DDC-SVC-MAN-0056 - MBE4000 Safe Operation and Preventative ...

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE

To the Operator

This guide contains instructions onthe safe operation and preventivemaintenance of your Detroit DieselMBE 4000 engine. Maintenanceinstructions cover routine engineservices such as lube oil and filterchanges in enough detail to permitself-servicing if desired.

The operator should become familiarwith the contents of this guide beforeoperating the engine or carrying outmaintenance procedures.

Power-driven equipment is onlyas safe as the person operating thecontrols. You are urged, as theoperator of this diesel engine, to keepfingers and clothing away from therevolving belts, drive shafts, etc. onengine installation.

Throughout this guide CAUTIONSregarding personal safety andNOTICES regarding engineperformance or service life willappear. To avoid personal injury andensure long engine service life, alwaysheed these instructions.

Whenever possible, it will benefityou to rely on an authorized DetroitDiesel® service outlet for all yourservice needs from maintenance tomajor parts replacement. Authorizedservice outlets worldwide stockfactory original parts and havethe specialized equipment and

experienced, trained personnelto provide prompt preventivemaintenance and skilled enginerepairs.

The information and specificationsin this publication are based on theinformation in effect at the time ofapproval for printing. Contact anauthorized Detroit Diesel serviceoutlet for information on the latestrevision. The right is reserved tomake changes at any time withoutobligation.

NOTICE:

Coolant must be inhibited withthe recommended SupplementalCoolant Additives (SCA) listed inthis guide. In addition, the enginecan be equipped with a coolantfilter/inhibitor system as an installedoption or as an after-sale item.Failure to check and maintain SCAlevels at required concentrations willresult in severe damage corrosionto the engine cooling system andrelated components.

Trademark Information

Detroit Diesel®, DDEC®, andDiagnostic Link® are registeredtrademarks of Detroit DieselCorporation. Nexiq™ is a trademarkof Nexiq Technologies, Inc. All othertrademarks are the property of theirrespective owners.

All information subject to change without notice. (Rev. 04/08) iDDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

ii All information subject to change without notice. (Rev. 04/08)DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION


TABLE OF CONTENTS

CAUTION SUMMARY .......................................................................... 1ENGINE OPERATION ..................................................................... 1PREVENTIVE MAINTENANCE ....................................................... 2ELECTRICAL SYSTEM ................................................................... 4COOLING SYSTEM ......................................................................... 6AIR INTAKE SYSTEM ...................................................................... 6FUEL SYSTEM ................................................................................ 7COMPRESSED AIR ......................................................................... 9LUBRICATING OIL AND FILTERS .................................................. 9

IDENTIFICATION ................................................................................. 10PERSONNEL REQUIREMENTS ..................................................... 11ENGINE CONVERSIONS AND MODIFICATIONS .......................... 11GENERAL VIEW OF THE MBE 4000 ENGINE ............................... 11ENGINE TYPE PLATE ..................................................................... 14

DETAILS ON THE PLATE .......................................................... 14ENGINE FEATURES ....................................................................... 15EXHAUST BRAKE/CONSTANT-THROTTLE VALVES .................... 16TURBO BRAKE, OPTIONAL ........................................................... 17EXHAUST GAS RECIRCULATION ................................................. 17ELECTRONIC ENGINE CONTROL SYSTEM ................................. 18

DDEC-ECU — ENGINE-RESIDENT CONTROL UNIT ............... 19VEHICLE CONTROL UNIT ......................................................... 20SENSOR LOCATIONS ................................................................ 20

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

CHECKING THE BATTERIES ..................................................... 22CHECKING THE OIL LEVEL ....................................................... 23CHECKING THE COOLANT LEVEL (COLD CHECK) ................ 24ADDING FUEL ............................................................................. 24PRIMING THE FUEL SYSTEM ................................................... 24

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

All information subject to change without notice. (Rev. 04/08) iiiDDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

TABLE OF CONTENTS

STARTING AN ENGINE THAT HAS NOT BEEN RUN FOR ALONG TIME ................................................................................. 26

MONITORING ENGINE OPERATION ............................................. 27BATTERY CHARGE .................................................................... 27OIL PRESSURE .......................................................................... 27EXCESSIVE IDLING ................................................................... 28

CHANGING THE IDLE SPEED ....................................................... 28SHUTTING DOWN THE ENGINE ................................................... 28

SHUTTING DOWN AFTER HIGH LOAD OPERATION ............... 28EMERGENCY RUNNING MODE .................................................... 29STOP ENGINE OVERRIDE OPTION .............................................. 29COLD WEATHER OPERATION ...................................................... 30

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

CLEANING AND STORAGE ............................................................... 31CLEANING THE ENGINE ................................................................ 31

HIGH-PRESSURE CLEANING EQUIPMENT ............................. 31CLEANING THE COOLING SYSTEM ............................................. 31

DEGREASING ............................................................................. 32STORAGE ........................................................................................ 33

TROUBLESHOOTING ......................................................................... 34EMERGENCY STARTING ............................................................... 34TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROLSYSTEM .......................................................................................... 34GENERAL TROUBLESHOOTING ................................................... 35

SERVICE PRODUCTS ......................................................................... 48DIESEL FUELS ................................................................................ 48

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

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

COOLANT ........................................................................................ 50FULLY-FORMULATED ANTIFREEZE ......................................... 50WATER ........................................................................................ 50COOLANT SPECIFICATIONS ..................................................... 51COOLANT CONCENTRATION ................................................... 51

iv All information subject to change without notice. (Rev. 04/08)DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION


SUPPLEMENTAL COOLANT ADDITIVES FOR FULLYFORMULATED COOLANT .......................................................... 52DROPOUT ................................................................................... 52NON-APPROVED COOLANTS ................................................... 52RECYCLED ANTIFREEZE .......................................................... 53CORROSION INHIBITORS ......................................................... 53DISPOSAL ................................................................................... 54

COLD WEATHER PRODUCTS ....................................................... 54WINTER-GRADE DIESEL FUEL ................................................. 54LOW-VISCOSITY ENGINE OIL ................................................... 55WINTER COOLANT ANTIFREEZE PROTECTION .................... 55BATTERIES ................................................................................. 55

TECHNICAL DATA .............................................................................. 56ENGINE DATA ................................................................................. 57TESTING AND ADJUSTING VALUES ............................................. 58

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

MAINTENANCE SCHEDULE TYPES ......................................... 60SEVERE SERVICE ................................................................. 60SHORT-HAUL ......................................................................... 61LONG-HAUL ........................................................................... 61MAINTENANCE SCHEDULE AND INTERVALOPERATIONS ......................................................................... 61MAINTENANCE INTERVALS .................................................. 61MAINTENANCE OPERATION SETS ...................................... 61

SCHEDULE USE ......................................................................... 62MAINTENANCE TABLES ................................................................ 63REQUIRED MAINTENANCE OPERATIONS ................................... 69

ENGINE INSPECTING ................................................................ 69VALVE LASH CHECKING AND ADJUSTING ............................. 69

GAINING ACCESS TO THE VALVES ..................................... 69CHOOSING A METHOD ......................................................... 70METHOD ONE ........................................................................ 71METHOD TWO ....................................................................... 72ADJUSTING VALVE LASH ...................................................... 73RESTORING THE VEHICLE TO OPERATING CONDITION .. 73

All information subject to change without notice. (Rev. 04/08) vDDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

TABLE OF CONTENTS

FUEL/WATER SEPARATOR PREFILTER ELEMENTCLEANING .................................................................................. 74FUEL PRO® 382 FUEL/WATER SEPARATOR ELEMENTREPLACEMENT .......................................................................... 75MAIN FUEL FILTER ELEMENT CHANGING .............................. 76ENGINE OIL AND FILTER CHANGING ...................................... 77

OPTIONAL OIL CENTRIFUGE ............................................... 80COOLANT CONCENTRATION AND INHIBITOR LEVELCHECKING .................................................................................. 81

COOLANT INHIBITOR TEST INTERVALS ............................. 82INHIBITOR LEVEL CHECKING .............................................. 84

COOLANT FLUSHING AND CHANGING ................................... 85COOLING SYSTEM INSPECTING ............................................. 86REAR ENGINE POWER TAKE-OFF (REPTO) .......................... 87

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

CUSTOMER ASSISTANCE ................................................................. 89WORKING WITH DDC SERVICE OUTLETS .................................. 93

STEP ONE ................................................................................... 93STEP TWO .................................................................................. 93STEP THREE .............................................................................. 94

LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 4000ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS ......... 95

TERMS OF COVERAGE ................................................................. 95USES ........................................................................................... 95DEFECTS .................................................................................... 95REPAIRS ..................................................................................... 95WARRANTY PERIOD .................................................................. 95LIKE REPLACEMENT ENGINE .................................................. 96SERVICE SUPPLIES .................................................................. 96ENGINE REMOVAL AND REINSTALLATION ............................. 96

THIS WARRANTY DOES NOT COVER: ......................................... 97REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 97FUEL INJECTION SYSTEM AFTER 100,000 MILES/160, 000KILOMETERS .............................................................................. 97MAINTENANCE ........................................................................... 97

vi All information subject to change without notice. (Rev. 04/08)DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION


INCIDENTAL OR CONSEQUENTIAL DAMAGES ...................... 97OTHER LIMITATIONS ................................................................. 97

LIMITED WARRANTY ON NEW DETROIT DIESEL MBE4000 ENGINES USED IN FIRE TRUCK OR CRASH VEHICLEAPPLICATIONS ................................................................................... 99

TERMS OF COVERAGE ................................................................. 99USES ........................................................................................... 99DEFECTS .................................................................................... 99REPAIRS ..................................................................................... 99WARRANTY PERIOD .................................................................. 99LIKE REPLACEMENT ENGINE .................................................. 100SERVICE SUPPLIES .................................................................. 100ENGINE REMOVAL AND REINSTALLATION ............................. 100

THIS WARRANTY DOES NOT COVER: ......................................... 100REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 100FUEL INJECTION SYSTEM AFTER 100,000 MILES/160, 000KILOMETERS .............................................................................. 100MAINTENANCE ........................................................................... 101INCIDENTAL OR CONSEQUENTIAL DAMAGES ...................... 101OTHER LIMITATIONS ................................................................. 101

All information subject to change without notice. (Rev. 04/08) viiDDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

TABLE OF CONTENTS

viii All information subject to change without notice. (Rev. 04/08)DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION


CAUTION SUMMARY

The following cautions must beobserved by the operator of thevehicle or equipment in which thisengine is installed and/or by thoseperforming basic engine preventivemaintenance. Failure to read and heedthese cautions and exercise reasonablecare for personal safety and thesafety of others when operating thevehicle/equipment or performing basicengine preventive maintenance mayresult in personal injury and engineand/or vehicle/equipment damage.

Engine OperationObserve the following cautions whenoperating the engine.

FIRE

To avoid injury from fire, keep allpotential ignition sources awayfrom diesel fuel, including openflames, sparks, and electricalresistance heating elements. Donot smoke when refueling.

PERSONAL INJURY

Diesel engine exhaust and someof its constituents are known tothe State of California to causecancer, birth defects, and otherreproductive harm.

□ Always start and operate anengine in a well ventilatedarea.

□ If operating an engine inan enclosed area, vent theexhaust to the outside.

□ Do not modify or tamperwith the exhaust system oremission control system.

All information subject to change without notice. (Rev. 04/08) 1DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

CAUTION SUMMARY

Preventive MaintenanceObserve the following cautions whenperforming preventative maintenance.

HOT OIL

To avoid injury from hot oil, donot operate the engine with therocker cover(s) removed.

PERSONAL INJURY

To avoid injury from slipping andfalling, immediately clean up anyspilled liquids.

USED ENGINE OIL

To avoid injury to skin fromcontact with the contaminants inused engine oil, wear protectivegloves and apron.

PERSONAL INJURY

To avoid injury when workingnear or on an operating engineequipped with an hydraulicclutch fan, remove loose itemsof clothing and jewelry. Tie backor contain long hair that couldbe caught in any moving partcausing injury. The hydraulic fanmay start without warning.

HOT COOLANT

To avoid scalding from theexpulsion of hot coolant, neverremove the cooling systempressure cap while the engine isat operating temperature. Wearadequate protective clothing(face shield, rubber gloves,apron, and boots). Remove thecap slowly to relieve pressure.

2 All information subject to change without notice. (Rev. 04/08)DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION


PERSONAL INJURY

To avoid injury from theprojection of tools or otherobjects that may fall on or behindthe vibration damper of anengine, always check and removethese items before starting theengine.

PERSONAL INJURY

To avoid injury from contactwith rotating parts when anengine is operating with the airinlet piping removed, install anair inlet screen shield over theturbocharger air inlet. The shieldprevents contact with rotatingparts.

PERSONAL INJURY

To avoid injury when usingcaustic cleaning agents, followthe chemical manufacturersusage, disposal, and safetyinstructions.

FIRE

To avoid injury from combustionof heated lubricating-oil vapors,stop the engine immediately if anoil leak is detected.

FIRE

To avoid injury from fire, do notsmoke or allow open flames whenworking on an operating engine.

FIRE

To avoid injury from fire from abuildup of volatile vapors, keepthe engine area well ventilatedduring operation.


CAUTION SUMMARY

Electrical SystemObserve the following cautions whenjump starting an engine, charging abattery, or working with the vehicleelectrical system.

PERSONAL INJURY

To avoid injury from accidentalengine startup while servicingthe engine, disconnect/disablethe starting system.

Electrical Shock

To avoid injury from electricalshock, use care when connectingbattery cables. The magneticswitch studs are at batteryvoltage.

Battery Explosion and Acid Burn

To avoid injury from batteryexplosion or contact with batteryacid, work in a well ventilatedarea, wear protective clothing,and avoid sparks or flames nearthe battery. If you come in contactwith battery acid:

□ Flush your skin with water.

□ Apply baking soda or lime tohelp neutralize the acid.

□ Flush your eyes with water.

□ Get medical attentionimmediately.

ELECTRICAL SHOCK

To avoid injury from electricalshock, do not touch batteryterminals, alternator terminals, orwiring cables while the engine isoperating.



Electrical Shock Hazard

High voltage can remain insidethe Electrostatic Oil Separatorafter removal. Wait 30 minutesafter turning off the ignitionbefore removing the separator.Never touch parts throughventilation openings or impelleropening with finger or conductiveitems (e.g. screwdriver or wire).High voltage can remain insidethe Electrostatic Oil Separator forup to 12 hours after the ignitionis turned off.


CAUTION SUMMARY

Cooling SystemObserve the following cautions whenservicing the cooling system.

HOT COOLANT


PERSONAL INJURY


Air Intake SystemObserve the following cautions whenworking on the air intake system.

PERSONAL INJURY

To avoid injury from hot surfaces,wear protective gloves, or allowengine to cool before removingany component.

PERSONAL INJURY

To avoid injury from contactwith rotating parts when anengine is operating with the airinlet piping removed, install anair inlet screen shield over theturbocharger air inlet. The shieldprevents contact with rotatingparts.



Fuel SystemObserve the following cautions whenfueling the vehicle or working withthe fuel system.

PERSONAL INJURY

To avoid injury from fuel spills,do not overfill the fuel tank.

FIRE

To avoid injury from fire, containand eliminate leaks of flammablefluids as they occur. Failure toeliminate leaks could result infire.

PERSONAL INJURY

To prevent the escape of highpressure fuel that can penetrateskin, ensure the engine hasbeen shut down for a minimumof 10 minutes before servicingany component within the highpressure circuit. Residual highfuel pressure may be presentwithin the circuit.

FIRE



CAUTION SUMMARY

FIRE

To avoid injury from fire causedby heated diesel-fuel vapors:

□ Keep those people who are notdirectly involved in servicingaway from the engine.

□ Stop the engine immediately ifa fuel leak is detected.

□ Do not smoke or allow openflames when working on anoperating engine.

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

□ To prevent a buildup ofpotentially volatile vapors,keep the engine area wellventilated during operation.



Compressed AirObserve the following cautions whenusing compressed air.

EYE INJURY

To avoid injury from flying debriswhen using compressed air, wearadequate eye protection (faceshield or safety goggles) and donot exceed 276 kPa (40 psi) airpressure.

Lubricating Oil and FiltersObserve the following cautions whenreplacing the engine lubricating oiland filters.

PERSONAL INJURY


FIRE

To avoid injury from combustionof heated lubricating-oil vapors,stop the engine immediately if anoil leak is detected.

FIRE

To avoid injury from fire, do notsmoke or allow open flames whenworking on an operating engine.

FIRE

To avoid injury from fire from abuildup of volatile vapors, keepthe engine area well ventilatedduring operation.


IDENTIFICATION

IDENTIFICATION

The MBE 4000 engine is built inaccordance with sound technologicalprinciples and based on state-of-the-arttechnology. It complies with all UnitedStates Environmental Protection

Agency (USEPA) and California AirResources Board (CARB) emissionstandards. An emission label isattached to the cylinder head cover, asrequired by law. See Figure 1.

Figure 1 Emission Label, MBE 4000



Despite this, the engine may constitutea risk of damage to property orinjury to persons under the followingconditions:

□ It is not used for its intendedpurpose.

□ It is modified or converted in anincorrect manner.

□ The safety instructions included inthis manual are disregarded.

Personnel RequirementsWork on the engine should be carriedout only by skilled technicians whohave been instructed in the specificskills necessary for the type of workbeing performed.

Engine Conversions andModificationsThe function and safety of the enginecould be affected if unauthorizedmodifications are made to it. DetroitDiesel will not accept responsibilityfor any resulting damage.

Tampering with the fuel injectionsystem and engine electronics couldalso affect the engine's power output orexhaust emission levels. Compliancewith the manufacturer's settingsand with statutory environmentalprotection regulations cannot then beguaranteed.

General View of the MBE4000 EngineFor a general view of the MBE 4000engine, showing major components,see Figure 2 for the left-hand side, andFigure 3 for the right-hand side.


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 Major Engine Components, Left Side



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


IDENTIFICATION

Engine Type PlateThe engine type plate is used toidentify the engine. It is located on theoil filter housing. See Figure 4.

Figure 4 Location of Engine TypePlate

Details on the Plate

The engine type reference, OM 460LA, is the production code. Thefirst three numbers of the engineserial number are the model number.See Figure 5.

Figure 5 Engine Type Plate

The last six numbers are the serialnumbers (745111 in see Figure 5).

NOTE:In addition to the fourteen digit numberetched on the crankcase, there is aten digit number used for warrantyand service that is found on theDDEC-ECU label. The ten digitnumber is derived from the fourteendigit number (see Figure 6).

Figure 6 Engine Serial Number



Engine FeaturesAll MBE 4000 engines arewater-cooled, four-stroke,direct-injection inline diesel engines.Each cylinder has a separate fuelinjection pump (unit pump) with ashort injection line to the injectionnozzle, which is located in the centerof the combustion chamber. The unitpumps are attached to the crankcaseand are driven from the camshaft.Each cylinder has two intake valvesand two exhaust valves.

Charge-air cooling and an exhaust gasturbocharger are standard equipment.

The engine has a fully electroniccontrol system consisting of aDDEC-ECU (Engine Control Unit)and a DDEC-VCU (Vehicle ControlUnit) connected by a proprietarydatalink. This system regulates theinjection quantity and timing usingsolenoid valves, allowing extremelylow-emission operation.

Standard engine braking is controlledby a pneumatically-operatedexhaust brake on the turbochargerand by a hydraulically-operatedconstant-throttle system. For greaterbraking power, an optional turbobrake is available.

The cylinder block has integrated oiland water channels. The upper sectionof the cylinder bore has a carbonscraper ring seated in a groove onthe top part of the cylinder. The six

individual cylinder heads are made ofcast iron. The cylinder head gasket isan adjustment-free seal with rubbersealing elements.

The pistons are made of aluminumalloy with ring carriers and a shallowcombustion chamber recess. Thepistons are cooled by oil spray nozzles.

The crankshaft is precision-forgedwith seven main bearings and eightcustom-forged counter weights, and avibration damper at the front end.

The camshaft is made ofinduction-hardened steel and hasseven cam bearings. Each cylinderhas cams for intake and exhaust valvesand a unit pump.

The valves are controlled by rollertappets, pushrods, and rocker arms.The intake and exhaust valves areopened and closed by a free-floatingvalve bridge.

There is a force-feed lubricating oilcircuit supplied by a gear-type oilpump. This pump is positioned at therear of the oil pan and driven by gearsfrom the crankshaft. The oil heatexchanger is integrated with the oilfilter housing on the right-hand side.

The gear-type fuel pump is locatednear the front of the crankcase on theleft hand side. The pump is drivenfrom the forward end of the camshaft.


IDENTIFICATION

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

The engine is cooled by a closedsystem using recirculated coolant;temperature is regulated automaticallyby a thermostat.

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

The alternator and coolant pump(and any other accessories) and therefrigerant compressor are driven by amain drive belt. The fan is driven byits own drive belt

Electrical equipment includes a starterand an alternator.

ExhaustBrake/Constant-ThrottleValvesTo increase braking performance,the engine is equipped with anexhaust brake on the turbochargerin conjunction with constant-throttlevalves on the cylinder head.See Figure 7.

NOTE:On EGR engines, the constant-throttlevalves are activated by engine oilpressure.

The exhaust back pressure is used bythe exhaust brake to increase brakingperformance.

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



The constant-throttle valves use theair that escapes through them on thecompression stroke to provide brakingforce. The constant throttles are smallvalves which are built into the cylinderheads. When open, a link is createdbetween the combustion chamber andthe exhaust port.

The engine brake is activated by theDDEC-VCU. In engine braking mode,an engine rpm range of up to 2,500rpm can be used by the operator.2,500 rpm, however, may never beexceeded. The engine is turned offautomatically when the engine rpm is:

□ Below 900 rpm for AllisonAutomatic Transmissions

□ Below 1100 rpm for all othertransmissions

Also, the engine brake is automaticallyturned off when the accelerator pedalis pressed.

NOTE:When in emergency running mode(constant rpm), the engine brake canbe activated only when the engine isin overrun. When constant rpm hasbeen attained, the engine brake isautomatically turned off.

Turbo Brake, OptionalFor high braking output, the MBE4000 engine can be equipped with anoptional turbo brake. The turbo brakeincreases the air mass flow through the

engine to provide very high brakinghorsepower.

The turbo brake can be operated eithermanually or automatically, throughthe cruise control function.

Because the charge air pressure ismaintained at a high level duringbraking, full throttle response isavailable immediately, if the operatordesires it, without any turbo lag.

The turbo brake is maintenance-free,highly reliable, and adds virtually noweight to the engine.

Exhaust Gas RecirculationThe purpose of the Exhaust GasRecirculation (EGR) System is toreduce engine exhaust gas emissionsin accordance with EPA regulations.

The MBE 4000 engines foron-highway EPA 2004 regulationapplications use a cooled EGR systemconsisting of an EGR cooler, EGRcontrol valves, reed valves, and anEGR mixer.

In the cooled EGR system, part of theexhaust gasses from the front threecylinders are routed from the exhaustmanifold through the EGR cooler, pastcontrol and reed valves, and are mixedwith the intake manifold charge air.


IDENTIFICATION

The addition of cooled exhaustgasses back into the combustionairflow reduces the peak in cylindercombustion temperature. Less oxidesof nitrogen (NOx) are produced atlower combustion temperatures.

The recycled exhaust gases are cooledbefore engine consumption in a tubeand shell engine water cooler.

Electronic Engine ControlSystemThe engine is equipped with a fullyelectronic control system. See Figure8.

Figure 8 Electronic Engine Control System

This system is composed of theDDEC-ECU (Engine Control Unit)

and the DDEC-VCU (Vehicle ControlUnit).



The two control units are connected bya proprietary datalink through whichall necessary data and informationcan be exchanged. The DDEC-VCUthen broadcasts all information on theJ1587 and J1939 datalinks, where itcan be read by minidiag2, the Nexiq™Diagnostic Data Reader (DDR) orDetroit Diesel Diagnostic Link®(DDDL) PC software.

The DDEC-ECU monitors boththe engine and the datalink. Whena malfunction or other problemis detected, the system selects anappropriate response; for example,the emergency running mode maybe activated. For more informationon the emergency running mode,refer to the “Emergency RunningMode” section under “Operations.”

DDEC-ECU — Engine-ResidentControl Unit

The DDEC-ECU (see see Figure 9)is located on the left-hand side of theengine.

The DDEC-ECU processes the datareceived from the DDEC-VCU, forexample the position of the acceleratorpedal, engine brake, etc.

Figure 9 DDEC-ECU

These data are evaluated togetherwith the data from the sensors onthe engine, such as coolant andfuel temperature and oil and chargepressure.

The data is then compared to thecharacteristic maps or lines stored inthe DDEC-ECU.

From these data, quantity and timingof injection are calculated and theunit pumps are actuated accordinglythrough the solenoid valves.

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

The DDEC-ECU data label has the 10digit engine serial number (see Figure6), the engine horse power and torque.


IDENTIFICATION

Vehicle Control Unit

The DDEC-VCU, see Figure10, communicates with the otherelectronic control units installed onthe vehicle over the J1587 and J1939data link.

Figure 10 DDEC-VCU

Sets of data for specific applicationsare stored in the DDEC-VCUincluding idle speed, maximumrunning speed, and speed limitation.

The DDEC-VCU receives data fromthe following sources:

□ The operator (accelerator pedalposition, engine brake switch)

□ Other electronic control units (theantilock brake system)

□ The DDEC-ECU (oil pressure andcoolant temperature)

From these data, instructions arecomputed for controlling the engine

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

The DDEC-VCU controlsvarious systems, for example,communications with the datalink andthe engine brake.

If the engine control system detectsa fault, the appropriate fault code isbroadcast on the datalink and can beread using minidiag2, the Nexiq DDRor DDDL PC software. Fault codeinformation may also be available onthe vehicle or equipment instrumentpanel.

Sensor Locations

Use caution when handling thesensors.

CHEMICAL BURNS

To avoid injury from chemicalburns, wear a face shield andneoprene or PVC gloves whenhandling sensor hoses.

The Engine Oil Pressure/TemperatureSensor is located at the base of the oilfilter.

See Figure 11 for sensor locations onthe MBE 4000 engine.



1. Intake Air Pressure/TemperatureSensor

5. Engine Coolant TemperatureSensor

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/TemperatureSensor

Figure 11 Sensor Location


OPERATION

OPERATION

Important: Before starting theengine, carefully read all operatinginstructions in this manual and do allthe recommended pretrip inspectionsand daily maintenance. Check theengine oil and fuel levels, and draincontaminants from the fuel/waterseparator (optional).

Before Starting the EngineNOTE:If you drain the fuel/water separatorcompletely, you may have to prime thefuel system.

Be sure you are familiar with all ofthe instruments, gauges and controlswhich are needed to operate theengine.

Note especially the location andfunction of the following:

□ Oil pressure gauge

□ Low oil pressure warning light

□ Coolant temperature gauge

□ High coolant temperature warninglight

□ Water in fuel warning light

□ Tachometer

□ Air restriction indicator

Watch for any signs of engineproblems when starting or driving. If

the engine overheats, uses excessivefuel or lubricating oil, vibrates,misfires, makes unusual noises, orshows an unusual loss of power, turnthe engine off as soon as possible anddetermine the cause of the problem.Engine damage may be avoided by aquick response to early indications ofproblems.

When starting the engine in coldweather, refer to the “ ServiceProducts” section.Checking the Batteries

Use only batteries that have beencorrectly filled and serviced. Toprovide corrosion protection, applydielectric grease, part number48-02349-000, liberally to theterminal pads. Approved suppliers arelisted in Table 1.

Manufacturer Lubricant orPart Number

Shell Oil Co. No. 71032; No.71306

Texaco, Inc. No. 955

Quaker State No. NYK-77

Table 1 Approved ElectricalLubricants



Battery Explosion and Acid Burn

To avoid injury from batteryexplosion or contact with batteryacid, work in a well ventilatedarea, wear protective clothing,and avoid sparks or flames nearthe battery. If you come in contactwith battery acid:

□ Flush your skin with water.

□ Apply baking soda or lime tohelp neutralize the acid.

□ Flush your eyes with water.

□ Get medical attentionimmediately.

Checking the Oil Level

Check the oil level as follows:

1. Check the oil level using the oildipstick (see Figure 12).

PERSONAL INJURY


Figure 12 Oil Dipstick

2. If necessary, top off by fillingengine oil through the oil fill cap(see Figure 13) to the maximumfill level on the oil dipstick.

Figure 13 Oil Fill Cap

For detailed procedures, refer to the“Maintenance” section.


OPERATION

Checking the Coolant Level(Cold Check)

Check coolant level as follows:

1. Ensure that all coolant plugs inthe bottom of the radiator and onthe radiator outlet pipe are secureand tight.

2. Check the coolant level. Thecooling system is correctly filledwhen the coolant is between themaximum and minimum markson the surge tank.

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

Adding Fuel

When adding fuel, pay attention to thefollowing:

□ Add winter or summer grade fuelaccording to the season of theyear.

□ Work in the cleanest conditionspossible.

□ Prevent water from entering thefuel tank.

For further information, refer to the“Service Products” section.

Priming the Fuel System

Prime the fuel system as follows:

NOTICE:Correct torque on the high pressurelines is critical. Incorrect torquescould result in leaks or lack of powerdue to restricted fuel flow.

1. Make sure that all high-pressureand low-pressure lines aresecurely tightened. For tighteningspecifications, refer to the”Technical Data” section.

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

NOTE:There should be a strong resistancein the hand pump, caused by thepressure buildup within the fuelsystem.

3. Crank the engine for 30 secondsat a time, but no longer. Wait atleast two minutes. The engineshould start within four 30-secondattempts.



Starting the EngineBefore operating the engine, do thework described under "Before Startingthe Engine." Start the engine asfollows:

NOTICE:Never attempt to start anyMercedes-Benz electronic engineusing ether or any other startingfluid. Serious engine damage couldresult.

PERSONAL INJURY

To avoid injury when workingnear or on an operating engine,remove loose items of clothingand jewelry. Tie back or containlong hair that could be caught inany moving part causing injury.

1. Turn on the ignition switch.

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

3. Check the engine for leaks.

[a] Check all hoses, hose clamps,and pipe unions on the enginefor tightness. Shut down theengine and tighten them ifnecessary.

[b] Check the oil feed and returnlines at the turbocharger fortightness. Shut down theengine and tighten them ifnecessary.

4. Shut down the engine.

5. Approximately five minutes aftershutdown, check the engine oillevel. If necessary, add oil up tothe maximum fill level on the oildipstick.

6. Check all the mounting fastenerson the engine for tightness.

Checking the Coolant Level (HotCheck)

Check the coolant levels as follows:

1. Allow the engine to run forapproximately five minutes at amoderate speed.


OPERATION

HOT COOLANT


2. Then, with the coolanttemperature above 50°C (122°F),recheck the coolant level.

3. Add more coolant if necessary.Open the heater valves beforeadding coolant.

4. Do not close the heater valvesuntil the engine has been runbriefly and the coolant levelagain checked and corrected asnecessary.

Starting an Engine That Has NotBeen Run for a Long Time

Before starting an engine which hasnot been run for a long time, certainspecial work must be carried out.Refer to the “Cleaning and Storage”section.

Important: At outside temperaturesbelow –20°C (–4°F), a coolantpreheater is recommended.

1. Chock the tires, place thetransmission in neutral, and setthe parking brake.

2. Turn on the ignition switch andstart the engine

3. If the engine doesn't start after20 seconds, stop. Try again afterwaiting about one minute.

NOTICE:Do not rev the engine if the oilpressure gauge indicates nooil pressure. To avoid enginedamage, shut down the enginewithin approximately ten seconds.Check to determine the cause of theproblem.

4. Monitor the oil pressure gaugeimmediately after starting theengine.

NOTE:Do not place the engine under full loaduntil it reaches operating temperature.



Monitoring EngineOperationWhile the engine is operating, monitorthe battery charge indicator light,the oil pressure and avoid excessiveidling.

Battery Charge

The battery charge indicator light(see Figure 14) must go out once theengine starts.

Figure 14 Battery Charge IndicatorLight

If the indicator light comes onwhile the engine is running, do thefollowing:

1. Shut down the engine.

2. Check the poly-V belt fortightness.

FIRE


3. Do a load test on the batteries.Charge or replace the batteries asneeded.

4. If necessary, visit the nearestauthorized dealer to have thealternator voltage and outputchecked.

Oil Pressure

When the engine has reached itsnormal operating temperature, theengine oil pressure must not dropbelow the following values:

□ 36 psi (250 kPa) at rated speed

□ 7 psi (50 kPa) at idling speed

If oil pressure drops below thesevalues, stop the engine and determinethe cause.


OPERATION

Excessive Idling

Never allow the engine to idle formore than 30 minutes. Excessiveidling can cause oil to leak from theturbocharger.

Changing the Idle SpeedThe rpm range of the MBE 4000engine is 600 to 850 rpm if theparameters in the DDEC-VCU are setto the default range.

Change the idle speed as follows:

1. Turn the cruise control switch tothe OFF position.

2. To increase the idle speed, pushthe "Resume" switch until the idleis fast enough.

3. To decrease the idle speed, pushthe "Decel" switch until the idleis slow enough.

Shutting Down the EngineIf the engine has been running at fulloutput or the coolant temperature hasbeen high, allow the engine to idlefor one to two minutes without load.Then turn off the ignition key switch.

If any the following occur, shut downthe engine immediately.

□ The oil pressure swings back andforth or falls sharply.

□ Engine power and rpm fall, eventhough the accelerator pedalremains steady.

□ The exhaust pipe gives off heavysmoke.

□ The coolant and/or oil temperatureclimb abnormally.

□ Abnormal sounds suddenly occurin the engine or turbocharger.

Shutting Down After High LoadOperation

After high load operation, do thefollowing:

NOTICE:After high load operation, allow theengine to idle for one to two minuteswithout load. Shutting down theengine without idling may causedamage to the turbocharger.

1. If the engine has been runningat full output or the coolanttemperature has been high, allowthe engine to idle for one to twominutes without load.

2. Turn off the ignition switch andshut down the engine.



Emergency Running ModeThe engine is equipped with theelectronic engine control system,which monitors the engine as it isrunning.

As soon as a fault is detected, it isevaluated and one of the followingmeasures is initiated.

NOTICE:To prevent possible serious enginedamage, have any faults correctedwithout delay by an authorizeddealer.

□ In conjunction with any dashboardor instrument panel display, thecode for the electronic controlunit reporting the fault can be readimmediately on the display.

□ Complete fault codes aretransmitted and can be readusing minidiag2, the Nexiq DDRor DDDL PC software.

□ If the fault is serious enough toimpair normal operation, theelectronic engine system switchesover to emergency running mode.When in emergency runningmode, the engine operates at aconstant 1300 rpm. This allowsyou to move the vehicle to aservice location.

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

Stop Engine OverrideOptionThe Stop Engine Override Option isused for a momentary override. TheDDEC-ECU will record the numberof times the override is activated aftera fault occurs.

Momentary Override – A StopEngine Override (SEO) switch is usedto override the shutdown sequence(see Figure). This override resets the60 second (30 seconds for oil pressure)shutdown timer, restoring power to thelevel when the Red Stop Lamp (RSL)was illuminated. The switch must berecycled after five seconds to obtain asubsequent override.

Figure 15 Typical SEO Switch andWarning Lamps

NOTE:The operator has the responsibility totake action to avoid engine damage.


OPERATION

Cold Weather OperationSpecial precautions must be takenduring cold weather. To protect yourengine, special cold weather handlingis required for fuel, engine oil, coolant,and batteries.

Winter Fronts

A winter front may be used to improvecab heating while idling. At least 25%of the grill opening should remainopen in sectioned stripes that runperpendicular to the charge air coolertube flow direction. This assures evencooling across each tube and reducesheader to tube stress and possiblefailure. Winter fronts should only beused when the ambient temperatureremains below -12.2° C (10° F).



CLEANING AND STORAGE

Special precautions should be takenfor a stored engine to protect the itsinterior and exterior.

Cleaning the EngineImportant: Observe all environmentalprotection regulations.

High-Pressure CleaningEquipment

Information on suitable cleaningand protective products is availablefrom any authorized dealer. Note theequipment manufacturer's operatinginstructions.

NOTICE:To prevent damage to enginecomponents, keep the watermoving at all times while cleaning.Never direct water onto electricalcomponents, plug connectors, sealsor flexible hoses.

Comply with the minimum workingdistance between the high-pressurenozzle and the surface being cleaned:

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

□ Approximately 12 inches (300mm) for 25-degree flat jets anddirt cutters

Cleaning the CoolingSystemImportant: Collect the used coolant,cleaning solutions, and washingliquids and dispose of them in anenvironmentally responsible manner.

Clean as follows:

NOTICE:Clean at moderate pressures only;otherwise the fins of the radiatorgrille could be damaged.

1. First remove debris (dust, insects,etc.) from the fins of the radiatorgrille.

EYE INJURY


2. Remove the debris by blowingthem through with compressed airor spraying them out with water.Work from the rear of the radiator(in the opposite direction of thenormal cooling air flow).


CLEANING AND STORAGE

3. Drain the coolant whenthe engine is cold. Fordetailed procedures, see thevehicle/chassis maintenancemanual. For types of coolant,refer to the “Service Products”section.

4. If the HVAC unit is connectedto the cooling system, open theregulating valves all the way.

Degreasing

Degrease as follows:

1. Fill the cooling system with a 5%solution (1.6 ounces per quart ofwater—50 grams per liter) of amildly alkaline cleaning agent,such as sodium carbonate.

2. Run the engine at moderate speeduntil the thermostat starts to open,at an operating temperature ofapproximately 80°C (176°F).Then run it for about five minuteslonger. Shut down the engine andallow it to cool to approximately50°C (112°F).

HOT COOLANT


3. Drain all the cleaning solution.

4. Flush the cleaning solution fromthe cooling system.

[a] Immediately after drainingthe cleaning solution, flushthe system with clean water.

[b] Once the clean water hasdrained, fill the system againwith clean water.

[c] Run the engine. Allowthe engine to warm up toapproximately 80°C (176°F),and then run it about fiveminutes longer.

[d] Drain the hot water.

5. Fill the cooling system with newcoolant. For detailed procedures,see the vehicle/chassismaintenance manual. Fortypes of coolant, refer to the“Service Products” section.



StorageRequired protective measures for theMBE 4000 engine depend on thefollowing:

□ The length of time that the enginewill be out of service

□ The climate and conditions wherethe engine is stored

After cleaning, engines should,whenever possible, be placed in a dry,well-ventilated place.

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

If the engine is to be out of servicefor 12 months or less, anticorrosionmeasures are not necessary, providedthat the place of storage are dry andwell-ventilated as described above.

If the engine is to be out of servicefor over 12 months, or underextraordinary storage or transportationconditions, then special protectivemeasures are necessary. Informationis available from any authorizeddealer. It is strongly recommendedthat you request this information.

NOTE:If the engine is to be out of servicefor over 18 months, the oil must bechanged before the engine can bebrought back into service.


TROUBLESHOOTING

TROUBLESHOOTING

In addition to operating the enginecarefully and maintaining it properly,make sure to correct any malfunctionpromptly.

Emergency StartingFor emergency starting procedures(jump starting), see the driver'smanual under the heading "EmergencyStarting With Jumper Cables."

Troubleshooting theElectronic Engine ControlSystemWhen the electronic engine controlsystem detects a fault, it broadcastsa message on the datalink. The dashdisplay will show the code "ECU128," indicating there is an enginefault.

Important: To read the completefault code, bring the vehicle to anauthorized dealer. Complete faultcodes can be read using minidiag2, theNexiq DDR or DDDL PC software.

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



General TroubleshootingThe tables that follow are designedto identify the causes of commonproblems, suggest further checks andappropriate remedies. When dealerservice is necessary, this is mentionedin the table.

NOTE:Remember to follow all cautions whentroubleshooting the engine.

Problem - The Engine Will Not Crank

Cause Remedy

The batteries are damaged or weak. Test the batteries. Replace them, ifneeded.

The ignition switch is damaged. Replace the ignition switch.

The battery cables are damagedand/or corroded. Replace the battery cables.

The starter is damaged and/or worn. Have an authorized dealer replace thestarter.

The clutch or transmission isdamaged.

Bring the vehicle to an authorizeddealer for service.

There is internal damage to theengine.



TROUBLESHOOTING

Problem—The Engine Turns Over Slowly

Cause Remedy


The ignition switch is damaged. Replace the ignition switch.

The battery cables are damagedand/or corroded Replace the battery cables.

The starter is damaged and/or worn. Have an authorized dealer replace thestarter.

The engine oil does not meet thecorrect specifications.

Change the engine oil, using thecorrect type of oil.

The transmission fluid does not meetthe correct specifications.

Change the transmission fluid, usingthe correct type of fluid.



Problem—The Engine Cranks, But Won't Start

Cause Remedy


The cranking speed is not set correctly. Bring the vehicle to an authorizeddealer 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 ismalfunctioning.

Check the intake air preheater, andreplace it, if necessary.

The camshaft TDC sensor and/or thecrank angle position sensor are out ofadjustment.

Push both sensors into their holes asfar as they will go. If this does notsolve the problem, bring the vehicle toan authorized dealer for service.

The camshaft TDC sensor and/orthe crank angle position sensor aredamaged.


There is air in the fuel system.Check the fuel lines for air pockets.Bleed the fuel system and start theengine.

The air filter is clogged. Clean or replace the air filter.

The fuel filter is clogged. Replace the filter element.

The exhaust brake valve ismalfunctioning.

Have an authorized dealer check theoperation of the valve.

The valves are not adjusted properly. Check the valve lash.

There are other problems in the fuelsystem.



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, ifnecessary.

There are leaks in the fuel lines. Check the fuel lines for leaks andrepair them, if necessary.


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

Clean and bleed the system. Havethe fuel lines and filters checked by anauthorized dealer.









Problem—The Engine Starts, But Dies

Cause Remedy

The fuel tank is low or empty. Add fuel and bleed the fuel system, ifnecessary.


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

Clean and bleed the system. Havethe fuel lines and filters checked by anauthorized dealer.





The constant-throttle valves aremalfunctioning.




Problem—The Engine Fan Doesn't Work

Cause RemedyThe fan hub is damaged. Replace the fan hub.

The fan wiring is damaged. Repair the fan wiring.

The parameter settings in theDDEC-ECU or DDEC-VCU areincorrect.

Have an authorized dealer reprogramthe control unit.


TROUBLESHOOTING

Problem—The Engine Fan Is Constantly On

Cause Remedy

The fan override switch is on. Check the operation of the fan overrideswitch.

The fan hub is damaged. Replace the fan hub

The parameter settings in theDDEC-ECU or DDEC-VCU areincorrect.

Have an authorized dealer reprogramthe control unit.

AC switch is damaged Check AC switch.

Problem—Fuel Consumption Is Too High

Cause RemedyThe tires are not properly inflated. Check all tires for correct pressure.

The air filter and/or intake air systemis clogged.

Check the air restriction indicator.Clean the intake air system andreplace the air filter if necessary.




The engine performs poorly, or doesnot develop full power.

The remedies are listed in "The EnginePerforms Poorly, Does Not DevelopFull Power."



Problem—The Engine Performs Poorly, Does NotDevelop Full Power

Cause Remedy






There are other problems with the fuelsystem.


The valves are not adjusted properly Check the valve lash.

The coolant temperature sensor isdamaged or reading incorrectly.


The fuel temperature sensor isdamaged or reading incorrectly.


The engine oil temperature sensor isdamaged or reading incorrectly.


The charge-air temperature sensor isdamaged or reading incorrectly.


There are problems with theDDEC-ECU or DDEC-VCU.





TROUBLESHOOTING

Problem—The Engine Is in Emergency Running Mode(constant speed 1,300 rpm)

Cause RemedyThe DDEC-ECU or DDEC-VCU isdamaged.


An incorrect parameter is in theDDEC-ECU or DDEC-VCU.

Bring the vehicle to an authorizeddealer and have the parametersettings reprogrammed in theDDEC-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 asneeded.

The poly-V belt is loose. Tighten or replace the poly-V belt.

The coolant temperature gauge and/orsensor is not reading correctly.


The radiator is damaged or dirty. Clean the radiator. Repair or replacethe radiator if necessary.

The coolant pump is damaged. Have an authorized dealer replace thecoolant pump.

The thermostat is damaged. Have an authorized dealer replace thecoolant pump.

The fan is not operating properly.

Bring the vehicle to an authorizeddealer and have the fan hub checkedor have the parameter settingsreprogrammed in the DDEC-ECU orDDEC-VCU.



Problem—The Coolant Temperature Is Below Normal

Cause RemedyThe coolant temperature gauge and/orsensor is not reading correctly.


The thermostat is damaged. Have an authorized dealer replace thethermostat.

The fan is not operating properly.

Bring the vehicle to an authorizeddealer and have the fan hub checked.Bring the vehicle to an authorizeddealer and have the parametersettings reprogrammed in theDDEC-ECU or DDEC-VCU.

Problem—The Cooling System Is Losing Coolant

Cause RemedyThere is an external coolant leak. Repair the leaking component.

The radiator cap is leaking. Replace the radiator cap.

The air compressor head is damaged. Have an authorized dealer replace theair compressor.

The cylinder head gasket is leaking. Have an authorized dealer replace thehead gasket.

Problem—There Is Coolant in the Engine Oil

Cause Remedy

The cylinder head gasket is damaged. Have an authorized dealer replace thehead gasket.

The oil/water heat exchanger isleaking.

Have an authorized dealer replace theheat exchanger.

There is an internal coolant leak. Bring the vehicle to an authorizeddealer for service.


TROUBLESHOOTING

Problem—There Is Foam in the Engine Oil

Cause RemedyThe oil level is too low or too high. Correct the oil level.

The oil has not been changed withinthe recommended interval. Change the oil.

The oil is not of the recommendedquality. Change the oil.

Problem—The Engine Oil Pressure Is Low

Cause RemedyThe oil pressure gauge and/or sensoris not reading correctly.


There is fuel in the oil. Bring the vehicle to an authorizeddealer for service.

The oil filter is clogged. Replace the filter element.

The oil filter bypass valve is damaged. Replace the bypass valve.

The oil pump and/or relief valve isdamaged.

Have an authorized dealer replace theoil pump.

Problem—The Engine Exhaust Is White

Cause RemedyThe fuel is of poor quality. Add fuel of the right quality.


Check the intake air preheater, andreplace it, if necessary.




Problem—The Engine Exhaust Is Black

Cause Remedy






Check that the heater is not staying onall of the time.


There is damage to the fuel system:the fuel pump, one or more fuelinjectors, or one or more unit pumpsare damaged.


The charge-air temperature sensor isdamaged.




Problem—The Engine Exhaust Is Blue

Cause RemedyThe engine oil level is too high(engine oil is reaching the combustionchamber).

Adjust the oil level, and then have theoil level checked by an authorizeddealer.

The turbocharger is leaking oil. Have an authorized dealer replace theturbocharger

The valve stem seals are loose ordamaged.

Have an authorized dealer replace theseals.

The piston rings are worn. Have an authorized dealer replace thepiston rings.


TROUBLESHOOTING

Problem—Engine Brake Performance Is Poor

Cause RemedyThe engine brake control switch isdamaged. Replace the switch

The exhaust brake is not operatingproperly.


The constant-throttle valves aremalfunctioning.


Components of the DDEC-ECU and/orDDEC-VCU are damaged.


Problem—Cruise Control Is Not Working

Cause RemedyOne or more of the cruise controlswitches are damaged. Replace the damaged switch.

Components of the DDEC-ECU and/orDDEC-VCU are damaged or notworking properly.


Problem—The Battery Charge Indicator Light Does NotCome On When the Engine Is Not Running

Cause RemedyThe bulb is damaged. Change the bulb.

The circuit is broken. Repair the break in the circuit.



Problem—The Battery Charge Indicator Light ComesOn 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 thebelt tensioner.

The belt tensioner is damaged. Have an authorized dealer replace thebelt tensioner.

The poly-V belt is worn or damaged. Replace the belt.

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

Have an authorized dealer replace thealternator.


SERVICE PRODUCTS

SERVICE PRODUCTS

Carefully match together thecomponents of the engine with thelubricants they need. Use only brandswhich have been tested and approvedby DDC. Information is availablefrom any authorized dealer.

Do not use special lubricant additives.None are needed, and the use ofadditives could affect warranty.

Important: Dispose of serviceproducts in an environmentallyresponsible manner. This includes anyparts which have been in contact withthem (for example, filters). Reclaimthem or recycle them, if possible,and be sure to comply with all legaldisposal requirements.

Diesel FuelsUse only commercially availablevehicle diesel fuel. Grades such asmarine diesel fuel, heating oil, andothers are not permissible.

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

If using diesel fuel with a high sulphurcontent, exceeding 0.5 percent byweight, change the engine oil atshorter intervals.

Fuel added from drums or cans couldbe contaminated. This could leadto malfunctions in the fuel system.

Always filter the fuel before addingit to the tank.

For information about fuel in coldweather operation, see the heading"Winter-Grade Diesel Fuel" later inthis chapter.

Flow Improvers

The effectiveness of flow improvers isnot guaranteed with all fuels. Complywith the product manufacturer'srecommendations. Any authorizeddealer can provide information onapproved flow improvers.

Kerosene

Keep the quantity added as low aspossible, bearing in mind the outsidetemperature.

The addition of five percent byvolume of kerosene will improvethe fuel's resistance to cold by about1°C (1.8°F). Never add more than 50percent kerosene to the fuel.



NOTICE:For safety reasons, add thekerosene to the diesel only in thefuel tank. Add the kerosene first,then the diesel. Run the engine fora short time to allow the mixture toreach all parts of the fuel system.

Engine OilsThe engine is delivered from thefactory filled with an approved engineoil.

NOTICE:The use of non-approved engineoils could affect warranty rights, andcause engine damage.

Only multigrade oils of AmericanPetroleum Institute (API) servicedesignation CI-4 will achieve properperformance for the cooled EGRengines. Look for the servicemark printed on the oil container.See Figure 16.

Figure 16 API Lubricant ServiceMark

When maintenance work is performed,record engine oil changes includingdetails of the brand used, thequality category, and the Societyof Automotive Engineers (SAE)viscosity rating of the oil. Whentopping off, use only engine oils ofthe correct API designation and SAErating.

For information about oil in coldweather operation, see the heading"Low-Viscosity Engine Oil" later inthis chapter.

Synthetic Oils

Synthetic oil may be used in MBE4000 engines, provided they are of thecorrect API designation and viscosity,as required for non-synthetic oil.


SERVICE PRODUCTS

Synthetic oil offers improvedlow-temperature flow propertiesand high-temperature resistance tooxidation. However, it is generallymore costly than non-synthetic oil.

Review carefully the productinformation published by the syntheticoil manufacturer. Performanceadditive systems often responddifferently in synthetic oil. Use ofsynthetic oil does not change therecommended oil change serviceinterval.

CoolantCoolant is a mixture of water andantifreeze. Under normal conditions,it is a mixture of 50 percent waterand 50 percent antifreeze, but underextreme cold weather conditions, asmuch as 60 percent antifreeze can beadded. For reasons of anticorrosionprotection and to raise the boilingpoint, the coolant must remain in thecooling system all year round.

Regardless of mileage, replacethe coolant every two years sincethe degree of corrosion protectiongradually drops with time.

Fully-Formulated Antifreeze

Antifreeze approved for use in theMBE 4000 engine is a mixture ofglycol compound (ethylene glycol),and corrosion inhibitors. Antifreeze

containing glycol compounds andcorrosion inhibitors is known asfully-formulated antifreeze.

NOTICE:Do not use propylene glycol.

Fully-formulated antifreeze has thefollowing properties:

□ It protects the radiator and enginefrom freezing.

□ It provides protection againstcorrosion and cavitation for allcomponents in the cooling system.

□ It raises the boiling point of thecoolant. This slows the rate ofevaporation, avoiding coolant lossat high temperatures.

Water

Water containing no additives isnot suitable as a coolant, even if noantifreeze protection is needed.

The water used in the coolant mustcomply with certain requirements,which are not always satisfied bydrinking water. If water quality isinadequate, the water must undergosuitable treatment.

The following types of water arepreferred for use in coolant:

□ Distilled water

□ Water purified by reverse osmosis



□ De-ionized water

NOTICE:In some areas, tap water cancontain high levels of dissolvedchlorides, sulfates, magnesium, andcalcium, causing scale deposits,sludge deposits and/or corrosion.These deposits can damage thecoolant pump and allow the engineto overheat.

Coolant Specifications

To avoid damage to the coolingsystem, use only an approvedcorrosion-inhibiting antifreeze.Approved antifreeze must befully-formulated and comply with

the requirements of the TruckMaintenance Council (TMC). Coolantspecifications are listed in Table 2.

Coolant Concentration

When topping off the cooling systemafter a drop in the coolant level, theconcentration of corrosion-inhibitingantifreeze in the coolant must be50 percent by volume. This affordsprotection down to a temperature of–37°C (–34°F). The cooling mixingratio is listed in Table 3.

NOTE:If the concentration is too low, thereis risk of corrosion/cavitation in thecooling system.

Type of Coolant RequirementFully-Formulated Ethylene Glycol TMC RP-329 Type "A"

Water plus Corrosion Inhibitors Temperature Must Not Fall Below0°C (32°F)

Table 2 Coolant Specifications

Antifreeze ProtectionDown to °C (°F)

Water %by Volume

Corrosion - InhibitingAntifreeze % by Volume

–37 (–34) 50 50

–52 (–62) 40 The cooling mix ratio is Max. 60

Table 3 Coolant Mixing Ratio


SERVICE PRODUCTS

For information about coolant incold weather operation, see theheading "Winter Coolant AntifreezeProtection" later in this chapter.

Supplemental Coolant Additivesfor Fully Formulated Coolant

The concentrations of some inhibitorswill gradually deplete during normalengine operation. SCAs replenishthe protection for cooling systemcomponents. The coolant mustbe maintained with the properconcentration of SCA. Detroit DieselPower Cool maintenance SCAs arerecommended.

NOTICE:Failure to properly maintain coolantwith SCA can result in damageto the cooling system and itsrelated components. Conversely,over-concentration of SCA inhibitorcan result in poor heat transfer,leading to engine damage.Always maintain concentrations atrecommended levels. Do not usetraditional SCAs with OAT coolant.

The proper application of SCA willprovide:

□ pH control

□ Restored inhibitor levels to preventcorrosion

□ Water-softening to deter formationof mineral deposits

□ Cavitation protection to protectwet sleeve cylinder liners

Dropout

Excessive amounts of some corrosioninhibitors can cause a gel or crystallinedeposit that reduces both heat transferand coolant flow. This deposit iscalled "dropout."

Dropout takes the color of the coolantwhen wet, but becomes a white or graypowder when dry. It can pick up solidparticles in the coolant and becomegritty. It will cause premature wearof the coolant pump seals and othercomponents of the cooling system.

The wet gel can be removed using analkaline (non-acid) cleaner containingeither sodium nitrite or sodiumtetraborate.

If the gel is allowed to dry, it isnecessary to disassemble the engineand clean it with a caustic solution,or physically clean the individualcomponents.

Non-Approved Coolants

The following types of coolant arenot approved for use in MBE 4000engines:

□ Antifreeze or coolant containingphosphate can cause dropout,



overheating, and damage tocoolant pump seals.

□ Automotive coolants offer noprotection against liner pitting,and generally contain high levelsof phosphate and silicate.

□ Antifreeze based on methyl alcoholcan damage the non-metalliccomponents of the cooling system.They are not suitable for use withdiesel engines because of theirlow boiling point.

□ Antifreeze based on methoxypropanol is not compatible withthe fluoroelastomer seals used inthe cooling system.

□ Glycol-based HVAC coolantscontain phosphates which candeposit on hot internal enginesurfaces and reduce heat transfer.

Recycled Antifreeze

Recycled antifreeze that complies withTMC RP-329 Type "A" (for ethyleneglycol) is approved for use in MBE4000 engines. The antifreeze mustbe recycled by distillation, reverseosmosis, or ion exchange.

Other recycled antifreeze, especiallyany antifreeze recycled by means offiltration processes, is not approved.

Corrosion Inhibitors

NOTICE:Do not mix types of corrosioninhibitors. Do not add additionalinhibitors to new, fully-formulatedantifreeze, or coolant containingnew, fully-formulated antifreeze.This can cause deposits or dropoutin the cooling system.

The following types of corrosioninhibitors are approved for use inMBE 4000 engines:

□ Supplemental Coolant Additives(SCAs)

□ Organic Acid Technology (OAT)Inhibitors

Corrosion inhibitors are veryimportant in maintaining enginelife. All corrosion inhibitors protectagainst corrosion caused by acid,and cavitation of wet cylinder liners.SCAs also protect against mineraldeposits.

The concentrations of some inhibitorswill gradually diminish during normalengine operation. To protect theengine, nitrite concentration mustbe checked at regular intervals, andinhibitors added as necessary. Theintervals are longer if OAT inhibitorsare used.


SERVICE PRODUCTS

NOTICE:Always maintain inhibitor at therecommended level. Failure toproperly maintain coolant with SCAcan result in damage to the coolingsystem and related components.Over-concentration of SCA inhibitorcan result in poor heating transferand lead to engine damage.

The following types of inhibitor mustnot be used in MBE 4000 engines:

□ Soluble oil additives cause poorheat transfer and lead to enginedamage.

□ Chromate additives can lead tothe build-up of "green slime"(chromium dioxide) in the engine,leading to engine damage.

Disposal

Coolants are biologically degradablesubstances.

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

Consult the local water supplyauthorities to determine the bestmethod of disposal.

A modern engine coolant has complextasks to perform. Do not allow anyform of "reprocessing" which consistsonly of mechanical purification.

Cold Weather ProductsSpecial precautions must be takenduring cold weather. To protect yourengine, take the following specialmeasures in cold weather.

□ Use the recommended coldweather fuel and engine oil.

□ Check the concentration ofantifreeze in your coolant.

□ Take special care of the batteries toensure proper cranking amperage

Winter-Grade Diesel Fuel

At low outside temperatures, paraffinmay separate from the diesel andaffect its ability to flow freely. Avoidbreakdowns caused by this problem(for example, blocked filters) by usingcold-resistant winter-grade dieselfuel with improved low-temperatureflow characteristics. In most cases,winter-grade fuel can be used withoutproblems at cold outside temperatures.

If using summer-grade fuel or a lesscold-resistant winter grade, a flowimprover or kerosene can be added.The amount needed depends on theoutside temperature.

Flow improver or petroleum spiritmust be mixed with diesel fuelbefore its flow characteristics havebeen adversely affected by paraffinseparation.



If changes have already been causedby paraffin separation, they can becorrected only by heating the entirefuel system.

Do not add anything to cold-resistantwinter-grade diesel fuels. The fuel'slow-temperature flow characteristicscould actually deteriorate withadditives.

FIRE

To avoid increased risk of a fuelfire, do not mix gasoline anddiesel fuel.

Low-Viscosity Engine Oil

When changing the engine oil,estimate the interval before yournext oil change. Choose an oilfrom the SAE viscosity classwhich corresponds to the outsidetemperatures anticipated during thisperiod of operation. See Figure 17.

Winter Coolant AntifreezeProtection

Before the temperature dips belowfreezing, check the concentration ofantifreeze in the coolant. If necessary,increase it.

Do not increase the proportion(mixing ratio) of corrosion-inhibitingantifreeze beyond 55 percent by

volume (this gives the maximumantifreeze protection). Furtherincreases in the mixing ratio wouldreduce the level of antifreezeprotection and adversely affect thecoolant's ability to dissipate heat.

Figure 17 Engine Oil TemperatureRanges

Batteries

Batteries should receive morefrequent maintenance and rechargingduring the cold season of the year.Careful maintenance and low currentconsumption will help to maintain thefull battery charge. Starting capacitydrops severely in cold weather. At–10°C (14°F) starting capacity isabout 60 percent of normal. If theengine is shut down or out of usefor an extended period of time, storethe batteries out of the vehicle in aheated area if possible. Ensure goodventilation when recharging.


TECHNICAL DATA

TECHNICAL DATA

General technical information islisted in Table 4.

Description MBE 4000 Engine

Engine Type Vertical, inline cylinder block withturbocharger 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 17.75:1

Starting Speed Approximately 100 rpm

Direction of Engine Rotation (viewedfrom flywheel) Counterclockwise

Starter Electric Motor

Table 4 General Technical Information



Engine DataThe engine weights are listed in Table5. The engine dimensions (readyfor shipment) are listed in Table 6.Also see Figure 18 and Figure 19.Coolant capacities are listed in Table7. Lubricating oil capacitiesarelisted in Table 8.

Engine Engine DryWeight

6-Cylinder 960 kg (2117 lb)

Table 5 Engine Weights

Figure 18 Side View

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.)

Table 6 Engine Dimensions

Figure 19 Front View

Description MBE 4000 EngineCoolant Capacity* Max. 70 L (74 qt)

*Does not include capacity of cooling system.

Table 7 Coolant Capacity


TECHNICAL DATA

Description Oil Pan Capacity Oil System FillCapacity †

EGR engines w/frontSump * 36 L (38 qts) 39.5 L (41.7 qts)

Non-EGR Enginesw/front Sump & Right

Hand Drive ExportApplications *

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 Enginesw/front Sump & Left

Hand Drive Applications40.0 L (42.3 qts) 43.5 L (46.0 qts)

Front Sump Engine s/n833529 and below 40.0 L (42.3 qts) 43.5 L (46.0 qts)

* Engine s/n 833530 and above† Including oil filter.

Table 8 Lubricating Oil Capacity

Testing and AdjustingValuesValve lash checking and adjustmentsare listed in Table 9. Engine Oil

Pressure is listed in Table 10.Coolant thermostat conditions arelisted in Table 11. Injector pressuresare listed in Table 12.

Valve Type Check For:mm (in.)

Adjust To:mm (in.)

Intake 0.30 to 0.60 (0.012 to 0.024) 0.40 (0.016)

Exhaust 0.50 to 0.80 (0.020 to 0.032) 0.60 (0.024)

Table 9 Valve Lash Checking and Adjustment



Engine Speed Minimum PressureAt idling rpm 50 kPa (7 psi)

At maximum rpm 250 kPa (36 psi)

Table 10 Engine Oil Pressure

Condition SpecificationStarts to open 81 to 85°C (177 to 185°F)

Fully open 95°C (203°F)

Minimum lift 8 mm (0.3 in.)

Table 11 Coolant Thermostat

Opening Pressure Value in kPa (Psi)Minimum opening pressure 25500 (3698)

Maximum opening pressure 27000 (3916)

Table 12 Injector Pressures


MAINTENANCE

MAINTENANCE

When performed on a regular basis,changing the engine oil and filters isthe least costly way of obtaining safeand reliable vehicle operation. Addedbenefits and savings occur when youcheck that the valves, fuel injectors,and oil and cooling circuits are in goodworking order during oil changes.

The maintenance section of thismanual explains when you shouldchange your oil and what to look forwhen checking for wear or damage.

For additional information, pleasecontact Detroit Diesel TechnicalService.

Scheduled IntervalsAll service intervals and maintenanceoperations are based on the parts andaccessories expressly approved foryour engine.

The scope and frequency ofmaintenance work are determinedby the engine's operating conditions:severe duty, short haul, or long haul.

Evidence of regular maintenance isessential if a warranty claim has to besubmitted.

If optional equipment is installed, besure to comply with the maintenancerequirements for these extra items.

Important: If the engine is stored formore than 18 months, the oil mustbe changed before the engine can bebrought into service.

Maintenance Schedule Types

There are three types of maintenanceschedule:

□ Schedule I (Severe Service)

□ Schedule II (Short Haul)

□ Schedule III (Long Haul)

To determine which schedule to use,find the distance traveled by thevehicle in a year, regardless of vehicletype.

Severe Service — Applies tovehicles that annually travel up to6000 miles (10,000 kilometers) orthat operate under severe conditions.Examples of Severe Service usageinclude: operation on extremely poorroads or where there is heavy dustaccumulation; constant exposureto extreme hot, cold, salt-air, orother extreme climates; frequentshort-distance travel; construction-siteoperation; city operation (fire truck,garbage truck); or farm operation.



Short-Haul — Applies to vehiclesthat annually travel up to 60,000 miles(100,000 kilometers) and operateunder normal conditions. Examplesof Short-Haul usage are: operationprimarily in cities and denselypopulated areas; local transport withinfrequent freeway travel; or highpercentage of stop-and-go travel.

Long-Haul — Long Haul(over-the-road transport) is forvehicles that annually travel more than60,000 miles (100,000 kilometers),with minimal city or stop-and-gooperation. Examples of Long-Haulusage are: regional delivery thatis mostly freeway miles; interstatetransport; or any road operation withhigh annual mileage.

Maintenance Schedule andInterval Operations — The threedifferent schedules of vehicle usage(severe, short haul, and long haul) arelisted in Table 13. For each schedule,the appropriate distance interval(in miles and kilometers) is givenfor performing and repeating eachmaintenance operation.

The descriptions of all maintenanceoperations, indicating all maintenanceoperation sets at which each operationmust be performed are listed in Table14, Table 15, and Table 16.

Maintenance Intervals — Thethree maintenance interval tables showwhich maintenance operation mustbe performed at the actual distances(in miles or kilometers) for eachmaintenance operation. The scheduleof actual distances is based on theintervals given in the MaintenanceSchedule Table (Table 13).

The three maintenance interval tablesare:

□ Maintenance Interval Table,Severe Service (Table 14)

□ Maintenance Interval Table, ShortHaul (Table 15)

□ Maintenance Interval Table, LongHaul ( Table 16)

Maintenance Operation Sets —Each Maintenance OperationsSets Table (M1 through M4) lists thedescriptions of only those maintenanceoperations that must be performed atthat maintenance operation set. Eachmaintenance operation set is listed ina separate Maintenance OperationsTable.

The descriptions of all maintenanceoperations, and the maintenanceoperation sets at which each operationmust be performed are listed in Table17 and Table 18.


MAINTENANCE

Schedule Use

Before placing your new vehiclein service, determine the correctmaintenance intervals that apply toyour intended use of the vehicle. Referto the Maintenance Schedule Tableto determine the distance interval atwhich each maintenance operationmust be performed to comply withyour vehicle's schedule.

When the vehicle reaches the actualdistance given for an interval, referto the Maintenance Interval Tablesto find the Maintenance OperationSet that applies to that interval. Thenperform the maintenance operationslisted in the applicable MaintenanceInterval Operation Table.

Complete each MaintenanceOperation Set at the required interval.For example, when you havecompleted Maintenance OperationSet M3 under the 16th maintenancenumber listed in the MaintenanceInterval Table, repeat the pattern. Forthe 17th maintenance, do MaintenanceOperation Set M1, under the firstmaintenance number listed in theMaintenance Interval Table.

NOTE:For Severe Service, the patternrepeats after 15 maintenancenumbers, not 16 (as for Short Hauland Long Haul).



Maintenance Tables

Maintenance IntervalsMaintenanceSchedule

MaintenanceIntervalOperation Frequency Miles Km

Maintenance 1 (M1) every 10,000 17,000

Optional oilcentrifuge

(change rotor)every 20,000 32,000


first 20,000 32,000

Schedule I(Severe Service)

vehicles thatannually travel

up to 6,000 miles(10,000 km)

Maintenance 3 (M3)then every 40,000 68,000

Maintenance 1 (M1) every 15,000 25 000




first 30,000 50 000Maintenance 3 (M3)

then every 60,000 100,000

Schedule II(Short Haul)vehicles that

annuallytravel up to60,000 miles(100,000 km)






first 50,000 84,000Maintenance 3 (M3)

then every 100,000 167,000

Schedule III(Long Haul)vehicles that

annually travelmore than

60,000 miles(100,000 km)


Table 13 Maintenance Schedule Table


MAINTENANCE

Maint. No MaintenanceInterval Miles Km

1 M1 10,000 17,000

2 M1, M2 and M3 20,000 32,000

3 M1 30,000 50,000

4 M1 and M2 40,000 67,000

5 M1 50,000 84, 000

6 M1, M2 and M3 60,000 100, 000

7 M1 70,000 117,000

8 M1 and M2 80,000 134,000

9 M1 90,000 150,000

10 M1, M2 and M3 100,000 167,000

11 M1 110,000 184,000

12 M1 and M2 120,000 200,000

13 M1 130,000 217,000

14 M1, M2 and M3 140,000 234,000

15 M1 150,000 250,000

16 M1 and M2 160,000 267,000

Table 14 Maintenance Intervals for Schedule I, Severe Service



Maint. No. MaintenanceInterval Miles Km

1 M1 15,000 25 000

2 M1, M2, and M3 30,000 50,000

3 M1 45,000 75,000

4 M1, M2 and M4 60,000 100,000

5 M1 75,000 125,000

6 M1, M2 and M3 90,000 150,000

7 M1 105,000 120,000

8 M1 and M2 120,000 200,000

9 M1 135,000 225,000

10 M1, M2, and M3 150,000 250,000

11 M1 165,000 275,000

12 M1, M2 and M4 180,000 300,000

13 M1 195,000 325,000

14 M1 and M2 210,000 350,000

15 M1 225,000 375,000

16 M1, M2 and M3 240,000 400,000

Table 15 Maintenance Intervals for Schedule II, Short Haul


MAINTENANCE

Maint. No MaintenanceInterval Miles Km

1 M1 25,000 42,000

2 M1, M2, M3and M4 50,000 84,000

3 M1 75,000 125,000

4 M1 and M2 100,000 167,000

5 M1 125,000 209,000

6 M1, M2, and M3 150,000 250 000

7 M1 175,000 292,000

8 M1 and M2 200,000 334,000

9 M1 225,000 375,000

10 M1, M2, M3and M4 250,000 417,000

11 M1 275,000 459,000

12 M1 and M2 300,000 500,000

13 M1 325,000 542,000

14 M1, M2, and M3 350,000 584,000

15 M1 375,000 625,000

16 M1 and M2 400,000 667,000

Table 16 Maintenance Intervals for Schedule III, Long Haul



Operation Description M1 M2 M3Engine 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.

Table 17 Required Maintenance Operations Sets, Schedule I


MAINTENANCE

Maintenance Operation Description M1 M2 M3 M4Engine Inspecting —

Valve Lash Checking and Adjusting† — — —

Fuel /Water Separator Prefilter Element Cleaning —

Main Fuel Filter Element Changing —


Coolant Concentration and Inhibitor LevelChecking

Coolant Flushing and Changing* — — —

Cooling System Inspecting —

Rear Engine Power Take-Off (REPTO) torsionaldamper 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 or1500 hours.

Table 18 Required Maintenance Operations Sets, Schedule II and III



Required MaintenanceOperationsThe following sections describe therequired maintenance operationslisted in Table 17 and listed in Table18.

Engine Inspecting

Inspect engine as follows:

1. Visually check the engine forsigns of leakage. A slightdampness at the sealing points isno cause for concern.

NOTE:More severe leaks, combined with acontinual loss of oil, must be correctedwithout delay.

2. Visually inspect all lines andhoses. Listen for any sound ofleaking. Make sure all pipes andhoses are undamaged, correctlypositioned to avoid chafing, andproperly secured.

Valve Lash Checking andAdjusting

A special engine cranking tool (J46167) is required for this procedure.

NOTE:Adjust the valve lash when the engineis cold. Wait at least 30 minutes aftershutdown, even if the engine ran onlya short time.

Gaining Access To The Valves—Gain access to the valves as follows:

NOTE:Clean the cylinder head covers beforeremoving it.

1. Remove the cylinder head covers.See Figure 20.

Figure 20 Cylinder Head Cover

2. Remove the inspection cover onthe flywheel housing.


MAINTENANCE

3. Fit the cranking tool into theinspection hole on the timingcase. See Figure 21.

Figure 21 Placing Cranking Tool

Choosing A Method — Select amethod for adjusting the valve lash.There are two acceptable methods foradjusting valve lash:

□ In order, according to the timingsequence used for fuel injection(see "Method One—Adjust EachCylinder In Firing Order")

□ By type of valve, depending oncrankshaft position (see "MethodTwo—Adjust All Valves UsingTwo Crankshaft Positions").

See Figure 22 for the cylinder andvalve layout on the MBE 4000 engine.

Figure 22 Cylinder and ValveLayout



Method One — Method one allowsyou to adjust each cylinder in theorder in which fuel is injected. Thecrankshaft must be repositionedafter each cylinder is adjusted aslisted in Table 19.

1. For each cylinder, use thecranking tool to turn over thecrankshaft until the piston isexactly at top dead center (TDC)in the compression stroke. Thevalves must be closed and it mustbe possible to turn the push rodswithout effort.

NOTE:When the piston in cylinder #1 is atignition TDC, the valves of cylinder #6will overlap, meaning that both intakeand exhaust valves are partially open,and show no measurable play whentested with a feeler gauge.

2. Check each valve and adjust it (ifnecessary), using the proceduresunder the headings "CheckingValve Lash" and "Adjusting ValveLash."

Engine Crankshaft Position CylindersIgnition TDC 1 5 3 6 2 4

MBE 4000Valve Overlap 6 2 4 1 5 3

Table 19 Valve Adjustment — Method One


MAINTENANCE

Method Two — Method two allowsyou to adjust all the valves using justtwo crankshaft positions.

1. Using the cranking tool, turn thecrankshaft until cylinder #1 isat the ignition TDC position (allvalves are closed) and cylinder#6 is at the valve overlap position(all valves are open).

2. Check the valves listed in Table20 in the "Ignition TDC" row ofand adjust them (if necessary),using the procedures under theheadings "Checking Valve Lash"and "Adjusting Valve Lash."

3. Using the cranking tool, turn thecrankshaft until cylinder #6 isat the ignition TDC position (allvalves are closed) and cylinder#1 is at the valve overlap position(all valves are open).

4. Using the same procedure, checkthe valves listed in Table 20 in the"Valve Overlap" row and adjustthem (if necessary), using theprocedures under the headings"Checking Valve Lash" and"Adjusting Valve Lash."

Cylinder Valve Types*Engine Cylinder #1 Crankshaft

Position 1 2 3 4 5 6Ignition TDC I/E I E I E —

MBE 4000Valve Overlap — E I E I I/E

*I = Intake Valve, E = Exhaust Valve

Table 20 Valve Adjustment — Method Two



Adjusting Valve Lash — Adjustvalve lash as follows:

1. If adjustment is needed, loosenthe locknut. See Figure 23.

Figure 23 Valve Lash Adjustment

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

NOTE:When adjusting the valves, adjust tothe exact setting. Use the range onlyfor checking adjustment.

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

4. Check the valve lash again.Adjust again if necessary.

Restoring The Vehicle ToOperating Condition — Restorethe vehicle to operation condition asfollows:

1. Install the cylinder head covers.

2. Remove the cranking tool fromthe inspection hole in the flywheelhousing.

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

Valve Type Check For :(mm (in.)

Adjust To:(mm (in.)

Intake 0.30 to 0.60 (0.012 to 0.024) 0.40 ( 0.016)

Exhaust 0.50 to 0.80 (0.020 to 0.032) 0.60 (0.024)

Table 21 Valve Lash Adjustment


MAINTENANCE

Fuel/Water Separator PrefilterElement Cleaning

Clean the prefilter element as follows:

1. Loosen the bleed screw.See Figure 24.

2. Unscrew the drain plug and drainthe fuel in the prefilter.

3. Twist off the sight bowl andremove the filter element from theseparator head.

4. Separate the sight bowl fromthe filter element. Clean thesight bowl. Discard the old filterelement and both O-rings.

5. Replace the filter element andO-rings.

6. Assemble the sight bowl and theprefilter element.

[a] Lubricate one O-ring with alight coating of engine oil andinsert it into the sight bowl.

[b] Screw the prefilter elementand sight bowl together.

7. Assemble the prefilter elementand the separator head.

[a] Lubricate the other O-ringwith a light coating of engineoil and insert it into the openend of the prefilter element.

[b] Screw the prefilter elementonto the separator head and

tighten firmly, using handsonly.

Figure 24 Fuel/Water Separator



NOTE:Do not use tools to tighten the prefilterelement.

8. Tighten the drain plug.

9. Prime the fuel system.

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

NOTE:There should be a strong resistancein the hand pump, caused by thepressure build-up within the fuelsystem.

[b] Crank the engine for 30seconds at a time, but nolonger. Before cranking theengine again, wait at least twominutes. The engine shouldstart within four 30 secondattempts.

Fuel Pro® 382 Fuel/WaterSeparator Element Replacement

Replace the fuel/water separatorelement as follows:

Figure 25 Fuel Pro® 382Fuel/Water Separator


MAINTENANCE

1. Remove the vent cap, open thedrain valve and drain fuel intoapproved container, until level isbelow the collar. See Figure 25.

2. Using a collar wrench removecollar and cover.

3. Remove the filter element fromthe separator head and discardfilter and O-rings. Dispose offilter properly.

4. Clean the cover and the mountingsurface on the body.

5. Install the filter element withbottom grommet, new coverO-ring, cover and collar. Handtighten only.

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

7. Replace O-ring on the vent capand install in cover. Hand tightenonly.

NOTE:Do not use tools to tighten the collaror vent cap.

8. Tighten the drain plug.

9. Crank the engine for 30 secondsat a time, but no longer. Beforecranking the engine again, waitat least two minutes. The engineshould start within four, 30second attempts.

10. Start the engine and raise the rpmfor one minute to purge the air.After the air is purged stop theengine, loosen the vent cap untilthe fuel level lowers to just abovethe collar. Tighten the vent capby hand. Check for leaks.

Main Fuel Filter ElementChanging

Change the main fuel filter element asfollows:

1. Open the fuel tank fill cap torelease pressure in the fuelsystem. Replace and tighten thecap.

2. Clean the outside of the fuel filterhousing (see Figure 26).

Figure 26 Main Fuel Filter



3. Using a 36-mm socket, unscrewthe cap on the main fuel filterhousing. Remove the cap and liftthe filter element a short distancewithin the filter housing allowingthe fuel to drain off the filter.

4. Remove the filter element fromthe cap and clean the filter cap.Discard the filter element and theO-ring from the cap.

NOTICE:To prevent damage to the filterhousing, do not allow dirt to get intothe filter housing.

5. Clean the filter housing cap.

6. Replace the O-ring.

7. Lubricate the filter element rubberseal with a light coat of fuel oiland insert it into the filter housing.Push down and rotate the filterelement while installing to ensureit is seated properly at the base ofthe housing.

NOTE:A properly seated filter element willhold the fuel in the filter housing andprevent it from draining back to thetank. If the fuel does not stay in thehousing the element is not seatedproperly, repeat steps 1 and 2.

8. Fill fuel filter housing with cleanfuel oil.

9. Install a new O-ring on the filtercap and screw the cap onto thefilter housing. Tighten the cap to25 N·m (18 lb·ft).

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

NOTE:There should be a strong resistancein the hand pump, caused by thepressure build-up within the fuelsystem.

11. Crank the engine for 30 secondsat a time, but no longer. Beforecranking again, wait at least twominutes, then crank again. Theengine should start within four30-second attempts.

12. Once the engine starts allow it toidle for at least one minute or untilidle is smooth before applyingthe throttle. Check the fuel filterhousing for leaks.


Select the SAE class (viscosity) on thebasis of the average air temperaturefor the season (see Figure 27).

NOTE:Continued use of a single SAE classwill result in frequent oil changes. Forthis reason, view the temperatureranges for the various SAE classes.


MAINTENANCE

Figure 27 Engine Oil TemperatureRanges

To ensure the engine is protectedand the oil stays clean until the nextoil change, use only oils of APIclassification CI-4.

Drain oil as follows:

1. Chock the tires, place thetransmission in neutral, and setthe parking brake.

NOTE:Change the engine oil only whenthe engine is at a temperature ofapproximately 60°C (140°F).

2. Using a 36-mm socket, unscrewthe oil filter cap (see Figure 28).

Figure 28 Oil Filter Cap

FIRE

To avoid injury from fire, keepopen flames, sparks, electricalresistance heating elements, orother potential ignition sourcesaway when draining lubricationoil. Do not smoke when draininglubricating oil.

3. Drain the oil.

[a] Place a suitable receptaclebeneath the oil drain plug onthe underside of the oil pan.

[b] Carefully unscrew the oildrain plug on the oil pan andallow the oil to drain out(see Figure 29).



Figure 29 Engine Oil Drain Plug,Oil Pan

[c] Discard the O-ring on the oildrain plug.

4. Remove both the filter cap andthe filter element. To release thefilter element, twist the loweredge of the filter element to theside (see Figure 30).

Figure 30 Cap with Oil FilterElement

NOTICE:To prevent damage to the filterhousing, ensure that no foreignobjects get inside it. Do not wipeclean the filter housing.

5. Replace the O-ring on the cap(see Figure 30).

6. Install the new filter into the cap.Make sure the filter element issecurely in place.

7. Screw the cap onto the oil filterhousing. Tighten the cap 45 N·m(33 lb·ft).

8. Install the oil drain plug, using anew O-ring. Tighten the plug 80N·m (60 lb·ft).

PERSONAL INJURY


9. Add new engine oil through theoil fill (see Figure 31) until themaximum fill level on the oildipstick has been reached. Enginefill capacity is 44 L (46 qts).


MAINTENANCE

Figure 31 Oil Fill

To avoid injury when workingnear or on an operating engine,remove loose items of clothing,jewelry, tie back or contain longhair that could be caught in anymoving part causing injury.

10. Start the engine with theaccelerator pedal in the idleposition. Monitor the oil pressuregauge.

NOTICE:Keep the engine running at idlingspeed until an oil pressure reading isobtained. If no oil pressure is shownafter approximately 10 seconds,stop the engine and determine thecause. Failure to do so could resultin engine damage.

11. Check the filter and oil drain plugfor signs of leakage.

12. Stop the engine. Check the oillevel again after approximatelyfive minutes. If necessary, add oilup to the maximum fill level onthe oil dipstick.

Optional Oil Centrifuge — Every20,000 miles (32,000 km) change theoil centrifuge rotor as follows:

1. Remove the cover of the oilcentrifuge.

2. Lift out the dirty rotor and replaceit with a clean one (see Figure32).

Figure 32 Rotor

3. Replace the centrifuge cover.



Coolant Concentration andInhibitor Level Checking

Check the coolant concentration asfollows:

HOT COOLANT


NOTE:Check and correct the coolant levelonly when the coolant temperature isbelow 50°C (122°F).

1. Open the cap on the surge tankslowly, to allow excess pressureto escape. Set the cap aside.

2. Before adding coolant,use a suitable tester tocheck the concentration ofcorrosion-inhibiting antifreeze.If the concentration is lowerthan 50 percent by volume,drain coolant/add antifreeze untilthe concentration is correct.The coolant mixing ratio islisted in Table 22.

AntifreezeProtection Down

to °C (°F)

Water Percentageby Volume

Corrosion-InhibitingAntifreeze

Percentage byVolume

–37 (–34) 50 50

–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


MAINTENANCE

NOTE:When topping off, use only apre-prepared coolant mixturecontaining a 50 percent concentrationby volume of corrosion-inhibitingantifreeze.

NOTICE:If the concentration of antifreeze istoo low, there is a risk of corrosionor cavitation in the cooling system.

3. Check the coolant level and addmore coolant if necessary.

Coolant Inhibitor TestIntervals — Coolant inhibitorlevel should be checked at theintervals listed in Table 23.

If topping off is needed, add coolantwhich is identical to the initial fillcoolant.

Check the nitrite concentration atregular intervals as listed in Table 24with a POWER Trac® 3–Way TestStrip. Nitrite levels must be within800–2400 PPM. Additional SCAmust be added to the coolant whenit becomes depleted, as indicated bya nitrite concentration of 800 PPMor less. If the nitrite concentrationis greater than 800 PPM, do notadd additional SCA. If the nitriteconcentration is above 2400 PPM, thesystem is over-inhibited and shouldbe partially drained and filled with a50/50 mix of water and EG.

NOTE:Drain intervals listed in Table 24 aredependent on proper maintenance.

Service Application Inhibitor Test Interval

On-highway Trucks and MotorCoaches

20,000 Miles (32,000 Kilometers

City Transit Coaches, Pick-up andDelivery Short Trip, and EmergencyVehicles

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

Industrial, Continuous Duty GeneratorSet, and all Other Applications

500 Hours or three months, whichevercomes first

Standby Generator Set 200 Hours or yearly, whichever comesfirst

Table 23 Required Coolant Inhibitor Test Intervals



Coolant Maintenance Interval Action

A. 20,000 miles (32,000 km)or 3 monthsB. 500 hours or 3 months

Test nitrite concentrationwith test strip, add SCA ordilute coolant as needed.

Antifreeze/Water+ SCA Inhibitor(DDC PowerCool) A. 300,000 miles (480,000 km)

or 2 yearsB. 2 years or 4,000 hours

Drain and clean system.Replace with new coolant.


Drain and clean system.Replace with new coolant.Ethylene

Glycol/Water +SCA Inhibitor A. 300,000 miles (480,000 km)

B. 2 years or 4,000 hoursDrain and clean system.Replace with new coolant.

A. 300,000 miles (480,000 km)or 2 yearsB. 5,000 hours

Add Power Cool PlusExtenderEthylene

Glycol/Water +OAT Inhibitor A. 600,000 miles (960,000 km)

or 4 yearsB. 4 years or 10,000 hours




Water Only +SCA Inhibitor A. 300,000 miles

(480,000 km) or 2 yearsB. 2 years or 4,000 hours


A. 300,000 miles(480,000 km) or 2 yearsB. 5,000 hours

Add Power Cool PlusExtender

Water Only +OAT Inhibitor A. 600,000 miles

(960,000 km) or 4 yearsB. 4 years or 10,000 hours


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

B = Industrial, generator set, and other applications

Table 24 Nitrite Interval Checks


MAINTENANCE

Inhibitor Level Checking — UseDetroit Diesel POWER Trac®3–wayCoolant Test Strips to measurenitrite and glycol concentrations.Cavitation/corrosion protection isindicated on the strip by the level ofnitrite concentration. Freeze/boil-overprotection is determined by glycolconcentration.

Check the inhibitor level as follows:

HOT COOLANT


1. Dip the test strip into the coolantfor one second, then remove it.Shake the strip vigorously toremove excess liquid.

2. Immediately compare the endpad to the color chart on thecontainer to determine the glycolconcentration.

3. Sixty seconds (one minute) afterdipping, compare the nitritepad to the color chart on thecontainer to determine the nitriteconcentration.

4. If the additive indicator (middlepad) shows any color change,this indicates the presence of anunauthorized inhibitor.

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

6. After each use, replace andtighten the cap on the test stripcontainer. Discard any test stripsthat have turned light pink or tanin color.

7. Close and tighten the cap on thesurge tank.



Coolant Flushing and Changing

Flush and change the coolant asfollows:

HOT COOLANT


1. Open the cap on the surge tankslowly, to allow excess pressureto escape. Set the cap aside.

2. Open the water regulating valvefor the heating system.

3. Place a large receptacleunderneath the coolant drainplug and open the coolant drainplug on the bottom of the radiator.See Figure 33.

NOTE:Make sure the coolant can flowunobstructed into the receptacle.

Figure 33 Coolant Drain Plug

NOTICE:Do not apply more than 20 psi (140kPa) air pressure for a radiatorflush; more pressure could damagethe radiator or heater core.

4. Start radiator flushing byattaching a flushing gun nozzle tothe radiator outlet and run waterin until the radiator is full.


MAINTENANCE

EYE INJURY


5. Apply no more than 140 kPa (20psi) air pressure intermittently tohelp dislodge sediment buildup inthe core.

6. Drain the radiator, and flush theradiator until clean water flowsfrom the radiator. Remove theflushing gun.

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

8. Add coolant in the specifiedconcentration until the maximummark on the surge tank is reached.

9. Start the engine and run it forabout one minute at varyingspeeds to release air pockets inthe cooling system. Ensure theheater valve is still open. Checkthe coolant level and add morecoolant if necessary.

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

Cooling System Inspecting

NOTE:Before doing this inspection, do either"Coolant Concentration Checking," or"Coolant Flushing and Changing."

Inspect the cooling system as follows:

HOT COOLANT


1. Inspect the radiator, condenser,coolant pump, engine oil cooler,freeze plugs, and heat exchangerfor damage and leaks.

2. Check all cooling system pipesand hoses for damage and leaks;ensure they are positioned toavoid chafing, and are securelyfastened.

3. Check the outside of the radiatorand condenser for blockage.Check fins for damage; straightenthem if necessary.



Rear Engine Power Take-Off(REPTO)

The REPTO accessory drive is anoption on the MBE 4000 engine. Thedrive provides continuous live poweranytime the engine is operating. TheREPTO is driven by the camshaft gearand is an integral part of a uniqueSAE#1 flywheel housing. All REPTOinstallations require a torsionalcoupling installed at the flange ofthe drive unit (i.e. hydraulic pump).The torsional coupling incorporates arubber element designed to reduce theunwanted stresses from reaching theengine. See Figure 34.

Figure 34 MBE 4000 REPTOConnection Illustration

REPTO Torsional DamperInspection — Inspect the REPTOtorsional damper as follows:

1. Inspect the outer casing of thetorsional damper for dents orbulges. If damage is found

replace the damper. Regardlessof the condition, the torsionalcoupling must be replaced atnormal engine overhaul.

2. Inspect the torsional damperrubber element as follows:

[a] Check the rubber element forbulges or cracks. If damage isfound replace the damper.

[b] Inspect the rubber elementteeth for wear. If the teethare worn to less than one-halfof the new part length (11.0mm [0.433 in.]), replace thetorsional damper. See Figure35.

Figure 35 REPTO TorsionalDamper

REPTO Torsional DamperCleaning — Clean the REPTOtorsional damper as follows:


MAINTENANCE

The torsional damper couplingwill withstand normal exposure tohydraulic oil, diesel fuel, anti-freezesolutions, and muriatic acid. Thecoupling should be washed with amild soap solution and rinsed withwater after contact with the aboveitems. The coupling can be powerwashed without damage as long as it isinstalled in the vehicle. If the couplingis power washed when not connectedto a cardan shaft, debris may be forcedinternally at the bolt flanges damagingthe coupling.



CUSTOMER ASSISTANCE

The satisfaction and good will of theowners of Detroit Diesel engines areof primary concern to Detroit Diesel

Corporation and its distributor/dealerorganizations.


CUSTOMER ASSISTANCE

DDC NORTH AMERICAN NAFTA ON-HIGHWAY OFFICESEASTERN REGION 1Suwanee, Georgia3325 Paddocks ParkwaySuwanee, GA 30024Telephone: 678-341-6100Fax: 678-341-6150

EASTERN REGION 2Detroit, Michigan13400 Outer Drive WestDetroit, MI 48239-4001Telephone: 313-592-5420Fax: 313-592-5887

WESTERN REGION 1Irvine, California7700 Irvine Center, Suite 275Irvine, CA 92618Telephone: 949-753-7710Fax: 949-753-7711

WESTERN REGION 2Irvine, California7700 Irvine Center, Suite 275Irvine, CA 92618Telephone: 949-753-7710Fax: 949-753-7711

CANADIAN REGIONLondon, OntarioDetroit Diesel of Canada, Ltd.150 Dufferin Ave., Suite 701London, ON N5A 5N6Phone: 519-661-0149Fax: 519-661-0171



MTU DETROIT DIESEL OFF-HIGHWAY SALES ANDCUSTOMER ASSURANCE CENTERS

CONSTRUCTION, INDUSTRIALAND MINING SALES (BX7)13400 Outer Drive, WestDetroit, MI 48239-4001Phone: 313-592-5608Fax: 313-592-5625

MARINE SALES (BX6)13400 Outer Drive, WestDetroit, MI 48239-4001Phone: 313-592-7806Fax: 313-592-5137

POWERGEN AND OIL FIELD SALES(BX11)13400 Outer Drive, WestDetroit, MI 48239-4001Phone: 313-592-5708Fax: 313-592-5158

GOVERNMENT SALES (BX9)13400 Outer Drive, WestDetroit, MI 48239-4001Phone: 313-592-5875Fax: 313-592-5158

CUSTOMER ASSURANCE (M24)13400 Outer Drive, WestDetroit, MI 48239-4001Phone: 313-592-5550Fax: 313-592-5717


CUSTOMER ASSISTANCE

DDC INTERNATIONAL REGIONAL OFFICE LOCATIONS

DETROIT DIESEL DISTRIBUTIONCENTER B.V.(On/Off-Highway)The NetherlandsRidderpoort 92984 RidderkerkThe NetherlandsPhone: (31) 180-442-900Fax: (31) 180-462-062

LATIN AMERICAN REGION(Off-Highway)Miami, Florida2277 N.W. 14th StreetLatin America BuildingMiami, FL 33125-0068Phone: 305-637-1555Fax: 305-637-1580

MTU DETROIT DIESEL AUSTRALIAPTY. LTD.(On/Off-Highway)Victoria – Melbourne488 Blackshaws RoadAltona North,Victoria 3205AustraliaPhone: (61) 3 9243-9292Fax: (61) 3 9243-9271

MTU ASIA PTE. LTD. (Off-Highway)SingaporeNo. 1 Benoi PlaceSingapore 629923Phone: (65) 6861-5922Fax: (65) 6861-3615 Sales Marine,Rail, C & I, ElectronicsFax: (65) 6860-9959 Sales PowerGen,Defense

MEXICO (On/Off-Highway)Detroit Diesel Allison de Mexico, S.A.Av. Santa Rosa 58Col. Ampliacion Norte54160 TlalnepantlaEdo. de MexicoMEXICOPhone: 52 55-5333-1803Fax: 52 55-5333-1875



Working with DDC ServiceOutletsAs the owner of a Detroit Dieselproduct you have a complete networkof over 1,000 Detroit Diesel serviceoutlets in the U.S. and Canada, plusmany outlets worldwide that areprepared to meet your parts andservice needs:

□ Service by trained personnel

□ Sales teams to help determine yourspecific power requirements

□ In many areas, emergency service24 hours a day

□ Complete parts support includingreliabilt® remanufactured parts

□ Product information and literature

We recognize however, that despitethe best intentions of everyoneconcerned, misunderstandings mayoccur. Normally, any situationthat arises in connection with thesale, operation, or service of yourproduct will be handled by theauthorized service outlet in your area(in the U.S. and Canada check theYellow Pages or service locator atwww.detroitdiesel.com for the DetroitDiesel service outlet nearest you).

To further assure your completesatisfaction, we have developed thefollowing procedure to use if you havea problem that has not been handledsatisfactorily.

Step One

Discuss your problem with a memberof management from the authorizedservice outlet. Frequently, complaintsare the result of a breakdown incommunication and can quickly beresolved by a member of management.If you have already discussed theproblem with the Sales or ServiceManager, contact the GeneralManager. If your complaint originateswith a dealer, explain the matterto a management member of thedistributorship with whom the dealerhas his service agreement.

Step Two

When it appears that your problemcannot readily be resolved at thedistributor level without additionalassistance, contact the DetroitDiesel Regional Product Support orOperations Manager responsible foryour local distributor. You will beassisted by a member of the Manager'sstaff, depending upon the nature ofyour problem.

Prior to this contact, have thefollowing information available:

□ Engine model and serial number

□ Name and location of authorizedservice outlet

□ Type and make of equipment


CUSTOMER ASSISTANCE

□ Engine delivery date andaccumulated miles or hoursof operation

□ Nature of problem

□ Chronological summary ofengine's history

Step Three

If you are still not satisfied, present theentire matter in writing or by phone to:

Sr. Vice President, Parts, Serviceand Customer SupportDetroit Diesel Corporation13400 Outer Drive, WestDetroit, Michigan 48239–4001Phone: 313–592–5000Fax: 313–592–7244

When contacting the regional orhome office, please keep in mind thatultimately your problem will likelybe resolved at the distributorship ordealership, utilizing their facilities,equipment, and personnel. Therefore,it is suggested that you followthe previously mentioned stepsin sequence when experiencing aproblem.



LIMITED WARRANTY ON NEW DETROIT DIESELMBE 4000 ENGINES USED IN ON-HIGHWAY VEHICLEAPPLICATIONS

Terms of Coverage

Uses

This warranty applies to the firstretail purchaser and subsequentowners during the WARRANTYPERIOD of new Detroit DieselMBE 4000 Engines (referred to asEngine) manufactured by DetroitDiesel Corporation and/or suppliedby Detroit Diesel Corporation orDetroit Diesel of Canada Limited(which are collectively referred to asDDC) for use in on-highway vehicleapplications operated in the UnitedStates or Canada.

Defects

This warranty covers EngineREPAIRS to correct any malfunctionoccurring during the WARRANTYPERIOD resulting from defects inmaterial or workmanship.

Repairs

To obtain warranty repairs, you mustrequest the needed repairs withinthe WARRANTY PERIOD from anauthorized DDC service outlet. Onlynew genuine parts or remanufacturedparts or components supplied or

approved by DDC will be used. DDCmay, at its discretion, replace ratherthan repair components. A reasonabletime must be allowed to performthe warranty repair after taking theengine to the authorized service outlet.The owner is responsible for thepercentage of repair costs shown inthe warranty period chart. Repairs willbe performed during normal businesshours.

Warranty Period

The WARRANTY PERIOD beginson the date the engine is delivered tothe first retail purchaser or put in useprior to sale at retail, whichever dateoccurs first, and ends at the time ormileage/kilometer limits shown in theWARRANTY PERIOD chart.


LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 4000 ENGINESUSED IN ON-HIGHWAY VEHICLE APPLICATIONS

Warranty Period

Warranty Limitations(Whichever Occurs First)

Repair Charges to bePaid by Owner

ItemMonths Miles/

Kilometers Parts Labor

Engine 0-24 Unlimited NoCharge No Charge

Accessories 0-24 0-100,000 mi0-160,000 km

NoCharge 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 Com-ponents* 25-60 0-500,000 mi

0-800,000 kmNo

Charge

100% of serviceoutlet'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 areplacement for an engine still underwarranty will assume the identityof the engine being replaced and beentitled to the remaining warrantycoverage.

Service Supplies

The cost of service supplies suchas coolant, oil and filters which arenot reusable due to needed warrantyrepairs is covered by this warranty.

Engine Removal andReinstallation

Reasonable labor costs for engineremoval and reinstallation, whennecessary to make a warranty repair,are covered by this warranty.



This Warranty Does NotCover:

Repairs Due to Accidents,Misuse, Storage Damage,Negligence or CertainModifications

Repairs due to an accident, misuse,misapplication, storage damage,negligence or modification exceedingDDC specifications are not covered bythis warranty.

Fuel Injection System After100,000 Miles/160, 000Kilometers

The repair or replacement of fuelinjection pump, high pressurelines and nozzles after 100,000miles/160,000 kilometers of operationis not covered by this warranty.

Maintenance

DDC is not responsible for thecost of maintenance or repairsdue to lack of performance ofrequired maintenance services asrecommended by DDC, or thefailure to use fuel, oil, lubricants andcoolant meeting DDC-recommendedspecifications. Performance of therequired maintenance and use ofproper fuel, oil, lubricants and coolantare the responsibility of the owner.Refer to the Engine Operator”s Guidefor details.

Incidental or ConsequentialDamages

Detroit Diesel Corporation isnot responsible for incidental orconsequential costs or expenses whichthe owner may incur as a result ofa malfunction or failure covered bythis warranty, such as communicationexpenses, meals, lodging, loss of useof the engine or vehicle (“downtime”),loss of time, inconveniences, cargoloss or damage, and other similar costsand experiences.

Other Limitations

Performance of REPAIRS is theexclusive Owner's remedy under thiswarranty. Detroit Diesel Corporationdoes not authorize ant person toassume or create for it any otherobligation or liability in connectionwith the engine or the accessories.


LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 4000 ENGINESUSED IN ON-HIGHWAY VEHICLE APPLICATIONS

THIS WARRANTY ANDTHE EMISSIONS CONTROLWARRANTY ARE THE ONLYWARRANTIES APPLICABLETO THE ENGINE AS USEDIN ON-HIGHWAY VEHICLEAPPLICATIONS. DETROIT DIESELCORPORATION MAKES NOOTHER WARRANTIES EXPRESSOR IMPLIED, INCLUDINGANY IMPLIED WARRANTYOF MERCHANTABILITY ORFITNESS FOR A PARTICULARPURPOSE. DETROIT DIESELCORPORATION SHALL NOT BELIABLE FOR ANY INCIDENTALOR CONSEQUENTIAL DAMAGESAS DESCRIBED ABOVE.

Some states do not allow the limitationof how long this warranty may lastor the limitation or exclusion ofincidental or consequential damages,so the above may not apply to you.This warranty gives you special legalrights, and you may also have otherrights which may vary from state tostate.



LIMITED WARRANTY ON NEW DETROIT DIESEL MBE4000 ENGINES USED IN FIRE TRUCK OR CRASHVEHICLE APPLICATIONS

Terms of Coverage

Uses

This warranty applies to the firstretail purchaser and subsequentowners during the WARRANTYPERIOD of new Detroit DieselMBE 4000 Engines (referred to asEngine) manufactured by DetroitDiesel Corporation and/or supplied byDetroit Diesel Corporation or DetroitDiesel of Canada Limited (whichare collectively referred to as DDC)for use in fire truck or crash vehicleapplications operated in the UnitedStates or Canada.

Defects

This warranty covers EngineREPAIRS to correct any malfunctionoccurring during the WARRANTYPERIOD resulting from defects inmaterial or workmanship.

Repairs

To obtain warranty repairs, you mustrequest the needed repairs withinthe WARRANTY PERIOD from anauthorized DDC service outlet. Onlynew genuine parts or remanufacturedparts or components supplied or

approved by DDC will be used. DDCmay, at its discretion, replace ratherthan repair components. A reasonabletime must be allowed to performthe warranty repair after taking theengine to the authorized service outlet.The owner is responsible for thepercentage of repair costs shown inthe warranty period chart. Repairs willbe performed during normal businesshours.

Warranty Period

The WARRANTY PERIOD beginson the date the engine is delivered tothe first retail purchaser or put in useprior to sale at retail, whichever dateoccurs first, and ends at the time ormileage/kilometer limits shown in theWARRANTY PERIOD chart.


LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 4000 ENGINESUSED IN FIRE TRUCK OR CRASH VEHICLE APPLICATIONS

Warranty Period

Warranty Limitations(Whichever Occurs First)

Repair Charges to bePaid by Owner

ItemMonths Miles/

Kilometers Parts Labor

Engine 0-60 0-100,000 mi0-160,000 km No Charge No Charge

Accessories 0-24 0-100,000 mi0-160,000 km No Charge No Charge

Table 26 Warranty Period Chart — On-highway Vehicle Applications

Like Replacement Engine

Engine(s) supplied by DDC as areplacement for an engine still underwarranty will assume the identityof the engine being replaced and beentitled to the remaining warrantycoverage.

Service Supplies

The cost of service supplies suchas coolant, oil and filters which arenot reusable due to needed warrantyrepairs is covered by this warranty.

Engine Removal andReinstallation

Reasonable labor costs for engineremoval and reinstallation, whennecessary to make a warranty repair,are covered by this warranty.

This Warranty Does NotCover:

Repairs Due to Accidents,Misuse, Storage Damage,Negligence or CertainModifications

Repairs due to an accident, misuse,misapplication, storage damage,negligence or modification exceedingDDC specifications are not covered bythis warranty.

Fuel Injection System After100,000 Miles/160, 000Kilometers

The repair or replacement of fuelinjection pump, high pressurelines and nozzles after 100,000miles/160,000 kilometers of operationis not covered by this warranty.



Maintenance

DDC is not responsible for thecost of maintenance or repairsdue to lack of performance ofrequired maintenance services asrecommended by DDC, or thefailure to use fuel, oil, lubricants andcoolant meeting DDC-recommendedspecifications. Performance of therequired maintenance and use ofproper fuel, oil, lubricants and coolantare the responsibility of the owner.Refer to the Engine Operator”s Guidefor details.

Incidental or ConsequentialDamages

Detroit Diesel Corporation isnot responsible for incidental orconsequential costs or expenses whichthe owner may incur as a result ofa malfunction or failure covered bythis warranty, such as communicationexpenses, meals, lodging, loss of useof the engine or vehicle (“downtime”),loss of time, inconveniences, cargoloss or damage, and other similar costsand experiences.

Other Limitations

Performance of REPAIRS is theexclusive Owner's remedy under thiswarranty. Detroit Diesel Corporationdoes not authorize ant person toassume or create for it any other

obligation or liability in connectionwith the engine or the accessories.

THIS WARRANTY ANDTHE EMISSIONS CONTROLWARRANTY ARE THE ONLYWARRANTIES APPLICABLETO THE ENGINE AS USEDIN ON-HIGHWAY VEHICLEAPPLICATIONS. DETROIT DIESELCORPORATION MAKES NOOTHER WARRANTIES EXPRESSOR IMPLIED, INCLUDINGANY IMPLIED WARRANTYOF MERCHANTABILITY ORFITNESS FOR A PARTICULARPURPOSE. DETROIT DIESELCORPORATION SHALL NOT BELIABLE FOR ANY INCIDENTALOR CONSEQUENTIAL DAMAGESAS DESCRIBED ABOVE.

Some states do not allow the limitationof how long this warranty may lastor the limitation or exclusion ofincidental or consequential damages,so the above may not apply to you.This warranty gives you special legalrights, and you may also have otherrights which may vary from state tostate.


DDC-SVC-MAN-0056 - MBE4000 Safe Operation and Preventative ...

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