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MBE 900 OPERATOR`S GUIDE

1. REPAIRS DUE TO ACCIDENTS MISUSE STORAGE DAMAGE NEGLIGENCE OR CERTAIN MODIFICATIONS MAINTENANGE orina Ri e tee d NR SERA UR INCIDENTAL OR CONSEQUENTIAL DAMAGES OTHER LIMITATIONS ana a nnne LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION 106 109 vii TABLE OF CONTENTS THIS WARRANTY DOES NOT COVER 112 REPAIRS DUE TO ACCIDENTS MISUSE STORAGE DAMAGE NEGLIGENCE OR CERTAIN MODIFICATIONS 112 113 INCIDENTAL OR CONSEQUENTIAL DAMAGES 113 OTHER LIMITATIONS emen 113 viii All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION CAUTION SUMMARY The following cautions must be observed by the operator of the vehicle or equipment in which this engine is installed and or by those performing basic engine preventive maintenance Failure to read and heed these cautions and exercise reasonable care for personal safety and the safety of others when operating the vehicle equipment or performing basic engine preventive maintenance may result in personal injury and en
2. Use special cold weather fuel and engine oil Check the concentration of antifreeze in your coolant Take special care of your batteries Winter Grade Diesel Fuel At low outside temperatures paraffin may separate from the diesel and affect its ability to flow freely Avoid breakdowns caused by this problem for example blocked filters by using cold resistant winter grade diesel fuel with improved low temperature flow characteristics In most cases winter grade fuel can be used without problems at cold outside temperatures If using summer grade fuel or a less cold resistant winter grade a flow improver or kerosene can be added with caution The amount needed depends on the outside temperature 61 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION SERVICE PRODUCTS A WARNING FIRE To avoid increased risk of a fuel fire do not mix gasoline and diesel fuel Flow improver or petroleum spirit must be mixed with diesel fuel before its flow characteristics have been adversely affected by paraffin separation If changes have already been caused by paraffin separation they can be corrected only by heating the entire fuel system Do not add anything to cold resistant winter grade diesel fuels The fuel s low temperature flow characteristics could actually deteriorate with additives Low Viscosity Engine Oil When changing the engine oil estimate the interval before
3. 58 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 time Fully Formulated Antifreeze Antifreeze approved for use in the MBE 900 engine is a mixture of glycol compounds either ethylene glycol or propylene glycol and corrosion inhibitors Antifreeze containing glycol compounds and corrosion inhibitors is known as fully formulated antifreeze Fully formulated antifreeze has the following properties It protects the radiator and engine from freezing It provides protection against corrosion and cavitation for all components in the cooling system It raises the boiling point of the coolant This slows the rate of evaporation avoiding coolant loss at high temperatures All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION Water Water containing no additives is not suitable as a coolant even if no antifreeze protection is needed The water used in the coolant must comply with certain requirements which are not always satisfied by drinking water If water quality is inadequate the water must undergo suitable treatment The following types of water are prefe
4. All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE OPERATION Important Before starting the engine noises or shows an unusual loss of do all the recommended pretrip power turn the engine off as soon inspections and daily maintenance as possible and determine the cause Check the engine oil and fuel levels Frequently engine damage may be and drain contaminants from the avoided by a quick response to early fuel water separator optional indications of problems 3 If you are starting the engine in cold Before Starting the Engine weather refer to Cold Weather Products in the Service Products NOTE section of this manual If you drain the fuel water separator completely you may have to prime the Checking the Batteries fuel system Use only batteries that have been Be sure you are familiar with all of correctly filled and serviced To the instruments gauges and controls provide corrosion protection apply which are needed to operate the dielectric grease part number engine 48 02349 000 liberally to the terminal pads Approved suppliers are Note especially the location and listed in Table 1 function of the following Oil Pressure Gauge Lubricant or Manufacturer Part Number Coolant Temperature Gauge a la No 71032 No Low Oil Pressure High Coolant Shell
5. Turbocharger Figure 10 Rear View of 4 Cylinder MBE 900 Non EGR Engine 20 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Engine Identification Number The engine identification numbers are lasered in large font onto an enlarged 902 914 00 310187 labeling surface on the rear right crankcase See Figure 11 Figure 12 Engine Identification Number The last six numbers are the serial numbers 310187 in Figure 12 See Figure 13 for an explanation of the first six numbers found in the Figure 11 Location of Engine engine identification number Identification Number See Figure 12 for an example of the numbers as they appear on the engine L ENGINE MODEL AND HP 4 4 CYL INLINE ENGINE 24 4 CYL INLINE 4 8L ENGINE 6 6 CYL INLINE ENGINE 26 6 CYL INLINE 7 2L ENGINE 0 4 CYL INLINE EGR ENGINE 2 6 CYL INLINE EGR ENGINE MBE 900 MBE 900 44345 Figure 13 Engine Identification All information subject to change without notice Rev 04 08 21 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION IDENTIFICATION NOTE In addition to the fourteen digit number etched on the crankcase there is a ten digit number used for warranty and service that is found on the DDEC ECU label The ten digit
6. certain special work must be carried out Refer to Storage under Cleaning and Storage All information subject to change without notice Rev 04 08 MBE 900 OPERATOR S GUIDE 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 NOTICE Do not rev the engine if the oil pressure gauge indicates no oil pressure To avoid engine damage shut down the engine if no oil pressure appears within approximately ten seconds Check to determine the cause of the problem 4 Monitor the oil pressure gauge immediately after starting the engine NOTE Do not place the engine under full load until it reaches operating temperature 35 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION OPERATION Monitoring Engine Operation While the engine is operating monitor the battery charge indicator light the oil pressure and avoid excessive idling Battery Charge The battery charge indicator light see Figure 25 must go out once the engine starts 41737 Figure 25 Battery Charge Indicator Light If the indicator light comes on while the engine is running do the following 36 WARNING FIRE
7. 48 The Engine Performs Poorly Does Not Develop Full Power in this section The air filter and or intake air system is clogged The engine performs poorly or does not develop full power 48 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Problem The Engine Performs Poorly Does Not Develop Full Power Check the air restriction indicator Clean the intake air system and replace the air filter if necessary The exhaust brake valve is Have an authorized dealer check the malfunctioning operation of the valve The fuel filter is clogged Replace the filter element There are other problems with the fuel Bring the vehicle to an authorized System dealer for service The valves are not adjusted properly Check the valve lash The air filter and or intake air system is clogged The coolant temperature sensor is Bring the vehicle to an authorized damaged or reading incorrectly dealer for service The fuel temperature sensor is Bring the vehicle to an authorized damaged or reading incorrectly dealer for service The engine oil temperature sensor is Bring the vehicle to an authorized damaged or reading incorrectly dealer for service The charge air temperature sensor Bring the vehicle to an authorized damaged or reading incorrectly dealer for service There are problems with the Bring the vehicle to an au
8. 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 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 pressure must not drop 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 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION Excessive Idling Never allow the engine to idle for more than 30 minutes Excessive idling can cause oil to leak from the turbocharger Changing the Idle Speed The rpm range of the MBE 900 engine is 600 rpm to 850 rpm if the parameters in the DDEC VCU are set to the default range Change the idling speed as follows 1 Turn the cruise control switch to the OFF position 2 To increase the idle speed push the Resume switch until the idle is fast enough 3 To decrease the idle speed push the Decel switch until the idle is slow en
9. and Figure 9 for a rear view of the 4 cylinder model All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE m UAI id eS 1 Turbocharger 7 EGR Mixer 2 Starter Motor 8 Oil Fill Cap 3 Flywheel Housing 9 Oil Filter 4 Exhaust Manifold 10 Turbocharger Compressor Out 5 EGR Cooler 11 Belt Tensioner Assembly 6 Cylinder Head Cover 12 Oil Pan Figure 5 Right Front View of the MBE 900 EGR Engine All information subject to change without notice Rev 04 08 15 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION IDENTIFICATION 1 Air Compressor 6 Oil Centrifuge 2 DDEC ECU 7 EGR Mixer 3 Fuel Filter 8 Oylinder Head Cover 4 Thermostat Housing 9 Flywheel Housing 5 Oil Fill Cap 10 Oil Pan Figure6 Left Rear View of the MBE 900 EGR Engine 16 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE q I 1023 bin ES 1 Fan 10 Cylinder Head Cover 2 Belt Tensioner 11 Fuel Filter 3 Alternator Pulley 12 Fuel Prefilter 4 Oil Filter 13 DDEC ECU 5 Turbo Compressor Out 14 Air Compressor optional 6 Intake Manifold Inlet 15 Power Steering Pump 7 Crankcase Breather 16 Oil Dipstick 8 Oil Fill Cap 17 Coolant Pump Pulley 9 I
10. for signs of leakage Figure 48 Oil Centrifuge 2 Lift out the dirty cartridge and replace it with a clean one 14 Check the oil level again after see Figure 49 approximately five minutes If necessary add oil up to the maximum fill level on the oil dipstick Do not overfill 13 Stop the engine 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 Ib ft Change the oil centrifuge cartridge as follows 90 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Coolant Concentration NOTE Checking Check and correct the coolant level only when the coolant temperature is Check coolant concentration as below 50 C 122 F follows 2 Before adding coolant use a suitable tester to WARNING HOT COOLANT To avoid scalding from the check the concentration of corrosion inhibiting antifreeze If the concentration is lower than 50 by volume drain coolant add antifreeze until the concentration is correct The coolant mixing ratio is listed in Table 29 expulsion of hot coolant never remove the cooling system pre
11. 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Problem The Coolant Temperature Is Below Normal The coolant temperature gauge and or Bring the vehicle to an authorized sensor is not reading correctly dealer for service The thermostat is damaged Have an authorized dealer replace the thermostat Bring the vehicle to an authorized dealer and have the fan hub checked Bring the vehicle to an authorized dealer and have the parameter settings reprogrammed in the DDEC ECU or DDEC VCU 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 tank is leaking Bring the vehicle to an authorized dealer EGR system has an internal leak A venice tern adtionasd The fan is not operating properly All information subject to change without notice Rev 04 08 1 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION TROUBLESHOOTING Problem There Is Coolant in the Engine Oil The cylinder head gasket is damaged Have an authorized dealer replace the head gasket The oil water heat exchanger is Have an authorized dealer replace the leaking heat exchanger Bring the vehicle to an authorized There is an internal coolant leak dealer for service Problem There Is Foam in the Engine Oil The oil level is too low or too high Correct the oil leve
12. 4 Shut down the engine 34 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 Fa N 1 Maximum Fill Level 2 Minimum Fill Level 41736 Figure 24 Oil Dipstick 6 Check all the mounting fasteners and belts on the engine for tightness Checking the Coolant Level Hot Check Check coolant level as follows 1 Allow the engine to run for approximately five minutes at a moderate speed All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION A WARNING 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 2 Then with the coolant temperature above 50 C 122 F recheck the coolant level 3 Add more coolant if necessary Open the heater valves before adding coolant 4 Do not close the heater valves until the engine has been run briefly and the coolant level again checked and corrected as necessary Starting an Engine That Has Not Been Run for an Extended Period Before starting an engine which has not been run for an extended period
13. MBE 900 ENGINES USED IN UNIMOG APPLICATIONS Warranty Period Warranty Limitations Repair Charges to Whichever Occurs First be Paid by Owner Miles Monts Hours Pars Engine Labor 24 Unlimited Unlimited No Charge Accessories 24 Unlimited Unlimited No Charge bi Charge Table 34 Warranty Period Chart UNIMOG Applications 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 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 112 This Warranty Does Not Cover Repairs Due to Accidents Misuse Storage Damage Negligence or Certain Modifications Repairs due to an accident misuse misapplication storage damage negligence or modification exceeding DDC specifications are not covered by this warranty All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION Maintenance DDC is not responsible for the cost of maintenance or repairs due to lack of perf
14. Oil Co 71306 Temperature Warning Light Texaco Inc No 955 Water In Fuel Warning Light Quaker State No NYK 77 Tachometer Air Restriction Indicator Table 1 Approved Electrical Lubricants When starting the engine and while driving watch for any signs of engine problems If the engine overheats uses excessive fuel or lubricating oil vibrates misfires makes unusual All information subject to change without notice Rev 04 08 3 1 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION OPERATION A WARNING n 1 Battery Explosion and Acid Burn To avoid injury from battery 1 2 explosion or contact with battery acid work in a well ventilated area wear protective clothing and avoid sparks or flames near 1 Maximum Fill Level the battery If you come in contact 2 Minimum Fill Level 41736 with battery acid Figure 22 Oil Dipstick Flush your skin with water Apply baking soda or lime to help neutralize the acid 2 If necessary top off by filling engine oil through the oil fill Flush your eyes with water collar see Figure 23 until the maximum fill level on the oil dipstick see Figure 22 has been reached For detailed procedures refer to the Maintenance Get medical attention immediately section Do not overfill Checking the Oil Level Check the oil level as follows 1 Check the oil level using the oil dipst
15. U S and Canada plus many outlets worldwide that are prepared to meet your parts and service needs Service by trained personnel Sales teams to help determine your specific power requirements In many areas emergency service 24 hours a day Complete parts support including reliabilt amp remanufactured parts Product information and literature We recognize however that despite the best intentions of everyone concerned misunderstandings may occur Normally any situation that arises in connection with the sale operation or service of your product will be handled by the authorized service outlet in your area in the U S and Canada check the Yellow Pages or service locator at www detroitdiesel com for the Detroit Diesel service outlet nearest you To further assure your complete satisfaction we have developed the following procedure to use if you have a problem that has not been handled satisfactorily 100 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 General Manager If your complaint originates with a dealer explain the matter to a management member of the distributorship with whom the dealer has his service agr
16. bus is a violation of Federal Law under the Clean Air Act This engine is certified to be operated on diesel fuel Figure 2 Emission Label 4 Cylinder EGR Engine All information subject to change without notice Rev 04 08 11 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION IDENTIFICATION See Figure 3 for the emission label for the 6 cylinder non EGR model Important Engine Information Ay DaimlerBenz AG Stuttgart Germany MercedesBenz Engine Model OM 906 LA CID 388 Engine Family Engine code XMBXH6 37DJA Code 1 Exhaust Emission Control System TC EMC CAC Date of engine manufacture 1998 Advertised Output SAE gr 209 kW 280 HP 2300 rpm Fuel rate at adv output 128 136 mm 9 stroke Valve lash cold ins 0 016 int 0 024 exh Basic injection timing 184 1 degrees BTDC Idle speed 600 50 rpm This engine conforms to U S EPA California and Canada regulations applicable to 1999 Model Year new heavy duty engines This engine has a primary intended service application as a medium HD diesel engine This engine is not certified for use in an urban bus as defined at 40 CFR 86 093 2 Sales of this engine for use in an urban bus is a violation Of Federal Law under the clean Air Act This engine is certified to be operated on diesel fuel Figure3 Emission Label Non EGR 6 Cylinder 12 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04
17. number is derived from the fourteen digit number see Figure 14 Description of the Engine All MBE 900 engines are water cooled four stroke direct injection diesel engines The cylinders are arranged inline on both the 6 cylinder and 4 cylinder models Each has a separate fuel injection pump unit pump with a short injection line to the injection nozzle which is located in the center of the combustion chamber The unit pumps are attached to the crankcase and are driven from the camshaft Each cylinder has two intake valves and one exhaust valve 902 914 00 310187 14 DIGIT ENGINE SERIAL NUMBER ETCHED ON THE CRANKCASE Figure 14 Engine Serial Number 22 Charge air cooling and an exhaust gas turbocharger are standard equipment on all MBE 900 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 system consists of an engine resident pump and nozzle control unit the DDEC ECU and a vehicle control unit the DDEC VCU The two are connected by a proprietary datalink Engine braking is controlled by a pneumatic and hydraulic 6 cylinder operated exhaust brake on the turbocharger and by a constant throttle system optional 0902 310187 10 DIGIT ENGINE SERIAL NUMBER LOCATED ON THE DDEC ECU LABEL 43775 All information
18. of the required maintenance and use of proper fuel oil lubricants and coolant are the responsibility of the owner Incidental or Consequential Damages Detroit Diesel Corporation is not responsible for incidental or consequential costs or expenses which the owner may incur as a result of a malfunction or failure covered by this warranty such as communication expenses meals lodging overtime towing loss of use of the engine or vehicle downtime loss of time inconvenience cargo loss or damage and other similar costs and expenses Other Limitations Performance of REPAIRS 15 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 All information subject to change without notice Rev 04 08 MBE 900 OPERATOR S GUIDE 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 NO OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE DETROIT DIESEL CORPORATION SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES AS DESCRIBED ABOVE Some states do not allow the limitation of how long this warranty may last or the limitation or exclusion of incidental o
19. steps in sequence when experiencing a problem All information subject to change without notice Rev 04 08 101 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900 ENGINES USED IN ON HIGHWAY VEHICLE APPLICATIONS LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900 ENGINES USED IN ON HIGHWAY VEHICLE APPLICATIONS Terms of Coverage Uses This warranty applies to the first retail purchaser and subsequent owners during the WARRANTY PERIOD of new Detroit Diesel MBE 900 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 on highway vehicle 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 102 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 responsibl
20. subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION The cylinder block has integrated oil and water channels The upper section of the cylinder bore is induction hardened The single piece cylinder head is made of cast iron The cylinder head gasket is a medal elastomere adjustment free seal with Viton sealing elements The pistons are made of aluminum alloy with a shallow combustion chamber recess The pistons are cooled by oil spray nozzles The crankshaft is precision forged with seven main bearings five on the 4 cylinder engine six of which have custom forged counterweights four on the 4 cylinder engine and a vibration damper at the front end The camshaft is made of case hardened steel and has seven main bearings five on the 4 cylinder engine Each cylinder has cams for intake and exhaust valves and a unit pump The valves are controlled by mushroom tappets pushrods and rocker arms The intake valves are opened and closed by a valve guided bridge There is a force feed lubricating oil circuit supplied by a rotary oil pump This pump is positioned at the front of the crankcase and driven by gears from the crankshaft All information subject to change without notice Rev 04 08 MBE 900 OPERATOR S GUIDE 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
21. 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 on the camshaft optional The vehicle is cooled by a closed system using recirculated coolant temperature is regulated automatically by a thermostat The alternator and coolant pump and any other accessories are driven by a belt with automatic belt tensioner Electrical equipment includes a starter and an alternator Exhaust Gas Recirculation The purpose of the Exhaust Gas Recirculation EGR System is to reduce engine exhaust gas emissions in accordance with EPA regulations The EGR system consists of an EGR cooler EGR valve reed valves on the MBE904 924 926 only and an EGR mixer The MBE 900 engines for on highway EPA 2004 regulation applications use a cooled EGR system 23 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION IDENTIFICATION Exhaust gases from the front three cylinders on six cylinder engines all four cylinders on four cylinder engines are routed from the exhaust manifold through the EGR cooler past control and reed valves and mixed with the intake manifold charge air The addition of cooled exhaust gases back into the combustion airflow reduces the peak in cylinder combustion temperature Less oxides of nitrogen NOx are produced at lower combustion temperatures Exhaust Brake Constant Thrott
22. your next oil change Choose an oil from the SAE viscosity class which corresponds to the outside temperatures anticipated during this period of operation See Figure 28 62 Engine oils SAE classifications Singlegrade oils Multigrade oils 41738 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 antifreeze beyond 55 percent by volume this gives the maximum antifreeze protection Further increases in the mixing ratio would reduce the level of antifreeze protection and adversely affect the coolant s ability to dissipate heat Batteries Batteries should receive more frequent maintenance and recharging during the cold season of the year All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Careful maintenance and low current consumption will help to maintain the full battery charge Starting capacity drops severely in cold weather For example 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
23. 0 6 Manm 193 000 Ls owes Ls ware we mee 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 Ill Long Haul 74 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE MBE904 MBE924 MBE906 MBE926 FUEL CONSUMPTION gal h e e N OPERATING HOURS h oco Figure 33 Oil Drain Interval Operating Hours vs Fuel Consumption All information subject to change without notice Rev 04 08 75 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MAINTENANCE Operation Descrintion Fuel Peter Eemer Cearna v Wain Fuel iter Element ave creona ans asno Engine Oil and Filter Changing Replace 906 and 926 Oil ze Centrifuge Cartridge Coolant Concentration Checking Coolant Flushing and Changing Cooling System Inspecting Table 19 Required Maintenance Operations Sets Schedule Maintenance Operation Description Wi M2 m3 Main Fuel Filter Element Changing Engine Oil and Filter Changing Replace 906 and 926 Oil Centrifuge Car
24. 0 32 000 Long Haul y 904 906 926 904 906 926 vehicles that Maint annually travel every 60 000 96 500 more than 60 000 miles Maint 96 500 km every 80 000 129 000 Table 15 Maintenance Schedule Table 1 1 2 2 1d 1 2 2 60 000 miles Maint 3 96 500 km every 75 000 121 000 1 1 2 2 3 3 All information subject to change without notice Rev 04 08 71 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MAINTENANCE Maintenance Interval M1 6 000 9 650 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 72 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Maintenance Interval M1 15 000 24 000 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 Il Short Haul All information subject to change without notice Rev 04 08 73 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MAINTENANCE Maintenance Interval M1 20 000 32 00
25. 0 50 to 0 80 0 020 to 0 032 0 60 0 024 Table 11 Valve Lash Checking and Adjustment At idling rpm 50 kPa 7 psi 250 kPa 6 pl Table 12 Engine Oil Pressure 81 to 85 177 to 185 Table 13 Coolant Thermostat Opening Pressure Value in kPa psi Minimum opening pressure 24 497 3 553 Maximum opening pressure 25 697 3 727 Table 14 Injector Pressure All information subject to change without notice Rev 04 08 67 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MAINTENANCE MAINTENANCE 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 For additional information please contact your regional office Scheduled Intervals 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 long haul or operating hours vs fuel consumption oil drain interval only Evidence of regular maintenance is essenti
26. 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE FRONT SIDE OF DDEC ECU UNIT 44150 1 EGR Temperature Sensor 4 Barometric Pressure Sensor integrated into DDEC ECU 2 Engine Coolant Temperature 5 Camshaft Position Sensor on Sensor camshaft 3 Supply Fuel Temperature Sensor 6 Crankshaft Position Sensor on timing case Figure 20 Sensor Location on the Left Side of the MBE 900 EGR Engine NOTE NOTE The 6 cylinder engine is shown The Barometric Pressure Sensor is sensor locations are similar on the integrated into the DDEC ECU 4 cylinder engine All information subject to change without notice Rev 04 08 29 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION IDENTIFICATION 4 FRONT SIDE OF DDEC ECU UNIT 43484 Engine Oil Pressure Temperature 5 Barometric Pressure Sensor Sensor integrated into DDEC ECU Engine Coolant Temperature 6 Camshaft Position Sensor on Sensor camshaft Intake Manifold Pressure Temper 7 Crankshaft Position Sensor on ature Sensor timing case Supply Fuel Temperature Sensor Figure 21 Sensor Location on the MBE 900 Non EGR Engine NOTE NOTE The 6 cylinder engine is shown The Engine Oil Level Sensor if used sensor locations are similar on the is located at the bottom of the oil pan 4 cylinder engine 30
27. 08 Copyright O 2008 DETROIT DIESEL CORPORATION See Figure 4 for the 4 cylinder non EGR model MBE 900 OPERATOR S GUIDE MercedesBenz Engine Model Engine Family Engine code Exhaust Emission Control System Date of engine manufacture Advertised Output SAE gr Fuel rate at adv output Valve lash cold ins Basic injection timing Idle speed Important Engine Information Ay DaimlerBenz AG Stuttgart Germany This engine conforms to U S EPA California and Canada regulations applicable to 2000 Model Year new heavy duty engines This engine has a primary intended service application as a medium HD diesel engine This engine is not certified for use in an urban bus as defined at 40 CFR 86 093 2 Sales of this engine for use in an urban bus is a violation of Federal Law under the Clean Air Act This engine is certified to be operated on diesel fuel 904 LA CID 259 YMBXH4 25DJA Code 1 TC EMC CAC 1999 142 kW 190 HP 2300 rpm 130 138 mm 7 stroke 0 016 int 0 024 exh 1941 degrees BTDC 700 50 rpm Figure4 Emission Label Non EGR 4 Cylinder Despite this the engine may constitute a risk of damage to property or injury to persons under the following conditions It is not used for its intended purpose It is modified or converted in an incorrect manner All information subject to change without notice Rev 04 08 The safety instructions included in this manua
28. 150 000 mi 0 240 000 km No Charge 0 100 000 mi 0 24 0 160 000 km No Charge Repair Charges to be Paid by Owner Labor No Charge No Charge Table 32 Warranty Period Chart School Bus Applications 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 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 106 This Warranty Does Not Cover Repairs Due to Accidents Misuse Storage Damage Negligence or Certain Modifications Repairs due to an accident misuse misapplication storage damage negligence or modification exceeding DDC specifications are not covered by this warranty All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION Maintenance DDC is not responsible for the cost of maintenance or repairs due to lack of performance of required maintenance services as recommended by DDC or the failure to use fuel oil lubricants and coolant meeting DDC recommended specifications Performance
29. 8 Copyright 2008 DETROIT DIESEL CORPORATION CLEANING AND STORAGE c Run the engine Allow the engine to warm up to approximately 80 C 176 F and then run it about five minutes longer d Drain the hot water 5 Fill the cooling system with new coolant For detailed procedures see the vehicle chassis maintenance manual For types of coolant refer to Coolant in the Service Products section Storage Required protective measures for the MBE 900 engine depend on the following The length of time that the engine will be out of service The climate and conditions where the engine is stored After cleaning engines should whenever possible be placed in a dry well ventilated area In all cases protect the engine against direct exposure to moisture rain splash water If the engine is to be out of service for 12 months or less anticorrosion measures are not necessary provided that the place of storage are dry and well ventilated as described above 42 If the engine is to be out of service for over 12 months or under extraordinary storage or transportation conditions then special protective measures are necessary Information is available from any authorized dealer It is strongly recommended that you request this information Important If the engine is to be out of service for over 18 months the oil must be changed before the engine can be brought back into service All i
30. All information subject to change without notice Rev 04 08 77 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION MAINTENANCE Operating Hours omponen aintenance Change oil and oil filter v Every 200 hours Fuel System Change filter and vent system fv vw memo Change oi rro nemis Charge oi ara ormer v C mece rea o e Table 23 UNIMOG Service Intervals 4200 5600 Operating Hours aint Operating Hours omponen aintenance Change oil and oil filter v Every 200 hours Fuel System Change filter and vent system v PTO Transmission Change oil and oil filter Change oil filter aba EIE sem Working Hydraulics Change oil and oil filter Table 24 UNIMOG Service Intervals 6300 7000 Operating Hours 78 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION Required Maintenance Operations MBE 900 OPERATOR S GUIDE 2 Visually inspect 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 The following sections describe the required maintenance operations listed in Table 19 and 20 Engine Inspecting Valve Lash Checking and Inspect the engine as follows Adjusting Important Adjust the valve lash when the engine is cold Wait at least 30 mi
31. BTDC 600 50 rpm This engine conforms to U S EPA California and Canada regulations applicable to 2004 Model Year new heavy duty engines This engine has a primary intended service application as a medium HD diesel engine This engine is not certified for use in an urban bus as defined at 40 CFR 86 093 2 Sales of this engine for use in an urban bus is a violation Of Federal Law under the clean Air Act This engine is certified to be operated on diesel fuel Figure 1 Emission Label 6 Cylinder EGR Engine 10 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Important Engine Information A DaimlerBenz AG Stuttgart Germany MercedesBenz Engine Model OM904LA CID 259 Engine Family Engine code 4MBXH4 25DJA Code 1 Exhaust Emission Control System TC EMC CAC EGR Date of engine manufacture 2004 Advertised Output SAE gr 170 HP 2200 rpm Fuel rate at adv output 128 4 mm 3 stroke Valve lash cold ins 0 016 int 0 024 exh Basic injection timing 11 1 BTDC Idle speed 700 50 rpm This engine conforms to U S EPA California and Canada regulations applicable to 2004 Model Year new heavy duty engines This engine has a primary intended service application as a medium HD diesel engine This engine is not certified for use in an urban bus as defined at 40 CFR 86 093 2 Sales of this engine for use in an urban
32. CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 42824 To the Operator This guide contains instructions on the safe operation and preventive maintenance of your Detroit Diesel MBE 900 engine Maintenance instructions cover routine engine services such as lube oil and filter changes in enough detail to permit self servicing if desired The operator should become familiar with the contents of this guide before operating the engine or carrying out maintenance procedures Power driven equipment is only as safe as the person operating the controls You are urged as the operator of this diesel engine to keep fingers and clothing away from the revolving belts drive shafts etc on engine installation Throughout this guide CAUTIONS regarding personal safety and NOTICES regarding engine performance or service life will appear To avoid personal injury and ensure long engine service life always heed these instructions Whenever possible it will benefit you to rely on an authorized Detroit Diesel service outlet for all your service needs from maintenance to major parts replacement Authorized service outlets worldwide stock factory original parts and have the specialized equipment and experienced trained All information subject to change without notice Rev 04 08 MBE 900 OPERAT
33. Components of the DDEC ECU and or DDEC VCU are damaged or not working properly Bring the vehicle to an authorized dealer for service 54 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Problem The Battery Charge Indicator Light Does Not Come On When the Engine Is Not Running The bulb is damaged Change the bulb The circuit is broken Repair the break in the circuit Problem The Battery Charge Indicator Light Comes On When the Engine is Running Check the belt tension if necessary The poly V belt is too loose have an authorized dealer replace the belt tensioner The belt tensioner is damaged 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 Have an authorized dealer replace the damaged rectifier or voltage regulator alternator All information subject to change without notice Rev 04 08 55 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION SERVICE PRODUCTS SERVICE PRODUCTS Use only the DDC recommended lubricants discussed in this section Additional information is available from any authorized dealer Do not use special lubricant additives None are needed and the use of additives could affect warranty coverage Important Dispose of service products in an environmentally respo
34. E eese 2 ELECTRICAL SYSTEM ei diete cepe tede 4 COOEING SYSTEM cioe ene besar eere PE Ma 6 AIPGINTAKE SYSTEM rte Deren i quts 6 FUEL SYSTEM s nu aa EEES 7 COMPRESSED AIR miniis ie a tides 9 LUBRICATING OIL AND FILTERS eee 9 IDENTIFICATION 5 dnb e test trate ipee t iu 10 PERSONNEL REQUIREMENTS sese 13 ENGINE CONVERSIONS AND MODIFICATIONS 14 GENERAL VIEW OF THE MBE 900 ENGINE 14 ENGINE IDENTIFICATION NUMBER eee 21 DESCRIPTION OF THE ENGINE esee 22 EXHAUST GAS RECIRCULATION seem 23 EXHAUST BRAKE CONSTANT THROTTLE VALVES OPTIONAL i emite 24 ELECTRONIC ENGINE CONTROL SYSTEM 25 DDEG EGI US See MS Aca O MM 26 DDEG VOLE niti eter en eaa cte Deeds 27 SENSOR LOCATIONS 28 OPERATION er Lec dde e dote ater depen 31 BEFORE STARTING THE ENGINE 31 CHECKING THE BATTERIES sse 31 CHECKING THE OIL LEVEL esses 32 CHECKING THE COOLANT LEVEL COLD CHECK 33 ADDING FUEL is itta eret tui n rane 33 PRIMING THE FUEL SYSTEM seen 33 STARTING THE ENGINE eese 33 CHECKING THE COOLANT LEVEL HO
35. E INJURY from the radiator Remove the flushing gun To avoid injury from flying debris when using compressed air wear 6 When the coolant has drained adequate eye protection face install the coolant drain plug on shield or safety goggles and do the radiator not exceed 276 kPa 40 psi air 7 Add coolant in the specified pressure concentration until the maximum mark on the surge tank is reached Coolant system capacity is c Apply no more than listed in Table 30 140 kPa 20 psi air pressure intermittently to help dislodge sediment buildup in the core 2 Coolant M z L Qt Table 30 Coolant System Capacity 8 Start the engine and run it for 10 Add coolant if necessary about one minute at varying speeds to release air pockets in the cooling system Make sure the heater valve is still open Check the coolant level and add more coolant if necessary 9 Shut down the engine 94 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Cooling System Inspecting dirt or debris Make sure the fins are not damaged and straighten WARN ING them if necessary 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 Rem
36. GING 86 ENGINE OIL AND FILTER CHANGING ee 87 Ole CENTRIFUGE ascent tt e tentes 90 COOLANT CONCENTRATION CHECKING 91 COOLANT FLUSHING AND CHANGING see 93 COOLING SYSTEM INSPECTING seen 95 CUSTOMER ASSISTANCE 7 eene 96 WORKING WITH DDC SERVICE OUTLETS 100 SIEP ONE 2 A ose ier 100 STEP ee eb ter Uer 100 STEP THREE TREE 101 LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900 ENGINES USED IN ON HIGHWAY VEHICLE APPLICATIONS 102 TERMS OF COVERAGE a 102 uj ER 102 DEFECTS tate etc e a de e EE 102 BEPAIBS ee eatin eater A Metin es 102 WARRANTY PERIOD iinan isinsin 102 LIKE REPLACEMENT ENGINE 22 103 SERVICE SUPPLIES cessisset tnnt 103 ENGINE REMOVAL AND REINSTALLATION 1038 THIS WARRANTY DOES NOT COVER 103 REPAIRS DUE TO ACCIDENTS MISUSE STORAGE DAMAGE NEGLIGENCE OR CERTAIN MODIFICATIONS 103 MAINTENANCE 104 INCIDENTAL OR CONSEQUENTIAL DAMAGES 104 OTHER LIMITATIONS ssssssseseeeeenere enne 104 LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900 ENGINES U
37. GR engines have an oil centrifuge and an oil filter Non EGR engines have only an oil filter 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 filter as follows 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 82 C 180 F 2 Using a 36 mm socket unscrew the oil filter cap See Figure 44 88 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 drain out See Figure 45 Discard the O ring on the oil drain plug Figure 45 Engine Oil Drain Plug Oil Pan 4 Remove both the filter cap and the filter element To release the All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION filter element twist the lower edge of the filter element to the side See Figure 46 FILTER lt ELEMENT 41764 Figure 46 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 th
38. 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 Long Haul Long Haul over the road transport is for vehicles that annually travel more than 100 000 kilometers 60 000 miles 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 Operating Hours vs Fuel Consumption Oil Drain Interval Only Operating hours vs fuel consumption is for operators who want an oil drain interval based on hours of operation instead of miles traveled See Figure 33 UNIMOG The UNIMOG engine has long maintenance intervals Maintenance Schedule and Interval Operations The three All information subject to change without notice Rev 04 08 MBE 900 OPERATOR S GUIDE 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 must be performed are listed in Table 15 Maintenance Intervals The three maintenance interval tables show which maintenance operation must be performed a
39. NG PERSONAL INJURY To 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 d WARNING 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 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION A WARNING PERSONAL INJURY To avoid injury from the projection of tools or other objects that may fall on or behind the vibration damper of an engine always check and remove these items before starting the engine A WARNING PERSONAL INJURY 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 prevents contact with rotating parts A WARNING PERSONAL INJURY To avoid injury when using caustic cleaning agents follow the chemical manufacturers usage disposal and safety instructions All information subject to change without notice Rev 04 08 MBE 900 OPE
40. OCK To avoid injury from electrical shock do not touch battery terminals alternator terminals or wiring cables while the engine is operating All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE A WARNING Electrical Shock Hazard High voltage can remain inside the Electrostatic Oil Separator after removal Wait 30 minutes after turning off the ignition before removing the separator Never touch parts through ventilation openings or impeller opening with finger or conductive items e g screwdriver or wire High voltage can remain inside the Electrostatic Oil Separator for up to 12 hours after the ignition is turned off All information subject to change without notice Rev 04 08 5 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION CAUTION SUMMARY Cooling System Observe the following cautions when servicing the cooling system A WARNING 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 A WARNING PERSONAL INJURY To avoid injury from slipping and falling immediately clean up any spilled liquids Air Intake System Observe the following caut
41. OR S GUIDE 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 information on the latest revision The right is reserved to make changes at any time without obligation NOTICE Coolant must be inhibited with the recommended Supplemental Coolant Additives SCA listed in this guide In addition the engine can be equipped with a coolant filter inhibitor system as an installed option or as an after sale item Failure to check and maintain SCA levels at required concentrations will result in severe damage corrosion to the engine cooling system and related components Trademark Information Detroit Diesel amp DDEC and Diagnostic Link are registered trademarks of Detroit Diesel Corporation Nexiq is a trademark of Nexiq Technologies Inc other trademarks are the property of their respective owners DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION ii All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE TABLE OF CONTENTS CAUTION SUMMARY 1 ENGINE OPERATION ee een 1 PREVENTIVE MAINTENANC
42. R CONSEQUENTIAL DAMAGES AS DESCRIBED ABOVE Some states do not allow the limitation of how long this warranty may last or the limitation or exclusion of incidental or consequential damages so the above may not apply to you This warranty gives you specific legal rights and you may also have other rights which may vary from state to state 113 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION
43. RATOR S GUIDE d WARNING FIRE To avoid injury from combustion of heated lubricating oil vapors stop the engine immediately if an oil leak is detected d WARNING FIRE To avoid injury from fire do not smoke or allow open flames when working on an operating engine d WARNING FIRE To avoid injury from fire from a buildup of volatile vapors keep the engine area well ventilated during operation DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION CAUTION SUMMARY Electrical System Observe the following cautions when jump starting an engine charging a battery or working with the vehicle electrical system A WARNING PERSONAL INJURY To avoid injury from accidental engine startup while servicing the engine disconnect disable the starting system A Electrical Shock To avoid injury from electrical shock use care when connecting battery cables The magnetic switch studs are at battery voltage d WARNING Battery Explosion and Acid Burn To avoid injury from battery explosion or contact with battery acid work in a well ventilated area wear protective clothing and avoid sparks or flames near the battery If you come in contact with battery acid Flush your skin with water Apply baking soda or lime to help neutralize the acid Flush your eyes with water Get medical attention immediately d WARNING ELECTRICAL SH
44. SED IN SCHOOL BUS APPLICATIONS 105 TERMS OF COVERAGE aeara aoni anamanna nA paranana Aad aai ae 105 USES ninia EN 105 DEFECTS 2 ente iter eM ette ende i ah 105 REPAIRS 21 HeLa Leder pt pee beg 105 vi All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE WARRANTY PERIOD eene nennen SERVIGE SUPPLIES ert er tees LIKE REPLACEMENT ENGINE ee ENGINE REMOVAL AND REINSTALLATION THIS WARRANTY DOES NOT COVER REPAIRS DUE TO ACCIDENTS MISUSE STORAGE DAMAGE NEGLIGENCE OR CERTAIN MODIFICATIONS MAINTENANCE eet ette epe siete p aeos et brise Eb Led INCIDENTAL OR CONSEQUENTIAL DAMAGES OTHER LIMITATIONS ete e epit LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900 ENGINES USED IN FIRE TRUCK OR CRASH VEHICLE APPLICATIONS iet keen santos EORR A MeL TERMS OF COVERAGE voce eret ede teg eee eere USES siesta tance rita te ee is DEFECTS Hp eite beste vaio RBEPAIBS iactat Dn amos WARRANTY PERIOD ertet te Pe io Pes LIKE REPLACEMENT ENGINE e SERVICE SUPPLIES dit eter Debe tege dett ENGINE REMOVAL AND REINSTALLATION THIS WARRANTY DOES NOT COVER
45. T CHECK 34 STARTING AN ENGINE THAT HAS NOT BEEN RUN FOR AN EXTENDED PERIOD ce ten eee e 35 All information subject to change without notice Rev 04 08 iii DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION TABLE OF CONTENTS MONITORING ENGINE OPERATION 36 BATTERY CHARGE ene m i fe ice etes 36 Ol PRESSURE ss aici a ener en aite Eneas 36 EXCESSIVE IDLING t tee eet t beds 37 CHANGING THE IDLE SPEED 1 see 37 SHUTTING DOWN THE ENGINE seem 37 SHUTTING DOWN AFTER HARD OPERATION 37 EMERGENCY RUNNING MODE semen 38 STOP ENGINE OVERRIDE OPTION nemen 38 COLD WEATHER OPERATION eene enne 39 WINTER FRONTS 39 CLEANING AND STORAGE eee 40 CLEANING THE ENGINE essen nennen 40 HIGH PRESSURE CLEANING EQUIPMENT 40 CLEANING THE COOLING SYSTEM 40 DEGREASING cerent tenente tentent 41 STORAGE ML es A eet diab d e a eT d 42 TROUBLESHOOTING sse enne nnns 43 EMERGENCY STARTING 43 TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL SYSTEM careo e Lees 43 GENERAL TROUBLESHOOTING seen 43 SERVICE PRODUCTS 1 seen enne 56 DIESEL FUELS ted
46. T DIESEL CORPORATION MAINTENANCE 2 Turn the adjusting screw until the valve lash is correct using the exact settings listed in Table 28 Use the range only for checking adjustment 3 Tighten the locknut 25 N m 18 lb ft 4 Check the valve lash again Adjust again if necessary Restoring The Vehicle To Operating Condition Restore to Engine Trim Panel operating condition as follows Charge Air Manifold Gasket Hexagon Socket Head Bolt 1 Install the cylinder head cover a E Cylinder Head Gasket 2 Remove the cranking device from Breather Hose the inspection hole in the timing case Figure 39 Cylinder Head Cover 3 Replace the end cover on the inspection hole and tighten the bolts 25 N m 18 lb ft Fuel Prefilter Element Cleaning Clean the fuel prefilter element as follows re Filter 41759 1 Open the fuel filler cap to release pressure in the fuel system Replace and tighten the cap Figure 40 Fuel Filters 2 Clean the outside of the prefilter housing Keep fuel away from hoses or pipes located beneath the filter See Figure 40 3 Unscrew the cap on the fuel prefilter Pull the cap and filter 84 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE element out of the prefilter housing See Figure 41 4 Clean the cap and the filter 7 Bleed the fue
47. UCTS Antifreeze Protection Water Corrosion Inhibiting Down to C F by Volume Antifreeze by Volume EET 52 62 The cooling mix ratio is Max 60 Table3 Coolant Mixing Ratio Important If the concentration NOTICE is too low there is risk of m DENM Failure to properly maintain coolant corrosion cavitation in the cooling with SCA can result in damage tem s NOCT to the cooling system and its For information about coolant in related components Conversely cold weather operation see the over concentration of SCA inhibitor heading Winter Coolant Antifreeze can result in poor heat transfer Protection later in this chapter leading to engine damage Always maintain concentrations at Supplemental Coolant Additives ecommended levels Do not use for Fully Formulated Coolant traditional SCAs with NOAT coolant The concentrations of some inhibitors will gradually deplete during normal engine operation SCAs replenish the protection for cooling system The proper application of SCA will components The coolant must provide be maintained with the proper pH control concentration of SCA Detroit Diesel TD POWER COOL maintenance SCAs Restored inhibitor levels to prevent corrosion are recommended Water softening to deter formation of mineral deposits Cavitation protection to protect wet sleeve cylinder liners 60 All information subject to change without n
48. VICE DDEC VCU TOOLS PROPRIETARY DDEC ECU VEHICLE DATA LINK ENGINE Figure 16 Electronic Engine Control System DDEC ECU The DDEC ECU see Figure 17 is located on the left hand side of the engine The DDEC ECU processes the data received from the DDEC VCU for example the position of the accelerator pedal engine brake etc Figure 17 DDEC ECU 26 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION These data are evaluated together with the data from the sensors on the engine such as coolant and fuel temperature and oil and charge pressure The data is then compared to the characteristic maps or lines stored in the DDEC ECU From these data quantity and timing of injection are calculated and the unit pumps are actuated accordingly through the solenoid valves NOTE To obtain a replacement DDEC ECU all the data given on the DDEC ECU label are required The DDEC ECU data label has the 10 digit engine serial number see Figure 14 the engine horse power and torque DDEC VCU The DDEC VCU communicates with any other electronic 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
49. Valve Overap e 2 41115 Table 26 Valve Adjustment Method One All information subject to change without notice Rev 04 08 81 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION MAINTENANCE Method Two Adjust 3 Using the cranking device turn Valves Using Two Crankshaft the crankshaft until cylinder 6 Positions Method two allows cylinder 74 on the four cylinder you to adjust all the valves using just engine is at the ignition TDC two crankshaft positions position all valves are closed and cylinder 1 is at the valve 1 Using the cranking device turn Ss overlap position valves are the crankshaft until cylinder 1 is at the ignition TDC position all open valves are closed and cylinder 6 4 Using the same procedure check cylinder 4 on the four cylinder the valves listed in Table 27 in the engine is at the valve overlap Valve Overlap row and adjust position all valves are open them if necessary using the procedures under the headings Checking Valve Lash and Adjusting Valve Lash 2 Check the valves listed in Table 27 in the Ignition TDC row and adjust them if necessary using the procedures under the headings Checking Valve Lash and Adjusting Valve Lash Cylinder 1 Cylinders Valve Types Crankshaft Position 1 pou ae 1 Intake Valve and Exhaust Valve Table 27 Valve Adjustm
50. 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 68 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 Schedule III Long Haul Operating Hours vs Fuel Consumption Oil Drain Interval Only UNIMOG Service Schedule To determine which schedule to use find the distance traveled by the vehicle in a year regardless of vehicle type Severe Service Applies to vehicles that annually travel up to 100 000 kilometers 60 000 miles 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 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION operation city operation fire truck garbage truck or farm operation Short Haul Applies to vehicles that annually travel up to 100 000 kilometers 60 000 miles and operate under normal conditions Examples of Short
51. and 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 six 30 second attempts Starting the Engine Before operating the engine follow the steps described in the Before Starting the Engine section Start the engine as follows NOTE As a safety function the electronic engine control system may be wired to start the engine only if the transmission is in neutral This is vehicle application specific 33 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION OPERATION NOTICE Never attempt to start the Mercedes Benz MBE 900 engine using ether or any other starting fluid Serious engine damage could result 1 Turn on the ignition switch 2 With the accelerator pedal in the idle position start the engine A WARNING PERSONAL INJURY To avoid injury when working near or on an operating engine remove loose items of clothing and jewelry Tie back or contain long hair that could be caught in any moving part causing injury 3 Check the engine for leaks a Check all hoses hose clamps and pipe unions on the 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
52. ant 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 Flush and change the coolant as follows 1 Open the cap on the surge tank slowly to allow excess pressure to escape 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 1s 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 All information subject to change without notice Rev 04 08 MBE 900 OPERATOR S GUIDE Figure 50 Coolant Drain Plug NOTE Make sure the coolant can flow unobstructed into the receptacle b Open the coolant drain plug on the bottom of the radiator 4 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 a Attach a flushing gun nozzle to the radiator outlet b Run water in until the radiator is full 93 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MAINTENANCE 5 Drain the radiator and flush the d WARNING radiator until clean water flows EY
53. atteries Replace them if needed The ignition switch is damaged Replace the ignition switch The battery cables are damaged Replace the battery cables and or corroded The starter is damaged and or worn Have an authorized dealer replace the starter The clutch or transmission is Bring the vehicle to an authorized damaged dealer for service There is internal damage to the Bring the vehicle to an authorized engine dealer for service Problem The Engine Turns Over Slowly 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 Replace the battery cables and or corroded The starter is damaged and or worn Have an authorized dealer replace the starter The engine oil does not meet the Change the engine oil using the correct specifications correct type of oil The transmission fluid does not meet Change the transmission fluid using the correct specifications the correct type of fluid 44 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Problem The Engine Cranks But Won t Start The batteries are damaged or weak Test the batteries Replace them if needed The cranking speed is not set correctly Bring the vehicle to anauthorized dealer for service No intake air preheater is insta
54. authorized dealer for service The camshaft TDC sensor and or the crank angle position sensor are out of adjustment The camshaft TDC sensor and or D Bring the vehicle to an authorized the crank angle position sensor are dealer for service damaged The constant throttle valves are Bring the vehicle to an authorized malfunctioning dealer for service There are other problems in the fuel Bring the vehicle to an authorized System dealer for service The parameter settings in the DDEC ECU or DDEC VCU are incorrect Have an authorized dealer reprogram the control unit All information subject to change without notice Rev 04 08 47 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION TROUBLESHOOTING Problem The Engine Fan Is Constantly On Check the operation of the fan override Switch The fan hub is damaged Replace the fan hub The parameter settings in the DDEC ECU or DDEC VCU are incorrect The fan override switch is on Have an authorized dealer reprogram the control unit Problem Fuel Consumption Is Too High The tires are not properly inflated Check all tires for correct pressure 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 Have an authorized dealer check the malfunctioning operation of the valve The remedies are listed in
55. d expenses Other Limitations Performance of REPAIRS 15 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 110 THIS WARRANTY AND THE EMISSIONS CONTROL WARRANTY ARE THE ONLY WARRANTIES APPLICABLE TO THE ENGINE AS USED IN FIRE TRUCK OR CRASH VEHICLE APPLICATIONS DETROIT DIESEL CORPORATION MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE DETROIT DIESEL CORPORATION SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES AS DESCRIBED ABOVE Some states do not allow the limitation of how long this warranty may last or the limitation or exclusion of incidental or consequential damages so the above may not apply to you This warranty gives you specific legal rights and you may also have other rights which may vary from state to state All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900 ENGINES USED IN UNIMOG APPLICATIONS Terms of Coverage Uses This warranty applies to the first retail purchaser and subsequent owners during the WARRANTY PERIOD of new Detroit Diesel MBE 900 Engines referred to as Eng
56. e O ring on the cap See Figure 46 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 18 Ib ft 8 Install the oil drain plug using a new O ring Tighten the plug 65 48 Ib ft All information subject to change without notice Rev 04 08 MBE 900 OPERATOR S GUIDE 9 Add new engine oil through the oil fill see Figure 47 Figure 47 Oil Fill WARNING 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 with a standard oil pan fill capacity is 16 7 quarts 15 8 L 10 Fill until the maximum fill level on the oil dipstick has been reached Do not overfill 89 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION MAINTENANCE NOTICE 1 Remove the cover of the oil ma centrifuge See Figure 48 Keep the engine running at idling speed until an oil pressure reading is obtained If no oil pressure is shown after approximately 10 seconds stop the engine and determine the cause Failure to do so could result in engine damage 11 Start the engine with the accelerator pedal in the idle position Monitor the oil pressure gauge 12 Check the filter and oil drain plug
57. e 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 first retail purchaser or put in use prior to sale at retail whichever date occurs first and ends at the time or mileage kilometer limits shown in the WARRANTY PERIOD chart All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Warranty Period Warranty Limitations Repair Charges to be Whichever Occurs First Paid by Owner Miles Parts Labor Kilometers 0 150 000 0 240 000 km No Charge No Charge 0 100 000 mi Table 31 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 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 All information subject to change without notice Rev 04 08 Warranty Period Chart On highway Vehicle Applicat
58. eement Step Two When it appears that your problem cannot readily be resolved at the distributor level without additional assistance contact the Detroit Diesel Regional Product Support or Operations Manager responsible for your local distributor You will be assisted by a member of the Manager s staff depending upon the nature of your problem Prior to this contact have the following information available Engine model and serial number Name and location of authorized service outlet Type and make of equipment All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Engine delivery date and accumulated miles or hours of operation Nature of problem Chronological summary of engine s history Step Three If you are still not satisfied present the entire matter in writing or by phone to Sr Vice President Parts Service and Customer Assurance Detroit Diesel Corporation 13400 Outer Drive West Detroit Michigan 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
59. ent Method Two 82 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Checking Valve Lash Check valve lash as follows 1 For each valve measure the valve lash with a feeler gauge between the rocker arm and valve stem exhaust valve or valve bridge intake valve It should be possible to pull the feeler gauge through with no more than light resistance 1 Adjusting Screw 2 If the value measured is within 2 Locknut the range listed in Table 28 in the Check For column check the next valve Figure 37 Intake Valves If the value measured is outside the range listed in Table 28 in the Check For column adjust the valve lash Adjusting Valve Lash Adjust valve lash as follows 1 If adjustment 1s needed loosen the locknut See Figure 37 for intake valves and Figure 38 for exhaust valves Use the exact 1 Adjusting Screw settingslisted in Table 28 in the 2 Locknut Adjust To column Figure 38 Exhaust Valves Valve Type Check For Adjust to 0 30 to 0 60 mm 0 012 to 0 024 in 0 40 mm 0 016 in 0 50 to 0 80 mm 0 020 to 0 032 in 0 60 mm 0 024 in Table 28 Valve Lash Checking and Adjustment All information subject to change without notice Rev 04 08 83 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROI
60. 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 70 Complete each Maintenance Operation Set at the required interval For example when you have completed Maintenance Operation Set M3 under the 16th maintenance number listed in the Maintenance Interval Table repeat the pattern For the 17th maintenance do Maintenance Operation Set M1 under the first maintenance number listed in the Maintenance Interval Table NOTE For Severe Service the pattern repeats after 15 maintenance numbers not 16 as for Short Haul and Long Haul All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Maintenance Tables and Graphs Maintenance Maint Maintenance Intervals Schedule Operation Frequency Schedule I Maint Book 6 000 9 650 Severe Service y 904 906 926 904 906 926 M vehicles that annually travel Maint up to 6 000 miles M every 18 000 29 000 9 650 km Schedule II Maint sver 15 000 24 000 Short Haul M y 904 906 926 904 906 926 vehicles that Maint annually every 60 000 96 500 travel up to M Schedule III Maint sver 20 00
61. gine and or vehicle equipment damage Engine Operation Observe the following cautions when operating the engine A WARNING FIRE To avoid injury from fire keep all potential ignition sources away from diesel fuel including open flames sparks and electrical resistance heating elements Do not smoke when refueling All information subject to change without notice Rev 04 08 MBE 900 OPERATOR S GUIDE WARNING 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 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION CAUTION SUMMARY Preventive Maintenance Observe the following cautions when performing preventative maintenance A WARNING HOT OIL To avoid injury from hot oil do not operate the engine with the rocker cover s removed A WARNING PERSONAL INJURY To avoid injury from slipping and falling immediately clean up any spilled liquids A USED ENGINE OIL To avoid injury to skin from contact with the contaminants in used engine oil wear protective gloves and apron d WARNI
62. he fuel system if necessary There are leaks in the fuel lines Check ine fuel Iines for eens and repair them if necessary The fuel filter is clogged Replace the filter element Clean and bleed the system Have the fuel lines and filters checked by an authorized dealer The fuel line the fuel prefilter or the screen in the fuel tank is blocked 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 out of adjustment The camshaft TDC sensor and or the crank angle position sensor are damaged There are other problems in the fuel Bring the vehicle to an authorized system dealer for service Bring the vehicle to an authorized dealer for service 46 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Problem The Engine Starts But Dies The fuel tank is low or empty inea bleed systemy it The fuel filter is clogged Replace the filter element Clean and bleed the system Have the fuel lines and filters checked by an authorized dealer The fuel line the fuel prefilter or the screen in the fuel tank is blocked Push both sensors into their holes as far as they will go If this does not solve the problem bring the vehicle to an
63. hool 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 All information subject to change without notice Rev 04 08 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 first retail purchaser or put in use prior to sale at retail whichever date occurs first and ends at the time or mileage kilometer limits listed in Table 32 the WARRANTY PERIOD chart 105 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900 ENGINES USED IN SCHOOL BUS APPLICATIONS Warranty Period Warranty Limitations Whichever Occurs First Engine Accessories Miles Months Pars 0
64. ice are damaged The charge air temperature sensor is Bring the vehicle to an authorized damaged dealer for service There is internal damage to the Bring the vehicle to an authorized engine dealer for service The air filter and or intake air system is clogged All information subject to change without notice Rev 04 08 53 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION TROUBLESHOOTING Problem The Engine Exhaust Is Blue The engine oil level is too high Adjust the oil level and then have the engine oil is reaching the combustion oil level checked by an authorized chamber dealer The turbocharger is leaking oil Have an authorized dealer replace the turbocharger The valve stem seals are loose or Have an authorized dealer replace the damaged Seals Have an authorized dealer replace the The piston rings are worn piston rings Problem Engine Brake Performance Is Poor The engine brake control switch is Replace the switch damaged The exhaust brake is not operating Have an authorized dealer check the properly operation of the valve The constant throttle valves are Bring the vehicle to an authorized malfunctioning dealer for service Components of the DDEC ECU and or Bring the vehicle to an authorized DDEC VCU are damaged dealer for service Problem Cruise Control Is Not Working One or more of the cruise control Replace the damaged switch switches are damaged
65. ick see Figure 22 A WARNING PERSONAL INJURY To avoid injury from slipping and falling immediately clean up any spilled liquids Figure 23 Fill Collar 32 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION Checking the Coolant Level Cold Check Check the coolant level as follows 1 Ensure that all coolant plugs in the bottom of the radiator and on the radiator outlet pipe are secure and tight 2 Check the coolant level The cooling system is correctly filled when the coolant is between the maximum and minimum marks on the surge tank NOTE For more information refer to the Maintenance section Adding Fuel Note the following when adding fuel Add winter or summer grade fuel according to the season of the year Work in the cleanest conditions possible Prevent water from entering the fuel tank For further information refer to Diesel Fuels in Service Products Priming the Fuel System Prime the fuel system as follows All information subject to change without notice Rev 04 08 MBE 900 OPERATOR S GUIDE 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 h
66. idle speed maximum running speed and speed limitation All information subject to change without notice Rev 04 08 MBE 900 OPERATOR S GUIDE 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 brake system The DDEC ECU oil pressure and coolant temperature From these data instructions are computed for controlling the engine and transmitted to the DDEC ECU via the proprietary datalink The DDEC VCU controls various systems for example communications with the datalink the engine brake and the constant throttle valves 21 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION IDENTIFICATION Sensor Locations A 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 iS EL ri 1 Intake Manifold Pressure Temper Engine Oil Pressure Sensor ature Sensor 2 Engine Oil Temperature Sensor Figure 19 Sensor Location on the Right Side of the MBE 900 EGR Engine 28 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04
67. ine damage have any faults corrected without delay by an authorized dealer In conjunction with the instrumentation control unit ICU the code for the electronic control unit reporting the fault can be read immediately on the display Complete fault codes are transmitted and can be read using ServiceLink at any authorized dealer If the fault is serious enough to impair normal operation the electronic engine system switches over to emergency running mode When in emergency running mode the engine operates at a constant 1300 rpm This allows you to move the vehicle to a service location 38 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 used to override the shutdown sequence see Figure 26 This override resets the 60 second 30 seconds for oil pressure shutdown timer restoring power to the level when the Red Stop Lamp RSL was illuminated The switch must be recycled after five seconds to obtain a subsequent override Mwy A 38 zB DIAGNOSTIC REQUEST STOP ENGINE VARNING OVERRIDE SWITCH MP Figure 26 Typical SEO Switch and Warning Lamps NOTE The operator has the responsibility to take action to avoid engine damage All information sub
68. ine 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 UNIMOG 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 All information subject to change without notice Rev 04 08 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 first retail purchaser or put in use prior to sale at retail whichever date occurs first and ends at the time or mileage kilometer limits listed in Table 34 the WARRANTY PERIOD chart 111 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION LIMITED WARRANTY ON NEW DETROIT DIESEL
69. ine Data for Non EGR Engine The engine weights are listed in Table 8 The engine dimensions are listed in Table 9 Also see Figure 31 and Figure 32 Coolant and lubricating oil capacities are listed in Table 10 Engine Dry Weight A MAXIMUM ENGINE LENGTH 44739 Figure 31 Engine Measurements 4 Cylinder 395 kg 871 Ib Side View 6 Cylinder 530 kg 1169 Ib Table 8 Engine Weights 4 Cylinder 6 Cylinder A 1025 mm 1219 mm 40 4 in 48 0 in B 686 mm B 810 mm 27 0 in 31 9 in 925 mm C 940 mm 36 4 in 37 0 in B MAXIMUM ENGINE WIDTH C MAXIMUM ENGINE HEIGHT 41740 Figure 32 Engine Measurements Table 9 Engine Dimensions Front View 4 Cylinder Engine 6 Cylinder Engine OL 9 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 For standard oil pan Table 10 Coolant and Lubricating Oil Capacity 66 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Testing and Adjusting Oil Pressure is listed in Table 12 Values Coolant thermostat conditions are listed in Table 13 Injector pressures are listed in Table 14 Valve lash checking and adjustments are listed in Table 11 Engine Valve Type Check For Adjust To mm in mm in 0 30 to 0 60 0 012 to 0 024 0 016 0 40
70. ions This Warranty Does Not Cover Repairs Due to Accidents Misuse Storage Damage Negligence or Certain Modifications Repairs due to an accident misuse misapplication storage damage negligence or modification exceeding DDC specifications are not covered by this warranty 103 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900 ENGINES USED IN ON HIGHWAY VEHICLE APPLICATIONS Maintenance DDC is not responsible for the cost of maintenance or repairs due to lack of performance of required maintenance services as recommended by DDC or the failure to use fuel oil lubricants and coolant meeting DDC recommended specifications Performance of the required maintenance and use of proper fuel oil lubricants and coolant are the responsibility of the owner Incidental or Consequential Damages Detroit Diesel Corporation is not responsible for incidental or consequential costs or expenses which the owner may incur as a result of a malfunction or failure covered by this warranty such as communication expenses meals lodging overtime towing loss of use of the engine or vehicle downtime loss of time inconvenience cargo loss or damage and other similar costs and expenses Other Limitations Performance of REPAIRS 15 the exclusive Owner s remedy under this warranty Detroit Diesel Corporation does not authorize any person to assume or c
71. ions when working on the air intake system d WARNING PERSONAL INJURY To avoid injury from hot surfaces wear protective gloves or allow engine to cool before removing any component d WARNING PERSONAL INJURY 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 prevents contact with rotating parts All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Fuel System WARNING 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 not smoke when refueling A PERSONAL INJURY To avoid injury from fuel spills do not overfill the fuel tank WARNING FIRE To avoid injury from fire contain and eliminate leaks of flammable fluids as they occur Failure to eliminate leaks could result in fire WARNING 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
72. ithout notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION Engine Data for EGR Engine The engine weights are listed in Table 5 The engine dimensions are listed in Table 6 Also see Figure 29 and Figure 30 Coolant and lubricating oil capacities are listed in Table 7 Engine Dry Weight 4 Oylinder 420 kg 926 Ib 6 Cylinder 560 kg 1235 Ib Table 5 4 Cylinder 6 Cylinder A 1025 mm 1219 mm 40 4 48 686 810 27 31 9 1000 1060 39 4 41 7 6 Engine Weights Engine Dimensions Description Lubricating Oil 4 Cylinder Engine MBE 900 OPERATOR S GUIDE mi A MAXIMUM ENGINE LENGTH 44061 Figure 29 Engine Measurements Side View ra o H 4 B B MAXIMUM ENGINE WIDTH C MAXIMUM ENGINE HEIGHT 44062 Figure 30 Engine Measurements Front View 6 Cylinder Engine Coolant Capacity Max 8 L 8 5 qt Max 12 5 L 13 2 qt 6 qt Capacity All information subject to change without notice Rev 04 08 Max 15 8 L 16 7 qt Max 29 L 30 6 qt Does not include capacity of cooling system For standard oil pan Table 7 Coolant and Lubricating Oil Capacity 65 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION TECHNICAL DATA Eng
73. ject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Cold Weather Operation Special precautions must be taken during cold weather To protect your engine special cold weather handling is required for fuel engine oil coolant and batteries For detailed information refer to the service manual Winter Fronts A winter front may be used to improve cab heating while idling At least 2596 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 All information subject to change without notice Rev 04 08 39 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION CLEANING AND STORAGE CLEANING AND STORAGE When an engine is to be stored for a period of time special precautions should be taken to protect the interior and exterior of the engine Cleaning the Engine Important Observe all environmental protection regulations High Pressure Cleaning Equipment Note the equipment manufacturer s operating instructions NOTICE To prevent damage to engine components during the cleaning process keep the water moving at all times Never direct water ont
74. l The oil has not been changed within Change the oil the recommended interval The oil is not of the recommended Change the oil quality Problem The Engine Oil Pressure Is Low The oil pressure gauge and or sensor Bring the vehicle to an authorized is not reading correctly dealer for service Bring the vehicle to an authorized The oil filter is clogged Replace the filter element The oil filter bypass valve is damaged Replace the bypass valve The oil pump and or relief valve is Have an authorized dealer replace the damaged oil pump 52 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Check the intake air preheater and malfunctioning replace it if necessary The valves are not adjusted properly Check the valve lash Problem The Engine Exhaust Is Black Check the air restriction indicator Clean the intake air system and replace the air filter if necessary The exhaust brake valve is Have an authorized dealer check the malfunctioning operation of the valve The intake air preheater is Check that the heater is not staying on malfunctioning 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 Bring the vehicle to an authorized injectors or one or more unit pumps dealer for serv
75. l 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 13 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION IDENTIFICATION Engine Conversions and Modifications The function and safety of the engine could be affected if unauthorized modifications are made Detroit Diesel will not accept responsibility for any resulting damage Tampering with the fuel injection system and engine electronics could also affect the engine s power output or exhaust emission levels Compliance with the manufacturer s settings and with statutory environmental protection regulations cannot then be guaranteed 14 General View of the MBE 900 Engine The 2004 on highway MBE 900 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 MBE 900 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 MBE 900 non EGR engine 6 cylinder model and Figure 8 for a side view of the 6 cylinder model right hand side See Figure 9 for a front view of the MBE 900 non EGR engine 4 cylinder model
76. l system element If the filter element replace it NOTICE Correct torque on the high pressure 5 Check the O ring on the cap and A lines is critical Incorrect torques replace it if necessary could result in leaks or lack of power 6 Insert the filter element into the due to restricted fuel flow prefilter housing and screw the cap onto the housing Tighten the cap 25 N m 18 lb ft 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 cranking the engine again wait at least two minutes The engine should start within four 30 second attempts 1 Cap pre filter 2 O ring 3 Filter Element 4 Filter Housing Figure 41 Fuel Prefilter All information subject to change without notice Rev 04 08 85 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MAINTENANCE Main Fuel Filter Element Changing Change the main fuel filter element as follows 1 Open the vehicle fuel tank filler cap to release pressure in the fuel system Replace and tighten the cap 2 Clean the outside of the fuel filter housing See Figure 40 3 Using a 36 mm socket wrench insert unscrew the cap on the fuel filter and remove it along wi
77. le Valves Optional To increase braking performance the engine can be equipped with an exhaust brake on the turbocharger in conjunction with constant throttle valves in the cylinder head See Figure 15 Figure 15 Constant Throttle Activation 24 The two systems operate independently 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 between the combustion chamber and the exhaust port When the engine brake is switched on the constant throttle valves are put under pressure which in turn opens the valves On the 6 cylinder model the constant throttle valves are activated 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 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION Below 900 rpm the engine brake is always turned off to prevent the engine from stalling Also the engine brake is automatically t
78. lled inst ll aniintake air preheater and it is too cold to start without one The intake air preheater is Check the intake air preheater and malfunctioning replace it if necessary Push both sensors into their holes as 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 out of adjustment The camshaft TDC sensor and or the crank angle position sensor are damaged Bring the vehicle to an authorized dealer for service 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 Replace the filter element The exhaust brake valve is Have an authorized dealer check the malfunctioning operation of the valve The valves are not adjusted properly Check the valve lash There are other problems in the fuel Bring the vehicle to an authorized System dealer for service Check for leaks add coolant to correct Coolant level is too low level There is air in the fuel system All information subject to change without notice Rev 04 08 45 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION TROUBLESHOOTING Problem The Engine Starts Only After Cranking for a Long Time The fuel tank is low or empty Add fuel and bleed t
79. nce used for fuel injection Method One Bytypeof valve depending on crankshaft position Method Two All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION 2 INTAKE VALVES mb EXHAUST VALVES X FLYWHEEL END NOTE CYLINDERS ARE NUMBERED FROM FORE TO AFT 41756 Figure 36 Cylinder and Valve Layout Method One Adjust Each Cylinder In Firing Order Method One allows you to adjust each cylinder in the order in which fuel is injected The crankshaft must Crankshaft Position Ignition m Pur ARS 1 MBE 900 OPERATOR S GUIDE be repositioned after each cylinder is adjusted as listed in Table 26 1 For each cylinder use the cranking device to rotate the crankshaft until the piston is exactly at top dead center TDC in the compression stroke The valves must be closed and it must be possible to turn the push rods without effort NOTE When the piston in cylinder 1 is at ignition TDC the valves of cylinder 6 cylinder 4 on the four cylinder engine will overlap meaning that both intake and exhaust valves are partially open and show no measurable play when tested with a feeler gauge 2 Check each valve and adjust it 1f necessary using the procedures under the headings Checking Valve Lash and Adjusting Valve Lash in this section Cylinders Ignition Em
80. nente datu e Ded eo al ae 56 FLOW IMPROVERS 56 KEROSENE entr e esee argu 56 ENGINE OIES niente den eren teer edendo 57 EGR ENGINES 4 iiti tionc Lnd UI ag Hp RUD epu ape 57 NON EGR ENGINES sse 58 SYNTHETIC OILS ce eene ees 58 COOLANT 1 tert epit e a Pk et ete Las 58 FULLY FORMULATED ANTIFREEZE 58 WATER tfc ettet ee tee rd eek EUR 59 COOLANT SPECIFICATIONS sese 59 COOLANT CONCENTRATION eene enn 59 iv All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE SUPPLEMENTAL COOLANT ADDITIVES FOR FULLY FORMULATED COOLANT eene nnns 60 DROPOUT ettet eset el ee es sh 61 DISPOSAL itae tt tein el beret e tette dogs 61 COLD WEATHER PRODUCTS seen 61 WINTER GRADE DIESEL FUEL eee 61 LOW VISCOSITY ENGINE OIL 62 WINTER COOLANT ANTIFREEZE PROTECTION 62 BATTERIES niente tipi 62 TECHNICAL DATA 3 tet Pc te a ea en ite 64 ENGINE DATA FOR EGR ENGINE see 65 ENGINE DATA FOR NON EGR ENGINE 66 TESTING AND ADJUSTING VALUES sense 67 MAINTENANCE neum e 68 SCHEDULED INTERVALS seen n
81. nformation subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION TROUBLESHOOTING In addition to operating the engine carefully and maintaining it properly make sure to correct any malfunction promptly Emergency Starting For emergency starting procedures jump starting see the driver s operator s manual under the heading Emergency Starting With Jumper Cables 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 1s 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 All information subject to change without notice Rev 04 08 MBE 900 OPERATOR S GUIDE General Troubleshooting The tables that follow are designed to identify the causes of common problems suggest further checks and appropriate remedies When dealer service is necessary it is mentioned in the table NOTE Remember to follow all cautions when troubleshooting the engine 43 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION TROUBLESHOOTING Problem The Engine Will Not Crank The batteries are damaged or weak Test the b
82. ngine removal and reinstallation when necessary to make a warranty repair are covered by this warranty All information subject to change without notice Rev 04 08 This Warranty Does Not Cover Repairs Due to Accidents Misuse Storage Damage Negligence or Certain Modifications Repairs due to an accident misuse misapplication storage damage negligence or modification exceeding DDC specifications are not covered by this warranty DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION 109 LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900 ENGINES USED IN FIRE TRUCK OR CRASH VEHICLE APPLICATIONS Maintenance DDC is not responsible for the cost of maintenance or repairs due to lack of performance of required maintenance services as recommended by DDC or the failure to use fuel oil lubricants and coolant meeting DDC recommended specifications Performance of the required maintenance and use of proper fuel oil lubricants and coolant are the responsibility of the owner Incidental or Consequential Damages Detroit Diesel Corporation is not responsible for incidental or consequential costs or expenses which the owner may incur as a result of a malfunction or failure covered by this warranty such as communication expenses meals lodging overtime towing loss of use of the engine or vehicle downtime loss of time inconvenience cargo loss or damage and other similar costs an
83. nns 68 MAINTENANCE SCHEDULE TYPES 68 SEVERE SERVICE 68 SHORT HALUL ancien tee 69 LONG HAUL tree terree eta ter e ees 69 OPERATING HOURS VS FUEL CONSUMPTION OIL DRAIN INTERVAL ONLY retten eate lea 69 UNIMOG x5 o reitera reet 69 MAINTENANCE SCHEDULE AND INTERVAL OPERATIONS 69 MAINTENANCE INTERVALS 69 MAINTENANCE OPERATION SETS 70 SCHEDULE USE coe eee tg Ente 70 MAINTENANCE TABLES AND GRAPHS 71 REQUIRED MAINTENANCE OPERATIONS 79 ENGINE INSPECTING esee 79 VALVE LASH CHECKING AND ADJUSTING 79 GAINING ACCESS TO THE VALVES 80 METHOD ONE ADJUST EACH CYLINDER IN FIRING ORDER Si incen edunt orte retra 81 METHOD TWO ADJUST ALL VALVES USING TWO CRANKSHAFT POSITIONS seen 82 CHECKING VALVE LASH sse 83 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION TABLE OF CONTENTS ADJUSTING VALVE LASH sese 83 RESTORING THE VEHICLE TO OPERATING CONDITION 84 FUEL PREFILTER ELEMENT CLEANING 84 MAIN FUEL FILTER ELEMENT CHAN
84. nsible manner This includes any parts which have been in contact with them for example filters Reclaim them or recycle them if possible and be sure to comply with all legal disposal requirements Diesel Fuels Use only commercially available vehicle diesel fuel Grades such as marine diesel fuel heating oil and others are not permissible Do not use fuel additives Using fuel additives could affect your warranty Only low sulfur diesel fuel should be used for EGR engines sulfur content 0 05 percent by weight For non EGR engines if 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 56 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 in cold weather operation refer to the section Winter Grade Diesel Fuel later in this chapter Flow Improvers The effectiveness of flow improvers is not guaranteed with all fuels Comply with the product manufacturer s recommendations Any authorized dealer can provide information on approved flow improvers Kerosene Keep the quantity added as low as possible bearing in mind the outside temperature The addition of five percent by volume of kerosene will impro
85. ntake Manifold Figure7 Front View of 6 Cylinder MBE 900 Non EGR Engine All information subject to change without notice Rev 04 08 17 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION IDENTIFICATION 1 Oylinder Head Cover 7 Alternator 2 Intake Manifold 8 Turbocharger 3 Exhaust Manifold 9 Starter Motor 4 Intake Manifold Inlet 10 Flywheel Housing 5 Oil Fill Cap 11 Exhaust Brake optional 6 Turbo Compressor Out Figure8 Side View of a 6 cylinder MBE 900 Non EGR Engine 18 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE 1 Cylinder Head Cover 9 Belt Tensioner 2 DDEC ECU Control Unit 10 Alternator Pulley 3 Fuel Prefilter 11 Intake Manifold Inlet 4 Air Compressor optional 12 Turbo Compressor Out 5 Power Steering Pump 13 Crankcase Breather 6 Oil Dipstick 14 Oil Fill Cap 7 Fuel Filter 15 Intake Manifold 8 Fan Figure9 Front View of 4 Cylinder MBE 900 Non EGR Engine All information subject to change without notice Rev 04 08 19 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION IDENTIFICATION o a A CO Oil Fill Cap 7 Starter Motor Turbo Compressor Outlet 8 Exhaust Brake optional Intake Manifold Inlet 9 Flywheel Housing Oil Filter 10 Exhaust Manifold Alternator 11 Intake Manifold
86. nutes after shutdown even if the engine ran only a short time 1 Visually check the engine for signs of leakage A slight dampness at the sealing points is no cause for alarm 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 A Engine Crankin S 9 9 46392 A Tool PART NUMBER J 46392 Table 25 Special Tool All information subject to change without notice Rev 04 08 719 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION MAINTENANCE Gaining Access To The Valves Gain access to the valves as follows NOTE Clean the cylinder head cover before removing it 1 Remove the cylinder head cover see Figure 34 Engine Trim Panel Charge Air Manifold Gasket Hexagon Socket Head Bolt Sealing Washer Cylinder Head Cover Oylinder Head Gasket Breather Hose Figure 34 Cylinder Head Cover 2 Remove the inspection cover on the timing case 3 Fit the cranking device listed in Table 25 into the 80 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 n order according to the timing seque
87. o change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE DDC INTERNATIONAL REGIONAL OFFICE LOCATIONS DETROIT DIESEL DISTRIBUTION CENTER B V On Off Highway The Netherlands Ridderpoort 9 2984 Ridderkerk The Netherlands Phone 31 180 442 900 Fax 31 180 462 062 MTU DETROIT DIESEL AUSTRALIA PTY LTD On Off Highway Victoria Melbourne 488 Blackshaws Road Altona North Victoria 3025 Australia Phone 61 3 9243 9292 Fax 61 3 9243 9271 MEXICO On Off Highway Detroit Diesel Allison de Mexico S A Av Santa Rosa 58 Col Ampliacion Norte San Juan Ixtacala Tlanepantla C P 54160 Edo de Mexico Phone 52 55 5333 1803 Fax 52 55 5333 1875 All information subject to change without notice Rev 04 08 LATIN AMERICAN REGION Off Highway Miami Florida 2277 N W 14th Street Latin America Building Miami FL 33125 0068 Phone 305 637 1555 Fax 305 637 1580 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 amp I Electronics Fax 65 6860 9959 Sales PowerGen Defense 99 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION CUSTOMER ASSISTANCE Working with DDC Service Outlets As the owner of a Detroit Diesel product you have a complete network of over 1 000 Detroit Diesel service outlets in the
88. o electrical components plug 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 Cooling System Important Collect the used coolant cleaning solutions and washing liquids Dispose of them in accordance with applicable laws regarding the protection of the environment NOTICE Clean at moderate pressures only otherwise the fins of the radiator grille could be damaged connectors seals or flexible hoses Comply with the minimum working distance between the high pressure nozzle and the surface being cleaned Approximately 700 mm 28 in for circular pattern jets Approximately 300 mm 12 in for 25 degree flat jets and dirt cutters 40 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION Clean as follows A WARNING 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 Remove debris dust insects etc from the fins of the radiator grille by blowing them through with compressed air or spraying them out with water Work from the rear of the radiator in the opposite direction of the normal cooling air fl
89. ormance of required maintenance services as recommended by DDC or the failure to use fuel oil lubricants and coolant meeting DDC recommended specifications Performance of the required maintenance and use of proper fuel oil lubricants and coolant are the responsibility of the owner Incidental or Consequential Damages Detroit Diesel Corporation is not responsible for incidental or consequential costs or expenses which the owner may incur as a result of a malfunction or failure covered by this warranty such as communication expenses meals lodging overtime towing loss of use of the engine or vehicle downtime loss of time inconvenience cargo loss or damage and other similar costs and expenses Other Limitations Performance of REPAIRS 15 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 All information subject to change without notice Rev 04 08 MBE 900 OPERATOR S GUIDE 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 OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE DETROIT DIESEL CORPORATION SHALL NOT BE LIABLE FOR ANY INCIDENTAL O
90. otice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION Dropout Excessive amounts of some corrosion inhibitors can cause a gel or crystalline deposit that reduces both heat transfer and coolant flow This deposit is called dropout Dropout takes the color of the coolant when wet but becomes a white or gray powder when dry It can pick up solid particles in the coolant and become gritty It will cause premature wear of the coolant pump seals and other components of the cooling system The wet gel can be removed using an alkaline non acid cleaner containing either sodium nitrite or sodium tetraborate If the gel is allowed to dry it is necessary to disassemble the engine and clean it with a caustic solution or physically clean the individual components Disposal Coolants are biologically degradable substances When disposing of used coolant comply with local legal requirements and waste water regulations Consult the local water supply authorities to determine the best method of disposal A modern engine coolant has complex tasks to perform Do not allow any All information subject to change without notice Rev 04 08 MBE 900 OPERATOR S GUIDE 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
91. ough Shutting Down the Engine If the engine has been running at full output or the coolant temperature has been high allow the engine to idle for one to two minutes without load Then turn off the ignition key switch If any the following occur shut down the engine immediately The oil pressure swings back and forth or falls sharply All information subject to change without notice Rev 04 08 MBE 900 OPERATOR S GUIDE 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 engine or turbocharger Shutting Down After Hard Operation NOTICE After hard operation if the engine has been running at full output or the coolant temperature has been high allow the engine to idle for one to two minutes without load Shutting down the engine without idling may cause damage to the turbocharger Turn off the ignition switch and shut down the engine 37 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION OPERATION Emergency Running Mode The engine is equipped with the electronic engine control system which monitors the engine as it 1s running As soon as a fault is detected it is evaluated and one of the following measures is initiated NOTICE To prevent possible serious eng
92. ove 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 Inspect the cooling system as follows 1 Inspect the radiator the condenser the coolant pump the engine oil cooler the freeze plugs and the heat exchanger for damage and leaks 2 Check all pipes and hoses in the cooling system for damage and leaks Make sure all pipes and hoses are properly positioned to avoid chafing and are securely fastened 3 Check the outside of the radiator and condenser for blockage by All information subject to change without notice Rev 04 08 95 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION CUSTOMER ASSISTANCE CUSTOMER ASSISTANCE The satisfaction and good will of the Corporation and its distributor dealer owners of Detroit Diesel engines are organizations of primary concern to Detroit Diesel NAFTA OFF HIGHWAY SALES AND CUSTOMER ASSURANCE CENTER pi NEWFOUNDLAND o ES o HAWAH PUERTO RICO 96 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE DDC NORTH AMERICAN NAFTA ON HIGHWAY OFFICES EASTERN REGION 1 Suwanee Georgia 3325 Paddocks Parkwa
93. ow 2 Drain the coolant when the engine is cold For detailed procedures see the vehicle chassis maintenance manual For types of coolant refer to Coolant in the Service Products section 3 If the HVAC unit is connected to the cooling system open the regulating valves all the way Degreasing Degrease as follows 1 Fill the cooling system with a 5 solution 1 6 ounces per quart of All information subject to change without notice Rev 04 08 MBE 900 OPERATOR S GUIDE water S0 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 WARNING 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 3 Drain all the cleaning solution 4 Flush the cleaning solution from the cooling system a Immediately after draining the cleaning solution flush the system with clean water b Once the clean water has drained fill the system again with clean water 41 DDC SVC MAN 0055 04 0
94. pressure may be present within the circuit All information subject to change without notice Rev 04 08 7 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION CAUTION SUMMARY A WARNING FIRE To avoid injury from fire caused by heated diesel fuel vapors Keep those people who are not directly involved in servicing away from the engine Stop the engine immediately if a fuel leak is detected Do not smoke or allow open flames when working on an operating engine Wear adequate protective clothing face shield insulated gloves and apron etc To prevent a buildup of potentially volatile vapors keep the engine area well ventilated during operation All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Compressed Air su WARNING Observe the following cautions when using compressed air FIRE To avoid injury from fire do not d WARNING 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 A 3 shield or safety goggles and do WARNING not exceed 276 kPa 40 psi air FIRE pressure IE To avoid injury from fire from a buildup of volatile vapors keep Lubricating Oil and Filters the engine area
95. r consequential damages so the above may not apply to you This warranty gives you specific legal rights and you may also have other rights which may vary from state to state 107 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900 ENGINES USED IN FIRE TRUCK OR CRASH VEHICLE APPLICATIONS LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900 ENGINES USED IN FIRE TRUCK OR CRASH VEHICLE APPLICATIONS Terms of Coverage Uses This warranty applies to the first retail purchaser and subsequent owners during the WARRANTY PERIOD of new Detroit Diesel MBE 900 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 fire truck or crash vehicle 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 108 may at its discretion replace rather than repair components A reasonable time must be allowed to perform the wa
96. reate for it any other obligation or liability in connection with the engine or the accessories 104 THIS WARRANTY AND THE EMISSIONS CONTROL WARRANTY ARE THE ONLY WARRANTIES APPLICABLE TO THE ENGINE AS USED IN ON HIGHWAY VEHICLE APPLICATIONS DETROIT DIESEL CORPORATION MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE DETROIT DIESEL CORPORATION SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES AS DESCRIBED ABOVE Some states do not allow the limitation of how long this warranty may last or the limitation or exclusion of incidental or consequential damages so the above may not apply to you This warranty gives you specific legal rights and you may also have other rights which may vary from state to state All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900 ENGINES USED IN SCHOOL BUS APPLICATIONS Terms of Coverage Uses This warranty applies to the first retail purchaser and subsequent owners during the WARRANTY PERIOD of new Detroit Diesel MBE 900 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 sc
97. ressure lines have been tightened to 25 N m 18 Ib 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 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 All information subject to change without notice Rev 04 08 MBE 900 OPERATOR S GUIDE Engine Oil and Filter Changing d WARNING 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 average air temperature for the season See Figure 43 View the temperature ranges for the various SAE classes as guidelines which can be exceeded for only a short time Engine oils SAE classifications Singlegrade oils Multigrade oils 41738 Figure 43 SAE Oil Viscosity Classes 87 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MAINTENANCE To insure the engine is protected and the oil stays clean until the next oil change use only oils of API classification CI4 The six cylinder E
98. rranty 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 first retail purchaser or put in use prior to sale at retail whichever date occurs first and ends at the time or mileage kilometer limits listed in Table 33 the WARRANTY PERIOD chart All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE Warranty Period Warranty Limitations Repair Charges to be Whichever Occurs First Paid by Owner Milesi Parts Labor Kilometers 0 150 000 oom 0 240 000 km No Charge No Charge 0 100 000 Accessories 0 160 000 km No Charge No Charge Table 33 Warranty Period Chart Fire Truck Crash Vehicle Applications 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 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 e
99. rred for use in coolant Distilled water Water purified by reverse osmosis De ionized water NOTICE In some areas tap water can contain high levels of dissolved 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 MBE 900 OPERATOR S GUIDE Coolant Specifications To avoid damage to the cooling system 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 concentration of corrosion inhibiting antifreeze in the coolant must be 50 percent by volume This affords protection down to a temperature of 37 C 34 F The cooling mixing ratio is listed in Table 3 Fully Formulated Ethylene Glycol TMC RP 329 Type A Fully Formulated Propylene Glycol TMC RP 330 Type A Temperature Must Not Fall Below 0 C 32 F Water plus Corrosion Inhibitors Table2 Coolant Specifications All information subject to change without notice Rev 04 08 59 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION SERVICE PROD
100. ssure 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 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 1 Open the cap on the surge tank slowly to allow excess pressure to escape Set the cap aside Corrosion Inhibiting Antifreeze Percentage by Volume Antifreeze Protection Down to C F Water Percentage by Volume Table 29 Coolant Mixing Ratio NOTICE If the concentration of antifreeze is NOTE When topping off use only a pre prepared coolant mixture containing a 50 concentration too low there is a risk of corrosion or cavitation in the cooling system All information subject to change without notice Rev 04 08 91 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION MAINTENANCE by volume of corrosion inhibiting antifreeze 3 Check the coolant level and add more coolant if necessary 4 Close and tighten the cap on the surge tank 92 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION Coolant Flushing and Changing A WARNING HOT COOLANT To avoid scalding from the expulsion of hot cool
101. t the actual distances in miles or kilometers for each maintenance operation M1 M3 The schedule of actual distances is based on the intervals listed in Table 15 The UNIMOG maintenance intervals for replacement of fluids and filters are listed by operating hours The maintenance interval tables are Maintenance Interval Table Severe Service information listed in Table 16 Maintenance Interval Table Short Haul information listed in Table 17 Maintenance Interval Table Long Haul information listed in Table 18 69 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MAINTENANCE The UNIMOG maintenance intervals for replacement of fluids and filters are listed in Table 21 Table 22 Table 23 and Table 24 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 Table 19 and Table 20 Schedule Use Before placing your new vehicle in service determine the correct maintenance intervals that apply to your intended use of the vehicle Refer to the Maintenance Schedule Table to determine the distance interval at which each maintenance operation must be performed to comply with your vehicle s schedule A detailed description of maintenance operations can be
102. th the filter element Pull both the cap and the filter element a short distance out of the filter housing See Figure 42 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 86 1 Cap main filter 2 O ring 3 Filter Element 4 Dirt Collector 5 Filter Housing Figure 42 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 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright 2008 DETROIT DIESEL CORPORATION 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 a Make sure that all high p
103. the vehicle in a heated area if possible Ensure good ventilation when recharging All information subject to change without notice Rev 04 08 63 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION TECHNICAL DATA TECHNICAL DATA General technical information is listed in Table 4 B m 4 Cylinder Engines 6 Cylinder Engines Vertical inline cylinder block with turbocharger Engine Type and charge air cooler Cooling System Liquid Circuit Combustion TERES 4 Stroke direct Sa diesel Number of Number of Cylinders Bore 4 17 in LL 4 17 in 102 mm 106 mm 102 mm 106 mm Stroke 5 11 in 5 35 in 5 11 in 5 35 in 130 mm 136 mm 130 mm 136 mm Displacement total 259 in 262 in 389 in 439 in p 4 25 liters 4 8 liters 6 37 liters 7 2 liters Compression Ratio 18 0 1 17 51 Starting Speed Approximately 100 rpm Direction of Engine Rotation viewed from Counterclockwise flywheel Starter Electric Motor The engine starts quickly without additional cold start Cold Start device in temperatures down to 15 C 5 F Temperature Limit An optional grid heater provides easy starting in Without starting aids extreme temperatures down 25 C 13 F and with battery 75 For temperatures below 25 C 13 F an optional charged grid heater with preheating for coolant and lube oil is available Table 4 General Technical Information 64 All information subject to change w
104. thorized DDEC ECU or DDEC VCU dealer for service There is internal damage to the Bring the vehicle to an authorized engine dealer for service All information subject to change without notice Rev 04 08 49 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION TROUBLESHOOTING Problem The Engine Is in Emergency Running Mode constant speed 1 300 rpm The DDEC ECU or DDEC VCU or sensor s solenoids and other electronic parts are damaged Bring the vehicle to an authorized dealer for service Problem The Coolant Temperature Is Above Normal Cause The coolant level is too low The poly V belt is loose The coolant temperature gauge and or sensor is not reading correctly The radiator is damaged or dirty The coolant pump is damaged The thermostat is damaged The fan is not operating properly 50 Remedy Check for coolant leaks and repair as needed Tighten or replace the poly V belt Bring the vehicle to an authorized dealer for service Clean the radiator Repair or replace the radiator if necessary Have an authorized dealer replace the coolant pump Have an authorized dealer replace the coolant pump Bring the vehicle to an authorized dealer and have the fan hub checked Bring the vehicle to an authorized dealer and have the parameter settings reprogrammed in the DDEC ECU or DDEC VCU All information subject to change without notice Rev 04 08 DDC SVC MAN
105. tridge Coolant Concentration Checking Coolant Flushing and Changing Cooling System Inspecting Table 20 Required Maintenance Operations Sets Schedule Il and Ill NOTE Oil Fuel and Filters Requirements If oil drain intervals are measured by 7SE270 available on the DDC operating hours an extension of the extranet oil drain interval may be possible Refer to DDC publication Lubricating 76 All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION MBE 900 OPERATOR S GUIDE NOTE The engine oil and oil filter MUST be changed EVERY 200 operating hours Mana Operating Hours omponen aintenance Change oil and oil filter oil and oil filter v Every 200 hours Fuel System Change filter and vent system v memes cwm Fo Tanemeson Change ot ang otter usus emori e es eer E Table 21 UNIMOG Service Intervals 200 1400 Operating Hours 8 TOMUS Operating Hours omponen aintenance P 2 100 2 800 3 500 Eni Change oil and oil filter oil and oil filter v Every 200 hours Fuel 1 Change filter and vent system FTO Transmission Change orara otter C meca ea T E Porn ina ra e HEH Table 22 UNIMOG Service Intervals 2100 3500 Operating Hours
106. urned off when the accelerator pedal is pressed NOTE When in emergency running mode constant rpm the engine brake can be activated only when the engine is in overrun When constant rpm has been attained the engine brake is automatically turned off Electronic Engine Control System The engine is equipped with a fully electronic control system Besides the engine and its related sensors this system is composed of the following The DDEC ECU engine control unit The DDEC VCU vehicle control unit located under the right hand dash panel The two control units are connected by a proprietary datalink through which all necessary data and information can be exchanged See Figure 16 The DDEC VCU then broadcasts all information on the J1587 and J1939 datalinks where it can be read by the Nexiq Diagnostic Data Reader DDR Detroit Diesel Diagnostic All information subject to change without notice Rev 04 08 MBE 900 OPERATOR S GUIDE Link amp DDDL PC based software or minidiag2 The engine control system monitors both the engine and the datalink When a malfunction or other problem is detected the system selects an appropriate response for example the emergency running mode may be activated 25 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION IDENTIFICATION DIAGNOSTIC CONNECTOR J1939 J1939 J1708 1587 J1708 1587 SER
107. utomotive Engineers SAE viscosity rating of the oil When topping off use only engine oils of the correct API designation and SAE rating Detroit Diesel POWER GUARD oils meet these specifications For information about oil in cold weather operation see the heading Low Viscosity Engine Oil later in this chapter 57 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION SERVICE PRODUCTS Non EGR Engines API CI 4 or CH 4 oils are recommended for use in all non EGR engines These oils are intended for engines with open breather systems Detroit Diesel POWER GUARD oils meet these specifications and are recommended Synthetic Oils Synthetic oil may be used in MBE 900 engines provided they are of the correct API designation and viscosity as required for non synthetic oil Synthetic oil offers improved low temperature flow properties and high temperature resistance to oxidation However it is generally more costly than non synthetic oil Review carefully the product information published by the synthetic oil manufacturer Performance additive systems often respond differently in synthetic oil Use of synthetic oil does not change the recommended oil change service interval Coolant Coolant is a mixture of water and antifreeze Under normal conditions it is a mixture of 50 percent water and 50 percent antifreeze but under extreme cold weather conditions as much as 60 percent antifreeze can be
108. ve the fuel s resistance to cold by about 1 C 1 8 F Never add more than 50 percent kerosene to the fuel All information subject to change without notice Rev 04 08 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION 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 factory filled with an approved engine oil NOTICE The use of non approved engine oils could affect warranty rights and cause engine damage To ensure long and trouble free service it is important to select oil of the correct viscosity and service designation EGR Engines Only multigrade oils of American 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 All information subject to change without notice Rev 04 08 MBE 900 OPERATOR S GUIDE SAE Viscosity Grade 15W 40 Classification CI 4 42541 Figure 27 Lubricant Service Mark When maintenance work is performed record engine oil changes including details of the brand used the quality category and the Society of A
109. well ventilated Observe the following cautions when Suring operation replacing the engine lubricating oil and filters WARNING PERSONAL INJURY To avoid injury from slipping and falling immediately clean up any spilled liquids WARNING FIRE To avoid injury from combustion of heated lubricating oil vapors stop the engine immediately if an oil leak is detected All information subject to change without notice Rev 04 08 9 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION IDENTIFICATION IDENTIFICATION The MBE 900 engine is built in accordance with sound technological principles and based on state of the art technology It complies with all United States Environmental Protection 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 Important Engine Information ON DaimlerBenz AG Stuttgart Germany MercedesBenz Engine Model Engine Family Engine code Exhaust Emission Control System Date of engine manufacture Advertised Output SAE gr Fuel rate at adv output Valve lash cold ins Basic injection timing Idle speed OM 906 LA CID 388 4MBXH6 37DJA Code 1 TC EMC CAC EGR 2004 260 HP 2200 rpm 132 7 3 stroke 0 016 int 0 024 exh 18 1
110. y Suwanee GA 30024 Telephone 678 341 6100 Fax 678 341 6150 WESTERN REGION 1 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 subject to change without notice Rev 04 08 EASTERN REGION 2 Detroit Michigan 13400 Outer Drive West Detroit MI 48239 4001 Telephone 313 592 5420 Fax 313 592 5887 WESTERN REGION 2 Irvine California 7700 Irvine Center Suite 275 Irvine CA 92618 Telephone 949 753 7710 Fax 949 753 7711 97 DDC SVC MAN 0055 04 08 Copyright O 2008 DETROIT DIESEL CORPORATION CUSTOMER ASSISTANCE MTU DETROIT DIESEL OFF HIGHWAY SALES AND CUSTOMER ASSURANCE CENTERS CONSTRUCTION INDUSTRIAL MARINE SALES BX6 AND MINING SALES BX7 13400 Outer Drive West 13400 Outer Drive West Detroit MI 48239 4001 Detroit MI 48239 4001 Phone 313 592 7806 Phone 313 592 5608 Fax 313 592 5137 Fax 313 592 5625 POWERGEN AND OIL FIELD SALES GOVERNMENT SALES BX9 BX11 13400 Outer Drive West 13400 Outer Drive West Detroit MI 48239 4001 Detroit MI 48239 4001 Phone 313 592 5875 Phone 313 592 5708 Fax 313 592 5158 Fax 313 592 5158 CUSTOMER ASSURANCE M24 13400 Outer Drive West Detroit MI 48239 4001 Phone 313 592 5550 Fax 313 592 5717 98 All information subject t

MBE 900 OPERATOR`S GUIDE

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