Detroit Diesel EPA04 MBE 900 User manual

DDC-SVC-MAN-0055
Specifications are subject to change without notice. Detroit Diesel Corporation
is registered to ISO 9001:2001. Copyright © Detroit Diesel Corporation.
All rights reserved. Detroit Diesel Corporation is a Daimler company.
Printed in U.S.A.
13400 Outer Drive, West, Detroit, Michigan 48239-4001
Telephone: [phone]
www.detroitdiesel.com
EPA04 MBE 900
Operator’s Manual

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 keep
fingers and clothing away from the
revolving belts, drive shafts, etc. on
engine installation.
Throughout this manual 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
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 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 trademark
of Nexiq Technologies, Inc. All other
trademarks are the property of their
respective owners.
All information subject to change without notice. (Rev. ) i
DDC-SVC-MAN-0055 Copyright © 2009 DETROIT DIESEL CORPORATION

ii All information subject to change without notice. (Rev. )
DDC-SVC-MAN-0055 Copyright © 2009 DETROIT DIESEL CORPORATION

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 ...................................................................... 5
FUEL 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 ............................................. 20
DESCRIPTION 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 ................................................................ 32
CHECKING THE COOLANT LEVEL (HOT CHECK) .................. 33
STARTING AN ENGINE THAT HAS NOT BEEN RUN FOR AN
EXTENDED PERIOD .................................................................. 34
All information subject to change without notice. (Rev. ) iii
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TABLEOFCONTENTS
MONITORING ENGINE OPERATION ............................................. 35
BATTERY CHARGE .................................................................... 35
OIL 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 ........................................................................................ 58
COOLANT SPECIFICATIONS ..................................................... 58
COOLANT CONCENTRATION ................................................... 58
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MBE 900 OPERATOR'S MANUAL
SUPPLEMENTAL COOLANT ADDITIVES FOR FULLY
FORMULATED COOLANT .......................................................... 59
DROPOUT ................................................................................... 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 .............................................................................. 63
ENGINE 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 ................................................................. 67
SHORT-HAUL ......................................................................... 68
LONG-HAUL ........................................................................... 68
OPERATING HOURS VS. FUEL CONSUMPTION (OIL DRAIN
INTERVAL ONLY) ................................................................... 68
UNIMOG .................................................................................. 68
MAINTENANCE SCHEDULE AND INTERVAL
OPERATIONS ......................................................................... 68
MAINTENANCE INTERVALS ................................................. 68
MAINTENANCE OPERATION SETS ...................................... 69
SCHEDULE USE ............................................................................. 69
MAINTENANCE TABLES AND GRAPHS ........................................ 70
REQUIRED MAINTENANCE OPERATIONS ................................... 78
ENGINE INSPECTING ................................................................ 78
VALVE LASH CHECKING AND ADJUSTING ............................. 78
GAINING ACCESS TO THE VALVES ..................................... 79
METHOD ONE: ADJUST EACH CYLINDER IN FIRING
ORDER ................................................................................... 80
METHOD TWO: ADJUST ALL VALVES USING TWO
CRANKSHAFT POSITIONS ................................................... 81
CHECKING VALVE LASH ....................................................... 82
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TABLEOFCONTENTS
ADJUSTING VALVE LASH ...................................................... 82
RESTORING THE VEHICLE TO OPERATING CONDITION .. 83
FUEL PREFILTER ELEMENT CLEANING ...................................... 83
MAIN FUEL FILTER ELEMENT CHANGING .................................. 85
ENGINE OIL AND FILTER CHANGING .......................................... 86
OIL CENTRIFUGE ....................................................................... 89
COOLANT CONCENTRATION CHECKING .................................... 90
COOLANT FLUSHING AND CHANGING ........................................ 91
COOLING SYSTEM INSPECTING .................................................. 93
CUSTOMER ASSISTANCE ................................................................. 94
WORKING WITH DDC SERVICE OUTLETS .................................. 98
STEP ONE ................................................................................... 98
STEP TWO .................................................................................. 98
STEP THREE .............................................................................. 99
LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900
ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS ......... 100
TERMS OF COVERAGE ................................................................. 100
USES ........................................................................................... 100
DEFECTS .................................................................................... 100
REPAIRS ..................................................................................... 100
WARRANTY PERIOD .................................................................. 100
LIKE REPLACEMENT ENGINE .................................................. 101
SERVICE SUPPLIES .................................................................. 101
ENGINE REMOVAL AND REINSTALLATION ............................. 101
THIS WARRANTY DOES NOT COVER: ......................................... 101
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 101
MAINTENANCE ........................................................................... 102
INCIDENTAL OR CONSEQUENTIAL DAMAGES ...................... 102
OTHER LIMITATIONS ................................................................. 102
LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900
ENGINES USED IN SCHOOL BUS APPLICATIONS ......................... 103
TERMS OF COVERAGE ................................................................. 103
USES ........................................................................................... 103
DEFECTS .................................................................................... 103
REPAIRS ..................................................................................... 103
vi All information subject to change without notice. (Rev. )
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MBE 900 OPERATOR'S MANUAL
WARRANTY PERIOD .................................................................. 103
SERVICE SUPPLIES .................................................................. 104
LIKE 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 .................................................................. 106
LIKE REPLACEMENT ENGINE .................................................. 107
SERVICE SUPPLIES .................................................................. 107
ENGINE REMOVAL AND REINSTALLATION ............................. 107
THIS WARRANTY DOES NOT COVER: ......................................... 107
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 107
MAINTENANCE ........................................................................... 108
INCIDENTAL OR CONSEQUENTIAL DAMAGES ...................... 108
OTHER LIMITATIONS ................................................................. 108
LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 900
ENGINES USED IN UNIMOG APPLICATIONS .................................. 109
TERMS OF COVERAGE ................................................................. 109
USES ........................................................................................... 109
DEFECTS .................................................................................... 109
REPAIRS ..................................................................................... 109
WARRANTY PERIOD .................................................................. 109
LIKE REPLACEMENT ENGINE .................................................. 110
SERVICE SUPPLIES .................................................................. 110
ENGINE REMOVAL AND REINSTALLATION ............................. 110
All information subject to change without notice. (Rev. ) vii
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TABLEOFCONTENTS
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
viii All information subject to change without notice. (Rev. )
DDC-SVC-MAN-0055 Copyright © 2009 DETROIT DIESEL CORPORATION

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 when
operating the engine.
FIRE
To avoid injury from fire, keep all
potential ignition sources away
from diesel fuel, including open
flames, sparks, and electrical
resistance heating elements. Do
not smoke when refueling.
PERSONAL INJURY
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
□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.
All information subject to change without notice. (Rev. ) 1
DDC-SVC-MAN-0055 Copyright © 2009 DETROIT DIESEL CORPORATION

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.
2All information subject to change without notice. (Rev. )
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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 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.
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
oilleakisdetected.
FIRE
To avoid injury from fire, do not
smoke or allow open flames when
workingonanoperatingengine.
FIRE
To avoid injury from fire from a
buildup of volatile vapors, keep
the engine area well ventilated
during operation.
All information subject to change without notice. (Rev. ) 3
DDC-SVC-MAN-0055 Copyright © 2009 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.
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 or flames near
the battery. If you come in contact
with battery acid:
□Flush your skin with water.
□Applybakingsodaorlimeto
help neutralize the acid.
□Flush your eyes with water.
□Get medical attention
immediately.
ELECTRICAL SHOCK
To avoid injury from electrical
shock, do not touch battery
terminals, alternator terminals, or
wiring cables while the engine is
operating.
4All information subject to change without notice. (Rev. )
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MBE 900 OPERATOR'S MANUAL
Cooling System
Observe the following cautions when
servicing the cooling system.
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.
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
Air Intake System
Observe the following cautions when
working on the air intake system.
PERSONAL INJURY
To avoid injury from hot surfaces,
wear protective gloves, or allow
engine to cool before removing
any component.
All information subject to change without notice. (Rev. ) 5
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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.
6All information subject to change without notice. (Rev. )
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MBE 900 OPERATOR'S MANUAL
Fuel System
Observe the following cautions when
fueling the vehicle or working with
the fuel system.
PERSONAL INJURY
To avoid injury from fuel spills,
do not overfill the fuel tank.
FIRE
To avoid injury from fire, contain
and eliminate leaks of flammable
fluids as they occur. Failure to
eliminate leaks could result in
fire.
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 if
afuelleakisdetected.
□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. ) 7
DDC-SVC-MAN-0055 Copyright © 2009 DETROIT DIESEL CORPORATION

CAUTION SUMMARY
Compressed Air
Observe the following cautions when
using compressed air.
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.
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 any
spilled liquids.
FIRE
To avoid injury from combustion
of heated lubricating-oil vapors,
stop the engine immediately if an
oil leak is detected.
FIRE
To avoid injury from fire, do not
smoke or allow open flames when
workingonanoperatingengine.
FIRE
To avoid injury from fire from a
buildup of volatile vapors, keep
the engine area well ventilated
during operation.
8All information subject to change without notice. (Rev. )
DDC-SVC-MAN-0055 Copyright © 2009 DETROIT DIESEL CORPORATION

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 Figure 1 for the
emission label for the 6-cylinder EGR
model and Figure 2 for the 4-cylinder
EGR model.
Figure 1 Emission Label, 6–Cylinder EGR Engine
All information subject to change without notice. (Rev. ) 9
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IDENTIFICATION
Figure 2 Emission Label, 4–Cylinder EGR Engine
10 All information subject to change without notice. (Rev. )
DDC-SVC-MAN-0055 Copyright © 2009 DETROIT DIESEL CORPORATION