EPA07 MBE 4000 OPERATOR'S MANUAL To the Operator This guide contains instructions on the safe operation and preventive maintenance of your Detroit Diesel EPA07 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.
NOTICE: Coolant must be inhibited with the recommended SCAs (supplemental coolant additives) listed in the How To section of this engine operator's 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. WARRANTY are registered trademarks of Detroit Diesel Corporation.
EPA07 MBE 4000 OPERATOR'S MANUAL TABLE OF CONTENTS INTRODUCTION .................................................................................. NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT .. PERSONNEL REQUIREMENTS ..................................................... ENGINE CONVERSIONS AND MODIFICATIONS .......................... 1 1 2 2 CAUTION SUMMARY .......................................................................... ENGINE OPERATION ......................................................
TABLE OF CONTENTS ELECTRIC STARTER ............................................................. RUNNING THE ENGINE ................................................................. OIL PRESSURE .......................................................................... WARM-UP ................................................................................... INSPECTION ............................................................................... TRANSMISSION .............................................
EPA07 MBE 4000 OPERATOR'S MANUAL STOP ENGINE OVERRIDE SWITCH ......................................... IMMEDIATE SPEED REDUCTION ............................................. RED STOP LAMP ........................................................................ DIAGNOSTIC TOOL .................................................................... FLASHING MALFUNCTION CODES ...................................... 43 44 44 44 44 DDEC VI ENGINE DRIVING TIPS .....................................................
TABLE OF CONTENTS MAINTENANCE ................................................................................... SCHEDULED INTERVALS .............................................................. MAINTENANCE SCHEDULE TYPES ......................................... SEVERE SERVICE ................................................................. SHORT-HAUL ......................................................................... LONG-HAUL .....................................................................
EPA07 MBE 4000 OPERATOR'S MANUAL FUEL CONTAMINATION ............................................................. 87 BIODIESEL ............................................................................. 88 PROHIBITED ADDITIVES ........................................................... 88 USED LUBRICATING OIL ....................................................... 88 FUEL ADDITIVES WITH SULFUR OR SULFATED ASH ........ 88 GASOLINE ...........................................................................
TABLE OF CONTENTS GLYCOL-BASED COOLANTS FORMULATED FOR HVAC ... ADDITIVES NOT RECOMMENDED ........................................... SOLUBLE OILS ....................................................................... CHROMATES .......................................................................... COOLANT INHIBITOR TEST INTERVALS ................................. SUPPLEMENTAL COOLANT ADDITIVES FOR FULLY FORMULATED COOLANT ...................................................... MAINTENANCE INTERVALS ...
EPA07 MBE 4000 OPERATOR'S MANUAL STEP ONE ................................................................................... 140 STEP TWO .................................................................................. 140 STEP THREE .............................................................................. 140 SPECIFICATIONS ................................................................................ FUEL AND LUBRICATING OIL FILTERS ........................................ OIL PAN CAPACITY ....
TABLE OF CONTENTS x DDC-SVC-MAN-0041 All information subject to change without notice.
EPA07 MBE 4000 OPERATOR'S MANUAL INTRODUCTION This guide is intended for use by the operator of an MBE 4000 diesel engine used in the following applications: □ On-Highway Vehicles □ Fire Truck or Crash/Rescue Vehicles Non-Genuine and Rebuilt Component Quality Alert Electronic engine controls have been instrumental in aiding engine manufacturers in meeting the stringent emission requirements of the U.S. Environmental Protection Agency (U.S.
INTRODUCTION Furthermore, modern engines exhibit operating parameters which require the use of proper fluids, such as fuel, coolant and lubricating oil, to maintain long engine life. The use of fluids that do not meet Detroit Diesel specifications may result in early wear out or engine failure. 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.
EPA07 MBE 4000 OPERATOR'S MANUAL 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..
CAUTION SUMMARY Preventive Maintenance Observe the following cautions when performing preventative maintenance. 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 OIL To avoid injury from hot oil, do not operate the engine with the rocker cover(s) removed.
EPA07 MBE 4000 OPERATOR'S MANUAL PERSONAL INJURY FIRE 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. To avoid injury from combustion of heated lubricating-oil vapors, stop the engine immediately if an oil leak is detected.
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. 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.
EPA07 MBE 4000 OPERATOR'S MANUAL Cooling System Air Intake System Observe the following cautions when servicing the cooling system. Observe the following cautions when working on the air intake system. HOT COOLANT PERSONAL INJURY 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.
CAUTION SUMMARY Fuel System Observe the following cautions when fueling the vehicle or working with the fuel system. 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. PERSONAL INJURY □ Stop the engine immediately if a fuel leak is detected. To avoid injury from fuel spills, do not overfill the fuel tank. □ Do not smoke or allow open flames when working on an operating engine.
EPA07 MBE 4000 OPERATOR'S MANUAL Compressed Air Observe the following cautions when using compressed air. FIRE To avoid injury from fire, do not smoke or allow open flames when working on an operating engine. 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.
CAUTION SUMMARY Figure 1 Hot Surfaces External and Internal Caution Figure 2 Heavy Aftertreatment Device Caution 10 DDC-SVC-MAN-0041 All information subject to change without notice.
EPA07 MBE 4000 OPERATOR'S MANUAL ENGINE IDENTIFICATION The MBE 4000 engine has a certification label, engine model and serial number for identification. Engine Components For a general view of the MBE 4000 engine, showing major components, see Figure 3 for the left-hand side, and Figure 4 for the right-hand side. See Figure 5 for left side sensor locations and see Figure 6 for right side sensor locations. All information subject to change without notice.
ENGINE IDENTIFICATION 1. Fuel Pump 9. Air Intake Manifold 2. Intake Throttle Valve 10. Fuel Filter Bracket 3. Air Intake Elbow 11. Fuel Filter and Lines 4. Alternator & A/C Mounting Bracket 12. Doser Block Assembly 5. Gas Mixer Housing 13. Engine Harness 6. Smart Injector Adaptor Frame (Internal) 14. MCM 7. Constant Throttle Valve (Internal) 15. Dipstick and Oil Fill 8.
EPA07 MBE 4000 OPERATOR'S MANUAL 1. Air Intake Elbow 8. EGR Cooler Bracket 2. Turbocharger 9. Grid Heater 3. Fuel Doser Valve 10. EGR Valve 4. Flywheel Housing 11. EGR Coolant Return 5. Hot EGR Cooler Pipe 12. Coolant Outlet 6. Exhaust Manifold 13. Coolant Inlet 7. EGR Cooler 14. Front Mount Figure 4 Major Engine Components, Right Side All information subject to change without notice.
ENGINE IDENTIFICATION 1. Fuel Temperature Sensor 5. Fuel Compensation Pressure Sensor 2. Intake Throttle Valve 6. Fuel Cut-off 3. Intake Manifold Pressure/Temperature Sensor 7. Fuel Line Pressure Sensor 4. Doser Block Asembly Figure 5 14 Left Side Sensor Locations DDC-SVC-MAN-0041 All information subject to change without notice.
EPA07 MBE 4000 OPERATOR'S MANUAL 1. EPV-1 4. EGR Delta-P Sensorr 2. Wastegate Actuator 5. Oil Pressure/Temperature Sensor 3. Turbocharger Pressure/Temperature Sensor Figure 6 Right Side Sensor Locations All information subject to change without notice.
ENGINE IDENTIFICATION Engine Model And Serial Number Designation The fourteen-digit engine model and serial number is located on the left front of the engine cylinder block, on the DDEC-MCM label and on the oil filter housing on the right-hand side of the engine. See Figure 7. and serial number contains the type reference followed by a sequential manufacturing number. The last six digits of the engine model and serial number is the serial number for the engine. See Figure 8.
EPA07 MBE 4000 OPERATOR'S MANUAL Certification Labels The MBE 4000 engine complies with all United States Environmental Protection Agency (USEPA) and California Air Resources Board Figure 9 (CARB) emission standards. An emission label is attached to the cylinder head cover, as required by law. See Figure 9. Emission Label, MBE 4000 All information subject to change without notice.
OPERATING INSTRUCTIONS FOR STARTING THE ENGINE OPERATING INSTRUCTIONS FOR STARTING THE ENGINE Following are instructions for starting the engine. First Time Start Preparation When preparing to start a new or newly overhauled engine which has been in storage, perform all of the operations listed below. Also refer to the “ENGINE STORAGE” section of this guide. Failure to follow these instructions may result in serious engine damage.
EPA07 MBE 4000 OPERATOR'S MANUAL concentration. In extremely hot environments, properly inhibited water may be used in the summer. Keep the coolant level at the bottom of the filler neck to allow for expansion of the coolant. For more detailed recommendations, Refer to “How to Select Coolant” in the “HOW-TO SECTION” of this guide. 3. Entrapped air must be purged after filling the cooling system. To do this, allow the engine to warm up with the pressure cap removed.
OPERATING INSTRUCTIONS FOR STARTING THE ENGINE PERSONAL INJURY To avoid injury from slipping and falling, immediately clean up any spilled liquids. Extended Storage — An engine in storage for an extended period of time (over winter, for example) may accumulate water in the oil pan through normal condensation of moisture (always present in the air) on the cold, internal surfaces of the engine. NOTICE: Failure to eliminate water-diluted lubricating oil may lead to serious engine damage at startup.
EPA07 MBE 4000 OPERATOR'S MANUAL NOTICE: NOTICE: Prolonged use of the starting motor and engine fuel pump to prime the fuel system can result in damage to the starter, fuel pump and injectors. Engines equipped with starting devices dependent on compressed air or gas reservoirs should always be primed before initial startup. Otherwise, reserve pressure can be exhausted and injectors may be damaged from lack of lubrication and cooling.
OPERATING INSTRUCTIONS FOR STARTING THE ENGINE Authorized Detroit Diesel service outlets are properly equipped and have the trained technicians to perform this service. Priming is not normally required if the filter elements are filled with clean fuel when installed and the lines are not drained of fuel. If the engine is equipped with a fuel/water separator, drain off any water that has accumulated. Water in fuel can seriously affect engine performance and may cause engine damage.
EPA07 MBE 4000 OPERATOR'S MANUAL 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: Manufacturer Lubricant or Part Number Shell Oil Co. No. 71032; No. 71306 Texaco, Inc. No. 955 Quaker State No.
OPERATING INSTRUCTIONS FOR STARTING THE ENGINE Starting the Engine-For The First Time Before starting the engine the first time, perform the operations listed in the System Checks section. NOTICE: To start an MBE 4000 engine, make sure the transmission is in neutral and turn the ignition key on. ENGINE EXHAUST The turbocharger may be seriously damaged if the engine is cranked with the air shutdown in the closed position.
EPA07 MBE 4000 OPERATOR'S MANUAL Start the engine after the lights go out. If starting a vehicle, start the engine with foot off the foot pedal. NOTICE: If the warning lights stay on, or do not come on momentarily after turning on the ignition, contact the Detroit Diesel Customer Support Center at 313–592–5800. Operating the engine under these circumstances may result in engine damage.
OPERATING INSTRUCTIONS FOR STARTING THE ENGINE Running the Engine Inspection While the engine is operating, monitor the battery charge indicator light, the oil pressure and avoid excessive idling. While the engine is idling, inspect the transmission, check for fluid leaks, check the crankcase and turbocharger. Oil Pressure Observe the oil pressure gage immediately after starting the engine.
EPA07 MBE 4000 OPERATOR'S MANUAL corrected. Authorized Detroit Diesel service outlets are properly equipped to perform this service. Avoid Unnecessary Idling Whenever possible, avoid unnecessary idling. Never allow the engine to idle for more than 30 minutes. Excessive idling can cause oil to leak from the turbocharger. During long engine idling periods with the transmission in neutral, the engine coolant temperature may fall below the normal operating range.
OPERATING INSTRUCTIONS FOR STARTING THE ENGINE BATTERY EXPLOSION To avoid injury from battery explosion when jump starting the engine, do not attach the cable end to the negative terminal of the disabled battery. Before attempting to jump start the engine, make sure the jumper cables are connected properly (positive to positive, negative to negative ground) and in the proper sequence (negative to negative ground last).
EPA07 MBE 4000 OPERATOR'S MANUAL ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic. PERSONAL INJURY To avoid injury when working near or on an operating engine, remove loose items of clothing and jewelry. Tie back or contain long hair that could be caught in any moving part causing injury. Starting the Engine-Routine Before a routine start, Refer tothe “Maintenance” section and see the daily checks for your engine.
OPERATING INSTRUCTIONS FOR STARTING THE ENGINE [b] Check the oil feed and return lines at the turbocharger for tightness. Shut down the engine and tighten them if necessary. 4. Shut down the engine. 5. Approximately five minutes after shutdown, check the engine oil level. If necessary, add oil up to the maximum fill level on the oil dipstick.(See Figure 13). Do not overfill. the radiator outlet pipe are secure and tight. 2. Check the coolant level.
EPA07 MBE 4000 OPERATOR'S MANUAL Battery Charge 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. 2. Then, with the coolant temperature above 50°C (122°F), recheck the coolant level. 3. Add more coolant if necessary. Open the heater valves (if equipped) before adding coolant. 4.
OPERATING INSTRUCTIONS FOR STARTING THE ENGINE 3. Do a load test on the batteries. Charge or replace the batteries as needed. 4. If necessary, visit the nearest authorized dealer to have the alternator voltage and output checked. 1. Turn the cruise control switch to the OFF position. 2. To increase the idle speed, push the "Resume" switch until the idle is fast enough. 3. To decrease the idle speed, push the "Decel" switch until the idle is slow enough.
EPA07 MBE 4000 OPERATOR'S MANUAL Shutting Down After High Load Operation After high load operation, do the following: NOTICE: After high load operation, if the engine has been running at full output or the coolant temperature has been high, allow the engine to idle for one or two minutes without load. Shutting down the engine without idling may cause damage to the turbocharger. Turn off the ignition switch and shut down the engine. All information subject to change without notice.
OPERATING INSTRUCTIONS FOR STARTING THE ENGINE Emergency Running Mode The engine is equipped with the electronic engine control system, which monitors the engine as it is running. For fault codes and their meanings, see the DDEC VI MBE 4000 Troubleshooting Guide (6SE568). Stop Engine Override Option As soon as a fault is detected, it is evaluated and one of the following measures is initiated.
EPA07 MBE 4000 OPERATOR'S MANUAL cooling across each tube and reduces header to tube stress and possible failure. Winter fronts should only be used when the ambient temperature remains below -12.2°C (10°F). Figure 15 Typical SEO Switch and Warning Lamps NOTE: The operator has the responsibility to take action to avoid engine damage. Cold Weather Operation Special precautions must be taken during cold weather.
DDEC VI SYSTEM DDEC VI SYSTEM The engine is equipped with a fully electronic control system, which regulates the fuel injection quantity and timing using solenoid valves, allowing extremely low-emission operation. Besides the engine and its related sensors, the system is composed of the following: Motor Control Module The MCM (See Figure 16) is located on the left-hand side of the engine.
EPA07 MBE 4000 OPERATOR'S MANUAL The data is then compared to the characteristic maps or lines stored in the MCM. From these data, quantity and timing of injection are calculated and the unit pumps are actuated accordingly through the solenoid valves. NOTE: To obtain a replacement MCM, all the data given on the MCM label are required. The MCM data label has the 10 digit engine serial number.
DDEC VI SYSTEM DDEC Features DDEC offers a variety of features and options designed to warn the operator of an engine malfunction. Options can range from warning panel lights to automatic reduction in engine power followed by automatic engine shutdown. DDEC has the ability to perform diagnostics for self-checks and continuous monitoring of other system components.
EPA07 MBE 4000 OPERATOR'S MANUAL LOSS OF VEHICLE CONTROL To avoid injury from the loss of vehicle control, do not use cruise control under these conditions: □ When it is not possible to keep the vehicle at a constant speed (on winding roads, in heavy traffic, in traffic that varies in speed, etc.). □ On slippery roads (wet pavement, ice-or snow-covered roads, loose gravel, etc.). NOTICE: When descending a hill with Cruise Control OFF, do not allow the engine to exceed 2500 rpm under any conditions.
DDEC VI SYSTEM Cruise Control can be overridden at any time with the throttle pedal if the vehicle is operating at less than the programmed Max Road Speed. Additionally, using either the brake or the clutch will disable Cruise Control. Data Recording Capability The DDEC VI contains the ability to extract detailed data on the engine’s use and performance using DDEC Reports software.
EPA07 MBE 4000 OPERATOR'S MANUAL Engine brakes will supply braking power even when in Cruise Control. MCM will control the amount of engine braking with respect to the Cruise Control set speed. The maximum amount of braking (low, medium, high) is selected with the dash switches. Engine Protection The DDEC engine protection system monitors all engine sensors and electronic components, and recognizes system malfunctions.
DDEC VI SYSTEM the parking brake is not set. Activating or momentarily changing the position of the service brake pedal, the clutch pedal, Stop Engine Override, the accelerator pedal, or park brake status during the final 30 seconds before a shutdown would otherwise occur will prevent the engine from shutting down and will reset the shutdown timer. After an automatic shutdown, the engine may be restarted and operated normally.
EPA07 MBE 4000 OPERATOR'S MANUAL The engine will only operate at reduced rpm until the battery voltage reaches a point where the MCM will no longer function and the engine shuts down. Should the AWL (Check Engine) come on for any reason, the vehicle can still be operated and the driver can proceed to the required destination. This condition should be reported to an authorized Detroit Diesel distributor or dealer.
DDEC VI SYSTEM Immediate Speed Reduction The immediate speed reduction option will bring engine rpm back to a predetermined speed, but will not shut down the engine. The engine should not be restarted after it has been shut down by the engine protection system, unless the problem has been located and corrected.
EPA07 MBE 4000 OPERATOR'S MANUAL □ Engine speed is <100 rpm and the SEO switch is put in the ON position. □ Vehicle speed is <3 mph and Park Brake is activated and the SEO switch is put in the ON position. □ Idle Governor is activated and the SEO switch is put in the ON position. The flashing code feature is deactivated to the OFF position or the listed conditions are no longer satisfied. See Figure 20.
DDEC VI SYSTEM The codes will continue to flash and repeat as long as the Diagnostic Request Switch is held in the ON position. Both CPC and MCM faults are included. Active Codes – The active codes will be flashed on the RSL (Stop Engine) in the order of most recent to least recent occurrence based on engine hours. Inactive Codes – The inactive codes will be flashed on the AWL (Check Engine) in the order of most recent to least recent occurrence based on engine hours.
EPA07 MBE 4000 OPERATOR'S MANUAL DDEC VI ENGINE DRIVING TIPS Driving with an electronically controlled engine feels different from driving with a mechanically governed engine. Accelerating the Vehicle Engine response versus pedal movement may feel different from the mechanical-governed engine you were driving. The Accelerator Pedal (AP) was designed to communicate “percentage” foot pedal travel to the engine's Motor Control Module (MCM). The engine will respond accordingly to the driver's demand.
DDEC VI ENGINE DRIVING TIPS speed in one mile-per-hour (1.6 kilometer-per-hour) increments, press the RSM/ACL Switch. To reduce road speed, press and hold the SET/CST Switch until the lower speed is reached. Turn the switch ON to energize the system. Remember as a check after each engine start, DDEC VI looks for a one time activation of the clutch (if equipped) and service brake before DDEC VI allows Cruise Control to be enabled.
EPA07 MBE 4000 OPERATOR'S MANUAL Use Cruise Control after down shifting on a hill to pull the hill. Hitting the RSM/ACL Switch (not the Set Switch) will keep the truck accelerating in the lower gears up to the rated engine speed. Cruise Control will disengage below 1000 rpm or 20 mph (32 kph) road speed. When using Cruise Control, if you want to pull the engine below 1000 rpm, remember to hold the throttle pedal to the floor to keep the engine pulling at wide-open throttle.
DDEC VI ENGINE DRIVING TIPS In general, when using a 7 or 9-speed transmission, you should always downshift between 1250 and 1300 rpm. This is true even on steep grades with heavy loads. When using an 18-, 15- or 13-speed transmission, you will need to downshift at an rpm that allows “less than rated” rpm before throttle application in the next gear down. You may want to limit engine speed to 1900 rpm in all gears.
EPA07 MBE 4000 OPERATOR'S MANUAL ENGINE BRAKE SYSTEM Certain MBE 4000 vehicle engines are equipped with engine brakes, commonly referred to as retarders. Before operating the vehicle, you must familiarize yourself with the retarder system to obtain optimum benefit from it. Engine brake control systems may vary slightly, depending on the engine brake configuration and cab design. However, basic operator controls are similar for all models.
ENGINE BRAKE SYSTEM The smaller cross-sectional area, of the small entry, increases the flow and speed of the exhaust stream to the exhaust turbine, which increases the exhaust turbine speed and increases the boost pressure. The small cross-sectional flow of the small entry will increase the total exhaust manifold pressure.
EPA07 MBE 4000 OPERATOR'S MANUAL The engine brake is activated by the Common Powertrain Controller (CPC). In engine braking mode, an engine rpm range of up to 2500 rpm can be used by the operator. 2500 rpm, however, may never be exceeded. The engine is turned off automatically when the engine rpm is: □ Below 900 rpm for Allison Automatic Transmissions □ Below 1100 rpm for all other transmissions Also, the engine brake is automatically turned off when the accelerator pedal is pressed.
ENGINE BRAKE SYSTEM Descending a Long, Steep Grade An explanation of “control speed” may be helpful in understanding how to use the engine brake system while descending a grade. Control Speed is the constant speed at which the forces pushing the vehicle forward on a grade are equal to the forces holding it back, without using the vehicle service brakes. In other words, this is the speed the vehicle will maintain without using the service brakes or fueling.
EPA07 MBE 4000 OPERATOR'S MANUAL your engine brake system before climbing hills and do not exceed a safe control speed. 4. Check your progressive braking switch often for proper position, since road conditions can change quickly. Never skip a step when operating the progressive braking switch. Always go from OFF to LOW and then to a higher position when on slippery roads.
ENGINE BRAKE SYSTEM On wet or slippery pavement, start with the master switch in the OFF position and use the gear you would normally use under these conditions. If the vehicle is maintaining traction, place the selective braking switch in the LOW position and turn ON the engine brake system. If the drive wheels are maintaining traction and you desire greater slowing power, move the braking switch to the next highest position.
EPA07 MBE 4000 OPERATOR'S MANUAL ENGINE SYSTEMS The engine systems are the following: Fuel System The fuel system consists of DDEC, fuel injectors, fuel manifolds (integral with the cylinder head), Electronic Unit Pumps (EUP), fuel pump, a cooling plate for the Motor Control Module (MCM) on non-automotive engines, primary and secondary fuel filters, and the necessary connecting fuel lines. The gear-type fuel pump is located near the front of the crankcase on the left hand side.
ENGINE SYSTEMS Electrical System The addition of cooled exhaust gasses back into the combustion airflow reduces the peak in cylinder combustion temperature. Less oxides of nitrogen (NOx) are produced at lower combustion temperatures. The electrical system consists of a starting motor, starting switch, battery-charging alternator, storage batteries, and the necessary wiring. Exhaust System Exhaust gases exit the cylinders through exhaust ports and the exhaust manifold.
EPA07 MBE 4000 OPERATOR'S MANUAL AFTERTREATMENT SYSTEM In order to meet current emissions regulations, the traditional muffler has been replaced by a new Aftertreatment Device (ATD). This device consists of a Diesel Oxidation Catalyst (DOC) and a Diesel Particulate Filter (DPF). Together these two components burn off collected particulate matter in a process called “regeneration.” The Figure 24 key to successful regeneration is high exhaust temperature for an extended period of time.
AFTERTREATMENT SYSTEM Operating Requirements Oxidation of the particulate matter is the key to filter performance. This requires that the catalyzing agent (platinum coated passages) are providing optimum enhancement to the oxidation process. The following requirements must be met, otherwise the ATD warranty may be compromised: NOTICE: Do not use kerosene or fuel blended with used lube oil.
EPA07 MBE 4000 OPERATOR'S MANUAL NOTE: The procedure will take up to 40 minutes (depends on engine type and the amount of soot accumulated in the filter). To initiate a parked regeneration, perform the following: 1. Keep engine at slow idle (cannot be in PTO mode). 2. Transmission is in neutral with parking brake ON. 3. Cycle the parking brake from OFF to ON. NOTE: Air tank pressure must be high enough for the parking brake switch to hold in the OFF position. 4.
AFTERTREATMENT SYSTEM □ Particulate filter part number and serial number There are two CPC options: □ DPF Stationary Regen Only = 0-Disabled Maintenance □ DPF Stationary Regen Only = 1-Enabled DPF Stationary Regen Only = 0-Disabled — This option allows the DPF Regen Switch to request a parked regeneration if the parked regeneration entry conditions are met. This option also allows MCM-initiated over-the-road regenerations to occur.
EPA07 MBE 4000 OPERATOR'S MANUAL DRIVER ACTIONS Name Indicator Lamp SOLID: Exhaust is at high temperature and vehicle is at low speed or parked. High Exhaust System Temperature (HEST) Lamp FLASHING: A Parked Regeneration is in process and the system is not up to temperature. Indicates a failure of an Emission Control Device. The MIL may illuminate at the same time as the Check Engine Lamp. Malfunction Indicator Lamp (MIL) SOLID: Indicates that a Regeneration may be needed.
DRIVER ACTIONS Indicator Lamp Name DPF Regeneration Lamp + Check Engine Lamp + Red Stop Lamp (RSL) Table 3 64 FLASHING + + Description Indicates that a Parked Regeneration MUST be performed. Driver Action A Parked Regeneration must be performed. ENGINE DERATE Driver Actions DDC-SVC-MAN-0041 All information subject to change without notice.
EPA07 MBE 4000 OPERATOR'S MANUAL INSTRUMENT PANEL LAMPS Lamp Table 4 Indicator Description Results Amber Warning Lamp (AWL) Indicates a fault with the engine controls. Vehicle can be driven to end of shift. Call for service. Red Stop Lamp (RSL) Indicates a major engine fault that may result in engine damage Engine derate and/or shutdown sequence will be initiated. Move the vehicle to the nearest safe location and shutdown the engine.
INSTRUMENT PANEL LAMPS The activation conditions are listed in Table 5. Lamp Lamp Solid Lamp Flashing □ Diagnostic Request Switch □ At the start of every ignition cycle (a bulb check). □ When an electronic system fault occurs (problem should be diagnosed as soon as possible). □ At the start of every ignition cycle (a bulb check). □ A potential engine damaging fault is detected. □ Parked regeneration is required. □ At the start of every ignition cycle (a bulb check).
EPA07 MBE 4000 OPERATOR'S MANUAL MAINTENANCE When performed on a regular basis, changing the engine oil and filters is the least costly way of obtaining safe and reliable vehicle operation. Added benefits and savings occur when you check that the valves, fuel injectors, and oil and cooling circuits are in good working order during oil changes.
MAINTENANCE Short-Haul — Applies to vehicles that annually travel up to 15,000 miles (24,000 kilometers) and operate under normal conditions. Examples of Short-Haul usage are: operation primarily in cities and densely populated areas; local transport with infrequent freeway travel; or high percentage of stop-and-go travel. Long-Haul — Long Haul (over-the-road transport) is for vehicles that annually travel more than 30,000 miles (48,000 kilometers), with minimal city or stop-and-go operation.
EPA07 MBE 4000 OPERATOR'S MANUAL Maintenance Tables Procedure Engine Oil and Filter Severe (hrs) Short-Haul (hrs) Long-Haul (hrs) 300 - or 3 Months 500 - or 6 months — 600 — — 600 then every 1200 — — Fuel Filter Valve Lash Adjustment Table 6 Maintenance Intervals by Engine Hours All information subject to change without notice.
MAINTENANCE Miles (X 1000) 10 12 20 24 30 36 40 48 50 60 Km (X 1000) 17 19 32 38 50 57 68 77 84 100 113 116 Item 1. Lubricating Oil/Filter 70 72 Procedure R 2. Cooling System R R R R R R Intervals are based on type of coolant used as listed in Table 17 in the How to Select Coolant section of this guide. 3. Valve Lash Checking and Adjustment First adjustment at 20,000 mi. (32,000 Km) and then every 40,000 mi. (68,000 Km) 4. Drive Belts I I I I I I I 5.
EPA07 MBE 4000 OPERATOR'S MANUAL 15 30 45 60 Miles (X 1000) 75 90 105 120 135 150 165 180 25 50 75 100 125 150 169 193 217 241 266 290 Km (X 1000) Item 1. Lubricating Oil/Filter Procedure R R 2. Cooling System R R R R R R R R R R Intervals are based on type of coolant used as listed in Table 17 in the How to Select Coolant section of this guide. 3. Valve Lash Checking and Adjustment First adjustment at 30,000 mi. (50,000 Km) and then every 60,000 mi. (100,000 Km) 4.
MAINTENANCE Miles (X 1000) 30 60 90 120 150 180 210 240 270 300 330 360 Km (X 1000) 50 100 150 198 241 290 338 386 435 483 531 579 Item Procedure 1. Lubricating Oil/Filter R 2. Cooling System R R R R R R R R R R R Intervals are based on type of coolant used as listed in Table 17 in the How to Select Coolant section of this guide. 3. Valve Lash Check and Adjustment First adjustment at 60,000 mi. (100,000 Km) and then every 120,000 mi. (198,000 Km) 4. Drive Belts I 5.
EPA07 MBE 4000 OPERATOR'S MANUAL Preventive Maintenance Intervals This section describes the items listed in the tables. As the operator of a vehicle, routine “Daily” inspections of the engine and chassis should be performed. This will provide the best opportunity to identify major concerns or concerns that could stretch a longer time span like slow coolant loss. For new or stored engines, refer to section “OPERATING INSTRUCTIONS FOR STARTING THE ENGINE” in this guide.
MAINTENANCE Lubricating Oil Filter: – The oil filter is a cartridge style element and is located on the front right side of the engine. See Figure 26. If followed correctly, an oil filter change can be performed quickly with minimal oil cleanup. Refer to section “How to Replace the Lube Oil and Filter” in this guide. Item 2 – Cooling System Coolant Flush and Fill – Proper maintenance of the cooling system is vital to its performance and longevity.
EPA07 MBE 4000 OPERATOR'S MANUAL ensure they are positioned to avoid chafing, and are securely fastened. 3. Check the outside of the radiator and condenser for blockage. Check fins for damage; straighten them if necessary. Proper maintenance of the cooling system is vital to its performance and longevity. The cooling system must, on a constant basis, deal with cavitation, temperature/pressure swings, and continuous threats on additive package.
MAINTENANCE PERSONAL INJURY To avoid injury from rotating belts and fans, do not remove and discard safety guards. Uneven belt wear can indicate a loose, wore out, or bad bearing on the auto tensioner. A build up of dirt or grime around the front bearing surface of the wheel can indicate a future bearing failure due to inadequate lubrication. Item 5 – Fuel/Water Separator Belt Replacement – Drive belts (V and poly-V) should be replaced every 2,000 hours or 100,000 miles (160,000 km).
EPA07 MBE 4000 OPERATOR'S MANUAL One method of determining when filters are plugged to the extent that they need replacing is based on the fuel pressure at the fuel filter housing. See an authorized Detroit Diesel repair facility to determine a clogged filter. The maximum pressure difference between the inlet and outlet of the fuel filter housing is 0.3 bar (4.0 psi). NOTE: Filter change intervals may be shortened to conform to established preventive maintenance schedules, but should never be extended.
MAINTENANCE Item 8– Exhaust System Item 11 – Vibration Damper The exhaust manifold retaining bolts and other connections should be inspected for leaks. The exhaust pipe rain cap should be checked for proper operation, if so equipped. With the introduction of an Aftertreatment system, the sealing of the exhaust system is critical and should be inspected regularly. The viscous vibration damper should be inspected periodically and replaced if dented or leaking.
EPA07 MBE 4000 OPERATOR'S MANUAL Item 12 – REPTO Torsional Damper Checking The REPTO accessory drive is an option on the MBE4000 engine. The drive provides continuous live power anytime the engine is operating. The REPTO is driven by the camshaft gear and is an integral part of a unique SAE#1 flywheel housing. All REPTO installations require a torsional coupling installed at the flange of the drive unit (i.e. hydraulic pump).
MAINTENANCE The torsional damper coupling will withstand normal exposure to hydraulic oil, diesel fuel, anti-freeze solutions, and muriatic acid. The coupling should be washed with a mild soap solution and rinsed with water after contact with the above items. The coupling can be power washed without damage as long as it is installed in the vehicle. 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.
EPA07 MBE 4000 OPERATOR'S MANUAL HOW-TO SECTION This section covers Detroit Diesel's recommendations on how to select lubricating oil, diesel fuel, and coolant and includes basic engine maintenance procedures which can be performed by the operator. NOTICE: Lubricating oil must have a sulfated ash level less than 1.
HOW-TO SECTION NOTICE: Monograde oils should not be used in MBE 4000 engines, regardless of API service classification. Monograde oils gel at lower ambient temperatures, reducing lubricant flow, and they do not provide adequate lubricity at higher engine operating temperatures. These factors can result in severe engine damage. Figure 32 Engine Oil Temperature Ranges Synthetic Oils The oils must be API CJ-4 that have demonstrated field performance in Detroit Diesel engines.
EPA07 MBE 4000 OPERATOR'S MANUAL The Use of Supplemental Additives Lubricants meeting the Detroit Diesel specifications outlined in this publication already contain a balanced additive treatment. Supplemental additives are generally not necessary and can even be harmful. These additives may be marketed as either oil treatments or engine treatments and are discouraged from use in Detroit Diesel engines.
HOW-TO SECTION Oil analysis may be used to determine whether this interval should be shortened, but it should not be used to lengthen the interval. For detailed information refer to publication Engine Requirements – Lubricating Oil, Fuel and Filters (7SE270), available from authorized Detroit Diesel distributors. Disposing of Waste Oil — Dispose of used lubricating oil and filters in an environmentally responsible manner, according to federal (EPA) and/or state recommendations.
EPA07 MBE 4000 OPERATOR'S MANUAL 7. Insert a new filter element into the cap. 8. Insert the element and cap assembly into the housing. Torque the cap to 25 N·m (18 lb·ft). 9. Drain the oil from the oil pan. 1. Oil Filter Cap 3. Oil Filter Housing 2. O-ring Figure 33 Oil Filter Element [a] Place a suitable receptacle beneath the oil drain plug on the underside of the oil pan. [b] Carefully unscrew the oil drain plug on the oil pan and allow the oil to drain out (See Figure 34).
HOW-TO SECTION PERSONAL INJURY To avoid injury from slipping and falling, immediately clean up any spilled liquids. 11. Add new engine oil through the oil fill tube (See Figure 35) until the maximum fill level on the oil dipstick has been reached.Listed in Table 11 are the engine fill capacities. Table 11 Figure 35 Oil Fill Tube Oil Pan Capacity Engine Oil System Fill Capacity (Includes oil filter) 36 L (38 qts) 39.5 L (41.
EPA07 MBE 4000 OPERATOR'S MANUAL up to the maximum fill level on the oil dipstick. Requirements – Lubricating Oil, Fuel and Filters (7SE270), available from authorized Detroit Diesel distributors. How to Select Diesel Fuel Detroit Diesel engines in 2007 are designed to operate ONLY on Ultra-Low Sulfur Diesel (ULSD) fuel, see Figure 36. NOTICE: Use only Ultra-Low Sulfur Diesel (ULSD) fuel (15 ppm sulfur content maximum), based on ASTM D2622 test procedure.
HOW-TO SECTION The use of supplemental fuel additives does not necessarily void the engine warranty. However, repair expenses which result from fuel system or engine component malfunctions or damage attributed to their use will not be covered. These products should be accompanied by performance data supporting their merit. It is not the policy of Detroit Diesel Corporation to test, evaluate, approve or endorse such products.
EPA07 MBE 4000 OPERATOR'S MANUAL Gasoline — The addition of gasoline to diesel fuel will create a serious fire hazard. The presence of gasoline in diesel fuel will reduce fuel cetane number and increase combustion temperatures. FIRE To avoid increased risk of a fuel fire, do not mix gasoline and diesel fuel. An optional fuel/water separator may be installed in place of the standard primary filter. Replace Main Fuel Filter Element Change the main fuel filter element as follows: 1.
HOW-TO SECTION 3. Using a 36-mm socket, unscrew the cap on the main fuel filter housing. Remove the cap and lift the filter element a short distance within the filter housing allowing the fuel to drain off the filter. 4. Remove the filter element from the cap and clean the filter cap. Discard the filter element and the O-ring from the cap. NOTICE: To prevent damage to the filter housing, do not allow dirt to get into the filter housing. 5. Clean the filter housing cap. 6. Replace the O-ring. 7.
EPA07 MBE 4000 OPERATOR'S MANUAL Fuel/Water Separator Prefilter Element Cleaning tighten firmly, using hands only. Clean the prefilter element as follows: 1. Loosen the bleed screw. See Figure 38. 2. Unscrew the drain plug and drain the fuel in the prefilter. 3. Twist off the sight bowl and remove the filter element from the separator head. 4. Separate the sight bowl from the filter element. Clean the sight bowl. Discard the old filter element and both O-rings. 5. Replace the filter element and O-rings.
HOW-TO SECTION NOTE: Do not use tools to tighten the prefilter element. 8. Tighten the drain plug. 9. Prime the fuel system. [a] If equipped with a hand pump on the fuel/water separator, work the hand pump until resistance is felt. NOTE: There should be a strong resistance in the hand pump, caused by the pressure build-up within the fuel system. [b] Crank the engine for 30 seconds at a time, but no longer. Before cranking the engine again, wait at least two minutes.
EPA07 MBE 4000 OPERATOR'S MANUAL 1. Remove the vent cap, open the drain valve and drain fuel into approved container, until level is below the collar. See Figure 39. 2. Using a collar wrench remove collar and cover. 3. Remove the filter element from the separator head and discard filter cover seal and vent seal. Dispose of filter properly. 4. Clean the cover and the mounting surface on the body. 5. Install the filter element with bottom grommet and new cover seal. Install the cover and collar.
HOW-TO SECTION 3. A fuel shutoff valve may be installed on the discharge side of the fuel filter. If installed, turn the handle on the shutoff valve to the closed position (perpendicular to the valve). 4. Open the drain valve at the base of the fuel processor and drain the fuel until it is below the bottom of the filter in the see-thru cover. Close the drain valve. The fuel may be returned to the tank. 5.
EPA07 MBE 4000 OPERATOR'S MANUAL to federal (EPA) and/or state recommendations. 8. Check to make sure the sealing grommet is included in the base of the replacement filter element, then install the element onto the center stud by pushing down and twisting slightly. 9. Check to make sure the spring is installed at the top of the cover. If missing, this spring must be replaced to insure proper filter operation. Wipe the cover lip and cover seal clean.
HOW-TO SECTION does nor require changing until the fuel level has risen to the top of the element, or after one year of service, whichever comes first. NOTICE: To avoid cover or vent dap damage, do not use tools to tighten the vent cap. Engine Out of Fuel — How to Restart When an engine has run out of fuel, there is a definite procedure to follow when restarting it. NOTICE: The starting motor and fuel pump should never be used to prime the fuel filters.
EPA07 MBE 4000 OPERATOR'S MANUAL priming pump for two to three minutes or until resistance is felt. 2. If the engine is equipped with only a priming port located on the fuel filter module, have an authorized repair facility prime the fuel system. NOTICE: To prevent damage to engine components, keep the water moving at all times while cleaning. Never direct water onto electrical components, plug connectors, seals or flexible hoses. 3. Crank the engine for 30 seconds at a time, but no longer.
HOW-TO SECTION Degreasing NOTICE: Clean at moderate pressures only; otherwise the fins of the radiator grille could be damaged. 1. First remove debris (dust, insects, etc.) from the fins of the radiator grille. 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. Degrease as follows: 1. Fill the cooling system with a 5% solution (1.
EPA07 MBE 4000 OPERATOR'S MANUAL “How to Select Coolant” section in this guide. 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. 3. Drain all the cleaning solution. 4. Flush the cleaning solution from the cooling system.
HOW-TO SECTION Fully Formulated Antifreeze — Contains all the necessary inhibitors to protect a diesel engine and does not, therefore, require a pre-charge of SCA before its first use. Initial–Fill Coolant — The coolant that is used in a new or rebuilt engine, or any time the cooling system is emptied and then refilled with new coolant. NOTICE: Required specifications for water, ethylene glycol, propylene glycol, inhibitor packages and inhibitor concentration are included in this publication.
EPA07 MBE 4000 OPERATOR'S MANUAL Product Coolant Fill Option Ethylene Glycol and Water + Conventional Corrosion Inhibitors 1 Commercial Equivalent of DDC Power Cool Propylene Glycol and Water + Conventional Corrosion Inhibitors 1 Ethylene Glycol & Water + OAT Inhibitors Water Only + Conventional Corrosion Inhibitors 2 Water Only + OAT Inhibitors 2 1 2 DDC Power Cool Fully Formulated TMC RP-329 Type A Antifreeze and Water Fully formulated TMC RP-330 "Type A" Antifreeze and Water DDC Power Cool Plus Water
HOW-TO SECTION NOTE: Fully formulated antifreeze does not require a dosage of SCA prior to initial use. Mixing EG or PG Antifreeze and Water — If a concentrated Ethylene Glycol (EG) or Propylene Glycol (PG) antifreeze is purchased, mix the antifreeze with water meeting the required quality standards and fill the cooling system. For water requirements, If a concentrated EG or PG antifreeze is purchased, mix the antifreeze with water meeting the required quality standards and fill the cooling system.
EPA07 MBE 4000 OPERATOR'S MANUAL Always verify that the freeze point and nitrite concentration of the antifreeze/water mix are correct by using a POWER Trac® 3-Way Test Strip. If chemical analysis is used, elements in the coolant must fall within the limits as listed in Table 13 Fully Formulated Glycol Coolant Concentration Limits Table 13 Boron 125 – 500 PPM Nitrite 900 – 3200 PPM Nitrate 200 – 3200 PPM Silicon 50 – 250 PPM Phosphorous 0 PPM pH 8.0 – 11.
HOW-TO SECTION OAT fully formulated antifreezes are available as concentrated and pre-mixed. Concentrated antifreezes should be mixed at 50% (50% antifreeze 50% water). OAT coolants should not be mixed with conventional coolants. If OAT and conventional coolants are mixed, no damage will result, but the long-life advantages of the OAT coolant will be lost. In this event, the coolant should be maintained as a fully formulated ESI (Extended Service Interval) coolant, not as an OAT coolant.
EPA07 MBE 4000 OPERATOR'S MANUAL Power Cool 3000 Coolant Concentration Limits Table 14 Boron 125 – 500 PPM Nitrite 900 – 3200 PPM Nitrate 0 – 1000 PPM Silicon 50 – 250 PPM Phosphorous 0 PPM pH 8.0 – 11.0 Power Cool 3000 Concentration Limits (5% Power Cool 3000/ 95% Water) POWER COOL 3000 SCA inhibitors should be mixed at 5% by volume with water (1 quart per 5 gallons of water). These additions can be made by adding liquid SCAs available in a variety of sizes.
HOW-TO SECTION Methyl Alcohol-Based Antifreeze — This must not be used because of its effect on the non-metallic components of the cooling system and its low boiling point. Automotive Type Coolants — These coolants generally contain high levels of phosphate and silicate, offer no liner pitting protection, and are not suitable for use in Detroit Diesel engines. Maximum Allowable Parts per Million Grains per Gallon Chlorides 40 2.5 Sulfates 100 5.
EPA07 MBE 4000 OPERATOR'S MANUAL (or equivalent sulfamic acid/sodium carbonate cleaner) and flushed.
HOW-TO SECTION □ Water softening to deter formation of mineral deposits. □ Cavitation protection to protect wet sleeve cylinder liners. Maintenance Intervals — Check the nitrite concentration at the regular intervalslisted in Table 17 with a Power Trac 3–Way Test Strip. 108 DDC-SVC-MAN-0041 All information subject to change without notice.
EPA07 MBE 4000 OPERATOR'S MANUAL Interval 1 Coolant Antifreeze / Water + SCA Inhibitor (DDC Power Cool) Ethylene Glycol / Water + SCA Inhibitor or Propylene Glycol / Water + SCA Inhibitor Ethylene Glycol / Water + OAT Inhibitor or Propylene Glycol / Water + OAT Inhibitor 20,000 Miles (32,000 km) or 3 Months* 300,000 Miles (480,000 km) 20,000 Miles (32,000 km) or 3 Months* Action Test nitrite concentration with test strip. Add SCA or dilute coolant as needed. Drain and clean system.
HOW-TO SECTION NOTICE: Failure to properly maintain coolant with SCA can result in damage to the cooling system and its related components. Conversely, over-concentration of SCA inhibitor can result in poor heat transfer, leading to engine damage. Always maintain concentrations at recommended levels. Do not use traditional SCAs with OAT coolant. Additional SCA must be added to the coolant when it becomes depleted, as indicated by a nitrite concentration of 900 PPM or less.
EPA07 MBE 4000 OPERATOR'S MANUAL Discard unused strips if they have turned light pink or tan. 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. For best results make the test while the coolant is between 50° – 140° F (10° – 60° C).
HOW-TO SECTION Dropout Excessive amounts of some inhibitors in the coolant can cause a gel or crystalline deposit that reduces heat transfer and coolant flow. The deposit, called “dropout,” takes the color of the coolant when wet, but appears as a white or gray powder when dry. It can pick up solid particles in the coolant and become gritty, causing excessive wear of water pump seals and other cooling system components.
EPA07 MBE 4000 OPERATOR'S MANUAL OAT Coolant Drain Interval — A properly maintained OAT-inhibited coolant will last 600,000 miles (960,000 km), four (4) years, or 10,000 operating hours, whichever comes first. At this time the coolant should be drained, and the cooling system should be thoroughly cleaned, flushed, and filled with new, properly inhibited OAT coolant.
HOW-TO SECTION Chemical Cleaner/Conditioner is used for heavy deposits or scale. Summary of Coolant Recommendations 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. 1. Always maintain the engine coolant to meet Detroit Diesel specifications. 2.
EPA07 MBE 4000 OPERATOR'S MANUAL 9. Where antifreeze/boil over protection is required, use only antifreeze that meets TMC RP-329 “Type A” EG or TMC RP-330 “Type A” PG specifications. Always maintain coolant at the proper level. 10. Do not use the following in Detroit Diesel engine cooling systems: □ Soluble oil □ High silicate, automotive-type antifreeze □ Chromate SCAs □ Methoxy propanol-base coolant □ Methyl alcohol-base coolant □ Sealer additives or coolant containing sealer additives.
HOW-TO SECTION Coolant Flushing and Changing Flush and change the coolant as follows: Do not apply more than 140 kPa (20 psi) air pressure for a radiator flush; more pressure could damage the radiator or heater core. 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. 1.
EPA07 MBE 4000 OPERATOR'S MANUAL 8. Add coolant in the specified concentration until the maximum mark on the surge tank is reached. 9. Start the engine and run it for about one minute at varying speeds to release air pockets in the cooling system. Ensure the heater valve is still open. Check the coolant level and add more coolant if necessary. 10. Shut down the engine, close and tighten the cap on the surge tank. 1.
TROUBLESHOOTING TROUBLESHOOTING In addition to operating the engine carefully and maintaining it properly, make sure to correct any malfunction promptly. When the electronic engine control system detects a fault, it broadcasts a message on the datalink. The dash display will show the code "Motor Control Module (MCM) 128," indicating there is an engine fault. Important: To read the complete fault code, bring the vehicle to an authorized dealer.
EPA07 MBE 4000 OPERATOR'S MANUAL 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 repair facility replace the starter. The engine oil does not meet the correct specifications.
TROUBLESHOOTING Problem—The Engine Cranks, But Won't Start Remedy Cause 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 repair facility 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.
EPA07 MBE 4000 OPERATOR'S MANUAL Problem—The Engine Starts Only After Cranking for a Long Time Cause Remedy The fuel tank is low or empty. Add fuel and prime 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 prefilter, or the screen in the fuel tank is blocked. Clean and prime the system.
TROUBLESHOOTING Problem—The Engine Starts, But Dies Remedy Cause The fuel tank is low or empty. Add fuel and prime the fuel system, if necessary. The fuel filter is clogged. Replace the filter element. The fuel line, the fuel prefilter, or the screen in the fuel tank is blocked. Clean and prime the system. Have the fuel lines and filters checked by an authorized repair facility. The camshaft position (CMP) sensor and/or the crankshaft position (CKP ) sensor are out of adjustment.
EPA07 MBE 4000 OPERATOR'S MANUAL 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 MCM or CPC are incorrect. Have an authorized repair facility reprogram the control unit. AC switch is damaged Check AC switch. Problem—Fuel Consumption Is Too High Cause Remedy The tires are not properly inflated. Check all tires for correct pressure.
TROUBLESHOOTING Problem—The Engine Performs Poorly, Does Not Develop Full Power Remedy Cause 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 repair facility check the operation of the valve. The fuel filter is clogged. Replace the filter element. There are other problems with the fuel system.
EPA07 MBE 4000 OPERATOR'S MANUAL Problem—The Engine Is in Emergency Running Mode (constant speed 1,300 rpm) Cause Remedy The MCM or CPC is damaged. Bring the vehicle to an authorized repair facility for service. An incorrect parameter is in the MCM or CPC. Bring the vehicle to an authorized repair facility and have the parameter settings reprogrammed in the MCM or CPC. Problem—The Coolant Temperature Is Above Normal Cause Remedy The coolant level is too low.
TROUBLESHOOTING Problem—The Coolant Temperature Is Below Normal Remedy Cause The coolant temperature gauge and/or sensor is not reading correctly. Bring the vehicle to an authorized repair facility for service. The thermostat is not operating properly. Have an authorized repair facility replace the thermostat. The fan is not operating properly. Bring the vehicle to an authorized repair facility and have the fan hub checked.
EPA07 MBE 4000 OPERATOR'S MANUAL 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 repair facility for service. There is fuel in the oil.
TROUBLESHOOTING 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 repair facility 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.
EPA07 MBE 4000 OPERATOR'S MANUAL 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 repair facility check the operation of the valve. The constant-throttle valves are malfunctioning. Bring the vehicle to an authorized repair facility for service. Components of the MCM and/or CPC are damaged. Bring the vehicle to an authorized repair facility for service.
TROUBLESHOOTING Problem—The Battery Charge Indicator Light Comes On When the Engine is Running Remedy Cause The poly-V belt is too loose. Check the belt tension; if necessary, Have an authorized repair facility replace the belt tensioner. The belt tensioner is damaged. Have an authorized repair facility replace the belt tensioner. The poly-V belt is worn or damaged. Replace the belt. The alternator is damaged (has a damaged rectifier or voltage regulator).
EPA07 MBE 4000 OPERATOR'S MANUAL ENGINE STORAGE When an engine is to be stored or removed from operation for a period of time, special precautions should be taken to protect the interior and exterior of the engine, transmission and other parts from rust accumulation and corrosion. The parts requiring attention and the recommended preparations are given below.
ENGINE STORAGE rusting of the outside diameter of the cylinder liners. 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. 6. Clean the exterior of the engine (except electrical parts) with fuel oil and dry with compressed air. 7. Seal all engine openings.
EPA07 MBE 4000 OPERATOR'S MANUAL a separate, portable supply of recommended fuel. NOTE: If engines are stored where condensation of water in the fuel tank may be a problem, additives containing methyl carbitol or butyl cellusolve may be added to the fuel. Follow manufacturer's instructions for treatment. Where biological contamination of fuel may be a problem, add a biocide such as Biobor® JF (or equivalent) to the fuel.
ENGINE STORAGE convenient, apply the rust preventive compound to the engine flywheel. If not, disengage the clutch mechanism to prevent the clutch disc from sticking to the flywheel. NOTE: Do not apply oil, grease or any wax-base compound to the flywheel. The cast iron will absorb these substances, which can “sweat” out during operation and cause the clutch to slip. 14. Drain the engine cooling system. 15. Drain the preservative oil from the engine crankcase.
EPA07 MBE 4000 OPERATOR'S MANUAL NOTICE: Do not use plastic sheeting for outdoor storage. Plastic is fine for indoor storage. When used outdoors, however, enough moisture can condense on the inside of the plastic to rust ferrous metal surfaces and pit aluminum surfaces. If a unit is stored outside for any extended period of time, severe corrosion damage can result. The stored engine should be inspected periodically.
ENGINE STORAGE or higher. Charge the battery, if necessary. 10. Service the air cleaner, if required. 11. Transmission: Follow the manufacturer's recommendations covering the return of the transmission to service. 12. Power Take-Off: If equipped, follow the manufacturer's recommendations covering the return of the power take-off to service. NOTE: The small amount of rust preventive which remains in the fuel system will cause smoky exhaust for a few minutes.
EPA07 MBE 4000 OPERATOR'S MANUAL CUSTOMER ASSISTANCE The satisfaction and good will of the owners of Detroit Diesel engines are of primary concern to Detroit Diesel and its distributor/dealer organizations.See Figure 41 for Detroit Diesel NAFTA On-Highway service regions. Figure 41 Detroit Diesel NAFTA On-Highway Service Regions All information subject to change without notice.
CUSTOMER ASSISTANCE NAFTA ON-HIGHWAY SERVICE REGIONS DETROIT DIESEL REGIONAL SALES OFFICES DETROIT DIESEL REGIONAL SERVICE OFFICES NORTHEAST REGION Detroit Diesel Powder Miss Plaza, Suite 3A 51 Gibralter Drive Morris Plains, NJ 07950-1274 Phone: 973-492-6555 Fax: 973-267-5922 NORTH EASTERN REGION Detroit Diesel 13400 Outer Drive West Detroit, MI 48239-4001 Telephone: 313-592-5420 Fax: 311-592-5887 CENTRAL REGION Detroit Diesel 9255 Indian Creek Parkway, Suite 850 Overland Park, KS 66210 Phone: 678-570-
EPA07 MBE 4000 OPERATOR'S MANUAL Road Service in the U.S. or Canada If you require road service for any reason in the U.S. or Canada, you may call the 1–800–445–1980 customer assistance phone number. An operator will assist you in determining what type of service is required. Not all problems are engine related and not all problems are covered by engine or vehicle warranties. YOU MAY BE RESPONSIBLE FOR REPAIR EXPENSES.
CUSTOMER ASSISTANCE Detroit Diesel has established a three-step procedure that customers should follow when experiencing a problem with any Detroit Diesel Product or Part. Detroit Diesel fully realizes that ultimately the customer's concerns will be resolved at the Distributor/Dealer level and therefore encourages customers to follow the procedure outlined below: Step One Customers should discuss the problem with a member of management from the authorized service outlet.
EPA07 MBE 4000 OPERATOR'S MANUAL SPECIFICATIONS This section lists the various POWER COOL engine products. Center (313 592–5800) if you need this specific information. Fuel and Lubricating Oil Filters POWER COOL ENGINE PRODUCTS Consult with a Detroit Diesel Distributor to obtain the proper fuel filters and lubricating oil filters. Maintenance of the cooling system requires the chemical make-up of the system to be balanced.
SPECIFICATIONS POWER COOL 2000 and 3000 Supplemental Coolant Additive Coolant Type Part Number Description 23507858 Pint Bottle – 12 Per case 23507859 Half Gallon Jug – 6 Per Case 23507860 5 Gallon Pail 23507861 55 Gallon Drum For Power Cool IEG Coolant Table 19 POWER COOL 2000 Supplemental Coolant Additive Coolant Type Part Number For POWER COOL IEG Coolant Table 20 142 Description 23507854 Pint Bottle – 12 Per Case 23507855 Half Gallon Jug – 6 Per Case 23507856 5 Gallon Pail 235
EPA07 MBE 4000 OPERATOR'S MANUAL POWER COOL 3000 Supplemental Additive Coolant Filters Part Number Coolant Type 23507545 23508425 23508426 For POWER COOL IEG Coolant 23507189 23508427 23508428 Table 21 Description 4 Ounce (1 Pint Equivalent) 8 Ounce (2 Pint Equivalent) 12 Ounce (3 Pint Equivalent) 16 Ounce (4 Pint Equivalent) 32 Ounce (8 Pint Equivalent) 53 Ounce (13 Pint Equivalent) POWER COOL 3000 Supplemental Additive Coolant Filters POWER COOL Supplemental Additive Need Release Coolant Filters
SPECIFICATIONS POWER COOL Plus Extended Life OAT Coolant Coolant Type Part Number 23519397 Concentrated 23519394 23519395 23519396 Pre-Blended 50:50 23519398 23519399 Table 23 Description 1 Gallon Jug – 6 Per Case 55 Gallon Drum Bulk Delivery – 1,000 Gallon Min. One Gallon Jug – 6 Per Case 55 Gallon Drum Bulk Delivery – 1,000 Gallon Min.
EPA07 MBE 4000 OPERATOR'S MANUAL POWER TRAC Coolant Testing And Analysis Products Application Part Number Indicates Nitrite, Molybdate & Glycol Levels Indicates Nitrite, Molybdate & Glycol Levels Indicates Nitrite, Molybdate & Glycol Levels Complete IEG/IPG Coolant Analysis Organic Coolant Analysis Table 26 23519401 23519402 23522774 23516921 23523398 Description 3-Way Coolant Test Strips (Single Foil Packs) 3-Way Coolant Test Strips (Bottle of 50) 3-Way Coolant Test Strips (Bottle of 10) Coolant An
