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MBE 900 ENGINE 2007 OPERATOR'S GUIDE

2. Check all cooling system pipes

and hoses for damage and leaks;
ensure they are positioned to
avoid cha

fi

ng, and are securely

fastened.

3. Check the outside of the radiator

and condenser for blockage.
Check

fi

ns for damage; straighten

them if necessary.

Item 3 – Valve Lash Checking
and Adjustment

Valve lash checking and adjustment
should be performed per the
maintenance intervals prescribed
under the proper service category
for the engine, Refer to section
Scheduled Intervals in this guide.
All three service categories (Severe,
Short Haul, and Long Haul) require
a “

fi

rst time” valve lash adjustment

at a shorter interval. After the
initial adjustment, all others are
based on the same mileage intervals.
Refer to section Maintenance Tables in
this guide. Proper valve lash clearance
allows the engine to produce the best
possible performance with the lowest
emissions. Valve lash adjustments
should be performed by an authorized
Detroit Diesel maintenance or repair
facility.

Item 4 – Drive Belts

Belts should be neither too tight nor
too loose. Belts that are too tight

impose extra loads on the crankshaft,
fan and/or alternator bearings,
shortening both belt and bearing life.
Excessively overtightened belts can
result in crankshaft breakage. A loose
belt will slip and generate excessive
heat that may cause damage to the belt
and accessory drive components.

PERSONAL INJURY

To avoid injury from rotating belts
and fans, do not remove and
discard safety guards.

Belt Replacement

– Drive belts (V

and poly-V) should be replaced every
2,000 hours or 100,000 miles (160,000
km).

After an extended time in service,
minor rib cracks may appear, usually
one or two cracks per inch is
considered normal. See Figure 29
A concern occurs when the belt ribs
exhibit severe multiple cracking or
“chunking”. At this point, the belt
should be replaced.

All information subject to change without notice.

(Rev. 04/08)

79

DDC-SVC-MAN-0040 0704

Copyright © 2008 DETROIT DIESEL CORPORATION

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Summary of Contents for MBE 900

Page 1: ......

Page 2: ...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...

Page 3: ...ty instructions Trademark Information DDC Detroit Diesel DDEC Optimized Idle Diagnostic Link reliabilt POWER Trac POWER COOL and POWER GUARD are registered trademarks of Detroit Diesel Corporation Delco Remy is a registered trademark of Delco Remy America Inc Bosch is a registered trademark of Robert Bosch Company N A Fuel Pro and Mega Filter are registered trademarks of Davco Manufacturing L L C ...

Page 4: ...NT SYSTEM 12 ENGINE IDENTIFICATION 14 ENGINE COMPONENTS 14 ENGINE MODEL AND SERIAL NUMBER DESIGNATION 19 CERTIFICATION LABELS 20 OPERATING INSTRUCTIONS FOR STARTING THE ENGINE 21 FIRST TIME START PREPARATION 21 SYSTEM CHECKS 21 COOLING SYSTEM CHECKS 21 LUBRICATION SYSTEM CHECKS 22 CHECKING THE OIL LEVEL 22 EXTENDED STORAGE 24 FUEL SYSTEM CHECKS 24 ADDING FUEL 26 PRIMING THE FUEL SYSTEM 26 OTHER CH...

Page 5: ...SSIVE IDLING 36 CHANGING THE IDLE SPEED 36 SHUTTING DOWN THE ENGINE 37 SHUTTING DOWN AFTER HIGH LOAD OPERATION 37 EMERGENCY RUNNING MODE 37 STOP ENGINE OVERRIDE OPTION 38 COLD WEATHER OPERATION 38 WINTER FRONTS 39 DDEC VI SYSTEM 40 MOTOR CONTROL MODULE 40 COMMON POWERTRAIN CONTROLLER 41 DDEC FEATURES 42 CRUISE CONTROL 42 DATA RECORDING CAPABILITY 44 ENGINE BRAKES 44 ENGINE PROTECTION 45 CALIFORNIA...

Page 6: ...ENDING A LONG STEEP GRADE 56 DRIVING ON WET OR SLIPPERY PAVEMENT 58 ENGINE SYSTEMS 59 FUEL SYSTEM 59 LUBRICATION SYSTEM 59 AIR SYSTEM 59 COOLING SYSTEM 59 ELECTRICAL SYSTEM 60 EXHAUST SYSTEM 60 EXHAUST GAS RECIRCULATION SYSTEM 60 AFTERTREATMENT SYSTEM 61 OPERATING REQUIREMENTS 62 MAINTENANCE 62 PARKED REGENERATION 63 HAZARDOUS APPLICATIONS 65 DPF STATIONARY REGEN ONLY 0 DISABLED 65 DPF STATIONARY ...

Page 7: ...10 AFTERTREATMENT SYSTEM ATS 81 ITEM 11 VIBRATION DAMPER 82 ITEM 12 FEPTO TORSIONAL DAMPER CHECKING 82 REQUIRED MAINTENANCE OPERATIONS 82 ENGINE INSPECTING 82 COOLANT CONCENTRATION CHECKING 82 COOLANT FLUSHING AND CHANGING 84 COOLING SYSTEM INSPECTING 86 HOW TO SECTION 87 HOW TO SELECT LUBRICATING OIL 87 LUBRICANT REQUIREMENTS 87 COLD WEATHER STARTING 87 SYNTHETIC OILS 88 THE USE OF SUPPLEMENTAL A...

Page 8: ...DEFINITIONS 101 APPROVED COOLANTS 101 EG WATER PLUS SCA INHIBITOR OR PG WATER PLUS SCA INHIBITOR 102 MIXING EG OR PG ANTIFREEZE AND WATER 103 RECYCLED ANTIFREEZE 104 EG WATER OAT INHIBITOR OR PG WATER OAT INHIBITOR 104 WATER ONLY SCA OR WATER ONLY OAT INHIBITOR 105 WATER REQUIREMENTS 107 COOLANTS NOT RECOMMENDED 107 ALL ANTIFREEZES AND COOLANTS CONTAINING PHOSPHATE 107 AUTOMOTIVE TYPE COOLANTS 107...

Page 9: ...COL COOLANT 116 COOLANT LIFE OF OAT COOLANT 116 COOLANT LIFE OF OTHER COOLANTS 116 COOLANT FLUSHING AND CHANGING 116 COOLING SYSTEM INSPECTING 118 TROUBLESHOOTING 119 ENGINE STORAGE 132 PREPARING ENGINE FOR STORAGE 132 TEMPORARY STORAGE 30 DAYS OR LESS 132 EXTENDED STORAGE MORE THAN 30 DAYS 133 PROCEDURE FOR RESTORING TO SERVICE AN ENGINE THAT HAS BEEN IN EXTENDED STORAGE 136 CUSTOMER ASSISTANCE 1...

Page 10: ...ITIVE COOLANT FILTERS 145 POWER COOL SUPPLEMENTAL ADDITIVE NEED RELEASE COOLANT FILTERS 145 POWER COOL PLUS EXTENDED LIFE OAT COOLANT 146 POWER COOL PLUS EXTENDER FOR USE WITH POWER COOL PLUS OAT COOLANT 146 POWER COOL COOLING SYSTEM CLEANERS 146 POWER TRAC COOLANT TESTING AND ANALYSIS PRODUCTS 147 All information subject to change without notice Rev 04 08 ix DDC SVC MAN 0040 0704 Copyright 2008 D...

Page 11: ...TABLE OF CONTENTS x All information subject to change without notice Rev 04 08 DDC SVC MAN 0040 0704 Copyright 2008 DETROIT DIESEL CORPORATION ...

Page 12: ...stributor or dealer an independent outlet or the operator or owner The owner is responsible for determining the suitability of components to maintain emissions compliance during the engine s useful emission life Detroit Diesel cautions that the indiscriminate rebuilding of precision components without the benefit of specifications specialized equipment and knowledge of the electronic operating sys...

Page 13: ...lls necessary for the type of work being performed Engine Conversions and Modifications The function and safety of the engine could be affected if unauthorized modifications are made Detroit Diesel will not accept responsibility for any resulting damage Tampering with the fuel injection system and engine electronics could also affect the engine s power output or exhaust emission levels Compliance ...

Page 14: ...l potential ignition sources away from diesel fuel including open flames sparks and electrical resistance heating elements Do not smoke when refueling HOT EXHAUST During parked regeneration the exhaust gases will be extremely HOT and could cause a fire if directed at combustible materials The vehicle must be parked outside PERSONAL INJURY Diesel engine exhaust and some of its constituents are know...

Page 15: ... 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 operat...

Page 16: ...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 engi...

Page 17: ...ion 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 ELECTRICAL SHOCK To avoid injur...

Page 18: ...ore removing the separator Never touch parts through ventilation openings or impeller opening with finger or conductive items e g screwdriver or wire High voltage can remain inside the Electrostatic Oil Separator for up to 12 hours after the ignition is turned off All information subject to change without notice Rev 04 08 7 DDC SVC MAN 0040 0704 Copyright 2008 DETROIT DIESEL CORPORATION ...

Page 19: ...ng 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 PERSONAL INJURY To avoid injury from contact with rotating parts when an engine is operating with the air inlet piping removed install an air ...

Page 20: ... To prevent the escape of high pressure fuel that can penetrate skin ensure the engine has been shut down for a minimum of 10 minutes before servicing any component within the high pressure circuit Residual high fuel pressure may be present within the circuit FIRE To avoid injury from fire keep all potential ignition sources away from diesel fuel including open flames sparks and electrical resista...

Page 21: ...g Aids Observe the following cautions when using starting aids FLAMES EXPLOSION AND TOXICITY To avoid injury from flames explosion and toxicants when using ether the following precautions must be taken Always wear goggles when testing If fluid enters the eyes or if fumes irritate the eyes wash eyes with large quantities of clean water for 15 minutes A physician preferably an eye specialist should ...

Page 22: ...ken Do not smoke when servicing ether system Work in well ventilated area Do not work near open flames pilot flames gas or oil heaters or sparks Do not weld or carry an open flame near the ether system if you smell ether or otherwise suspect a leak All information subject to change without notice Rev 04 08 11 DDC SVC MAN 0040 0704 Copyright 2008 DETROIT DIESEL CORPORATION ...

Page 23: ...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 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 Aftertreatment System Observe the follo...

Page 24: ...S GUIDE Figure 1 Hot Surfaces External and Internal Caution Figure 2 Heavy Aftertreatment Device Caution All information subject to change without notice Rev 04 08 13 DDC SVC MAN 0040 0704 Copyright 2008 DETROIT DIESEL CORPORATION ...

Page 25: ...to reduce engine exhaust gas emissions in accordance with EPA regulations See Figure 3 for a right front view of the MBE 900 EGR engine single turbocharger model and Figure 4 for a left rear view See Figure 5 for a right front view of the MBE 900 EGR engine dual stage turbocharger model and Figure 6 for left side front view 14 All information subject to change without notice Rev 04 08 DDC SVC MAN ...

Page 26: ...Intake Throttle 11 Belt Tensioner Assembly 5 EGR Valve 12 Oil Filter 6 EGR Delivery Pipe 13 Turbocharger Single Stage 7 Front Lifting Bracket 14 Exhaust Brake Figure 3 Right Front View of the MBE 900 Engine Single Stage Turbocharger All information subject to change without notice Rev 04 08 15 DDC SVC MAN 0040 0704 Copyright 2008 DETROIT DIESEL CORPORATION ...

Page 27: ...er Head Cover 11 120 Pin Connector 5 EGR Mixer Housing 12 Fuel Filter Water Separator 6 Electrostatic Oil Separator 13 Oil Dipstick 7 Flywheel Housing Figure 4 Left Rear View of the MBE 900 Engine Single Turbocharger 16 All information subject to change without notice Rev 04 08 DDC SVC MAN 0040 0704 Copyright 2008 DETROIT DIESEL CORPORATION ...

Page 28: ...ipe 4 Dual Stage Turbocharger 11 EGR Cooler Coolant Return Tube 5 Wastegate Actuator 12 EGR Cooler Supply Tube 6 Exhaust Elbow 13 Oil Supply Line to 2nd Turbo 7 EGR Cooler Figure 5 Right Front View of the MBE 900 Engine Dual Stage Turbocharger All information subject to change without notice Rev 04 08 17 DDC SVC MAN 0040 0704 Copyright 2008 DETROIT DIESEL CORPORATION ...

Page 29: ...reather Hose 15 31 Pin Connector 6 Cylinder Head Cover 16 21 Pin Connector 7 EGR Valve 17 Motor Control Module MCM 8 Air Intake Mixer Housing 18 Fuel Heat Exchanger 9 Air Intake Manifold 19 120 Pin Connector 10 Air Intake Throttle 20 Dipstick Location Figure 6 Left Side View of the MBE 900 Engine Dual Stage Turbocharger 18 All information subject to change without notice Rev 04 08 DDC SVC MAN 0040...

Page 30: ...ey appear on the engine Figure 8 Engine Identification Number The last six numbers are the serial numbers 310187 in Figure 8 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 MCM label The ten digit number is derived from the fourteen digit number see Figure 9 Figure 9 Engine Serial Number All inform...

Page 31: ...ttached to the cylinder head cover as required by law See Figure 10 for the emission label for the 2007 6 cylinder EGR model NOTE The horsepower rating on the emission label is for the highest engine rating and not necessarily the rating of your engine Figure 10 Engine Emission Label EPA07 20 All information subject to change without notice Rev 04 08 DDC SVC MAN 0040 0704 Copyright 2008 DETROIT DI...

Page 32: ...es 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 How to Select Coolant in the HOW TO SECTION section of this guide System Chec...

Page 33: ...ow of oil to all bearing surfaces at initial engine startup the engine lubrication system should be charged with a commercially available pressure pre lubricator If this is impractical rocker covers should be removed and clean lubricating oil should be poured over the rocker arms The oil should be the same weight and viscosity as that used in the crankcase After pre lubricating add additional oil ...

Page 34: ... at the BOTTOM of that bend For the minimum oil level it is noted at the TOP of the bend 6 Figure 12 Oil Fill Cap If the oil level is below the minimum bend add oil to bring it up the maximum level see Figure 11 Do NOT fill beyond the maximum fill level on the dipstick since overfilling may result in high oil consumption and possible severe engine damage If necessary add additional oil All informa...

Page 35: ...esel recommends replacing the engine lubricating oil and filters after extended storage Fuel System Checks Fill the tanks with the recommended fuel Keeping tanks full reduces water condensation and helps keep fuel cool which is important to engine performance Full tanks also reduce the chance for microbe black slime growth For fuel recommendations refer to the How to Select Diesel Fuel section in ...

Page 36: ...cation NOTICE Engines equipped with starting devices dependent on compressed air or gas reservoirs should always be primed before initial startup Otherwise reserve pressure can be exhausted and injectors may be damaged from lack of lubrication and cooling To insure prompt starting and even running the fuel system must be primed if air has entered the fuel system Priming can be performed by using t...

Page 37: ... 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 the HOW TO SECTION of this guide Priming the Fuel System Prime the fuel system as follows 1 If equipped with a hand pump on the fuel filter or fuel water separator work...

Page 38: ...id or low maintenance batteries are used make sure battery electrolyte level is normal Use only batteries that have been correctly filled and serviced To provide corrosion protection apply dielectric grease 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 App...

Page 39: ...ther or otherwise suspect a leak To start an MBE 900 engine make sure the transmission is in neutral and turn the ignition key on ENGINE EXHAUST To avoid injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic PERSONAL INJURY To avoid injury when working near or on an operating engine remove loose items of clothing and jewelry Tie back or con...

Page 40: ...ion in neutral and set the parking brake 2 With foot OFF the foot pedal turn on the ignition switch and start the engine 3 If the engine doesn t start after 30 seconds stop Try again after waiting two minutes The engine should start within four 30 second attempts 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 p...

Page 41: ...dling check the automatic transmission if equipped for proper oil level and add oil as required Fluid Leaks Look for coolant fuel or lubricating oil leaks If any are found shut down the engine immediately and have the leaks repaired after the engine has cooled Crankcase If the engine oil was replaced stop the engine after normal operating temperature has been reached Allow the oil to drain back in...

Page 42: ...n NOTICE Stopping a turbocharged engine immediately after high speed operation without allowing a sufficient cool down period may cause damage to the turbocharger as it will continue to turn without an oil supply to the bearings 2 Allow the engine to run between idle and 1000 rpm with no load for four or five minutes This allows the engine to cool and permits the turbocharger to slow down After fo...

Page 43: ...n the proper sequence negative to negative ground last 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 wa...

Page 44: ...el system 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 NOTICE Never attempt to start the 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 engi...

Page 45: ...ve the dipstick and read the oil level dipstick See Figure 14 The figure shows a comparison between the bends on the dipstick and a crosshatch pattern on a conventional dipstick Note the exact area noted on the bends For example the maximum oil level will be at the BOTTOM of that bend For the minimum oil level it is noted at the TOP of the bend 10 Figure 15 Oil Fill Cap If the oil level is below t...

Page 46: ...follows 1 Allow the engine to run for approximately five minutes at a moderate speed 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 5...

Page 47: ...tor voltage and output checked Do a load test on the batteries 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 Excessive Idling Never allow the engine to idle for more t...

Page 48: ...ing Down After High Load 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 Emergency Running Mode The engine is equipped with the ele...

Page 49: ... 60 second 30 seconds for oil pressure shutdown timer restoring power to the level when the RSL Stop Engine was illuminated The switch must be recycled after five seconds to obtain a subsequent override Figure 17 Typical SEO Switch and Warning Lamps NOTE The operator has the responsibility to take action to avoid engine damage Cold Weather Operation Special precautions must be taken during cold we...

Page 50: ...pes that run perpendicular to the charge air cooler tube flow direction This assures even cooling across each tube and reduces header to tube stress and possible failure Winter fronts should only be used when the ambient temperature remains below 12 2 C 10 F All information subject to change without notice Rev 04 08 39 DDC SVC MAN 0040 0704 Copyright 2008 DETROIT DIESEL CORPORATION ...

Page 51: ... be read by the diagnostic tool 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 The Accelerator Pedal Assembly AP eliminates the need for any throttle linkage Motor Control Module The MCM see Figure 18 is located on the left hand sid...

Page 52: ...ta for specific applications is stored in the CPC These include idle speed maximum running speed and speed limitation Figure 19 CPC The CPC 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 MCM oil pressure and coolant temperature From these data instructions are computed fo...

Page 53: ...ith any DDEC engine Cruise Control will operate in either Engine or Vehicle Speed Mode and maintain a targeted speed MPH or RPM by increasing or decreasing fueling The targeted speed can be selected and adjusted with dash mounted switches See Figure 20 Figure 20 Typical Cruise Control Switches Cruise Control may also be programmed to permit fast idle using the Cruise Control switches With the engi...

Page 54: ...is recommended that Max Cruise Set Speed be set to the default to allow proper operation of other features such as Fuel Economy Incentive and PasSmart The Vehicle Speed Limit should be used to limit vehicle throttle speed When the SPD CNTL is in the ON position Cruise Control is engaged by momentarily contacting the SET CST Switch As a check after each engine start DDEC looks for a one time activa...

Page 55: ... least a Pentium II computer with at least 256 MB of RAM Engine Brakes Engine brakes are enabled by a dash mounted On Off switch with a separate intensity switch to select low medium or high braking power LOSS OF VEHICLE CONTROL To avoid injury from loss of vehicle control do not activate the Engine Brake system under the following conditions On wet or slippery pavement unless the vehicle is equip...

Page 56: ...e high oil or coolant temperature or low coolant level PERSONAL INJURY To avoid injury from engine shutdown in an unsafe situation ensure the operator knows how to override the stop engine condition on a DDEC equipped unit NOTICE Engines equipped with the power down shutdown option have a system override button or switch to allow engine operation for a short period of time Using the override butto...

Page 57: ...hicle types that wish to have the shutdown feature disabled should consult with California authorities to determine if their vehicles qualify for the exemption Idle Shutdown Timer This feature is an optional 1 100 minute idle shutdown system Its purpose is to conserve fuel by eliminating excessive idling and allowing a turbocharger cool down period To activate the shutdown the transmission must be...

Page 58: ...ed power down sequence until it shuts down completely A Stop Engine Override can be procured in case the vehicle is to operate in a critical location Stop Engine Override Switch This feature allows the operator to override the automatic stop engine sequence This is done by pressing the Stop Engine Override Switch every 15 to 20 seconds to prevent engine shutdown from occurring NOTE The Stop Engine...

Page 59: ... been corrected the DDEC system will return the engine to normal operation The temperature of air in the intake system is increased with the addition of an EGR DDEC is programmed to reduce fueling power for a short time to reduce air and coolant temperatures when necessary DDEC will store an information code that this event occurred but no corrective action is required as this action is designed t...

Page 60: ...s the switch is made from RSL Stop Engine to AWL Check Engine When code flashing is initiated the active codes will be flashed on the RSL Stop Engine Then the inactive codes will be flashed on the AWL Check Engine When all the inactive codes have been flashed the process of flashing all the active codes followed by all the inactive codes will repeat until the conditions for code flashing are no lo...

Page 61: ...s will be flashed on the RSL Stop Engine in the order of most recent to least recent occurrence based on engine hours Inactive Codes The inactive codes will be flashed on the AWL Check Engine in the order of most recent to least recent occurrence based on engine hours 50 All information subject to change without notice Rev 04 08 DDC SVC MAN 0040 0704 Copyright 2008 DETROIT DIESEL CORPORATION ...

Page 62: ...alf throttle an advantage when driving under slippery conditions If you require wide open throttle engine response either accelerating or just plain pulling hard the throttle AP will have to be held to the floor To obtain 100 fueling at any speed the AP will have to be maintained at the fully pressed position Cruise Control For added driver convenience and comfort DDEC VI also features a Cruise Co...

Page 63: ... per hour increments press the RSM ACL Switch To reduce road speed press and hold the SET CST Switch until the lower speed is reached Cruise Control is deactivated by slightly pressing the service brakes clutch pedal or trailer brake The On Off Switch will also deactivate Cruise Control Cruise Control will maintain vehicle speed even on up grades unless power requirements demand a downshift And of...

Page 64: ...e function is turned ON in the MCM programming the engine retarders will come on low when your set road speed increases a few miles per hour kilometers per hour above your cruise set speed If your speed continues to increase the MCM will increase the engine retarders braking power progressively When the vehicle returns to the set cruise speed the engine retarders will turn off until you need them ...

Page 65: ...e EGR gas flow may be noticeable to the tuned attentive ear The turbocharger operates at higher boost pressure forcing EGR gas flow through the EGR plumbing In some situations the driver may believe he she has experienced a charge air cooler system leak Even connecting trailer light and air hoses the driver may hear a different tone exhaust and under hood with the engine idling If equipped with a ...

Page 66: ...t 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 ...

Page 67: ...ive braking switch in the LOW position 2 If you find you are still using the service brakes move the switch to a higher position until you do not need to use the service brakes to slow the vehicle down 3 If you are carrying a heavier load and road traction is good move the progressive braking switch to the High position 4 Check your progressive braking switch often for proper position since road c...

Page 68: ...speed limits while descending a grade may result in loss of vehicle control which could cause personal injury NOTICE Failure to keep the vehicle within safe control speed limits while descending a grade may result in vehicle or property damage or both 3 Do not exceed the safe control speed of your vehicle Example You could descend a 6 grade under control only at 16 kph 10 mph without an engine bra...

Page 69: ... the trailer brakes may be desirable to help keep the trailer stretched out Follow the manufacturer s recommended operating procedure when using your trailer brakes On wet or slippery pavement start with the master switch in the OFF position and use the gear you would normally use under these conditions If the vehicle is maintaining traction place the selective braking switch in the LOW position a...

Page 70: ...crankshaft The oil cooler is located on the right side front of the cylinder block near the oil filter Air System The outside air drawn into the engine passes through the air filter and is pulled into the turbocharger and compressed It then moves to the air to air charge cooler heat exchanger and is cooled Next it flows to the intake manifold and into the cylinders where it mixes with atomized fue...

Page 71: ...tarding engine timing The EGR valve has been moved to the top of the engine for improved serviceability The EGR system consists of an EGR cooler EGR valve and an EGR mixer The MBE 900 engines for on highway EPA 2007 regulation applications use a cooled EGR system along with an Aftertreatment System to meet the emission standards On the 260 350 horsepower engines the EGR is fed by all six cylinders...

Page 72: ...e matter in a process called regeneration The key to successful regeneration is high exhaust temperature for an extended period of time Without adequate temperatures for regeneration the filter will continue to trap particulates and eventually plug In order to avoid plugging Detroit Diesel has designed an actively regenerated Aftertreatment System ATS See Figure 25 Figure 25 Aftertreatment System ...

Page 73: ...le or illumination of an AWL Check Engine or RSL Stop Engine are indications of a system problem Should this occur refer to the Aftertreatment System Technician s Guide 7SE63 or contact the Detroit Diesel Customer Support Center at 313 592 5800 Illumination of the Diesel Particulate Filter DPF lamp indicates that a parked regeneration is required There is a need to periodically remove accumulated ...

Page 74: ... DPF regeneration occurs after the initial DPF Regeneration Lamp illumination the lamp will begin blinking and a parked regeneration should be initiated as soon as possible If the flashing DPF is still ignored the AWL Check Engine listed in Table 3 will illuminate This will be accompanied by a 25 engine torque reduction 3 If parked regeneration is still not initiated a standard 60 second engine sh...

Page 75: ...If no regen request switch is present DDDL 7 0 must be connected for initiation using the service routines menu Select DPF Regen Request Start Figure 26 Regen Request Switch Cycle the park brake OFF to ON once an ignition cycle Cycle the clutch pedal if configured once an ignition cycle Park Brake must be ON and the clutch must be released Engine should be on the idle governor can not be in Fast I...

Page 76: ...lly triggered over the road regenerations DPF Manual Regen Only Enable Enabled NOTE This is for hazardous applications only There are two CPC options DPF Stationary Regen Only 0 Disabled DPF Stationary Regen Only 1 Enabled DPF Stationary Regen Only 0 Disabled This option allows the DPF Regeneration Switch to request a parked regeneration or an over the road regeneration If the conditions previousl...

Page 77: ... replacement Vehicle mileage at the time of cleaning or replacement Particulate filter part number and serial number 66 All information subject to change without notice Rev 04 08 DDC SVC MAN 0040 0704 Copyright 2008 DETROIT DIESEL CORPORATION ...

Page 78: ...ntinues to increase Lamp will shut of during regeneration Lamp Solid parked regeneration required Lamp Flashing parked regeneration required immediately High Exhaust System Temperature HEST Lamp This is an information indicator Indicates exhaust temperature is above a preset limit and the unit is operating at low vehicle speed Lamp flashes once every ten seconds during a parked regen Lamp is yello...

Page 79: ... the start of every ignition cycle a bulb check Indicates the fuel filter has a high level of water and must be drained Light stays lit indicating water must be drained from filter Table 4 Water in Fuel Instrument Panel Lamp 68 All information subject to change without notice Rev 04 08 DDC SVC MAN 0040 0704 Copyright 2008 DETROIT DIESEL CORPORATION ...

Page 80: ...tdown occurs Diagnostic Request Switch is used to activate the RSL to flash active codes Parked regeneration is required At the start of every ignition cycle a bulb check When a parked regeneration is required immediately If the lamp flashing is ignored derate and or shutdown could occur At the start of every ignition cycle a bulb check Vehicle speed is less than 5 mph and the DPF outlet temperatu...

Page 81: ...aintenance requirements for these extra items Important If the engine is stored for more than 18 months the oil must be changed and the lubrication system must be primed before the engine can be brought into service See MBE 900 Service Manual 6SE9007 Maintenance Schedule Types There are three types of maintenance schedule Severe Service Short Haul Long Haul To determine which schedule to use find ...

Page 82: ...ble Short Haul listed in Table 8 Maintenance Interval Table Long Haul listed in Table 9 Schedule Use Before placing your new vehicle in service determine the correct maintenance intervals that apply to your intended use of the vehicle Refer to section Maintenance Tables to determine the distance interval at which each maintenance operation must be performed to comply with your vehicle s schedule W...

Page 83: ...Long Haul hrs Engine Oil and Filter 350 500 or 6 months Fuel Filter 700 1000 Valve Lash Adjustment 1400 2500 Table 6 Maintenance Intervals by Engine Hours 72 All information subject to change without notice Rev 04 08 DDC SVC MAN 0040 0704 Copyright 2008 DETROIT DIESEL CORPORATION ...

Page 84: ...tem I I I I I I I I I I I 9 Air Compressor I I I I I I I I I I I 10 Aftertreatment Device Inspect same as exhaust system interval ash removal at 150 000 Miles 240 000 Km 11 Vibration Damper Replace at major overhaul or earlier if dented or leaking 12 FEPTO I I I I I I I I I I I I Change lubricating oil filter per above schedule or every 350 hours Adjust valve lash per above schedule or every 10 50...

Page 85: ...or R R R R R R 6 Fuel Filters Pre Filters R R R R R R 7 Air System I I I I I I I I I I I I 8 Exhaust System I I I I I I I I I I I I 9 Air Compressor I I I I I I I I I I I I 10 Aftertreatment Device Inspect same as exhaust system interval ash removal at 150 000 Miles 240 000 Km 11 Vibration Damper Replace at major overhaul or earlier if dented or leaking 12 FEPTO I I I I I All items are described i...

Page 86: ...r Separator Follow manufacturer s recommendations 6 Fuel Filters R R R 7 Air System I I I I I I I I I I I 8 Exhaust System I I I I I I I I I I I 9 Air Compressor I I I I I I I I I I I 10 Aftertreat ment Device Inspect same as exhaust system interval ash removal at 150 000 Miles 240 000 Km 11 Vibration Damper Inspect at oil changes Replace at major overhaul or earlier if dented or leaking 12 FEPTO ...

Page 87: ... as a lever or twist lock design that must be disengaged before pulling the dipstick out of the guide tube Use a shop rag to wipe off the end of the dipstick Wait 15 seconds to allow any crankcase pressure to dissipate through the guide tube and let the oil level settle in the oil pan Reinstall the dipstick and make sure it is fully inserted into the guide tube Remove the dipstick and read the oil...

Page 88: ...t with an authorized Detroit Diesel service outlet for the cause Fuel or coolant dilution of lubricating oil can result in serious engine damage Before adding lubricating oil refer to the How to Select Lubricating Oil section in this guide Lubricating Oil Filter The oil filter is a cartridge style element and is located on the front right side of the engine See Figure 28 If followed correctly an o...

Page 89: ...us threats on the additive package Once the additives have been depleted from the coolant it will only be a matter of time until the engine components suffer Refer to the How to Select Coolant section in this guide Cooling System Inspection Inspect the cooling system as follows HOT COOLANT To avoid scalding from the expulsion of hot coolant never remove the cooling system pressure cap while the en...

Page 90: ...emissions Valve lash adjustments should be performed by an authorized Detroit Diesel maintenance or repair facility Item 4 Drive Belts Belts should be neither too tight nor too loose Belts that are too tight impose extra loads on the crankshaft fan and or alternator bearings shortening both belt and bearing life Excessively overtightened belts can result in crankshaft breakage A loose belt will sl...

Page 91: ...sensor will indicate when the trapped water needs to be drained If the water in fuel sensor is not available periodic draining of the trapped water should be performed Item 6 Fuel Filters The final filter is housed within the fuel filter module The filter element filters particles down 4 micron and is snapped into the cap Item 7 Air System Air Cleaner The air cleaner element should be inspected pe...

Page 92: ...ced as required Item 8 Exhaust System The exhaust manifold retaining bolts and other connections should be inspected for leaks The exhaust pipe rain cap should be checked for proper operation if so equipped With the introduction of an Aftertreatment system the sealing of the exhaust system is critical and should be inspected regularly Item 9 Air Compressor The air compressor incorporates three of ...

Page 93: ...equired Maintenance Operations The following sections describe the required maintenance operations Engine Inspecting Inspect the engine as follows 1 Visually check the engine for signs of leakage A slight dampness at the sealing points is no cause for alarm NOTE More severe leaks combined with a continual loss of oil must be corrected without delay 2 Visually inspect all lines and hoses Listen for...

Page 94: ...0 by volume drain coolant add antifreeze until the concentration is correct The coolant mixing ratio is listed in Table 10 NOTE Concentrations of more than 55 by volume should not be used as this is the level which affords the maximum antifreeze protection down to 45 C 49 F Higher concentrations adversely affect heat dissipation Antifreeze Protection Down to C F Water Percentage by Volume Corrosio...

Page 95: ...ure to escape Set the cap aside 2 Open the water regulating valve for the heating system 3 Drain the coolant from the engine a Place a receptacle underneath the coolant drain plug Choose one that is large enough to hold the expected quantity of coolant NOTE Make sure the coolant can flow unobstructed into the receptacle b Open the coolant drain plug on the bottom of the radiator 4 Flush the radiat...

Page 96: ...tion until the maximum mark on the surge tank is reached Coolant system capacity is listed in Table 11 Description Value L qt Engine Coolant Capacity all vehicles L Qt Engine capacity 12 12 7 Business Class Coolant System Capacity L Qt Total capacity 23 6 25 Antifreeze quantity at 50 11 8 12 5 Antifreeze quantity at 55 13 1 13 8 Table 11 Coolant System Capacity 8 Start the engine and run it for ab...

Page 97: ... Coolant Flushing and Changing Inspect the cooling system as follows 1 Inspect the radiator the condenser the water pump the engine oil cooler the freeze plugs and the heat exchanger for damage and leaks 2 Check all pipes and hoses in the cooling system for damage and leaks Make sure all pipes and hoses are properly positioned to avoid chafing and are securely fastened 3 Check the outside of the r...

Page 98: ...eve the long and trouble free service which Detroit Diesel engines are designed to provide The proper lubricating oil for model year 2007 MBE 900 engines is selected based on SAE viscosity grade and API American Petroleum Institute service designation Only oils licensed to display the API symbol should be used See Figure 31 Figure 31 API Lubricant Symbol NOTICE Lubricating oil must have a sulfated...

Page 99: ... the SAE class viscosity on the basis of the average air temperature for the season see Figure 32 Figure 32 Engine Oil Temperature Ranges Synthetic Oils Synthetic oils may be used in Detroit Diesel engines provided they are API licensed and meet the performance and chemical requirements of non synthetic oils outlined in this publication Synthetic oils offer improved low temperature flow properties...

Page 100: ...ar protective gloves and apron Refer to section Maintenance Tables for the maximum intervals at which the engine may operate before the oil and filters must be changed Oil analysis may be used to determine whether this interval should be shortened but it should not be used to lengthen the interval The use of fuels with sulfur content above 0 05 mass percent will require a shortening of drain inter...

Page 101: ...basis of the average air temperature for the season See Figure 33 View the temperature ranges for the various SAE classes as guidelines which can be exceeded for only a short time Figure 33 SAE Oil Viscosity Classes To insure the engine is protected and the oil stays clean until the next oil change use only oils of API classification CJ 4 Only the 260 350 horsepower models except motorcoach have a...

Page 102: ...g 4 Remove both the filter cap and the filter element To release the filter element twist the lower edge of the filter element to the side See Figure 35 Figure 35 Cap with Oil Filter Element 5 Inspect the inside of the filter housing to ensure there is no debris 6 Replace the O ring on the cap See Figure 35 7 Install the new filter into the cap Make sure the filter element is securely in place 8 S...

Page 103: ... Monitor the oil pressure gauge 13 Check the filter and oil drain plug for signs of leakage 14 Stop the engine 15 Check the oil level again after approximately five minutes If necessary add oil up to the maximum fill level on the oil dipstick Do not overfill Oil Centrifuge Only the 260 350 horsepower models except motorcoach have an oil centrifuge NOTICE Both the primary lube oil filter front of e...

Page 104: ...ory engine performance long engine life and acceptable exhaust emission levels In general fuels meeting the properties of ASTM designation D 975 grades 1 D and 2 D have provided satisfactory performance The fuels used must be clean completely distilled stable and non corrosive For more information regarding the significance of these properties and selection of the proper fuel refer to publication ...

Page 105: ... not be covered These products should be accompanied by performance data supporting their merit It is not the policy of Detroit Diesel Corporation to test evaluate approve or endorse such products Biodiesel Biodiesel fuels meeting ASTM D 6751 specification prior to blending can be mixed up to 5 maximum by volume in petroleum diesel fuel Detroit Diesel highly recommends biodiesel fuels made from so...

Page 106: ...esel fuel will create a serious fire hazard The presence of gasoline in diesel fuel will reduce fuel cetane number and increase combustion temperatures FIRE To avoid increased risk of a fuel fire do not mix gasoline and diesel fuel Tanks which contain a mixture of gasoline and diesel fuel should be drained and cleaned as soon as possible Detroit Diesel Corporation will not be responsible for any d...

Page 107: ... 5 Main Fuel Filter Return Outlet 13 Main Fuel Filter 6 Outlet of Fuel Prefilter 14 Main Fuel Filter Outlet 7 Filling Valve 15 Main Fuel Filter Inlet 8 Inlet for Fuel Prefilter A Unfiltered Fuel B Prefiltered Fuel D Fuel Injector Leak Fuel C Cleaned Fuel E Fuel Return Line to Fuel Tank Figure 39 Fuel Filter Water Separator 96 All information subject to change without notice Rev 04 08 DDC SVC MAN 0...

Page 108: ...d lubricate with clean engine oil See Figure 39 9 Thread the bowl into the housing and tighten bowl to 13 5 N m 120 lb in 10 Connect the electrical connector plug to the fuel pre heater element Install the ground lead for the fuel pre heater to the fuel filter water separator housing 11 Connect the WIF sensor harness connector to the fuel filter water separator housing 12 Ensure fuel drain lever i...

Page 109: ...sistance is felt 2 If the engine is equipped with only a priming port located on the fuel filter module have an authorized repair facility prime the fuel system 3 Crank the engine for 30 seconds at a time but no longer Before cranking the engine again wait at least two minutes The engine should start within four 30 second attempts 4 If the engine fails to start ensure the vehicle has adequate fuel...

Page 110: ... to Clean the Cooling System Important Collect the used coolant cleaning solutions and washing liquids and dispose of them in an environmentally responsible manner Clean as follows NOTICE Clean at moderate pressures only otherwise the fins of the radiator grille could be damaged 1 First remove debris dust insects etc from the fins of the radiator grille EYE INJURY To avoid injury from flying debri...

Page 111: ...ing from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at operating temperature Wear adequate protective clothing face shield rubber gloves apron and boots Remove the cap slowly to relieve pressure 3 Drain all the cleaning solution 4 Flush the cleaning solution from the cooling system a Immediately after draining the cleaning solution flush the syste...

Page 112: ...lated Antifreeze Contains all the necessary inhibitors to protect a diesel engine and does not therefore require a pre charge of SCA before its first use Initial Fill Coolant The coolant that is used in a new or rebuilt engine or any time the cooling system is emptied and then refilled with coolant OAT Organic Acid Technology An inhibitor system based on organic acid inhibitors instead of traditio...

Page 113: ...on Inhibitors 2 Water DDC Power Cool 3000 Water Only OAT Inhibitors 2 Water DDC Power Cool Plus 6000 1 Preferred Coolant 2 Water only coolant systems offer no freeze protection and should not be used where ambient temperatures can fall to 0 C 32 F Table 12 Initial Fill Coolant Options EG Water Plus SCA Inhibitor or PG Water Plus SCA Inhibitor These products are available as fully formulated phosph...

Page 114: ...tial use Mixing EG or PG Antifreeze and Water If a concentrated ethylene glycol EG or propylene glycol PG antifreeze is purchased mix the antifreeze with water meeting the required quality standardslisted in Table 15 and fill the cooling system If a pre diluted fully formulated coolant is purchased fill the cooling system For best overall performance a coolant consisting of 50 concentration of ant...

Page 115: ...cled antifreeze or coolants of these types are preferred Other recycled coolants especially coolants recycled through filtration processes are not recommended EG Water OAT Inhibitor or PG Water OAT Inhibitor Ethylene glycol and propylene glycol are also available with a OAT corrosion package These coolants require less maintenance over the useful life of the engine OAT coolants maintained as detai...

Page 116: ...oit Diesel approved SCAs or OAT corrosion inhibitors must be added to the water to provide required corrosion and cavitation erosion protection OAT inhibitors such as Power Cool Plus 6000 are available for water only systems Inhibitor should be mixed at 7 5 10 by volume with water For a list of Power Cool products refer to section POWER COOL ENGINE PRODUCTS in this guide Traditional SCA Power Cool...

Page 117: ...te 900 3200 PPM Nitrate 200 1000 PPM Silicon 50 250 PPM Phosphorous 0 PPM pH 8 0 11 0 Table 14 Power Cool 3000 Concentration Limits 5 Power Cool 3000 95 Water 106 All information subject to change without notice Rev 04 08 DDC SVC MAN 0040 0704 Copyright 2008 DETROIT DIESEL CORPORATION ...

Page 118: ... in Detroit Diesel engines All Antifreezes And Coolants Containing Phosphate These coolants are not recommended Drop out overheating and water pump seal failures can result from the use of coolant or inhibitor packages based on phosphate Automotive Type Coolants These coolants generally contain high levels of phosphate and silicate offer no liner pitting protection and are not suitable for use in ...

Page 119: ...oxide commonly called green slime This in turn can result in engine damage due to poor heat transfer Cooling systems operated with chromium inhibited coolant must be chemically cleaned with Power Cool dry chemical cooling system cleaner conditionerrefer to section POWER COOL Cooling System Cleaners or equivalent sulfamic acid sodium carbonate cleaner and flushed Coolant Inhibitor Test Intervals Th...

Page 120: ...ly deplete during normal engine operation SCAs replenish the protection for cooling system components The coolant must be maintained with the proper concentration of SCA Detroit Diesel Power Cool maintenance SCAs are recommended The proper application of SCA will provide pH control Restored inhibitor levels to prevent corrosion Water softening to deter formation of mineral deposits Cavitation prot...

Page 121: ...e Glycol Water OAT Inhibitor or Propylene Glycol Water OAT Inhibitor 600 000 Miles 960 000 km Drain and clean system Replace with new coolant 20 000 Miles 32 000 km or 3 Months Test nitrite concentration with test strip Add SCA or dilute coolant as needed Water Only SCA Inhibitor 300 000 Miles 480 000 km Drain and clean system Replace with new coolant 300 000 Miles 480 000 km or 2 Years Add Power ...

Page 122: ...no inhibitors and should conform to ASTM D4985 This will dilute the over concentrated inhibitors NOTE In non OAT systems nitrite concentration of 5000 PPM or higher on an MBE 900 engine suggests problematic additive over concentration This condition must be corrected by immediate draining and flushing of the cooling system Refill the system with new fully formulated or pre charged coolant Check th...

Page 123: ...ter each use Discard unused strips if they have turned light pink or tan A factory coolant analysis program is available through authorized Detroit Diesel service outlets Part numbers are inrefer to section POWER COOL ENGINE PRODUCTS and refer to section POWER TRAC Coolant Testing And Analysis Products in the Specifications section To verify coolant acceptability submit a sample for coolant analys...

Page 124: ...a caustic solution or physically clean individual components Coolant Extender Inhibitor Additive for OAT Coolant The inhibitors in OAT coolant must also be maintained but less often than traditional SCA type coolants A portable test is available to test the levels of OAT inhibitors in coolant Where this is not used fleet testing has determined that a OAT coolant extender package should be added to...

Page 125: ...lter elements liquid packages and in fully formulated Power Cool antifreeze NOTE Power Cool 3000 liquid SCA is more compatible with hard water than Power Cool 2000 SCA Power Cool Coolant Filter Elements Power Cool coolant filter elements spin on canisters are available in various sizes suitable for cooling systems of varying capacities Selection of the proper element size is vital when pre chargin...

Page 126: ...text of this section to determine the proper dosage Mixing of different manufacturers technologies brands could cause cooling system problems 4 Maintain the inhibitor at the prescribed concentration Test the nitrite concentration by using a titration kit or Detroit Diesel Power Trac 3 Way Coolant Test Strips Add SCA only if the nitrite concentration is below 900 PPM Do not use SCA in OAT coolant a...

Page 127: ...ysis every 300 000 miles 480 000 km three 3 years or 5 000 operating hours whichever comes first Submit the sample in a DDC Power Trac Coolant Test Bottle Required part numbers are in refer to section POWER COOL ENGINE PRODUCTS Coolant Life of OAT Coolant A properly maintained OAT coolant may be operated 600 000 miles 960 000 km four 4 years or until overhaul whichever comes first At this time the...

Page 128: ... 4 Start radiator flushing by attaching a flushing gun nozzle to the radiator outlet and run water in until the radiator is full EYE INJURY To avoid injury from flying debris when using compressed air wear adequate eye protection face shield or safety goggles and do not exceed 276 kPa 40 psi air pressure 5 Apply no more than 140 kPa 20 psi air pressure intermittently to help dislodge sediment buil...

Page 129: ...is at operating temperature Wear adequate protective clothing face shield rubber gloves apron and boots Remove the cap slowly to relieve pressure 1 Inspect the radiator condenser water pump engine oil cooler freeze plugs and heat exchanger for damage and leaks 2 Check all cooling system pipes and hoses for damage and leaks ensure they are positioned to avoid chafing and are securely fastened 3 Che...

Page 130: ... 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 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 ...

Page 131: ...ttery cables The starter is damaged and or worn Have an authorized repair facility replace the starter The engine oil does not meet the correct specifications Change the engine oil using the correct type of oil The transmission fluid does not meet the correct specifications Change the transmission fluid using the correct type of fluid 120 All information subject to change without notice Rev 04 08 ...

Page 132: ...lity for service The camshaft position sensor CMP and or the crank angle position sensor are damaged Bring the vehicle to an authorized repair facility for service There is air in the fuel system Check the fuel lines for leaks Prime the fuel system and start the engine according to the instructions in the How to Replace Fuel Filter The air filter is clogged Clean or replace the air filter The fuel...

Page 133: ...by an authorized dealer The camshaft position CMP sensor and or the crankshaft position CKP 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 repair facility for service The camshaft position CMP sensor and or the crankshaft position CKP sensor are damaged Bring the vehicle to an authorized r...

Page 134: ... an authorized repair facility for service The camshaft position CMP sensor and or the crank angle position sensor are damaged Bring the vehicle to an authorized repair facility for service The constant throttle valves are malfunctioning Bring the vehicle to an authorized repair facility for service There are other problems in the fuel system Bring the vehicle to an authorized repair facility for ...

Page 135: ...blem Fuel Consumption Is Too High Cause Remedy The tires are not properly inflated Check all tires for correct pressure The air filter and or intake air system is clogged Check the air restriction indicator Clean the intake air system and replace the air filter if necessary The exhaust brake valve is malfunctioning Have an authorized repair facility check the operation of the valve 124 All informa...

Page 136: ...e sensor is damaged or reading incorrectly Bring the vehicle to an authorized repair facility for service The fuel temperature sensor is damaged or reading incorrectly Bring the vehicle to an authorized repair facility for service The engine oil temperature sensor is damaged or reading incorrectly Bring the vehicle to an authorized repair facility for service The charge air temperature sensor is d...

Page 137: ...ctly Bring the vehicle to an authorized repair facility for service The radiator is damaged or dirty Clean the radiator Repair or replace the radiator as necessary The water pump is damaged Have an authorized repair facility replace the water pump The thermostat is not operating properly Have an authorized repair facility replace the thermostat The fan is not operating properly Bring the vehicle t...

Page 138: ...e the parameter settings reprogrammed in the MCM or CPC Problem The 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 repair facility replace the air compressor The cylinder head gasket is leaking Have an authorized repair facility re...

Page 139: ...thin the recommended interval Change the oil The oil is not of the recommended quality Change the oil Problem The Engine Oil Pressure Is Low Cause Remedy The oil pressure gauge and or sensor is not reading correctly Bring the vehicle to an authorized repair facility for service There is fuel in the oil Bring the vehicle to an authorized repair facility for service The oil filter is clogged Replace...

Page 140: ...ioning Have an authorized repair facility 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 repair facility for...

Page 141: ... control switch is damaged Replace the switch The exhaust brake is not operating properly Have an authorized repair facility check the operation of the valve The constant throttle valves are malfunctioning Bring the vehicle to an authorized repair facility for service Components of the MCM and or CPC are damaged Bring the vehicle to an authorized repair facility for service Problem Cruise Control ...

Page 142: ...he poly V belt is too loose Check the belt tension if necessary Have an authorized repair facility replace the belt tensioner The belt tensioner is damaged Have an authorized repair facility 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 repair facility replace the alternator A...

Page 143: ...s follow this procedure 1 With the engine at ambient temperature and cool to the touch drain engine crankcase oil into a suitable container Dispose of the oil in an environmentally friendly manner according to state and or federal EPA recommendations 2 Fill the crankcase to the proper level with the recommended viscosity and grade of oil 3 Fill the fuel tank with the recommended grade of fuel oil ...

Page 144: ...oling system and flush with clean soft water Refill with clean soft water and add a rust inhibitor to the cooling system 2 Circulate the coolant by operating the engine until normal operating temperature is reached 3 Stop the engine 4 With the engine at ambient temperature and cool to the touch drain the engine crankcase oil into a suitable container Remove the oil filters Dispose of the oil and f...

Page 145: ...Then disconnect the fuel return line and the inlet line at the primary filter and securely plug both to retain the fuel in the engine 10 Transmission Follow the manufacturer s recommendations for prolonged storage 11 Power Take Off If equipped follow manufacturer s recommendations for prolonged storage NOTICE Failure to properly seal off the turbocharger air inlet and exhaust outlet openings befor...

Page 146: ...place Keep the battery fully charged and check the level and specific gravity of the electrolyte regularly 17 Insert heavy paper strips between the pulleys and drive belts to prevent sticking 18 Seal all engine openings including the exhaust outlet with moisture resistant tape Use cardboard plywood or metal covers where practical 19 Clean and dry the exterior painted surfaces of the engine and spr...

Page 147: ...s to their proper positions 3 Wash the exterior of the engine with fuel oil to remove the rust preventive Do not wash electrical components 4 Remove the rust preventive from the flywheel Flush any soluble oil rust inhibitor if used in the cooling system 5 Remove the paper strips from between the pulleys and drive belts 6 Fill the crankcase to the proper level with the required grade of lubricating...

Page 148: ...center bearing housing Refer to Lubrication System Checks in the OPERATING INSTRUCTIONS FOR STARTING THE ENGINE section of this guide ENGINE EXHAUST To avoid injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic 14 After all preparations are completed start the engine NOTE The small amount of rust preventive which remains in the fuel system...

Page 149: ...oncern to Detroit Diesel Corporation and its distributor dealer organizations See Figure 40 for Detroit Diesel NAFTA On Highway service regions Figure 40 Detroit Diesel NAFTA On Highway Service Regions 138 All information subject to change without notice Rev 04 08 DDC SVC MAN 0040 0704 Copyright 2008 DETROIT DIESEL CORPORATION ...

Page 150: ...iesel 3325 Paddocks Parkway Suite 230 Suwanne GA 30024 Phone 678 341 6100 Fax 678 341 6150 SOUTHERN REGION Detroit Diesel 3325 Paddocks Parkway Suite 230 Suwanne GA 30024 Phone 678 341 6100 Fax 678 341 6150 WESTERN REGION Detroit Diesel 7700 Irvine Center Suite 275 Irvine CA 92618 Phone 949 753 7710 Fax 949 753 7711 CANADA REGION Detroit Diesel of Canada Ltd 150 Dufferin Ave Suite 701 London ON N5...

Page 151: ...fore calling Customer Assistance please do the following Check coolant level Check fuel level Check DDEC fuses Check for fuel leaks Make sure manual shutoff valve if installed on the fuel filter adaptor fuel processor body or fuel supply line is open Check the oil level on the dipstick Check diagnostic codes If you call have the following information available Engine serial number Vehicle make and...

Page 152: ...iesel Product or Part Detroit Diesel fully realizes that ultimately the customer s concerns will be resolved at the Distributor Dealer level and therefore encourages customers to follow the procedure outlined below Step One Customers should discuss the problem with a member of management from the authorized service outlet Frequently complaints are the result of a breakdown in communication and can...

Page 153: ...onological summary of engine s repair history Step Three If the customer is still not satisfied he she should present the entire matter in writing or by phone to Director of Technical Service or Manager Service Operations BX5 Detroit Diesel 13400 Outer Drive West Detroit Michigan 48239 4001 Phone 313 592 5000 Fax 313 592 5888 142 All information subject to change without notice Rev 04 08 DDC SVC M...

Page 154: ...stem requires the chemical make up of the system to be balanced POWER COOL Fully Formulated IEG Coolant The part numbers and sizes of concentrated POWER COOL and pre blended 50 50 POWER COOL are listed in Table 18 Coolant Type Part Number Description 23512138 1 Gallon Jug 6 Per Case 23512139 55 Gallon Drum 23529295 330 Gallon Tote Concentrated 23512140 Bulk Delivery 1 000 Gallon Min 23528203 1 Gal...

Page 155: ...61 55 Gallon Drum Table 19 POWER COOL 2000 Supplemental Coolant Additive Coolant Type Part Number Description 23507854 Pint Bottle 12 Per Case 23507855 Half Gallon Jug 6 Per Case 23507856 5 Gallon Pail For POWER COOL IEG Coolant 23507857 55 Gallon Drum Table 20 POWER COOL 3000 Supplemental Coolant Additive 144 All information subject to change without notice Rev 04 08 DDC SVC MAN 0040 0704 Copyrig...

Page 156: ... POWER COOL IEG Coolant 23508428 53 Ounce 13 Pint Equivalent Table 21 POWER COOL 3000 Supplemental Additive Coolant Filters POWER COOL Supplemental Additive Need Release Coolant Filters Coolant Type Part Number Description NF2091 For 0 8 Gallon Systems For POWER COOL IEG Coolant 23516489 For 8 20 Gallon Systems Table 22 POWER COOL Supplemental Additive Need Release Coolant Filters All information ...

Page 157: ...xtender For Use With POWER COOL Plus OAT Coolant Coolant Type Part Number Description For Power Cool Plus 23519400 Quart Bottle 6 Per Case Table 24 POWER COOL Plus Extender for Use with POWER COOL Plus OAT Coolant POWER COOL Cooling System Cleaners Coolant Type Part Number Description 200164 On Half Gallon Jug 6 Per Case 200105 5 Gallon Pail On Line Cleaner 200155 55 Gallon Drum Twin Pack 201549 T...

Page 158: ...Way Coolant Test Strips Bottle of 50 Indicates Nitrite Molybdate Glycol Levels 23522774 3 Way Coolant Test Strips Bottle of 10 Complete IEG IPG Coolant Analysis 23516921 Coolant Analysis Bottle Carton of 6 Organic Coolant Analysis 23523398 Laboratory Coolant Analysis Bottle Carton of 6 Table 26 POWER TRAC Coolant Testing And Analysis Products All information subject to change without notice Rev 04...

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