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TABLE OF CONTENTS
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
TROUBLESHOOTING ......................................................................... 43
EMERGENCY STARTING ............................................................... 43
TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL
SYSTEM .......................................................................................... 43
GENERAL TROUBLESHOOTING ................................................... 43
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
CAUTION SUMMARY
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.
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.
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.
Electrical System
Observe the following cautions when
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.
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.
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
Observe the following cautions when
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
flames, sparks, and electrical
resistance heating elements. Do
PERSONAL INJURY
not smoke when refueling.
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.
FIRE
To avoid injury from fire caused
by heated diesel-fuel vapors:
To prevent a buildup of
potentially volatile vapors,
keep the engine area well
ventilated during operation.
Compressed Air
Observe the following cautions when
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.
Observe the following cautions when
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
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.
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.
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.
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.
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.
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
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.
Figure 19 Sensor Location on the Right Side of the MBE 900 EGR Engine
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.
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
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
Figure 23 Oil Fill Collar
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.
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.
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
flames, sparks, and electrical
Battery Charge resistance heating elements. Do
not smoke when refueling.
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.
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).
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.
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
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.
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.
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.
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
FIRE
To avoid increased risk of a fuel
fire, do not mix gasoline and
diesel fuel.
TECHNICAL DATA
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.)
Figure 30 Engine Measurements
Table 6 Engine Dimensions (Front View)
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.)
Figure 32 Engine Measurements
Table 9 Engine Dimensions (Front View)
Condition Specification
Starts to open 81 to 85C (177 to 185F)
Fully open 95C (203F)
Minimum lift 8 mm ( 0.3 in.)
MAINTENANCE
Maintenance
Maint. No Miles Km
Interval
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.
Maintenance
Maint. No. Miles Km
Interval
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
* 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.
Maintenance
Maint. No Miles Km
Interval
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
* 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.
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
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
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
Operating Hours
Component Maintenance
4,200 4,900 5,600
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
Operating Hours
Component Maintenance
6,300 7,000
Engine Change oil and oil filter Every 200 hours
Fuel System Change filter and vent system
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.
Engine Cranking
Kent-Moore J-46392
Tool
NOTE:
Clean the cylinder head cover before
removing it.
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
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).
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.
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).
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:
Corrosion-Inhibiting
Antifreeze
Water Percentage Antifreeze
Protection Down
by Volume Percentage by
toC (F)
Volume
37 (347) 50 50
45 (49) 45 Maximum 55
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.
by volume of corrosion-inhibiting
antifreeze.
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
Figure 50 Coolant Drain Plug
at operating temperature. Wear
adequate protective clothing
NOTE:
(face shield, rubber gloves,
Make sure the coolant can flow
apron, and boots). Remove the
unobstructed into the receptacle.
cap slowly to relieve pressure.
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.
HOT COOLANT
To avoid scalding from the
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
cap slowly to relieve pressure.
NOTE:
Before doing this inspection, make
sure to do either maintenance
operation, "Coolant Concentration
Checking," or maintenance operation,
"Coolant Flushing and Changing."
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
Step Three
If you are still not satisfied, present the
entire matter in writing or by phone to:
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
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.
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
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 0-60 No Charge No Charge
0-240,000 km
0-100,000 mi
Accessories 0-24 No Charge No Charge
0-160,000 km
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.
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 0-60 No Charge No Charge
0-240,000 km
0-100,000 mi
Accessories 0-24 No Charge No Charge
0-160,000 km
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.
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
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
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.