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DDC-SVC-MAN-0055
Specifications are subject to change without notice. Detroit Diesel Corporationis registered to ISO 9001:2001. Copyright Detroit Diesel Corporation.All rights reserved. Detroit Diesel Corporation is a Daimler company.Printed in U.S.A.
13400 Outer Drive, West, Detroit, Michigan 48239-4001
Telephone: 313-592-5000
www.detroitdiesel.com
EPA04 MBE 900
Operators Manual
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MBE 900 OPERATOR'S MANUAL
To the Operator
This manual 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 manual 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 keepfingers and clothing away from the
revolving belts, drive shafts, etc. on
engine installation.
Throughout this manualCAUTIONS
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 serviceoutlets worldwide stock factory
original parts and have the specialized
equipment and experienced, trained
personnel to provide prompt
preventive maintenance and skilledengine 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 tomake changes at any time without
obligation.
NOTICE:
Coolant must be inhibited with
the recommended Supplemental
Coolant Additives (SCA) listed in
this manual. 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, DDEC, and
Diagnostic Link are registered
trademarks of Detroit Diesel
Corporation. Nexiq is a trademarkof Nexiq Technologies, Inc. All other
trademarks are the property of their
respective owners.
All information subject to change without notice. (Rev. ) iDDC-SVC-MAN-0055 Copyright 2009 DETROIT DIESEL CORPORATION
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ii All information subject to change without notice. (Rev. )DDC-SVC-MAN-0055 Copyright 2009 DETROIT DIESEL CORPORATION
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MBE 900 OPERATOR'S MANUAL
TABLE OF CONTENTS
CAUTION SUMMARY .......................................................................... 1
ENGINE OPERATION ..................................................................... 1
PREVENTIVE MAINTENANCE ....................................................... 2
ELECTRICAL SYSTEM ................................................................... 4
COOLING SYSTEM ......................................................................... 5
AIR INTAKE SYSTEM ...................................................................... 5FUEL SYSTEM ................................................................................ 7
COMPRESSED AIR ......................................................................... 8
LUBRICATING OIL AND FILTERS .................................................. 8
IDENTIFICATION ................................................................................. 9
PERSONNEL REQUIREMENTS ..................................................... 12
ENGINE CONVERSIONS AND MODIFICATIONS .......................... 13
GENERAL VIEW OF THE MBE900 ENGINE .................................. 13
ENGINE IDENTIFICATION NUMBER ............................................. 20DESCRIPTION OF THE ENGINE .................................................... 21
EXHAUST GAS RECIRCULATION ............................................. 22
EXHAUST BRAKE/CONSTANT-THROTTLE VALVES,
OPTIONAL ....................................................................................... 23
ELECTRONIC ENGINE CONTROL SYSTEM ................................. 24
DDEC-ECU .................................................................................. 25
DDEC-VCU .................................................................................. 26
SENSOR LOCATIONS .................................................................... 27
OPERATION ........................................................................................ 30
BEFORE STARTING THE ENGINE ................................................ 30
CHECKING THE BATTERIES ..................................................... 30
CHECKING THE OIL LEVEL ....................................................... 31
CHECKING THE COOLANT LEVEL (COLD CHECK) ................ 32
ADDING FUEL ............................................................................. 32
PRIMING THE FUEL SYSTEM ................................................... 32
STARTING THE ENGINE ................................................................ 32CHECKING THE COOLANT LEVEL (HOT CHECK) .................. 33
STARTING AN ENGINE THAT HAS NOT BEEN RUN FOR AN
EXTENDED PERIOD .................................................................. 34
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TABLE OF CONTENTS
MONITORING ENGINE OPERATION ............................................. 35
BATTERY CHARGE .................................................................... 35OIL PRESSURE .......................................................................... 35
EXCESSIVE IDLING ................................................................... 36
CHANGING THE IDLE SPEED ....................................................... 36
SHUTTING DOWN THE ENGINE ................................................... 36
SHUTTING DOWN AFTER HARD OPERATION ........................ 36
EMERGENCY RUNNING MODE .................................................... 37
STOP ENGINE OVERRIDE OPTION .............................................. 37
COLD WEATHER OPERATION ...................................................... 38
WINTER FRONTS ....................................................................... 38
CLEANING AND STORAGE ............................................................... 39
CLEANING THE ENGINE ................................................................ 39
HIGH-PRESSURE CLEANING EQUIPMENT ............................. 39
CLEANING THE COOLING SYSTEM ............................................. 39
DEGREASING ............................................................................. 40
STORAGE ........................................................................................ 41
TROUBLESHOOTING ......................................................................... 42
EMERGENCY STARTING ............................................................... 42
TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL
SYSTEM .......................................................................................... 42
GENERAL TROUBLESHOOTING ................................................... 42
SERVICE PRODUCTS ......................................................................... 55
DIESEL FUELS ................................................................................ 55
FLOW IMPROVERS .................................................................... 55
KEROSENE ................................................................................. 55
ENGINE OILS .................................................................................. 56
EGR ENGINES ............................................................................ 56
NON-EGR ENGINES ................................................................... 57
SYNTHETIC OILS ....................................................................... 57
COOLANT ........................................................................................ 57
FULLY-FORMULATED ANTIFREEZE ......................................... 57
WATER ........................................................................................ 58COOLANT SPECIFICATIONS ..................................................... 58
COOLANT CONCENTRATION ................................................... 58
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MBE 900 OPERATOR'S MANUAL
SUPPLEMENTAL COOLANT ADDITIVES FOR FULLY
FORMULATED COOLANT .......................................................... 59DROPOUT ................................................................................... 60
DISPOSAL ................................................................................... 60
COLD WEATHER PRODUCTS ....................................................... 60
WINTER-GRADE DIESEL FUEL ................................................. 60
LOW-VISCOSITY ENGINE OIL ................................................... 61
WINTER COOLANT ANTIFREEZE PROTECTION .................... 61
BATTERIES ................................................................................. 61
TECHNICAL DATA .............................................................................. 63ENGINE DATA FOR EGR ENGINE ................................................. 64
ENGINE DATA FOR NON-EGR ENGINE ........................................ 65
TESTING AND ADJUSTING VALUES ............................................. 66
MAINTENANCE ................................................................................... 67
SCHEDULED INTERVALS .............................................................. 67
MAINTENANCE SCHEDULE TYPES ......................................... 67
SEVERE SERVICE ................................................................. 67SHORT-HAUL ......................................................................... 68
LONG-HAUL ........................................................................... 68
OPERATING HOURS VS. FUEL CONSUMPTION (OIL DRAIN
INTERVAL ONLY) ................................................................... 68
UNIMOG .................................................................................. 68
MAINTENANCE SCHEDULE AND INTERVAL
OPERATIONS ......................................................................... 68
MAINTENANCE INTERVALS ................................................. 68
MAINTENANCE OPERATION SETS ...................................... 69
SCHEDULE USE ............................................................................. 69
MAINTENANCE TABLES AND GRAPHS ........................................ 70
REQUIRED MAINTENANCE OPERATIONS ................................... 78
ENGINE INSPECTING ................................................................ 78
VALVE LASH CHECKING AND ADJUSTING ............................. 78
GAINING ACCESS TO THE VALVES ..................................... 79
METHOD ONE: ADJUST EACH CYLINDER IN FIRING
ORDER ................................................................................... 80METHOD TWO: ADJUST ALL VALVES USING TWO
CRANKSHAFT POSITIONS ................................................... 81
CHECKING VALVE LASH ....................................................... 82
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MBE 900 OPERATOR'S MANUAL
WARRANTY PERIOD .................................................................. 103
SERVICE SUPPLIES ..................................................................104LIKE REPLACEMENT ENGINE ..................................................104
ENGINE REMOVAL AND REINSTALLATION ............................. 104
THIS WARRANTY DOES NOT COVER: ......................................... 104
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS .........................104
MAINTENANCE ...........................................................................105
INCIDENTAL OR CONSEQUENTIAL DAMAGES ......................105
OTHER LIMITATIONS .................................................................105
LIMITED WARRANTY ON NEW DETROIT DIESEL MBE
900 ENGINES USED IN FIRE TRUCK OR CRASH VEHICLE
APPLICATIONS ...................................................................................106
TERMS OF COVERAGE .................................................................106
USES ...........................................................................................106
DEFECTS ....................................................................................106
REPAIRS .....................................................................................106
WARRANTY PERIOD .................................................................. 106LIKE REPLACEMENT ENGINE ..................................................107
SERVICE SUPPLIES ..................................................................107
ENGINE REMOVAL AND REINSTALLATION ............................. 107
THIS WARRANTY DOES NOT COVER: ......................................... 107
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS .........................107
MAINTENANCE ...........................................................................108
INCIDENTAL OR CONSEQUENTIAL DAMAGES ......................108OTHER LIMITATIONS .................................................................108
LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900
ENGINES USED IN UNIMOG APPLICATIONS .................................. 109
TERMS OF COVERAGE .................................................................109
USES ...........................................................................................109
DEFECTS ....................................................................................109
REPAIRS .....................................................................................109
WARRANTY PERIOD .................................................................. 109LIKE REPLACEMENT ENGINE ..................................................110
SERVICE SUPPLIES ..................................................................110
ENGINE REMOVAL AND REINSTALLATION ............................. 110
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TABLE OF CONTENTS
THIS WARRANTY DOES NOT COVER: ......................................... 110
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 110
MAINTENANCE ...........................................................................111
INCIDENTAL OR CONSEQUENTIAL DAMAGES ......................111
OTHER LIMITATIONS .................................................................111
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MBE 900 OPERATOR'S MANUAL
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 engine
and/or vehicle/equipment damage.
Engine Operation
Observe the following cautions whenoperating the engine.
FIRE
To avoid injury from fire, keep all
potential ignition sources awayfrom diesel fuel, including open
flames, sparks, and electrical
resistance heating elements. Do
not smoke when refueling.
PERSONAL INJURY
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
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.
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CAUTION SUMMARY
Preventive Maintenance
Observe the following cautions when
performing preventative maintenance.
HOT OIL
To avoid injury from hot oil, do
not operate the engine with the
rocker cover(s) removed.
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
USED ENGINE OIL
To avoid injury to skin from
contact with the contaminants in
used engine oil, wear protective
gloves and apron.
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.
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.
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MBE 900 OPERATOR'S MANUAL
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.
PERSONAL INJURY
To avoid injury from contactwith 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.
PERSONAL INJURY
To avoid injury when using
caustic cleaning agents, follow
the chemical manufacturers
usage, disposal, and safety
instructions.
FIRE
To avoid injury from combustion
of heated lubricating-oil vapors,
stop the engine immediately if an
oil leak is detected.
FIRE
To avoid injury from fire, do not
smoke or allow open flames when
working on an operating engine.
FIRE
To avoid injury from fire from a
buildup of volatile vapors, keepthe engine area well ventilated
during operation.
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CAUTION SUMMARY
Electrical System
Observe the following cautions when
jump starting an engine, charging a
battery, or working with the vehicle
electrical system.
PERSONAL INJURY
To avoid injury from accidental
engine startup while servicing
the engine, disconnect/disable
the starting system.
Electrical Shock
To avoid injury from electrical
shock, use care when connecting
battery cables. The magnetic
switch studs are at battery
voltage.
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 orflames near
the battery. If you come in contact
with battery acid:
Flush your skin with water.
Apply baking soda or lime to
help neutralize the acid.
Flush your eyes with water.
Get medical attention
immediately.
ELECTRICAL SHOCK
To avoid injury from electricalshock, do not touch battery
terminals, alternator terminals, or
wiring cables while the engine is
operating.
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MBE 900 OPERATOR'S MANUAL
Cooling System
Observe the following cautions whenservicing the cooling system.
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, neverremove 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.
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
Air Intake System
Observe the following cautions whenworking on the air intake system.
PERSONAL INJURY
To avoid injury from hot surfaces,
wear protective gloves, or allowengine to cool before removing
any component.
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CAUTION SUMMARY
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.
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MBE 900 OPERATOR'S MANUAL
Fuel System
Observe the following cautions whenfueling the vehicle or working with
the fuel system.
PERSONAL INJURY
To avoid injury from fuel spills,
do not overfill the fuel tank.
FIRETo avoid injury from fire, contain
and eliminate leaks offlammable
fluids as they occur. Failure to
eliminate leaks could result in
fire.
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.
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 ifa 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.
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CAUTION SUMMARY
Compressed Air
Observe the following cautions when
using compressed air.
EYE INJURY
To avoid injury from flying debris
when using compressed air, wearadequate eye protection (face
shield or safety goggles) and do
not exceed 276 kPa (40 psi) air
pressure.
Lubricating Oil and Filters
Observe the following cautions when
replacing the engine lubricating oil
and filters.
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up anyspilled liquids.
FIRE
To avoid injury from combustionof heated lubricating-oil vapors,
stop the engine immediately if an
oil leak is detected.
FIRE
To avoid injury from fire, do not
smoke or allow open flames when
working on an operating engine.
FIRE
To avoid injury from fire from a
buildup of volatile vapors, keep
the engine area well ventilated
during operation.
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MBE 900 OPERATOR'S MANUAL
IDENTIFICATION
The MBE900 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 Figure1for the
emission label for the 6-cylinder EGR
model and Figure2for the 4-cylinder
EGR model.
Figure 1 Emission Label, 6Cylinder EGR Engine
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IDENTIFICATION
Figure 2 Emission Label, 4Cylinder EGR Engine
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MBE 900 OPERATOR'S MANUAL
See Figure3for the emission label for
the 6-cylinder non-EGR model. .
Figure 3 Emission Label, NonEGR 6-Cylinder
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IDENTIFICATION
See Figure4 for the 4-cylinder
non-EGR model
Figure 4 Emission Label, NonEGR 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.
The safety instructions included in
this manual are disregarded.
Personnel Requirements
Work on the engine should be carried
out only by skilled technicians whohave been instructed in the specific
skills necessary for the type of work
being performed.
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MBE 900 OPERATOR'S MANUAL
Engine Conversions and
Modifi
cationsThe 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.
General View of the
MBE900 EngineThe 2004 on-highway MBE900
engine is equipped with an Exhaust
Gas Recirculation (EGR) system to
reduce engine exhaust gas emissions
in accordance with EPA regulations.
See Figure5 for a right front view of
the MBE900 EGR engine, 6-cylinder
model, and Figure6for a left rearview.
The off-highway engine used
in construction and industrial
applications does not have an EGR
system. See Figure7for a front view
of the MBE900 non-EGR engine,
6-cylinder model, and Figure8for
a side view of the 6-cylinder model(right-hand side).
See Figure9for a front view of the
MBE900 non-EGR engine, 4-cylinder
model, and Figure9for a rear view of
the 4-cylinder model.
All information subject to change without notice. (Rev. ) 13DDC-SVC-MAN-0055 Copyright 2009 DETROIT DIESEL CORPORATION
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IDENTIFICATION
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 MBE900 EGR Engine
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MBE 900 OPERATOR'S MANUAL
1. Air Compressor 6. Oil Centrifuge
2. DDEC-ECU 7. EGR Mixer
3. Fuel Filter 8. Cylinder Head Cover
4. Thermostat Housing 9. Flywheel Housing
5. Oil Fill Cap 10. Oil Pan
Figure 6 Left Rear View of the MBE900 EGR Engine
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IDENTIFICATION
1. Fan 10. Cylinder Head Cover
2. Belt Tensioner 11. Fuel Filter
3. Alternator Pulley 12. Fuel Prefilter
4. Oil Filter 13. DDEC-ECU
5. Turbo Compressor Out 14. Air Compressor (optional)
6. Intake Manifold Inlet 15. Power-Steering Pump
7. Crankcase Breather 16. Oil Dipstick
8. Oil Fill Cap 17. Coolant Pump Pulley
9. Intake Manifold
Figure 7 Front View of 6Cylinder MBE900 Non-EGR Engine
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MBE 900 OPERATOR'S MANUAL
1. Cylinder Head Cover 7. Alternator
2. Intake Manifold 8. Turbocharger
3. Exhaust Manifold 9. Starter Motor
4. Intake Manifold Inlet 10. Flywheel Housing
5. Oil Fill Cap 11. Exhaust Brake (optional)
6. Turbo Compressor Out
Figure 8 Side View of a 6cylinder MBE900 Non-EGR Engine
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IDENTIFICATION
1. Cylinder Head Cover 9. Belt Tensioner
2. DDEC-ECU Control Unit 10. Alternator Pulley
3. Fuel Prefilter 11. Intake Manifold Inlet
4. Air Compressor (optional) 12. Turbo Compressor Out
5. Power-Steering Pump 13. Crankcase Breather
6. Oil Dipstick 14. Oil Fill Cap
7. Fuel Filter 15. Intake Manifold
8. Fan
Figure 9 Front View of 4Cylinder MBE900 Non-EGR Engine
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MBE 900 OPERATOR'S MANUAL
1. Oil Fill Cap 7. Starter Motor
2. Turbo Compressor Outlet 8. Exhaust Brake (optional)
3. Intake Manifold Inlet 9. Flywheel Housing
4. Oil Filter 10. Exhaust Manifold
5. Alternator 11. Intake Manifold
6. Turbocharger
Figure 10 Rear View of 4Cylinder MBE900 Non-EGR Engine
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IDENTIFICATION
Engine Identification
NumberThe engine identification numbers are
lasered in large font onto an enlarged
labeling surface on the rear right
crankcase. See Figure11.
Figure 11 Location of Engine
Identification Number
See Figure12 for an example of the
numbers as they appear on the engine.
Figure 12 Engine Identification
Number
The last six numbers are the serial
numbers (310187 in Figure12).
See Figure13 for an explanation of
the first six numbers found in the
engine identification number.
Figure 13 Engine Identification
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MBE 900 OPERATOR'S MANUAL
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
number is derived from the fourteen
digit number (see Figure14).
Description of the Engine
All MBE900 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 injectionnozzle, 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.
Charge-air cooling and an exhaust gas
turbocharger are standard equipmenton all MBE900 engines (charge
pressure limitation is optional).
The engine has a fully electronic
control system, which regulates the
fuel injection quantity and timing
using solenoid valves, allowing
extremely low-emission operation.
The control 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).
Figure 14 Engine Serial Number
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IDENTIFICATION
The cylinder block has integrated
oil and water channels. The uppersection 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 combustionchamber 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 bymushroom 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.
The oil cooler is located near the front
of the crankcase on the right-hand sidenear the water pump.
The gear-type fuel pump is bolted to
the front of the crankcase. The pump
is driven from the forward end of the
camshaft.
The air compressor, with a
power-steering pump attached,is driven by a gear 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 MBE900 engines for on-highwayEPA 2004 regulation applications use
a cooled EGR system.
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MBE 900 OPERATOR'S MANUAL
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.
ExhaustBrake/Constant-ThrottleValves, 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
The two systems operate
independently of each other andin 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 putunder 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.
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IDENTIFICATION
Below 900 rpm, the engine brake
is always turned off to prevent theengine from stalling. Also, the engine
brake is automatically turned 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 ControlSystem
The engine is equipped with a fully
electronic control system. Besides theengine 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 Figure16.
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
Link (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.
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MBE 900 OPERATOR'S MANUAL
Figure 16 Electronic Engine Control System
DDEC-ECU
The DDEC-ECU (see Figure17) islocated 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
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IDENTIFICATION
These data are evaluated together
with the data from the sensors onthe 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 areactuated 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 Figure18.
Data for specific applications is stored
in the DDEC-VCU. These include idle
speed, maximum running speed, and
speed limitation.
Figure 18 DDEC-VCU
The DDEC-VCU receives data from
the following sources:
The operator (accelerator pedal
position, engine brake switch)
Other electronic control units
(for example, the anti-lock brake
system)
The DDECECU (oil pressure
and coolant temperature)
From these data, instructions are
computed for controlling the engine
and transmitted to the DDEC-ECU viathe proprietary datalink.
The DDEC-VCU controls
various systems, for example,
communications with the datalink, the
engine brake, and the constant-throttle
valves.
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MBE 900 OPERATOR'S MANUAL
Sensor Locations
See Figure19and Figure20forsensor locations on the MBE900 EGR
engine. See Figure21for sensor
locations on the MBE900 non-EGR
engine.
CHEMICAL BURNS
To avoid injury from chemical
burns, wear a face shield and
neoprene or PVC gloves when
handling sensor hoses.
1. Intake Manifold Pressure/Temper-
ature Sensor
3. Engine Oil Pressure Sensor
2. Engine Oil Temperature Sensor
Figure 19 Sensor Location on the Right Side of the MBE900 EGR Engine
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IDENTIFICATION
1. EGR Temperature Sensor 4. Barometric Pressure Sensor
(integrated into DDEC-ECU)
2. Engine Coolant Temperature
Sensor
5. Camshaft Position Sensor (on
camshaft)
3. Supply Fuel Temperature Sensor 6. Crankshaft Position Sensor (on
timing case)
Figure 20 Sensor Location on the Left Side of the MBE900 EGR Engine
NOTE:
The 6-cylinder engine is shown;
sensor locations are similar on the
4-cylinder engine.
NOTE:
The Barometric Pressure Sensor is
integrated into the DDEC-ECU.
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MBE 900 OPERATOR'S MANUAL
1. Engine Oil Pressure/Temperature
Sensor
5. Barometric Pressure Sensor
(integrated into DDEC-ECU)
2. Engine Coolant Temperature
Sensor
6. Camshaft Position Sensor (on
camshaft)
3. Intake Manifold Pressure/Temper-
ature Sensor
7. Crankshaft Position Sensor (on
timing case)
4. Supply Fuel Temperature Sensor
Figure 21 Sensor Location on the MBE900 Non-EGR Engine
NOTE:
The 6-cylinder engine is shown;
sensor locations are similar on the
4-cylinder engine.
NOTE:
The Engine Oil Level Sensor, if used,
is located at the bottom of the oil pan.
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OPERATION
OPERATION
Important: Before starting the engine,
do all the recommended pretrip
inspections and daily maintenance.
Check the engine oil and fuel levels,
and drain contaminants from the
fuel/water separator (optional).
Before Starting the Engine
NOTE:
If you drain the fuel/water separator
completely, you may have to prime the
fuel system.
Be sure you are familiar with all of
the instruments, gauges and controlswhich are needed to operate the
engine.
Note especially the location and
function of the following:
Oil Pressure Gauge
Coolant Temperature Gauge
Low Oil Pressure/High Coolant
Temperature Warning Light
Water In Fuel Warning Light
Tachometer
Air Restriction Indicator
When starting the engine, and while
driving, watch for any signs of engineproblems. If the engine overheats,
uses excessive fuel or lubricating
oil, vibrates, misfires, makes unusual
noises, or shows an unusual loss of
power, turn the engine off as soon
as possible and determine the cause.
Frequently, engine damage may be
avoided by a quick response to early
indications of problems.
If you are starting the engine in cold
weather, refer to "Cold WeatherProducts" in the Service Products
section of this manual.
Checking the Batteries
Use only batteries that have been
correctly filled and serviced. To
provide corrosion protection, applydielectric grease, part number
48-02349-000, liberally to the
terminal pads. Approved suppliers are
listed in Table1.
Manufacturer Lubricant or
Part Number
Shell Oil, Co. No. 71032; No.71306
Texaco, Inc. No. 955
Quaker State No. NYK-77
Table 1 Approved Electrical
Lubricants
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MBE 900 OPERATOR'S MANUAL
NOTICE:
Never attempt to start the
Mercedes-Benz MBE900 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.
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 theengine and tighten them if
necessary.
4. Shut down the engine.
5. Approximately five minutes after
shutdown, check the engine oillevel. If necessary, add oil up to
the maximum fill level on the oil
dipstick (see Figure24). Do not
overfill.
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.
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OPERATION
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 50C (122F),
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,
certain special work must be carried
out. Refer to Storage, under
Cleaning and Storage.
Important: At outside temperatures
below 20C ( 4F), a coolantpreheater 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 after20 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 enginedamage, 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.
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MBE 900 OPERATOR'S MANUAL
Monitoring Engine
OperationWhile 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 Figure25) must go out once the
engine starts.
Figure 25 Battery Charge Indicator
Light
If the indicator light comes on
while the engine is running, do the
following:
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.
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 itsnormal 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 determinethe cause.
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OPERATION
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 MBE900
engine is 600 rpm to 850 rpm if theparameters 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 idleis fast enough.
3. To decrease the idle speed, push
the "Decel" switch until the idle
is slow enough.
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 andforth or falls sharply.
Engine power and rpm fall, even
though the accelerator pedalremains 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 thecoolant 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 shutdown the engine.
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MBE 900 OPERATOR'S MANUAL
Emergency Running Mode
The engine is equipped with theelectronic engine control system,
which monitors the engine as it is
running.
As soon as a fault is detected, it is
evaluated and one of the following
measures is initiated.
NOTICE:
To prevent possible serious engine
damage, have any faults corrected
without delay by an authorized
dealer.
In conjunction with theinstrumentation 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.
Stop Engine Override
OptionThe 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 Figure26). 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 afterfive seconds to obtain a
subsequent override.
Figure 26 Typical SEO Switch and
Warning Lamps
NOTE:
The operator has the responsibility to
take action to avoid engine damage.
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OPERATION
Cold Weather Operation
Special precautions must be taken
during cold weather. To protect
your engine, special cold weather
handling is required for fuel, engine
oil, coolant, and batteries. For detailed
information, refer to the service
manual.
Winter Fronts
A winter front may be used to improve
cab heating while idling. At least 25%
of the grill opening should remain
open in sectioned stripes that run
perpendicular to the charge air cooler
tube flow direction. This assures even
cooling across each tube and reducesheader to tube stress and possible
failure. Winter fronts should only be
used when the ambient temperature
remains below 12.2 C (10 F).
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MBE 900 OPERATOR'S MANUAL
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
onto electrical components, plug
connectors, seals orflexible 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 dirtcutters
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 CoolingSystem
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.
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CLEANING AND STORAGE
Clean as follows:
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.
1. 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 airflow).
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
water50 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 80C (176F).
Then run it for about five minutes
longer. Shut down the engine and
allow it to cool to approximately50C (112F).
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, neverremove 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.
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MBE 900 OPERATOR'S MANUAL
[c] Run the engine. Allow
the engine to warm up toapproximately 80C (176F),
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 MBE900 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 andwell-ventilated as described above.
If the engine is to be out of service
for over 12 months, or underextraordinary 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 oilmust be changed before the engine
can be brought back into service.
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TROUBLESHOOTING
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 theElectronic Engine Control
SystemWhen the electronic engine control
system detects a fault, it broadcasts
a message on the datalink. The dash
display will show the code "ECU
128," indicating there is an engine
fault.
Important: To read the complete
fault code, bring the vehicle to an
authorized dealer. Complete fault
codes can be read using ServiceLink.
For fault codes and their meanings,
see the service/workshop manual.
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.
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MBE 900 OPERATOR'S MANUAL
Problem - The Engine Will Not Crank
Cause Remedy
The batteries are damaged or weak. Test the batteries. Replace them, if
needed.
The ignition switch is damaged. Replace the ignition switch.
The battery cables are damaged
and/or corroded. Replace the battery cables.
The starter is damaged and/or worn.
Have an authorized dealer replace the
starter.
The clutch or transmission is
damaged.
Bring the vehicle to an authorized
dealer for service.
There is internal damage to the
engine.
Bring the vehicle to an authorized
dealer for service.
ProblemThe Engine Turns Over Slowly
Cause Remedy
The batteries are damaged or weak. Test the batteries. Replace them, if
needed.
The ignition switch is damaged. Replace the ignition switch.
The battery cables are damaged
and/or corroded Replace the battery cables.
The starter is damaged and/or worn. Have an authorized dealer replace thestarter.
The engine oil does not meet the
correct specifications.
Change the engine oil, using the
correct type of oil.
The transmissionfluid does not meet
the correct specifications.
Change the transmission fluid, using
the correct type offluid.
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ProblemThe Engine Cranks, But Won't Start
Cause Remedy
The batteries are damaged or weak. Test the batteries. Replace them, if
needed.
The cranking speed is not set correctly. Bring the vehicle to an authorized
dealer for service.
No intake air preheater is installed,
and it is too cold to start without one. Install an intake air preheater.
The intake air preheater is
malfunctioning.
Check the intake air preheater, and
replace it, if necessary.
The camshaft TDC sensor and/or the
crank angle position sensor are out of
adjustment.
Push both sensors into their holes as
far as they will go. If this does not
solve the problem, bring the vehicle to
an authorized dealer for service.
The camshaft TDC sensor and/or
the crank angle position sensor are
damaged.
Bring the vehicle to an authorized
dealer for service.
There is air in the fuel system.
Check the fuel lines for leaks. Bleed
the fuel system and start the engine
according to the instructions in the
service manual.
The airfilter is clogged. Clean or replace the air filter.
The fuel filter is clogged. Replace the filter element.
The exhaust brake valve is
malfunctioning.
Have an authorized dealer check the
operation of the valve.
The valves are not adjusted properly. Check the valve lash.
There are other problems in the fuel
system.
Bring the vehicle to an authorized
dealer for service.
Coolant level is too low. Check for leaks, add coolant to correct
level.
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ProblemThe Engine Starts Only After Cranking for a Long Time
Cause Remedy
The fuel tank is low or empty. Add fuel and bleed the fuel system, if
necessary.
There are leaks in the fuel lines. Check the fuel lines for leaks and
repair them, if necessary.
The fuel filter is clogged. Replace the filter element.
The fuel line, the fuel prefilter, or thescreen in the fuel tank is blocked.
Clean and bleed the system. Have
the fuel lines and filters checked by anauthorized dealer.
The camshaft TDC sensor and/or the
crank angle position sensor are out of
adjustment.
Push both sensors into their holes as
far as they will go. If this does not
solve the problem, bring the vehicle to
an authorized dealer for service.
The camshaft TDC sensor and/or
the crank angle position sensor are
damaged.
Bring the vehicle to an authorized
dealer for service.
There are other problems in the fuel
system.
Bring the vehicle to an authorized
dealer for service.
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TROUBLESHOOTING
ProblemThe Engine Starts, But Dies
Cause Remedy
The fuel tank is low or empty. Add fuel and bleed the fuel system, if
necessary.
The fuel filter is clogged. Replace the filter element.
The fuel line, the fuel prefilter, or the
screen in the fuel tank is blocked.
Clean and bleed the system. Have
the fuel lines and filters checked by an
authorized dealer.
The camshaft TDC sensor and/or the
crank angle position sensor are out of
adjustment.
Push both sensors into their holes as
far as they will go. If this does not
solve the problem, bring the vehicle to
an authorized dealer for service.
The camshaft TDC sensor and/or
the crank angle position sensor are
damaged.
Bring the vehicle to an authorized
dealer for service.
The constant-throttle valves are
malfunctioning.
Bring the vehicle to an authorized
dealer for service.
There are other problems in the fuel
system.
Bring the vehicle to an authorized
dealer for service.
ProblemThe Engine Fan Doesn't Work
Cause Remedy
The fan hub is damaged. Replace the fan hub.
The fan wiring is damaged. Repair the fan wiring.
The parameter settings in the
DDEC-ECU or DDEC-VCU are
incorrect.
Have an authorized dealer reprogram
the control unit.
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MBE 900 OPERATOR'S MANUAL
ProblemThe Engine Fan Is Constantly On
Cause Remedy
The fan override switch is 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.
Have an authorized dealer reprogram
the control unit.
ProblemFuel Consumption Is Too High
Cause Remedy
The tires are not properly inflated. Check all tires for correct pressure.
The airfilter and/or intake air system
is clogged.
Check the air restriction indicator.
Clean the intake air system and
replace the airfi
lter if necessary.The fuel filter is clogged. Replace the filter element.
The exhaust brake valve is
malfunctioning.
Have an authorized dealer check the
operation of the valve.
The engine performs poorly, or does
not develop full power.
The remedies are listed in-47"The
Engine Performs Poorly, Does Not
Develop Full Power in this section.
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TROUBLESHOOTING
ProblemThe Engine Performs Poorly, Does Not
Develop Full Power
Cause Remedy
The airfilter and/or intake air system
is clogged.
Check the air restriction indicator.
Clean the intake air system and
replace the airfilter if necessary.
The exhaust brake valve is
malfunctioning.
Have an authorized dealer check the
operation of the valve.
The fuel filter is clogged. Replace the filter element.
There are other problems with the fuel
system.
Bring the vehicle to an authorized
dealer for service.
The valves are not adjusted properly Check the valve lash.
The coolant temperature sensor is
damaged or reading incorrectly.
Bring the vehicle to an authorized
dealer for service.
The fuel temperature sensor is
damaged or reading incorrectly.
Bring the vehicle to an authorized
dealer for service.
The engine oil temperature sensor is
damaged or reading incorrectly.
Bring the vehicle to an authorized
dealer for service.
The charge-air temperature sensor is
damaged or reading incorrectly.
Bring the vehicle to an authorized
dealer for service.
There are problems with the
DDEC-ECU or DDEC-VCU.
Bring the vehicle to an authorized
dealer for service.
There is internal damage to theengine.
Bring the vehicle to an authorizeddealer for service.
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MBE 900 OPERATOR'S MANUAL
ProblemThe Engine Is in Emergency Running Mode
(constant speed 1,300 rpm)Cause Remedy
The DDEC-ECU or DDEC-VCU
or sensor(s), solenoids and other
electronic parts are damaged.
Bring the vehicle to an authorized
dealer for service.
ProblemThe Coolant Temperature Is Above Normal
Cause Remedy
The coolant level is too low. Check for coolant leaks, and repair as
needed.
The poly-V belt is loose. Tighten or replace the poly-V belt.
The coolant temperature gauge and/or
sensor is not reading correctly.
Bring the vehicle to an authorized
dealer for service.
The radiator is damaged or dirty. Clean the radiator. Repair or replacethe radiator if necessary.
The coolant pump is damaged. Have an authorized dealer replace the
coolant pump.
The thermostat is damaged. Have an authorized dealer replace the
coolant pump.
The fan is not operating properly.
Bring the vehicle to an authorized
dealer and have the fan hub checked.
Bring the vehicle to an authorizeddealer and have the parameter
settings reprogrammed in the
DDEC-ECU or DDEC-VCU.
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TROUBLESHOOTING
ProblemThe Coolant Temperature Is Below Normal
Cause Remedy
The coolant temperature gauge and/or
sensor is not reading correctly.
Bring the vehicle to an authorized
dealer for service.
The thermostat is damaged. Have an authorized dealer replace the
thermostat.
The fan is not operating properly.
Bring the vehicle to an authorized
dealer and have the fan hub checked.
Bring the vehicle to an authorizeddealer and have the parameter
settings reprogrammed in the
DDEC-ECU or DDEC-VCU.
ProblemThe Cooling System Is Losing Coolant
Cause Remedy
There is an external coolant leak. Repair the leaking component.
The radiator cap is leaking. Replace the radiator cap.
The air compressor head is damaged. 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. Bring the vehicle to an authorized
dealer.
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MBE 900 OPERATOR'S MANUAL
ProblemThere Is Coolant in the Engine Oil
Cause Remedy
The cylinder head gasket is damaged. Have an authorized dealer replace the
head gasket.
The oil/water heat exchanger is
leaking.
Have an authorized dealer replace the
heat exchanger.
There is an internal coolant leak. Bring the vehicle to an authorized
dealer for service.
ProblemThere Is Foam in the Engine Oil
Cause Remedy
The oil level is too low or too high. Correct the oil level.
The oil has not been changed within
the recommended interval. Change the oil.
The oil is not of the recommendedquality.
Change the oil.
ProblemThe Engine Oil Pressure Is Low
Cause Remedy
The oil pressure gauge and/or sensor
is not reading correctly.
Bring the vehicle to an authorized
dealer for service.
There is fuel in the oil. Bring the vehicle to an authorized
dealer for service.
The oil filter is clogged. Replace the filter element.
The oil filter bypass valve is damaged. Replace the bypass valve.
The oil pump and/or relief valve is
damaged.
Have an authorized dealer replace the
oil pump.
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ProblemThe Engine Exhaust Is White
Cause Remedy
The fuel is of poor quality. Add fuel of the right quality.
The intake air preheater is
malfunctioning.
Check the intake air preheater, and
replace it, if necessary.
The valves are not adjusted properly. Check the valve lash.
ProblemThe Engine Exhaust Is Black
Cause Remedy
The airfilter and/or intake air system
is clogged.
Check the air restriction indicator.
Clean the intake air system and
replace the airfilter if necessary.
The exhaust brake valve is
malfunctioning.
Have an authorized dealer check the
operation of the valve.
The intake air preheater is
malfunctioning.
Check that the heater is not staying on
all of the time.
The valves are not adjusted properly. Check the valve lash.
There is damage to the fuel system:
the fuel pump, one or more fuel
injectors, or one or more unit pumps
are damaged.
Bring the vehicle to an authorized
dealer for service.
The charge-air temperature sensor isdamaged.
Bring the vehicle to an authorizeddealer for service.
There is internal damage to the
engine.
Bring the vehicle to an authorized
dealer for service.
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ProblemThe Engine Exhaust Is Blue
Cause Remedy
The engine oil level is too high
(engine oil is reaching the combustion
chamber).
Adjust the oil level, and then have the
oil level checked by an authorized
dealer.
The turbocharger is leaking oil. Have an authorized dealer replace the
turbocharger
The valve stem seals are loose or
damaged.
Have an authorized dealer replace the
seals.
The piston rings are worn. Have an authorized dealer replace the
piston rings.
ProblemEngine Brake Performance Is Poor
Cause Remedy
The engine brake control switch is
damaged. Replace the switch
The exhaust brake is not operating
properly.
Have an authorized dealer check the
operation of the valve.
The constant-throttle valves are
malfunctioning.
Bring the vehicle to an authorized
dealer for service.
Components of the DDEC-ECU and/or
DDEC-VCU are damaged.
Bring the vehicle to an authorized
dealer for service.
ProblemCruise Control Is Not Working
Cause Remedy
One or more of the cruise control
switches are damaged. Replace the damaged switch.
Components of the DDEC-ECU and/or
DDEC-VCU are damaged or notworking properly.
Bring the vehicle to an authorized
dealer for service.
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ProblemThe Battery Charge Indicator Light Does Not
Come On When the Engine Is Not Running
Cause Remedy
The bulb is damaged. Change the bulb.
The circuit is broken. Repair the break in the circuit.
ProblemThe Battery Charge Indicator Light Comes
On When the Engine is Running
Cause Remedy
The poly-V belt is too loose.
Check the belt tension; if necessary,
have an authorized dealer replace the
belt tensioner.
The belt tensioner is damaged. Have an authorized dealer replace the
belt tensioner.
The poly-V belt is worn or damaged. Replace the belt.
The alternator is damaged (has a
damaged rectifier or voltage regulator).
Have an authorized dealer replace the
alternator.
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MBE 900 OPERATOR'S MANUAL
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
responsible 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 fueladditives 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.
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 sectionWinter-Grade Diesel Fuel" later in
this chapter.
Flow Improvers
The effectiveness offlow 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 offive percent by
volume of kerosene will improve
the fuel's resistance to cold by about
1C (1.8F). Never add more than 50
percent kerosene to the fuel.
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SERVICE PRODUCTS
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 OilsThe 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 PGOS 93K214 or CI-4
Plus quality engine oils will achieve
proper performance for the cooled
EGR engines. Detroit Diesel POWER
GUARD oils meet this specificationand are recommended. Look for
the service mark printed on the oil
container. See Figure27.
Figure 27 API Lubricant Service
Mark
When maintenance work is performed,
record engine oil changes including
details of the brand used, the
quality category, and the Societyof Automotive Engineers (SAE)
viscosity rating of the oil. When
topping off, use only engine oils
of the correct