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 filter 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.
ii All information subject to change without notice. (Rev.
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE TABLE OF CONTENTS CAUTION SUMMARY .......................................................................... ENGINE OPERATION ..................................................................... PREVENTIVE MAINTENANCE ....................................................... ELECTRICAL SYSTEM ................................................................... COOLING SYSTEM ......................................................................... AIR INTAKE SYSTEM ....
TABLE OF CONTENTS STARTING AN ENGINE THAT HAS NOT BEEN RUN FOR A LONG TIME ................................................................................. MONITORING ENGINE OPERATION ............................................. BATTERY CHARGE .................................................................... OIL PRESSURE .......................................................................... EXCESSIVE IDLING ...................................................................
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE SUPPLEMENTAL COOLANT ADDITIVES FOR FULLY FORMULATED COOLANT .......................................................... DROPOUT ................................................................................... NON-APPROVED COOLANTS ................................................... RECYCLED ANTIFREEZE .......................................................... CORROSION INHIBITORS ......................................................... DISPOSAL ....................
TABLE OF CONTENTS FUEL/WATER SEPARATOR PREFILTER ELEMENT CLEANING .................................................................................. FUEL PRO® 382 FUEL/WATER SEPARATOR ELEMENT REPLACEMENT .......................................................................... MAIN FUEL FILTER ELEMENT CHANGING .............................. ENGINE OIL AND FILTER CHANGING ...................................... OPTIONAL OIL CENTRIFUGE ...............................................
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 .......................................
TABLE OF CONTENTS viii All information subject to change without notice. (Rev.
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.
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.
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE PERSONAL INJURY FIRE 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. To avoid injury from combustion of heated lubricating-oil vapors, stop the engine immediately if an oil leak is detected.
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 flames near the battery.
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 finger or conductive items (e.g. screwdriver or wire). High voltage can remain inside the Electrostatic Oil Separator for up to 12 hours after the ignition is turned off.
CAUTION SUMMARY Cooling System Air Intake System Observe the following cautions when servicing the cooling system. Observe the following cautions when working on the air intake system. HOT COOLANT PERSONAL INJURY 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.
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 FIRE To avoid injury from fire, keep all potential ignition sources away from diesel fuel, including open flames, sparks, and electrical resistance heating elements. Do not smoke when refueling. To avoid injury from fuel spills, do not overfill the fuel tank.
CAUTION SUMMARY FIRE To avoid injury from fire caused by heated diesel-fuel vapors: □ Keep those people who are not directly involved in servicing away from the engine. □ Stop the engine immediately if a fuel leak is detected. □ Do not smoke or allow open flames when working on an operating engine. □ Wear adequate protective clothing (face shield, insulated gloves and apron, etc.). □ To prevent a buildup of potentially volatile vapors, keep the engine area well ventilated during operation.
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE Compressed Air Observe the following cautions when using compressed air. FIRE To avoid injury from fire, do not smoke or allow open flames when working on an operating engine. EYE INJURY To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure.
IDENTIFICATION IDENTIFICATION 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. 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 Figure 1 10 Emission Label, MBE 4000 All information subject to change without notice. (Rev.
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. 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. □ It is modified or converted in an incorrect manner. □ The safety instructions included in this manual are disregarded.
IDENTIFICATION 1. EGR Outlet Pipe 8. Engine Trim Cover 2. Coolant Pump 9. Crankcase Breather 3. Thermostat Housing 10. Air Compressor 4. Modulated EGR Valve 11. Fuel Filter Housing 5. EGR Cooler 12. Oil Pan 6. EGR Shutoff Valve (hidden) 13. EGR Mixer 7. Air Intake Manifold 14. Air Conditioning Compressor Figure 2 12 Major Engine Components, Left Side All information subject to change without notice. (Rev.
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE 1. Oil Filter 7. EGR Cooler 2. Air Solenoid Valve (Engine Brake) 8. Reed Valve Housing 3. Turbocharger 9. EGR Control Valve 4. EGR Hot Pipe 10. EGR Mixer 5. Exhaust Manifold 11. Alternator 6. EGR Shutoff Valve 12. Belt Tensioner Figure 3 Major Engine Components, Right Side All information subject to change without notice. (Rev.
IDENTIFICATION Engine Type Plate The engine type plate is used to identify the engine. It is located on the oil filter housing. See Figure 4. Figure 5 Engine Type Plate The last six numbers are the serial numbers (745111 in see Figure 5). Figure 4 Location of Engine Type Plate Details on the Plate The engine type reference, OM 460 LA, is the production code. The first three numbers of the engine serial number are the model number. See Figure 5.
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.
IDENTIFICATION The air compressor, with a power-steering pump attached, is driven by a gear on the camshaft. Exhaust Brake/Constant-Throttle Valves The engine is cooled by a closed system using recirculated coolant; temperature is regulated automatically by a thermostat. 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.
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.
IDENTIFICATION The addition of cooled exhaust gasses back into the combustion airflow reduces the peak in cylinder combustion temperature. Less oxides of nitrogen (NOx) are produced at lower combustion temperatures. Electronic Engine Control System The engine is equipped with a fully electronic control system. See Figure 8. The recycled exhaust gases are cooled before engine consumption in a tube and shell engine water cooler.
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.
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.
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE 1. Intake Air Pressure/Temperature Sensor 5. Engine Coolant Temperature Sensor 2. EGR Temperature Sensor 6. Barometric Pressure Sensor (Integrated into DDEC-ECU) 3. Camshaft Position Sensor 7. Supply Fuel Temperature Sensor 4. Crankshaft Position Sensor 8. Engine Oil Pressure/Temperature Sensor Figure 11 Sensor Location All information subject to change without notice. (Rev.
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). 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.
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE Battery Explosion and Acid Burn To avoid injury from battery explosion or contact with battery acid, work in a well ventilated area, wear protective clothing, and avoid sparks or flames near the battery. If you come in contact with battery acid: □ Flush your skin with water. □ Apply baking soda or lime to help neutralize the acid. □ Flush your eyes with water. □ Get medical attention immediately. Figure 12 Oil Dipstick 2.
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 filled when the coolant is between the maximum and minimum marks on the surge tank. For more information, refer to the “Maintenance” section.
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: [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. NOTICE: Never attempt to start any Mercedes-Benz electronic engine using ether or any other starting fluid. Serious engine damage could result. 5.
OPERATION HOT COOLANT To avoid scalding from the expulsion of hot coolant, never remove the cooling system pressure cap while the engine is at operating temperature. Wear adequate protective clothing (face shield, rubber gloves, apron, and boots). Remove the cap slowly to relieve pressure. 2. Then, with the coolant temperature above 50°C (122°F), recheck the coolant level. 3. Add more coolant if necessary. Open the heater valves before adding coolant. 4.
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 fire, keep all potential ignition sources away from diesel fuel, including open flames, sparks, and electrical resistance heating elements. Do not smoke when refueling. 3.
OPERATION Excessive Idling □ Engine power and rpm fall, even though the accelerator pedal remains steady. Never allow the engine to idle for more than 30 minutes. Excessive idling can cause oil to leak from the turbocharger. □ The exhaust pipe gives off heavy smoke. Changing the Idle Speed □ The coolant and/or oil temperature climb abnormally. 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.
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.
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 flow direction.
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 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 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.
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).
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.
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. The ignition switch is damaged.
TROUBLESHOOTING Problem—The Engine Turns Over Slowly Cause Remedy The batteries are damaged or weak. Test the batteries. Replace them, if needed. The ignition switch is damaged. Replace the ignition switch. The battery cables are damaged and/or corroded Replace the battery cables. The starter is damaged and/or worn. Have an authorized dealer replace the starter. The engine oil does not meet the correct specifications. Change the engine oil, using the correct type of oil.
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. Install an intake air preheater. The intake air preheater is malfunctioning. Check the intake air preheater, and replace it, if necessary.
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. Check the fuel lines for leaks and repair them, if necessary. The fuel filter is clogged. Replace the filter element. The fuel line, the fuel prefilter, or the screen in the fuel tank is blocked. Clean and bleed the system. Have the fuel lines and filters checked by an authorized dealer.
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. Replace the filter element. The fuel line, the fuel prefilter, or the screen in the fuel tank is blocked. Clean and bleed the system. Have the fuel lines and filters checked by an authorized dealer. The camshaft TDC sensor and/or the crank angle position sensor are out of adjustment.
TROUBLESHOOTING Problem—The Engine Fan Is Constantly On Cause Remedy The fan override switch is on. Check the operation of the fan override switch. The fan hub is damaged. Replace the fan hub The parameter settings in the DDEC-ECU or DDEC-VCU are incorrect. Have an authorized dealer reprogram the control unit. AC switch is damaged Check AC switch. Problem—Fuel Consumption Is Too High Cause Remedy The tires are not properly inflated. Check all tires for correct pressure.
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. Have an authorized dealer check the operation of the valve. The fuel filter is clogged. Replace the filter element. There are other problems with the fuel system.
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.
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. Have an authorized dealer replace the thermostat. The fan is not operating properly. Bring the vehicle to an authorized dealer and have the fan hub checked.
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. Change the oil. The oil is not of the recommended quality. Change the oil. Problem—The Engine Oil Pressure Is Low Cause Remedy The oil pressure gauge and/or sensor is not reading correctly. Bring the vehicle to an authorized dealer for service. There is fuel in the oil.
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. Have an authorized dealer check the operation of the valve. The intake air preheater is malfunctioning. Check that the heater is not staying on all of the time. The valves are not adjusted properly.
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. Have an authorized dealer check the operation of the valve. The constant-throttle valves are malfunctioning. Bring the vehicle to an authorized dealer for service. Components of the DDEC-ECU and/or DDEC-VCU are damaged. Bring the vehicle to an authorized dealer for service.
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. Have an authorized dealer replace the belt tensioner. The poly-V belt is worn or damaged. Replace the belt. The alternator is damaged (has a damaged rectifier or voltage regulator).
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, filters).
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 filled with an approved engine oil. NOTICE: The use of non-approved engine oils could affect warranty rights, and cause engine damage.
SERVICE PRODUCTS Synthetic oil offers improved low-temperature flow 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.
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE the requirements of the Truck Maintenance Council (TMC). Coolant specifications are listed in Table 2. □ 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.
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.
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.
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.
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE If changes have already been caused by paraffin 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 flow characteristics could actually deteriorate with additives. volume (this gives the maximum antifreeze protection).
TECHNICAL DATA TECHNICAL DATA General technical information is listed in Table 4. Description Engine Type MBE 4000 Engine Vertical, inline cylinder block with turbocharger and charge-air cooler Cooling System Liquid Circuit Combustion Principle 4-Stroke direct-injection diesel Number of Cylinders 6 Bore 128 mm (5.04 in.) Stroke 166 mm (6.54 in.) Displacement (total) 12.816 liters (782 in³) Compression Ratio 17.
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE Engine Data Dimension Size Length (A) 1338.7 mm (53.1 in.) Width (B) 1069.3 mm (42.1 in.) Height (C) 1130.3 mm (44.5 in.) 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.
TECHNICAL DATA Description Oil Pan Capacity Oil System Fill Capacity † EGR engines w/front Sump * 36 L (38 qts) 39.5 L (41.7 qts) Non-EGR Engines w/front Sump & Right Hand Drive Export Applications * 36 L (38 qts) 39.5 L (41.7 qts) Rear Sump Applications 40.0 L (42.3 qts) 43.5 L (46.0 qts) Non-EGR Engines w/front Sump & Left Hand Drive Applications 40.0 L (42.3 qts) 43.5 L (46.0 qts) Front Sump Engine s/n 833529 and below 40.0 L (42.3 qts) 43.5 L (46.
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE Table 10 Table 11 Engine Speed Minimum Pressure At idling rpm 50 kPa (7 psi) At maximum rpm 250 kPa (36 psi) Engine Oil Pressure Condition Specification Starts to open 81 to 85°C (177 to 185°F) Fully open 95°C (203°F) Minimum lift 8 mm (0.3 in.
MAINTENANCE MAINTENANCE When performed on a regular basis, changing the engine oil and filters is the least costly way of obtaining safe and reliable vehicle operation. Added benefits 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.
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.
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 find the Maintenance Operation Set that applies to that interval.
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 Frequency Miles Km Maintenance 1 (M1) every 10,000 17,000 Optional oil centrifuge (change rotor) every 20,000 32,000 Maintenance 2 (M2) every 20,000 32,000 first 20,000 32,000 then every 40,000 68,000 Maintenance 1 (M1) every 15,000 25 000 Optional oil centrifuge (change rotor) every
MAINTENANCE Maint.
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE Maint. No.
MAINTENANCE Maint.
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE Operation Description M1 M2 M3 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 * Coolant flushing and changing must be done at least every two years.
MAINTENANCE Maintenance Operation Description M1 Engine Inspecting — Valve Lash Checking and Adjusting† — Fuel /Water Separator Prefilter Element Cleaning — Main Fuel Filter Element Changing — M2 M3 — — — — — — M4 Engine Oil and Filter Changing Coolant Concentration and Inhibitor Level Checking Coolant Flushing and Changing* — Cooling System Inspecting — Rear Engine Power Take-Off (REPTO) torsional damper checking‡ — * Coolant flushing and changing must be done at least every two y
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE Required Maintenance Operations Gaining Access To The Valves — Gain access to the valves as follows: The following sections describe the required maintenance operations listed in Table 17 and listed in Table 18. NOTE: Clean the cylinder head covers before removing it. Engine Inspecting 1. Remove the cylinder head covers. See Figure 20. Inspect engine as follows: 1. Visually check the engine for signs of leakage.
MAINTENANCE 3. Fit the cranking tool into the inspection hole on the timing case. See Figure 21. Figure 21 See Figure 22 for the cylinder and valve layout on the MBE 4000 engine. Placing Cranking Tool Choosing A Method — Select a method for adjusting the valve lash.
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.
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.
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE Adjusting Valve Lash — Adjust valve lash as follows: 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. Restoring The Vehicle To Operating Condition — Restore the vehicle to operation condition as follows: 1. Install the cylinder head covers.
MAINTENANCE Fuel/Water Separator Prefilter Element Cleaning tighten firmly, using hands only. Clean the prefilter element as follows: 1. Loosen the bleed screw. See Figure 24. 2. Unscrew the drain plug and drain the fuel in the prefilter. 3. Twist off the sight bowl and remove the filter element from the separator head. 4. Separate the sight bowl from the filter element. Clean the sight bowl. Discard the old filter element and both O-rings. 5. Replace the filter element and O-rings. 6.
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.
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 filter element from the separator head and discard filter and O-rings. Dispose of filter properly. 4. Clean the cover and the mounting surface on the body. 5. Install the filter element with bottom grommet, new cover O-ring, cover and collar. Hand tighten only. 6.
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE 3. Using a 36-mm socket, unscrew the cap on the main fuel filter housing. Remove the cap and lift the filter element a short distance within the filter housing allowing the fuel to drain off the filter. 4. Remove the filter element from the cap and clean the filter cap. Discard the filter 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 filter housing cap. 6.
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 classification 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 filter cap (see Figure 28).
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE 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). Figure 29 Engine Oil Drain Plug, Oil Pan [c] Discard the O-ring on the oil drain plug. 4. Remove both the filter cap and the filter element. To release the filter element, twist the lower edge of the filter element to the side (see Figure 30). 6. Install the new filter into the cap.
MAINTENANCE 11. Check the filter and oil drain plug for signs of leakage. 12. Stop the engine. Check the oil level again after approximately five minutes. If necessary, add oil up to the maximum fill level on the oil dipstick. Figure 31 Oil Fill 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.
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE Coolant Concentration and Inhibitor Level Checking NOTE: Check and correct the coolant level only when the coolant temperature is below 50°C (122°F). Check the coolant concentration as follows: 1. Open the cap on the surge tank slowly, to allow excess pressure to escape. Set the cap aside. HOT COOLANT 2. Before adding coolant, use a suitable tester to check the concentration of corrosion-inhibiting antifreeze.
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. Coolant Inhibitor Test Intervals — Coolant inhibitor level should be checked at the intervals listed in Table 23.
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE Coolant Antifreeze/Water + SCA Inhibitor (DDC Power Cool) Ethylene Glycol/Water + SCA Inhibitor Ethylene Glycol/Water + OAT Inhibitor Water Only + SCA Inhibitor Water Only + OAT Inhibitor Maintenance Interval Action 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 Drain and clean system.
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.
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.
MAINTENANCE Cooling System Inspecting EYE INJURY To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure. 5. Apply no more than 140 kPa (20 psi) air pressure intermittently to help dislodge sediment buildup in the core. 6. Drain the radiator, and flush the radiator until clean water flows from the radiator. Remove the flushing gun. 7.
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 flywheel housing. All REPTO installations require a torsional coupling installed at the flange of the drive unit (i.e. hydraulic pump).
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 flanges damaging the coupling.
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 All information subject to change without notice. (Rev. 04/08) Corporation and its distributor/dealer organizations.
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 926
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE MTU DETROIT DIESEL OFF-HIGHWAY SALES AND CUSTOMER ASSURANCE CENTERS CONSTRUCTION, INDUSTRIAL AND MINING SALES (BX7) 13400 Outer Drive, West Detroit, MI 48239-4001 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 All information subject to change witho
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 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 DETROIT DIESEL AUSTRALIA PTY. LTD.
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.
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 satisfied, present the entire matter in writing or by phone to: Sr.
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 first 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-highwa
LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 4000 ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS Warranty Period Warranty Limitations (Whichever Occurs First) Item Repair Charges to be Paid by Owner Months Miles/ Kilometers Parts Labor Engine 0-24 Unlimited No Charge No Charge Accessories 0-24 0-100,000 mi 0-160,000 km No 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: Major Components*
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE This Warranty Does Not Cover: Repairs Due to Accidents, Misuse, Storage Damage, Negligence or Certain Modifications Repairs due to an accident, misuse, misapplication, storage damage, negligence or modification exceeding DDC specifications are not covered by this warranty.
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.
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 first 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
LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 4000 ENGINES USED IN FIRE TRUCK OR CRASH VEHICLE APPLICATIONS Warranty Period Warranty Limitations (Whichever Occurs First) Item Repair Charges to be Paid by Owner Months Miles/ Kilometers Parts Labor Engine 0-60 0-100,000 mi 0-160,000 km No Charge No Charge Accessories 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 replacem
EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE 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 specifications. 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.