MBE 900 – Section 13.1 Scheduled Intervals

Section 13.1
Scheduled Intervals

When performed on a regular basis, changing the engine oil and filters is the least costly way of obtaining safe and reliable vehicle operation. Added benefits and savings occur when you check that the valves, fuel injectors, and oil and cooling circuits are in good working order during oil changes.‪

The maintenance section of this manual explains when you should change your oil and what to look for when checking for wear or damage.‪

All service intervals and maintenance operations are based on the parts and accessories expressly approved for your engine.‪

The scope and frequency of maintenance work are determined by the engine's operating conditions: severe duty, short haul, or long haul.‪

Evidence of regular maintenance is essential 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.‪

Note: If the engine is stored for more than 18 months, the oil must be changed before the engine can be brought into service.

Section 13.1.1
Maintenance Schedule Types

All service intervals and maintenance operations are based on the parts and accessories expressly approved for your engine.‪

• Schedule I (Severe Service) — Severe service applies to vehicles that annually travel up to 6,000 miles (9,650 kilometers) or that operate under severe conditions. Examples of Severe Service usage include: operation on extremely poor roads or where there is heavy dust accumulation; constant exposure to extreme hot, cold, salt-air, or other extreme climates; frequent short-distance travel; construction-site operation; city operation (fire truck, garbage truck); or farm operation.
• Schedule II (Short Haul) — Short haul applies to vehicles that annually travel up to 60,000 miles (96,500 kilometers) and operate under normal conditions. Examples of Short-Haul usage are: operation primarily in cities and densely populated areas; local transport with infrequent freeway travel; or high percentage of stop-and-go travel.
• Schedule III (Long Haul) — Long Haul (over-the-road transport) is for vehicles that annually travel more than 60,000 miles (96,500 kilometers), with minimal city or stop-and-go operation. Examples of Long-Haul usage are: regional delivery that is mostly freeway miles; interstate transport; or any road operation with high annual mileage.

Section 13.1.1.1
Maintenance Schedule and Interval Operations

The three different schedules of vehicle usage (severe, short haul, and long haul) are listed in Table "Maintenance Schedule Table" . For each schedule, the appropriate distance interval (in miles and kilometers) is given for performing and repeating each maintenance operation.‪

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

The descriptions of all maintenance operations, indicating all maintenance operation sets at which each operation must be performed are listed in Table "Maintenance Intervals for Schedule I, Severe Service" , listed in Table "Maintenance Intervals for Schedule II, Short Haul" , and listed in Table "Maintenance Intervals for Schedule III, Long Haul" .‪

The three maintenance interval tables show which maintenance operation must be performed at the actual distances (in miles or kilometers) for each maintenance operation (M1–M3). The schedule of actual distances is based on the intervals given in the Maintenance Schedule Table.‪

Maint. No‪	Maintenance Interval‪	Miles‪	Km‪
1‪	M1*‪	6000‪	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 an oil centrifuge filter to meet the above intervals, the cartridge in the centrifuge has the same interval as the primary oil filter. 4–cylinder engines do not use the oil centrifuge.

Maint. No.‪	Maintenance Interval‪	Miles‪	Km‪
1‪	M1*‪	15,000‪	24,000‪
2‪	M1‪	30,000‪	48,000‪
3‪	M1‪	45,000‪	72,000‪
4‪	M1 and M2‪	60,000‪	96,500‪
5‪	M1and 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	240,000‪
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 an oil centrifuge filter to meet the above intervals, the cartridge in the centrifuge has the same interval as the primary oil filter. 4–cylinder engines do not use the oil centrifuge.

Maint. No‪	Maintenance Interval‪	Miles‪	Km‪
1‪	M1*‪	20,000‪	32,000‪
2‪	M1‪	40,000‪	64,000‪
3‪	M1 and M2‪	60,000‪	96,500‪
4‪	M1 and M3‪	80,000‪	128,000‪
5‪	M1‪	100,000‪	160,000‪
6‪	M1 and M2‪	120,000‪	193,000‪
7‪	M1‪	140,000‪	225,000‪
8‪	M1 and M3‪	160,000‪	257,000‪
9‪	M1 and M2‪	180,000‪	290,000‪
10‪	M1‪	200,000‪	322,000‪
11‪	M1‪	220,000‪	354,000‪
12‪	M1,M2 and M3‪	240,000‪	386,000‪
13‪	M1‪	260,000‪	418,000‪
14‪	M1‪	280,000‪	450,000‪
15‪	M1 and M2‪	300,000‪	482,000‪
16‪	M1 and M3‪	320,000‪	515,000‪

* 6–cylinder engines use an oil centrifuge filter to meet the above intervals, the cartridge in the centrifuge has the same interval as the primary oil filter. 4–cylinder engines do not use the oil centrifuge.

Section 13.1.1.2
Maintenance Operation Sets

Each Maintenance Operations Sets Table (M1 through M3) lists the descriptions of only those maintenance operations that must be performed at that maintenance operation set. Each maintenance operation set is listed in a separate Maintenance Operations Table.‪

The description of all maintenance operations, and the maintenance operation sets at which each operation must be performed are listed in Table "Required Maintenance Operations Sets, Schedule I" and listed in Table "Required Maintenance Operations Sets, Schedule II and III" .‪

Operation Description‪		M1‪	M2‪
	Engine Inspecting‪	√‪	√‪
	Oil Centrifuge Cartridge (906 and 926)‪	√‪	√‪
	Fuel Pre-Filter Element Cleaning‪	‪	√‪
	Main Fuel Filter Element Changing‪	‪	√‪
	Engine Oil and Filter Changing‪	√‪	√‪
	Coolant Concentration Checking‪	√‪	√‪
	Coolant Flushing and Changing‪	‪	√‪
	Cooling System Inspecting‪	√‪	√‪

Maintenance Operation Description‪		M1‪	M2‪	M3‪
	Engine Inspecting‪	‪	√‪	√‪
	Valve Lash Checking and Adjusting‪	‪	‪	√‪
	Fuel Pre-Filter Element Cleaning‪	‪	√‪	√‪
	Main Fuel Filter Element Changing‪	‪	√‪	√‪
	Engine Oil and Filter Changing‪	√‪	√‪	√‪
	OIl Centrifuge Cartridge (906 and 926)‪	√‪	√‪	√‪
	Coolant Concentration Checking‪	‪	√‪	√‪
	Coolant Flushing and Changing‪	‪	‪	√‪
	Cooling System Inspecting‪	‪	√‪	√‪

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

Section 13.1.2
Fuel Pre-Filter Element Cleaning

Clean the fuel pre-filter 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 pre-filter housing. Keep fuel away from hoses or pipes located beneath the filter. See Figure "Fuel Filters" .
   

   1. Main Fuel Filter‪

   2. Fuel Pre-Filter‪

   Figure 1. Fuel Filters

3. Unscrew the cap on the fuel pre-filter. Pull the cap and filter element out of the pre-filter housing. See Figure "Fuel Pre-Filter" .
   

   1. Cap (pre-filter)‪	3. Filter Element‪
   2. O-ring‪	4. Filter Housing‪

   Figure 2. Fuel Pre-Filter

4. Clean the cap and the filter element. If the filter element is heavily soiled or damaged, replace it.
5. Check the O-ring on the cap and replace it if necessary.
6. Insert the filter element into the pre-filter housing and screw the cap onto the housing. Tighten the cap 25 N·m (18 lb·ft).
7. Bleed the fuel system.

   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.‪

   PERSONAL INJURY ‪
   To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.‪

   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.‪ Always start and operate an engine in a well ventilated area. If operating an engine in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system or emission control system.

   1. 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).
   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 engine again, wait at least two minutes. The engine should start within four 30-second attempts.

Section 13.1.3
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.
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 short distance out of the filter housing. Allow the fuel to drain off the filter into the housing.
4. Remove the cap with the filter element. To release the 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. See Figure "Main Fuel Filter" .
   

   1. Cap (main filter)‪	4. Dirt Collector‪
   2. O-ring‪	5. Filter Housing‪
   3. Filter Element‪

   Figure 3. Main Fuel Filter

6. Clean the cap and the dirt collector.
7. Replace the O-ring.
8. Install the new filter element in the cap. Make sure the filter element is securely in place.
9. Insert the dirt collector into the filter housing. Make sure the dirt collector is positioned properly in the filter housing.
10. Screw on the cap with the filter element. Tighten the cap 25 N·m (18 lb·ft).

    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.‪

11. Bleed the fuel system.

    PERSONAL INJURY ‪
    To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.‪

    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.‪ Always start and operate an engine in a well ventilated area. If operating an engine in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system or emission control system.

    1. 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).
    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 engine again, wait at least two minutes. The engine should start within four 30-second attempts.
12. Start the engine. Check the fuel filter for leaks.

Section 13.1.4
Engine Oil and Filter Changing

Select the SAE class (viscosity) on the basis of the average air temperature for the anticipated ambient temperature range that the engine will start and operate. See Figure "SAE Oil Viscosity Classes" .‪

Figure 4. SAE Oil Viscosity Classes

To insure the engine is protected and the oil stays clean until the next oil change, use only oils of API classification CI-4.‪

Drain the oil as follows:‪

Note: SAE viscosity grade 15W-40 is the recommended oil grade.

PERSONAL INJURY ‪
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.‪

1. Chock the tires, place the transmission in neutral, and set the parking brake.

   Note: Change the engine oil only when the engine is at an operating temperature of approximately 180°F (82°C).

2. Using a 36-mm socket, unscrew the oil filter cap.
   

   Figure 5. Oil Filter Cap

   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.‪

3. Drain the oil. See Figure "Engine Oil Drain Plug, Oil Pan" .
   1. Place a suitable receptacle beneath the oil drain plug on the underside of the oil pan.
   2. Carefully unscrew the oil drain plug on the oil pan and allow the oil to drain out.
   3. Discard the O-ring on the oil drain plug.
   

   Figure 6. Engine Oil Drain Plug, Oil Pan

4. Remove both the filter cap and the filter element. See Figure "Cap with Oil Filter Element" . To release the filter element, twist the lower edge of the filter element to the side.
   

   1. Cap‪	3. Filter Element‪
   2. O-ring‪

   Figure 7. Cap with Oil Filter Element

   NOTICE:
   To prevent damage to the filter housing, ensure that no foreign objects get inside it. Do not wipe clean the filter housing.‪

5. Replace the O-ring on the cap. See Figure "Cap with Oil Filter Element" .
6. Install the new filter into the cap. Make sure the filter element is securely in place.
7. Screw the cap onto the oil filter housing. Tighten the cap 25 N·m (18 lb·ft).
   

   1. Cover‪	3. Seal Ring‪
   2. Spinner cartridge‪	4. Oil Centrifuge Housing‪

   Figure 8. Oil Centrifuge and Cartridge

8. Remove the cover and seal ring from the oil centrifuge. Discard seal ring. See Figure "Oil Centrifuge and Cartridge" .
9. Remove the dirty cartridge and replace it with a clean one. See Figure "Oil Centrifuge and Cartridge" .
10. Replace the centrifuge cover and new seal ring. Tighten cover to 40 N·m (30 lb·ft).
11. Install the oil drain plug, using a new O-ring. Tighten the plug 65 N·m (48 lb·ft).
12. Add new engine oil through the oil fill. See Figure "Oil Fill Collar" .
    

    Figure 9. Oil Fill Collar

    PERSONAL INJURY ‪
    To avoid injury from slipping and falling, immediately clean up any spilled liquids.‪

    Note: The engine oil fill capacity with standard oil pan, including oil filter, for the six-cylinder engine is 29.0 Liters (30.6 qt) . For the four-cylinder engine, oil fill capacity is 15.8 Liter (16.7 qt).

13. Fill until the maximum fill level on the oil dipstick has been reached. Do not overfill.

    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.‪ Always start and operate an engine in a well ventilated area. If operating an engine in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system or emission control system.

    NOTICE:
    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.‪

14. Start the engine with the accelerator pedal in the idle position. Monitor the oil pressure gauge.
15. Check the filter and oil drain plug for signs of leakage.
16. Stop the engine.
17. Check the oil level again after approximately five minutes. If necessary, add oil up to the maximum fill level on the oil dipstick. Do not overfill.

Section 13.1.5
Coolant Concentration Checking

Check coolant concentration as follows:‪

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.‪

1. Open the cap on the surge tank slowly, to allow excess pressure to escape. Set the cap aside.

   Note: Check and correct the coolant level only when the coolant temperature is below 122°F (50°C).

2. Before adding coolant, use a suitable tester to check the concentration of corrosion-inhibiting antifreeze. If the concentration is lower than 50% by volume, add antifreeze until the concentration is correct. The coolant mixing ratio is listed in Table "Coolant Mixing Ratio" .

   Antifreeze Protection Down to °F (°C)‪	Water Percentage by Volume‪	Corrosion-Inhibiting Antifreeze Percentage by Volume‪
   –34 (–37)‪	50‪	50‪
   –49 (–45)‪	45‪	Maximum 55*‪

   Table 26. Coolant Mixing Ratio
   
   *Concentrations of more than 55% by volume should not be used, as this is the level which affords the maximum antifreeze protection, down to -49°F (-45°C). Higher concentrations adversely affect heat dissipation.

   NOTICE:
   If the concentration of antifreeze is too low, there is a risk of corrosion or cavitation in the cooling system.‪

   Note: When topping off, use only a prepared coolant mixture containing a 50% concentration by volume of corrosion-inhibiting antifreeze.

3. Check the coolant level and add more coolant if necessary.
4. Close the cap on the surge tank.

Section 13.1.6
Coolant Flushing and Changing

Flush and change the coolant as follows:‪

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.‪

1. Open the cap on the surge tank slowly, to allow excess pressure to escape.

   PERSONAL INJURY ‪
   To avoid injury from scalding, drain the radiator when the engine and coolant are cool.‪

2. Drain the coolant from the engine. See Figure "Coolant Drain Plug" . Coolant system capacity is listed in Table "Coolant System Capacity" .
   

   Figure 10. Coolant Drain Plug

   System‪	Description‪	Capacity — 4–Cylinder‪ Liters (Quarts)‪	Capacity — 6–Cylinder‪ Liters (Quarts)‪
   Engine Coolant Capacity (all vehicles)‪	Engine capacity‪	8 (8.5)‪	12 (12.7)‪
   Business Class Coolant System Capacity‪	Total capacity‪	19.9 (20)‪	23.7 (25)‪
   	Antifreeze quantity at 50%‪	9.9 (10.5)‪	11.8 (12.5)‪
   	Antifreeze quantity at 55%‪	10.9 (11.5)‪	13.1 (13.8)‪

   Table 30. Coolant System Capacity
3. Flush the radiator.

   NOTICE:
   When flushing the radiator, do not apply more than 140 kPa (20 psi) air pressure. Excessive pressure can damage the radiator or heater core.‪

   1. Attach a flushing nozzle to the radiator outlet.
   2. Run water in until the radiator is full.

      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 pressure.‪

   3. Apply no more than 140 kPa (20 psi) air pressure intermittently to help dislodge sediment buildup in the core.
4. Drain the radiator, and flush the radiator until clean water flows from the radiator. Remove the flushing device.
5. When the coolant has drained, install the coolant drain plug on the radiator.
6. Add coolant in the specified concentration until the maximum mark on the surge tank is reached. Coolant system capacity is listed in Table "Coolant System Capacity" .

   PERSONAL INJURY ‪
   To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.‪

   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.‪ Always start and operate an engine in a well ventilated area. If operating an engine in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system or emission control system.

7. Start the engine and run it for 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.
8. Shut down the engine.
9. Add coolant if necessary.

Section 13.1.7
Cooling System Inspecting

Inspect the cooling system as follows:‪

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.‪

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 dirt or debris. Make sure the fins are not damaged, and straighten them if necessary.