Detroit Diesel EPA04 MBE 4000 Operator's Manual
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Detroit Diesel EPA04 MBE 4000 Operator's Manual

Detroit Diesel EPA04 MBE 4000 Operator's Manual

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  • Page 2 Nexiq Technologies, Inc. All other factory original parts and have trademarks are the property of their the specialized equipment and respective owners. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 3 All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 4: Table Of Contents

    ADDING FUEL ................24 PRIMING THE FUEL SYSTEM ........... 24 STARTING THE ENGINE ..............25 CHECKING THE COOLANT LEVEL (HOT CHECK) ....25 All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 5 ENGINE OILS .................. 49 SYNTHETIC OILS ............... 49 COOLANT ..................50 FULLY-FORMULATED ANTIFREEZE ......... 50 WATER ..................50 COOLANT SPECIFICATIONS ............. 51 COOLANT CONCENTRATION ........... 51 All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 6 CHOOSING A METHOD ............70 METHOD ONE ................ 71 METHOD TWO ............... 72 ADJUSTING VALVE LASH ............73 RESTORING THE VEHICLE TO OPERATING CONDITION .. 73 All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 7 WORKING WITH DDC SERVICE OUTLETS ........93 STEP ONE ................... 93 STEP TWO .................. 93 STEP THREE ................94 LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 4000 ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS ..95 TERMS OF COVERAGE ..............95 USES ................... 95 DEFECTS ..................
  • Page 8 FUEL INJECTION SYSTEM AFTER 100,000 MILES/160, 000 KILOMETERS ................100 MAINTENANCE ................101 INCIDENTAL OR CONSEQUENTIAL DAMAGES ...... 101 OTHER LIMITATIONS ..............101 All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 9 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...

  • Page 10: Caution Summary

    To avoid injury from fire, keep all potential ignition sources away from diesel fuel, including open flames, sparks, and electrical resistance heating elements. Do not smoke when refueling. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 11: Preventive Maintenance

    To avoid injury to skin from contact with the contaminants in used engine oil, wear protective gloves and apron. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 12 PERSONAL INJURY To avoid injury when using caustic cleaning agents, follow the chemical manufacturers usage, disposal, and safety instructions. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 13: Electrical System

    To avoid injury from electrical voltage. shock, do not touch battery terminals, alternator terminals, or wiring cables while the engine is operating. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 14 (e.g. screwdriver or wire). High voltage can remain inside the Electrostatic Oil Separator for up to 12 hours after the ignition is turned off. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 15: Cooling System

    To avoid injury from slipping and turbocharger air inlet. The shield falling, immediately clean up any prevents contact with rotating spilled liquids. parts. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 16: Fuel System

    10 minutes before servicing any component within the high pressure circuit. Residual high fuel pressure may be present within the circuit. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 17 (face shield, insulated gloves and apron, etc.). □ To prevent a buildup of potentially volatile vapors, keep the engine area well ventilated during operation. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 18: Compressed Air

    FIRE To avoid injury from combustion of heated lubricating-oil vapors, stop the engine immediately if an oil leak is detected. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 19: Identification

    It complies with all United attached to the cylinder head cover, as States Environmental Protection required by law. See Figure 1. Figure 1 Emission Label, MBE 4000 All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 20: Personnel Requirements

    Compliance with the manufacturer's settings and with statutory environmental protection regulations cannot then be guaranteed. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 21 13. EGR Mixer 6. EGR Shutoff Valve (hidden) 14. Air Conditioning Compressor 7. Air Intake Manifold Figure 2 Major Engine Components, Left Side All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 22 4. EGR Hot Pipe 11. Alternator 5. Exhaust Manifold 12. Belt Tensioner 6. EGR Shutoff Valve Figure 3 Major Engine Components, Right Side All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 23: Engine Type Plate

    (see Figure 6). first three numbers of the engine serial number are the model number. See Figure 5. Figure 6 Engine Serial Number All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 24: Engine Features

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

  • Page 25: Exhaust Brake/Constant-Throttle Valves

    Electrical equipment includes a starter the exhaust brake to increase braking and an alternator. performance. Figure 7 Constant-Throttle Activation (shown with EGR system removed) All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 26: Turbo Brake, Optional

    For high braking output, the MBE 4000 engine can be equipped with an optional turbo brake. The turbo brake increases the air mass flow through the All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 27: Electronic Engine Control System

    Figure 8 Electronic Engine Control System This system is composed of the and the DDEC-VCU (Vehicle Control DDEC-ECU (Engine Control Unit) Unit). All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 28: Ddec-Ecu - Engine-Resident Control Unit

    The DDEC-ECU data label has the 10 digit engine serial number (see Figure 6), the engine horse power and torque. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 29: Vehicle Control Unit

    See Figure 11 for sensor locations on From these data, instructions are the MBE 4000 engine. computed for controlling the engine All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 30 (Integrated into DDEC-ECU) 3. Camshaft Position Sensor 7. Supply Fuel Temperature Sensor 4. Crankshaft Position Sensor 8. Engine Oil Pressure/Temperature Sensor Figure 11 Sensor Location All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 31: Operation

    Table 1 Approved Electrical Lubricants □ Tachometer □ Air restriction indicator Watch for any signs of engine problems when starting or driving. If All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 32: Checking The Oil Level

    PERSONAL INJURY To avoid injury from slipping and For detailed procedures, refer to the falling, immediately clean up any “Maintenance” section. spilled liquids. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 33: Checking The Coolant Level (Cold Check)

    □ Prevent water from entering the fuel tank. For further information, refer to the “Service Products” section. Priming the Fuel System Prime the fuel system as follows: All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 34: Starting The Engine

    [a] Check all hoses, hose clamps, and pipe unions on the engine for tightness. Shut down the engine and tighten them if necessary. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 35: Starting An Engine That Has Not Been Run For Along Time

    Refer to the “Cleaning and Storage” section. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 36: Monitoring Engine Operation

    If oil pressure drops below these 1. Shut down the engine. values, stop the engine and determine the cause. 2. Check the poly-V belt for tightness. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 37: Excessive Idling

    2. Turn off the ignition switch and the engine immediately. shut down the engine. □ The oil pressure swings back and forth or falls sharply. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 38: Emergency Running Mode

    The operator has the responsibility to service location. take action to avoid engine damage. For fault codes and their meanings, see the vehicle service manual. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 39: Cold Weather Operation

    Winter fronts should only be used when the ambient temperature remains below -12.2° C (10° F). All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 40: Cleaning And Storage

    Work from the rear of the radiator mm) for 25-degree flat jets and (in the opposite direction of the dirt cutters normal cooling air flow). All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 41: Degreasing

    5. Fill the cooling system with new coolant. For detailed procedures, see the vehicle/chassis maintenance manual. For types of coolant, refer to the “Service Products” section. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 42: Storage

    12 months or less, anticorrosion measures are not necessary, provided that the place of storage are dry and well-ventilated as described above. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 43: Troubleshooting

    Nexiq DDR or DDDL PC software. For fault codes and their meanings, see the next section in this guide. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 44: General Troubleshooting

    Bring the vehicle to an authorized damaged. dealer for service. There is internal damage to the Bring the vehicle to an authorized engine. dealer for service. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 45 The transmission fluid does not meet Change the transmission fluid, using the correct specifications. the correct type of fluid. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 46 The valves are not adjusted properly. Check the valve lash. Bring the vehicle to an authorized There are other problems in the fuel system. dealer for service. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 47 There are other problems in the fuel Bring the vehicle to an authorized system. dealer for service. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 48 The fan wiring is damaged. Repair the fan wiring. The parameter settings in the Have an authorized dealer reprogram DDEC-ECU or DDEC-VCU are the control unit. incorrect. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 49 The remedies are listed in "The Engine The engine performs poorly, or does Performs Poorly, Does Not Develop not develop full power. Full Power." All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 50 Bring the vehicle to an authorized DDEC-ECU or DDEC-VCU. dealer for service. There is internal damage to the Bring the vehicle to an authorized engine. dealer for service. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 51 The fan is not operating properly. or have the parameter settings reprogrammed in the DDEC-ECU or DDEC-VCU. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 52 Have an authorized dealer replace the heat exchanger. leaking. Bring the vehicle to an authorized There is an internal coolant leak. dealer for service. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 53 The intake air preheater is Check the intake air preheater, and malfunctioning. replace it, if necessary. The valves are not adjusted properly. Check the valve lash. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 54 The valve stem seals are loose or Have an authorized dealer replace the damaged. seals. Have an authorized dealer replace the The piston rings are worn. piston rings. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 55 Come On When the Engine Is Not Running Remedy Cause The bulb is damaged. Change the bulb. The circuit is broken. Repair the break in the circuit. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 56 The poly-V belt is worn or damaged. Replace the belt. The alternator is damaged (has a Have an authorized dealer replace the alternator. damaged rectifier or voltage regulator). All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 57: Service Products

    Fuel added from drums or cans could be contaminated. This could lead to malfunctions in the fuel system. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 58: Engine Oils

    Synthetic oil may be used in MBE 4000 engines, provided they are of the correct API designation and viscosity, as required for non-synthetic oil. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 59: Coolant

    MBE 4000 engine is a mixture of glycol compound (ethylene glycol), □ Distilled water and corrosion inhibitors. Antifreeze □ Water purified by reverse osmosis All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 60: Coolant Specifications

    Down to °C (°F) by Volume Antifreeze % by Volume –37 (–34) –52 (–62) The cooling mix ratio is Max. 60 Table 3 Coolant Mixing Ratio All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 61: Supplemental Coolant Additives For Fully Formulated Coolant

    MBE 4000 □ pH control engines: □ Restored inhibitor levels to prevent □ Antifreeze or coolant containing corrosion phosphate can cause dropout, All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 62: Recycled Antifreeze

    filtration processes, is not approved. inhibitors added as necessary. The intervals are longer if OAT inhibitors are used. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 63: Disposal

    A modern engine coolant has complex been adversely affected by paraffin tasks to perform. Do not allow any separation. form of "reprocessing" which consists only of mechanical purification. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 64: Low-Viscosity Engine Oil

    Ensure good Do not increase the proportion ventilation when recharging. (mixing ratio) of corrosion-inhibiting antifreeze beyond 55 percent by All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 65: Technical Data

    Compression Ratio 17.75:1 Starting Speed Approximately 100 rpm Direction of Engine Rotation (viewed Counterclockwise from flywheel) Starter Electric Motor Table 4 General Technical Information All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 66: Engine Data

    Front View Description MBE 4000 Engine Coolant Capacity* Max. 70 L (74 qt) *Does not include capacity of cooling system. Table 7 Coolant Capacity All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 67: Testing And Adjusting Values

    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 All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 68 Table 11 Coolant Thermostat Opening Pressure Value in kPa (Psi) Minimum opening pressure 25500 (3698) Maximum opening pressure 27000 (3916) Table 12 Injector Pressures All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 69: Maintenance

    (fire truck, garbage truck); or farm operation. If optional equipment is installed, be sure to comply with the maintenance requirements for these extra items. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 70: Short-Haul

    17 and Table 18. must be performed are listed in Table 14, Table 15, and Table 16. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 71: Schedule Use

    Set that applies to that interval. Then numbers, not 16 (as for Short Haul perform the maintenance operations and Long Haul). listed in the applicable Maintenance Interval Operation Table. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 72: Maintenance Tables

    84,000 60,000 miles Maintenance 3 (M3) (100,000 km) then every 100,000 167,000 every Maintenance 4 (M4) 200,000 334,000 Table 13 Maintenance Schedule Table All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 73 217,000 M1, M2 and M3 140,000 234,000 150,000 250,000 M1 and M2 160,000 267,000 Table 14 Maintenance Intervals for Schedule I, Severe Service All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 74 325,000 M1 and M2 210,000 350,000 225,000 375,000 M1, M2 and M3 240,000 400,000 Table 15 Maintenance Intervals for Schedule II, Short Haul All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 75 542,000 M1, M2, and M3 350,000 584,000 375,000 625,000 M1 and M2 400,000 667,000 Table 16 Maintenance Intervals for Schedule III, Long Haul All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 76 Cooling System Inspecting * Coolant flushing and changing must be done at least every two years. Table 17 Required Maintenance Operations Sets, Schedule I All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 77 first at 60,000 miles or 3000 hours and then every 30,000 miles or 1500 hours. Table 18 Required Maintenance Operations Sets, Schedule II and III All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 78: Required Maintenance Operations

    Adjust the valve lash when the engine the flywheel housing. is cold. Wait at least 30 minutes after shutdown, even if the engine ran only a short time. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 79: Choosing A Method

    (see "Method One—Adjust Each Cylinder In Firing Order") □ By type of valve, depending on crankshaft position (see "Method Two—Adjust All Valves Using Two Crankshaft Positions"). All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 80: Method One

    Engine Crankshaft Position Cylinders Ignition TDC MBE 4000 Valve Overlap Table 19 Valve Adjustment — Method One All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 81: Method Two

    — Ignition TDC MBE 4000 — Valve Overlap *I = Intake Valve, E = Exhaust Valve Table 20 Valve Adjustment — Method Two All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 82: Adjusting Valve Lash

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

  • Page 83: Cleaning

    [b] Screw the prefilter element Figure 24 Fuel/Water Separator onto the separator head and All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 84: Fuel Pro® 382 Fuel/Water Separator Element Replacement

    30 second attempts. Fuel Pro® 382 Fuel/Water Separator Element Replacement Replace the fuel/water separator element as follows: Fuel Pro® 382 Figure 25 Fuel/Water Separator All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 85: Main Fuel Filter Element Changing

    The engine should start within four, 30 second attempts. Figure 26 Main Fuel Filter All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 86: Engine Oil And Filter Changing

    For this reason, view the temperature 8. Fill fuel filter housing with clean ranges for the various SAE classes. fuel oil. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 87 filter cap (see Figure 28). [b] Carefully unscrew the oil drain plug on the oil pan and allow the oil to drain out (see Figure 29). All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 88 fill level on the oil dipstick has been reached. Engine Figure 30 Cap with Oil Filter fill capacity is 44 L (46 qts). Element All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 89: Optional Oil Centrifuge

    3. Replace the centrifuge cover. after approximately 10 seconds, stop the engine and determine the cause. Failure to do so could result in engine damage. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 90: Coolant Concentration And Inhibitor Level Checking

    –52 (–62) Maximum 60* *Concentrations of 60 percent affords the maximum antifreeze protection. Higher concentrations adversely affect heat dissipation. Table 22 Coolant Mixing Ratio All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 91: Coolant Inhibitor Test Intervals

    first Set, and all Other Applications Standby Generator Set 200 Hours or yearly, whichever comes first Table 23 Required Coolant Inhibitor Test Intervals All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 92 A = On-highway trucks and motor coaches, city transit coaches, pickup and delivery, short trip, and emergency vehicles. B = Industrial, generator set, and other applications Table 24 Nitrite Interval Checks All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 93: Inhibitor Level Checking

    Shake the strip vigorously to remove excess liquid. 2. Immediately compare the end pad to the color chart on the container to determine the glycol concentration. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 94: Coolant Flushing And Changing

    See Figure 33. NOTE: Make sure the coolant can flow unobstructed into the receptacle. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 95: Cooling System Inspecting

    10. Shut down the engine, close and Check fins for damage; straighten tighten the cap on the surge tank. them if necessary. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 96: Rear Engine Power Take-Off (Repto)

    Cleaning — Clean the REPTO torsional damper as follows: 1. Inspect the outer casing of the torsional damper for dents or bulges. If damage is found All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 97 If the coupling is power washed when not connected to a cardan shaft, debris may be forced internally at the bolt flanges damaging the coupling. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 98: Customer Assistance

    The satisfaction and good will of the Corporation and its distributor/dealer owners of Detroit Diesel engines are organizations. of primary concern to Detroit Diesel All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 99 Fax: 949-753-7711 CANADIAN REGION London, Ontario Detroit Diesel of Canada, Ltd. 150 Dufferin Ave., Suite 701 London, ON N5A 5N6 Phone: 519-661-0149 Fax: 519-661-0171 All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 100 Detroit, MI 48239-4001 Phone: 313-592-5875 Phone: 313-592-5708 Fax: 313-592-5158 Fax: 313-592-5158 CUSTOMER ASSURANCE (M24) 13400 Outer Drive, West Detroit, MI 48239-4001 Phone: 313-592-5550 Fax: 313-592-5717 All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 101 Detroit Diesel Allison de Mexico, S.A. Av. Santa Rosa 58 Col. Ampliacion Norte 54160 Tlalnepantla Edo. de Mexico MEXICO Phone: 52 55-5333-1803 Fax: 52 55-5333-1875 All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 102: Working With Ddc Service Outlets

    □ Type and make of equipment a problem that has not been handled satisfactorily. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 103: Step Three

    Therefore, it is suggested that you follow the previously mentioned steps in sequence when experiencing a problem. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 104: Limited Warranty On New Detroit Diesel Mbe 4000 Engines Used In On-Highway Vehicle Applications

    WARRANTY PERIOD from an authorized DDC service outlet. Only new genuine parts or remanufactured parts or components supplied or All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 105: Like Replacement Engine

    LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 4000 ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS Warranty Period Warranty Limitations Repair Charges to be (Whichever Occurs First) Paid by Owner Item Miles/ Months Parts Labor Kilometers Engine 0-24 Unlimited No Charge Charge...

  • Page 106: This Warranty Does Not Cover

    Refer to the Engine Operator”s Guide for details. All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...
  • Page 107 LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 4000 ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS THIS WARRANTY AND THE EMISSIONS CONTROL WARRANTY ARE THE ONLY WARRANTIES APPLICABLE TO THE ENGINE AS USED IN ON-HIGHWAY VEHICLE APPLICATIONS. DETROIT DIESEL CORPORATION MAKES NO...

  • Page 108: Limited Warranty On New Detroit Diesel Mbe 4000 Engines Used In Fire Truck Or Crash Vehicle Applications

    WARRANTY PERIOD from an authorized DDC service outlet. Only new genuine parts or remanufactured parts or components supplied or All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

  • Page 109: Like Replacement Engine

    LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 4000 ENGINES USED IN FIRE TRUCK OR CRASH VEHICLE APPLICATIONS Warranty Period Warranty Limitations Repair Charges to be (Whichever Occurs First) Paid by Owner Item Miles/ Months Parts Labor Kilometers 0-100,000 mi Engine...

  • Page 110: Maintenance

    Performance of REPAIRS is the exclusive Owner's remedy under this warranty. Detroit Diesel Corporation does not authorize ant person to assume or create for it any other All information subject to change without notice. (Rev. 04/08) DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION...

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