filling engine oil through the oil fill collar see Figure 23 until the maximum fill level on the oil dipstick see Figure 22 has been reached ...

Page 42: ...ws NOTICE Correct torque on the high pressure lines is critical Incorrect torques could result in leaks or lack of power due to restricted fuel flow 1 Make sure that all high pressure and low pressure lines are securely tightened 2 If equipped with a hand pump on the fuel water separator work the hand pump 50 times 3 Crank the engine for 30 seconds at a time but no longer Before cranking the engin...

Page 43: ...e engine for tightness Shut down the engine and tighten them if necessary 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 5 Approximately five minutes after shutdown check the engine oil level If necessary add oil up to the maximum fill level on the oil dipstick see Figure 24 Do not overfill Figure 24...

Page 44: ...ed period certain special work must be carried out Refer to Storage under Cleaning and Storage Important At outside temperatures below 20 C 4 F a coolant preheater is recommended 1 Chock the tires place the transmission in neutral and set the parking brake 2 Turn on the ignition switch and start the engine 3 If the engine doesn t start after 20 seconds stop Try again after waiting about one minute...

Page 45: ...ks and electrical resistance heating elements Do not smoke when refueling 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 Oil Pressure When the engine has reached its normal operating temperature the engine oil...

Page 46: ...e 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 Engine power and rpm fall even though the accelerator pedal remains steady The exhaust pipe gives off heavy smoke The coolant and or oil temperature climb abnormally Abnormal sounds suddenly occur in the engi...

Page 47: ...o emergency running mode When in emergency running mode the engine operates at a constant 1300 rpm This allows you to move the vehicle to a service location Stop Engine Override Option The Stop Engine Override Option is used for a momentary override The DDEC ECU will record the number of times the override is activated after a fault occurs Momentary Override A Stop Engine Override SEO switch is us...

Page 48: ... 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 38 All information subject to ...

Page 49: ...ween 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 After cleaning and especially when using a high pressure jet or grease removing agent lubricate the engine Information on suitable cleaning and protective products is available from any authorized dealer Cleaning the Co...

Page 50: ...5 solution 1 6 ounces per quart of water 50 grams per liter of a mildly alkaline cleaning agent such as sodium carbonate 2 Run the engine at moderate speed until the thermostat starts to open at an operating temperature of approximately 80 C 176 F Then run it for about five minutes longer Shut down the engine and allow it to cool to approximately 50 C 112 F HOT COOLANT To avoid scalding from the e...

Page 51: ...tilated 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 If the engine is to be out of service for over 12 months or under extraordinary storage or transportation conditions t...

Page 52: ...h 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 General Troubleshooting The tables that follow are designed to identify the causes of common problems suggest further checks ...

Page 53: ... authorized dealer for service Problem The Engine Turns Over Slowly Cause Remedy The batteries are damaged or weak Test the batteries Replace them if needed The ignition switch is damaged Replace the ignition switch The battery cables are damaged and or corroded Replace the battery cables The starter is damaged and or worn Have an authorized dealer replace the starter The engine oil does not meet ...

Page 54: ...zed dealer for service The camshaft TDC sensor and or the crank angle position sensor are damaged Bring the vehicle to an authorized dealer for service There is air in the fuel system Check the fuel lines for leaks Bleed the fuel system and start the engine according to the instructions in the service manual The air filter is clogged Clean or replace the air filter The fuel filter is clogged Repla...

Page 55: ...e the fuel lines and filters checked by an authorized dealer The camshaft TDC sensor and or the crank angle position sensor are out of adjustment Push both sensors into their holes as far as they will go If this does not solve the problem bring the vehicle to an authorized dealer for service The camshaft TDC sensor and or the crank angle position sensor are damaged Bring the vehicle to an authoriz...

Page 56: ...he vehicle to an authorized dealer for service The camshaft TDC sensor and or the crank angle position sensor are damaged Bring the vehicle to an authorized dealer for service The constant throttle valves are malfunctioning Bring the vehicle to an authorized dealer for service There are other problems in the fuel system Bring the vehicle to an authorized dealer for service Problem The Engine Fan D...

Page 57: ...l tires for correct pressure The air filter and or intake air system is clogged Check the air restriction indicator Clean the intake air system and replace the air filter if necessary The fuel filter is clogged Replace the filter element The exhaust brake valve is malfunctioning Have an authorized dealer check the operation of the valve The engine performs poorly or does not develop full power The...

Page 58: ...mperature sensor is damaged or reading incorrectly Bring the vehicle to an authorized dealer for service The fuel temperature sensor is damaged or reading incorrectly Bring the vehicle to an authorized dealer for service The engine oil temperature sensor is damaged or reading incorrectly Bring the vehicle to an authorized dealer for service The charge air temperature sensor is damaged or reading i...

Page 59: ...and or sensor is not reading correctly Bring the vehicle to an authorized dealer for service The radiator is damaged or dirty Clean the radiator Repair or replace the radiator if necessary The coolant pump is damaged Have an authorized dealer replace the coolant pump The thermostat is damaged Have an authorized dealer replace the coolant pump The fan is not operating properly Bring the vehicle to ...

Page 60: ...ettings reprogrammed in the DDEC ECU or DDEC VCU Problem The 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 Have an authorized dealer replace the air compressor The cylinder head gasket is leaking Have an authorized dealer replace the head gasket Top...

Page 61: ... changed within the recommended interval Change the oil The oil is not of the recommended quality Change the oil Problem The Engine Oil Pressure Is Low Cause Remedy The oil pressure gauge and or sensor is not reading correctly Bring the vehicle to an authorized dealer for service There is fuel in the oil Bring the vehicle to an authorized dealer for service The oil filter is clogged Replace the fi...

Page 62: ...e is malfunctioning Have an authorized dealer check the operation of the valve The intake air preheater is malfunctioning Check that the heater is not staying on all of the time The valves are not adjusted properly Check the valve lash There is damage to the fuel system the fuel pump one or more fuel injectors or one or more unit pumps are damaged Bring the vehicle to an authorized dealer for serv...

Page 63: ... brake control switch is damaged Replace the switch The exhaust brake is not operating properly Have an authorized dealer check the operation of the valve The constant throttle valves are malfunctioning Bring the vehicle to an authorized dealer for service Components of the DDEC ECU and or DDEC VCU are damaged Bring the vehicle to an authorized dealer for service Problem Cruise Control Is Not Work...

Page 64: ... Remedy The poly V belt is too loose Check the belt tension if necessary have an authorized dealer replace the belt tensioner The belt tensioner is damaged Have an authorized dealer replace the belt tensioner The poly V belt is worn or damaged Replace the belt The alternator is damaged has a damaged rectifier or voltage regulator Have an authorized dealer replace the alternator 54 All information ...

Page 65: ...f you are 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 Fuel added from drums or cans could be contaminated This could lead to malfunctions in the fuel system Always filter the fuel before adding it to the tank Ensure there is no water in the fuel For information about fuel...

Page 66: ... CI 4 Plus quality engine oils 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 Figure 27 API Lubricant Service Mark When maintenance work is performed record engine oil changes including details of the brand used the quality category and the So...

Page 67: ... and 50 percent antifreeze but under extreme cold weather conditions as much as 60 percent antifreeze can be added For reasons of anticorrosion protection and to raise the boiling point the coolant with a minimum 50 of antifreeze must remain in the cooling system all year round Regardless of mileage replace the coolant every two years since the degree of corrosion protection gradually drops with t...

Page 68: ...stem use only an approved corrosion inhibiting antifreeze Approved antifreeze must be fully formulated and comply with the requirements of the Truck Maintenance Council TMC Coolant specifications are listed in Table 2 Detroit Diesel POWER COOL products meet these specifications and are recommended Coolant Concentration When topping off the cooling system after a drop in the coolant level the conce...

Page 69: ...tion for cooling system components The coolant must be maintained with the proper concentration of SCA Detroit Diesel POWER COOL maintenance SCAs are recommended NOTICE Failure to properly maintain coolant with SCA can result in damage to the cooling system and its related components Conversely over concentration of SCA inhibitor can result in poor heat transfer leading to engine damage Always mai...

Page 70: ... the best method of disposal A modern engine coolant has complex tasks to perform Do not allow any form of reprocessing which consists only of mechanical purification Cold Weather Products Special precautions must be taken during cold weather To protect your engine take the following special measures in cold weather Use special cold weather fuel and engine oil Check the concentration of antifreeze...

Page 71: ...m the SAE viscosity class which corresponds to the outside temperatures anticipated during this period of operation See Figure 28 Figure 28 Engine Oil Temperature Ranges Winter Coolant Antifreeze Protection Before the temperature dips below freezing check the concentration of antifreeze in the coolant If necessary increase it Do not increase the proportion mixing ratio of corrosion inhibiting anti...

Page 72: ...xample at 10 C 14 F 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 62 All information subject to change without notice Rev DDC SVC MAN 0055 Copyright 2009 DETROIT DIESEL CORPORATION ...

Page 73: ... liters 389 in 6 37 liters 439 in 7 2 liters Compression Ratio 18 0 1 17 5 1 Starting Speed Approximately 100 rpm Direction of Engine Rotation viewed from flywheel Counterclockwise Starter Electric Motor Cold Start Temperature Limit Without starting aids and with battery 75 charged The engine starts quickly without additional cold start device in temperatures down to 15 C 5 F An optional grid heat...

Page 74: ...mm 48 in B 686 mm 27 in B 810 mm 31 9 in C 1000 mm 39 4 in C 1060 mm 41 7 in Table 6 Engine Dimensions Figure 29 Engine Measurements Side View Figure 30 Engine Measurements Front View Description 4 Cylinder Engine 6 Cylinder Engine Coolant Capacity Max 8 L 8 5 qt Max 12 5 L 13 2 qt Lubricating Oil Capacity Max 15 8 L 16 7 qt Max 29 L 30 6 qt Does not include capacity of cooling system For standard...

Page 75: ...1219 mm 48 0 in B 686 mm 27 0 in B 810 mm 31 9 in C 925 mm 36 4 in C 940 mm 37 0 in Table 9 Engine Dimensions Figure 31 Engine Measurements Side View Figure 32 Engine Measurements Front View Description 4 Cylinder Engine 6 Cylinder Engine Coolant Capacity Max 8 5 L 9 0 qt Max 12 5 L 13 2 qt Lubricating Oil Capacity Max 15 8 L 16 7 qt Max 29 0 L 30 6 qt Does not include capacity of cooling system F...

Page 76: ...32 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 85 C 177 to 185 F Fully open 95 C 203 F Minimum lift 8 mm 0 3 in Table 13 Coolant Thermostat Opening Pressure Value in kPa psi Minimum opening pressure 24 497 3 553 Maximum opening ...

Page 77: ...al if a warranty claim has to be submitted If optional equipment is installed be sure to comply with the maintenance requirements for these extra items Important If the engine is stored for more than 18 months the oil must be changed before the engine can be brought into service Maintenance Schedule Types There are five types of maintenance schedule Schedule I Severe Service Schedule II Short Haul...

Page 78: ...tenance Schedule and Interval Operations The three different schedules of vehicle usage severe short haul and long haul are listed in Table 15 For each schedule the appropriate distance interval in miles and kilometers is given for performing and repeating each maintenance operation The descriptions of all maintenance operations indicating all maintenance operation sets at which each operation mus...

Page 79: ...led 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 Complete each Maintenance Operation Set at th...

Page 80: ...906 926 24 000 904 906 926 Maint 2 M2 every 60 000 96 500 Schedule II Short Haul vehicles that annually travel up to 60 000 miles 96 500 km Maint 3 M3 every 75 000 121 000 Maint 1 M1 every 20 000 904 906 926 32 000 904 906 926 Maint 2 M2 every 60 000 96 500 Schedule III Long Haul vehicles that annually travel more than 60 000 miles 96 500 km Maint 3 M3 every 80 000 129 000 Table 15 Maintenance Sch...

Page 81: ...00 110 000 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 All information subject to c...

Page 82: ... 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 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 17 Maintenance Intervals for Schedule II Short Haul 72 All i...

Page 83: ...0 354 000 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 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 18 Maintenance Intervals for Schedule III Long H...

Page 84: ...MAINTENANCE Figure 33 Oil Drain Interval Operating Hours vs Fuel Consumption 74 All information subject to change without notice Rev DDC SVC MAN 0055 Copyright 2009 DETROIT DIESEL CORPORATION ...

Page 85: ...sh 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 If oil drain intervals are measured by operating hours an extension of the...

Page 86: ... Change oil and oil filter Table 21 UNIMOG Service Intervals 200 1400 Operating Hours Operating Hours Component Maintenance 2 100 2 800 3 500 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 22 UNIMOG ...

Page 87: ...Table 23 UNIMOG Service Intervals 4200 5600 Operating Hours Operating Hours Component Maintenance 6 300 7 000 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 24 UNIMOG Service Intervals 6300 7000 Oper...

Page 88: ...all lines and hoses Listen for any sound of leaking Make sure all pipes and hoses are undamaged correctly positioned to avoid chafing and properly secured Valve Lash Checking and Adjusting Important Adjust the valve lash when the engine is cold Wait at least 30 minutes after shutdown even if the engine ran only a short time The special tool listed in Table 25 is required for this procedure Tool De...

Page 89: ...e inspection hole on the timing case see Figure 35 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...

Page 90: ...he 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 open and show no measurable play when tested with a feeler gauge 2 Check each valve and adjust it if necessary using the procedures under the headings Checking Valve Lash and Adjusting Valve Lash in this section Engine Cra...

Page 91: ...g device turn the crankshaft until cylinder 6 cylinder 4 on the four cylinder engine is at the ignition TDC position all valves are closed and cylinder 1 is at the valve overlap position valves are open 4 Using the same procedure check the valves listed in Table 27 in the Valve Overlap row and adjust them if necessary using the procedures under the headings Checking Valve Lash and Adjusting Valve ...

Page 92: ...isted 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 37 Intake Valves Figure 38 Exhaust Valves Valve Type Check For Adjust to Intake 0 30 to 0 60 mm 0 012 to...

Page 93: ...nspection hole in the timing case 3 Replace the end cover on the inspection hole and tighten the bolts 25 N m 18 lb ft 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 2 Clean the outside of the prefilter housing Keep fuel away from hoses or pipes located beneath the filter See ...

Page 94: ...on the high pressure lines is critical Incorrect torques could result in leaks or lack of power due to restricted fuel flow a Make sure that all high pressure lines have been tightened to 25 N m 18 lb ft and all banjo bolts to 40 N m 30 lb ft 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 crank...

Page 95: ...e filter element twist the lower edge of the filter element to one side NOTICE To prevent damage to the filter housing do not allow dirt to get into the filter housing Do not empty the dirt collector into the filter case 5 Pull the dirt collector out of the filter housing using the tabs on either side Figure 42 Main Fuel Filter 6 Clean the cap and the dirt collector 7 Replace the O ring 8 Install ...

Page 96: ...gine should start within four 30 second attempts 12 Start the engine Check the fuel filter for leaks Engine Oil and Filter Changing FIRE To avoid injury from fire keep open flames sparks electrical resistance heating elements or other potential ignition sources away when draining lubrication oil Do not smoke when draining lubricating oil NOTE Select the SAE class viscosity on the basis of the aver...

Page 97: ... in neutral and set the parking brake NOTE Change the engine oil only when the engine is at an operating temperature of approximately 82 C 180 F 2 Using a 36 mm socket unscrew the oil filter cap See Figure 44 Figure 44 Oil Filter Cap 3 Place a suitable receptacle beneath the oil drain plug on the underside of the oil pan Carefully unscrew the oil drain plug on the oil pan and allow the oil to drai...

Page 98: ...m 18 lb ft 8 Install the oil drain plug using a new O ring Tighten the plug 65 N m 48 lb ft 9 Add new engine oil through the oil fill see Figure 47 Figure 47 Oil Fill PERSONAL INJURY To avoid injury from slipping and falling immediately clean up any spilled liquids NOTE Engine oil fill capacity with a standard oil pan for the six cylinder engine is 30 6 quarts 29 0 L For the four cylinder engine w...

Page 99: ...ary 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 cartridge side of engine must be replaced at each oil drain interval Change the oil centrifuge cartridge as follows 1 Remove the cover of the oil centrifuge See Figure 4...

Page 100: ...oncentration is lower than 50 by volume drain coolant add antifreeze until the concentration is correct The coolant mixing ratio is listed in Table 29 NOTE Concentrations of more than 55 by volume should not be used as this is the level which affords the maximum antifreeze protection down to 45 C 49 F Higher concentrations adversely affect heat dissipation Antifreeze Protection Down to C F Water P...

Page 101: ...pe Set the cap aside 2 Open the water regulating valve for the heating system 3 Drain the coolant from the engine See Figure 50 Coolant system capacity is listed in Table 30 a Place a receptacle underneath the coolant drain plug Choose one that is large enough to hold the expected quantity of coolant Figure 50 Coolant Drain Plug NOTE Make sure the coolant can flow unobstructed into the receptacle ...

Page 102: ...il the maximum mark on the surge tank is reached Coolant system capacity is listed in Table 30 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 ...

Page 103: ...e 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 out...

Page 104: ...d good will of the owners of Detroit Diesel engines are of primary concern to Detroit Diesel Corporation and its distributor dealer organizations 94 All information subject to change without notice Rev DDC SVC MAN 0055 Copyright 2009 DETROIT DIESEL CORPORATION ...

Page 105: ...887 WESTERN REGION 1 Irvine California 7700 Irvine Center Suite 275 Irvine CA 92618 Telephone 949 753 7710 Fax 949 753 7711 WESTERN REGION 2 Irvine California 7700 Irvine Center Suite 275 Irvine CA 92618 Telephone 949 753 7710 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 All information...

Page 106: ...01 Phone 313 592 7806 Fax 313 592 5137 POWERGEN AND OIL FIELD SALES BX11 13400 Outer Drive West Detroit MI 48239 4001 Phone 313 592 5708 Fax 313 592 5158 GOVERNMENT SALES BX9 13400 Outer Drive West Detroit MI 48239 4001 Phone 313 592 5875 Fax 313 592 5158 CUSTOMER ASSURANCE M24 13400 Outer Drive West Detroit MI 48239 4001 Phone 313 592 5550 Fax 313 592 5717 96 All information subject to change wit...

Page 107: ...ff Highway Victoria Melbourne 488 Blackshaws Road Altona North Victoria 3025 Australia Phone 61 3 9243 9292 Fax 61 3 9243 9271 MTU ASIA PTE LTD Off Highway Singapore No 1 Benoi Place Singapore 629923 Phone 65 6861 5922 Fax 65 6861 3615 Sales Marine Rail C I Electronics Fax 65 6860 9959 Sales PowerGen Defense MEXICO On Off Highway Detroit Diesel Allison de Mexico S A Av Santa Rosa 58 Col Ampliacion...

Page 108: ...following procedure to use if you have a problem that has not been handled satisfactorily Step One Discuss your problem with a member of management from the authorized service outlet Frequently complaints are the result of a breakdown in communication and can quickly be resolved by a member of management If you have already discussed the problem with the Sales or Service Manager contact the Genera...

Page 109: ...13400 Outer Drive West Detroit Michigan 48239 4001 Phone 1 313 592 5000 Fax 1 313 592 7244 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 experien...

Page 110: ...l 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 may at its discretion replace rather than repair components A reasonable time must be allowed to perform the warranty repair after taking the...

Page 111: ...ining warranty coverage Service Supplies The cost of service supplies such as coolant oil and filters which are 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 This Warranty Does Not Cover Repairs Due to Acciden...

Page 112: ...ses 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 THIS WARRANTY AND THE EMISSIONS CONTROL WARRANTY ARE THE ONLY WARRANTIES APPLICABLE TO THE ENGINE AS USED IN ON HIGHWAY VEHICLE APPLICAT...

Page 113: ...airs 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 may at its discretion replace rather than repair components A reasonable time must be allowed to perform the warranty repair after taking the engine to the authorized service outlet The ow...

Page 114: ...anty Like Replacement Engine Engine s supplied by DDC as a replacement for an engine still under warranty will assume the identity of the engine being replaced and be entitled to the remaining warranty coverage Engine Removal and Reinstallation Reasonable labor costs for engine removal and reinstallation when necessary to make a warranty repair are covered by this warranty This Warranty Does Not C...

Page 115: ...ce 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 THIS WARRANTY AND THE EMISSIONS CONTROL WARRANTY ARE THE ONLY WARRANTIES APPLICABLE TO THE ENGINE AS USED IN SCHOOL BUS APPLICATIONS DETROIT DIESEL CORPORATION MAKES N...

Page 116: ...n 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 may at its discretion replace rather than repair components A reasonable time must be allowed to perform the warranty repair after t...

Page 117: ...emaining warranty coverage Service Supplies The cost of service supplies such as coolant oil and filters which are 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 This Warranty Does Not Cover Repairs Due to Acci...

Page 118: ...ses 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 THIS WARRANTY AND THE EMISSIONS CONTROL WARRANTY ARE THE ONLY WARRANTIES APPLICABLE TO THE ENGINE AS USED IN FIRE TRUCK OR CRASH VEHICLE...

Page 119: ... 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 may at its discretion replace rather than repair components A reasonable time must be allowed to perform the warranty repair after taking the engine to the authorized service outlet The owner ...

Page 120: ...titled to the remaining warranty coverage Service Supplies The cost of service supplies such as coolant oil and filters which are 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 This Warranty Does Not Cover Repa...

Page 121: ...ance 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 THIS WARRANTY AND THE EMISSIONS CONTROL WARRANTY ARE THE ONLY WARRANTIES APPLICABLE TO THE ENGINE AS USED IN UNIMOG APPLICATIONS DETROIT DIESEL CORPORATION MAKES NO ...

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