Detroit diesel Mbe4000 User manual

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MBE 4000 SERVICE MANUAL

REVISION NOTIFICATION

Modifications to this manual are announced in the form of Service Information

Bulletins. The bulletins include attachment pages and are posted on the World Wide Web

(www.detroitdiesel.com/svc/sibindex.htm).

Revisions to this manual will be sent marked with a revision bar (see Example 2). Sections

containing revisions will have a third line in the page footer (compare Examples 1 and 2).

ENGINE EXHAUST

Consider the following before servicing engines:

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MBE 4000 SERVICE MANUAL

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.

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MBE 4000 SERVICE MANUAL

TABLE OF CONTENTS

GENERAL INFORMATION ...................................................................... 1

SCOPE AND USE OF THIS MANUAL ..................................................... 3

GENERAL DESCRIPTION ...................................................................... 3

ELECTRONIC ENGINE CONTROL SYSTEM ......................................... 4

ENGINE BRAKING POWER .................................................................... 7

GENERAL SPECIFICATIONS AND ENGINE VIEWS ............................. 7

ENGINE MODEL AND SERIAL NUMBER ............................................... 14

EXHAUST GAS RECIRCULATION (EGR) SYSTEM ............................... 16

SAFETY INSTRUCTIONS AND PRECAUTIONS .................................... 20

ENGLISH TO METRIC CONVERSION .................................................... 32

DECIMAL AND METRIC EQUIVALENTS ................................................ 33

TORQUE SPECIFICATIONS ................................................................... 35

1ENGINE

1.1 CYLINDER HEAD COVER ...................................................................... 1-3

1.2 CYLINDER HEAD .................................................................................... 1-5

1.3 CYLINDER BLOCK .................................................................................. 1-24

1.4 EGR CYLINDER HEAD AND BLOCK ..................................................... 1-40

1.5 EGR FRONT AND REAR LIFTER BRACKETS ....................................... 1-43

1.6 ENGINE BRAKE ...................................................................................... 1-45

1.7 FRONT RADIAL SEAL ............................................................................. 1-51

1.8 REAR RADIAL SEAL ............................................................................... 1-54

1.9 CRANKSHAFT ASSEMBLY ..................................................................... 1-57

1.10 FRONT COVER HOUSING ..................................................................... 1-82

1.11 CRANKSHAFT VIBRATION DAMPER ..................................................... 1-84

1.12 FLYWHEEL .............................................................................................. 1-86

1.13 RING GEAR ............................................................................................. 1-96

1.14 PILOT BEARING ...................................................................................... 1-100

1.15 ENGINE CRANKING TOOL ..................................................................... 1-102

1.16 FLYWHEEL HOUSING ............................................................................. 1-104

1.17 PISTON, PISTON RING, AND CONNECTING ROD ............................... 1-106

1.18 EGR PISTON, PISTON RING, AND CONNECTING ROD ...................... 1-135

1.19 VALVES .................................................................................................... 1-138

1.20 EGR VALVES ........................................................................................... 1-161

1.21 ROCKER ARM ......................................................................................... 1-166

1.22CAMSHAFT AND CAMSHAFT SENSOR ................................................ 1-170

1.23 EGR CAMSHAFT ..................................................................................... 1-181

1.A ADDITIONAL INFORMATION .................................................................. 1-183

2FUELSYSTEM

2.1 INJECTOR UNIT PUMP ........................................................................... 2-3

2.2 EGR INJECTOR UNIT PUMP .................................................................. 2-11

2.3FUEL INJECTOR LINE ............................................................................ 2-13

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MBE 4000 SERVICE MANUAL

2.4 FUEL INJECTOR NOZZLE ...................................................................... 2-18

2.5 EGR FUEL INJECTOR NOZZLE ............................................................. 2-24

2.6 PROTECTIVE SLEEVE ........................................................................... 2-25

2.7 DDEC ELECTRONIC CONTROL UNIT ................................................... 2-29

2.8 FUEL HEAT EXCHANGER ...................................................................... 2-34

2.9 FUEL FILTER ........................................................................................... 2-37

2.10 EGR FUEL FILTER .................................................................................. 2-41

2.11 FUEL PUMP ............................................................................................. 2-43

2.12 FUEL SYSTEM INSPECTION ................................................................. 2-47

2.A ADDITIONAL INFORMATION .................................................................. 2-57

3 LUBRICATION SYSTEM

3.1 OIL PAN ................................................................................................... 3-3

3.2 OIL SPRAY NOZZLE ............................................................................... 3-9

3.3 EGR CAMSHAFT LUBRICATION SPRAYER .......................................... 3-13

3.4 OIL PUMP ................................................................................................ 3-14

3.5 EGR OIL PUMP AND PICK UP TUBE ..................................................... 3-21

3.6 OIL FILTER .............................................................................................. 3-23

3.7 OIL HEAT EXCHANGER AND FILTER HOUSING .................................. 3-26

3.8 OIL PRESSURE AND TEMPERATURE SENSOR .................................. 3-32

3.A ADDITIONAL INFORMATION .................................................................. 3-35

4 COOLING SYSTEM

4.1 COOLING SYSTEM ................................................................................. 4-3

4.2 COOLANT PUMP .................................................................................... 4-8

4.3 EGR COOLANT PUMP ............................................................................ 4-20

4.4 FRONT IDLER AND TENSIONER SUPPORT ........................................ 4-22

4.5 THERMOSTAT ......................................................................................... 4-25

4.6 EGR THERMOSTAT HOUSING ............................................................... 4-30

4.7 COOLANT TEMPERATURE SENSOR .................................................... 4-32

4.A ADDITIONAL INFORMATION .................................................................. 4-35

5 FUEL, LUBRICATING OIL, AND COOLANT

5.1 FUEL ........................................................................................................ 5-3

5.2 LUBRICATING OIL ................................................................................... 5-5

5.3 COOLANT ................................................................................................ 5-7

5.A ADDITIONAL INFORMATION .................................................................. 5-13

6 AIR INTAKE SYSTEM

6.1 INTAKE MANIFOLD ................................................................................. 6-3

6.2 CHARGE PRESSURE/TEMPERATURE SENSOR ................................. 6-5

6.3 TURBOCHARGER ................................................................................... 6-6

6.A ADDITIONAL INFORMATION .................................................................. 6-17

7EXH

AUST SYSTEM

7.1 EXHAUST MANIFOLD ............................................................................. 7-3

7.2EXHAUST BRAKE ASSEMBLY ............................................................... 7-6

7.3 EGR EXHAUST MANIFOLD .................................................................... 7-14

7.4 EGR COOLER AND COOLER SUPPORT BRACKET ............................ 7-26

7.5EGR CONTROL VALVE, GAS OUTLET PIPE, AND GAS MIXER .......... 7-43

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MBE 4000 SERVICE MANUAL

7.6 EPV (ELECTRONIC PROPORTIONAL VALVE) AND WABCO®AIR

SOLENOID VALVE ................................................................................... 7-51

7.7 HENGST®BREATHER FILTER ............................................................... 7-55

7.A ADDITIONAL INFORMATION .................................................................. 7-59

8 ELECTRICAL EQUIPMENT

8.1 DRIVE BELTS .......................................................................................... 8-3

8.A ADDITIONAL INFORMATION .................................................................. 8-15

9 POWER TAKE-OFF

9.1 POWER TAKE-OFF ................................................................................. 9-3

10 SPECIAL EQUIPMENT

10.1 AIR COMPRESSOR ................................................................................ 10-3

10.A ADDITIONAL INFORMATION .................................................................. 10-11

11 OPERATION AND VERIFICATION

11.1 PREPARATION FOR A FIRST TIME START ........................................... 11-3

11.2 STARTING THE ENGINE ......................................................................... 11-7

11.3 RUNNING THE ENGINE .......................................................................... 11-10

11.4 STOPPING THE ENGINE ........................................................................ 11-12

12 ENGINE TUNE-UP

12.1 VALVE LASH CHECKING ........................................................................ 12-3

12.2 ADJUSTING VALVE LASH ....................................................................... 12-10

13 PREVENTIVE MAINTENANCE

13.1 SCHEDULED INTERVALS ....................................................................... 13-3

14 ENGINE STORAGE

14.1 PREPARING ENGINE FOR STORAGE ................................................... 14-3

15 MECHANICAL TROUBLESHOOTING

15.1 TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL

SYSTEM .................................................................................................. 15-3

15.2 GENERAL TROUBLESHOOTING ........................................................... 15-4

INDEX ................................................................................................. Index-1

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MBE 4000 SERVICE MANUAL

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GENERAL INFORMATION

Section Page

SCOPE AND USE OF THIS MANUAL ....................................................... 3

GENERAL DESCRIPTION ......................................................................... 3

ELECTRONIC ENGINE CONTROL SYSTEM ............................................ 4

ENGINE BRAKING POWER ....................................................................... 7

GENERAL SPECIFICATIONS AND ENGINE VIEWS ................................ 7

ENGINE MODEL AND SERIAL NUMBER ................................................. 14

EXHAUST GAS RECIRCULATION (EGR) SYSTEM .................................. 16

SAFETY INSTRUCTIONS AND PRECAUTIONS ....................................... 20

ENGLISH TO METRIC CONVERSION ...................................................... 32

DECIMAL AND METRIC EQUIVALENTS ................................................... 33

TORQUE SPECIFICATIONS ...................................................................... 35

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MBE 4000 SERVICE MANUAL

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MBE 4000 SERVICE MANUAL

SCOPE AND USE OF THIS MANUAL

This manual contains complete instructions on operation, adjustment (tune-up), preventive

maintenance, and repair (including complete overhaul) for the MBE 4000 engine. This manual

was written primarily for persons servicing and overhauling the engine. In addition, this manual

contains all of the instructions essential to the operators and users. Basic maintenance and

overhaul procedures are common to all MBE 4000 engines, and apply to all engine models.

This manual is divided into numbered sections. Section one covers the engine (less major

assemblies). The following sections cover a complete system such as the fuel system, lubrication

system, or air system. Each section is divided into subsections which contain complete

maintenance and operating instructions for a specific engine subassembly. Each section begins

with a table of contents. Pages and illustrations are numbered consecutively within each section.

Information can be located by using the table of contents at the front of the manual or the table of

contents at the beginning of each section. Information on specific subassemblies or accessories

within the major section is listed immediately following the section title.

GENERAL DESCRIPTION

The MBE 4000 Engine described in this manual is a water-cooled, four-stroke, direct injection

diesel engine. The cylinders are arranged in line. Each cylinder has a separate fuel injection pump

(unit pump) with a short injection line to the injection nozzle, which is located in the center of

the combustion chamber. The unit pumps are attached to the crankcase and are driven from the

camshaft. Each cylinder has two intake valves and two exhaust valves.

Charge-air cooling and an exhaust gas turbocharger are standard equipment on all MBE 4000

engines.

The engine has a fully electronic control system, which regulates the injection quantity and timing

using solenoid valves, allowing extremely low-emission operation. The control system consists of

an engine-resident pump and nozzle control unit (the DDEC-ECU) and a vehicle control unit (the

DDEC-VCU). The two are connected by a proprietary datalink.

Engine braking is controlled by a pneumatically-operated exhaust brake on the turbocharger and

by a constant-throttle system. For greater braking power, an optional turbo brake is available.

The cylinder block has integrated oil and water channels. The upper section of the cylinder bore

is induction-hardened. The six individual cylinder heads are made of cast iron. The cylinder head

gasket is an adjustment-free seal with rubber sealing elements.

The pistons are made of aluminum alloy with ring carriers and a shallow combustion chamber

recess. The pistons are cooled by oil spray nozzles.

The crankshaft is precision-forged with seven main bearings and eight custom-forged counter

weights, and a vibration damper at the front end.

The camshaft is made of induction-hardened steel and has seven main bearings. Each cylinder has

cams for intake and exhaust valves and a unit pump.

The valves are controlled by mushroom tappets, pushrods, and rocker arms. The intake and

exhaust valves are opened and closed by a valve-guided bridge.

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MBE 4000 SERVICE MANUAL

There is a force-feed lubricating oil circuit supplied by a gear-type oil pump. This pump is

positioned at the rear of the oil pan and driven by gears from the crankshaft. The oil heat

exchanger is located near the front of the crankcase on the right-hand side near the turbocharger.

The gear-type fuel pump is located near the front of the crankcase on the left hand side. The pump

is driven from the forward end of the camshaft.

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

The engine is cooled by a closed system using recirculated coolant; temperature is regulated

automatically by a thermostat.

There are three drive belts, each with its own automatic belt tensioner. The alternator and coolant

pump (and any other accessories) are driven by a main drive belt. The fan and the air conditioner

compressor are each driven by their own drive belt.

ELECTRONIC ENGINE CONTROL SYSTEM

The engine is equipped with a fully electronic control system. Besides the engine and its related

sensors, this system is composed of the DDEC-ECU, or engine control unit, and the DDEC-VCU,

or vehicle control unit. The two control units are connected by a proprietary datalink through

which all necessary data and information can be exchanged. The DDEC-VCU then broadcasts

all information on the J1587 and J1939 datalinks, where it can be read by minidiag2, Nexiq™

Diagnostic Data Reader (DDR), or Detroit Diesel Diagnostic Link®(DDDL) PC software.

The DDEC-ECU monitors both the engine and the datalink. When a malfunction or other

problem is detected, the system selects an appropriate response; for example, the emergency

running mode may be activated.

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MBE 4000 SERVICE MANUAL

DDEC-ECU — Engine-Resident Control Unit

The DDEC-ECU control unit is located on the left-hand side of the engine. See Figure 1. The

DDEC-ECU processes the data received from the DDEC-VCU, for example the position of the

accelerator pedal, engine brake, etc. These data are evaluated together with the data from the

sensors on the engine, such as, charge and oil pressure and coolant and fuel temperature. The

data is then compared to the characteristic maps or lines stored in the DDEC-ECU. From these

data, quantity and timing of injection are calculated and the unit pumps are actuated accordingly

through the solenoid valves.

Figure 1 DDEC-ECU Control Unit Location

NOTE:

To obtain a replacement DDEC-ECU, all the data given on the DDEC-ECU label are

required.

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MBE 4000 SERVICE MANUAL

DDEC-VCU — Vehicle Control Unit

The vehicle control unit (DDEC-VCU) communicates with other electronic control units installed

on the vehicle over the J1587 datalink. See Figure 2. Within the DDEC-VCU, sets of data for

specific applications are stored. These include idle speed, maximum running speed, and speed

limitation.

Figure 2 Vehicle Control Unit (DDEC-VCU)

The DDEC-VCU receives data from the following sources:

The operator (accelerator pedal position, engine brake switch)

Other electronic control units (for example, the antilock brake system)

The DDEC-ECU control unit (data such as oil pressure and coolant temperature)

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MBE 4000 SERVICE MANUAL

From these data, instructions are computed for controlling the engine and transmitted to the

DDEC-ECU via the proprietary datalink. The DDEC-VCU controls various systems, for example,

communications with the datalink, the engine brake, and the constant-throttle valves. If the

engine control system detects a fault, the appropriate fault code is broadcast on the datalink

and can be read using minidiag2. When there is a fault, the code for the control unit reporting

the fault can be read directly on the display.

ENGINE BRAKING POWER

Exhaust Brake/Constant-Throttle Valves

To increase braking performance, the engine is equipped with an exhaust brake on the

turbocharger in conjunction with constant-throttle valves on the cylinder head.

NOTE:

The constant-throttle values are activated by engine oil pressure.

The exhaust back-pressure is used by the exhaust brake to increase braking performance.

Optional Turbo Brake

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 engine to provide up to 600 brake

horsepower. The turbo brake can be operated either manually or automatically, through the

cruise control function.

Because the charge air pressure is maintained at a high level during braking, full throttle response

is available immediately, if the operator desires it, without any turbo lag.

The turbo brake is maintenance-free, highly reliable, and adds virtually no weight to the engine.

GENERAL SPECIFICATIONS AND ENGINE VIEWS

For a general view of the MBE 4000 engine, showing major components, see Figure 3 for the

left-hand side, and see Figure 4 for the right-hand side.

For a general view of the MBE 4000 engine, showing ports and fluid lines, see Figure 5 for the

left-hand side and see Figure 6 for the right-hand side.

For a general view of the MBE 4000 engine, showing sensor locations, see Figure 7. Two sensors

are not easily visible from the left-hand side of the engine: the charge pressure/temperature

sensor, located on the right-hand side of the charge air manifold, and the oil pressure/temperature

sensor located at the base of the oil filter.

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MBE 4000 SERVICE MANUAL

1. Front Camshaft Cover 8. Power Steering Pump

2. Thermostat Housing 9. DDEC-ECU Control Unit

3. Coolant Pump 10. Fuel Heat Exchanger

4. Charge-Air (Intake) Manifold 11. Oil Pan

5. Engine Trim Cover 12. Fuel Filter

6. Crankcase Breather 13. Fuel Pump

7. Air Compressor 14. Air Conditioner Compressor

Figure 3 Left Side, Major Engine Components

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MBE 4000 SERVICE MANUAL

1. Starter 8. Alternator

2. Exhaust Brake Valve 9. Oil Filter

3. Exhaust Brake Cylinder 10. Oil Fill Tube

4. Exhaust Manifold 11. Oil Heat Exchanger

5. Cylinder Head Cover 12. Oil Dipstick

6. Fan 13. Turbocharger

7. Belt Tensioner

Figure 4 Right Side, Major Engine Components

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MBE 4000 SERVICE MANUAL

1. Fuel Spill Line 5. Coolant Line (to air compressor)

2. Thermostat Outlet 6. Hydraulic Line (to power steering pump)

3. Charge Air Inlet 7. Electronic Engine Harness Connector

4. Open Breather Tube 8. Fuel Feed Line

Figure 5 Left Side, Ports and Lines

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MBE 4000 SERVICE MANUAL

1. Oil Drain Plug 5. Turbocharger Outlet Pipe

2. Turbo Oil Return Line 6. Dipstick

3. Constant-Throttle Inlet 7. Oil Fill Cap

4. Exhaust Brake Valve Outlet 8. Coolant Pump Inlet Pipe

Figure 6 Right Side, Ports and Lines

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MBE 4000 SERVICE MANUAL

1. Intake Manifold Pressure/Temperature Sensor 5. Barometric Pressure Sensor (integrated into

DDEC-ECU)

2. TDC Sensor (on camshaft) 6. Fuel Temperature Sensor

3. Crank Angle Position Sensor 7. Oil Pressure/Temperature Sensor

4. Coolant Temperature Sensor

Figure 7 Sensor Locations

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