Detroit Diesel EPA04 MBE 4000 Manual

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE
To the Operator
This guide contains instructions on
the safe operation and preventive
maintenance of your Detroit Diesel
MBE 4000 engine. Maintenance
instructions cover routine engine
services such as lube oil and filter
changes in enough detail to permit
self-servicing if desired.
The operator should become familiar
with the contents of this guide before
operating the engine or carrying out
maintenance procedures.
Power-driven equipment is only
as safe as the person operating the
controls. You are urged, as the
operator of this diesel engine, to keep
fingers and clothing away from the
revolving belts, drive shafts, etc. on
engine installation.
Throughout this guide CAUTIONS
regarding personal safety and
NOTICES regarding engine
performance or service life will
appear. To avoid personal injury and
ensure long engine service life, always
heed these instructions.
Whenever possible, it will benefit
you to rely on an authorized Detroit
Diesel® service outlet for all your
service needs from maintenance to
major parts replacement. Authorized
service outlets worldwide stock
factory original parts and have
the specialized equipment and
experienced, trained personnel
to provide prompt preventive
maintenance and skilled engine
repairs.
The information and specifications
in this publication are based on the
information in effect at the time of
approval for printing. Contact an
authorized Detroit Diesel service
outlet for information on the latest
revision. The right is reserved to
make changes at any time without
obligation.
NOTICE:
Coolant must be inhibited with
the recommended Supplemental
Coolant Additives (SCA) listed in
this guide. In addition, the engine
can be equipped with a coolant
filter/inhibitor system as an installed
option or as an after-sale item.
Failure to check and maintain SCA
levels at required concentrations will
result in severe damage corrosion
to the engine cooling system and
related components.
Trademark Information
Detroit Diesel®, DDEC®, and
Diagnostic Link® are registered
trademarks of Detroit Diesel
Corporation. Nexiq™ is a trademark
of Nexiq Technologies, Inc. All other
trademarks are the property of their
respective owners.
All information subject to change without notice. (Rev. 04/08) i
DDC-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

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE
TABLE OF CONTENTS
CAUTION SUMMARY .......................................................................... 1
ENGINE OPERATION ..................................................................... 1
PREVENTIVE MAINTENANCE ....................................................... 2
ELECTRICAL SYSTEM ................................................................... 4
COOLING SYSTEM ......................................................................... 6
AIR INTAKE SYSTEM ...................................................................... 6
FUEL SYSTEM ................................................................................ 7
COMPRESSED AIR ......................................................................... 9
LUBRICATING OIL AND FILTERS .................................................. 9
IDENTIFICATION ................................................................................. 10
PERSONNEL REQUIREMENTS ..................................................... 11
ENGINE CONVERSIONS AND MODIFICATIONS .......................... 11
GENERAL VIEW OF THE MBE 4000 ENGINE ............................... 11
ENGINE TYPE PLATE ..................................................................... 14
DETAILS ON THE PLATE .......................................................... 14
ENGINE FEATURES ....................................................................... 15
EXHAUST BRAKE/CONSTANT-THROTTLE VALVES .................... 16
TURBO BRAKE, OPTIONAL ........................................................... 17
EXHAUST GAS RECIRCULATION ................................................. 17
ELECTRONIC ENGINE CONTROL SYSTEM ................................. 18
DDEC-ECU — ENGINE-RESIDENT CONTROL UNIT ............... 19
VEHICLE CONTROL UNIT ......................................................... 20
SENSOR LOCATIONS ................................................................ 20
OPERATION ........................................................................................ 22
BEFORE STARTING THE ENGINE ................................................ 22
CHECKING THE BATTERIES ..................................................... 22
CHECKING THE OIL LEVEL ....................................................... 23
CHECKING THE COOLANT LEVEL (COLD CHECK) ................ 24
ADDING FUEL ............................................................................. 24
PRIMING THE FUEL SYSTEM ................................................... 24
STARTING THE ENGINE ................................................................ 25
CHECKING THE COOLANT LEVEL (HOT CHECK) .................. 25
All information subject to change without notice. (Rev. 04/08) iii
DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

TABLEOFCONTENTS
STARTING AN ENGINE THAT HAS NOT BEEN RUN FOR A
LONG TIME ................................................................................. 26
MONITORING ENGINE OPERATION ............................................. 27
BATTERY CHARGE .................................................................... 27
OIL PRESSURE .......................................................................... 27
EXCESSIVE IDLING ................................................................... 28
CHANGING THE IDLE SPEED ....................................................... 28
SHUTTING DOWN THE ENGINE ................................................... 28
SHUTTING DOWN AFTER HIGH LOAD OPERATION ............... 28
EMERGENCY RUNNING MODE .................................................... 29
STOP ENGINE OVERRIDE OPTION .............................................. 29
COLD WEATHER OPERATION ...................................................... 30
WINTER FRONTS ....................................................................... 30
CLEANING AND STORAGE ............................................................... 31
CLEANING THE ENGINE ................................................................ 31
HIGH-PRESSURE CLEANING EQUIPMENT ............................. 31
CLEANING THE COOLING SYSTEM ............................................. 31
DEGREASING ............................................................................. 32
STORAGE ........................................................................................ 33
TROUBLESHOOTING ......................................................................... 34
EMERGENCY STARTING ............................................................... 34
TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL
SYSTEM .......................................................................................... 34
GENERAL TROUBLESHOOTING ................................................... 35
SERVICE PRODUCTS ......................................................................... 48
DIESEL FUELS ................................................................................ 48
FLOW IMPROVERS .................................................................... 48
KEROSENE ................................................................................. 48
ENGINE OILS .................................................................................. 49
SYNTHETIC OILS ....................................................................... 49
COOLANT ........................................................................................ 50
FULLY-FORMULATED ANTIFREEZE ......................................... 50
WATER ........................................................................................ 50
COOLANT SPECIFICATIONS ..................................................... 51
COOLANT CONCENTRATION ................................................... 51
iv All information subject to change without notice. (Rev. 04/08)
DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE
SUPPLEMENTAL COOLANT ADDITIVES FOR FULLY
FORMULATED COOLANT .......................................................... 52
DROPOUT ................................................................................... 52
NON-APPROVED COOLANTS ................................................... 52
RECYCLED ANTIFREEZE .......................................................... 53
CORROSION INHIBITORS ......................................................... 53
DISPOSAL ................................................................................... 54
COLD WEATHER PRODUCTS ....................................................... 54
WINTER-GRADE DIESEL FUEL ................................................. 54
LOW-VISCOSITY ENGINE OIL ................................................... 55
WINTER COOLANT ANTIFREEZE PROTECTION .................... 55
BATTERIES ................................................................................. 55
TECHNICAL DATA .............................................................................. 56
ENGINE DATA ................................................................................. 57
TESTING AND ADJUSTING VALUES ............................................. 58
MAINTENANCE ................................................................................... 60
SCHEDULED INTERVALS .............................................................. 60
MAINTENANCE SCHEDULE TYPES ......................................... 60
SEVERE SERVICE ................................................................. 60
SHORT-HAUL ......................................................................... 61
LONG-HAUL ........................................................................... 61
MAINTENANCE SCHEDULE AND INTERVAL
OPERATIONS ......................................................................... 61
MAINTENANCE INTERVALS .................................................. 61
MAINTENANCE OPERATION SETS ...................................... 61
SCHEDULE USE ......................................................................... 62
MAINTENANCE TABLES ................................................................ 63
REQUIRED MAINTENANCE OPERATIONS ................................... 69
ENGINE INSPECTING ................................................................ 69
VALVE LASH CHECKING AND ADJUSTING ............................. 69
GAINING ACCESS TO THE VALVES ..................................... 69
CHOOSING A METHOD ......................................................... 70
METHOD ONE ........................................................................ 71
METHOD TWO ....................................................................... 72
ADJUSTING VALVE LASH ...................................................... 73
RESTORING THE VEHICLE TO OPERATING CONDITION .. 73
All information subject to change without notice. (Rev. 04/08) v
DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

TABLEOFCONTENTS
FUEL/WATER SEPARATOR PREFILTER ELEMENT
CLEANING .................................................................................. 74
FUEL PRO® 382 FUEL/WATER SEPARATOR ELEMENT
REPLACEMENT .......................................................................... 75
MAIN FUEL FILTER ELEMENT CHANGING .............................. 76
ENGINE OIL AND FILTER CHANGING ...................................... 77
OPTIONAL OIL CENTRIFUGE ............................................... 80
COOLANT CONCENTRATION AND INHIBITOR LEVEL
CHECKING .................................................................................. 81
COOLANT INHIBITOR TEST INTERVALS ............................. 82
INHIBITOR LEVEL CHECKING .............................................. 84
COOLANT FLUSHING AND CHANGING ................................... 85
COOLING SYSTEM INSPECTING ............................................. 86
REAR ENGINE POWER TAKE-OFF (REPTO) .......................... 87
REPTO TORSIONAL DAMPER INSPECTION ....................... 87
REPTO TORSIONAL DAMPER CLEANING ........................... 87
CUSTOMER ASSISTANCE ................................................................. 89
WORKING WITH DDC SERVICE OUTLETS .................................. 93
STEP ONE ................................................................................... 93
STEP TWO .................................................................................. 93
STEP THREE .............................................................................. 94
LIMITED WARRANTY ON NEW DETROIT DIESEL MBE 4000
ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS ......... 95
TERMS OF COVERAGE ................................................................. 95
USES ........................................................................................... 95
DEFECTS .................................................................................... 95
REPAIRS ..................................................................................... 95
WARRANTY PERIOD .................................................................. 95
LIKE REPLACEMENT ENGINE .................................................. 96
SERVICE SUPPLIES .................................................................. 96
ENGINE REMOVAL AND REINSTALLATION ............................. 96
THIS WARRANTY DOES NOT COVER: ......................................... 97
REPAIRS DUE TO ACCIDENTS, MISUSE,STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 97
FUEL INJECTION SYSTEM AFTER 100,000 MILES/160, 000
KILOMETERS .............................................................................. 97
MAINTENANCE ........................................................................... 97
vi All information subject to change without notice. (Rev. 04/08)
DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE
INCIDENTAL OR CONSEQUENTIAL DAMAGES ...................... 97
OTHER LIMITATIONS ................................................................. 97
LIMITED WARRANTY ON NEW DETROIT DIESEL MBE
4000 ENGINES USED IN FIRE TRUCK OR CRASH VEHICLE
APPLICATIONS ................................................................................... 99
TERMS OF COVERAGE ................................................................. 99
USES ........................................................................................... 99
DEFECTS .................................................................................... 99
REPAIRS ..................................................................................... 99
WARRANTY PERIOD .................................................................. 99
LIKE REPLACEMENT ENGINE .................................................. 100
SERVICE SUPPLIES .................................................................. 100
ENGINE REMOVAL AND REINSTALLATION ............................. 100
THIS WARRANTY DOES NOT COVER: ......................................... 100
REPAIRS DUE TO ACCIDENTS, MISUSE,STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 100
FUEL INJECTION SYSTEM AFTER 100,000 MILES/160, 000
KILOMETERS .............................................................................. 100
MAINTENANCE ........................................................................... 101
INCIDENTAL OR CONSEQUENTIAL DAMAGES ...................... 101
OTHER LIMITATIONS ................................................................. 101
All information subject to change without notice. (Rev. 04/08) vii
DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

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

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE
CAUTION SUMMARY
The following cautions must be
observed by the operator of the
vehicle or equipment in which this
engine is installed and/or by those
performing basic engine preventive
maintenance. Failure to read and heed
these cautions and exercise reasonable
care for personal safety and the
safety of others when operating the
vehicle/equipment or performing basic
engine preventive maintenance may
result in personal injury and engine
and/or vehicle/equipment damage.
Engine Operation
Observe the following cautions when
operating the engine.
FIRE
To avoid injury from fire, keep all
potential ignition sources away
from diesel fuel, including open
flames, sparks, and electrical
resistance heating elements. Do
not smoke when refueling.
PERSONAL INJURY
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
□Always start and operate an
engine in a well ventilated
area.
□If operating an engine in
an enclosed area, vent the
exhaust to the outside.
□Do not modify or tamper
with the exhaust system or
emission control system.
All information subject to change without notice. (Rev. 04/08) 1
DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

CAUTION SUMMARY
Preventive Maintenance
Observe the following cautions when
performing preventative maintenance.
HOT OIL
To avoid injury from hot oil, do
not operate the engine with the
rocker cover(s) removed.
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
USED ENGINE OIL
To avoid injury to skin from
contact with the contaminants in
used engine oil, wear protective
gloves and apron.
PERSONAL INJURY
To avoid injury when working
near or on an operating engine
equipped with an hydraulic
clutch fan, remove loose items
of clothing and jewelry. Tie back
or contain long hair that could
be caught in any moving part
causing injury. The hydraulic fan
may start without warning.
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
at operating temperature. Wear
adequate protective clothing
(face shield, rubber gloves,
apron, and boots). Remove the
cap slowly to relieve pressure.
2All information subject to change without notice. (Rev. 04/08)
DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE
PERSONAL INJURY
To avoid injury from the
projection of tools or other
objects that may fall on or behind
the vibration damper of an
engine, always check and remove
these items before starting the
engine.
PERSONAL INJURY
To avoid injury from contact
with rotating parts when an
engine is operating with the air
inlet piping removed, install an
air inlet screen shield over the
turbocharger air inlet. The shield
prevents contact with rotating
parts.
PERSONAL INJURY
To avoid injury when using
caustic cleaning agents, follow
the chemical manufacturers
usage, disposal, and safety
instructions.
FIRE
To avoid injury from combustion
of heated lubricating-oil vapors,
stop the engine immediately if an
oilleakisdetected.
FIRE
To avoid injury from fire, do not
smoke or allow open flames when
workingonanoperatingengine.
FIRE
To avoid injury from fire from a
buildup of volatile vapors, keep
the engine area well ventilated
during operation.
All information subject to change without notice. (Rev. 04/08) 3
DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

CAUTION SUMMARY
Electrical System
Observe the following cautions when
jump starting an engine, charging a
battery, or working with the vehicle
electrical system.
PERSONAL INJURY
To avoid injury from accidental
engine startup while servicing
the engine, disconnect/disable
the starting system.
Electrical Shock
To avoid injury from electrical
shock, use care when connecting
battery cables. The magnetic
switch studs are at battery
voltage.
Battery Explosion and Acid Burn
To avoid injury from battery
explosion or contact with battery
acid, work in a well ventilated
area, wear protective clothing,
and avoid sparks or flames near
the battery. If you come in contact
with battery acid:
□Flush your skin with water.
□Applybakingsodaorlimeto
help neutralize the acid.
□Flush your eyes with water.
□Get medical attention
immediately.
ELECTRICAL SHOCK
To avoid injury from electrical
shock, do not touch battery
terminals, alternator terminals, or
wiring cables while the engine is
operating.
4All information subject to change without notice. (Rev. 04/08)
DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE
Electrical Shock Hazard
High voltage can remain inside
the Electrostatic Oil Separator
after removal. Wait 30 minutes
after turning off the ignition
before removing the separator.
Never touch parts through
ventilation openings or impeller
opening with finger or conductive
items (e.g. screwdriver or wire).
High voltage can remain inside
the Electrostatic Oil Separator for
up to 12 hours after the ignition
is turned off.
All information subject to change without notice. (Rev. 04/08) 5
DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

CAUTION SUMMARY
Cooling System
Observe the following cautions when
servicing the cooling system.
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
at operating temperature. Wear
adequate protective clothing
(face shield, rubber gloves,
apron, and boots). Remove the
cap slowly to relieve pressure.
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
Air Intake System
Observe the following cautions when
working on the air intake system.
PERSONAL INJURY
To avoid injury from hot surfaces,
wear protective gloves, or allow
engine to cool before removing
any component.
PERSONAL INJURY
To avoid injury from contact
with rotating parts when an
engine is operating with the air
inlet piping removed, install an
air inlet screen shield over the
turbocharger air inlet. The shield
prevents contact with rotating
parts.
6All information subject to change without notice. (Rev. 04/08)
DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE
Fuel System
Observe the following cautions when
fueling the vehicle or working with
the fuel system.
PERSONAL INJURY
To avoid injury from fuel spills,
do not overfill the fuel tank.
FIRE
To avoid injury from fire, contain
and eliminate leaks of flammable
fluids as they occur. Failure to
eliminate leaks could result in
fire.
PERSONAL INJURY
To prevent the escape of high
pressure fuel that can penetrate
skin, ensure the engine has
been shut down for a minimum
of 10 minutes before servicing
any component within the high
pressure circuit. Residual high
fuel pressure may be present
within the circuit.
FIRE
To avoid injury from fire, keep all
potential ignition sources away
from diesel fuel, including open
flames, sparks, and electrical
resistance heating elements. Do
not smoke when refueling.
All information subject to change without notice. (Rev. 04/08) 7
DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

CAUTION SUMMARY
FIRE
To avoid injury from fire caused
by heated diesel-fuel vapors:
□Keep those people who are not
directly involved in servicing
away from the engine.
□Stop the engine immediately if
a fuel leak is detected.
□Do not smoke or allow open
flames when working on an
operating engine.
□Wear adequate protective
clothing (face shield,
insulated gloves and apron,
etc.).
□To prevent a buildup of
potentially volatile vapors,
keeptheengineareawell
ventilated during operation.
8All information subject to change without notice. (Rev. 04/08)
DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE
Compressed Air
Observe the following cautions when
using compressed air.
EYE INJURY
To avoid injury from flying debris
when using compressed air, wear
adequate eye protection (face
shield or safety goggles) and do
not exceed 276 kPa (40 psi) air
pressure.
Lubricating Oil and Filters
Observe the following cautions when
replacing the engine lubricating oil
and filters.
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
FIRE
To avoid injury from combustion
of heated lubricating-oil vapors,
stop the engine immediately if an
oil leak is detected.
FIRE
To avoid injury from fire, do not
smoke or allow open flames when
workingonanoperatingengine.
FIRE
To avoid injury from fire from a
buildup of volatile vapors, keep
the engine area well ventilated
during operation.
All information subject to change without notice. (Rev. 04/08) 9
DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

IDENTIFICATION
IDENTIFICATION
The MBE 4000 engine is built in
accordance with sound technological
principles and based on state-of-the-art
technology. It complies with all United
States Environmental Protection
Agency (USEPA) and California Air
Resources Board (CARB) emission
standards. An emission label is
attached to the cylinder head cover, as
required by law. See Figure 1.
Figure 1 Emission Label, MBE 4000
10 All information subject to change without notice. (Rev. 04/08)
DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION

EPA04 MBE 4000 ENGINE OPERATOR'S GUIDE
Despite this, the engine may constitute
a risk of damage to property or
injury to persons under the following
conditions:
□It is not used for its intended
purpose.
□It is modified or converted in an
incorrect manner.
□The safety instructions included in
this manual are disregarded.
Personnel Requirements
Work on the engine should be carried
out only by skilled technicians who
have been instructed in the specific
skills necessary for the type of work
being performed.
Engine Conversions and
Modifications
The function and safety of the engine
could be affected if unauthorized
modifications are made to it. Detroit
Diesel will not accept responsibility
for any resulting damage.
Tampering with the fuel injection
system and engine electronics could
also affect the engine's power output or
exhaust emission levels. Compliance
with the manufacturer's settings
and with statutory environmental
protection regulations cannot then be
guaranteed.
General View of the MBE
4000 Engine
For a general view of the MBE 4000
engine, showing major components,
see Figure 2 for the left-hand side, and
Figure 3 for the right-hand side.
All information subject to change without notice. (Rev. 04/08) 11
DDC-SVC-MAN-0056 04/08 Copyright © 2008 DETROIT DIESEL CORPORATION