Detroit Diesel MBE4000 Operating and installation instructions

NUMBER: 1–MBE 4000–07 S.M. REF.: seetable1 ENGINE: MBE 4000 DATE: February 2007
SUBJECT: LOW POWER CONCERN
PUBLICATION: EPA-04 MBE 4000 SERVICE MANUAL (6SE412)
The service manual has been restructured to add a “Low Power Concern” chapter. Previously the
troubleshooting concerns were found in chapter 15, now each troubleshooting concern has its own
chapter.
Service Manual Chapter Decsription
15 Troubleshooting The Electronic Engine Control System
16 General Mechanical Troubleshooting
17 Low Power Concern
Table 1 Troubleshooting Chapters
Chapter 17 includes factors that affect wheel horsepower and other associated low power information.
ADDITIONAL SERVICE INFORMATION
Additional service information is available in the Detroit Diesel MBE 4000 Service Manual, 6SE412.
Thenextrevisiontothismanualwill include the revised information.

15 TROUBLESHOOTING THE ELECTRONIC ENGINE
CONTROL SYSTEM
Section Page
15.1 ELECTRONIC ENGINE CONTROL SYSTEM ......................................... 15- 3

(Rev. 2007) All information subject to change without notice.
15-2 From Bulletin 1–MBE 4000–07 6SE412 0702 Copyright © 2007 DETROIT DIESEL CORPORATION

MBE 4000 SERVICE MANUAL 6SE412
15.1 ELECTRONIC ENGINE CONTROL SYSTEM
When the electronic engine control system detects a fault, it broadcasts a message on the datalink.
The dash display will show the code "ECU 128," indicating there is an engine fault.
NOTE:
To read the complete fault code, refer to the MBE Electronic Controls Troubleshooting
Guide (6SE422) or bring the vehicle to an authorized repair facility. Complete fault
codes can be read using minidiag2.
All information subject to change without notice. (Rev. 2007)
6SE412 0702 Copyright © 2007 DETROIT DIESEL CORPORATION From Bulletin 1–MBE 4000–07 15-3

15.1 ELECTRONIC ENGINE CONTROL SYSTEM
(Rev. 2007) All information subject to change without notice.
15-4 From Bulletin 1–MBE 4000–07 6SE412 0702 Copyright © 2007 DETROIT DIESEL CORPORATION

16 GENERAL MECHANICAL TROUBLESHOOTING
Section Page
16.1 MECHANICAL TROUBLESHOOTING .................................................... 16-3

(Rev. 2007) All information subject to change without notice.
16-2 From Bulletin 1–MBE 4000–07 6SE412 0702 Copyright © 2007 DETROIT DIESEL CORPORATION

MBE 4000 SERVICE MANUAL 6SE412
16.1 MECHANICAL TROUBLESHOOTING
The tables that follow are designed to identify the causes of common problems, suggest further
checks and appropriate remedies. When dealer service is necessary, this is mentioned in the table.
Problem - The Engine Will Not Crank
Cause Remedy
The batteries are damaged or weak. Test the batteries. Replace them, if needed.
The ignition switch is damaged. Replace the ignition switch.
The battery cables are damaged and/or corroded. Replace the battery cables.
The starter is damaged and/or worn. Have an authorized dealer replace the starter.
The clutch or transmission is damaged. Bring the vehicle to an authorized dealer for service.
There is internal damage to the engine. Bring the vehicle to an authorized dealer for service.
Problem—The Engine Turns Over Slowly
Cause Remedy
The batteries are damaged or weak. Test the batteries. Replace them, if needed.
The ignition switch is damaged. Replace the ignition switch.
The battery cables are damaged and/or corroded Replace the battery cables.
The starter is damaged and/or worn. Have an authorized dealer replace the starter.
The engine oil does not meet the correct specifications. Change the engine oil, using the correct type of oil.
The transmission fluid does not meet the correct
specifications. Change the transmission fluid, using the correct type of fluid.
All information subject to change without notice. (Rev. 2007)
6SE412 0702 Copyright © 2007 DETROIT DIESEL CORPORATION From Bulletin 1–MBE 4000–07 16-3

16.1 MECHANICAL TROUBLESHOOTING
Problem—The Engine Cranks, But Won't Start
Cause Remedy
The batteries are damaged or weak. Test the batteries. Replace them, if needed.
The cranking speed is not set correctly. Bring the vehicle to an authorized dealer for service.
No intake air preheater is installed, and it is too cold to
start without one. Install an intake air preheater.
The intake air preheater is malfunctioning. Check the intake air preheater, and replace it, if
necessary.
The camshaft TDC sensor and/or the crank angle
position sensor are out of adjustment.
Push both sensors into their holes as far as they will go.
If this does not solve the problem, bring the vehicle to an
authorized dealer for service.
The camshaft TDC sensor and/or the crank angle
position sensor are damaged. Bring the vehicle to an authorized dealer for service.
There is air in the fuel system. Check the fuel lines for air pockets. Bleed the fuel
system and start the engine.
The air filter is clogged. Clean or replace the air filter.
The fuel filter is clogged. Replace the filter element.
The exhaust brake valve is malfunctioning. Have an authorized dealer check the operation of the
valve.
The valves are not adjusted properly. Check the valve lash.
There are other problems in the fuel system. Bring the vehicle to an authorized dealer for service.
Problem—The Engine Starts Only After Cranking for a Long Time
Cause Remedy
The fuel tank is low or empty. Add fuel and bleed the fuel system, if necessary.
There are leaks in the fuel lines. Check the fuel lines for leaks and repair them, if
necessary.
The fuel filter is clogged. Replace the filter element.
The fuel line, the fuel pre-filter, or the screen in the fuel
tank is blocked. Clean and bleed the system. Have the fuel lines and filters checked by an authorized dealer.
The camshaft TDC sensor and/or the crank angle
position sensor are out of adjustment.
Push both sensors into their holes as far as they will go.
If this does not solve the problem, bring the vehicle to an
authorized dealer for service.
The camshaft TDC sensor and/or the crank angle
position sensor are damaged. Bring the vehicle to an authorized dealer for service.
There are other problems in the fuel system. Bring the vehicle to an authorized dealer for service.
(Rev. 2007) All information subject to change without notice.
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MBE 4000 SERVICE MANUAL 6SE412
Problem—The Engine Starts, But Dies
Cause Remedy
The fuel tank is low or empty. Add fuel and bleed the fuel system, if necessary.
The fuel filter is clogged. Replace the filter element.
The fuel line, the fuel pre-filter, or the screen in the fuel
tank is blocked. Clean and bleed the system. Have the fuel lines and filters checked by an authorized dealer.
The camshaft TDC sensor and/or the crank angle
position sensor are out of adjustment.
Push both sensors into their holes as far as they will go.
If this does not solve the problem, bring the vehicle to an
authorized dealer for service.
The camshaft TDC sensor and/or the crank angle
position sensor are damaged. Bringthevehicletoanauthorizeddealerforservice.
The constant-throttle valves are malfunctioning. Bring the vehicle to an authorized dealer for service.
There are other problems in the fuel system. Bring the vehicle to an authorized dealer for service.
Problem—The Engine Fan Doesn't Work
Cause Remedy
The fan hub is damaged. Replace the fan hub.
The fan wiring is damaged. Repair the fan wiring.
The parameter settings in the PLD or VCU control unit
are incorrect. Have an authorized dealer reprogram the control unit.
Problem—The Engine Fan Is Constantly On
Cause Remedy
The fan override switch is on. Check the operation of the fan override switch.
The fan hub is damaged. Replace the fan hub
The parameter settings in the PLD or VCU control unit
are incorrect. Have an authorized dealer reprogram the control unit.
Problem—Fuel Consumption Is Too High
Cause Remedy
The tires are not properly inflated. Check all tires for correct pressure.
The air filter and/or intake air system is clogged. Check the air restriction indicator. Clean the intake air
system and replace the air filter if necessary.
The fuel filter is clogged. Replace the filter element.
The exhaust brake valve is malfunctioning. Have an authorized dealer check the operation of the
valve.
The engine performs poorly, or does not develop full
power. The remedies are listed in "The Engine Performs Poorly, Does Not Develop Full Power."
All information subject to change without notice. (Rev. 2007)
6SE412 0702 Copyright © 2007 DETROIT DIESEL CORPORATION From Bulletin 1–MBE 4000–07 16-5

16.1 MECHANICAL TROUBLESHOOTING
Problem—The Engine Performs Poorly, Does Not Develop Full Power
Cause Remedy
The air filter and/or intake air system is clogged. Check the air restriction indicator. Clean the intake air
system and replace the air filter if necessary.
The exhaust brake valve is malfunctioning. Have an authorized dealer check the operation of the
valve.
The fuel filter is clogged. Replace the filter element.
There are other problems with the fuel system. Bring the vehicle to an authorized dealer for service.
The valves are not adjusted properly Check the valve lash. See
The coolant temperature sensor is damaged or reading
incorrectly. Bring the vehicle to an authorized dealer for service.
The fuel temperature sensor is damaged or reading
incorrectly. Bring the vehicle to an authorized dealer for service.
The engine oil temperature sensor is damaged or
reading incorrectly. Bring the vehicle to an authorized dealer for service.
The charge-air temperature sensor is damaged or
reading incorrectly. Bring the vehicle to an authorized dealer for service.
There are problems with the PLD or VCU control unit. Bring the vehicle to an authorized dealer for service.
There is internal damage to the engine. Bring the vehicle to an authorized dealer for service.
Problem—The Engine Performs Poorly, Does Not Develop Full Power
Cause Remedy
The air filter and/or intake air system is clogged. Check the air restriction indicator. Clean the intake air
system and replace the air filter if necessary.
The exhaust brake valve is malfunctioning. Have an authorized dealer check the operation of the
valve.
The fuel filter is clogged. Replace the filter element.
There are other problems with the fuel system. Bring the vehicle to an authorized dealer for service.
The valves are not adjusted properly Check the valve lash. See
The coolant temperature sensor is damaged or reading
incorrectly. Bring the vehicle to an authorized dealer for service.
The fuel temperature sensor is damaged or reading
incorrectly. Bring the vehicle to an authorized dealer for service.
The engine oil temperature sensor is damaged or
reading incorrectly. Bring the vehicle to an authorized dealer for service.
The charge-air temperature sensor is damaged or
reading incorrectly. Bring the vehicle to an authorized dealer for service.
There are problems with the PLD or VCU control unit. Bring the vehicle to an authorized dealer for service.
There is internal damage to the engine. Bring the vehicle to an authorized dealer for service.
(Rev. 2007) All information subject to change without notice.
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MBE 4000 SERVICE MANUAL 6SE412
Problem—The Engine Is in Emergency Running Mode (constant speed 1,300 rpm)
Cause Remedy
The PLD or VCU control unit is damaged. Bring the vehicle to an authorized dealer for service.
Problem—The Coolant Temperature Is Above Normal
Cause Remedy
The coolant level is too low. Check for coolant leaks, and repair as needed.
The poly-V belt is loose. Tighten or replace the poly-V belt.
The coolant temperature gauge and/or sensor is not
reading correctly. Bringthevehicletoanauthorizeddealerforservice.
The radiator is damaged or dirty. Clean the radiator. Repair or replace the radiator if
necessary.
The coolant pump is damaged. Have an authorized dealer replace the coolant pump.
The thermostat is damaged. Have an authorized dealer replace the coolant pump.
The fan is not operating properly.
Bringthevehicletoanauthorizeddealerandhavethe
fan hub checked.
Bringthevehicletoanauthorizeddealerandhavethe
parameter settings reprogrammed in the engine control
unit (PLD) or vehicle control unit (VCU).
Problem—The Coolant Temperature Is Below Normal
Cause Remedy
The coolant temperature gauge and/or sensor is not
reading correctly. Bringthevehicletoanauthorizeddealerforservice.
The thermostat is damaged. Have an authorized dealer replace the thermostat.
The fan is not operating properly.
Bringthevehicletoanauthorizeddealerandhavethe
fan hub checked.
Bringthevehicletoanauthorizeddealerandhavethe
parameter settings reprogrammed in the engine control
unit (PLD) or vehicle control unit (VCU).
Problem—The Cooling System Is Losing Coolant
Cause Remedy
There is an external coolant leak. Repair the leaking component.
The radiator cap is leaking. Replace the radiator cap.
The air compressor head is damaged. Have an authorized dealer replace the air compressor.
The cylinder head gasket is leaking. Have an authorized dealer replace the head gasket.
All information subject to change without notice. (Rev. 2007)
6SE412 0702 Copyright © 2007 DETROIT DIESEL CORPORATION From Bulletin 1–MBE 4000–07 16-7

16.1 MECHANICAL TROUBLESHOOTING
Problem—There Is Coolant in the Engine Oil
Cause Remedy
The cylinder head gasket is damaged. Have an authorized dealer replace the head gasket.
The oil/water heat exchanger is leaking. Have an authorized dealer replace the heat exchanger.
There is an internal coolant leak. Bring the vehicle to an authorized dealer for service.
Problem—There Is Foam in the Engine Oil
Cause Remedy
The oil level is too low or too high. Correct the oil level.
The oil has not been changed within the recommended
interval. Change the oil.
The oil is not of the recommended quality. Change the oil.
Problem—The Engine Oil Pressure Is Low
Cause Remedy
The oil pressure gauge and/or sensor is not reading
correctly. Bring the vehicle to an authorized dealer for service.
There is fuel in the oil. Bring the vehicle to an authorized dealer for service.
The oil filter is clogged. Replace the filter element.
The oil filter bypass valve is damaged. Replace the bypass valve.
The oil pump and/or relief valve is damaged. Have an authorized dealer replace the oil pump.
Problem—The Engine Exhaust Is White
Cause Remedy
The fuel is of poor quality. Add fuel of the right quality.
The intake air preheater is malfunctioning. Check the intake air preheater, and replace it, if
necessary.
The valves are not adjusted properly. Check the valve lash.
(Rev. 2007) All information subject to change without notice.
16-8 From Bulletin 1–MBE 4000–07 6SE412 0702 Copyright © 2007 DETROIT DIESEL CORPORATION

MBE 4000 SERVICE MANUAL 6SE412
Problem—The Engine Exhaust Is Black
Cause Remedy
The air filter and/or intake air system is clogged. Check the air restriction indicator. Clean the intake air
system and replace the air filter if necessary.
The exhaust brake valve is malfunctioning. Have an authorized dealer check the operation of the
valve.
The intake air preheater is malfunctioning. Check that the heater is not staying on all of the time.
The valves are not adjusted properly. Check the valve lash.
There is damage to the fuel system: the fuel pump, one
or more fuel injectors, or one or more unit pumps are
damaged. Bringthevehicletoanauthorizeddealerforservice.
The charge-air temperature sensor is damaged. Bring the vehicle to an authorized dealer for service.
There is internal damage to the engine. Bring the vehicle to an authorized dealer for service.
Problem—The Engine Exhaust Is Blue
Cause Remedy
The engine oil level is too high (engine oil is reaching
the combustion chamber). Adjust the oil level, and then have the oil level checked by an authorized dealer.
The turbocharger is leaking oil. Have an authorized dealer replace the turbocharger
The valve stem seals are loose or damaged. Have an authorized dealer replace the seals.
The piston rings are worn. Have an authorized dealer replace the piston rings.
Problem—Engine Brake Performance Is Poor
Cause Remedy
The engine brake control switch is damaged. Replace the switch
The exhaust brake is not operating properly. Have an authorized dealer check the operation of the
valve.
The constant-throttle valves are malfunctioning. Bring the vehicle to an authorized dealer for service.
Components of the PLD and/or VCU control unit are
damaged. Bringthevehicletoanauthorizeddealerforservice.
Problem—Cruise Control Is Not Working
Cause Remedy
One or more of the cruise control switches are damaged. Replace the damaged switch.
Components of the PLD and/or VCU control unit are
damaged or not working properly. Bringthevehicletoanauthorizeddealerforservice.
All information subject to change without notice. (Rev. 2007)
6SE412 0702 Copyright © 2007 DETROIT DIESEL CORPORATION From Bulletin 1–MBE 4000–07 16-9

16.1 MECHANICAL TROUBLESHOOTING
Problem—The Battery Charge Indicator Light Does Not Come On When the Engine Is Not Running
Cause Remedy
The bulb is damaged. Change the bulb.
The circuit is broken. Repair the break in the circuit.
Problem—The Battery Charge Indicator Light Comes On When the Engine is Running
Cause Remedy
The poly-V belt is too loose. Check the belt tension; if necessary, have an authorized
dealer replace the belt tensioner.
The belt tensioner is damaged. Have an authorized dealer replace the belt tensioner.
he poly-V belt is worn or damaged. Replace the belt.
The alternator is damaged (has a damaged rectifier or
voltage regulator). Have an authorized dealer replace the alternator.
(Rev. 2007) All information subject to change without notice.
16-10 From Bulletin 1–MBE 4000–07 6SE412 0702 Copyright © 2007 DETROIT DIESEL CORPORATION

17 LOW POWER CONCERN
Section Page
17.1 FACTORS THAT AFFECT WHEEL HORSEPOWER .............................. 17-3
17.2 LOW HORSEPOWER INTERVIEW ......................................................... 17-6
17.3 AERATED FUEL ..................................................................................... 17-13
17.4 RESTRICTED AIR CLEANER ELEMENT ............................................... 17-15
17.5 RESTRICTED OR CRACKED CHARGE AIR COOLER OR LEAKING
INTAKE MANIFOLD ................................................................................. 17-16
17.6 FAULTY EXHAUST SYSTEM .................................................................. 17-18
17.7 HIGH INLET AIR TEMPERATURE .......................................................... 17-20
17.8 VERIFICATION OF POWER WITH CHASSIS DYNAMOMETER ........... 17-22

(Rev. 2007) All information subject to change without notice.
17-2 From Bulletin 1–MBE 4000–07 6SE412 0702 Copyright © 2007 DETROIT DIESEL CORPORATION

MBE 4000 SERVICE MANUAL
17.1 FACTORS THAT AFFECT WHEEL HORSEPOWER
The factors affecting wheel horsepower are listed in Table 17-1.
To begin low horsepower diagnosis, refer to section 17.2
Factors Considerations
Power Rating Is the correct power rating programmed into the PLD? Is the driver aware of
the effects that cruise power, or the lack of cruise power has on perceived
power?
Road Speed Setting Is the road speed setting causing a perceived lack of power?
Crank Case Overfilled If the crank case level is too high, there will be a loss of power due to
churning losses created by the crank shaft throws contacting the oil.
Fuel Blend (specific gravity) Check the specific gravity of the fuel/vehicle system. A good number 2
diesel fuel has a specific gravity of 0.840 or higher @ 60°F. It should be
noted that No. 1 diesel fuel can reduce horsepower to 7% less than No.
2 fuel. Blends of No. 1 and No. 2 (common in winter) will produce less
horsepower, depending on the percent of the blend. This is a common
concern when dealing with low power complaints in cold climate locations.
Fuel Filter Restriction Check for fuel flow restrictions which can be caused by fuel heaters, water
separators, fuel flow meters, undersize or improperly routed/damaged fuel
lines, faulty check valves, contaminated fuel filters or high fuel pressure
resulting from a plugged restricted fitting or regulator valve. Replacing the
fuel filter is often the best recommendation in lieu of testing for the filter
condition. Make sure the recommended fuel filter is being used. Refer to
Technical Service Letter (05-TS-12REV – MBE 4000 Fuel Filter Update).
Fuel System Leak Fuel system leaks which result in aerated fuel are normally caused by a
leak at the connections and /or filters between the suction side of the fuel
pump to the supply tank and not between the pressure side of the pump
and engine.
Fuel Tank Vent Restriction A plugged fuel tank vent will create a vacuum in the tank and result in a
loss in fuel pressure at the injectors. This will reduce fuel delivery rate.
Air in Fuel Aerated fuel, caused by a fuel system leak, will result in reduced fuel
delivery and late injection timing.
Plugged or Cracked Fuel Tank Stand
Pipe If the fuel tank stand pipe is plugged by a shop rag, fuel delivery will be restricted. A cracked stand pipe will allow air to enter the fuel system and
reduce fuel flow and cause late injection timing.
Faulty Injector/Unit Pump A faulty injector/unit pump will limit fuel delivery and alter the combustion
process such that power is compromised. Using Idle Smooth Balance
(ISB) in DDDL can help identify a faulty injector nozzle.
Valve Lash Incorrect valve lash will alter the combustion process such that power is
compromised.
Air Flow Restriction Air flow must not be inhibited by a plugged filter, or inadequate inlet air
duct shrouding.
Faulty Turbocharger A turbocharger that has wheel rubbing, oil leaks, bent blades, etc. will not
provide adequate air supply.
All information subject to change without notice. (Rev. 2007)
6SE412 0702 Copyright © 2007 DETROIT DIESEL CORPORATION From Bulletin 1–MBE 4000–07 17-3

17.1 FACTORS THAT AFFECT WHEEL HORSEPOWER
Factors Considerations
Temperature Controlled Fan A faulty thermo control will cause the fan to be locked on and drain power
on a continuous basis.
Air System Leaks (gaskets and seals) Air system leaks will result in insufficient air for optimum combustion.
Biodiesel Should not be higher than 5%. Refer to Engine Requirements – Lubricating
Oil, Fuel and Filters, (7SE270), available from authorized Detroit Diesel
distributors.
Charge Air Cooler Leak Air system leaks will result in insufficient air for optimum combustion.
Climate (fresh air temp) The maximum allowable temperature rise from ambient air to engine inlet
is 15°F. Undersized or dirty air cleaner element, as well as damaged or
obstructed air inlet piping can cause low power. Make sure under-hood
hot air is not being taken in. Pressure drop across the air to air charge
cooler should be checked (3.0 in. Hg maximum from turbo discharge to
intake manifold). Check turbocharger boost pressure and compare to
specification.
Altitude Performance Site altitude has an effect on engine horsepower. Expect approximately 2%
loss in power when operating at an altitude of 1 mile, relative to sea level.
PLD/VCU Settings Make sure vehicle settings such as: axle ratio, tire size, top gear ratio, etc.
are set correctly to avoid a false sense of engine performance.
EGR Valve A misadjusted or malfunctioning EGR valve will alter the amount of oxygen
available for combustion as well as introduce inert gas that does not
promote combustion.
Exhaust Restriction A damaged, undersized, or otherwise restricted muffler or exhaust system
can result in high exhaust back pressure. Refer to the engine specification
sheets for maximum allowable pressure.
Barometric Pressure Sensor The engine will transition between EGR and boost mode at an altitude
of 13,120 ft. Altitude is determined by the Barometric Pressure Sensor
located in the PLD. A faulty Barometric Pressure Sensor will compromise
the availability of boost pressure.
EPV and Supply Lines Variable pressure output devices control the variable geometry turbo vanes
and EGR valve position. Improper turbo vane or EGR valve positions will
alter the air flow system balance and subsequently the combustion process.
Air Compressor Leak An air compressor leak will cause the air compressor to work more and
increase the parasitic load on the engine.
Air Conditioner Leak An air conditioner leak will cause the air conditioner to work more and
increase the parasitic load on the engine.
Excessive Play in Power Steering
System Continuous movement of the steering wheel will call for continuous work by the power steering unit. This will increase the parasitic load on the engine.
Alternator Load Excessive use of vehicle electrical power will cause increased use of the
alternator. This will increase the parasitic load on the engine.
Tire Pressure Under inflated tires will significantly increase driveline resistance to rotation.
Trailer Aerodynamics/Alignment A trailer that has poor aerodynamics or has misaligned axles (causing dog
tailing) will significantly increase vehicle inertia and resistance to forward
motion.
Vehicle Payload As vehicle loading increases, vehicle inertia and resistance to forward
motion increases.
(Rev. 2007) All information subject to change without notice.
17-4 From Bulletin 1–MBE 4000–07 6SE412 0702 Copyright © 2007 DETROIT DIESEL CORPORATION

MBE 4000 SERVICE MANUAL
Factors Considerations
Winter-front Installation Improper installation or usage of a winter-front will result in extremely high
intake air temperatures and reduced mass flow of air into the combustion
chamber.
Vehicle Application Unusual applications such as triple drive axles, PTO's, pumps, high air
compressor duty cycle, etc., will have higher parasitic loses resulting in less
horsepower at the wheels.
Foot Pedal Make sure the foot pedal has complete travel. The foot pedal position can
be monitored on DDDL (accelerator pedal pos.)
Table 17-1 Factors Affecting Wheel Horsepower
All information subject to change without notice. (Rev. 2007)
6SE412 0702 Copyright © 2007 DETROIT DIESEL CORPORATION From Bulletin 1–MBE 4000–07 17-5