Detroit Diesel EPA04 MBE 4000 Maintenance Instruction

Below you will find brief information for MBE 4000 Engine. This guide outlines safe operation and preventive maintenance for the Detroit Diesel MBE 4000 engine. It covers routine services, features like exhaust brake and electronic engine control, and troubleshooting tips for optimal performance and longevity.

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EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

To the Operator

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

MBE 4000 engine. Maintenance instructions cover routine engine services such as lube oil and fi lter changes in enough detail to permit self-servicing if desired.

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

Power-driven equipment is only as safe as the person operating the controls. You are urged, as the operator of this diesel engine, to keep fi ngers and clothing away from the revolving belts, drive shafts, etc. on engine installation.

Throughout this guide

CAUTIONS regarding personal safety and

NOTICES regarding engine performance or service life will appear. To avoid personal injury and ensure long engine service life, always heed these instructions.

Whenever possible, it will bene fi t 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 speci fi cations in this publication are based on the information in effect at the time of approval for printing. Contact an authorized Detroit Diesel service outlet for information on the latest revision. The right is reserved to make changes at any time without obligation.

NOTICE:

Coolant must be inhibited with the recommended Supplemental

Coolant Additives (SCA) listed in this guide. In addition, the engine can be equipped with a coolant filter/inhibitor system as an installed option or as an after-sale item.

Failure to check and maintain SCA levels at required concentrations will result in severe damage corrosion to the engine cooling system and related components.

Trademark Information

Detroit Diesel®, DDEC®, and

Diagnostic Link® are registered trademarks of Detroit Diesel

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

All information subject to change without notice.

(Rev. 04/08)

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

CAUTION SUMMARY ..........................................................................

ENGINE OPERATION .....................................................................

PREVENTIVE MAINTENANCE .......................................................

ELECTRICAL SYSTEM ...................................................................

COOLING SYSTEM .........................................................................

AIR INTAKE SYSTEM ......................................................................

FUEL SYSTEM ................................................................................

COMPRESSED AIR .........................................................................

LUBRICATING OIL AND FILTERS ..................................................

IDENTIFICATION

................................................................................. 10

PERSONNEL REQUIREMENTS ..................................................... 11

ENGINE CONVERSIONS AND MODIFICATIONS .......................... 11

GENERAL VIEW OF THE MBE 4000 ENGINE ............................... 11

ENGINE TYPE PLATE ..................................................................... 14

DETAILS ON THE PLATE .......................................................... 14

ENGINE FEATURES ....................................................................... 15

EXHAUST BRAKE/CONSTANT-THROTTLE VALVES .................... 16

TURBO BRAKE, OPTIONAL ........................................................... 17

EXHAUST GAS RECIRCULATION ................................................. 17

ELECTRONIC ENGINE CONTROL SYSTEM ................................. 18

DDEC-ECU — ENGINE-RESIDENT CONTROL UNIT ............... 19

VEHICLE CONTROL UNIT ......................................................... 20

SENSOR LOCATIONS ................................................................ 20

OPERATION

........................................................................................ 22

BEFORE STARTING THE ENGINE ................................................ 22

CHECKING THE BATTERIES ..................................................... 22

CHECKING THE OIL LEVEL ....................................................... 23

CHECKING THE COOLANT LEVEL (COLD CHECK) ................ 24

ADDING FUEL ............................................................................. 24

PRIMING THE FUEL SYSTEM ................................................... 24

STARTING THE ENGINE ................................................................ 25

CHECKING THE COOLANT LEVEL (HOT CHECK) .................. 25

All information subject to change without notice.

(Rev. 04/08)

TABLE OF CONTENTS

STARTING AN ENGINE THAT HAS NOT BEEN RUN FOR A

LONG TIME ................................................................................. 26

MONITORING ENGINE OPERATION ............................................. 27

BATTERY CHARGE .................................................................... 27

OIL PRESSURE .......................................................................... 27

EXCESSIVE IDLING ................................................................... 28

CHANGING THE IDLE SPEED ....................................................... 28

SHUTTING DOWN THE ENGINE ................................................... 28

SHUTTING DOWN AFTER HIGH LOAD OPERATION ............... 28

EMERGENCY RUNNING MODE .................................................... 29

STOP ENGINE OVERRIDE OPTION .............................................. 29

COLD WEATHER OPERATION ...................................................... 30

WINTER FRONTS ....................................................................... 30

CLEANING AND STORAGE

............................................................... 31

CLEANING THE ENGINE ................................................................ 31

HIGH-PRESSURE CLEANING EQUIPMENT ............................. 31

CLEANING THE COOLING SYSTEM ............................................. 31

DEGREASING ............................................................................. 32

STORAGE ........................................................................................ 33

TROUBLESHOOTING

......................................................................... 34

EMERGENCY STARTING ............................................................... 34

TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL

SYSTEM .......................................................................................... 34

GENERAL TROUBLESHOOTING ................................................... 35

SERVICE PRODUCTS

......................................................................... 48

DIESEL FUELS ................................................................................ 48

FLOW IMPROVERS .................................................................... 48

KEROSENE ................................................................................. 48

ENGINE OILS .................................................................................. 49

SYNTHETIC OILS ....................................................................... 49

COOLANT ........................................................................................ 50

FULLY-FORMULATED ANTIFREEZE ......................................... 50

WATER ........................................................................................ 50

COOLANT SPECIFICATIONS ..................................................... 51

COOLANT CONCENTRATION ................................................... 51

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

SUPPLEMENTAL COOLANT ADDITIVES FOR FULLY

FORMULATED COOLANT .......................................................... 52

DROPOUT ................................................................................... 52

NON-APPROVED COOLANTS ................................................... 52

RECYCLED ANTIFREEZE .......................................................... 53

CORROSION INHIBITORS ......................................................... 53

DISPOSAL ................................................................................... 54

COLD WEATHER PRODUCTS ....................................................... 54

WINTER-GRADE DIESEL FUEL ................................................. 54

LOW-VISCOSITY ENGINE OIL ................................................... 55

WINTER COOLANT ANTIFREEZE PROTECTION .................... 55

BATTERIES ................................................................................. 55

TECHNICAL DATA

.............................................................................. 56

ENGINE DATA ................................................................................. 57

TESTING AND ADJUSTING VALUES ............................................. 58

MAINTENANCE

................................................................................... 60

SCHEDULED INTERVALS .............................................................. 60

MAINTENANCE SCHEDULE TYPES ......................................... 60

SEVERE SERVICE ................................................................. 60

SHORT-HAUL ......................................................................... 61

LONG-HAUL ........................................................................... 61

MAINTENANCE SCHEDULE AND INTERVAL

OPERATIONS ......................................................................... 61

MAINTENANCE INTERVALS .................................................. 61

MAINTENANCE OPERATION SETS ...................................... 61

SCHEDULE USE ......................................................................... 62

MAINTENANCE TABLES ................................................................ 63

REQUIRED MAINTENANCE OPERATIONS ................................... 69

ENGINE INSPECTING ................................................................ 69

VALVE LASH CHECKING AND ADJUSTING ............................. 69

GAINING ACCESS TO THE VALVES ..................................... 69

CHOOSING A METHOD ......................................................... 70

METHOD ONE ........................................................................ 71

METHOD TWO ....................................................................... 72

ADJUSTING VALVE LASH ...................................................... 73

RESTORING THE VEHICLE TO OPERATING CONDITION .. 73

All information subject to change without notice.

(Rev. 04/08)

TABLE OF CONTENTS

FUEL/WATER SEPARATOR PREFILTER ELEMENT

CLEANING .................................................................................. 74

FUEL PRO® 382 FUEL/WATER SEPARATOR ELEMENT

REPLACEMENT .......................................................................... 75

MAIN FUEL FILTER ELEMENT CHANGING .............................. 76

ENGINE OIL AND FILTER CHANGING ...................................... 77

OPTIONAL OIL CENTRIFUGE ............................................... 80

COOLANT CONCENTRATION AND INHIBITOR LEVEL

CHECKING .................................................................................. 81

COOLANT INHIBITOR TEST INTERVALS ............................. 82

INHIBITOR LEVEL CHECKING .............................................. 84

COOLANT FLUSHING AND CHANGING ................................... 85

COOLING SYSTEM INSPECTING ............................................. 86

REAR ENGINE POWER TAKE-OFF (REPTO) .......................... 87

REPTO TORSIONAL DAMPER INSPECTION ....................... 87

REPTO TORSIONAL DAMPER CLEANING ........................... 87

CUSTOMER ASSISTANCE

................................................................. 89

WORKING WITH DDC SERVICE OUTLETS .................................. 93

STEP ONE ................................................................................... 93

STEP TWO .................................................................................. 93

STEP THREE .............................................................................. 94

LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 4000

ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS

......... 95

TERMS OF COVERAGE ................................................................. 95

USES ........................................................................................... 95

DEFECTS .................................................................................... 95

REPAIRS ..................................................................................... 95

WARRANTY PERIOD .................................................................. 95

LIKE REPLACEMENT ENGINE .................................................. 96

SERVICE SUPPLIES .................................................................. 96

ENGINE REMOVAL AND REINSTALLATION ............................. 96

THIS WARRANTY DOES NOT COVER: ......................................... 97

REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,

NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 97

FUEL INJECTION SYSTEM AFTER 100,000 MILES/160, 000

KILOMETERS .............................................................................. 97

MAINTENANCE ........................................................................... 97

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

INCIDENTAL OR CONSEQUENTIAL DAMAGES ...................... 97

OTHER LIMITATIONS ................................................................. 97

LIMITED WARRANTY ON NEW DETROIT DIESEL MBE

4000 ENGINES USED IN FIRE TRUCK OR CRASH VEHICLE

APPLICATIONS

................................................................................... 99

TERMS OF COVERAGE ................................................................. 99

USES ........................................................................................... 99

DEFECTS .................................................................................... 99

REPAIRS ..................................................................................... 99

WARRANTY PERIOD .................................................................. 99

LIKE REPLACEMENT ENGINE .................................................. 100

SERVICE SUPPLIES .................................................................. 100

ENGINE REMOVAL AND REINSTALLATION ............................. 100

THIS WARRANTY DOES NOT COVER: ......................................... 100

REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,

NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 100

FUEL INJECTION SYSTEM AFTER 100,000 MILES/160, 000

KILOMETERS .............................................................................. 100

MAINTENANCE ........................................................................... 101

INCIDENTAL OR CONSEQUENTIAL DAMAGES ...................... 101

OTHER LIMITATIONS ................................................................. 101

All information subject to change without notice.

(Rev. 04/08)

TABLE OF CONTENTS viii

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

CAUTION SUMMARY

The following cautions must be observed by the operator of the vehicle or equipment in which this engine is installed and/or by those performing basic engine preventive maintenance. Failure to read and heed these cautions and exercise reasonable care for personal safety and the safety of others when operating the vehicle/equipment or performing basic engine preventive maintenance may result in personal injury and engine and/or vehicle/equipment damage.

Engine Operation

Observe the following cautions when operating the engine.

PERSONAL INJURY

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

□ Always start and operate an engine in a well ventilated area.

□ If operating an engine in an enclosed area, vent the exhaust to the outside.

□ Do not modify or tamper with the exhaust system or emission control system.

FIRE

To avoid injury from fi re, keep all potential ignition sources away from diesel fuel, including open fl ames, sparks, and electrical resistance heating elements. Do not smoke when refueling.

All information subject to change without notice.

(Rev. 04/08)

CAUTION SUMMARY

Preventive Maintenance

Observe the following cautions when performing preventative maintenance.

HOT OIL

To avoid injury from hot oil, do not operate the engine with the rocker cover(s) removed.

PERSONAL INJURY

To avoid injury 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.

PERSONAL INJURY

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

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.

USED ENGINE OIL

To avoid injury to skin from contact with the contaminants in used engine oil, wear protective gloves and apron.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

PERSONAL INJURY

To avoid injury from the projection of tools or other objects that may fall on or behind the vibration damper of an engine, always check and remove these items before starting the engine.

FIRE

To avoid injury from combustion of heated lubricating-oil vapors, stop the engine immediately if an oil leak is detected.

PERSONAL INJURY

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

FIRE

To avoid injury from fi re, do not smoke or allow open fl ames when working on an operating engine.

FIRE

To avoid injury from fi re from a buildup of volatile vapors, keep the engine area well ventilated during operation.

PERSONAL INJURY

To avoid injury when using caustic cleaning agents, follow the chemical manufacturers usage, disposal, and safety instructions.

All information subject to change without notice.

(Rev. 04/08)

CAUTION SUMMARY

Electrical System

Observe the following cautions when jump starting an engine, charging a battery, or working with the vehicle electrical system.

PERSONAL INJURY

To avoid injury from accidental engine startup while servicing the engine, disconnect/disable the starting system.

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 fl ames near the battery. If you come in contact with battery acid:

□ Flush your skin with water.

□ Apply baking soda or lime to help neutralize the acid.

□ Flush your eyes with water.

□ Get medical attention immediately.

Electrical Shock

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

ELECTRICAL SHOCK

To avoid injury from electrical shock, do not touch battery terminals, alternator terminals, or wiring cables while the engine is operating.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Electrical Shock Hazard

High voltage can remain inside the Electrostatic Oil Separator after removal. Wait 30 minutes after turning off the ignition before removing the separator.

Never touch parts through ventilation openings or impeller opening with fi nger 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)

CAUTION SUMMARY

Cooling System

Observe the following cautions when servicing the cooling system.

Air Intake System

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

HOT COOLANT

To avoid scalding from the expulsion of hot coolant, never remove the cooling system pressure cap while the engine is at operating temperature. Wear adequate protective clothing

(face shield, rubber gloves, apron, and boots). Remove the cap slowly to relieve pressure.

PERSONAL INJURY

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

PERSONAL INJURY

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

PERSONAL INJURY

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Fuel System

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

PERSONAL INJURY

To avoid injury from fuel spills, do not over fi ll the fuel tank.

FIRE

To avoid injury from fi re, keep all potential ignition sources away from diesel fuel, including open fl ames, sparks, and electrical resistance heating elements. Do not smoke when refueling.

FIRE

To avoid injury from fi re, contain and eliminate leaks of fl ammable fl uids as they occur. Failure to eliminate leaks could result in fi re.

PERSONAL INJURY

To prevent the escape of high pressure fuel that can penetrate skin, ensure the engine has been shut down for a minimum of 10 minutes before servicing any component within the high pressure circuit. Residual high fuel pressure may be present within the circuit.

All information subject to change without notice.

(Rev. 04/08)

CAUTION SUMMARY

FIRE

To avoid injury from fi re 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 fl ames when working on an operating engine.

□ Wear adequate protective clothing (face shield, insulated gloves and apron, etc.).

□ To prevent a buildup of potentially volatile vapors, keep the engine area well ventilated during operation.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Compressed Air

Observe the following cautions when using compressed air.

FIRE

To avoid injury from fi re, do not smoke or allow open fl ames when working on an operating engine.

EYE INJURY

To avoid injury from fl ying 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 fi lters.

FIRE

To avoid injury from fi re from a buildup of volatile vapors, keep the engine area well ventilated during operation.

PERSONAL INJURY

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

FIRE

To avoid injury from combustion of heated lubricating-oil vapors, stop the engine immediately if an oil leak is detected.

All information subject to change without notice.

(Rev. 04/08)

IDENTIFICATION

IDENTIFICATION

The MBE 4000 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.

Figure 1 Emission Label, MBE 4000

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

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 modi fi ed 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 speci fi c skills necessary for the type of work being performed.

Engine Conversions and

Modi

cations

The function and safety of the engine could be affected if unauthorized modi fi cations are made to it. 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

4000 Engine

For a general view of the MBE 4000 engine, showing major components, see Figure 2 for the left-hand side, and

Figure 3 for the right-hand side.

All information subject to change without notice.

(Rev. 04/08)

IDENTIFICATION

1. EGR Outlet Pipe

2. Coolant Pump

3. Thermostat Housing

4. Modulated EGR Valve

5. EGR Cooler

6. EGR Shutoff Valve (hidden)

7. Air Intake Manifold

8. Engine Trim Cover

9. Crankcase Breather

10. Air Compressor

11. Fuel Filter Housing

12. Oil Pan

13. EGR Mixer

14. Air Conditioning Compressor

Figure 2 Major Engine Components, Left Side

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

1. Oil Filter

2. Air Solenoid Valve (Engine Brake)

3. Turbocharger

4. EGR Hot Pipe

5. Exhaust Manifold

6. EGR Shutoff Valve

7. EGR Cooler

8. Reed Valve Housing

9. EGR Control Valve

10. EGR Mixer

11. Alternator

12. Belt Tensioner

Figure 3 Major Engine Components, Right Side

All information subject to change without notice.

(Rev. 04/08)

IDENTIFICATION

Engine Type Plate

The engine type plate is used to identify the engine. It is located on the oil fi

lter housing. See Figure 4.

Figure 5 Engine Type Plate

Figure 4 Location of Engine Type

Plate

Details on the Plate

The engine type reference, OM 460

LA, is the production code. The fi rst three numbers of the engine serial number are the model number.

See Figure 5.

The last six numbers are the serial

numbers (745111 in see Figure 5).

NOTE:

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

DDEC-ECU label. The ten digit number is derived from the fourteen

digit number (see Figure 6).

Figure 6 Engine Serial Number

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Engine Features

All MBE 4000 engines are water-cooled, four-stroke, direct-injection inline diesel engines.

Each cylinder has a separate fuel injection pump (unit pump) with a short injection line to the injection nozzle, which is located in the center of the combustion chamber. The unit pumps are attached to the crankcase and are driven from the camshaft.

Each cylinder has two intake valves and two exhaust valves.

Charge-air cooling and an exhaust gas turbocharger are standard equipment.

The engine has a fully electronic control system consisting of a

DDEC-ECU (Engine Control Unit) and a DDEC-VCU (Vehicle Control

Unit) connected by a proprietary datalink. This system regulates the injection quantity and timing using solenoid valves, allowing extremely low-emission operation.

Standard engine braking is controlled by a pneumatically-operated exhaust brake on the turbocharger and by a hydraulically-operated constant-throttle system. For greater braking power, an optional turbo brake is available.

The cylinder block has integrated oil and water channels. The upper section of the cylinder bore has a carbon scraper ring seated in a groove on the top part of the cylinder. The six individual cylinder heads are made of cast iron. The cylinder head gasket is an adjustment-free seal with rubber sealing elements.

The pistons are made of aluminum alloy with ring carriers and a shallow combustion chamber recess. The pistons are cooled by oil spray nozzles.

The crankshaft is precision-forged with seven main bearings and eight custom-forged counter weights, and a vibration damper at the front end.

The camshaft is made of induction-hardened steel and has seven cam bearings. Each cylinder has cams for intake and exhaust valves and a unit pump.

The valves are controlled by roller tappets, pushrods, and rocker arms.

The intake and exhaust valves are opened and closed by a freefl oating valve bridge.

There is a force-feed lubricating oil circuit supplied by a gear-type oil pump. This pump is positioned at the rear of the oil pan and driven by gears from the crankshaft. The oil heat exchanger is integrated with the oil fi lter housing on the right-hand side.

The gear-type fuel pump is located near the front of the crankcase on the left hand side. The pump is driven from the forward end of the camshaft.

All information subject to change without notice.

(Rev. 04/08)

IDENTIFICATION

The air compressor, with a power-steering pump attached, is driven by a gear on the camshaft.

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

There are two main drive belts, each with its own automatic belt tensioner.

The alternator and coolant pump

(and any other accessories) and the refrigerant compressor are driven by a main drive belt. The fan is driven by its own drive belt

Electrical equipment includes a starter and an alternator.

Exhaust

Brake/Constant-Throttle

Valves

To increase braking performance, the engine is equipped with an exhaust brake on the turbocharger in conjunction with constant-throttle valves on the cylinder head.

See Figure 7.

NOTE:

On EGR engines, the constant-throttle valves are activated by engine oil pressure.

The exhaust back pressure is used by the exhaust brake to increase braking performance.

Figure 7 Constant-Throttle Activation (shown with EGR system removed)

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

The constant-throttle valves use the air that escapes through them on the compression stroke to provide braking force. The constant throttles are small valves which are built into the cylinder heads. When open, a link is created between the combustion chamber and the exhaust port.

The engine brake is activated by the

DDEC-VCU. In engine braking mode, an engine rpm range of up to 2,500 rpm can be used by the operator.

2,500 rpm, however, may never be exceeded. The engine is turned off automatically when the engine rpm is:

□ Below 900 rpm for Allison

Automatic Transmissions

□ Below 1100 rpm for all other transmissions

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.

Turbo Brake, Optional

For high braking output, the MBE

4000 engine can be equipped with an optional turbo brake. The turbo brake increases the air mass fl ow through the engine to provide very high braking horsepower.

The turbo brake can be operated either manually or automatically, through the cruise control function.

Because the charge air pressure is maintained at a high level during braking, full throttle response is available immediately, if the operator desires it, without any turbo lag.

The turbo brake is maintenance-free, highly reliable, and adds virtually no weight to the engine.

Exhaust Gas Recirculation

The purpose of the Exhaust Gas

Recirculation (EGR) System is to reduce engine exhaust gas emissions in accordance with EPA regulations.

The MBE 4000 engines for on-highway EPA 2004 regulation applications use a cooled EGR system consisting of an EGR cooler, EGR control valves, reed valves, and an

EGR mixer.

In the cooled EGR system, part of the exhaust gasses from the front three cylinders are routed from the exhaust manifold through the EGR cooler, past control and reed valves, and are mixed with the intake manifold charge air.

All information subject to change without notice.

(Rev. 04/08)

IDENTIFICATION

The addition of cooled exhaust gasses back into the combustion air fl ow reduces the peak in cylinder combustion temperature. Less oxides of nitrogen (NOx) are produced at lower combustion temperatures.

The recycled exhaust gases are cooled before engine consumption in a tube and shell engine water cooler.

Electronic Engine Control

System

The engine is equipped with a fully electronic control system. See Figure

Figure 8 Electronic Engine Control System

This system is composed of the

DDEC-ECU (Engine Control Unit) and the DDEC-VCU (Vehicle Control

Unit).

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

The two control units are connected by a proprietary datalink through which all necessary data and information can be exchanged. The DDEC-VCU then broadcasts all information on the

J1587 and J1939 datalinks, where it can be read by minidiag2, the Nexiq™

Diagnostic Data Reader (DDR) or

Detroit Diesel Diagnostic Link®

(DDDL) PC software.

The DDEC-ECU 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. For more information on the emergency running mode,

refer to the “Emergency Running

Mode” section under “Operations.”

DDEC-ECU — Engine-Resident

Control Unit

The DDEC-ECU (see see Figure 9)

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 9 DDEC-ECU

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

6), the engine horse power and torque.

All information subject to change without notice.

(Rev. 04/08)

IDENTIFICATION

Vehicle Control Unit

The DDEC-VCU, see Figure

10, communicates with the other

electronic control units installed on the vehicle over the J1587 and J1939 data link.

and transmitted to the DDEC-ECU via the proprietary data link.

The DDEC-VCU controls various systems, for example, communications with the datalink and the engine brake.

If the engine control system detects a fault, the appropriate fault code is broadcast on the datalink and can be read using minidiag2, the Nexiq DDR or DDDL PC software. Fault code information may also be available on the vehicle or equipment instrument panel.

Sensor Locations

Use caution when handling the sensors.

Figure 10 DDEC-VCU

Sets of data for speci fi c applications are stored in the DDEC-VCU including idle speed, maximum running speed, and speed limitation.

The DDEC-VCU receives data from the following sources:

□ The operator (accelerator pedal position, engine brake switch)

□ Other electronic control units (the antilock brake system)

□ The DDEC-ECU (oil pressure and coolant temperature)

From these data, instructions are computed for controlling the engine

CHEMICAL BURNS

To avoid injury from chemical burns, wear a face shield and neoprene or PVC gloves when handling sensor hoses.

The Engine Oil Pressure/Temperature

Sensor is located at the base of the oil fi lter.

See Figure 11 for sensor locations on the MBE 4000 engine.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

1. Intake Air Pressure/Temperature

Sensor

2. EGR Temperature Sensor

3. Camshaft Position Sensor

4. Crankshaft Position Sensor

5. Engine Coolant Temperature

Sensor

6. Barometric Pressure Sensor

(Integrated into DDEC-ECU)

7. Supply Fuel Temperature Sensor

8. Engine Oil Pressure/Temperature

Sensor

Figure 11 Sensor Location

All information subject to change without notice.

(Rev. 04/08)

OPERATION

OPERATION

Important:

Before starting the engine, carefully read all operating instructions in this manual and 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

□ Low oil pressure warning light

□ Coolant temperature gauge

□ High coolant temperature warning light

□ Water in fuel warning light

□ Tachometer

□ Air restriction indicator

Watch for any signs of engine problems when starting or driving. If the engine overheats, uses excessive fuel or lubricating oil, vibrates, mis fi res, makes unusual noises, or shows an unusual loss of power, turn the engine off as soon as possible and determine the cause of the problem.

Engine damage may be avoided by a quick response to early indications of problems.

When starting the engine in cold

weather, refer to the “ Service

Products” section.

Checking the Batteries

Use only batteries that have been correctly fi lled 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

Shell Oil Co.

Texaco, Inc.

Quaker State

Lubricant or

Part Number

No. 71032; No.

71306

No. 955

No. NYK-77

Table 1 Approved Electrical

Lubricants

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Battery Explosion and Acid Burn

□ Flush your skin with water.

□ Apply baking soda or lime to help neutralize the acid.

□ Flush your eyes with water.

□ Get medical attention immediately.

Figure 12 Oil Dipstick

2. If necessary, top off by fi lling engine oil through the oil fi ll cap

(see Figure 13) to the maximum

fi ll level on the oil dipstick.

Checking the Oil Level

Check the oil level as follows:

1. Check the oil level using the oil

dipstick (see Figure 12).

PERSONAL INJURY

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

Figure 13 Oil Fill Cap

For detailed procedures, refer to the

“Maintenance” section.

All information subject to change without notice.

(Rev. 04/08)

OPERATION

Checking the Coolant Level

(Cold Check)

Check 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 fi lled when the coolant is between the maximum and minimum marks on the surge tank.

For more information, refer to the

“Maintenance” section.

Adding Fuel

When adding fuel, pay attention to the following:

□ 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 the

“Service Products” section.

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. For tightening speci fi cations, refer to the

”Technical Data” section.

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

NOTE:

There should be a strong resistance in the hand pump, caused by the pressure buildup within the fuel system.

3. Crank the engine for 30 seconds at a time, but no longer. Wait at least two minutes. The engine should start within four 30-second attempts.

Priming the Fuel System

Prime the fuel system as follows:

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Starting the Engine

Before operating the engine, do the work described under "Before Starting the Engine." Start the engine as follows:

NOTICE:

Never attempt to start any

Mercedes-Benz electronic engine using ether or any other starting fluid. Serious engine damage could result.

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.

[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 fi ve minutes after shutdown, check the engine oil level. If necessary, add oil up to the maximum fi ll level on the oil dipstick.

6. Check all the mounting fasteners on the engine for tightness.

Checking the Coolant Level (Hot

Check)

Check the coolant levels as follows:

1. Allow the engine to run for approximately fi ve minutes at a moderate speed.

1. Turn on the ignition switch.

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

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.

All information subject to change without notice.

(Rev. 04/08)

OPERATION

HOT COOLANT

To avoid scalding from the expulsion of hot coolant, never remove the cooling system pressure cap while the engine is at operating temperature. Wear adequate protective clothing

(face shield, rubber gloves, apron, and boots). Remove the cap slowly to relieve pressure.

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.

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 brie fl y and the coolant level again checked and corrected as necessary.

Starting an Engine That Has Not

Been Run for a Long Time

Before starting an engine which has not been run for a long time, certain special work must be carried out.

Refer to the “Cleaning and Storage”

section.

NOTICE:

Do not rev the engine if the oil pressure gauge indicates no oil pressure. To avoid engine damage, shut down the engine 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.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

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 14) must go out once the

engine starts.

FIRE

To avoid injury from fi re, keep all potential ignition sources away from diesel fuel, including open fl ames, sparks, and electrical resistance heating elements. Do not smoke when refueling.

Figure 14 Battery Charge Indicator

Light

If the indicator light comes on while the engine is running, do the following:

1. Shut down the engine.

2. Check the poly-V belt for tightness.

3. Do a load test on the batteries.

Charge or replace the batteries as needed.

4. If necessary, visit the nearest authorized dealer to have the alternator voltage and output checked.

Oil Pressure

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

□ 36 psi (250 kPa) at rated speed

□ 7 psi (50 kPa) at idling speed

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

All information subject to change without notice.

(Rev. 04/08)

OPERATION

Excessive Idling

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

Changing the Idle Speed

The rpm range of the MBE 4000 engine is 600 to 850 rpm if the parameters in the DDEC-VCU are set to the default range.

Change the idle 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 High Load

Operation

After high load operation, do the following:

NOTICE:

After high load operation, allow the engine to idle for one to two minutes without load. Shutting down the engine without idling may cause damage to the turbocharger.

1. 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.

2. Turn off the ignition switch and shut down the engine.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

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.

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). 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 fi ve seconds to obtain a subsequent override.

□ In conjunction with any dashboard or instrument panel display, 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 minidiag2, the Nexiq DDR or DDDL PC software.

□ 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.

For fault codes and their meanings, see the vehicle service manual.

Figure 15 Typical SEO Switch and

Warning Lamps

NOTE:

The operator has the responsibility to take action to avoid engine damage.

All information subject to change without notice.

(Rev. 04/08)

OPERATION

Cold Weather Operation

Special precautions must be taken during cold weather. To protect your engine, special cold weather handling is required for fuel, engine oil, coolant, and batteries.

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 fl ow 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)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

CLEANING AND STORAGE

Special precautions should be taken for a stored engine to protect the its interior and exterior.

Cleaning the Engine

Important:

Observe all environmental protection regulations.

High-Pressure Cleaning

Equipment

Information on suitable cleaning and protective products is available from any authorized dealer. Note the equipment manufacturer's operating instructions.

Cleaning 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 fi ns of the radiator grille.

NOTICE:

To prevent damage to engine components, keep the water moving at all times while cleaning.

Never direct water onto electrical components, plug connectors, seals or flexible hoses.

EYE INJURY

To avoid injury from fl ying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure.

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

□ Approximately 28 inches (700 mm) for circular pattern jets

□ Approximately 12 inches (300 mm) for 25-degree fl at jets and dirt cutters

2. Remove the debris by blowing them through with compressed air or spraying them out with water.

Work from the rear of the radiator

(in the opposite direction of the normal cooling air fl ow).

All information subject to change without notice.

(Rev. 04/08)

CLEANING AND STORAGE

3. Drain the coolant when the engine is cold. For detailed procedures, see the vehicle/chassis maintenance manual. For types of coolant,

refer to the “Service Products”

section.

4. 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 fi ve minutes longer. Shut down the engine and allow it to cool to approximately

50°C (112°F).

HOT COOLANT

To avoid scalding from the expulsion of hot coolant, never remove the cooling system pressure cap while the engine is at operating temperature. Wear adequate protective clothing

(face shield, rubber gloves, apron, and boots). Remove the cap slowly to relieve pressure.

3. Drain all the cleaning solution.

4. Flush the cleaning solution from the cooling system.

[a] Immediately after draining the cleaning solution, fl ush the system with clean water.

[b] Once the clean water has drained, fi ll the system again with clean water.

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

“Service Products” section.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Storage

Required protective measures for the

MBE 4000 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 place.

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.

NOTE:

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

All information subject to change without notice.

(Rev. 04/08)

TROUBLESHOOTING

TROUBLESHOOTING

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

Emergency Starting

For emergency starting procedures

(jump starting), see the driver's 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 minidiag2, the

Nexiq DDR or DDDL PC software.

For fault codes and their meanings, see the next section in this guide.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

General Troubleshooting

The tables that follow are designed to identify the causes of common problems, suggest further checks and appropriate remedies. When dealer service is necessary, this 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.

Replace the ignition switch.

The ignition switch is damaged.

The battery cables are damaged and/or corroded.

Replace the battery cables.

The starter is damaged and/or worn.

The clutch or transmission is damaged.

There is internal damage to the engine.

Have an authorized dealer replace the starter.

Bring the vehicle to an authorized dealer for service.

All information subject to change without notice.

(Rev. 04/08)

TROUBLESHOOTING

Problem—The Engine Turns Over Slowly

Cause Remedy

The batteries are damaged or weak.

Test the batteries. Replace them, if needed.

Replace the ignition switch.

The ignition switch is damaged.

The battery cables are damaged and/or corroded

Replace the battery cables.

The starter is damaged and/or worn.

The engine oil does not meet the correct specifications.

The transmission fluid does not meet the correct specifications.

Have an authorized dealer replace the starter.

Change the engine oil, using the correct type of oil.

Change the transmission fluid, using the correct type of fluid.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Problem—The Engine Cranks, But Won't Start

Cause Remedy

The batteries are damaged or weak.

Test the batteries. Replace them, if needed.

The cranking speed is not set correctly.

Bring the vehicle to an authorized dealer for service.

No intake air preheater is installed, and it is too cold to start without one.

The intake air preheater is malfunctioning.

The camshaft TDC sensor and/or the crank angle position sensor are out of adjustment.

Install an intake air preheater.

Check the intake air preheater, and replace it, if necessary.

Push both sensors into their holes as far as they will go. If this does not solve the problem, bring the vehicle to an authorized dealer for service.

The camshaft TDC sensor and/or the crank angle position sensor are damaged.

Bring the vehicle to an authorized dealer for service.

There is air in the fuel system.

The air filter is clogged.

The fuel filter is clogged.

Check the fuel lines for air pockets.

Bleed the fuel system and start the engine.

Clean or replace the air filter.

Replace the filter element.

The exhaust brake valve is malfunctioning.

Have an authorized dealer check the operation of the valve.

The valves are not adjusted properly.

Check the valve lash.

There are other problems in the fuel system.

Bring the vehicle to an authorized dealer for service.

All information subject to change without notice.

(Rev. 04/08)

TROUBLESHOOTING

Problem—The Engine Starts Only After Cranking for a Long Time

Cause Remedy

The fuel tank is low or empty.

Add fuel and bleed the fuel system, if necessary.

There are leaks in the fuel lines.

The fuel filter is clogged.

The fuel line, the fuel prefilter, or the screen in the fuel tank is blocked.

The camshaft TDC sensor and/or the crank angle position sensor are out of adjustment.

Check the fuel lines for leaks and repair them, if necessary.

Replace the filter element.

Clean and bleed the system. Have the fuel lines and filters checked by an authorized dealer.

Push both sensors into their holes as far as they will go. If this does not solve the problem, bring the vehicle to an authorized dealer for service.

The camshaft TDC sensor and/or the crank angle position sensor are damaged.

There are other problems in the fuel system.

Bring the vehicle to an authorized dealer for service.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Problem—The Engine Starts, But Dies

Cause Remedy

The fuel tank is low or empty.

Add fuel and bleed the fuel system, if necessary.

The fuel filter is clogged.

The fuel line, the fuel prefilter, or the screen in the fuel tank is blocked.

The camshaft TDC sensor and/or the crank angle position sensor are out of adjustment.

Replace the filter element.

Clean and bleed the system. Have the fuel lines and filters checked by an authorized dealer.

Push both sensors into their holes as far as they will go. If this does not solve the problem, bring the vehicle to an authorized dealer for service.

The camshaft TDC sensor and/or the crank angle position sensor are damaged.

The constant-throttle valves are malfunctioning.

There are other problems in the fuel system.

Bring the vehicle to an authorized dealer for service.

Problem—The Engine Fan Doesn't Work

Cause Remedy

The fan hub is damaged.

Replace the fan hub.

Repair the fan wiring.

The fan wiring is damaged.

The parameter settings in the

DDEC-ECU or DDEC-VCU are incorrect.

Have an authorized dealer reprogram the control unit.

All information subject to change without notice.

(Rev. 04/08)

TROUBLESHOOTING

Problem—The Engine Fan Is Constantly On

Cause Remedy

The fan override switch is on.

Check the operation of the fan override switch.

Replace the fan hub The fan hub is damaged.

The parameter settings in the

DDEC-ECU or DDEC-VCU are incorrect.

AC switch is damaged

Have an authorized dealer reprogram the control unit.

Check AC switch.

Problem—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.

The fuel filter is clogged.

The exhaust brake valve is malfunctioning.

The engine performs poorly, or does not develop full power.

Check the air restriction indicator.

Clean the intake air system and replace the air filter if necessary.

Replace the filter element.

Have an authorized dealer check the operation of the valve.

The remedies are listed in "The Engine

Performs Poorly, Does Not Develop

Full Power."

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Problem—The Engine Performs Poorly, Does Not

Develop Full Power

Cause Remedy

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.

The fuel filter is clogged.

There are other problems with the fuel system.

The valves are not adjusted properly

The coolant temperature sensor is damaged or reading incorrectly.

The fuel temperature sensor is damaged or reading incorrectly.

The engine oil temperature sensor is damaged or reading incorrectly.

The charge-air temperature sensor is damaged or reading incorrectly.

There are problems with the

DDEC-ECU or DDEC-VCU.

There is internal damage to the engine.

Have an authorized dealer check the operation of the valve.

Replace the filter element.

Bring the vehicle to an authorized dealer for service.

Check the valve lash.

Bring the vehicle to an authorized dealer for service.

All information subject to change without notice.

(Rev. 04/08)

TROUBLESHOOTING

Problem—The Engine Is in Emergency Running Mode

(constant speed 1,300 rpm)

Cause Remedy

The DDEC-ECU or DDEC-VCU is damaged.

Bring the vehicle to an authorized dealer for service.

An incorrect parameter is in the

DDEC-ECU or DDEC-VCU.

Bring the vehicle to an authorized dealer and have the parameter settings reprogrammed in the

DDEC-ECU or DDEC-VCU.

Problem—The Coolant Temperature Is Above Normal

Cause Remedy

The coolant level is too low.

Check for coolant leaks, and repair as needed.

The poly-V belt is loose.

The coolant temperature gauge and/or sensor is not reading correctly.

The radiator is damaged or dirty.

The coolant pump is damaged.

The thermostat is damaged.

The fan is not operating properly.

Tighten or replace the poly-V belt.

Bring the vehicle to an authorized dealer for service.

Clean the radiator. Repair or replace the radiator if necessary.

Have an authorized dealer replace the coolant pump.

Bring the vehicle to an authorized dealer and have the fan hub checked or have the parameter settings reprogrammed in the DDEC-ECU or

DDEC-VCU.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Problem—The Coolant Temperature Is Below Normal

Cause Remedy

The coolant temperature gauge and/or sensor is not reading correctly.

Bring the vehicle to an authorized dealer for service.

The thermostat is damaged.

The fan is not operating properly.

Have an authorized dealer replace the thermostat.

Bring the vehicle to an authorized dealer and have the fan hub checked.

Bring the vehicle to an authorized dealer and have the parameter settings reprogrammed in the

DDEC-ECU or DDEC-VCU.

Problem—The Cooling System Is Losing Coolant

Cause Remedy

There is an external coolant leak.

Repair the leaking component.

The radiator cap is leaking.

The air compressor head is damaged.

The cylinder head gasket is leaking.

Replace the radiator cap.

Have an authorized dealer replace the air compressor.

Have an authorized dealer replace the head gasket.

Problem—There Is Coolant in the Engine Oil

Cause Remedy

The cylinder head gasket is damaged.

Have an authorized dealer replace the head gasket.

The oil/water heat exchanger is leaking.

There is an internal coolant leak.

Have an authorized dealer replace the heat exchanger.

Bring the vehicle to an authorized dealer for service.

All information subject to change without notice.

(Rev. 04/08)

TROUBLESHOOTING

Problem—There Is Foam in the Engine Oil

Cause Remedy

The oil level is too low or too high.

Correct the oil level.

The oil has not been changed within the recommended interval.

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 dealer for service.

There is fuel in the oil.

The oil pump and/or relief valve is damaged.

Bring the vehicle to an authorized dealer for service.

The oil filter is clogged.

Replace the filter element.

The oil filter bypass valve is damaged.

Replace the bypass valve.

Have an authorized dealer replace the oil pump.

Problem—The Engine Exhaust Is White

Cause Remedy

The fuel is of poor quality.

Add fuel of the right quality.

The intake air preheater is malfunctioning.

Check the intake air preheater, and replace it, if necessary.

The valves are not adjusted properly.

Check the valve lash.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Problem—The Engine Exhaust Is Black

Cause Remedy

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.

The intake air preheater is malfunctioning.

Have an authorized dealer check the operation of the valve.

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.

The charge-air temperature sensor is damaged.

There is internal damage to the engine.

Bring the vehicle to an authorized dealer for service.

Problem—The Engine Exhaust Is Blue

Cause Remedy

The engine oil level is too high

(engine oil is reaching the combustion chamber).

Adjust the oil level, and then have the oil level checked by an authorized dealer.

The turbocharger is leaking oil.

The valve stem seals are loose or damaged.

The piston rings are worn.

Have an authorized dealer replace the turbocharger

Have an authorized dealer replace the seals.

Have an authorized dealer replace the piston rings.

All information subject to change without notice.

(Rev. 04/08)

TROUBLESHOOTING

Problem—Engine Brake Performance Is Poor

Cause Remedy

The engine brake control switch is damaged.

Replace the switch

The exhaust brake is not operating properly.

The constant-throttle valves are malfunctioning.

Components of the DDEC-ECU and/or

DDEC-VCU are damaged.

Have an authorized dealer check the operation of the valve.

Bring the vehicle to an authorized dealer for service.

Problem—Cruise Control Is Not Working

Cause Remedy

One or more of the cruise control switches are damaged.

Replace the damaged switch.

Components of the DDEC-ECU and/or

DDEC-VCU are damaged or not working properly.

Bring the vehicle to an authorized dealer for service.

Problem—The Battery Charge Indicator Light Does Not

Come On When the Engine Is Not Running

Cause Remedy

The bulb is damaged.

Change the bulb.

The circuit is broken.

Repair the break in the circuit.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Problem—The Battery Charge Indicator Light Comes

On When the Engine is Running

Cause Remedy

The poly-V belt is too loose.

Check the belt tension; if necessary, have an authorized dealer replace the belt tensioner.

The belt tensioner is damaged.

The poly-V belt is worn or damaged.

The alternator is damaged (has a damaged rectifier or voltage regulator).

Have an authorized dealer replace the belt tensioner.

Replace the belt.

Have an authorized dealer replace the alternator.

All information subject to change without notice.

(Rev. 04/08)

SERVICE PRODUCTS

SERVICE PRODUCTS

Carefully match together the components of the engine with the lubricants they need. Use only brands which have been tested and approved by DDC. Information is available from any authorized dealer.

Do not use special lubricant additives.

None are needed, and the use of additives could affect warranty.

Important:

Dispose of service products in an environmentally responsible manner. This includes any parts which have been in contact with them (for example, fi lters). Reclaim them or recycle them, if possible, and be sure to comply with all legal disposal requirements.

Diesel Fuels

Use only commercially available vehicle diesel fuel. Grades such as marine diesel fuel, heating oil, and others are not permissible.

Do not use fuel additives. Using fuel additives could affect your warranty.

If using diesel fuel with a high sulphur content, exceeding 0.5 percent by weight, change the engine oil at shorter intervals.

Fuel added from drums or cans could be contaminated. This could lead to malfunctions in the fuel system.

Always fi lter the fuel before adding it to the tank.

For information about fuel in cold weather operation, see the heading

"Winter-Grade Diesel Fuel" later in this chapter.

Flow Improvers

The effectiveness of fl ow improvers is not guaranteed with all fuels. Comply with the product manufacturer's recommendations. Any authorized dealer can provide information on approved fl ow improvers.

Kerosene

Keep the quantity added as low as possible, bearing in mind the outside temperature.

The addition of fi ve percent by volume of kerosene will improve the fuel's resistance to cold by about

1°C (1.8°F). Never add more than 50 percent kerosene to the fuel.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

NOTICE:

For safety reasons, add the kerosene to the diesel only in the fuel tank. Add the kerosene first, then the diesel. Run the engine for a short time to allow the mixture to reach all parts of the fuel system.

Engine Oils

The engine is delivered from the factory fi lled with an approved engine oil.

NOTICE:

The use of non-approved engine oils could affect warranty rights, and cause engine damage.

Only multigrade oils of American

Petroleum Institute (API) service designation CI-4 will achieve proper performance for the cooled EGR engines. Look for the service mark printed on the oil container.

See Figure 16.

Figure 16 API Lubricant Service

Mark

When maintenance work is performed, record engine oil changes including details of the brand used, the quality category, and the Society of Automotive Engineers (SAE) viscosity rating of the oil. When topping off, use only engine oils of the correct API designation and SAE rating.

For information about oil in cold weather operation, see the heading

"Low-Viscosity Engine Oil" later in this chapter.

Synthetic Oils

Synthetic oil may be used in MBE

4000 engines, provided they are of the correct API designation and viscosity, as required for non-synthetic oil.

All information subject to change without notice.

(Rev. 04/08)

SERVICE PRODUCTS

Synthetic oil offers improved low-temperature fl ow properties and high-temperature resistance to oxidation. However, it is generally more costly than non-synthetic oil.

Review carefully the product information published by the synthetic oil manufacturer. Performance additive systems often respond differently in synthetic oil. Use of synthetic oil does not change the recommended oil change service interval.

Coolant

Coolant is a mixture of water and antifreeze. Under normal conditions, it is a mixture of 50 percent water and 50 percent antifreeze, but under extreme cold weather conditions, as much as 60 percent antifreeze can be added. For reasons of anticorrosion protection and to raise the boiling point, the coolant must remain in the cooling system all year round.

Regardless of mileage, replace the coolant every two years since the degree of corrosion protection gradually drops with time.

Fully-Formulated Antifreeze

Antifreeze approved for use in the

MBE 4000 engine is a mixture of glycol compound (ethylene glycol), and corrosion inhibitors. Antifreeze containing glycol compounds and corrosion inhibitors is known as fully-formulated antifreeze.

NOTICE:

Do not use propylene glycol.

Fully-formulated antifreeze has the following properties:

□ It protects the radiator and engine from freezing.

□ It provides protection against corrosion and cavitation for all components in the cooling system.

□ It raises the boiling point of the coolant. This slows the rate of evaporation, avoiding coolant loss at high temperatures.

Water

Water containing no additives is not suitable as a coolant, even if no antifreeze protection is needed.

The water used in the coolant must comply with certain requirements, which are not always satis fi ed by drinking water. If water quality is inadequate, the water must undergo suitable treatment.

The following types of water are preferred for use in coolant:

□ Distilled water

□ Water puri fi ed by reverse osmosis

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

□ De-ionized water

NOTICE:

In some areas, tap water can contain high levels of dissolved chlorides, sulfates, magnesium, and calcium, causing scale deposits, sludge deposits and/or corrosion.

These deposits can damage the coolant pump and allow the engine to overheat.

Coolant Speci fi cations

To avoid damage to the cooling system, use only an approved corrosion-inhibiting antifreeze.

Approved antifreeze must be fully-formulated and comply with

Type of Coolant

Fully-Formulated Ethylene Glycol

Water plus Corrosion Inhibitors

Table 2 Coolant Speci fi cations the requirements of the Truck

Maintenance Council (TMC). Coolant speci fi cations are listed in Table 2.

Coolant Concentration

When topping off the cooling system after a drop in the coolant level, the concentration of corrosion-inhibiting antifreeze in the coolant must be

50 percent by volume. This affords protection down to a temperature of

–37°C (–34°F). The cooling mixing ratio is listed in Table 3.

NOTE:

If the concentration is too low, there is risk of corrosion/cavitation in the cooling system.

Requirement

TMC RP-329 Type "A"

Temperature Must Not Fall Below

0°C (32°F)

Antifreeze Protection

Down to °C (°F)

–37 (–34)

–52 (–62)

Water % by Volume

Table 3 Coolant Mixing Ratio

Corrosion - Inhibiting

Antifreeze % by Volume

The cooling mix ratio is Max. 60

All information subject to change without notice.

(Rev. 04/08)

SERVICE PRODUCTS

For information about coolant in cold weather operation, see the heading "Winter Coolant Antifreeze

Protection" later in this chapter.

Supplemental Coolant Additives for Fully Formulated Coolant

The concentrations of some inhibitors will gradually 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.

NOTICE:

Failure to properly maintain coolant with SCA can result in damage to the cooling system and its related components. Conversely, over-concentration of SCA inhibitor can result in poor heat transfer, leading to engine damage.

Always maintain concentrations at recommended levels. Do not use traditional SCAs with OAT coolant.

The proper application of SCA will provide:

□ pH control

□ Restored inhibitor levels to prevent corrosion

□ Water-softening to deter formation of mineral deposits

□ Cavitation protection to protect wet sleeve cylinder liners

Dropout

Excessive amounts of some corrosion inhibitors can cause a gel or crystalline deposit that reduces both heat transfer and coolant fl ow. This deposit is called "dropout."

Dropout takes the color of the coolant when wet, but becomes a white or gray powder when dry. It can pick up solid particles in the coolant and become gritty. It will cause premature wear of the coolant pump seals and other components of the cooling system.

The wet gel can be removed using an alkaline (non-acid) cleaner containing either sodium nitrite or sodium tetraborate.

If the gel is allowed to dry, it is necessary to disassemble the engine and clean it with a caustic solution, or physically clean the individual components.

Non-Approved Coolants

The following types of coolant are not approved for use in MBE 4000 engines:

□ Antifreeze or coolant containing phosphate can cause dropout,

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE overheating, and damage to coolant pump seals.

□ Automotive coolants offer no protection against liner pitting, and generally contain high levels of phosphate and silicate.

□ Antifreeze based on methyl alcohol can damage the non-metallic components of the cooling system.

They are not suitable for use with diesel engines because of their low boiling point.

□ Antifreeze based on methoxy propanol is not compatible with the fl uoroelastomer seals used in the cooling system.

□ Glycol-based HVAC coolants contain phosphates which can deposit on hot internal engine surfaces and reduce heat transfer.

Recycled Antifreeze

Recycled antifreeze that complies with

TMC RP-329 Type "A" (for ethylene glycol) is approved for use in MBE

4000 engines. The antifreeze must be recycled by distillation, reverse osmosis, or ion exchange.

Other recycled antifreeze, especially any antifreeze recycled by means of fi ltration processes, is not approved.

Corrosion Inhibitors

NOTICE:

Do not mix types of corrosion inhibitors. Do not add additional inhibitors to new, fully-formulated antifreeze, or coolant containing new, fully-formulated antifreeze.

This can cause deposits or dropout in the cooling system.

The following types of corrosion inhibitors are approved for use in

MBE 4000 engines:

□ Supplemental Coolant Additives

(SCAs)

□ Organic Acid Technology (OAT)

Inhibitors

Corrosion inhibitors are very important in maintaining engine life. All corrosion inhibitors protect against corrosion caused by acid, and cavitation of wet cylinder liners.

SCAs also protect against mineral deposits.

The concentrations of some inhibitors will gradually diminish during normal engine operation. To protect the engine, nitrite concentration must be checked at regular intervals, and inhibitors added as necessary. The intervals are longer if OAT inhibitors are used.

All information subject to change without notice.

(Rev. 04/08)

SERVICE PRODUCTS

NOTICE:

Always maintain inhibitor at the recommended level. Failure to properly maintain coolant with SCA can result in damage to the cooling system and related components.

Over-concentration of SCA inhibitor can result in poor heating transfer and lead to engine damage.

The following types of inhibitor must not be used in MBE 4000 engines:

□ Soluble oil additives cause poor heat transfer and lead to engine damage.

□ Chromate additives can lead to the build-up of "green slime"

(chromium dioxide) in the engine, leading to engine damage.

Disposal

Coolants are biologically degradable substances.

When disposing of used coolant, comply with local legal requirements and waste water regulations.

Consult the local water supply authorities to determine the best method of disposal.

A modern engine coolant has complex tasks to perform. Do not allow any form of "reprocessing" which consists only of mechanical puri fi cation.

Cold Weather Products

Special precautions must be taken during cold weather. To protect your engine, take the following special measures in cold weather.

□ Use the recommended cold weather fuel and engine oil.

□ Check the concentration of antifreeze in your coolant.

□ Take special care of the batteries to ensure proper cranking amperage

Winter-Grade Diesel Fuel

At low outside temperatures, paraf fi n may separate from the diesel and affect its ability to fl ow freely. Avoid breakdowns caused by this problem

(for example, blocked fi lters) by using cold-resistant winter-grade diesel fuel with improved low-temperature fl ow characteristics. In most cases, winter-grade fuel can be used without problems at cold outside temperatures.

If using summer-grade fuel or a less cold-resistant winter grade, a fl ow improver or kerosene can be added.

The amount needed depends on the outside temperature.

Flow improver or petroleum spirit must be mixed with diesel fuel before its fl ow characteristics have been adversely affected by paraf fi n separation.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

If changes have already been caused by paraf fi n separation, they can be corrected only by heating the entire fuel system.

Do not add anything to cold-resistant winter-grade diesel fuels. The fuel's low-temperature fl ow characteristics could actually deteriorate with additives.

volume (this gives the maximum antifreeze protection). Further increases in the mixing ratio would reduce the level of antifreeze protection and adversely affect the coolant's ability to dissipate heat.

FIRE

To avoid increased risk of a fuel fi re, do not mix gasoline and diesel fuel.

Low-Viscosity Engine Oil

When changing the engine oil, estimate the interval before your next oil change. Choose an oil from the SAE viscosity class which corresponds to the outside temperatures anticipated during this

period of operation. See Figure 17.

Winter Coolant Antifreeze

Protection

Before the temperature dips below freezing, check the concentration of antifreeze in the coolant. If necessary, increase it.

Do not increase the proportion

(mixing ratio) of corrosion-inhibiting antifreeze beyond 55 percent by

Figure 17 Engine Oil Temperature

Ranges

Batteries

Batteries should receive more frequent maintenance and recharging during the cold season of the year.

Careful maintenance and low current consumption will help to maintain the full battery charge. Starting capacity drops severely in cold weather. At

–10°C (14°F) starting capacity is about 60 percent of normal. If the engine is shut down or out of use for an extended period of time, store the batteries out of the vehicle in a heated area if possible. Ensure good ventilation when recharging.

All information subject to change without notice.

(Rev. 04/08)

TECHNICAL DATA

TECHNICAL DATA

General technical information is listed in Table 4.

Description

Engine Type

Cooling System

Combustion Principle

Number of Cylinders

Bore

Stroke

Displacement (total)

Compression Ratio

Starting Speed

Direction of Engine Rotation (viewed from flywheel)

Starter

Table 4 General Technical Information

MBE 4000 Engine

Vertical, inline cylinder block with turbocharger and charge-air cooler

Liquid Circuit

4-Stroke direct-injection diesel

128 mm (5.04 in.)

166 mm (6.54 in.)

12.816 liters (782 in³)

17.75:1

Approximately 100 rpm

Counterclockwise

Electric Motor

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Engine Data

The engine weights are listed in Table

5. The engine dimensions (ready for shipment) are listed in Table 6.

Also see Figure 18 and Figure 19.

Coolant capacities are listed in Table

7. Lubricating oil capacities

arelisted in Table 8.

Engine

Engine Dry

Weight

960 kg (2117 lb) 6-Cylinder

Table 5 Engine Weights

Dimension

Length (A)

Width (B)

Height (C)

Size

1338.7 mm

(53.1 in.)

1069.3 mm

(42.1 in.)

1130.3 mm

(44.5 in.)

Table 6 Engine Dimensions

Figure 18 Side View Figure 19 Front View

Description

Coolant Capacity*

*Does not include capacity of cooling system.

Table 7 Coolant Capacity

MBE 4000 Engine

Max. 70 L (74 qt)

All information subject to change without notice.

(Rev. 04/08)

TECHNICAL DATA

Description Oil Pan Capacity

EGR engines w/front

Sump *

Non-EGR Engines w/front Sump & Right

Hand Drive Export

Applications *

Rear Sump Applications

Non-EGR Engines w/front Sump & Left

Hand Drive Applications

36 L (38 qts)

40.0 L (42.3 qts)

Front Sump Engine s/n

833529 and below

40.0 L (42.3 qts)

* Engine s/n 833530 and above

† Including oil filter.

Table 8 Lubricating Oil Capacity

Oil System Fill

Capacity †

39.5 L (41.7 qts)

43.5 L (46.0 qts)

Testing and Adjusting

Values

Valve lash checking and adjustments are listed in Table 9. Engine Oil

Pressure is listed in Table 10.

Coolant thermostat conditions are listed in Table 11. Injector pressures are listed in Table 12.

Valve Type

Intake

Exhaust

Check For: mm (in.)

0.30 to 0.60 (0.012 to 0.024)

0.50 to 0.80 (0.020 to 0.032)

Table 9 Valve Lash Checking and Adjustment

Adjust To: mm (in.)

0.40 (0.016)

0.60 (0.024)

All information subject to change without notice.

(Rev. 04/08)

Engine Speed

At idling rpm

At maximum rpm

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Minimum Pressure

50 kPa (7 psi)

250 kPa (36 psi)

Table 10 Engine Oil Pressure

Condition

Starts to open

Fully open

Minimum lift

Table 11 Coolant Thermostat

Opening Pressure

Minimum opening pressure

Maximum opening pressure

Table 12 Injector Pressures

Speci fi cation

81 to 85°C (177 to 185°F)

95°C (203°F)

8 mm (0.3 in.)

Value in kPa (Psi)

25500 (3698)

27000 (3916)

All information subject to change without notice.

(Rev. 04/08)

MAINTENANCE

MAINTENANCE

When performed on a regular basis, changing the engine oil and fi lters is the least costly way of obtaining safe and reliable vehicle operation. Added bene fi ts and savings occur when you check that the valves, fuel injectors, and oil and cooling circuits are in good working order during oil changes.

The maintenance section of this manual explains when you should change your oil and what to look for when checking for wear or damage.

For additional information, please contact Detroit Diesel Technical

Service.

Scheduled Intervals

All service intervals and maintenance operations are based on the parts and accessories expressly approved for your engine.

The scope and frequency of maintenance work are determined by the engine's operating conditions: severe duty, short haul, or long haul.

Evidence of regular maintenance is essential if a warranty claim has to be submitted.

If optional equipment is installed, be sure to comply with the maintenance requirements for these extra items.

Important:

If the engine is stored for more than 18 months, the oil must be changed before the engine can be brought into service.

Maintenance Schedule Types

There are three types of maintenance schedule:

□ Schedule I (Severe Service)

□ Schedule II (Short Haul)

□ Schedule III (Long Haul)

To determine which schedule to use, fi nd the distance traveled by the vehicle in a year, regardless of vehicle type.

Severe Service — Applies to vehicles that annually travel up to

6000 miles (10,000 kilometers) or that operate under severe conditions.

Examples of Severe Service usage include: operation on extremely poor roads or where there is heavy dust accumulation; constant exposure to extreme hot, cold, salt-air, or other extreme climates; frequent short-distance travel; construction-site operation; city operation ( fi re truck, garbage truck); or farm operation.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Short-Haul — Applies to vehicles that annually travel up to 60,000 miles

(100,000 kilometers) and operate under normal conditions. Examples of Short-Haul usage are: operation primarily in cities and densely populated areas; local transport with infrequent freeway travel; or high percentage of stop-and-go travel.

Long-Haul — Long Haul

(over-the-road transport) is for vehicles that annually travel more than

60,000 miles (100,000 kilometers), with minimal city or stop-and-go operation. Examples of Long-Haul usage are: regional delivery that is mostly freeway miles; interstate transport; or any road operation with high annual mileage.

Maintenance Schedule and

Interval Operations — The three different schedules of vehicle usage

(severe, short haul, and long haul) are listed in Table 13. For each schedule, the appropriate distance interval

(in miles and kilometers) is given for performing and repeating each maintenance operation.

The descriptions of all maintenance operations, indicating all maintenance operation sets at which each operation must be performed are listed in Table

14, Table 15, and Table 16.

Maintenance Intervals — The three maintenance interval tables show which maintenance operation must be performed at the actual distances

(in miles or kilometers) for each maintenance operation. The schedule of actual distances is based on the intervals given in the Maintenance

Schedule Table (Table 13).

The three maintenance interval tables are:

□ Maintenance Interval Table,

Severe Service (Table 14)

□ Maintenance Interval Table, Short

Haul (Table 15)

□ Maintenance Interval Table, Long

Haul ( Table 16)

Maintenance Operation Sets —

Each Maintenance Operations

Sets Table (M1 through M4) lists the descriptions of only those maintenance operations that must be performed at that maintenance operation set. Each maintenance operation set is listed in a separate Maintenance Operations

Table.

The descriptions of all maintenance operations, and the maintenance operation sets at which each operation must be performed are listed in Table

17 and Table 18.

All information subject to change without notice.

(Rev. 04/08)

MAINTENANCE

Schedule Use

Before placing your new vehicle in service, determine the correct maintenance intervals that apply to your intended use of the vehicle. Refer to the Maintenance Schedule Table to determine the distance interval at which each maintenance operation must be performed to comply with your vehicle's schedule.

When the vehicle reaches the actual distance given for an interval, refer to the Maintenance Interval Tables to fi nd the Maintenance Operation

Set that applies to that interval. Then perform the maintenance operations listed in the applicable Maintenance

Interval Operation Table.

Complete each Maintenance

Operation Set at the required interval.

For example, when you have completed Maintenance Operation

Set M3 under the 16th maintenance number listed in the Maintenance

Interval Table, repeat the pattern. For the 17th maintenance, do Maintenance

Operation Set M1, under the fi rst maintenance number listed in the

Maintenance Interval Table.

NOTE:

For Severe Service, the pattern repeats after 15 maintenance numbers, not 16 (as for Short Haul and Long Haul).

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Maintenance Tables

Maintenance

Schedule

Schedule I

(Severe Service) vehicles that annually travel up to 6,000 miles

(10,000 km)

Maintenance

Interval

Operation

Maintenance 1 (M1)

Optional oil centrifuge

(change rotor)

Maintenance 2 (M2)

Maintenance 3 (M3)

Maintenance Intervals

Frequency Miles every every every first then every every

Schedule II

(Short Haul) vehicles that annually travel up to

60,000 miles

(100,000 km)

Maintenance 1 (M1)

Optional oil centrifuge

(change rotor)

Maintenance 2 (M2)

Maintenance 3 (M3) every every first then every every

Schedule III

(Long Haul) vehicles that annually travel more than

60,000 miles

(100,000 km)

Maintenance 4 (M4)

Optional oil centrifuge

(change rotor)

Maintenance 1 (M1)

Maintenance 2 (M2)

Maintenance 3 (M3) every every every first then every every Maintenance 4 (M4)

Table 13 Maintenance Schedule Table

10,000

20,000

40,000

15,000

20,000

17,000

32,000

68,000

25 000

32,000

30,000

50,000

50 000

60,000 100,000

120,000 200,000

20,000 32,000

25,000

50,000

42,000

84,000

100,000 167,000

200,000 334,000

All information subject to change without notice.

(Rev. 04/08)

MAINTENANCE

Maint. No

Maintenance

Interval

M1, M2 and M3

M1 and M2

M1, M2 and M3

M1 and M2

M1, M2 and M3

M1 and M2

M1, M2 and M3

M1 and M2

Miles

10,000

20,000

30,000

40,000

50,000

60,000

70,000

80,000

90,000

100,000

110,000

120,000

130,000

140,000

150,000

160,000

17,000

32,000

50,000

67,000

84, 000

100, 000

117,000

134,000

150,000

167,000

184,000

200,000

217,000

234,000

250,000

267,000

Table 14 Maintenance Intervals for Schedule I, Severe Service

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Maint. No.

Maintenance

Interval

M1, M2, and M3

M1, M2 and M4

M1, M2 and M3

M1 and M2

M1, M2, and M3

M1, M2 and M4

M1 and M2

M1, M2 and M3

Miles

15,000

30,000

45,000

60,000

75,000

90,000

105,000

120,000

135,000

150,000

165,000

180,000

195,000

210,000

225,000

240,000

25 000

50,000

75,000

100,000

125,000

150,000

120,000

200,000

225,000

250,000

275,000

300,000

325,000

350,000

375,000

400,000

Table 15 Maintenance Intervals for Schedule II, Short Haul

All information subject to change without notice.

(Rev. 04/08)

MAINTENANCE

Maint. No

Maintenance

Interval

M1, M2, M3 and M4

M1 and M2

M1, M2, and M3

M1 and M2

M1, M2, M3 and M4

M1 and M2

M1, M2, and M3

M1 and M2

Miles

25,000

50,000

75,000

100,000

125,000

150,000

175,000

200,000

225,000

250,000

275,000

300,000

325,000

350,000

375,000

400,000

42,000

84,000

125,000

167,000

209,000

250 000

292,000

334,000

375,000

417,000

459,000

500,000

542,000

584,000

625,000

667,000

Table 16 Maintenance Intervals for Schedule III, Long Haul

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Operation Description

Engine Inspecting

M1 M2 M3

Valve Lash Checking and Adjusting

Fuel /Water Separator Prefilter Element Cleaning

Main Fuel Filter Element Changing

Engine Oil and Filter Changing

Coolant Concentration and Inhibitor Level Checking

Coolant Flushing and Changing*

— —

—

Cooling System Inspecting

* Coolant flushing and changing must be done at least every two years.

Table 17 Required Maintenance Operations Sets, Schedule I

All information subject to change without notice.

(Rev. 04/08)

MAINTENANCE

Maintenance Operation Description

Engine Inspecting

Valve Lash Checking and Adjusting† —

Fuel /Water Separator Prefilter Element Cleaning —

Main Fuel Filter Element Changing —

Engine Oil and Filter Changing

Coolant Concentration and Inhibitor Level

Checking

Coolant Flushing and Changing*

Cooling System Inspecting

—

M1 M2 M3 M4

—

— —

Rear Engine Power Take-Off (REPTO) torsional damper checking‡

— — —

* Coolant flushing and changing must be done at least every two years.

† For Schedule II and III, the valve lash checking and adjusting must be done first at 60,000 miles and then every M4.

‡ For Schedule II, the REPTO torsional damper checking must be done first at 60,000 miles or 3000 hours and then every 30,000 miles or

1500 hours.

Table 18 Required Maintenance Operations Sets, Schedule II and III

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Required Maintenance

Operations

The following sections describe the required maintenance operations

listed in Table 17 and listed in Table

18.

Engine Inspecting

Inspect engine as follows:

1. Visually check the engine for signs of leakage. A slight dampness at the sealing points is no cause for concern.

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 any sound of leaking. Make sure all pipes and hoses are undamaged, correctly positioned to avoid cha fi ng, and properly secured.

Valve Lash Checking and

Adjusting

A special engine cranking tool (J

46167) is required for this procedure.

NOTE:

Adjust the valve lash when the engine is cold. Wait at least 30 minutes after shutdown, even if the engine ran only a short time.

Gaining Access To The Valves —

Gain access to the valves as follows:

NOTE:

Clean the cylinder head covers before removing it.

1. Remove the cylinder head covers.

See Figure 20.

Figure 20 Cylinder Head Cover

2. Remove the inspection cover on the fl ywheel housing.

All information subject to change without notice.

(Rev. 04/08)

MAINTENANCE

3. Fit the cranking tool into the inspection hole on the timing

case. See Figure 21.

See Figure 22 for the cylinder and

valve layout on the MBE 4000 engine.

Figure 21 Placing Cranking Tool

Choosing A Method — Select a method for adjusting the valve lash.

There are two acceptable methods for adjusting valve lash:

□ In order, according to the timing sequence used for fuel injection

(see "Method One—Adjust Each

Cylinder In Firing Order")

□ By type of valve, depending on crankshaft position (see "Method

Two—Adjust All Valves Using

Two Crankshaft Positions").

Figure 22 Cylinder and Valve

Layout

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Method One — Method one allows you to adjust each cylinder in the order in which fuel is injected. The crankshaft must be repositioned after each cylinder is adjusted as listed in Table 19.

1. For each cylinder, use the cranking tool to turn over the crankshaft until the piston is exactly at top dead center (TDC) in the compression stroke. The valves must be closed and it must be possible to turn the push rods without effort.

Engine

MBE 4000

Crankshaft Position

Ignition TDC

Valve Overlap

Table 19 Valve Adjustment — Method One

NOTE:

When the piston in cylinder #1 is at ignition TDC, the valves of cylinder #6 will overlap, meaning that both intake and exhaust valves are partially open, and show no measurable play when tested with a feeler gauge.

2. Check each valve and adjust it (if necessary), using the procedures under the headings "Checking

Valve Lash" and "Adjusting Valve

Lash."

Cylinders

3 6

4 1

All information subject to change without notice.

(Rev. 04/08)

MAINTENANCE

Method Two — Method two allows you to adjust all the valves using just two crankshaft positions.

1. Using the cranking tool, turn the crankshaft until cylinder #1 is at the ignition TDC position (all valves are closed) and cylinder

#6 is at the valve overlap position

(all valves are open).

2. Check the valves listed in Table

20 in the "Ignition TDC" row of

and adjust them (if necessary), using the procedures under the headings "Checking Valve Lash" and "Adjusting Valve Lash."

3. Using the cranking tool, turn the crankshaft until cylinder #6 is at the ignition TDC position (all valves are closed) and cylinder

#1 is at the valve overlap position

(all valves are open).

4. Using the same procedure, check

the valves listed in Table 20 in the

"Valve Overlap" row and adjust them (if necessary), using the procedures under the headings

"Checking Valve Lash" and

"Adjusting Valve Lash."

Engine

Cylinder #1 Crankshaft

Position

Ignition TDC

MBE 4000

Valve Overlap

*I = Intake Valve, E = Exhaust Valve

Table 20 Valve Adjustment — Method Two

Cylinder Valve Types*

1 2 3 4 5 6

I/E I E I E —

— E I E I I/E

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Adjusting Valve Lash — valve lash as follows:

Adjust

1. If adjustment is needed, loosen

the locknut. See Figure 23.

NOTE:

When adjusting the valves, adjust to the exact setting. Use the range only for checking adjustment.

3. Tighten the locknut 50 N·m (37 lb·ft).

4. Check the valve lash again.

Adjust again if necessary.

Figure 23 Valve Lash Adjustment

2. Turn the adjusting screw until the valve lash is correct. Use the exact settings listed in Table 21.

Valve Type

Intake

Exhaust

Check For :

(mm (in.)

0.30 to 0.60 (0.012 to 0.024)

0.50 to 0.80 (0.020 to 0.032)

Table 21 Valve Lash Adjustment

Restoring The Vehicle To

Operating Condition — Restore the vehicle to operation condition as follows:

1. Install the cylinder head covers.

2. Remove the cranking tool from the inspection hole in the fl ywheel housing.

3. Replace the end cover on the inspection hole and tighten the bolts 25 N·m (18 lb·ft).

Adjust To:

(mm (in.)

0.40 ( 0.016)

0.60 (0.024)

All information subject to change without notice.

(Rev. 04/08)

MAINTENANCE

Fuel/Water Separator Pre fi lter

Element Cleaning

Clean the pre fi lter element as follows:

1. Loosen the bleed screw.

See Figure 24.

2. Unscrew the drain plug and drain the fuel in the pre fi lter.

3. Twist off the sight bowl and remove the fi lter element from the separator head.

4. Separate the sight bowl from the fi lter element. Clean the sight bowl. Discard the old fi lter element and both O-rings.

5. Replace the fi lter element and

O-rings.

6. Assemble the sight bowl and the pre fi lter element.

[a] Lubricate one O-ring with a light coating of engine oil and insert it into the sight bowl.

[b] Screw the pre fi lter element and sight bowl together.

7. Assemble the pre fi lter element and the separator head.

[a] Lubricate the other O-ring with a light coating of engine oil and insert it into the open end of the pre fi lter element.

[b] Screw the pre fi lter element onto the separator head and tighten only.

fi rmly, using hands

Figure 24 Fuel/Water Separator

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

NOTE:

Do not use tools to tighten the prefilter element.

8. Tighten the drain plug.

9. Prime the fuel system.

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

NOTE:

There should be a strong resistance in the hand pump, caused by the pressure build-up within the fuel system.

[b] 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.

Fuel Pro ® 382 Fuel/Water

Separator Element Replacement

Replace the fuel/water separator element as follows:

Figure 25 Fuel Pro ® 382

Fuel/Water Separator

All information subject to change without notice.

(Rev. 04/08)

MAINTENANCE

1. Remove the vent cap, open the drain valve and drain fuel into approved container, until level is

below the collar. See Figure 25.

2. Using a collar wrench remove collar and cover.

3. Remove the fi lter element from the separator head and discard fi lter and O-rings. Dispose of fi lter properly.

4. Clean the cover and the mounting surface on the body.

5. Install the fi lter element with bottom grommet, new cover

O-ring, cover and collar. Hand tighten only.

6. Fill cover half-way with clean fuel through the vent cap opening.

7. Replace O-ring on the vent cap and install in cover. Hand tighten only.

NOTE:

Do not use tools to tighten the collar or vent cap.

8. Tighten the drain plug.

9. 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.

10. Start the engine and raise the rpm for one minute to purge the air.

After the air is purged stop the engine, loosen the vent cap until the fuel level lowers to just above the collar. Tighten the vent cap by hand. Check for leaks.

Main Fuel Filter Element

Changing

Change the main fuel fi lter element as follows:

1. Open the fuel tank fi ll cap to release pressure in the fuel system. Replace and tighten the cap.

2. Clean the outside of the fuel fi lter

housing (see Figure 26).

Figure 26 Main Fuel Filter

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

3. Using a 36-mm socket, unscrew the cap on the main fuel fi lter housing. Remove the cap and lift the fi lter element a short distance within the fi lter housing allowing the fuel to drain off the fi lter.

4. Remove the fi lter element from the cap and clean the fi lter cap.

Discard the fi lter element and the

O-ring from the cap.

NOTICE:

To prevent damage to the filter housing, do not allow dirt to get into the filter housing.

5. Clean the fi lter housing cap.

6. Replace the O-ring.

7. Lubricate the fi lter element rubber seal with a light coat of fuel oil and insert it into the fi lter housing.

Push down and rotate the fi lter element while installing to ensure it is seated properly at the base of the housing.

NOTE:

A properly seated filter element will hold the fuel in the filter housing and prevent it from draining back to the tank. If the fuel does not stay in the housing the element is not seated properly, repeat steps 1 and 2.

8. Fill fuel fi lter housing with clean fuel oil.

9. Install a new O-ring on the fi lter cap and screw the cap onto the fi lter housing. Tighten the cap to

25 N·m (18 lb·ft).

10. If equipped with a hand pump on the fuel/water separator, work the hand pump until resistance is felt.

NOTE:

There should be a strong resistance in the hand pump, caused by the pressure build-up within the fuel system.

11. Crank the engine for 30 seconds at a time, but no longer. Before cranking again, wait at least two minutes, then crank again. The engine should start within four

30-second attempts.

12. Once the engine starts allow it to idle for at least one minute or until idle is smooth before applying the throttle. Check the fuel fi lter housing for leaks.

Engine Oil and Filter Changing

Select the SAE class (viscosity) on the basis of the average air temperature

for the season (see Figure 27).

NOTE:

Continued use of a single SAE class will result in frequent oil changes. For this reason, view the temperature ranges for the various SAE classes.

All information subject to change without notice.

(Rev. 04/08)

MAINTENANCE

Figure 27 Engine Oil Temperature

Ranges

To ensure the engine is protected and the oil stays clean until the next oil change, use only oils of API classi fi cation CI-4.

Drain oil as follows:

1. Chock the tires, place the transmission in neutral, and set the parking brake.

NOTE:

Change the engine oil only when the engine is at a temperature of approximately 60°C (140°F).

2. Using a 36-mm socket, unscrew the oil fi

lter cap (see Figure 28).

Figure 28 Oil Filter Cap

FIRE

To avoid injury from fi re, keep open fl ames, sparks, electrical resistance heating elements, or other potential ignition sources away when draining lubrication oil. Do not smoke when draining lubricating oil.

3. Drain the oil.

[a] Place a suitable receptacle beneath the oil drain plug on the underside of the oil pan.

[b] Carefully unscrew the oil drain plug on the oil pan and allow the oil to drain out

(see Figure 29).

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Figure 29 Engine Oil Drain Plug,

Oil Pan

[c] Discard the O-ring on the oil drain plug.

4. Remove both the fi lter cap and the fi lter element. To release the fi lter element, twist the lower edge of the fi lter element to the

side (see Figure 30).

NOTICE:

To prevent damage to the filter housing, ensure that no foreign objects get inside it. Do not wipe clean the filter housing.

5. Replace the O-ring on the cap

(see Figure 30).

6. Install the new fi lter into the cap.

Make sure the fi lter element is securely in place.

7. Screw the cap onto the oil fi lter housing. Tighten the cap 45 N·m

(33 lb·ft).

8. Install the oil drain plug, using a new O-ring. Tighten the plug 80

N·m (60 lb·ft).

Figure 30 Cap with Oil Filter

Element

PERSONAL INJURY

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

9. Add new engine oil through the oil fi

ll (see Figure 31) until the

maximum fi ll level on the oil dipstick has been reached. Engine fi ll capacity is 44 L (46 qts).

All information subject to change without notice.

(Rev. 04/08)

MAINTENANCE

Figure 31 Oil Fill

11. Check the fi lter and oil drain plug for signs of leakage.

12. Stop the engine. Check the oil level again after approximately fi ve minutes. If necessary, add oil up to the maximum fi ll level on the oil dipstick.

Optional Oil Centrifuge — Every

20,000 miles (32,000 km) change the oil centrifuge rotor as follows:

1. Remove the cover of the oil centrifuge.

2. Lift out the dirty rotor and replace it with a clean one (see Figure

32).

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

10. Start the engine with the accelerator pedal in the idle position. Monitor the oil pressure gauge.

NOTICE:

Keep the engine running at idling speed until an oil pressure reading is obtained. If no oil pressure is shown after approximately 10 seconds, stop the engine and determine the cause. Failure to do so could result in engine damage.

Figure 32 Rotor

3. Replace the centrifuge cover.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Coolant Concentration and

Inhibitor Level Checking

Check the coolant concentration as follows:

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.

NOTE:

Check and correct the coolant level only when the coolant temperature is below 50°C (122°F).

1. Open the cap on the surge tank slowly, to allow excess pressure to escape. Set the cap aside.

2. Before adding coolant, use a suitable tester to check the concentration of corrosion-inhibiting antifreeze.

If the concentration is lower than 50 percent by volume, drain coolant/add antifreeze until the concentration is correct.

The coolant mixing ratio is

listed in Table 22.

Antifreeze

Protection Down to °C (°F)

–37 (–34)

Water Percentage by Volume

Corrosion-Inhibiting

Antifreeze

Percentage by

Volume

–52 (–62) 40 Maximum 60*

*Concentrations of 60 percent affords the maximum antifreeze protection.

Higher concentrations adversely affect heat dissipation.

Table 22 Coolant Mixing Ratio

All information subject to change without notice.

(Rev. 04/08)

MAINTENANCE

NOTE:

When topping off, use only a pre-prepared coolant mixture containing a 50 percent concentration by volume of corrosion-inhibiting antifreeze.

NOTICE:

If the concentration of antifreeze is too low, there is a risk of corrosion or cavitation in the cooling system.

3. Check the coolant level and add more coolant if necessary.

Check the nitrite concentration at

regular intervals as listed in Table 24

with a

POWER Trac

® 3–Way Test

Strip. Nitrite levels must be within

800–2400 PPM. Additional SCA must be added to the coolant when it becomes depleted, as indicated by a nitrite concentration of 800 PPM or less. If the nitrite concentration is greater than 800 PPM, do not add additional SCA. If the nitrite concentration is above 2400 PPM, the system is over-inhibited and should be partially drained and fi lled with a

50/50 mix of water and EG.

NOTE:

Drain intervals listed in Table 24 are

dependent on proper maintenance.

Coolant Inhibitor Test

Intervals — Coolant inhibitor level should be checked at the intervals listed in Table 23.

If topping off is needed, add coolant which is identical to the initial fi ll coolant.

Service Application

On-highway Trucks and Motor

Coaches

City Transit Coaches, Pick-up and

Delivery Short Trip, and Emergency

Vehicles

Industrial, Continuous Duty Generator

Set, and all Other Applications

Standby Generator Set

Inhibitor Test Interval

20,000 Miles (32,000 Kilometers

6,000 Miles (9,600 Kilometers) or three months, whichever comes first

500 Hours or three months, whichever comes first

200 Hours or yearly, whichever comes first

Table 23 Required Coolant Inhibitor Test Intervals

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Coolant Maintenance Interval Action

Antifreeze/Water

+ SCA Inhibitor

(DDC Power

Cool)

Ethylene

Glycol/Water +

SCA Inhibitor

A. 20,000 miles (32,000 km) or 3 months

B. 500 hours or 3 months

Test nitrite concentration with test strip, add SCA or dilute coolant as needed.

A. 300,000 miles (480,000 km) or 2 years

B. 2 years or 4,000 hours

A. 20,000 miles (32,000 km) or 3 months

B. 500 hours or 3 months

Drain and clean system.

Replace with new coolant.

Drain and clean system.

Replace with new coolant.

A. 300,000 miles (480,000 km)

B. 2 years or 4,000 hours

Drain and clean system.

Replace with new coolant.

Ethylene

Glycol/Water +

OAT Inhibitor

Water Only +

SCA Inhibitor

Water Only +

OAT Inhibitor

A. 300,000 miles (480,000 km) or 2 years

B. 5,000 hours

A. 600,000 miles (960,000 km) or 4 years

B. 4 years or 10,000 hours

A. 20,000 miles (32,000 km) or 3 months

B. 500 hours or 3 months

A. 300,000 miles

(480,000 km) or 2 years

B. 2 years or 4,000 hours

A. 300,000 miles

(480,000 km) or 2 years

B. 5,000 hours

A. 600,000 miles

(960,000 km) or 4 years

B. 4 years or 10,000 hours

Add Power Cool Plus

Extender

Drain and clean system.

Replace with new coolant.

Drain and clean system.

Replace with new coolant.

Drain and clean system.

Replace with new coolant.

Add Power Cool Plus

Extender

Drain and clean system.

Replace with new coolant.

A = On-highway trucks and motor coaches, city transit coaches, pickup and delivery, short trip, and emergency vehicles.

B = Industrial, generator set, and other applications

Table 24 Nitrite Interval Checks

All information subject to change without notice.

(Rev. 04/08)

MAINTENANCE

Inhibitor Level Checking — Use

Detroit Diesel

POWER Trac

®3–way

Coolant Test Strips to measure nitrite and glycol concentrations.

Cavitation/corrosion protection is indicated on the strip by the level of nitrite concentration. Freeze/boil-over protection is determined by glycol concentration.

Check the inhibitor level as follows:

HOT COOLANT

To avoid scalding from the expulsion of hot coolant, never remove the cooling system pressure cap while the engine is at operating temperature. Wear adequate protective clothing

(face shield, rubber gloves, apron, and boots). Remove the cap slowly to relieve pressure.

3. Sixty seconds (one minute) after dipping, compare the nitrite pad to the color chart on the container to determine the nitrite concentration.

4. If the additive indicator (middle pad) shows any color change, this indicates the presence of an unauthorized inhibitor.

5. If there is any doubt about the quality of the coolant, change the coolant.

6. After each use, replace and tighten the cap on the test strip container. Discard any test strips that have turned light pink or tan in color.

7. Close and tighten the cap on the surge tank.

1. Dip the test strip into the coolant for one second, then remove it.

Shake the strip vigorously to remove excess liquid.

2. Immediately compare the end pad to the color chart on the container to determine the glycol concentration.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Coolant Flushing and Changing

Flush and change the coolant as follows:

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.

1. Open the cap on the surge tank slowly, to allow excess pressure to escape. Set the cap aside.

2. Open the water regulating valve for the heating system.

3. Place a large receptacle underneath the coolant drain plug and open the coolant drain plug on the bottom of the radiator.

See Figure 33.

NOTE:

Make sure the coolant can flow unobstructed into the receptacle.

Figure 33 Coolant Drain Plug

NOTICE:

Do not apply more than 20 psi (140 kPa) air pressure for a radiator flush; more pressure could damage the radiator or heater core.

4. Start radiator fl ushing by attaching a fl ushing gun nozzle to the radiator outlet and run water in until the radiator is full.

All information subject to change without notice.

(Rev. 04/08)

MAINTENANCE

EYE INJURY

To avoid injury from fl ying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure.

Cooling System Inspecting

NOTE:

Before doing this inspection, do either

"Coolant Concentration Checking," or

"Coolant Flushing and Changing."

Inspect the cooling system as follows:

5. Apply no more than 140 kPa (20 psi) air pressure intermittently to help dislodge sediment buildup in the core.

6. Drain the radiator, and fl ush the radiator until clean water fl ows from the radiator. Remove the fl ushing gun.

7. When the coolant has drained, install the coolant drain plug on the radiator.

8. Add coolant in the speci fi ed concentration until the maximum mark on the surge tank is reached.

9. Start the engine and run it for about one minute at varying speeds to release air pockets in the cooling system. Ensure the heater valve is still open. Check the coolant level and add more coolant if necessary.

10. Shut down the engine, close and tighten the cap on the surge tank.

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.

1. Inspect the radiator, condenser, coolant 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 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.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Rear Engine Power Take-Off

(REPTO)

The REPTO accessory drive is an option on the MBE 4000 engine. The drive provides continuous live power anytime the engine is operating. The

REPTO is driven by the camshaft gear and is an integral part of a unique

SAE#1 fl ywheel housing. All REPTO installations require a torsional coupling installed at the fl ange of the drive unit (i.e. hydraulic pump).

The torsional coupling incorporates a rubber element designed to reduce the unwanted stresses from reaching the

engine. See Figure 34.

replace the damper. Regardless of the condition, the torsional coupling must be replaced at normal engine overhaul.

2. Inspect the torsional damper rubber element as follows:

[a] Check the rubber element for bulges or cracks. If damage is found replace the damper.

[b] Inspect the rubber element teeth for wear. If the teeth are worn to less than one-half of the new part length (11.0

mm [0.433 in.]), replace the torsional damper. See Figure

35.

Figure 34 MBE 4000 REPTO

Connection Illustration

REPTO Torsional Damper

Inspection — Inspect the REPTO torsional damper as follows:

1. Inspect the outer casing of the torsional damper for dents or bulges. If damage is found

Figure 35 REPTO Torsional

Damper

REPTO Torsional Damper

Cleaning — Clean the REPTO torsional damper as follows:

All information subject to change without notice.

(Rev. 04/08)

MAINTENANCE

The torsional damper coupling will withstand normal exposure to hydraulic oil, diesel fuel, anti-freeze solutions, and muriatic acid. The coupling should be washed with a mild soap solution and rinsed with water after contact with the above items. The coupling can be power washed without damage as long as it is installed in the vehicle. If the coupling is power washed when not connected to a cardan shaft, debris may be forced internally at the bolt fl anges damaging the coupling.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

CUSTOMER ASSISTANCE

The satisfaction and good will of the owners of Detroit Diesel engines are of primary concern to Detroit Diesel

Corporation and its distributor/dealer organizations.

All information subject to change without notice.

(Rev. 04/08)

CUSTOMER ASSISTANCE

DDC NORTH AMERICAN NAFTA ON-HIGHWAY OFFICES

EASTERN REGION 1

Suwanee, Georgia

3325 Paddocks Parkway

Suwanee, GA 30024

Telephone: 678-341-6100

Fax: 678-341-6150

EASTERN REGION 2

Detroit, Michigan

13400 Outer Drive West

Detroit, MI 48239-4001

Telephone: 313-592-5420

Fax: 313-592-5887

WESTERN REGION 1

Irvine, California

7700 Irvine Center, Suite 275

Irvine, CA 92618

Telephone: 949-753-7710

Fax: 949-753-7711

WESTERN REGION 2

Irvine, California

7700 Irvine Center, Suite 275

Irvine, CA 92618

Telephone: 949-753-7710

Fax: 949-753-7711

CANADIAN REGION

London, Ontario

Detroit Diesel of Canada, Ltd.

150 Dufferin Ave., Suite 701

London, ON N5A 5N6

Phone: 519-661-0149

Fax: 519-661-0171

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

MTU DETROIT DIESEL OFF-HIGHWAY SALES AND

CUSTOMER ASSURANCE CENTERS

CONSTRUCTION, INDUSTRIAL

AND MINING SALES (BX7)

MARINE SALES (BX6)

13400 Outer Drive, West

Detroit, MI 48239-4001

Phone: 313-592-7806

Fax: 313-592-5137 Phone: 313-592-5608

Fax: 313-592-5625

POWERGEN AND OIL FIELD SALES

(BX11)

13400 Outer Drive, West

Detroit, MI 48239-4001

Phone: 313-592-5708

Fax: 313-592-5158

CUSTOMER ASSURANCE (M24)

13400 Outer Drive, West

Detroit, MI 48239-4001

Phone: 313-592-5550

Fax: 313-592-5717

GOVERNMENT SALES (BX9)

13400 Outer Drive, West

Detroit, MI 48239-4001

Phone: 313-592-5875

Fax: 313-592-5158

All information subject to change without notice.

(Rev. 04/08)

CUSTOMER ASSISTANCE

DDC INTERNATIONAL REGIONAL OFFICE LOCATIONS

DETROIT DIESEL DISTRIBUTION

CENTER B.V.(On/Off-Highway)

The Netherlands

Ridderpoort 9

2984 Ridderkerk

The Netherlands

Phone: (31) 180-442-900

Fax: (31) 180-462-062

MTU DETROIT DIESEL AUSTRALIA

PTY. LTD.(On/Off-Highway)

Victoria – Melbourne

488 Blackshaws Road

Altona North,Victoria 3205

Australia

Phone: (61) 3 9243-9292

Fax: (61) 3 9243-9271

LATIN AMERICAN REGION

(Off-Highway)

Miami, Florida

2277 N.W. 14th Street

Latin America Building

Miami, FL 33125-0068

Phone: 305-637-1555

Fax: 305-637-1580

MTU ASIA PTE. LTD. (Off-Highway)

Singapore

No. 1 Benoi Place

Singapore 629923

Phone: (65) 6861-5922

Fax: (65) 6861-3615 Sales Marine,

Rail, C & I, Electronics

Fax: (65) 6860-9959 Sales PowerGen,

Defense

MEXICO (On/Off-Highway)

Detroit Diesel Allison de Mexico, S.A.

Av. Santa Rosa 58

Col. Ampliacion Norte

54160 Tlalnepantla

Edo. de Mexico

MEXICO

Phone: 52 55-5333-1803

Fax: 52 55-5333-1875

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Working with DDC Service

Outlets

As the owner of a Detroit Diesel product you have a complete network of over 1,000 Detroit Diesel service outlets in the U.S. and Canada, plus many outlets worldwide that are prepared to meet your parts and service needs:

□ Service by trained personnel

□ Sales teams to help determine your speci fi c power requirements

□ In many areas, emergency service

24 hours a day

□ Complete parts support including reliabilt® remanufactured parts

□ Product information and literature

We recognize however, that despite the best intentions of everyone concerned, misunderstandings may occur. Normally, any situation that arises in connection with the sale, operation, or service of your product will be handled by the authorized service outlet in your area

(in the U.S. and Canada check the

Yellow Pages or service locator at www.detroitdiesel.com for the Detroit

Diesel service outlet nearest you).

To further assure your complete satisfaction, we have developed the following procedure to use if you have a problem that has not been handled satisfactorily.

Step One

Discuss your problem with a member of management from the authorized service outlet. Frequently, complaints are the result of a breakdown in communication and can quickly be resolved by a member of management.

If you have already discussed the problem with the Sales or Service

Manager, contact the General

Manager. If your complaint originates with a dealer, explain the matter to a management member of the distributorship with whom the dealer has his service agreement.

Step Two

When it appears that your problem cannot readily be resolved at the distributor level without additional assistance, contact the Detroit

Diesel Regional Product Support or

Operations Manager responsible for your local distributor. You will be assisted by a member of the Manager's staff, depending upon the nature of your problem.

Prior to this contact, have the following information available:

□ Engine model and serial number

□ Name and location of authorized service outlet

□ Type and make of equipment

All information subject to change without notice.

(Rev. 04/08)

CUSTOMER ASSISTANCE

□ Engine delivery date and accumulated miles or hours of operation

□ Nature of problem

□ Chronological summary of engine's history

Step Three

If you are still not satis fi ed, present the entire matter in writing or by phone to:

Sr. Vice President, Parts, Service and Customer Support

Detroit Diesel Corporation

13400 Outer Drive, West

Detroit, Michigan 48239–4001

Phone: 313–592–5000

Fax: 313–592–7244

When contacting the regional or home of fi ce, please keep in mind that ultimately your problem will likely be resolved at the distributorship or dealership, utilizing their facilities, equipment, and personnel. Therefore, it is suggested that you follow the previously mentioned steps in sequence when experiencing a problem.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

LIMITED WARRANTY ON NEW DETROIT DIESEL

MBE 4000 ENGINES USED IN ON-HIGHWAY VEHICLE

APPLICATIONS

Terms of Coverage

Uses

This warranty applies to the fi rst retail purchaser and subsequent owners during the WARRANTY

PERIOD of new Detroit Diesel

MBE 4000 Engines (referred to as

Engine) manufactured by Detroit

Diesel Corporation and/or supplied by Detroit Diesel Corporation or

Detroit Diesel of Canada Limited

(which are collectively referred to as

DDC) for use in on-highway vehicle applications operated in the United

States or Canada.

Defects

This warranty covers Engine

REPAIRS to correct any malfunction occurring during the WARRANTY

PERIOD resulting from defects in material or workmanship.

approved by DDC will be used. DDC may, at its discretion, replace rather than repair components. A reasonable time must be allowed to perform the warranty repair after taking the engine to the authorized service outlet.

The owner is responsible for the percentage of repair costs shown in the warranty period chart. Repairs will be performed during normal business hours.

Warranty Period

The WARRANTY PERIOD begins on the date the engine is delivered to the fi rst retail purchaser or put in use prior to sale at retail, whichever date occurs fi rst, and ends at the time or mileage/kilometer limits shown in the

WARRANTY PERIOD chart.

Repairs

To obtain warranty repairs, you must request the needed repairs within the WARRANTY PERIOD from an authorized DDC service outlet. Only new genuine parts or remanufactured parts or components supplied or

All information subject to change without notice.

(Rev. 04/08)

LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 4000 ENGINES

USED IN ON-HIGHWAY VEHICLE APPLICATIONS

Item

Engine

Accessories

Major Components*

Warranty Period

Warranty Limitations

(Whichever Occurs First)

Repair Charges to be

Paid by Owner

Months

Miles/

Kilometers

Parts Labor

0-24 Unlimited

Charge

No Charge

0-24

0-100,000 mi

0-160,000 km

Charge

No Charge

Upon expiration of the 24 month warranty coverage, but within 500,000 mi/8000,000 km of use, the warranty continues to apply as follows:

25-60

0-500,000 mi

0-800,000 km

Charge

100% of service outlet's normal charge

* Cylinder Block/Head, Crankshaft, Camshaft, Main Bearing Bolts,

Flywheel Housing, Connecting Rod Assemblies, Oil Cooler Housing,

Water Pump Housing and Air Inlet Housing.

Table 25 Warranty Period Chart — On-highway Vehicle Applications

Like Replacement Engine

Engine(s) supplied by DDC as a replacement for an engine still under warranty will assume the identity of the engine being replaced and be entitled to the remaining warranty coverage.

Service Supplies

The cost of service supplies such as coolant, oil and fi lters which are not reusable due to needed warranty repairs is covered by this warranty.

Engine Removal and

Reinstallation

Reasonable labor costs for engine removal and reinstallation, when necessary to make a warranty repair, are covered by this warranty.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

This Warranty Does Not

Cover:

Repairs Due to Accidents,

Misuse, Storage Damage,

Negligence or Certain

Modi fi cations

Repairs due to an accident, misuse, misapplication, storage damage, negligence or modi fi cation exceeding

DDC speci fi cations are not covered by this warranty.

Fuel Injection System After

100,000 Miles/160, 000

Kilometers

The repair or replacement of fuel injection pump, high pressure lines and nozzles after 100,000 miles/160,000 kilometers of operation is not covered by this warranty.

Maintenance

DDC is not responsible for the cost of maintenance or repairs due to lack of performance of required maintenance services as recommended by DDC, or the failure to use fuel, oil, lubricants and coolant meeting DDC-recommended speci fi cations. Performance of the required maintenance and use of proper fuel, oil, lubricants and coolant are the responsibility of the owner.

Refer to the Engine Operator”s Guide for details.

Incidental or Consequential

Damages

Detroit Diesel Corporation is not responsible for incidental or consequential costs or expenses which the owner may incur as a result of a malfunction or failure covered by this warranty, such as communication expenses, meals, lodging, loss of use of the engine or vehicle (“downtime”), loss of time, inconveniences, cargo loss or damage, and other similar costs and experiences.

Other Limitations

Performance of REPAIRS is the exclusive Owner's remedy under this warranty. Detroit Diesel Corporation does not authorize ant person to assume or create for it any other obligation or liability in connection with the engine or the accessories.

All information subject to change without notice.

(Rev. 04/08)

LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 4000 ENGINES

USED IN ON-HIGHWAY VEHICLE APPLICATIONS

THIS WARRANTY AND

THE EMISSIONS CONTROL

WARRANTY ARE THE ONLY

WARRANTIES APPLICABLE

TO THE ENGINE AS USED

IN ON-HIGHWAY VEHICLE

APPLICATIONS. DETROIT DIESEL

CORPORATION MAKES NO

OTHER WARRANTIES EXPRESS

OR IMPLIED, INCLUDING

ANY IMPLIED WARRANTY

OF MERCHANTABILITY OR

FITNESS FOR A PARTICULAR

PURPOSE. DETROIT DIESEL

CORPORATION SHALL NOT BE

LIABLE FOR ANY INCIDENTAL

OR CONSEQUENTIAL DAMAGES

AS DESCRIBED ABOVE.

Some states do not allow the limitation of how long this warranty may last or the limitation or exclusion of incidental or consequential damages, so the above may not apply to you.

This warranty gives you special legal rights, and you may also have other rights which may vary from state to state.

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

LIMITED WARRANTY ON NEW DETROIT DIESEL MBE

4000 ENGINES USED IN FIRE TRUCK OR CRASH

VEHICLE APPLICATIONS

Terms of Coverage

Uses

This warranty applies to the fi rst retail purchaser and subsequent owners during the WARRANTY

PERIOD of new Detroit Diesel

MBE 4000 Engines (referred to as

Engine) manufactured by Detroit

Diesel Corporation and/or supplied by

Detroit Diesel Corporation or Detroit

Diesel of Canada Limited (which are collectively referred to as DDC) for use in fi re truck or crash vehicle applications operated in the United

States or Canada.

Defects

This warranty covers Engine

REPAIRS to correct any malfunction occurring during the WARRANTY

PERIOD resulting from defects in material or workmanship.

The owner is responsible for the percentage of repair costs shown in the warranty period chart. Repairs will be performed during normal business hours.

Warranty Period

WARRANTY PERIOD chart.

Repairs

All information subject to change without notice.

(Rev. 04/08)

LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 4000 ENGINES

USED IN FIRE TRUCK OR CRASH VEHICLE APPLICATIONS

Item

Engine

Accessories

Warranty Period

Warranty Limitations

(Whichever Occurs First)

Months

Miles/

Kilometers

Repair Charges to be

Paid by Owner

Parts Labor

0-60

0-100,000 mi

0-160,000 km

No Charge No Charge

0-24

0-100,000 mi

0-160,000 km

No Charge No Charge

Table 26 Warranty Period Chart — On-highway Vehicle Applications

Like Replacement Engine

Engine(s) supplied by DDC as a replacement for an engine still under warranty will assume the identity of the engine being replaced and be entitled to the remaining warranty coverage.

Service Supplies

The cost of service supplies such as coolant, oil and fi lters which are not reusable due to needed warranty repairs is covered by this warranty.

Engine Removal and

Reinstallation

Reasonable labor costs for engine removal and reinstallation, when necessary to make a warranty repair, are covered by this warranty.

This Warranty Does Not

Cover:

Repairs Due to Accidents,

Misuse, Storage Damage,

Negligence or Certain

Modi fi cations

Repairs due to an accident, misuse, misapplication, storage damage, negligence or modi fi cation exceeding

DDC speci fi cations are not covered by this warranty.

Fuel Injection System After

100,000 Miles/160, 000

Kilometers

The repair or replacement of fuel injection pump, high pressure lines and nozzles after 100,000 miles/160,000 kilometers of operation is not covered by this warranty.

100

All information subject to change without notice.

(Rev. 04/08)

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

Maintenance

Refer to the Engine Operator”s Guide for details.

Incidental or Consequential

Damages

Other Limitations

THIS WARRANTY AND

THE EMISSIONS CONTROL

WARRANTY ARE THE ONLY

WARRANTIES APPLICABLE

TO THE ENGINE AS USED

IN ON-HIGHWAY VEHICLE

APPLICATIONS. DETROIT DIESEL

CORPORATION MAKES NO

OTHER WARRANTIES EXPRESS

OR IMPLIED, INCLUDING

ANY IMPLIED WARRANTY

OF MERCHANTABILITY OR

FITNESS FOR A PARTICULAR

PURPOSE. DETROIT DIESEL

CORPORATION SHALL NOT BE

LIABLE FOR ANY INCIDENTAL

OR CONSEQUENTIAL DAMAGES

AS DESCRIBED ABOVE.

Some states do not allow the limitation of how long this warranty may last or the limitation or exclusion of incidental or consequential damages, so the above may not apply to you.

This warranty gives you special legal rights, and you may also have other rights which may vary from state to state.

All information subject to change without notice.

(Rev. 04/08)

101

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Key features

Electronic Engine Control System
Exhaust Gas Recirculation for reduced emissions
Standard exhaust brake with constant-throttle system
Optional turbo brake for increased braking power
Water-cooled, four-stroke, direct-injection inline diesel engine
Diagnostic capabilities through DDEC-ECU and DDEC-VCU

Frequently asked questions

The purpose of the Exhaust Gas Recirculation (EGR) System is to reduce engine exhaust gas emissions in accordance with EPA regulations.

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 of the problem.

To the Operator

Trademark Information

TABLE OF CONTENTS

CAUTION SUMMARY

Engine Operation

Preventive Maintenance

Electrical System

Cooling System

Air Intake System

Fuel System

Compressed Air

Lubricating Oil and Filters

IDENTIFICATION

Personnel Requirements

Engine Conversions and

Modi

cations

General View of the MBE

4000 Engine

Engine Type Plate

Engine Features

Exhaust

Brake/Constant-Throttle

Valves

Turbo Brake, Optional

Exhaust Gas Recirculation

Electronic Engine Control

System

OPERATION

Before Starting the Engine

Starting the Engine

Monitoring Engine

Operation

Changing the Idle Speed

Shutting Down the Engine

Emergency Running Mode

Stop Engine Override

Option

Cold Weather Operation

CLEANING AND STORAGE

Cleaning the Engine

Cleaning the Cooling

System

Storage

TROUBLESHOOTING

Emergency Starting

Troubleshooting the

Electronic Engine Control

System

General Troubleshooting

SERVICE PRODUCTS

Diesel Fuels

Engine Oils

Coolant

Cold Weather Products

TECHNICAL DATA

Engine Data

Testing and Adjusting

Values

MAINTENANCE

Scheduled Intervals

Maintenance Tables

Required Maintenance

Operations

CUSTOMER ASSISTANCE

Working with DDC Service

Outlets

LIMITED WARRANTY ON NEW DETROIT DIESEL

MBE 4000 ENGINES USED IN ON-HIGHWAY VEHICLE

APPLICATIONS

Terms of Coverage

This Warranty Does Not

Cover:

LIMITED WARRANTY ON NEW DETROIT DIESEL MBE

4000 ENGINES USED IN FIRE TRUCK OR CRASH

VEHICLE APPLICATIONS

Terms of Coverage

This Warranty Does Not

Cover:

What should I do before starting the engine?