MBE 926 Manual

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MBE 900 OPERATOR'S GUIDE MBE 900 OPERATOR'S GUIDE

To the Operator

This guide contains instructions on This guide contains instructions on the safe operation and preventive the safe operation and preventive maintenance of your Detroit Diesel maintenance of your Detroit Diesel MBE 900 eng

MBE 900 engine. ine. MainMaintenatenancence instructions cover routine engine instructions cover routine engine services such as lube oil and

services such as lube oil and ﬁﬁlter lter changes in enough detail to permit changes in enough detail to permit self-ser

self-servicing if vicing if desireddesired..

The operator should become familiar The operator should become familiar with the contents of this guide before with the contents of this guide before operating the engine or carrying out operating the engine or carrying out maintenance

maintenance proceduprocedures.res.

Power-driven equipment is only Power-driven equipment is only as safe as the person operating the as safe as the person operating the cont

controlsrols. . YYou are urgeou are urged, as d, as thethe

operator of this diesel engine, to keep operator of this diesel engine, to keep ﬁ

ﬁngers and clothing away from thengers and clothing away from the revolving belts, drive shafts, etc. on revolving belts, drive shafts, etc. on engine

engine installationinstallation.. Throughout this guide

Throughout this guide CAUTIONSCAUTIONS regarding personal safety and

regarding personal safety and NOTICES

NOTICES regarding engineregarding engine performance or service life will performance or service life will

appear. To avoid personal injury and appear. To avoid personal injury and ensure long engine service life,

ensure long engine service life, alwaysalways heed these instructions.

heed these instructions.

Whenever possible, it will bene

Whenever possible, it will beneﬁﬁt yout you to rely on an authorized Detroit Diesel to rely on an authorized Detroit Diesel service outlet for all your service

service outlet for all your service needs from maintenance to major needs from maintenance to major parts replacement. Authorized service parts replacement. Authorized service

outlets worldwide stock factory outlets worldwide stock factory

original parts and have the specialized original parts and have the specialized equipment and experienced, trained equipment and experienced, trained

personnel to provide prompt personnel to provide prompt

preventive maintenance and skilled preventive maintenance and skilled

engine repairs. engine repairs.

The information and speci

The information and speciﬁﬁcationscations in this publication are based on the in this publication are based on the information in effect at the time of information in effect at the time of appr

approvaoval l for prinfor printingting. . ConContact antact an authorized Detroit Diesel service authorized Detroit Diesel service outlet for information on the latest outlet for information on the latest revi

revisionsion. . The righThe right is t is resereserverved tod to make changes at any time without make changes at any time without obligation.

obligation.

NOTICE: NOTICE:

Coolant must be inhibited with Coolant must be inhibited with the recommended Supplemental the recommended Supplemental Coolant Additives (SCA) listed in Coolant Additives (SCA) listed in this guide

this guide. . In additioIn addition, the enginen, the engine can be equipped with a coolant can be equipped with a coolant

ﬁﬁlter/inhibitor system as an installedlter/inhibitor system as an installed option or as an after-sale item. option or as an after-sale item. Failure to check and maintain SCA Failure to check and maintain SCA levels at required concentrations will levels at required concentrations will result in severe damage corrosion result in severe damage corrosion to the engine cooling system and to the engine cooling system and related components.

related components.

Trademark Information

Detroit Diesel®, DDEC®, and Detroit Diesel®, DDEC®, and Diagnostic Link® are registered Diagnostic Link® are registered trademarks of Detroit Diesel trademarks of Detroit Diesel

Corporation. Nexiq™ is a trademark Corporation. Nexiq™ is a trademark of Nexiq Technologies, Inc. All other of Nexiq Technologies, Inc. All other trademarks are the property of their trademarks are the property of their respective owners.

respective owners.

All information subject to change without notice.

All information subject to change without notice. (Rev. 04/08)(Rev. 04/08) ii DDC-S

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ii

ii All information subject to change without notice.All information subject to change without notice. (Rev. 04/08)(Rev. 04/08) DDC-S

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MBE 900 OPERATOR'S GUIDE

opening with ﬁﬁnger or conductivenger or conductive items (e.g. screwdriver or wire). items (e.g. screwdriver or wire). High voltage can remain inside High voltage can remain inside the Electrostatic Oil Separator for the Electrostatic Oil Separator for up to 12 hours after the ignition up to 12 hours after the ignition is turned off.

is turned off.

All information subject to change without notice. (Rev. 04/08)(Rev. 04/08) 55 DDC-S

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CAUTION SUMMARY CAUTION SUMMARY

Cooling System

Observe the following cautions when Observe the following cautions when servicing the cooling system.

servicing the cooling system.

HOT COOLANT HOT COOLANT To avoid scalding from the To avoid scalding from the

expulsion of hot coolant, never expulsion of hot coolant, never remove the cooling system remove the cooling system

pressure cap while the engine is pressure cap while the engine is at operating tem

at operating temperatureperature. . Wear Wear adequate protective clothing adequate protective clothing (face shield, rubber gloves, (face shield, rubber gloves, apr

apron, and boots). on, and boots). RemRemove theove the cap slowly to relieve pressure. cap slowly to relieve pressure.

PERSONAL INJURY PERSONAL INJURY

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

spilled liquids.

Air Intake System

Observe the following cautions when Observe the following cautions when working on the air intake system. working on the air intake system.

To avoid injury from hot surfaces, To avoid injury from hot surfaces, wear protective gloves, or allow wear protective gloves, or allow engine to cool before removing engine to cool before removing any component.

any component.

PERSONAL INJURY PERSONAL INJURY To avoid injury from contact To avoid injury from contact with rotating parts when an with rotating parts when an engine is operating with the air engine is operating with the air inlet piping removed, install an inlet piping removed, install an air inlet screen shield over the air inlet screen shield over the turbocharger air inlet. The shield turbocharger air inlet. The shield prevents contact with rotating prevents contact with rotating parts.

parts.

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6 All information subject to change without notice.All information subject to change without notice. (Rev. 04/08)(Rev. 04/08) DDC-S

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Fuel System

Observe the following cautions when Observe the following cautions when fueling the vehicle or working with fueling the vehicle or working with the fuel system.

the fuel system.

To avoid injury from fuel spills, To avoid injury from fuel spills, do not over

do not over ﬁﬁll the fuel tank.ll the fuel tank.

FIRE FIRE To avoid injury from

To avoid injury from _ﬁ_ﬁre, containre, contain and eliminate leaks of

and eliminate leaks of ﬂﬂammableammable

ﬂ

ﬂuids as they occur. uids as they occur. FailFailure toure to eliminate leaks could result in eliminate leaks could result in

ﬁ ﬁre.re.

PERSONAL INJURY PERSONAL INJURY To prevent the escape of high To prevent the escape of high pressure fuel that can penetrate pressure fuel that can penetrate skin, ensure the engine has skin, ensure the engine has been shut down for a minimum been shut down for a minimum of 10 minutes before servicing of 10 minutes before servicing any component within the high any component within the high pressur

pressure circuite circuit. . Residual higResidual highh fuel pressure may be present fuel pressure may be present within the circuit.

within the circuit.

FIRE FIRE To avoid injury from

To avoid injury from _ﬁ_ﬁre, keep allre, keep all potential ignition sources away potential ignition sources away from diesel fuel, including open from diesel fuel, including open

ﬂ

ﬂames, sparks, and electricalames, sparks, and electrical resistance heating elements. Do resistance heating elements. Do not smoke when refueling.

not smoke when refueling.

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CAUTION SUMMARY

FIRE

To avoid injury from ﬁre caused by heated diesel-fuel vapors:

□ Keep those people who are not

directly involved in servicing away from the engine.

□ Stop the engine immediately if

a fuel leak is detected.

□ Do not smoke or allow open

ﬂames when working on an operating engine.

□ Wear adequate protective

clothing (face shield,

insulated gloves and apron, etc.).

□ To prevent a buildup of

potentially volatile vapors, keep the engine area well ventilated during operation.

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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

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, keep the engine area well ventilated during operation.

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IDENTIFICATION

The MBE 900 engine is built in

accordance with sound technological principles and based on state-of-the-art

technology. It complies with all United States Environmental Protection

Agency (USEPA) and California Air Resources Board (CARB) emission

standards. An emission label is

attached to the cylinder head cover, as required by law. See Figure 1 for the emission label for the 6-cylinder EGR model and Figure 2 for the 4-cylinder EGR model.

Figure 1 Emission Label, 6–Cylinder EGR Engine

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Figure 2 Emission Label, 4–Cylinder EGR Engine

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IDENTIFICATION

See Figure 3 for the emission label for the 6-cylinder non-EGR model. .

Figure 3 Emission Label, Non–EGR 6-Cylinder

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See Figure 4 for the 4-cylinder non-EGR model

Figure 4 Emission Label, Non–EGR 4-Cylinder

Despite this, the engine may constitute a risk of damage to property or

injury to persons under the following conditions:

□ It is not used for its intended

purpose.

□ It is modiﬁed or converted in an

incorrect manner.

□ The safety instructions included in

this manual are disregarded.

Personnel Requirements

Work on the engine should be carried out only by skilled technicians who have been instructed in the speciﬁc skills necessary for the type of work being performed.

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IDENTIFICATION

Engine Conversions and

Modi

ﬁ

cations

The function and safety of the engine could be affected if unauthorized modiﬁcations are made. Detroit Diesel will not accept responsibility for any resulting damage.

Tampering with the fuel injection system and engine electronics could also affect the engine's power output or exhaust emission levels. Compliance with the manufacturer's settings

and with statutory environmental protection regulations cannot then be

guaranteed.

General View of the MBE

900 Engine

The 2004 on-highway MBE 900 engine is equipped with an Exhaust Gas Recirculation (EGR) system to reduce engine exhaust gas emissions in accordance with EPA regulations. See Figure 5 for a right front view of the MBE 900 EGR engine, 6-cylinder model, and Figure 6 for a left rear view.

The off-highway engine used in construction and industrial

applications does not have an EGR system. See Figure 7 for a front view of the MBE 900 non-EGR engine, 6-cylinder model, and Figure 8 for a side view of the 6-cylinder model (right-hand side).

See Figure 9 for a front view of the MBE 900 non-EGR engine, 4-cylinder model, and Figure 9 for a rear view of the 4-cylinder model.

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1. Turbocharger 7. EGR Mixer 2. Starter Motor 8. Oil Fill Cap 3. Flywheel Housing 9. Oil Filter

4. Exhaust Manifold 10. Turbocharger Compressor Out 5. EGR Cooler 11. Belt Tensioner Assembly

6. Cylinder Head Cover 12. Oil Pan

Figure 5 Right Front View of the MBE 900 EGR Engine

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IDENTIFICATION

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 MBE 900 EGR Engine

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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 6–Cylinder MBE 900 Non-EGR Engine

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IDENTIFICATION

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 6–cylinder MBE 900 Non-EGR Engine

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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 4–Cylinder MBE 900 Non-EGR Engine

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IDENTIFICATION

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 4–Cylinder MBE 900 Non-EGR Engine

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Engine Identi

ﬁﬁ

cation

Number

The engine identi

The engine identiﬁﬁcation numbers arecation numbers are lasered in large font onto an enlarged lasered in large font onto an enlarged labeling surface on the rear right labeling surface on the rear right crankcase. See Figure

crankcase. See Figure 1111..

Fig

Figure ure 111 1 LocLocatation ion of Eof Enginginene Identi

Identiﬁﬁcation Number cation Number

See Figure

See Figure 1212 for an example of thefor an example of the numbers as they appear on the engine. numbers as they appear on the engine.

Fi

Figugure re 12 12 EnEngigine ne IdIdenentiti_ﬁ_ﬁcationcation Number

Number

The last six numbers are the serial The last six numbers are the serial numbers (310187 in Figure

numbers (310187 in Figure 1212).). See Figure

See Figure 1313 for an explanation of for an explanation of the

the ﬁﬁrst six numbers found in therst six numbers found in the engine identi

engine identiﬁﬁcation number.cation number.

Fig

Figure ure 13 13 EngEngine ine IdeIdentntiiﬁﬁcationcation

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IDENTIFICATION IDENTIFICATION

NOTE: NOTE:

In addition to the fourteen digit number In addition to the fourteen digit number etched on the crankcase, there is a etched on the crankcase, there is a ten digit number used for warranty ten digit number used for warranty and service that is found on the and service that is found on the DDE

DDEC-EC-ECU labeCU label. l. The ten digThe ten digitit number is derived from the fourteen number is derived from the fourteen digit number (see Figure

digit number (see Figure 1414).).

Description of the Engine

All MBE 900 engines are All MBE 900 engines are water-coo

water-cooled, led, four-sfour-stroke,troke,

direct-injection diesel engines. direct-injection diesel engines.

The cylinders are arranged inline on The cylinders are arranged inline on both the 6-cylinder and 4-cylinder both the 6-cylinder and 4-cylinder

mod

models. els. Each haEach has a s a sepaseparate fuerate fuell injection pump (unit pump) with a injection pump (unit pump) with a short injection line to the injection short injection line to the injection nozzle, which is located in the center nozzle, which is located in the center of the combustion chamber. The unit of the combustion chamber. The unit pumps are attached to the crankcase pumps are attached to the crankcase

and are driven from the camshaft. and are driven from the camshaft. Each cylinder has two intake valves Each cylinder has two intake valves and one exhaust valve.

and one exhaust valve.

Charge-air cooling and an exhaust gas Charge-air cooling and an exhaust gas turboch

turbocharger are arger are standarstandard d equipmenequipmentt on all MBE 900 engines (charge on all MBE 900 engines (charge press

pressure limitation ure limitation is is optionaoptional).l). The engine has a fully electronic The engine has a fully electronic control system, which regulates the control system, which regulates the fuel injection quantity and timing fuel injection quantity and timing using solenoid valves, allowing using solenoid valves, allowing extremely

extremely low-emisslow-emission ion operatiooperation.n. The control system consists of an The control system consists of an engine-resident pump and nozzle engine-resident pump and nozzle control unit (the DDEC-ECU) and a control unit (the DDEC-ECU) and a vehi

vehicle contcle controlrol unit (thunit (thee DDECDDEC-VC-VCU).U). Th

Thee twtwoo araree coconnnnecectetedd byby aa prpropopririetetararyy datalink.

datalink.

Engine braking is controlled by a Engine braking is controlled by a pneumat

pneumatic ic and and hydraulihydraulic c (6-cyli(6-cylinder)nder) operated exhaust brake on the

operated exhaust brake on the

turbocharger and by a constant-throttle turbocharger and by a constant-throttle system

system (option(optional).al).

Fig

Figurure e 14 14 EngEngine ine SeSeriarial Nl Numumber ber

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22 All information subject to change without notice.All information subject to change without notice. (Rev. 04/08)(Rev. 04/08) DDC-S

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The cylinder block has integrated The cylinder block has integrated oil and water chan

oil and water channelsnels. . The uppeThe upper r section of the cylinder bore is

section of the cylinder bore is induction

induction-harden-hardened. ed. The single-pieceThe single-piece cylinder head is made of cast

cylinder head is made of cast iron

iron. . The cyliThe cylindender head gaskr head gasket is aet is a medal-elas

medal-elastomere, tomere, adjustmenadjustment-freet-free seal with Viton® sealing elements. seal with Viton® sealing elements. The pistons are made of aluminum The pistons are made of aluminum alloy with a shallow combustion alloy with a shallow combustion cham

chamber recber recess. ess. The pisThe pistons aretons are cooled by oil spray nozzles.

cooled by oil spray nozzles.

The crankshaft is precision-forged The crankshaft is precision-forged with seven main bearings (

with seven main bearings (ﬁﬁve onve on the 4-cylinder engine), six of which the 4-cylinder engine), six of which have

have custom-fcustom-forgeorged d counterwcounterweightseights (four on the 4-cylinder engine), and a (four on the 4-cylinder engine), and a vibration damper at the front end. vibration damper at the front end. The camshaft is made of

The camshaft is made of

case-hardened steel and has seven case-hardened steel and has seven main bearings (

main bearings (ﬁﬁve on the 4-cylinder ve on the 4-cylinder engi

engine)ne). . Each cylinEach cylinder has cams for der has cams for intake and exhaust valves and a unit intake and exhaust valves and a unit pump.

pump.

The valves are controlled by The valves are controlled by mushroom tappets, pushrods, and mushroom tappets, pushrods, and rock

rocker arms. er arms. The intaThe intake valves areke valves are opened and closed by a valve-guided opened and closed by a valve-guided bridge.

bridge.

There is a force-feed lubricating oil There is a force-feed lubricating oil circuit supplied by a rotary oil pump. circuit supplied by a rotary oil pump. This pump is positioned at the front This pump is positioned at the front of the crankcase and driven by gears of the crankcase and driven by gears from the crankshaft.

from the crankshaft.

The oil cooler is located near the front The oil cooler is located near the front of the

of the crankcascrankcase on e on the right-hand sidethe right-hand side near the water pump.

near the water pump.

The gear-type fuel pump is bolted to The gear-type fuel pump is bolted to the front of the crankcase. The pump the front of the crankcase. The pump is driven from the forward end of the is driven from the forward end of the camshaft.

camshaft.

The air compressor, with a The air compressor, with a power-steering pump attached, power-steering pump attached,

is driven by a gear on the camshaft is driven by a gear on the camshaft (optional).

(optional).

The vehicle is cooled by a closed The vehicle is cooled by a closed system using recirculated coolant; system using recirculated coolant; temperature is regulated automatically temperature is regulated automatically by a thermostat.

by a thermostat.

The alternator and coolant pump (and The alternator and coolant pump (and any other accessories) are driven by a any other accessories) are driven by a belt with automatic belt tensioner. belt with automatic belt tensioner.

Electrical equipment includes a starter Electrical equipment includes a starter and an alternator.

and an alternator.

Exhaust Gas Recirculation Exhaust Gas Recirculation

The purpose of the Exhaust Gas The purpose of the Exhaust Gas Recirculation (EGR) System is to Recirculation (EGR) System is to reduce engine exhaust gas emissions reduce engine exhaust gas emissions in

in accordanaccordance ce with EPwith EPA A regulatioregulations.ns. The EGR system consists of an EGR The EGR system consists of an EGR cooler, EGR valve, reed valves (on the cooler, EGR valve, reed valves (on the MBE904/924/926 only), and an EGR MBE904/924/926 only), and an EGR mixer.

mixer. The MBE

The MBE 900 engines for on-highway900 engines for on-highway EPA 2004 regulation applications use EPA 2004 regulation applications use a cooled EGR system.

a cooled EGR system.

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IDENTIFICATION

Exhaust gases from the front three cylinders on six cylinder engines (all four cylinders on four cylinder engines) are routed from the exhaust manifold through the EGR cooler, past control and reed valves, and

mixed with the intake manifold charge air. The addition of cooled exhaust gases back into the combustion

air ﬂow reduces the peak in cylinder combustion temperature. Less oxides of nitrogen (NOx) are produced at lower combustion temperatures.

Exhaust

Brake/Constant-Throttle

Valves, Optional

To increase braking performance, the engine can be equipped with an exhaust brake on the turbocharger in conjunction with constant-throttle valves in the cylinder head. See Figure 15.

Figure 15 Constant — Throttle Activation

The two systems operate

independently of each other and in combination.

Exhaust back pressure is used by the exhaust brake to increase braking performance. The constant-throttle

valves use the air that escapes through them on the compression stroke to provide braking force.

The constant-throttles valves are small valves which are built into the cylinder head and positioned opposite the exhaust valve. When open, a link is created between the combustion chamber and the exhaust port.

When the engine brake is switched on, the constant-throttle valves are put under pressure, which in turn opens the valves.

On the 6-cylinder model, the

constant-throttle valves are activated by engine oil pressure. On 4-cylinder

engines, the constant-throttle valves are activated by compressor air pressure.

The engine brake is activated by the DDEC-VCU and can be activated only at engine speeds up to 2700 rpm.

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Below 900 rpm, the engine brake is always turned off to prevent the engine 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 Control

System

The engine is equipped with a fully electronic control system. Besides the engine and its related sensors, this system is composed of the following:

□ The DDEC-ECU (engine control

unit)

□ The DDEC-VCU (vehicle control

unit) located under the right-hand dash panel

The two control units are connected by a proprietary datalink through which all necessary data and information can be exchanged. See Figure 16.

The DDEC-VCU then broadcasts all information on the J1587 and J1939 datalinks, where it can be read by the Nexiq™ Diagnostic Data Reader (DDR), Detroit Diesel Diagnostic

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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IDENTIFICATION

Figure 16 Electronic Engine Control System

DDEC-ECU

The DDEC-ECU (see Figure 17) is located on the left-hand side of the engine.

The DDEC-ECU processes the data received from the DDEC-VCU, for example the position of the accelerator pedal, engine brake, etc.

Figure 17 DDEC-ECU

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These data are evaluated together with the data from the sensors on the engine, such as coolant and fuel temperature and oil and charge pressure.

The data is then compared to the characteristic maps or lines stored in the DDEC-ECU. From these data, quantity and timing of injection are calculated and the unit pumps are actuated accordingly through the solenoid valves.

NOTE:

To obtain a replacement DDEC-ECU, all the data given on the DDEC-ECU label are required.

The DDEC-ECU data label has the 10 digit engine serial number (see Figure 14), the engine horse power and

torque.

DDEC-VCU

The DDEC-VCU communicates with any other electronic control unit installed on the vehicle over the J1587 data link. See Figure 18.

Data for speciﬁc applications is stored in the DDEC-VCU. These include 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 DDEC—ECU (oil pressure

and coolant temperature) From these data, instructions are computed for controlling the engine and transmitted to the DDEC-ECU via the proprietary datalink.

The DDEC-VCU controls various systems, for example,

communications with the datalink, the engine brake, and the constant-throttle valves.

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IDENTIFICATION

Sensor Locations

See Figure 19 and Figure 20 for sensor locations on the MBE 900

EGR engine. See Figure 21 for sensor locations on the MBE 900 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 MBE 900 EGR Engine

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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 MBE 900 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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IDENTIFICATION

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 MBE 900 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

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 controls which 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 engine problems. 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 Weather Products" 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, apply

dielectric grease, part number 48-02349-000, liberally to the

terminal pads. Approved suppliers are listed in Table 1.

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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OPERATION

Battery Explosion and Acid Burn To avoid injury from battery

explosion or contact with battery acid, work in a well ventilated area, wear protective clothing, and avoid sparks or _ﬂames near the battery. If you come in contact with battery acid:

□ Flush your skin with water. □ Apply baking soda or lime to

help neutralize the acid.

□ Flush your eyes with water. □ Get medical attention

immediately.

Checking the Oil Level

Check the oil level as follows:

1. Check the oil level using the oil dipstick (see Figure 22).

PERSONAL INJURY

Figure 22 Oil Dipstick

2. If necessary, top off by filling engine oil through the oil fill collar (see Figure 23) until the maximum fill level on the oil dipstick (see Figure 22) has been reached. For detailed procedures, refer to the ”Maintenance”

section. Do not over ﬁll.

Figure 23 Oil Fill Collar

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Checking the Coolant Level (Cold Check)

Check the coolant level as follows: 1. Ensure that all coolant plugs in

the bottom of the radiator and on the radiator outlet pipe are secure and tight.

2. Check the coolant level. The cooling system is correctly ﬁlled when the coolant is between the maximum and minimum marks on the surge tank.

NOTE:

For more information, refer to the ”Maintenance” section.

Adding Fuel

Note the following when adding fuel:

□ Add winter or summer grade fuel

according to the season of the year.

□ Work in the cleanest conditions

possible.

□ Prevent water from entering the

fuel tank. For further information refer to “Diesel Fuels” in “Service Products.”

Priming the Fuel System

Prime the fuel system as follows:

NOTICE:

Correct torque on the high pressure lines is critical. Incorrect torques could result in leaks or lack of power due to restricted fuel ﬂow.

1. Make sure that all high-pressure and low-pressure lines are

securely tightened.

2. If equipped with a hand pump on the fuel/water separator, work the hand pump 50 times.

3. Crank the engine for 30 seconds at a time, but no longer. Before cranking the engine again, wait at least two minutes. The engine should start within six 30-second attempts.

Starting the Engine

Before operating the engine, follow the steps described in the “Before Starting the Engine” section. Start the engine as follows:

NOTE:

As a safety function, the electronic engine control system may be wired to start the engine only if the transmission is in neutral. This is vehicle application speciﬁc.

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OPERATION

NOTICE:

Never attempt to start the

Mercedes-Benz MBE 900 engine using ether or any other starting

ﬂuid. Serious engine damage could result.

1. Turn on the ignition switch.

2. With the accelerator pedal in the idle position, start the engine.

PERSONAL INJURY To avoid injury when working near or on an operating engine, remove loose items of clothing and jewelry. Tie back or contain long hair that could be caught in any moving part causing injury.

3. Check the engine for leaks.

[a] Check all hoses, hose clamps, and pipe unions on the engine for tightness. Shut down the engine and tighten them if necessary.

[b] Check the oil feed and return lines at the turbocharger for tightness. Shut down the engine and tighten them if necessary.

4. Shut down the engine.

5. Approximately five minutes after shutdown, check the engine oil level. If necessary, add oil up to the maximum fill level on the oil dipstick (see Figure 24). Do not over fill.

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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2. Then, with the coolant

temperature above 50°C (122°F), recheck the coolant level.

3. Add more coolant if necessary. Open the heater valves before adding coolant.

4. Do not close the heater valves until the engine has been run brieﬂy and the coolant level

again checked and corrected as necessary.

Starting an Engine That Has Not Been Run for an Extended Period

Before starting an engine which has not been run for an extended period, certain special work must be carried out. Refer to “Storage,” under

“Cleaning and Storage.”

Important: At outside temperatures below –20°C (– 4°F), a coolant preheater is recommended.

1. Chock the tires, place the

transmission in neutral, and set the parking brake.

2. Turn on the ignition switch and start the engine

3. If the engine doesn't start after 20 seconds, stop. Try again after waiting about one minute.

NOTICE:

Do not rev the engine if the oil pressure gauge indicates no oil pressure. To avoid engine damage, shut down the engine if no oil pressure appears within approximately ten seconds. Check to determine the cause of the

problem.

4. Monitor the oil pressure gauge immediately after starting the engine.

NOTE:

Do not place the engine under full load until it reaches operating temperature.

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OPERATION

Monitoring Engine

Operation

While the engine is operating, monitor the battery charge indicator light,

the oil pressure and avoid excessive idling.

Battery Charge

The battery charge indicator light (see Figure 25) must go out once the engine starts.

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 its normal operating temperature, the engine oil pressure must not drop below the following values:

□ 36 psi (250 kPa) at rated speed □ 7 psi (50 kPa) at idling speed

If oil pressure drops below these values, stop the engine and determine the cause.

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Excessive Idling

Never allow the engine to idle for more than 30 minutes. Excessive idling can cause oil to leak from the turbocharger.

Changing the Idle Speed

The rpm range of the MBE 900 engine is 600 rpm to 850 rpm if the parameters in the DDEC-VCU are set

to the default range.

Change the idling speed as follows: 1. Turn the cruise control switch to

the OFF position.

2. To increase the idle speed, push the "Resume" switch until the idle is fast enough.

3. To decrease the idle speed, push the "Decel" switch until the idle is slow 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 and

forth or falls sharply.

□ Engine power and rpm fall, even

though the accelerator pedal remains steady.

□ The exhaust pipe gives off heavy

smoke.

□ The coolant and/or oil temperature

climb abnormally.

□ Abnormal sounds suddenly occur

in the engine or turbocharger.

Shutting Down After Hard Operation

NOTICE:

After hard operation, if the engine has been running at full output or the coolant temperature has been high, allow the engine to idle for one to two minutes without load. Shutting down the engine without idling may cause damage to the turbocharger.

Turn off the ignition switch and shut down the engine.

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OPERATION

Emergency Running Mode

The engine is equipped with the electronic 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 the

instrumentation control unit

(ICU), the code for the electronic control unit reporting the fault can be read immediately on the display.

□ Complete fault codes are

transmitted and can be read using ServiceLink at any authorized dealer.

□ If the fault is serious enough to

impair normal operation, the

electronic engine system switches over to emergency running mode. When in emergency running

mode, the engine operates at a constant 1300 rpm. This allows you to move the vehicle to a service location.

Stop Engine Override

Option

The Stop Engine Override Option is used for a momentary override. The DDEC-ECU will record the number of times the override is activated after a fault occurs.

Momentary Override – A Stop Engine Override (SEO) switch is used to override the shutdown sequence (see Figure 26). This override resets the 60 second (30 seconds for oil pressure) shutdown timer, restoring power to the level when the Red Stop Lamp (RSL) was illuminated. The switch must be recycled after ﬁve seconds to obtain a subsequent override.

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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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 reduces header to tube stress and possible failure. Winter fronts should only be used when the ambient temperature remains below –12.2° C (10° F).

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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 or ﬂexible hoses.

Comply with the minimum working distance between the high-pressure nozzle and the surface being cleaned:

□ Approximately 700 mm (28 in.)

for circular pattern jets

□ Approximately 300 mm (12 in.)

for 25-degree ﬂat jets and dirt cutters

After cleaning, and especially when using a high-pressure jet or grease-removing agent, lubricate the engine. Information on suitable cleaning and protective products is available from any authorized dealer.

Cleaning the Cooling

System

Important: Collect the used coolant, cleaning solutions, and washing

liquids. Dispose of them in accordance with applicable laws regarding the protection of the environment.

NOTICE:

Clean at moderate pressures only; otherwise the ﬁns of the radiator grille could be damaged.

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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 air ﬂow).

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

water—50 grams per liter) of a mildly alkaline cleaning agent, such as sodium carbonate.

2. Run the engine at moderate speed until the thermostat starts to open, at an operating temperature of approximately 80°C (176°F). Then run it for about ﬁve minutes longer. Shut down the engine and allow it to cool to approximately 50°C (112°F).

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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[c] Run the engine. Allow the engine to warm up to approximately 80°C (176°F), and then run it about ﬁve minutes longer.

[d] Drain the hot water.

5. Fill the cooling system with new coolant. For detailed procedures, see the vehicle/chassis

maintenance manual. For types of coolant, refer to “Coolant” in the “Service Products” section.

Storage

Required protective measures for the MBE 900 engine depend on the following:

□ The length of time that the engine

will be out of service

□ The climate and conditions where

the engine is stored

After cleaning, engines should,

whenever possible, be placed in a dry, well-ventilated area.

In all cases, protect the engine against direct exposure to moisture (rain/splash water).

If the engine is to be out of service for 12 months or less, anticorrosion measures are not necessary, provided that the place of storage are dry and well-ventilated as described above.

If the engine is to be out of service for over 12 months, or under

extraordinary storage or transportation conditions, then special protective measures are necessary. Information is available from any authorized dealer. It is strongly recommended that you request this information. Important: If the engine is to be out

of service for over 18 months, the oil must be changed before the engine can be brought back into service.

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TROUBLESHOOTING

In addition to operating the engine carefully and maintaining it properly, make sure to correct any malfunction promptly.

Emergency Starting

For emergency starting procedures (jump starting), see the

driver's/operator's manual under

the heading "Emergency Starting With Jumper Cables."

Troubleshooting the

Electronic Engine Control

System

When the electronic engine control system detects a fault, it broadcasts a message on the datalink. The dash display will show the code "ECU 128," indicating there 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.

MBE 926 Manual

To the Operator

To the Operator

Trademark Information

Trademark Information

TABLE OF CONTENTS

...

1

ENGINE OPERATION ...

1

PREVENTIVE MAINTENANCE ...

2

ELECTRICAL SYSTEM ...

4

COOLING SYSTEM ...

6

AIR INTAKE SYSTEM ...

6

FUEL SYSTEM ...

7

COMPRESSED AIR ...

9

LUBRICATING OIL AND FILTERS ...

9

... 10

PERSONNEL REQUIREMENTS ... 13

ENGINE CONVERSIONS AND MODIFICATIONS ... 14

GENERAL VIEW OF THE MBE 900 ENGINE ... 14

ENGINE IDENTIFICATION NUMBER ... 21

DESCRIPTION OF THE ENGINE ... 22

EXHAUST GAS RECIRCULATION ... 23

EXHAUST BRAKE/CONSTANT-THROTTLE VALVES,

OPTIONAL ... 24

ELECTRONIC ENGINE CONTROL SYSTEM ... 25

DDEC-ECU ... 26

DDEC-VCU ... 27

SENSOR LOCATIONS ... 28

... 31

BEFORE STARTING THE ENGINE ... 31

CHECKING THE BATTERIES ... 31

CHECKING THE OIL LEVEL ... 32

CHECKING THE COOLANT LEVEL (COLD CHECK) ... 33

ADDING FUEL ... 33

PRIMING THE FUEL SYSTEM ... 33

STARTING THE ENGINE ... 33

CHECKING THE COOLANT LEVEL (HOT CHECK) ... 34

STARTING AN ENGINE THAT HAS NOT BEEN RUN FOR AN

EXTENDED PERIOD ... 35

MONITORING ENGINE OPERATION ... 36

BATTERY CHARGE ... 36

OIL PRESSURE ... 36

EXCESSIVE IDLING ... 37

CHANGING THE IDLE SPEED ... 37

SHUTTING DOWN THE ENGINE ... 37

SHUTTING DOWN AFTER HARD OPERATION ... 37

EMERGENCY RUNNING MODE ... 38

STOP ENGINE OVERRIDE OPTION ... 38

COLD WEATHER OPERATION ... 39

WINTER FRONTS ... 39

... 40

CLEANING THE ENGINE ... 40

HIGH-PRESSURE CLEANING EQUIPMENT ... 40

CLEANING THE COOLING SYSTEM ... 40

DEGREASING ... 41

STORAGE ... 42

... 43

EMERGENCY STARTING ... 43

TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL

SYSTEM ... 43

GENERAL TROUBLESHOOTING ... 43

... 56

DIESEL FUELS ... 56

FLOW IMPROVERS ... 56

KEROSENE ... 56

ENGINE OILS ... 57

EGR ENGINES ... 57

NON-EGR ENGINES ... 58

SYNTHETIC OILS ... 58

COOLANT ... 58

FULLY-FORMULATED ANTIFREEZE ... 58